Komatsu 95 Series Diesel Engine Shop Manual - PDF DOWNLOAD

Page 1

SEBE61460114

Shop Manual

!!i SERIES DIESEL ENGINE

This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.

January 1998

Copyright 1998 Komatsu America International Company

OO@-1


CONTENTS No. of page

01

GENERAL . . . . ..‘...............................,..........‘..,.....................

11

STRUCTURE AND FUNCTION

12

TESTING AND ADJUSTING

13

DISASSEMBLY

14

MAINTENANCE

15

REPAIR AND REPLACEMENT

01-001

. . . . . ..n................................

11-001

,....,.,.,....................m..,..........

12-001

. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .

13-001

STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-001

.. ..... . .. ... ..... ... .... ..... ..... ... . ..

15-001

AND ASSEMBLY

95 SERIES


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15-001 15-002 15-003 15-004 15-005

95 SERIES

0°Z5



SAFETY

SAFETY

NOTICE

SAFETY SAFETY

NOTICE

IMPORTANT SAFETY NOTICE Proper

service

and

repair

is extremely

service and repair techniques are both effective designed

manual.

for the specific

injury to workers,

The cautions

take the necessary

situation

operation.

and described

require the use of tools specially

is used to mark safety precautions

these symbols

should

arises or may possibly

always

arise, first consider

in operation

carefully

6. Decide

are extremely and

Manual

the machine.

out any greasing

read all the precautions which

dangerous.

Maintenance

BEFORE operating

1. Before carrying

a place

in the repair

the tools Always

workshop

parts. Always

and parts in their

correct

to keep

places.

keep the work area clean and make

sure that there is no dirt or oil on the floor.

or repairs,

given on the decals

Smoke

only in the areas provided

ing. Never smoke while

for smok-

working.

are fixed to the machine.

2. When

carrying

out any operation,

wear safety shoes and helmet. loose work clothes,

always

. Always

or clothes with buttons

safety glasses when

wear

safety

glasses

ing parts with a grinder, 3. If welding trained,

FOR WORK

Before

adding

oil or making

park the machine wear

hitting

parts with a hammer. . Always

PREPARATIONS

Do not wear

missing.

repairs are needed, experienced

when

welder

always carry

carrying

out welding

ways

welding

gloves,

wear

grind-

etc.

work. When

have a out the

work,

apron,

al-

hand

shield, cap and other clothes suited for welding work. When

care-

safety, and

keep tools and removed Mistakes

in this

be followed

actions to deal with the situation.

PRECAUTIONS

Read the Operation

The

in this manual

purpose.

the symbol A

accompanying

fully. If any dangerous

GENERAL

for safe machine

by Komatsu

and safe. Some of these techniques

by Komatsu

To prevent

important

recommended

out any operation

or more workers, ating procedure

with two

always agree on the operbefore

starting.

Always

in-

form your fellow workers before starting any step of the operation.

Before starting

work,

REPAIR signs on the controls

in the operator’s Keep all tools

Before

starting

or tracks

compartment.

in good condition

the correct way to use them.

and the

blade,

ripper,

bucket or any other work equipment

to the

ground.

If this

work,

lower

is not possible,

insert

the

safety pin or use blocks to prevent the work equipment

from falling.

to lock all the control

In addition,

be sure

levers and hang warn-

ing signs on them.

the

machine

with

before starting 10. Remove

or assembling, blocks,

jacks

support or stands

work.

all mud and oil from

the steps or

other places used to get on and off the machine. Always steps when Never

and learn

to prevent

moving.

9. When disassembling

carrying

hang UNDER

from

repairs,

on hard, level ground,

block the wheels machine

any

jump

impossible

use the handrails,

getting

ladders

or

on or off the machine.

on or off the machine. to use the handrails,

steps, use a stand to provide

If it is

ladders

or

safe footing.

00-3


SAFETY NOTICE

SAFETY

PRECAUTIONS DURING WORK

19. Be sure to assemble original

11 When removing or

hydraulic

loosen them spurting Before

the oil filler cap, drain plug pressure

slowly

to prevent

plugs,

the oil from

or removing

of the oil, water

remove

the pressure

or air circuits, completely

first

from

the

and

oil in the

the engine

circuits

is stopped,

are hot

so be careful

that they will not be damaged

20. When sure

installing that

high pressure

they

for the oil and water

carrying

ful when circuits.

are

installing Also,

are correctly

not to get burned. Wait

out any work

to cool

before

on the oil or water

circuits.

21 When

the battery.

Always

the negative

(-1 terminal

remove

the lead from

assembling

use a hoist

22. When

aligning

or hand. caught

ample

capacity.

Install

the lifting

which

has

Use a hoist

or crane

and

the component

operate from

hit-

part. Do not work with

any

15. When

removing

covers which

ternal

pressure

or under

spring,

always

leave

are under in-

pressure

two

bolts

sides. Slowly

removing

to break wiring 17. When

from

a

in position

release the pres-

components,

or damage

be careful

the wiring.

may cause electrical removing

piping,

not

Damaged

fires.

stop the fuel or oil

from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. on the floor

Fuel or oil

can cause you to slip, or can

even start fires. 18. As a general

rule, do not use gasoline

to

wash parts. In particular,

use only the mini-

mum

washing

parts.

00-4

parts such as guards, violently

or rotate at

careful

to check

correctly.

Be careful

not to get your

in a hole.

measuring

hydraulic

that the measuring

of gasoline

when

24. Take care when

pressure,

tool is correctly

electrical

removing

tracks of track-type When

removing

rates suddenly,

sure, then slowly loosen the bolts to remove. 16. When

When

check assem-

at the correct

part still raised by the hoist or crane.

on opposite

parts, always torques.

bled before taking any measurements. equipment

to prevent

ting any other

23. When

equipment

parts

two holes, never insert your

fingers

lifting

or installing

be particularly

fingers

use

care-

connecting

tightening

vibrate

Check that the wire rope, chains and hooks are free from damage.

Damaged

tubes for high pressure

protective

or parts which high speed,

hoses, make

installed.

or crane.

Always

is be-

so be extremely

that they are installed

first.

14. When raising heavy components,

places.

be sure

by contact

not twisted.

check that

use the specified installing

13. Before starting work, remove the leads from

slowly

parts with new parts.

hoses and wires,

tubes are dangerous,

water

when

installing

ing operated.

compo-

circuit. 12. The

Replace any damaged . When

with other parts when the machine

out. disconnecting

nents

measuring

all parts again in their

places.

or installing

the

machines.

the track,

the track sepa-

so never let anyone stand at

either end of the track.


GENERAL

FOREWORD

FOREWORD GENERAL This

shop

serviceman

manual

has been

an accurate

prepared

as an aid to improve

understanding

repairs and make judgements.

the quality

of the product and by showing

Make sure you understand

of repairs

by giving

the

him the correct way to perform

the contents

of this manual

and use it to full

effect at every opportunity.

This shop manual

mainly

service workshop.

For ease of understanding,

chapters

are further

contains

divided

the necessary

technical

the manual

information is divided

for operations

performed

into the following

chapters;

in a these

into the each main group of components.

STRUCTURE AND FUNCTION This section explains an understanding

the structure

of the structure,

and function

of each component.

but also serves as reference

It serves not only to give

material

for troubleshooting.

TESTING AND ADJUSTING This

section

adjustments

explains

Troubleshooting

DISASSEMBLY This section assembling

checks

charts correlating

before

and

after

performing

repairs,

as well

as

of the checks and repairs.

“Problems”

to “Causes” are also included

in this section.

AND ASSEMBLY explains

the order to be followed

each component,

MAINTENANCE

to be made

to be made at completion

when

as well as precautions

removing,

installing,

disassembling

or

to be taken for these operations.

STANDARD

This section gives the judgement

standards

when

inspecting

disassembled

parts.

NOTICE The

specifications

time

and

with

the

contained

without latest

any

advance

in this notice.

shop

manual

Use the

are subject

specifications

to change given

in the

at any book

date.

00-5


HOW TO READ THE SHOP MANUAL

FOREWORD

HOW TO READ THE SHOP MANUAL VOLUMES

REVISED EDITION MARK

Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

When

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series

pages.

Electrical volume: Attachments volume:

1

Each issued as one volume to cover all models

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available.

DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.

a manual

((iJo@....)

is revised,

is recorded

an edition

on the

bottom

mark of the

REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume):

10 -3

Example

a

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

3. Additional

pages:

by a hyphen

page number.

Additional

pages are indi-

(-1 and number

after the

File as in the example.

Example: 1o-4 10-4-I > 1O-4-2 1o-5

*

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

2 (Engine volume):

Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item.

00-6

Item

+ Item number (IO. Structure and Function) Consecutive page number for each item.

cated

Remarks

Symbol

12-203 Added

pages ---c~~:~~~I~ 12-204

I

Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants, etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water must be drained, and quantity to be drained.


HOISTING INSTRUCTIONS

FOREWORD

HOISTING INSTRUCTIONS HOISTING Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol &

.

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal

of all bolts fastening

the part to the relative 2) Check for existence ing interference

the

part caus-

part to be re-

moved.

79%

41%

71%

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

A

WIRE ROPES 1) Use adequate weight

88%

SAD00479

of another

with

100%

parts.

ropes

depending

of parts to be hoisted,

on the

referring

to

the table below: 4)

Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter

Ir

1

Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg) when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN (1000 kg) vertically, at various hanging angles.

Allowable

load

mm

kN

tons

10

9.8

1.0

11.2

13.7

1.4

12.5

15.7

1.6

14

21.6

2.2

to 19.6 kN (2000 kg} of total weight

16

27.5

2.8

suspended.

18

35.3

3.6

(1000

20

43.1

4.4

hanging

22.4

54.9

5.6

30

98.1

10.0

40

176.5

18.0

50

274.6

28.0

60

392.2

40.0

When two ropes sling a load vertically, This weight

kg} when

two

angle.

becomes

ropes

make

On the other

ropes are subjected

up

can be 9.8 kN a 120”

hand, two

to an excessive

force

as large as 39.2 kN (4000 kg1 if they sling a 19.6 kN {2000 kg) load at a lifting angle of 150”.

The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used.

2) Sling wire ropes from the middle portion of the hook.

I

I

I

I

I

30

60

90

120

Liftina

ankle

[detree)

I

I 60 SAD00480

00-7


COATING MATERIALS

FOREWORD

COATING

MATERIALS

Ir The recommended coating materials such as adhesives, gasket sealants and greases disassembly and assembly are listed below. + For coating materials not listed below, use the equivalent of products shown in this list.

Q’W

Category

Container

Main applications, l

790-129-9030

150 g

Tube l

790-129-9050

LT-IB

20 g (2 pes.)

Polyethylene container

50 g

Polyethylene container

l

LT-2

0994040030

LT-3

790-129-9060

Adhesive:

(Set of adhesive and hardening agent)

1 kg lardeniny I agent: 500 g

l

l

used for

features

Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal. Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs. Used as adhesive or sealant for metal, glass and plastic.

Can

Adhesives 250 g

IPolyethylene container

75 g

Tube

50 g

Polyethylene container

29

Polyethylene container

. Used as sealant for machined

l

l

Three bond 1735

790-129-9140

l

l

Used as heat-resisting ing engine.

sealant

holes. for repair-

Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.

I l

Aro;;;pha 790-129-9130

l

l

Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.

I

Loctite 646-50

l

79A-12991

IO

790-129-9010

Gasket sealant

00-8

LG-3

50 cc

200 g

1 kg

Polyethylene container

Tube

l

l

Features: Resistance to heat, chemicals Used at joint portions subject to high temperatures. Used as adhesive or sealant for gaskets and packing of power train case, etc. Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations, used to prevent seizure. Used as sealant for heat resistance gasket for high temperature locations such as engine precombustion chamber, exhaust pipe, etc.


COATING MATERIALS

FOREWORD

Category

(omatsu code

LG-4

Part No.

790-129-9020

Q’ty

200 g

Container

Tube

Main applications,

features

. Features: Resistance to water, oil . Used as sealant for flange surface, thread. . Also possible to use as sealant for flanges with large clearance.

. Used as sealant for mating surfaces of final drive case, transmission

case.

. Used as sealant for various LG-5

790-129-9080

1 kg

‘olyethylene container

threads, pipe joints, flanges. . Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.

. Features: Silicon based, resistance to heat, Gasket sealant

cold 0994040011

250 g

Tube

. Used as sealant for flange surface, tread. . Used as sealant for oil pan, final drive case, etc.

. Features:

Molybdenum disulphide lubricant

LG-7

09920-00150

150 g

Tube

Three bond 1211

790-129-9090

100 g

Tube

LM-G

09940-00051

60 g

Can

LM-P

09940-00040

200 g

Tube

Silicon based, quick hardening type . Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.

. Used as heat-resisting

sealant for repairing

engine.

. Used as lubricant for sliding portion (to prevent from squeaking).

. Used to prevent seizure or scuffling of the

. General purpose type

G2-LI

SYG2-4OOLI SYG2-350LI SYG2-4OOLI-A SYG2-160LI SYGA-16OCNLl

GZ-CA

SYG2-4QOCA SYG2-350CA SYG2-4OOCA-A Various SYG2-16OCA SYGA-16OCNCI

Grease

Vlolybdenum disulphide lubricant

SYG2-400M

thread when press fitting or shrink fitting.

. Used as lubricant for linkage, bearings, etc.

Various

400 g (IO per case)

Various

. Used for normal Various

8elows type 1

bearing steam.

temperature, light load at places in contact with water or

. Used for places with heavy load

00-9


FOREWORD

STANDARD

STANDARD TIGHTENING TORQUE

TIGHTENING

TORQUE

STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS Use these torques

for metric

bolts and nuts. (Always

use torque

wrench).

Thread diameter of bolt

Width across flats

mm

mm

Nm

bm

6 8 10 12 14

10 13 17 19 22

13.2f 1.4 31f3 66f7 113flO 177f19

1.35kO.15 3.2f0.3 6.7kO.7 11.5+1 18+2

16 18 20 22 24

24 27 30 32 36

279+30 382+39 549+59 745k83 927f103

28.5?3 39+4 56+6 76f8.5 94.5f 10.5

27 30 33 36 39

41 46 50 55 60

1320+140 1720f190 221Ok240 2750f290 329Ok340

Thread diameter of bolt

Width across flats

mm

mm

Nm

6 8 10 12

10 13

7.85+ 1.95 18.6f 4.9 40.2+ 5.9 82.35k7.85

:7"

135+15 175+20 225+25 280f30 335+35

bm 0.8kO.2 1.9f0.5 4.1f0.6 8.4f0.8

TIGHTENING TORQUE OF HOSE NUTS Use these torques Nominal

No.

for hose nuts. Thread

02 03 04 05 06 10 12 14

diameter

Width

Tightening

across flat

mm

mm

Nm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

24.5+ 4.9 49+ 19.6 78.5f 19.6 137.3f29.4 176.5f29.4 196.lf 49 245.2f49 294.2f 49

torque kgm 2.5+ 0.5 5+2 8f2 14f3 18f3 2055 25f5 3055

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques Thread

00-l0

diameter

for split flange Width

bolts.

across flat

mm

mm

10 12 16

14 17 22

Tightening Nm 65.7f6.8 112k9.8 279k29

torque k9m 6.7f0.7 11.5*1 28.5?3


FOREWORD

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR Use these torques Nominal

for O-ring Thread

No.

boss connector diameter

Width

mm 02 03,04 05,06 IO,12 14

14 20 24 33 42

Tightening

across flat mm

Nm

Variesdepending on type of connector.

torque kgm 3.5kO.5 9.5+1 14.5f2 43f6 89.5f 13.5

34.3f4.9 93.1f9.8 142.1f19.6 421.4f58.8 877.1f132.3

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR Use these torques

Nominal

for O-ring Thread

No.

08 10 12 14 16 18 20 24 30 33 36 42 52

-

boss connector diameter

Width

Tightenil

across flat

mm

mm

8 10 12 14 16 18 20 24 30 33 36 42 52

14 17 19 22 24 27 30 32 32 36 -

ns1 torque

Nm

-

7.35f1.47 11.27f 1.47 17.64f1.96 22.54? 1.96 29.4+ 4.9 39.2f 4.9 49f4.9 68.6f9.8 107.8f14.7 127.4k 19.6 151.9f.24.5 210.7k29.4 323.4rf: 44.1

_

kgm

-

0.75kO.15 1.15+0.15 1.8kO.2 2.3f 0.2 3f0.5 4f0.5 5kO.5 7+1 llf1.5 13f2 15.5f2.5 21.5f3 33* 4.5

TIGHTENING TORQUES OF FLARE NUT Use these torques

for O-ring

Thread diameter

Width across flat

mm 14 18 22 24 30 33 36 42

boss connector _

Tightening torque

mm

Nm

kgm

19 24 27 32 36 41 46 55

24.5k4.9 49f 19.6 78.5f19.6 137.3k29.4 176.5k29.4 196.1+49 245.2f 49 294.2f 49

2.5kO.5 5+2 8+2 14+3 18+3 20f5 25f5 30f5

00-l 1


FOREWORD

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS) Use these torques Thread

for metric

bolts and nuts of 102 Series Engine.

diameter mm

Tightening

torque

Nm

6

IO 24 43 77

8 10 12

kgm 1.02 2.45 4.38 7.85

f 2 f 4 f 6 f12

f 0.20 f 0.41 zk0.61 + 1.22

TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS) Use these torques Thread

TIGHTENING

diameter

Tightening

mm

Nm

6 8 10 12 14

8f2 10+2 12 f2 24 f 4 36 k 5

torque kgm 0.81 1.02 1.22 2.45 3.67

f 0.20 I?0.20 + 0.20 + 0.41 f 0.51

TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS)

Use these torques Thread

for inches tapered

screws of 102 Series Engine.

diameter

inches 1 / 16 118 114 318

l/2 314 1

00-12

for metric eye joints of 102 Series Engine.

Tightening Nm 3+1 8+2 12+2 15 f 24 f 36 + 60 +

torque kgm

2 4 5 9

0.31 0.81 1.22 1.53 2.45 3.67 6.12

?r: 0.10 + 0.20 * 0.20 zk0.41 f 0.41 f 0.51 + 0.92


FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION

::$ 5

BY THICKNESS

Number of

I

65

CurreMrating

Dia. of strands Cross section

0.32

I

5.23

I

I

4.6

15

84

0.45

13.36

7.0

40

85

0.80

42.73

11.4

60 100

I

127

I

0.80

I

217

I

0.80

CLASSIFICATION

63.84

I

109.1

I

13.6

I

17.6

Applicable

circuit

12

Starting, lighting,

20

Lighting,

signal etc.

37

Charging

and signal

signal etc.

:,

230

Starting

BY COLOR AND CODE

T

Charging

C

Ground

Starting

W

Lighting

Instrument

R

Y

Signal

Other

G

L

Green

Blue

GW

LW

2 IG Ireen & Whitc llue &White GR

LR

3 :C ireen & Red GY 4

;

IG reen & Yellov /Code1

WG

1

-

1

5

-

Color White & Green

-

-

Code

-

-

-

/Color1

-

RG

YL

GB

Red & Green Yellow & BlurtG Ireen & Blacl RL

YW

Blue & Red LY lue & Yellow LB %lue & Black

GL

6

I

-

I

-

I Red 8~ Blue bellow

& White?Gireen & Blue

00-l 3


FOREWORD

CONVERSION TABLE

CONVERSION

TABLE

METHOD OF USING THE CONVERSION TABLE The Conversion details

Table

of the method

in this section

EXAMPLE . Method of using the Conversion 1.

Convert (I)

is provided

of using the Conversion

to enable

Table,

simple

conversion

see the example

Table to convert from millimeters

of figures.

For

given below.

to inches

55 mm into inches.

Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal line from @.

(2) Locate the number

5 in the row across the top, take this as @, then draw a perpendicular

line

down from @. (3) Take the point where from millimeters 2.

the two lines cross as 0.

to inches.

Therefore,

This point @ gives the value when

converting

55 mm = 2.165 inches.

Convert 550 mm into inches.

(I) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm.

(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm)

was divided by 10,so multiply2.165 inches by 10 (movethe

point one place to the right)to returnto the originalvalue. This gives 550 mm

Millimeters

00-14

1 mm = 0.03937 in 8

9

0

1

2

3

4

5:

6

7

0 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

0.197; 0.591! 0.984; 1.378: 1.772;

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.536 1.929

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

9 0 10 20 30 40

a...

to inches

decimal

= 21.65 inches.

0

i

.............. ..............2.008 ..............2.047 ............... ............12.1651 ............1.969 2.087 2.126 50 .,.... 2.480 2.520 2.559 60 2.362 2.402 2.441 2.874 2.756 2.795 2.835 2.913 2.953 70 3.268 3.150 3.189 3.228 3.307 3.346 80 3.740 3.543 3.622 3.661 3.701 90 3.583


CONVERSION

FOREWORD

Millimeters

TABLE

to Inches 1 mm = 0.03937

1

2

3

4

5

6

7

8

9

0

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

50

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

0

.

in

0

Kilogram

0

to Pound

0

1 kg = 2.2046 lb 3

4

5

6

7

8

9

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

IO

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

20

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

30

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

40

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

50

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

60

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

70

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

80

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

90

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-M


CONVERSIONTABLE

FOREWORD

Literto U.S. Gallon It = 0.2642

0

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

10

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

20

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

30

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

40

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

50

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

60

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

70

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

80

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

90

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

0

Liter

U.S. Gal

to U.K. Gallon If! = 0.21997

U.K. Gal

0

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

30

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

0

00-16


CONVERSIONTABLE

FOREWORD

kgm to ft. lb 1 kQm = 7.233 ft. lb 0

1

2

3

4

5

6

7

8

9

\ 7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

0

0

10

00-17


FOREWORD

kg/cm*

CONVERSIONTABLE

to lb/in* 1kg/cm2 = 14.2233 lb/in2

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

70

995.6

0

0

10

1010

1024

1038

1053

1067

1081

1095

1109

1124

80

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

90

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

00-18


CONVERSION TABLE

FOREWORD

Temperature Fahrenheit-Centigrade Conversion

; a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-

ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8”F

“C

“F

1

I

“C

OF

I

“c

I

“F

“C

“F

-40.4

-40

-40.0

-11.7

11

51.8

7.8

46

114.8

27.2

81

117.8

-37.2

-35

-31.0

-11.1

12

53.6

8.3

47

116.6

27.8

82

179.6

-34.4

-30

-22.0

-10.6

13

55.4

8.9

48

118.4

28.3

83

181.4

-31.7

-25

-13.0

-10.0

14

57.2

9.4

49

120.2

28.9

84

183.2

-28.9

-20

-4.0

-9.4

15

59.0

10.0

50

122.0

29.4

85

185.0

-28.3

-19

-2.2

-8.9

16

60.8

10.6

51

123.8

30.0

86

186.8

-27.8

-18

-0.4

-8.3

17

62.6

11.1

52

125.6

30.6

87

188.6

-27.2

-17

1.4

-7.8

18

64.4

11.7

53

127.4

31.1

65

190.4

-26.7

-16

3.2

-7.2

19

66.2

12.2

54

129.2

31.7

89

192.2

-26.1

-15

5.0

-6.7

20

68.0

12.8

55

131.0

32.2

96

194.0

-25.6

-14

6.8

-6.1

21

69.8

13.3

56

132.8

32.8

91

195.8

-25.0

-13

8.6

-5.6

22

71.6

13.9

57

134.6

33.3

92

197.6

-24.4

-12

10.4

-5.0

23

73.4

14.4

58

136.4

33.9

93

199.4

-23.9

-11

12.2

-4.4

24

75.2

15.0

59

138.2

34.4

94

201.2

-23.3

-10

14.0

-3.9

25

77.0

15.6

60

140.0

35.0

95

203.0

-22.8

-9

15.8

-3.3

26

78.8

16.1

61

141.8

35.6

96

204.8

-22.2

-8

17.6

-2.8

27

80.6

16.7

62

143.6

36.1

97

206.6

-21.7

-7

19.4

-2.2

28

82.4

17.2

63

145.4

36.7

98

208.4

-21.1

-6

21.2

-1.7

29

84.2

17.8

64

147.2

37.2

99

210.2

-20.6

-5

23.0

-1.1

30

86.0

18.3

65

149.0

37.8

166

212.0

-20.0

-4

24.8

-0.6

31

87.8

18.9

66

150.8

40.6

105

221.0

-19.4

-3

26.6

0

32

89.6

19.4

67

152.6

43.3

110

230.0

-18.9

-2

28.4

0.6

33

91.4

20.0

68

154.4

46.1

115

239.0

-18.3

-1

30.2

1.1

34

93.2

20.6

69

156.2

48.9

120

248.0

-17.8

0

32.0

1.7

35

95.0

21.1

70

158.0

51.7

125

257.0

-17.2

1

33.8

2.2

36

96.8

21.7

71

159.8

54.4

130

266.0

-16.7

2

35.6

2.8

37

98.6

22.2

72

161.6

57.2

135

275.0

-16.1

3

37.4

3.3

38

100.4

22.8

73

163.4

60.0

146

284.0

-15.6

4

39.2

3.9

39

102.2

23.3

74

165.2

62.7

145

293.0

-15.0

5

41.0

4.4

40

104.0

23.9

75

167.0

65.6

150

302.0

-14.4

6

42.8

5.0

41

105.8

24.4

76

168.8

68.3

155

311.0

-13.9

7

44.6

5.6

42

107.6

25.0

77

170.6

71.1

160

320.0

-13.3

8

46.4

6.1

43

109.4

25.6

78

172.4

73.9

165

329.0

-12.8

9

48.2

6.7

44

111.2

26.1

79

174.2

76.7

170

338.0

-12.2

IO

50.0

7.2

45

113.0

26.7

80

176.0

79.4

175

347.0

00-19



ENGINE 01

GENERAL

General view

......................................................

Specifications

.....................................................

General

assembly

Engine performance Weight

95 SERIES

table

drawing curve

........................... ................................

.......................................................

01-002 01-004 01-005-21 01-026 01-077

O’zol


GENERAL

GENERAL

The

general

product

views

on which

may

differ

depending

on

the engine is mounted.

1. Crankshaft

pulley

2. Fan 3. Fuel filter 4.

Intake

manifold

5. Fuel injection 6. Starting

pump

motor

7. Oil filter 8. Alternator 9. Dipstick IO.

Exhaust

manifold

11. Oil filler 12. Thermostat

6204POO4

0902

EW

VIEW *

4D95L-W-1

VI

95 SERIES

the


GENERAL

GENERAL VIEW

6D95L-1

4

5

6

7

1. Vibration

8

damper

2. Fan 3. Water pump 4. Thermostat 5. Fuel filter 6. Fuel injection pump 7. Electrical intake air heater 8.

Intake manifold

9. Muffler 10. Starting motor

6206POOl

11

12

13

14

11. Oil filter

15

12.

Exhaust manifold

13. Oil cooler 14.

Dipstick

15. Alternator 16.

Crankshaft

pulley

6206POO2

95 SERIES

01203


SPECIFICATIONS

GENERAL

SPECIFICATIONS

Engine

Applicable Number of cylinder Total piston

3D95S-W-1

model

machine

- Bore x Stroke

displacement

PC40-5 PC40-6

model

PC5OUU-1 3 -

(mm)

EC35Z-2 EC35ZS-2

95 x 95 2,020

(cc)

1-3-2

Firing order Overall

length

(mm)

763

763

689

Overall

width

(mm)

539

539

623

(mm)

689

689

756

-

-

-

38.5/2,500

35/2,650

12.2/l ,800

13/I ,800

Overall height (Excluding exhaust Overall height (Including exhaust Flywheel

pipe) pipe)

horsepower

Maximum

torque

(mm) (HP/rpm)

38.5/2,600

(kgmjrpm)

12.5/l ,800

High idling speed

(rpm)

2,750 -

Low idling speed

@pm)

950 -

Minimum

fuel consumption

Dry weight

ratio (g/HPh)

(kg)

2,650 -

2,850

950 -

1,000

193 234

I

Centrifugal,

Governor Lubricating

oil capacity

1,000

(Q)

Coolant

(C) 12V,35A

Alternator motor

Battery

700

193

192

234

205 type

all speed type

(Q)

(Refill capacity) capacity

-

2,750

YPES9CL

Fuel pump

Starting

’

12 V. 2.0 kW 12V,70Ahxl -

12V,35A 12 V, 2.0 kW 12V,70Ahxl

12V.

14A

12 V, 2.0 kW 12V,65Ahxl

-

Air compressor Others

01Z04

95 SERIES


GENERAL

SPECIFICATIONS

3D95S-W-1

EC35ZSB-2

I 3 - 95 x 95 2,020 1-3-2

689 622 756

35/2,600 13/l ,800 700 192 205 YPES3CL Centrifugal,

type

all speed type

5.0 (4.6) (up to 17145) 7.8 (7.0) (17146 and up) 7.0 12V,14A 12 V. 2.0 kW 12V.65Ahxl

-

95 SERIES

O’-go5


GENERAL

SPECIFICATIONS

Engine model

Applicable

Number of cylinder Total piston

machine

4D95S-W-1

- Bore x Stroke

displacement

DPOA,P,S,Q,PL,PLL-6 DPlA,P,S,Q,PLB

model

EC50Z, 25-5

(mm)

4 -

95 x 95 2,690

(cc)

Firing order

l-2-4-3

Overall

length

(mm)

782.5

767

Overall

width

(mm)

598.2

529

(mm)

972.5

750

Overall height (Excluding exhaust Overall height (Including exhaust Flywheel

pipe) pipe)

horsepower

Maximum

torque

-

(mm) (HP/rpm)

39.512.450

4512,800

(kgm/rpm:

15.5/1,300

15/2,000

High idling speed

(rpm)

2,800 -

Low idling speed

(rpm)

800 -

Minimum

I

fuel consumption

ratio (g/HPh)

-

2,900 850

1,450 -

188

1,550

185

_ Dry weight

(kg)

285

270

Fuel pump

Bosch PES-A type

Governor

Bosch RSV centrifugal,

Lubricating

oil capacity

(Q)

8.0

7.5

(Refill capacity)

(a)

(7.0)

(7)

Coolant

(a)

10

13

capacity

Alternator Starting

24V,15A motor

Battery

24 V, 2.8 kW 12V,45Ahx2

Turbocharger

-

Air compressor

-

Others

-

O’-Og5-’

24V,

all speed type

15A

2.4 V, 2.8 kW 12V,45Ahx2

-

I

-

I

95 SERIES


GENERAL

SPECIFICATIONS

4D95S-1 DPOAG, P, PG, PL, PLL-7 (A)

4D95L-W-1

D21A, AG, PG, S, QG-7 (A) 4 -

WA50-1

WA40-1

WA70-1

I 4-95x115

95 x 95 2,690

3,260

1-2-4-3

1-2-4-3

l-

871.5

871.5

744

767

600

600

556

550

972.5

972.5

781

763

921

-

-

-

-

-

39.5/2,450

39.5/2,450

55/2,500

41/2,200

55/2,200

15.5/1,300

15.5/1,300

16.6/ 1,600

19/1,400

20.8/1,500

2,530 800 -

2,630

2,530 -

850

800 -

165

2,630 850

800 -

165

2,750

2,350 -

850

800 -

170

2,450

I

303

255 Bosch

305

593

2,320 -

850

180

I

I 300

2,650 -

746

800 -

I

2,420 850

180 275

PES-A type

Bosch RSV centrifugal,

all speed

type

8

8

6.0

8

8

(7)

(7)

(5.0)

(7)

(7)

10

10

9

9

12

12V, 15A 24 V, 25 A

12V,15A 24 V, 25 A

24 V, 25 A

24 V, 25 A

24 V, 2.8 kW

24 V, 2.8 kW

24 V, 2.8 kW

24 V, 2.8 kW

12V,45Ahx2

12V,45Ahx2

12V,35A 12 V, 2.5 kW 12V,BOAhxl

12V,70Ahx2

12V,65Ahx2

-

-

-

-

-

-

-

-

-

-

-

-

-

95 SERIES

-

O’-F2


GENERAL

SPECIFICATIONS

Engine

Applicable Number Total

of cylinder

model

machine

model

- Bore x Stroke

piston displacement

PC60, 6OL-3 PC6OU-3

I

PC60, 6OL-5 PC6OU-5 4-95x

I

PC60, 6OL-6 PC70-6

115

3,260

(cc)

1-2-4-3

I 797

768

931.0

622

647

542 (excluding mount bracket)

750

771

-

-

-

1.047.1

(kW(HP)/rpm)

44(59)/2,400

40.3(54)/2,100

40.3(54)/2,100

(Nm(kgmhpm)

196(20)/1,500

200(20.4)/1,500

225.5(23)/1,500

High idling speed

(rpm)

2,590 - 2,690

2,250 - 2,350

2,250 - 2,350

Low idling speed

(rpm)

850 - 900

800 - 850

950 - 1,000

217(160)

217(160)

217(160)

270

292 (excluding muffler)

Overall

.o 2

I

(mm)

Firing order

z

4D95L-1

I

(mm)

length

Overall

width

Overall

height exhaust

(mm)

E (Excluding .n

Overall height (Including exhaust Flywheel

pipe) pipe)

horsepower

Maximum

torque

Minimum

fuel consumption

Dry weight

(mm)

I (mm)

I

ratio (g/kWh(g/HPh)) (kg)

I

270

I

Fuel pump

Bosch PES-A type

Governor

Bosch RSV centrifugal,

I

Lubricating

oil capacity

all speed type

@I

8

9

7

(Refill capacity)

(e)

(7)

(7.5)

(6.5)

Coolant

(e)

9

9

10

capacity

Alternator Starting

24 V, 25 A motor

Battery

24V,

15A

24 V, 15 A

24 V, 2.8 kW

24 V, 2.8 kW

24 V, 2.8 kW

12 V, 65 Ah x 2

12 V, 65 Ah x 2

12 V, 65 Ah x 2

Turbocharger

-

-

-

Air compressor

-

-

-

Others

-

-

-

O’-“:5-3

95 SERIES


GENERAL

SPECIFICATIONS

4D95L-1 PC60-6, PC6OL-6F (Blade spec.)

PC60-7 (Blade spec.)

PC60-7

PC70-7

PC70-7 (Blade spec.)

4-95x115 3,260 l-2-4-3 931.0

931

931

931

931

542 (excluding mount bracket)

752

752

752

752

-

-

-

1,047.l

1,093

1,093

1,093

1,093

40.3(54)/2,100

41(54)/1,900

41(54)/1,900

41(54)/1,900

41(54)/1,900

225.5(23)/1,500

225.5(23)/1,500

225.5(23)/1,500

225.5(23)/1,500

225.5(23)/1,500

2,250 - 2,350

2,050 - 2,150

2,050 - 2,150

2,050 - 2,150

2,050 - 2,150

950 - 1,000

950 - 1,000

225(166)

224(165)

224(165)

224(165)

224(165)

292 (excluding muffler)

320

325

320

325

11

11

950-

1,000

950-

1,000

950-

1,000

Bosch PES-Atype Bosch

RSV

centrifugal,allspeed type

8

11

11

(7)

(10.5)

(10.5)

10 24V,25A 24 V, 2.8 kW 12 V,60

Ah x 2

I

(IO.51

I

(10.5)

12.5 12.5 12.5 12.5 (4.5:excluding radiator)(4.5:excluding radiator)(4.5:excluding radiator)(4.5:excluding radiator) 24V.15A 24 V, 2.8 kW 12 V,65

Ah x 2

24 V,25

A

24 V, 2.8 kW 12 V.60

Ah x 2

24V,15A 24 V, 2.8 kW 12 V,60

Ah x 2

24 V,25 A 24 V, 2.8 kW 12V,60Ahx2

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

95 SERIES

O’-o:5-4


GENERAL

SPECIFICATIONS

Engine

Applicable Number Total

of cylinder

4D95L-1

model

machine

- Bore x Stroke

piston displacement

PC75UU-1

model (mm)

PC75UU-2 4-95x

PC80-3

115

3,260

(cc)

Firing order

l-2-4-3 I-

Overall

length

(mm)

1,001

1,001

769

Overall

width

(mm)

656

656

647

(mm)

802

802

771

Overall height (Excluding exhaust Overall height (Including exhaust Flywheel

pipe) pipe)

horsepower

Maximum

torque

-

(mm) (kW(HP)/rpm (Nm(kgm)hpm

-

40.3(54)/l

,900

200(20.4)/1,500

41(54)/l

-

,900

47.8l64.1 I/2,400 210(21.4)/1,600

225.5(23)/1,500

High idling speed

(rpm)

2,050 - 2,150

2,050 - 2,150

2,500 - 2,600

Low idling speed

(rpm)

950 - 1,000

1,000 - 1,050

900 - 950

217(160)

217(160)

217(160)

270

295

270

Minimum

fuel consumption

Dry weight

ratio (gbWh(g/HPh) (kg)

Fuel pump

Bosch PES-A type

Governor

Bosch RSV centrifugal,

Lubricating

oil capacity

all speed type

(e)

9

9

9

(Refill capacity)

(e)

(7.5)

(7.5)

(7.5)

Coolant

(e)

9

10

9

24 V, 15 A

24 V, 15 A

24 V, 2.8 kW

24 V, 2.8 kW

12 V, 60 Ah x 2

12 V, 65 Ah x 2

capacity

24V,

Alternator Starting

motor

Battery

15A

24 V, 2.8 kW 12V,65Ahx2

Turbocharger

-

-

-

Air compressor

-

-

-

Others

-

-

-

O’-OF

95 SERIES


GENERAL

SPECIFICATIONS

4D95L-1 PC90-1

PW60-3

EC75Z, ZS-3

D21A-7T (Trimming spec.)

4-95x115

3,260 l-2-4-3 928

760

753

871.5

542 (excluding mount bracket)

693

636

600

-

740

7 (including muffler) 960

972.5

1,047.l

-

!S (excluding muffler) 745

-

47.8l64.1 j/2,300

49.2(66)/2,500

47.7(64)/3,000

37(49)/2,450

225.5(23)/l ,500

209.8(21.4)/l ,600

197(20.1)/2,000

171.6(17.5)/1,300

2,425 - 2,525

2,600 - 2,700

-

-

950 - 1,000

900 - 950

-

2,530 - 2,630

224(165)

224(165)

217(160)

217(160)

295 (including muffler)

270

270

287

Bosch PES-A type Bosch RSV centrifugal,

all speed type

7

8

8

8

(6.5)

(7)

(7)

(7)

4.5 (excluding radiator)

11.5

13

24V, 15A

24 V, 25 A (with vacuum pump)

24 V, 2.8 kW

24 V, 2.8 kW

12V,60Ahx2

12V,65Ahx2

24V,

15A

24 V, 2.8 kW 12V,65Ahx2

24 V, 2.8 kW 12 V, 45 Ah x 2

-

-

-

-

-

-

-

-

95 SERIES

O’-“z5-6


GENERAL

SPECIFICATIONS

Engine

Applicable Number Total

of cylinder

model

machine

S4D95L-1

model

- Bore x Stroke

piston displacement

PC1 00-5

(mm)

PC1 00-6 4-95x

PC1 20-5

115

3,260

(cc)

Firing order

l-2-4-3

Overall

length

(mm)

769

998

769

Overall

width

(mm)

605

640

605

(mm)

877

Overall height (Excluding exhaust Overall height (Including exhaust Flywheel

pipe)

horsepower

Maximum

-

(mm)

pipe)

torque

-

877 -

1,133

(kW(HP)/rpm)

58.9(78.9)/2,100

(Nm(kgm)/rpml

299(30.5)/1,500

59(79)/2,100 299(30.5)/l

62.5(83.8)/2,200 299(30.5)/l

,500

,500

High idling speed

(rpm)

2,240 - 2,360

2,240 - 2,360

2,340 - 2,460

Low idling speed

(rpm)

900 - 950

900 - 950

900 - 950

210(155)

210(155)

210(155)

320

355

320

Minimum

fuel consumption

Dry weight

ratio

(g/kWh(g/HPh)l (kg)

Fuel pump

Bosch PES-A type

Governor

Bosch RSV centrifugal,

Lubricating

oil capacity

all speed type

12.0

ce,

12.0

(Refill capacity)

@I

(11.0)

Coolant

(e)

10.3

15.7

24 V, 25 A

24 V, 25 A

24 V, 25 A

24 V, 5.5 kW

24 V, 5.5 kW

24 V, 5.5 kW

12 V, 80 Ah x 2

12 V, 80 Ah x 2

capacity

Alternator Starting

motor

Battery Turbocharger

GARRET

CO. T31

Air compressor

-

Others

-

O’ -OF7

(11.0)

GARRET

CO. T31

12.0

I I

(11.0) 10.3

12V,80Ahx2 GARRET

CO. T31

95 SERIES


SPECIFICATIONS

GENERAL

S4D95L-1 PC1 20-6 PC128UU-1

JV70DW-1 4-95x

115

3,260 l-2-4-3 995

797

641

618

-

847 -

1,133 63.0(84.0)/2,200

55.2(73.9)/2,000

299(30.5)/1,500

299(30.5)/l

,500

2,340 - 2,460

2,200 - 2,280

900 - 950

900 - 950

208( 155)

210(157)

355

318

Bosch PES-A type Bosch RSV centrifugal,

all speed type T-

12.0

9.5

(11.0)

(8.8)

15.7 (engine

12.0 only: 4.5)

24 V, 35 A

24 V, 35 A

24 V, 5.5 kW

24 V, 5.5 kW

12V80Ahx2 GARRET

T31 type

12 V 110 Ah x 2 GARRET

T31 type

-

-

-

-

95 SERIES

O’-Oi05-*


GENERAL

SPECIFICATIONS

Engine

Applicable Number

of cylinder

Total

piston

Firing

order

model

machine

6D95L-1

model

- Bore x Stroke

displacement

D31A,

D31E F, FL, FLL, S, Q, AM, SM-20(A)

P, S, Q-18

(mm)

6-95x

D3,A_2

D3,F_2A

115

4,890

(cc)

‘t-5-3-6-2-4

Overall

length

(mm)

1,056

1,056

1,075

Overall

width

(mm)

620

620

625

(mm)

1,093

1,093

1,100

(mm)

-

-

(kW(HP)/rpm)

52.2(70)/2,350

52.2(70)/2,350

(Nm(kgm)/rpm)

265(27)/1,400

265(27)/1,400

Overall height (Excluding exhaust Overall height (Including exhaust Flywheel

pipe)

horsepower

Maximum High

pipe)

torque

59.7(80)/2,500 270(27.5)/1,400

idling

speed

(rpm)

2,600 - 2,700

2,535 - 2,635

2,650 - 2,750

Low idling

speed

(rpm)

700 - 750

700 - 750

700 - 750

217(160)

217(160)

217(160)

Minimum

fuel

consumption

Dry weight

ratio

(g/kWh(g/HPh)) (kg)

420

439

430 I

I Fuel pump

Bosch

Governor

Bosch

Lubricating (Refill

oil capacity

capacity)

Coolant

capacity

PES-A type

RSV centrifugal,

all speed

type

(e)

12.5

13

13

@I

(10.5)

(11)

(11)

ce,

22

22.3

I

22

Alternator Starting

motor

Battery Turbocharger

-

-

-

Air compressor

-

-

-

Others

-

-

-

O’-OF9

95 SERIES


GENERAL

SPECIFICATIONS

6D95L-1 D37E-2

PCIOO-3

D37E, P-5 (A)

PC120-3

PC150-3

6-95x115 4,890 l-5-3-6-2-4 1,075

1,075

1,043

1,043

1,043

625

625

619

619

619

1,100

1,100

862

862

862

-

-

-

-

-

56(75)/2,350

60(80)/2,500

59(79)/2,100

63(85)/2,200

66(88.7)/2,200

267(27.2)/1,400

270(27.5)/1,400

300(30.5)/1,400

309(31.5)/1,400

300(30.5)/1,400

2,600 - 2,700

2,650 - 2,750

2,250 - 2,350

2,350 - 2,450

2,350 - 2,450

700-750

850-

700-750

217(160)

900

850-900

850-900

217(160)

217(160)

217(160)

217(160)

439

405

405

405

Bosch PES-Atype Bosch RSV

centrifugal,allspeed type

11.5

13

12.5

12.5

12.5

(9.5)

(11)

(10.5)

(10.5)

(10.5)

22.3

16

16

16

22

24V,15A 24V,24

24V.15A 24 V, 5.5 kW 12 V,70Ah

x 2

A

24 V, 5.5 kW 12 V,70Ah

x 2

24V,25A

24 V,25A 24 V, 5.5 kW 12 V, IlOAh

x2

24 V, 5.5 kW 12 V, 110 Ah x 2

-

-

-

-

-

-

-

-

-

-

-

-

95 SERIES

24V.25A 24 V, 5.5 kW 12V,llOAhx2

01-005-10


GENERAL

SPECIFICATIONS

Engine

Applicable Number

of cylinder

Total

piston

Firing

order

2 .-o g i .n

model

machine

6D95L-1

model

- Bore x Stroke

displacement

PW150-1 (mm)

WAIOO-1 WRI l-l 6-95x

WAIOO-1 (Engine No. 46799 and up)

115

4,890

(cc)

l-5-3-6-2-4 1,029

Overall

length

(mm)

1,043

1,029

Overall

width

(mm)

619

809

809

(mm)

862

1,081

1,081

1,142

1,142

Overall height (Excluding exhaust Overall height (Including exhaust Flywheel

pipe)

horsepower

8 :

Maximum

E

High

‘t $

Low idling

65(87)/2,400

54(73)/2,400

(Nmhm)/rpm)

314(32)/1,600

284(29)/1,600

314(32)/l

speed

(rpm)

2,600 - 2,700

2,600 - 2,700

2,600 - 2,700

speed

(rpm)

850 - 900

(kW(HP)/rpm)

torque

idling

Minimum

-

(mm)

pipe)

fuel

consumption

Dry weight

ratio

(g/kWh(g/HPh)) (kg)

(Refill

oil capacity

capacity)

Coolant

capacity

Alternator Starting

224(165)

425

437

437

PE-A type

Bosch RSV centrifugal, all speed type

Lubricating

motor

Battery Turbocharger Air compressor Others

O’-OF-’ ’

675 - 725

217(160)

Bosch

Governor

300 - 850 (up to 25582) $75- 725 (25583 and up)

,600

217(160)

I

Fuel pump

63(84)/2,400

Bosch

PES-A type

Bosch RSV centrifugal, all soeed tvoe

(Q)

12.5

13.0

13.0

(Q)

(10.5)

(11.0)

(11.0)

16

17

17

24 V, 25 A

24 V, 25 A

24 V, 25 A

24 V, 5.5 kW

24 V, 5.5 kW

24 V, 5.5 kW

12 V, 110 Ah x 2

12 V, 110 Ah x 2

12 V, 110 Ah x 2

(Q)

I

-

Single Made cylinder, bJouble ZExEL actingvp~

-

-

-

-

-

-

95 SERIES


SPECIFICATIONS

GENERAL

6D95L-1 WA120-1

EGGOB,

GD313A-1

BS-1

6-95x115 4,890 l-5-3-6-2-4 1,029

1,041

1,133

809

809

620

1,081

1,160

1,142

-

63(85)/2,500

63(85)/2,500

315(32.1)/1,600

311(31.7)/1,500

2,700 - 2,800

2,700 - 2,800

800-850 217(160)

&ii+ 56(74:9)/1:800 (60 Hz)

Max. 1,560 (50 Hz) Max. 1,872 (60 Hz) 800-

750 -850 224(165)

I

850

224(165)(at ratedoutput) 402

413 Bosch Bosch RSV

PES-A type

centrifugal,allspeed type

12.5

11

12.5

(IO.51

(9)

(10.5)

20 24V.25A 24 V, 5.5 kW 12 V, 110 Ah x 2

17 24V,25A 24 V, 5.5 kW 12V.80Ahx2

-

-

-

-

-

-

95 SERIES

I

24V,15A 24 V, 2.8 kW

i!4V,4.5kW (48720and up) 12V,70Ahx2


GENERAL

SPECIFICATIONS

Engine

Applicable Number Total

of cylinder

model

machine

S6D95L-1

model

- Bore x Stroke

piston displacement

PC150-3 PC1 5OLC-3

(mm)

PC1 50-5

I

6-95x

I

PC1 80-3

115

4,890

(cc)

Firing order

l-5-3-6-2-4 -r

Overall

length

(mm)

1,043

1,043 (excluding muffler: 1,212 (including muffler)

Overall

width

(mm)

610

612

(mm)

873

928

Overall height (Excluding exhaust Overall height (Including exhaust Flywheel

pipe) pipe)

horsepower

-

-

74(99)/2,200

74(99)/2,000

(mm) (kW(HP)/rpm)

78(105)/2,200

(Nm(kgml/rpml

373(38)/1,400

392(40)/1,400

High idling speed

(rpm)

2,350 - 2,450

2,140 - 2,260

Low idling speed

(rpm)

850 - 900

900 - 950

217(160)

217(160)

415

440

Maximum

torque

Minimum

fuel consumption

Dry weight

ratio (glkWh(g/HPh)) (kg)

Fuel pump

389(39.7)/1,400 2,350 - 2,450 800 -

850

217(160)

Bosch PES-A type

Governor

Bosch RSV centrifugal,

Lubricating

oil capacity

@I

Coolant

(E)

capacity

Alternator

#80273 -: 19.5

12.5

#81773 -: 19.5

12.5

12.5 (10.5)

(18.5)

(10.5)

(18.5)

(10.5)

(e)

(Refill capacity)

all speed type

19

15.9

18.5

24 V, 25 A

24 V, 25 A

24 V. 25 A

Starting

motor

24 V, 5.5 kW

24 V, 5.5 kW

24 V, 5.5 kW

Battery

12 V, 110 Ah x 2

12 V, 80 Ah x 2

12 V, 110 Ah x 2

Turbocharger

GARRET

CO. T31

Air compressor Others

O’-OF-’ 3

-

-

-

95 SERIES


GENERAL

SPECIFICATIONS

S6D95L-1 PC200-5 BR200-1

PC200-6

(Engine

PWI 00-3 No. up to 36829)

(Engine

PWI 00-3 No. 36830 and up)

6-95x115 4,890 l-5-3-6-2-4 1,391

1,340

1,044

1,044

727

822

660

660

818

-

873

873

1,095

1,264

-

-

92( 123)/2,050

99(133)/2,200

74(99)/l,900

490(50)/1,600

412(42)/1,400

412(42)/1,400

2,190 - 2,310

2,360

2,050 - 2,150

2,350 - 2,450

875 - 925

975

850 - 900

850 - 900

476(48.5)/1,500

- 2,480 - 1,025

214(158)

202(149)

Bosch

I 420

Bosch Bosch

(22.5)

19.7

20.7

24 V. 25 A

24 V, 30 A

24 V, 25 A

24 V, 5.5 kW

24 V, 5.5 kW

24 V, 5.5 kW

12 V, 110 Ah GARRET

x 2

CO. T04B

12 V, 110

SCHWITZER

-

-

-

-

95 SERIES

Ah

PE-A type

RSV centrifugal,

all speed

type

I_

23.5

(18.5)

420

I

PES-A type

Bosch RSV centrifugal, aff soeed tvDe ,, 19.5

227(167)

217(160)

522

432

81(108.5)/2,100

x 2 S2D

24 V. 25 A 24 V, 5.5

12 V, 120 Ah x 2

12V,llOAhx2

GARRET

GARRET

CO. T31

kW

CO. T31

Made by ZEXEL Made by ZEXEL ingle cylinder, double acting type Single cylinder, double acting type -

O’-ot2-‘4


GENERAL

SPECIFICATIONS

Engine

Applicable Number Total

-

of cylinder

model

machine

S6D95L-1

model

- Bore x Stroke

piston displacement

WA180-1

WA1 80-3

(mm)

6-95x

.o ii .-i n

115

4,890

(cc)

Firing order

ii?

WA250-3

l-5-3-6-2-4

Overall

length

(mm)

1,047

1,047

1,121

Overall

width

(mm)

761

761

701

(mm)

1,220

1,220

1,214

Overall height (Excluding exhaust Overall height (Including exhaust Flywheel

pipe) pipe)

horsepower

Maximum

torque

-

(mm)

-

-

(kW(HP)/rpml

82.0(1 lOY2.500

82.0(110)/2,400

97.0(130)/2,400

(NmlkgmIhpm:

397(40.5)/1,600

417(42.5)/1,600

441(45.0)/1,600

High idling speed

(rpm)

2,700 - 2,800

2,600 - 2.700

2,550 - 2,650

Low idling speed

(rpm)

750 - 850

750 - 850

750 - 800

217(160)

217(160)

217(160)

510

525

Minimum

fuel consumption

ratio (g/kWh(g/l-lPh)

I Dry weight

510

(kg)

Fuel pump

Bosch PES-A type

Governor

Bosch RSV centrifugal,

all speed type

ce,

12.5

12.5

12.5

(Refill capacity)

(U

(10.5)

(10.5)

(10.5)

Coolant

(J?)

Lubricating

oil amount

capacity

Alternator Starting

motor

Battery Turbocharger

20

(engine

only: 8.5)

(engine

22.5 only: 7.5)

24 V, 25 A

24 V, 35 A

24 V. 35 A

24 V, 5.5 kW

24 V, 5.5 kW

24 V, 5.5 kW

12 V 110 Ah x 2

12 V 110 Ah x 2

12VllOAhx2 GARRET

T31 type

GARRET

T31 type

GARRET

131 type

Air compressor

-

-

-

Others

-

-

-

O’-oF’5

95 SERIES


SPECIFICATIONS

GENERAL

S6D95L-1 I

GD461A-1

I

GD510R-1

GD511A, GD513A.

R-l R-l

6-95x

115

I

LW80-1

I

EG85B,

BS-1

4,890 l-5-3-6-2-4 1,041

1,042

1,153

809

676

620

1,151

1,002

942

-

-

1,150

431(44)/l

420(42.8)/1,500 2,700

2,700

- 2,800

750

101(135)/2,900

93(125)/2,500

84( 113)/2,500

850

- 850

431(44)/1,600

,600

3,050

- 2,800

850

- 950

- 900

217(160)

217(160)

231(170)

- 3,150

410

435 Bosch Bosch

RSV

PES-A

all speed

435(44.4)/l 3,400

Max. Max.

- 3,500

750

type

(50 (60

- 800

1,560 1,872 750

224(165)

224(165)

(50 (60

- 850

420 Bosch PES-A type Bosch RSV centrifugal, all speed type

11

11

11

12.5

12.5

(10.5)

(9)

(9)

(10.5)

(10.5)

17

34

34

24 V, 25 A

24 V, 25 A

24 V, 25 A

24 V, 25 A

24 V, 5.5 kW

24 V. 5.5 kW

24 V, 5.5

kW

24 V, 5.5 kW

I

12A95E41RAh

12V,80Ahx2 GARRET

CO. -

-

-

-

-

-

95 SERIES

30

radiator1

24V.15A 24 V, 2.8 kW !4 V, 4.5 kW (45334 and up) x 2

GARRET CO. T31 (With waist gate)

T31

Hz) Hz)

(at rated output)

450

18.7 8.5: excluding

Hz) Hz)

,800

Bosch PE-A type 3osch RLD centrifugal, half all speed type

type

centrifugal,

64(85.8)/1,500 74(99.6)/1,800

11 0(148)/3,000

12 V, 70 Ah x 2 GARRET

CO. T31

Made by ZEXEL ngle cylinder,doubleactingtype

-

-

O’-002-’ 6


GENERAL

SPECIFICATIONS

Engine

Applicable Number

-

of cylinder

Total

piston

Firing

order

z

.o 2

E .a

model

machine

S6D95L-1

model

- Bore x Stroke

displacement

6-95x

(mm)

115

4,890

(cc)

l-5-3-6-2-4

Overall

length

(mm)

1,391

1,153

1,153

Overall

width

(mm)

727

620

620

(mm)

818

942

942

(mm)

1,095

1,150

1,150

Overall height (Excluding exhaust Overall height (Including exhaust Flywheel

pipe) pipe)

Maximum

(Nm(kgml/rprr

torque

476(48.51/l

idling

speed

(rpm)

2,200 - 2,320

Low

idling

speed

(rpm)

925 - 975

fuel consumption

Dry weight

ratio

(gntWhIg/HPh (kg)

432

420 (STD) 420 (STD) 435 (Elect. governor, opl 435 (Elect. governor, op)

Bosch

capacity)

Coolant

capacity

PES-A type governor type

RSV centrifugal,

or

all speed

type

ce,

18.5

12.5

12.5

U?)

(17.5)

(11.3)

(11.3)

(e)

15.6 24 V, 25 A

Alternator Starting

1,570 (50 Hz) 1,872 (60 Hz) 800 - 850

800 - 850

Bosch Electronical

oil capacity

Max. Max.

1,560 (50 Hz) 1,872 (60 Hz)

223{165)(At rated output) 223{165I(At max. output)

Governor

(Refill

Max. Max.

-

202I1491

Fuel pump

Lubricating

(50 Hz) 71.3{95.6)/1,500 (50 Hz) (60 Hz) 33.1{111.4}/1,800 (60 Hz)

-

,500

High

Minimum

64{85.8}/1,500 74{99.6}/1,800

92(123)/2,050

(kWIHPVrpm

horsepower

7.5

I I

24V,

l5A

I

7.5 24 V, 15 A

24 V, 5.5 kW

motor

Battery Turbocharger

c

Air compressor Others

O’-OF-’ 7

95 SERIES


SPECIFICATIONS

GENERAL

SA6D95L-1 PC220-5, BR300-1 (With air to air aftercooler)

PC220-6 (With air to air aftercooler) 6-95x

115

4,890 l-5-3-6-2-4 1,391

1,340

813

822

818

-

1,264

1,095 114{153}/2,200

118{158Y2,300

527{53.7}/1,500

554{56.5}/1,600

2,355 - 2,475

2,470 - 2,590

925 - 975

975 - 1,025

202{149}

214{158}

448

525

Bosch PES-A type Electronical govern01 type or Bosch RSV centrifugal, all speed type #81676

Bosch PES-A type Bosch RSV centrifugal, all speed type

-

19.5 (18.5)

18.5 (17.5)

23.5 (22.5)

16

20.7

24 V, 25 A

24 V. 30 A

24 V, 5.5 kW

24 V, 5.5 kW

12 V 110 Ah x 2

12 V 110 Ah x 2

GARRET

CO. T04B -

Aftercooler

95 SERIES

SCHWITZER

-

S2D

I

I

I

Aftercooler

01 -OO_S-18


SPECIFICATIONS

GENERAL

Engine

Applicable Number

of cylinder

Total

piston

Firing

order

model

SAA6D95LE-1 WING100 _WlOO-1, LWlOOM-1)

machine

- Bore x Stroke

displacement

6-95x

115

4.89 {4,8901

e ICC}

l-5-3-6-2-4

Overall

length

mm

1,042

Overall

width

mm

736

mm

1,189

mm

-

Overall height (excluding exhaust Overall height (including exhaust Flywheel

pipe)

pipe)

horsepower

Maximum

torque

High

idling

speed

Low

idling

speed

Minimum

fuel

consumption

ratic

Dry weight Fuel injection

kW/rpm IHP/rpmI

118/3,000 {158/3,000}

Nm/rpm kgm/rpmI

457/l ,800 (Net) {46.6/1,8001 (Net)

rpm

3,400 - 3,500

(Net) (Net)

rpm

750 - 800

g/kW.h {g/HP-h}

215 (Net) {I 60) (Net)

kg

489 BOSCH

pump BOSCH

Governor Lubricating oil amount (refill capacity)

I

Coolant

I

amount

Alternator Starting

I

mm

e

RLD centrifugal,

12.5 (10.5)

e (engine

only:

PES-A type

I

half all speed

type

I

85)

24 V, 50 A motor

Battery

24 V, 4.5 kW 12 V 100 Ah x 2 (95E41R x 2)

Turbocharger

GARRET T31 Type Jvith waist gate valve)

Air compressor

ZEXEL reciprocation, jingle cylinder type

Others

O’-Og5-’ 9

With air cooled aftercooler

95 SERIES


GENERAL

95 SERIES

SPECIFICATIONS

O’-oo2-20


GENERAL ASSEMBLY DRAWING

GENERAL

GENERAL ASSEMBLY 3D95S-W-1

DRAWING

LEFT SIDE VIEW (For EC35Z,ZS-2)

Crankshaft

center

F t

\

‘\

Flywheel housing rear surtace

6206F500

01-005-21 a3

95 SERIES


GENERAL ASSEMBLY DRAWING

GENERAL

3D95S-W-1

RIGHT SIDE VIEW (For EC35Z,ZS-2)

T

-

Coolant (drain)

-

II -

Crankshaft center

/

\ Flywheel housing rear surface

324.5

i )

6206F501

95 SERIES

01-005-22 @


GENERAL ASSEMBLY DRAWING

GENERAL

3D95S-W-1

FRONT VIEW (For EC35Z,ZS-2)

L

509.5 285

Water temperature

switch

/ Water temperature gauge pick-up port /

8 -I

Crankshaft -~

center

6206F502

O’ -oiF23

95 SERIES


GENERAL ASSEMBLY DRAWING

GENERAL

3D95S-W-1

REAR VIEW (For EC35Z. ZS-2)

Crankshaft

center

6206F503

95 SERIES

01-005-24 @a


u

~

_34.8

t-l

34.8

Flywheel

housing rear surface


GENERAL

4D95S-W-1

GENERAL

ASSEMBLY

DRAWING

RIGHT SIDE VIEW (For D20,21-6)

-

-

03

-

0 -

.I

6204F207

95 SERIES

01-005-26 @


GENERAL

4D95S-W-1

GENERAL ASSEMBLY DRAWING

FRONT VIEW (For D20,21-6)

I

289.5 *

Crankshaft

center

t

245

225

6204 F208

01-005-27 a3

95 SERIES


GENERALASSEMBLY DRAWING

GENERAL

4D95S-W-1

REAR VIEW (For D20,21-6)

,

1 , 7

Crankshaft

center

IO-10x1.5 Depth

I8 (239)

(259)

I

6204FZG9

95 SERIES

01-005-28 @


GENERAL

GENERAL

4D95L-1

LEFT

SIDE

VIEW

ASSEMBLY

DRAWING

(For PC60-3)

Out let for heater Xrection of wind

/

Water temperature gauge pick-up

Crankshaft center I

n!

2

4 -

10x1.5

t

O’-go6

95 SERJES


GENERAL

GENERAL

4D95L-1

RIGHT

SIDE

VIEW

ASSEMBLY

DRAWING

(For PC60-3)

rankshaft center

4 -

10 x’1.5

Oil pressure switch 15

6204FOO2

95 SERIES

Ol-go7


4D95L-1

ASSEMBLY

GENERAL

GENERAL

FRONT

VIEW

DRAWING

(For PC60-3)

312

4

Dust indicator pick-up

ankshaft center

6204FOO3

0 l-$08

95 SERIES


GENERAL

GENERAL

4D95L-1

REAR VIEW

(For

ASSEMBLY

DRAWING

PC60-3)

i’

/ 6 - 12x1.75

6204 FO04

95 SERIES

0 1-go9


GENERAL

GENERAL

4D95L-1

LEFT

SIDE

+ Direction of wind

VIEW

ASSEMBLY

DRAWING

(For PC60-5, PC6OU-5)

.-P

760.0 -;

2 z

Crankshaft center

Depth 18

F614601051

Ol-g9-1

95 SERIES


GENERAL

4D95L-1

GENERAL

RIGHT

SIDE

VIEW

ASSEMBLY

DRAWING

(For PC60-5, PC6OU-5)

208.2

Coolant (To radiator)

Crankshaft center

4-12x1.75,

3

Depth 21

15.4-

I pl_

a

’

z 479.4

N

45

F614601052

95 SERIES

0 l -0;9-2


GENERAL

GENERAL

4D95L-1

FRONT

VIEW

(For PC60-5,

ASSEMBLY

DRAWING

PC6OU-5)

270.7\_j F614601053

0 l -0;9-3

95 SERIES


GENERAL

4D95L-1

GENERAL

REAR

VIEW

(For

11-10~~~_. .._

PC60-5,

ASSEMBLY

DRAWING

PC6OU-5)

I I

225

95 SERIES

I

225

1

F614601054

Ol-0$9-4


GENERAL

GENERAL

4D95L-W-1

LEFT

SIDE

VIEW

ASSEMBLY

DRAWING

(For WA40-1)

Direction of wind

Tachometer pick-up \

Crankshaft center

6204FOO5

Ol-$lO

95 SERIES


GENERAL

GENERAL

4D95L-W-1

RIGHT

SIDE

VIEW

ASSEMBLY

DRAWING

(For WA40-1)

Coolant

(to

radiator)

6204FOO6

95 SERIES

Ol-gll


GENERAL

4D95L-W-1

GENERAL

FRONT

VIEW

a307.1

DRAWING

(For WA40-1)

Outlet

_

ASSEMBLY

for

heater

f /

Water

temperature

gauge

pick-up

ft center

6204FOO7

01-$12

95 SERIES


GENERAL

GENERAL

4D95L-W-1

REAR

VIEW

ASSEMBLY

DRAWING

(For WA40-1)

Crankst

6204FOO8

i / 6--12X

I .75

01-$13


GENERAL ASSEMBLY DRAWING

GENERAL

S4D95L-1

LEFT SIDE VIEW (For PCIOO-5, PC120-5)

3

Dire Of \I\

.4-10X

Cranl

1.5 Depth 18

aft center

u!

4-10 X 1.5 Depth18

o’-oi3-1

95 SERIES


GENERAL ASSEMBLY DRAWING

GENERAL

S4D95L-1

RIGHT SIDE VIEW (For PC1 00-5, PC120-5)

Coolant (to radiator)

‘\

4-10X

I .5Depth

18

15.4

:

226.4336.4

-I

1

419.4 6206F901 A

95 SERIES

o’-G 3-2


GENERAL

S4D95L-1

GENERAL

ASSEMBLY

DRAWING

FRONT VIEW (For PC1 00-5, PC1 20-5)

H

605

I

radiator)

shaft center

6206F902

01-023-3

95 SERIES

A


GENERAL ASSEMBLY DRAWING

GENERAL

S4D95L-1

REAR VIEW (For PCIOO-5, PC1 20-5)

6-12Xl.75Depth20

eJ

b-

PI I-lOXl.sDepth

240

18

240

6206F903A

95

SERIES

O’-“A3-4


GENERAL ASSEMBLY DRAWING

GENERAL

S4D95L-1

*

(PClOO-6)

There may be differences machine model.

according

to the

View from left

Water temperature gauge pickup pot-t

4-

10 x 1.5 depth 18

Center of crankshaft

479.4

’ .

SME00211

View from right

1. Ill

z

-

Engine cooling water drain plug

Center of crankshaft

‘Oil

pressure

Oil pressure

479.4

*’-“k3-5

.

1451_

switch (low pressure)

switch (high pressure) SME00.212

95 SERIES


GENERAL

S4D95L-1 View

GENERAL ASSEMBLY DRAWING

(PClOO-6)

from front

From radiator

- Center of cranksh laft

SME00213

View

from rear

drill hole

IO x 1.5 drill hole

‘crankshaft 4 - 12 x 1.75 depth 20

depth 18

SME00214

95 SERIES

o’-%3-6


GENERAL

6D95L-1

GENERAL ASSEMBLY DRAWING

LEFT

SIDE

VIEW

(For PC1003,

PClOOL-3,

PC120-3)

Direction ,f wind c3 7

c :

6206FOO

oy14

95 SERIES

I


GENERAL

GENERAL ASSEMBLY DRAWING

6D95L-1

RIGHT

SIDE

VIEW

(For PClOO-3, PClOOL-3,

PC120-3)

ant : adiatol r)

ICrankshaft centel z

-

\I/1

-

I

I

I

I

r

,_

,-

I

6206FOO2

95 SERIES

01-p


GENERAL

6D95L-1

GENERAL

FRONT

VIEW

(For PClOO-3, PClOOL-3,

ASSEMBLY

DRAWING

PC12031

6206FOO3

01-p

95 SERIES


GENERAL ASSEMBLY DRAWING

GENERAL

6D95L-1

REAR

VIEW

(For PClOO-3,

655

,-

PClOOL-3,

PC120-3)

/

_

center

_

A

\-?c-I

I

12- IOX 1.5’ CL

95 SERIES

01-$17


GENERAL

S6D95L-1

GENERAL ASSEMBLY DRAWING

LEFT

SIDE

VIEW

(For PC150-3,

PC15OLC-3)

Coolant (from radiator) Water temperature gauge pick-up \

e

\

jirectio If wind

r _l5.4 Crankshaft center ,” z 37

6-10X

\:

654.4

z 4-‘2x z m .E z 2

‘.75

6207F001

Ol-$18

95 SERIES


GENERAL

S6D95L-1

GENERAL

RIGHT

SIDE ‘VIEW

(For PC150-3,

ASSEMBLY

DRAWING

PC15OLC-3)

Coolant (to radiator)

Crankshaft

center

/ 4-12X

1.5 1.75 15.4 s _m

654.4

45 45 )T-

6207~002

95 SERIES

01g19


GENERAL

S6D95L-1

GENERAL

FRONT

VIEW

(For PC150-3,

ASSEMBLY

DRAWING

PC15OLC-3)

Cra

6207FOO3

01 g20

95 SERIES


GENERAL

S6D95L-1

GENERAL

REAR

VIEW

(For PC150-3,

12- IOX 1.5 ’

)

ASSEMBLY

DRAWING

PC15OLC-3)

240

)

240

1

6207FOO4

95 SERIES

01g21


GENERAL ASSEMBLY DRAWING

GENERAL

S6D95L-1 (PC200-6)

*

There may be differences machine model.

according

to the

View from left

-Center

of crankshaft

SME00215

View from right

Oil cooler cooling _ water drain plug -

Oil pressure

Engine cooling water drain plug

switch

Cenl :er of crankshaft

SME00216

o’-02-’

95 SERIES


GENERAL

S6D95L-1

GENERAL ASSEMBLY DRAWING

(PCZOO-6) -

View from front

Center

of crank

SME00217

View from rear

I-

IO x 1.5 drill hole 2 - 8H8 depth

of crankshaft

20-

SME00218

95 SERIES

o’-02’-2 1


GENERAL ASSEMBLY DRAWING

GENERAL

SA6D95L-1

LEFT SIDE VIEW (For PC220-5)

128.4

1127

45

145I_

654.4

cl 6206F848

O’-k822

95 SERIES


GENERAL ASSEMBLY DRAWING

GENERAL

SA6D95L-1

Crankshaft

RIGHT SIDE VIEW (For PC220-5)

center

\

5-10x1.5 Depth 20

c 654.4

145 I 45

-

6206F649

95 SERIES

01:23


GENERAL

SA6D95L-1

GENERAL ASSEMBLY DRAWING

FRONT VIEW (For PC220-5)

6206F850

95 SERIES


GENERAL

SA6D95L-1

GENERAL ASSEMBLY DRAWING

REAR VIEW (For PC220-5) 4

164

-

6206F851

95 SERIES

0 1-g25


GENERAL ASSEMBLY DRAWING

GENERAL

SA6D95L-1

+

(PC220-6)

View from left

There may be differences machine model.

1140

accol *ding to the

1

Center of crankshaft

c

3-10x 1.5 depth 18

70

/II 4545

i

Orll d

SME00219

View from I

1&Y

c

O’-OF

654.4 ’ 881.4

I45l45l SME00220

95 SERIES


GENERAL ASSEMBLY DRAWING

GENERAL

SA6095L-1

(PC220-6)

View from front

Center of CrankshaftI,,

SME00221

View from rear

8-lOx1.5depth18

enter of crankshaft 11 -10 x 1.5 depth 18

SME00222

95 SERIES

O’-“z5-2


GENERAL

ENGINE

ENGINE PERFORMANCE 3D95S-W-1 Flywheel

PERFORMANCE

CURVE

CURVE

(For PC40-5, PC40-6) horsepower:

Maximum Minimum

38.5 HP/2,600 12.5 kgm/l,800

torque: fuel consumption

ratio:

rpm rpm

193 g/HPh

20

0

30

25 c I 5 a

20

220

2

210 15

200 190 180 170

1200

1400

1600

1800

2000

2200

2400

2600

2800

2 h p .o ;i; L s 'g E :

3000

Engine speed (rpm) F614601070

O’-:26

95 SERIES


GENERAL

3D95S-W-1 Flywheel

ENGINE

CURVE

(For PC5OUU-1) 38.5 HP/2,500

horsepower:

Maximum Minimum

PERFORMANCE

12.2 kgm/l,800

torque: fuel consumption

ratio:

rpm rpm

193 g/HPh

15 Torque

-z

z

--

/-

10

;

z

b + 5

220 210

1000

1200

1400

1600

1800

2000

2200

2400

2600

g

2800

'Enginespeed (rpm) F614601071

95 SERIES

O’-ki27


GENERAL

3D95S-W-1 Flywheel

ENGINE

(For EC35Z,ZS-2,

Minimum

35 HP/2,650

torque: fuel consumption

CURVE

EC35ZSB-2)

horsepower:

Maximum

PERFORMANCE

ratio:

13 kgm/l,800 192 g/HPh

rpm rpm

Engine speed (rpm)

6206F508

O’-:**

95 SERIES


ENGINE

GENERAL

4D95S-W-1 Flywheel

CURVE

(For D20A. P, S-6) (For D21A, P, S-6) 39.5 HP/2,450

horsepower:

Maximum Minimum

PERFORMANCE

15.5 kgm/1,300

torque: fuel consumption

ratio:

rpm rpm

188 g/HPh

25 230 20

220

15

Z

210

Et 9

200

.p E

190 10

180 - 170

5

160

s ._ E E zi : 0 3 I.&

- 150 0

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

Engine speed (y-W F614601072

95 SERIES

O’-ki29


GENERAL

4D95S-W-1 Flywheel

ENGINE PERFORMANCE CURVE

(For EC502, ZS-5) horsepower:

45 HP/Z,800

Maximum

torque:

Minimum

fuel consumption

rpm

15 kgm/2,000 ratio:

rpm

185 g/HPh

.55

5

50

0 /

Y

45

5-

0

1400

I600

I800

2000

2200

2400

2600

2800

3000

3200

Engine speed (rpm) 6206F618

O’-ki30

95 SERIES


ENGINE PERFORMANCE CURVE

GENERAL

(For DZOAG, P, PG. PL, PLL-7(A)) (For D21 A, AG, PG. S, QG-7)

4D95S-1 Flywheel Maximum Minimum

39.5 HP/2,450

horsepower:

15.5 kgm/l,300

torque: fuel consumption

ratio:

rpm rpm

165 g/HPh

20

15 z 10

5

z? J P :

0

45

40

35

30

6 E. S g 0

25

20

15

10

5

0

1000

1200

1400

1600

1800

2000

2200

2600

2800

Engine speed @pm) F614601101

95 SERIES

01-030-l 0



ENGINE PERFORMANCE CURVE

GENERAL

4D95S-1 (For WA50-1) Flywheel Maximum Minimum

55 HP/2,500

horsepower:

rpm

16.6 kgm/l,600

torque: fuel consumption

ratio:

rpm

170 g/HPh

20. -210 15

200 -,I90

lo--.

e’

180

consumpti0n ratio -

--

- 170

5

160

- 150 0

IO00

I200

I400

I600

1800

2000

2200

2400

2600

2800

Engine speed (rpm) 6202FOOl

95 SERIES

01:31


GENERAL

ENGINE

4D95L-W-1

PERFORMANCE

CURVE

(For WA40-1)

Flywheel

horsepower:.

Maximum

torque:

Minimum

fuel consumption

41 HP/2,200

rpm

19 kgmD.400 ratio:

rpm

180 g/HPh

50

40

30 z I ; a ; 0 20

,

10

0

1000

1200

1400

1600 Engine

O’-ki32

1800 speed

2000 (rpm)

2200

2400

2600 F614601040

95 SERIES


GENERAL

ENGINE

4D95L-W-1 Flywheel

PERFORMANCE

CURVE

(For WA70-I) horsepower:

Maximum

torque:

Minimum

fuel consumption

55 HP/2,200

rpm

20.8 kgm/l,500 ratio:

rpm

180 g/HPh

Torque

50

/

0

20

220 - 210 200 190

10

180 170 160 150

0

800

1000

1200

1400 Engine

1600 speed

1800

2000

2200

2400

ham)

F614601073

95 SERIES

O’-6i33


GENERAL

ENGINE

(For

CURVE

PC6OL-3,

Maximum Minimum

PERFORMANCE

20 kgm/l,500 fuel consumption

ratio:

rpm

160 g/HPh

20

60

0

200

0

1000

1200

1400

1600

1800

2000

2200

2400

z 4

190

B .z

180 170

2 6 'E

160

: .,=

150

8 = I=

2600

Engine speed (rpm) F614601050

01 -c&34

95 SERIES


GENERAL

4D95L-1

ENGINE

(For PC60-5,

PERFORMANCE

CURVE

PC6OU-5)

Flywheel horsepower:

54 HP/2,100

Maximum

torque:

20.4 kgm/l,600

Minimum

fuel consumption

ratio:

rpm rpm

160 g/HPh

50 -

t 40

-

5 ; a ; 0

30 -

t

20

180

10

60

100

1600 Engine

1800

2000

2200

2400

speed (rpm) F614601055

95 SERIES O’

-;35


ENGINE

GENERAL

PERFORMANCE

CURVE

4D95L-1 (For PC60-5, PC6OL-5, PC6OU-5) Flywheel

54 HP/2,100

horsepower:

rpm

20.4 kgm/l,500

Maximum

torque:

Minimum

fuel consumption

ratio:

rpm

160 g/HPh

70

20

65

15

60

-z m

10

Y a, $ b I-

55

50

45

25

5 -150 O-

1000

1200

1400

1600

1800

2000

2200

2400

2600

T ,'

2800

Engine speed hrn) F614601074

O’-ki36

95 SERIES


GENERAL

ENGINE PERFORMANCE CURVE

4D95L-1 (For PC60-6, PC70-6) Flywheel Minimum

54 HP/2,100

horsepower:

Maximum

rpm

23 kgm/l,500

torque: fuel consumption

ratio:

rpm

160 g/HPh

20

--

10 ~-

0.

600

800

1000

1200

1400

1600

1800

2000

2200

2400

Engine speed (rpm) F614601075

95 SERIES

01-z37


ENGINE PERFORMANCE CURVE

GENERAL

4D95L-1

(For PC60-7, PC70-7) 40.3 kW (54 HP)/1,900 rpm 226 Nm (23 kgm)/1,500

Flywheel horsepower: Minimum

fuel consumption

60

50

40

/

30

I

20

/

\

IO

0

600

800

IO00

I200

1400

1600

Engine speed (rPm)

O’-Oi7-’

1800

2000

2200 6206F1018

95 SERIES


GENERAL

ENGINE PERFORMANCE CURVE

4D95L-1 (For PC75UU-1) Flywheel

horsepower:

Maximum Minimum

54 HP/l ,900 rpm

torque:

20.4 kgm/l,500

fuel consumption

ratio:

rpm

160 g/HPh

35

E

30

E S P 05

25

20

15

600

800

1200

1400

1600

Engine speed (rpm) F614601076

95 SERIES

O’-OZ7-*


GENERAL

ENGINE PERFORMANCE CURVE,

4D95L-1 (For PC75UU-2) Flywheel horsepower: Maximum torque: Minimum fuel consumption

ratio:

40.3 kW (54 HP)/1,900 rpm 226 Nm (23 kgmV1,500 rpm 217 g/kWh (160 g/HPh)

15

60

IO

55

5

50

0

z m Y sj ab l-

45

25

600

800

1000

1200

1400

1600

Engine speed (rpm)

O’-if8

1800

2000

2200

2400 6206F957

95 SERIES


ENGINE PERFORMANCE CURVE

GENERAL

4D95L-1 (For PC80-3) Flywheel Maximum Minimum

64.1 HP/2,400

horsepower:

rpm

21.4 kgm/l,600

torque: fuel consumption

ratio:

rpm

160 g/HPh

20

1000

1200

1400

1600

Engine

1800

speed

2000

2200

2400

210

2

200

!? 5

190

-@

180

,E

170

'L E z

160

6 o

2600

(rpm) F614601077

95 SERIES 01-$39


GENERAL

ENGINE

PERFORMANCE

CURVE

4D95L-1 (For PC90-1) Flywheel

horsepower:

Maximum

torque:

Minimum

fuel consumption

ratio:

64.1 HP/2,300

rpm

23 kgm/l,500 165 g/HPh

rpm

60

0 800

1000

1200

1400

1600

1800

2000

2200

2400

2600

Engine speed (rpm) F614601078

O’-ii40

95 SERIES


ENGINE

GENERAL

4D95L-1

PERFORMANCE

CURVE

(For PW60-3)

Flywheel horsepower:

66 HP/2,500rpm

Maximum

torque:

2 1.4kgm/ 1,600rpm

Minimum

fuel consumption

ratio:

165glHph

_

0

1000

1200

1400

1600

Fuel consumption

1800

2000

Engine speed (rpm)

ratio

2200

2400

2600

F614601079

95 SERIES 0'-ii4'


GENERAL

4D95L-1

ENGINE PERFORMANCE CURVE

(For EC752, ZS-3)

Flywheel horsepower: Maximum torque: Minimum fuel consumption

48 kW (64 HPV3,OOO rpm 197 Nm (20.1 kgm)/2,000 ratio: 217 g/kWh (160 g/HPh)

Engine

o’-“iY

rm

speed (rpm)

95 SERIES


ENGINE PERFORMANCE CURVE

GENERAL

4D95L-1

(For D21A-7TI

Flywheel horsepower: Maximum torque: Minimum fuel consumption

37 kW (49 HP)/2,450 rpm 172 Nm (17.5 kgmV1,300 rpm ratio: 217 g/kWh (160 g/HPh)

20

15 -z 102 2 e 5r-o

0

50,

40

0

600

1000

1200

1400

1600

Enginespeed

95 SERIES

1800 (rpm)

2000

2200

2400

2600

2600 SDEOOl62

O’-Oil-*


GENERAL

S4D95L-1 Flywheel Maximum Minimum

ENGINE PERFORMANCE CURVE

(For PCIOO-5, PCIOO-6) horsepower:

78.9 HP/2,100

torque:

rpm

30.5 kgm/1,500

fuel consumption

ratio:

rpm

155 g/HPh

40

Torque 30

/----

20

-z m Y sj P z

10

0

90

80

70 /

II

60 -

50 -

40

/

220

r

210 30 -

190

F B 0 '5

180

E ';'a

200

\ 20

170 Qti,

lO--p--w

z

160 150

E 2 c x 5 I=

0 1000

1200

1400

1600

Engine speed

1800

2200

2400

2600

(rpm)

F614601080

O’-:42

95 SERIES


ENGINE

GENERAL

S4D95L-1 Flywheel

(For PC120-5,

Maximum Minimum

PC120-6,

30.5 kgm/l,500

torque: fuel consumption

ratio:

CURVE

PC128UU-1)

83.8 HP /2,200

horsepower:

PERFORMANCE

rpm rpm

155 g/HPh

10

-_

160

/

- 150

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

Engine speed (rPm) F614601081

95 SERIES

O’-:43


GENERAL

ENGINE

S4D95L-1 (For JV7ODW-1) Flywheel horsepower: Maximum torque:

L

60-

: 0 a a, v)

50-

z _c aI a, 1I 3 x IL

PERFORMANCE

CURVE

55.2 kW (73.9 HPY2,OOO rpm 299 Nm (30.5 kgm)/1,500 rpm

60 40

40-

50

30

30-

40

30 20 I

20-

20 10

10-

o-

lo-

0

o

::

600

1000

1200

1400 Ens

O’-Oi3-’

i ne

1600 speed

1600 (rpm)

2000

2200

2400 SDE00921

95 SERIES



GENERAL

ENGINE

PERFORMANCE

CURVE

6D95L-1 (For D31A. P, S, Q-1 8) Flywheel

horsepower:

Maximum Minimum

70 HP/2,350

torque:

rpm

26.6 kgm/1,400

fuel consumption

ratio:

rpm

160 g/HPh

10

80

60

220 210 200 190 180 170 160 150 1000

1200

1400

1600

1800

2000

f z c" .P P 6 ‘g E : z z zl IL

2400

Engine speed (rpm) F614601082

*’-li44

95 SERIES


GENERAL

ENGINE

6D95L-1

PERFORMANCE

CURVE

(For D31E. P, PL, PLL, S, Q, AM, SM-20(A))

Flywheel

horsepower:

Maximum Minimum

70 HP/2,350

torque:

27 kgm/l,400

fuel consumption

ratio:

rpm rpm

160 g/HPh

25

20

5

60

50 K

11 5 n S 0

40

220

=

210

% 2 .P E

200

30

190 180 170

0

1000

1200

1400

1600

1800

2000

2200

2400

2600

6 'g E 2

160

5 ~

150

z

2800

Engine speed (rpm)

F614601102

95 SERIES O'-%f4-'


GENERAL

ENGINE

PERFORMANCE

CURVE

6D95L-1 (For D37A-2, D37P-2A) Flywheel

horsepower:

Maximum

80 HP/2,500

torque:

Minimum

rpm

27.5 kgm/l,400

fuel consumption

ratio:

rpm

160 g/HPh

40

IO

60 .

200 190 180 170 160 150 140 130

g ? p .P z L s 'g E 2 6 _" 2 u

0 1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

Engine speed (rpm) F614601083

O’-z4-*

95 SERIES


ENGINE

GENERAL

PERFORMANCE

CURVE

(For D37E. P-5(A))

6D95L-1 Flywheel Maximum Minimum

80 HP/2,500

horsepower:

rpm

27.5 kgm/l,400

torque: fuel consumption

ratio:

rpm

160 g/HPh

80

60

50 r E 5 %a

40

30

20

Fuel consumption ratio lO---------'

0

1000

1200

1400

1600

Engine

1800

speed

2000

2200

2400

2600

2800

@pm) F614601103

95 SERIES

Ol-$45


ENGINE PERFORMANCE CURVE

GENERAL

6D95L-1

(For PClOO-3,

Flywheel

PClOOL-3) 79 HP/2,100

horsepower:

t-pm

Maximumtorque:

30.5 kgm/l,400

Minimum

160 g/HPh

fuel consumption

I

I 0

ratio:

800

1000

1200

1400

rpm

1600

1800

2000

2200

2400

2600

Enginespeed (rpm) F614601041

O’-r

95 SERIES


ENGINE PERFORMANCE CURVE

GENERAL

6D95L-1

(For PC120-3)

Flywheel

85 HP/2,200 rpm

horsepower:

:

Maximum

toqrue

31.5 kgm/l,400

Minimum

fuel consumption

ratio:

rpm

160 g/HPh

80

60

220 210 200 .C E 180

I

I

Fuel consumotion

0

1000

1400

ratio

E 2

I

1800

2200

2600

SERIES O’


GENERAL

ENGINE

6D95L-1

(For

Flywheel

PERFORMANCE

CURVE

PW150-1)

horsepower:

Maximum

torque:

Minimum

fuel consumption

87 HP/2,400 32 kgm/l,600 ratio:

rpm rpm

160 g/HPh

80

60

z E z a S 0

50

40

30

20

10

0

1600 Engine

1800 speed

2000

2200

2400

2600

2800

(rpm) F614601043

O’-ii4*

95 SERIES


ENGINE

GENERAL

PERFORMANCE

CURVE

6D95L-1 (For WA1 00-1, WRI I-l) Flywheel

73HP/2,400

horsepower:

29kgm/l,600

Maximum

torque:

Minimum

fuel consumption

ratio:

rpm rpm

160 g/HPh

90

80

70

60

50

40

200

30

190 180

20

170 160

10

150

0

1000

1200

1400

1600

1800

2000

2200

2400

2600

Engine speed (rpm) F614601051

95 SERIES

01$49


GENERAL

ENGINE PERFORMANCE CURVE

6D95L-1 (For WAIOO-1, Flywheel Maximum Minimum

Engine No. 46799 and up)

horsepower:

84 HP/2,400

torque:

rpm

32 kgm/1,600

fuel consumption

ratio:

rpm

165 g/HPh

40

-

--

-

T%ue \

60

Lz F n .P F

20 \

-

6 ';a E : 5; " s

consumption ratio

10

O1400

1800

2200

2600

3

IO

Engine speed (rpm)

O’

95 SERIES


GENERAL

ENGINE PERFORMANCE CURVE

6D95L-1 (For WA1 20-I) Flywheel Maximum Minimum

horsepower:

85 HP/2,500

torque:

rpm

32.1 kgm/1,600

fuel consumption

ratio:

rpm

160 g/HPh

r35

\

\

- 30

\

I

25

80

60 /

u

50

30

/

20 Fuel

consumption ratio

10

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

Engine speed (rpm) F614601085

95 SERIES

01p


GENERAL

ENGINE

PERFORMANCE

CURVE

6D95L-1 (For GD313A-1) Flywheel Maximum Minimum

horsepower:

85 HP/Z,500

torque: fuel consumption

rpm

31.7 kgm/l,500 ratio:

rpm

165 g/HPh

40

0

FM

consumption ratio

1600

1800

2000

2200

2400

2600

190

.g

'80

5 ._ 'a

170

E 2

160

z

150

5 2

2800

Engine speed (rpm) F614601086

0 1-t&52

95 SERIES


GENERAL

ENGINE PERFORMANCE CURVE

6D95L-1 (For EG60-1, EG65-1) Flywheel Minimum

horsepower: fuel consumption

ratio:

65.1 HP/l,500

rpm (50 Hz)

74.9 HP/l,800

rpm (60 Hz)

165 g/HPh

100

80

60 ?i E 'j p.

60 Hz -* 50

2 40

30

220

z

210

: p

200

-;

190

.s 'L E 2

180 170 160

1100

1200

1300

1400

1500

1600

1700

1800

1900

z u L?

2000

Engine speed (rpm) F614601087

95 SERIES o'-$53


ENGINE PERFORMANCE CURVE

GENERAL

S6D95L-1

(For PC1 50-3, PC1 5OLG3)

Flywheel horsepower:

99 HP/2,200

Maximum

39.7 kgm/l,400

Minimum

torque: fuel consumption

ratio:

rpm rpm

160 g/HPh

30 -c 20

; s b k

IO

200

2 s

190

'5

180

.: 'L $

170 160 150 0

1000

1200

1400

1600

1800

2000

2200

2400

2 z I=

2600

Engine speed (rpm) F614601052-1

Ol-$54

95

SERIES


ENGINE PERFORMANCE CURVE

GENERAL

S6D95L-1 (For PC1 50-5) Flywheel Maximum Minimum

99 HP/2,000

horsepower:

rpm

40 kgm/l,400

torque: fuel consumption

ratio:

rpm

160 g/HPh

I

70 / I

50

40

/ /

30

200 - 190

20

180 10

-170

--

160 -150

O-

600

800

1000

1200

1400

1600

1800

2000

I 2200

2 % B .p z : .P z E zi 6 0 5 I=

2400

Engine speed (rpm) F614601088

95 SERIES

Ol-g55


ENGINE PERFORMANCE CURVE

GENERAL

S6D95L-1 (For PC200-5, BR200-1) Flywheel horsepower:

123 HP/2,050

Maximum

49.5 kgm/l,900

Minimum

z z S 0. 5

torque: fuel consumption

ratio:

rpm rpm

151 g/HPh

80

0

60

0

600

800

1000

1200

1400

1600

1800

2000

2200

2400

Engine speed Irpm) 6206F803A

O’-F

95 SERIES


GENERAL

S6D95L-1

ENGINE PERFORMANCE CURVE

(For PC200-6)

Flywheel horsepower: Maximum torque: Minimum fuel consumption

99 kW (133 HP)/2,200 rpm 490 Nm (50 kgm)/1,600 rpm ratio: 214 g/kWh (158 g/HPh)

30

z 2

140

5 P 20

z

E

E 5 p. 5

80

0

60

0

400

800

1200

1600

2000

2400

Engine speed (rpm) 6206FlOOl

95 SERIES

O’-v-’



ENGINE PERFORMANCE CURVE

GENERAL

S6D95L-1 Flywheel Maximum Minimum

(For PWI 00-3, Engine No. up to 36829) horsepower:

99 HP/l,900

rpm

42 kgm/l,400

torque: fuel consumption

ratio:

rpm

160 g/HPh

3

3

I

I

/

3

0

/

0

0

0

220

0

0

0

_

210

g

200

F 9 0

190

'E

180

6 'XT

170

r fj

160

:

150

3 LL

600

800

1000

1200

1400

1600

1800

2000

2200

2400

Engine speed (rPm) F614601089

95 SERIES 01-$57


GENERAL

S6D95L-1

ENGINE PERFORMANCE CURVE

(For PWI 00-3, Engine No. 36830 and up)

Flywheel

horsepower:

Maximum

torque:

Minimum

fuel consumption

108.5 HP/2,100 42 kgm/1,400 ratio:

rpm rpm

167 g/HPh

40

90

80

70 _

60

50

40

30

20

10

0 800

1000

1200

1400

1600

1800

2000

2200

2400

2600

Engine speed (rpm) F614601090

Ol-g58

95 SERIES


GENERAL

ENGINE

S6Dg5L-1

(For WA150-1,

Engine

CURVE

No. up to 47624)

Flywheel horsepower:

94 HP/2,400

Maximum

torque:

36 kgm/l,600

Minimum

fuel consumption

ratio:

PERFORMANCE

rpm rpm

160 g/HPh

60

190 180

B .P E

170

‘i

160

a 5 0

:

0

1000

1200

1400

1600 Engine

1800 speed

2000

2200

2400

2600

(rpm) F614601053

95 SERIES

01-$59


GENERAL

S6D95L-1

ENGINE PERFORMANCE CURVE

(For WA150-1,

Engine

Flywheel horsepower: Maximum torque: Minimum fuel consumption

800

1000

No. 47625 and up)

81 kW (108 HP)/2,400 rpm 392 Nm (40 kgm)/1,600 rpm ratio: 224 g/kWh (165 g/HPh)

1200

1400

1600

1800

2000

Engine speed Wxn)

O’-if0

2200

2400

2600

2800 6206F968

95 SERIES


ENGINE PERFORMANCE CURVE

GENERAL

S6D95L-1

(For WA180-1)

Flywheel Maximum Minimum

110 HP/2300

horsepower:

40.5 kgm/l,600

torque: fuel consumption

ratio:

rpm rpm

160 g/HPh

40

30 z 01 120

110

80

40 30

_

Z 180

20 170 10 160

Ob

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

%

9 .P E 6 ._ 'L E 2 6 0 z I=

2800

Engine speed (rpm) F614601091

95 SERIES

O’-FO-’


ENGINE

GENERAL

S6D95L-1 (For WA180-3) Flywheel horsepower: Maximum torque:

PERFORMANCE

CURVE

82.0 kW (110 HP)/2,400 rPm 417 Nm (42.5 kgmV1,600 rpm

-40

400

.30

300

a, 3 CT L

20

200

:

IO

100

I

I

0

a

3

z

Y

Lo

12080IOO-

80-

100

60-

60-

80

60 40-

40-

40 20-

20-

o-

20

o-

n ”

" 1000

1200

1600

1400

Ens

O’-%“-2 1

i ne

1600

speed

2000

(rpm)

2200

2400

2600 SDE00922

95 SERIES


GENERAL

ENGINE

S6D95L-1 (For WA250-31 Flywheel horsepower: Maximum torque:

PERFORMANCE

CURVE

97.0 kW (130 HP)/2,400 rpm 441 Nm (45.0 kgm)/1,600 rpm

E

9

E

50

-500

40

-400

IO

0

1200

1400

Ens

95 SERIES

1600

1600

i ne

speed

2000

(r pm)

2200

2400

100

/ 0

2600 SOE00923

O’-o&o-3 1



ENGINE PERFORMANCE CURVE

GENERAL

S6D95L-1

(For GD461A-1)

Flywheel

horsepower:

Maximum Minimum

113 HP/Z,500

torque:

42.8 kgm/l,500

fuel consumption

ratio:

rpm rpm

170 g/HPh

40

30

.20

\

120

110

/

-z rsr Y 2 P :

10

I

0

100

50

40 -

30 - 200 190

20

-180

A'

170

/

lo.-\ -

Fuel consumption ratio

-160

0 1200

1400

1600

1800

2000

2200

2400

2600

2800

2 % ?? .? E 5 'g E z 6 " % IL

3000

Engine speed (rpm) F614601092

95 SERIES

O’-hi?’


GENERAL

ENGINE PERFORMANCE CURVE

S6D95L-1 (For GD51 OR-l) Flywheel Maximum Minimum

horsepower: torque: fuel consumption

ratio:

125 HP/2,500

rpm

44 kgm/l,600

rpm

160 g/HPh

50

40

10

0

80

1000

1200

1400

1600

1800

2000

2200

2400

2600

170

5

160

; " z y'

2800

Engine speed @pm) F614601093

01-t&62

95 SERIES


GENERAL

S6D95L-1

ENGINE PERFORMANCE CURVE

(For GD51 IA, R-l, GD513A, R-l)

Flywheel Maximum Minimum

horsepower: torque: fuel consumption

ratio:

135 HP/2,900

rpm

44 kgm/l,600

rpm

160 g/HPh

50

40

30

$ Y

20

;

2

10 \

0

/

/

/

/

I

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

3200

Engine speed (rpm) F614601094

95 SERIES

01g43


ENGINE PERFORMANCE CURVE

GENERAL

S6D95L-1 (For LW80-1) Flywheel horsepower: Maximum torque: Minimum fuel consumption

110 kW (148 HPV3,OOO rpm 435 Nm (44.4 kgmV1,800 rpm ratio: 224 g/kWh (165 g/HPh)

160-7

140/

IZO-

I

I

.<

\ \

IOO-

\

\ \

40-

0

1000

is00

2000

2500

3000

3500

Engine speed @pm)

62OSF964

O’-if3-’

95 SERIES


GENERAL

ENGINE PERFORMANCE CURVE

S6D95L-1 (For EG85B, BS-1, DCA85, QAS85) Flywheel Minimum

horsepower: fuel consumption

ratio:

85.8 HP/l,500

rpm (50 Hz)

99.6 HP/l,800

rpm (60 Hz)

165 g/HPh

(at rated output)

90

I

80 -

70

,

60 Hz-m

50Hz--c

60

50

40

30

20

10

0

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

Engine speed (rPm) F614601095

95 SERIES

O’-Oi3-*


GENERAL

ENGINE PERFORMANCE CURVE

SA6D95L-1 (For PC220-5, BR300-I) Flywheel horsepower: Maximum torque: Minimum fuel consumption

114 kW (153 HP)/2,200 rpm 527 Nm (53.7 kgm)/1,500 rpm ratio: 202 g/kWh (149 g/HPh)

-

Torque

60

.

-I

20

J e g

60

Engine speed (rpm)

O’-if4

6206F804A

95 SERIES


ENGINE

GENERAL

SA6D95L-1

PERFORMANCE

CURVE

(For PCZZO-6)

Flywheel horsepower: Maximum torque: Minimum fuel consumption

0

400

118 kW (158 HP)/2,300 rpm 554 Nm (56.5 kgm)/1,600 rpm ratio: 214 g/kWh (158 g/HPh)

800

1600

1200 Engine

speed

2000

2400

(rPm) 6206F1002

95 SERIES

O’P


GENERAL

ENGINE

PERFORMANCE

CURVE

SAA6D95LE-1 [WING100 (LWIOO-1, LWIOOM-I)] Flywheel horsepower: 118 kW {I58 HPY3,OOO rpm (Net) Maximum torque: 457 Nm j46.6 kgmI/?,800 rpm (Net)

-

-

-

-

-

-

/

-

7 -

-

3 _:

-

-

/ -

-

-

-

-

-

-

-

-

-

I-2.

‘u/e \ t

i

-

-

-

-

-

-

-

-

-

-

-

:: 150

E

s

2

-

-

-

-50

500

-

.40

400

\-

.30

300

.20

200

-10

100

,O

0

-

-

a, zl : a c

/

-

-

-

IOC

I

7

-

/

100

-

-

-

-

-

d .i <

50 /

-

50

I

-

-

-

-

/

0

0

it-

500

1.500

Ens

O’-Oi5-’

-

-

-

1.000

i ne

2.500

2~000

speed

(r pm)

-

-

3.000 SWE01174

95 SERIES



WEIGHT TABLE

GENERAL

WEIGHT TABLE * There may be differences No

according

to the machine

model.

3D95 s-w-1

Main item

Item

4D95 s-w-1

-

1

Turbocharger

2

Cylinder

head assembly

Cylinder head, valve, valve sorino

3

Cylinder

block assembly

Cylinder block, main block, cylinder liner

4

Gear case (front cover)

5

Oil pan

bearing

22

28

66

70

3

3

3

1.6

2

2

3

2

-E 13

f

I 6

Flywheel

assembly

Flywheel,

27

ring gear

25

21

22

-

7

Flywheel

11

housing Rear plate:

25.5

20 8

Crankshaft

9

Camshaft

assembly assembly

10

Piston, connecting rod assembly

11

Oil pump

12

Fuel injection

13

Water

-

pump

-74 Alternator Ti - Starting motor -16

Air compressor

O’-F

pump

Crankshaft, Camshaft,

crankshaft

gear

cam gear, thrust plate

Piston, piston ring, piston connecting rod

pin,

21

25

3.2

5.5

2

2

0.5

0.5

4.2

9

5.2

6

These differ according (See STRUCTURE

-

-

40

11

11 5

-

c I

-

25

1

25

+-I-+

c 0.5

1

0.5

10

9

3.1

12 6

to the machine model. AND FUNCTION)

-

-

95 SERIES


GENERAL

WEIGHT TABLE

Unit: kg 4D95 L-l

S4D95 L-l

SA4D95 L-l

6D95 L-l

S6D95 L-l

SA6D95 L-l

Remarks

-

I

7

I

7

I

-

I

7T6

I

‘I”

I LW80-1

28

I

28

I

28

I

41

I

41

I

41

I

70

70

2.6

70

105

105

105

-

-

-

-

PCIOO,

2.6

2.6 2.6

D31, PC150, WA150, GD355, EG85, WAIOO, WA200, WRII

2.4 3

3 2

2

6

16

16 4.4 22 25

I

I

-

I

I

3

120,

PWIOO,

PC128UU

PWl50

6

6

-

-

19

WA40

-

9.1

9.1

PClOO, 120, PC128UU,

PC200-6,

PC220-6

PC60,

PC75,

PW60,

WA70

LW80-

1

-

I

-

-

I

25

WA70

PC80,

-

27

27

-

30

30

-

-

32

32

-

-

-

-

25

25

25

PC60, PC75, PC80, PW60, WA70, WA100,WA150,WR11, EC50, EC75, EG33, EG40,

11

-

WA80-

28

-

D20,D21,D31,PC100,PC120,PC128UU, PW15O.WA40

PCIOO,

-

27

-

11 -

25 28

25

25

1 F”;;Vl;J, D31

PCl28Uy

PC100

PC120

WAIOO, WA150,

-

-

-

-

25

25

36.5

36.5

36.5

5.5

5.5

5.5

7.5

7.5

7.5

2

2

2

2

2

2

0.5

0.5

0.5

0.5

0.5

0.5

IO

13.5

13.5

13

D31,

PC60,

10

D31,

PC60,

6

-

95 SERIES

6

-

6

-

6.5

-

WRII,

EG85 iv'000

PC200-6,

PC220-6

12

12

6.5

6

7.1

7.1

7.0

-

PWIOO, GD355, EG60, EG85

1

25.2

9

EGT

PC128UUbC150

1 WA40

25

10.5

EG60,

120,

LW80-1,

PC150,

PC128UU

PC80, PC80,

PW60, PC200-6,

WA70 PC220-6

PC220-6

O’F7



ENGINE II

GENERAL

STRUCTURE

STRUCTURE

AND FUNCTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-001-1

COOLING SYSTEM Cooling system chart

INTAKE

AND EXHAUST

SYSTEM

Intake and exhaust system FTG air cleaner Turbocharger

Water

. . . . . . . . . . . . . . . . . . . . . . 1 I-009-2

Corrosion

. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 11-016-I

. . . . . . . . . . . . . . . .._.............................

1 I-019-7

Starting

head

..............................................

1 I-020

...............................................

1 I-030

Cylinder

block ..............................................

1 I-036

Cylinder

liner ...............................................

1 I-040

Valve system

Main circulation Timing gear

..............................

1 I-093

...........................

1 I-094

housing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-096 motor

Electrical

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-097

intake air heater

.. . . . .. .. . . .. . . . . .. . . . .

1 T-099

ACCESSORY Air compressor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 l-101

1 I-042

.................................................

1 I-054

..................

1 I-058

. . . .. . . . . . .. . . .. . . . . .. . . .

1 I-059

SYSTEM

Lubrication Oil pump Oil filter

system

and flywheel

LUBRICATION

and fan drive

ELECTRICAL SYSTEM Alternator

Flywheel

II-092

resistor ........................................

Thermostat

BODY

Cylinder

II-089

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-019

After-cooler ENGINE

..................................

pump .................................................

system chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-063 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-063-I

Oil cooler

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-064

FUEL SYSTEM Fuel system chart ........................................ Fuel injection Governor

pump ................................

1 I-066 11-067-I

......................................................

1 I-080

Feed pump ...................................................

1 I-084

Fuel injection

nozzle ....................................

Fuel cut solenoid

......................................

Engine stop motor .................................... Fuel filter ................................................. Water

separator

95 SERIES

..........................................

1

II-086 1 I-087-2 1 I-087-5 11-087-I

0

II-088

’‘iO’


STRUCTURE AND FUNCTION

GENERAL STRUCTURE

GENERAL STRUCTURE *

3D95S-W-1 19

20.

There

21

may be differences

22

according

to the machine

model.

24

23

18 17 18

III

15

~28

14

6206F513A

1. Front seal

11. Oil ring

21. Valve

12. Second 13. Top ring

23. Rocker

arm spring

4. Crankshaft

gear

14. Piston

24. Rocker

arm bracket

5. Connecting

rod

15. Water

3. Crankshaft

ring

spring

pulley

2. Crankshaft

pump

22. Head cover

25. Cylinder

head block

6. Cam bushing

16. Intake valve

26. Cylinder

7. Cam gear

17. Exhaust

27. Push rod

8. Front cover

18. Thermostat

28. Flywheel

19. Fan

29. Tappet

9. Connecting 10. Piston

“%‘-’

pin

rod bushing

20. Valve

valve

guide

30. Main bearing

95 SERIES


STRUCTURE

GENERAL

AND FUNCTION

STRUCTURE

6206F514

31.

Engine

41. Oil filler cap

Rear seal

42.

32. Ring gear

Rocker

arm

33. Rear plate

43. Fuel injection

34. Thrust

44. Fuel filter

bearing

36. Connecting

rod cap

46. Starting

Model: Type:

3D95S-W-1 In-line, 3 cylinder,

water cooled,

swirl type combustion

45. Fuel injection

35. Camshaft

nozzle

.

pump

chamber,

4 cycle diesel engine

motor

47. Oil strainer

37. Oil pan 38. Oil filter 39. Oil level gauge 40. Exhaust

95 SERIES

manifold

’ 1-oP2


STRUCTURE

AND

FUNCTION

GENERAL

STRUCTURE

4D95L-1

20

21

22

23

24

25

13 12 11 10 9 8 7 6 5 4 3 2 1

BI

I’

I

6204FlOl

1. Crankshaft 2.

pulley

Front oil seal

11. Oil ring

21.

Valve guide

12. Second ring

22.

Valve spring Cylinder head cover

3. Crankshaft

13. Top ring

23.

4. Crankshaft gear

14.

24.

Rocker arm bracket

5. Connecting rod

15. Piston

25.

Rocker arm spring

6. Camshaft bushing

16. Water pump

26.

Cylinder head

7. Camshaft gear

17.

Intake valve

27.

Cylinder block

8.

18.

Exhaust valve

28.

Push rod

Front cover

9. Connecting rod bushing 10.

Piston pin

’ ’-go2

Fan pulley

19. Thermostat

29.

Flywheel housing

20.

30.

Flywheel

Fan

95 SERIES


STRUCTURE

AND

GENERAL

FUNCTION

STRUCTURE

6204F102A

31.

Ring gear

41.

Oil cooler

Engine:

32.

Tappet

42.

Exhaust manifold

Type:

33.

Main bearing

43.

Oil filler cap

water-cooled,

44.

Rocker arm

fuel injection, 4-cycle diesel engine.

34.

Rear oil seal

35.

Thrust bearing

45.

Fuel injection nozzle

36.

Oil pan

46.

Electrical intake air heater

37.

Camshaft

47.

Intake manifold

36.

Connecting rod cap

48.

Fuel injection pump

39.

Oil filter

49.

Starting motor

40.

Dipstick

50.

Oil strainer

95 SERIES

4D95L-1 In-line, 4cylinder, direct

’ ’-go3


STRUCTURE

AND

FUNCTION

GENERAL

STRUCTURE

4D95L-W-1 4D95S-W-1

3‘8

3’6

3’5

6204F103A

Oil ring

21.

Valve guide

2. Front oil seal

12. Second ring

22.

Valve spring

3. Crankshaft

13. Top ring

23.

Cylinder head cover Rocker arm bracket

1. Crankshaft

pulley

11.

i7

4. Crankshaft

gear

14. Water pump

24.

5. Connecting

rod

15.

Piston

25.

Rocker arm shaft

6. Camshaft bushing

16.

Fan pulley

26.

Cylinder head

7. Camshaft gear

17.

Intake valve

27.

Cylinder

8. Front cover

18.

Exhaust valve

28.

Push rod

19. Thermostat

29,

Flywheel

20.

30.

Flywheel

9. Connecting 10. Piston pin

11 -go4

rod bushing

Fan

block housing

95 SERIES


STRUCTURE

AND

FUNCTION

GENERAL

STRUCTURE

6204F104A

31.

Ring gear

41.

Oil cooler

32.

Tappet

42.

Exhaust manifold

33.

Main bearing

43.

Filler cap

34.

Rear oil seal

44.

Rocker arm

Engine:

4D95SW-1 Type:

In-line,

4qlinders,

combustion

35.

Turust bearing

45.

Glow plug

36.

Oil pan

46.

Fuel injection

37.

Camshaft

47.

Hot plug

38.

48.

Intake manifold

39.

Connecting rod cap Oil filter

49.

Fuel injection pump

40.

Dipstick

50.

Starting motor

51.

Oil strainer

95 SERIES

4D95L-W-1

nozzle

chamber

water

cooled,

(whirl

pre-

chamber)

type, 4-cycle diesel engine

l l -go5


STRUCTURE

AND

FUNCTION

GENERAL

STRUCTURE

6D95L-1

6206FlOl

1. Fan

11. Piston

2. Camshaft 3. Front

gear

cover

4. Connecting

rod bushing

12.

Intake

13.

Exhaust

valve valve

21.

Cylinder

22.

Push rod

block

23.

Flywheel

14. Valve guide

24.

Flywheel

housing

5. Piston pin

15. Thermostat

25.

Tappet

6. Oil ring

16. Valve spring

26.

Camshaft

7. Second ring

17. Cylinder

27.

Rear oil seal

8. Top ring

18.

Rocker

arm shaft

28.

Main bearing

9. Water pump

19.

Rocker

arm bracket

29.

Ring gear

20.

Cylinder

30.

Thrust

10.

Fan pulley

‘-’-kios

head cover

head

bushing

bearing

95 SERIES

A


STRUCTURE

AND

FUNCTION

GENERAL

STRUCTURE

47 43

48 49

42

50

6206F

31.

Camshaft

41.

Dipstick

Engine:

32.

Oil pan

42.

Oil cooler

Type:

33.

Connecting

rod

43.

Exhaust

34.

Connecting

rod cap

44.

Filler cap

35.

Crankshaft

45.

Rocker

36.

Crankshaft

46.

Fuel injection

37.

Front

47.

Electrical

gear

oil seal

38.

Crankshaft

39.

Vibration

40.

Oil filter

manifold

6D95L-1 In-line,

6qlinders,

fuel injection,

4-cycle

water-cooled,

direct

diesel engine.

arm nozzle

intake air heater

pulley

48.

intake

damper

49.

Fuel injection

50.

Starting

51.

Oil strainer

95 SERIES

IO2

manifold pump

motor

11-go7


STRUCTURE

AND

FUNCTION

GENERAL

STRUCTURE

S6D95L-1

*.

6207FlOlA

_I

1. Thermostat

11. Cylinder head cover

21.

Main bearing cap

2. Valve spring

12. Cylinder head

22.

Main bearing cap bolt

3.

Valve guide

13. Tappet

23.

Crankshaft

4.

Intake valve

14.

Flywheel housing

24.

Front oil seal Crankshaft

gear

5. Piston

15.

Ring gear

25.

6.

16.

Flywheel

26.

Connecting rod cap

17. Camshaft

27.

Connecting rod bearing

8. Top ring

18.

Rear seal

28.

Crankshaft

9. Second ring

19.

Main bearing

29.

Vibration

20.

Thrust bearing

30.

Camshaft gear

Exhaust valve

7. Valve seat insert

IO.

Oil ring

’’-go*

pulley damper

95 SERIES


STRUCTURE

AND

GENERAL

FUNCTION

STRUCTURE

42

6207

F102A

Connecting rod

41.

Fuel injection nozzle

Engine:

32.

Piston pin

42.

Electrical intake air heater

Type:

33.

Water pump

43.

Intake manifold

water-cooled,

34.

Cylinder block

44.

Fuel injection pump

fuel injection, 4-cycle

35.

Fan pulley

45.

Starting motor

diesel engine with

46.

Oil strainer

turbocharger.

31.

36.

Fan

37.

Turbocharger

47.

Oil filter

38.

Oil filler cap

48.

Dipstick

39.

Rocker arm

49.

Oil cooler

40.

Intake connector

50.

Exhaust manifold

95 SERIES

pipe

S6D95L-1 In-line, 6cylinder, direct

’’-go9



STRUCTURE AND FUNCTION

INTAKE AND EXHAUST SYSTEM

INTAKE AND EXHAUST SYSTEM INTAKE AND EXHAUST SYSTEM 3D95S-W-1

*

(EC352,ZS-2)

There may be differences

according

to the machine

model.

INTAKE SYSTEM :

1.

Air cleaner

2.

Hose

3.

Intake manifold

A.

Intake port

6206F515

EXHAUST SYSTEM

1.

Exhaust manifold

2.

Muffler

3.

Pipe

B.

Exhaust port

6206F516

95 SERIES

’ ’-OF2


STRUCTURE AND FUNCTION

4D95L-W-

INTAKE AND EXHAUST SYSTEM

1 (WA40-1)

rl 6204Flll

1. 2. 3. 4. 5. 6. 7. 8.

Intake manifold Air cleaner cap Air cleaner element Air cleaner body Air hose Muffler Exhaust pipe Exhaust manifold

“iF”

95 SERIES


STRUCTURE AND FUNCTION

INTAKE AND EXHAUST SYSTEM

4

III

/---’

-T

J /6

6204F112

A. Air intake B. Exhaust outlet

95 SERIES

’’%’’


INTAKE AND EXHAUST SYSTEM

STRUCTURE AND FUNCTION

4D95L-1

(PC60-3)

Ir

There may be differences to the machine model.

according

6204F107

1. 2. 3. 4. 5. 6. 7. 8. 9.

Intake manifold Air connector Electrical intake air heater Intake pipe Air cleaner element Air cleaner element Muffler Exhaust pipe Exhaust manifold

‘Y2

95 SERIES


INTAKE AND EXHAUST SYSTEM

STRUCTURE AND FUNCTION

n

6204F108

A. Air intake B.

Exhaust

95 SERIES

outlet

‘T3


STRUCTURE AND FUNCTION

4D95L-1

(PC1 00-6, PC120-6,

INTAKE AND EXHAUST SYSTEM

PC128UU-1)

(Intake equipment)

d---t-!&#-+;

-ii----H--wi

I

j

!

SME00223

1. 2. 3. 4.

Air connector Electrical intake air heater Engine breather pipe Intake manifold

“i’4

A: Air supply inlet

95 SERIES


STRUCTURE AND FUNCTION

S4D95L-1

(PCIOO-6,

PC120-6,

INTAKE AND EXHAUST SYSTEM

PC128UU-1)

(Exhaust equipment)

1. Muffler Exhaust pipe Exhaust pipe (turbocharger Turbocharger Exhaust manifold

2. 3. 4. 5.

95 SERIES

SME00224

- muffler)

“-:‘5


STRUCTURE AND FUNCTION

6D95L-1

(PCIOO-3,

INTAKE AND EXHAUST SYSTEM

PC120-3)

6206F103

1. Inner element

2. Outer element 3. 4. 5. 6. 7. 8. 9. 10.

11. Connector pipe 12. Exhaust manifold

Air cleaner body Air hose Connector Electrical intake air heater Intake manifold Vacuator valve Exhaust pipe Muffler

“%Y

95 SERIES


STRUCTURE

AND

FUNCTION

INTAKE

AND EXHAUST

SYSTEM

6206F104

A. B. a.

Air intake Exhaust outlet Dust indicator pickup port

95 SERIES

“-~5-2


STRUCTURE AND FUNCTION

INTAKE AND EXHAUST SYSTEM

S6D95L-1 (PC150-3)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Muffler Intake manifold Electrical intake air heater Air cleaner body Outer element Inner element Air cleaner cap Turbocharger Exhaust pipe Exhaust manifold

’’‘k’5-3

6207F108

95 SERIES


STRUCTURE AND FUNCTION

INTAKE AND EXHAUST SYSTEM

8 \

A. Air intake B. Exhaust outlet

95 SERIES

6207F109

“-v4


STRUCTURE AND FUNCTION

S6D95L-1

INTAKE AND EXHAUST SYSTEM

(PC200-6)

(Intake equipment)

\

,/

“A., \

,’ ---__----

5

/’

/

ME00225

1. 2. 3.

4.

Intake manifold Electrical intake air heater Air connector Engine breather (separately

’’-: 5-5

A: Air supply inlet

located breather)

95 SERIES


STRUCTURE AND FUNCTION

INTAKE AND EXHAUST SYSTEM

SA6D95L-1 (PC220-6) (Intake equipment)

B

A

ME00226

1. 2. 3. 4.

Engine breather (separately Air connector Electrical intake air heater Intake manifold

95 SERIES

located breather)

A. To aftercooler B. To intake manifold

’’3 5-6


STRUCTURE AND FUNCTION

INTAKE AND EXHAUST SYSTEM

S6D95L-1 (PC200-6) SA6D95L-1 (PC220-6) (Exhaust equipment)

ME00227

1. 2. 3. 4. 5.

Exhaust pipe Muffler Exhaust pipe (turbocharger Turbocharger Exhaust manifold

’’-K’ 5-7

- muffler)

95 SERIES



STRUCTURE

AIR

AND

FUNCTION

INTAKE

AND

EXHAUST

SYSTEM

CLEANER 1.

Air cleaner body

2.

Fin

3.

Outer element

4.

Inner element

5.

Evacuator valve

6.

Dust cap

A.

To engine

F614601001

Structure and function . The air cleaner is a centrifugal cyclone

tube)

EVACUATOR

VALVE

type (with a built-in

which also uses filter

paper. The air

cleaner contains guide fins to whirl

the intake air

and allow the separated coarse dust to accumulate in the dust cap. The accumulated

dust is drained out

of the air cleaner by means of a evacuator valve.

F614601002

Structure

and function

.

evacuator

The

rubber

valve

is an automatic

valve. The valve outlet

dust drain

port is kept closed

under negative pressure. When the engine stops, the outlet port opens, discharging the dust.

11-p

95 SERIES


STRUCTURE AND FUNCTION

INTAKE AND EXHAUST SYSTEM

FTG AIR CLEANER

FHG type

FTG type

Guide vane (sleeve)

6

5

4

6137FOO9-10

Features

*

Structure

The element diameter

has the same diameter

of the body is smaller.

[The inlet is in the direction guide vane is not needed;

*

but the outside

of the connection, ample centrifugal

so a force

*

Air containing

dust is sucked into the tangential through inlet (I), and the dust is separated out by the centrifugal separating effect of vane (3). With the addition of primary element

(4), more than 99.9% of

can be obtained

the dust is removed,

is simpler.

passes through safety element is sucked into the engine.

with a simple spiral guide vane.] There is no dust pan or guide vane, so the structure

so the air is clean before

it

(5) and outlet (2) and

The dust and water separated

out by vane (3) circuthe inside wall of the body, and flies into valve (6), from where it is automatically

latesaround vacuator

discharged

95 SERIES

to the outside.

’ ‘-P-l



STRUCTURE

DUST

AND

INTAKE

FUNCTION

AND

EXHAUST

SYSTEM

INDICATOR

F614601003

Structure

Action

and function

The dust indicator connector between

is installed to the side of the air

and connected the

air

cleaner

.

the

engine.

It

the dust indicator

signal is indicated),

of the air intake passage and

required after the dust indicator actuates

When

elements

is

actuated under the negative air intake pressure.

notch

If the air cleaner is clogged with dust, the negative

condition.

air pressure in the air intake compressing

passage will increase,

a spring in the dust indicator

which

and depress the top button

and

restore

the

If the engine is operated replacing

(when

the

the

red

elements,

indicator

to release the to

again without the

dust

its

original

cleaning or

indicator

will

actuate again.

will, in turn, actuate the indicator. If the dust indicator

*

actuated

clean or replace the air cleaner

is once actuated

(indicating

a

red signal), the notch will be applied, enabling us to confirm when

the the

increased

negative

resistance

even

air pressure is eliminated

air intake

(for

example, when the engine stops.) Dust indicator

actuating pressure: 635 mm Hz 0 or more

95 SERIES

1317


STRUCTURE

AND

FUNCTION

INTAKE

AND

EXHAUST

SYSTEM

MUFFLER

A.

From engine

F614601004

Structure

.

and function

The main purpose of this muffler exhaust

noise. The muffler

exhaust temperature The

heat

and

is to muffler

the

also helps to lower the

by expanding the exhaust air.

noise energy of the exhaust

gases

which enter through the inlet port are reduced while the gases pass through

the large and small holes in

the muffler. Many factors have been taken into consideration order to obtain and muffler

performance,

performance of the muffler

11-X$8

a good match

between

in

the engine

to ensure that the engine

is not adversely affected

by the action

and the exhaust resistance.

95 SERIES


STRUCTURE

AND

FUNCTION

INTAKE

AND

EXHAUST

SYSTEM

TURBOCHARGER T-31

D

10

11

12

i5 6207FllOA

1. Piston ring

A.

Ambient

2.

Back plate

B.

Compressed air outlet

3. Thrust bearing

C.

Exhaust gas inlet

4. Seal ring

D.

Exhaust gas outlet

5.

E.

Lubricating oil inlet

F.

Lubricating oil outlet

Retainer

6. Center housing 7. Journal bearing 8. Piston ring 9. Shroud 10.

Lock nut

11.

Blower impeller

12.

Blower housing

13.

Turbine housing

14. Turbine impeller 15. Thrust collar

95 SERIES

air inlet

TURBOCHARGER Type: Overall length: Overall width: Overall height: Weight: Continuous rotating speed: Max. air supply: Compression ratio: Applicable exhaust temp.: Direction of rotation:

GARRETT CO. T-31 211 mm 189 mm 159 mm 7 k9 150,000 rpm 15.6 kg/min. 2.8 Max. 700°C Clockwise (see from blower side)

(Wheel shaft)

’l-F9


STRUCTURE AND FUNCTION

T31 (with

waste

INTAKE AND EXHAUST SYSTEM

gate) (LW80-1,

1

2

LW80M-1)

3

4

56

7

8

9

6207FllOA-1

1. 2. 3. 4. 5. 6. 7. 8. 9. IO. 11. 12. 13. 14.

Piston ring Back plate Thrust bearing Seal ring Retainer Center housing Journal bearing Piston ring Shroud Lock nut Blower impeller Blower housing Turbine housing Turbine impeller (Wheel shaft)

“-;9-’

A. B. C. D. E. F.

Ambient air inlet Compressed air outlet Exhaust gas inlet Exhaust gas outlet Lubricating oil inlet Lubricating oil outlet

TURBOCHARGER Type: Overall length: Overall width: Overall height: Weight: Direction of rotation:

GARRETT CO. T-31 220 mm 200 mm 179 mm 7.6 kg Clockwise (see from blower side)

95 SERIES


STRUCTURE

AND

FUNCTION

INTAKE

Fl\

AND

EXHAUST

SYSTEM

l-2 6 6206F965

15. 16. 17. 18. 19. 20. 21. 22.

Retaining ring Elbow housing assembly Nut, rod end Rod Actuator assembly (swing Hose Rod end Arm and valve assembly

95 SERIES

Actuator set pressure 865 f 25 mmHg (at 0.38 mm lift)

valve controller)

’’-%i 9-2 1


STRUCTURE AND FUNCTION

INTAKE AND EXHAUST SYSTEM

Outline of waste gate valve This restricts any unnecessary turbocharged pressure from the compressor and maintains a suitable turbocharged pressure (set turbocharged pressure) in order to prevent any excessive load on the engine. To achieve this, waste gate valve (I) is installed in the exhaust passage before the turbine. If turbocharged pressure (A) near the compressor output port becomes high and exceeds the set pressure of the actuator (swing valve control) (2), waste gate valve (swing valve) (I) opens. The waste gate valve starts to open at point c where the lines from engine speed a and turbocharged pressure b cross.

From exhaust arged

6206F966

t

I

X:

Before actuator is actuated

Y:

Actuator actuated

Engine speed 6206F967

.

The pressure (A) near the outlet port of the compressor passes through (B), and acts on actuator (2). Waste gate valve (I) opens, and part of the exhaust gas is bypassed and does not go through the turbine, so the pressure in the turbine drops and the set turbocharged pressure is maintained.

High turbocharged

6206F968

’’-!a’ 9-3

95 SERIES


INTAKE AND EXHAUST

STRUCTURE AND FUNCTION

TURBOCHARGER

Turbocharger

SAFETY

SYSTEM

VALVE

1

safety valve

2

1

3 4 5 6

6206F969

1. Cover 2. Shaft 3. Guide bushing 4. Spring 5. Valve 6. Nut 7. Valve seat 8. Spring seat 9. Casing 10. Retainer

6206F970

Actuating pressure 105 f 7 kPA (785 k 50 mmHg)

Outline . In the same way as with the waste gate valve, there is a safety valve installed in the intake manifold system to release any excessive turbocharged pressure (excess boost pressure) from the compressor.

95 SERIES

“-z9-4


STRUCTURE

AND

FUNCTION

INTAKE

AND

EXHAUST

SYSTEM

T04B

14FO36

1. Locknut

12. Turbine housing

2. Blower housing

13. Piston ring

3.

4. Thrust collar

14. Turbine impeller (Wheel shaft)

Blower impeller

5. Back plate

A.

Air inlet

6. Thrust bearing

B.

Air outlet

7. Seal ring

C.

Gas inlet

8. Center housing

D.

Gas outlet

9. Retaining ring

E.

Oil inlet

10. Journal bearing

F.

Oil outlet

11. Shroud

’’-i’9-5

TURBOCHARGER Type: Overall length: Overall width: Overall height: Weight: Continuous rotating speed: Max. air supply: Compression ratio: Applicable exhaust temp.: Direction of rotation:

GARRETT CO. T04B 225 mm 210 mm 180 mm 6.5 kg 125,000 rpm 22 kg/min. 3.0 Max. 675°C Clockwise (see from blower side)

95 SERIES


INTAKE AND EXHAUST SYSTEM

STRUCTURE AND FUNCTION

SCHWITZER

S2D

,lO

.ll

6206F953

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

O-ring O-ring Snap ring Oil deflector Thrust bearing Thrust collar (spacer sleeve) Center housing Shroud (back plate) Turbine housing Piston ring Turbine impeller (wheel shaft) Clip Clamp Journal bearing

95 SERIES

15. 16. 17. 18. 19. 20. 21. 22.

Thrust ring Blower housing Locknut Blower impeller Thrower sleeve Piston ring Insert Snap ring

A. B.

Oil inlet port (from engine main gallery) Oil outlet port (to oil

C. D. E. F.

pan) Intake port Air supply outlet port Exhaust inlet port Exhaust outlet port

Turbocharger Schwitzer S2D Type: Overall length: 212 mm Overall width: 170 mm Overall height: 168 mm Weight: 7 kg Direction of rotation: Clockwise (as seen from blower)

“-t9-6


INTAKE AND EXHAUST SYSTEM

STRUCTURE AND FUNCTION

AFTER-COOLER (Air-cooled type) SA6D95L-1

-A

-B

Section X - X 6206F517-1

1.

Tank

A:

From turbocharger

2.

Side support

B:

To intake manifold

3.

Tube

4.

Fin

’’-“A9-7

95 SERIES


STRUCTURE

AND

INTAKE

FUNCTION

AND

EXHAUST

SYSTEM

AFTER-COOLER (Water cooled type) SA6D95L-1

6206F517

1.

Cover

A:

2.

Case

B: To intake

3.

After-cooler

95 SERIES

From turbocharger manifold

core

’’-OA9-*


ENGINE BODY

STRUCTURE AND FUNCTION

ENGINE BODY CYLINDER HEAD

*

There

may be differences

according

to the machine

model.

3D95S-W-1

6206F5

1. Glow wire

7. Valve

2. Head bolt

8. Breather

3. Cylinder

’ ’-ih20

head

9. Glow

seat insert pipe

plug

4. Head cover

10. Nozzle holder

5. Oil filler cap

11. Nozzle

6. Valve

12. Plug

guide

18

95 SERIES


STRUCTURE

AND FUNCTION

ENGINE

BODY

View Z

6206F519

Section A-A

Cylinder

* . . . *

head

For swirl chamber Unitized

structure

2 valves

(1 cylinder)

Injection

nozzle:

Installed

to outside

Glow

95 SERIES

Valve type

.

seat

Exhaust

side:

Seat insert

press fitted

Head cover

-

Float mount

type

of head cover

plug installed

’ ’-oio-1


STRUCTURE

ENGINE

AND FUNCTION

BODY

4D95S-1

6202FOO2

1. Cylinder

8. Bracket

head

9. Nozzle holder

2. Head cover

10. Seat gasket

3. Oil filler cap 4. Valve

11. Glow plug

guide

5. Head bolt (Tightening turning

angle)

by plastic

range a:

Blow-by

suction

port

(to intake)

6. Lead plate 7. Breather

’ ’-“io-2

pipe

95 SERIES


STRUCTURE AND FUNCTION

ENGINE BODY

a \-

View

Z

Section B - B Section A -A

6206F106

Head cover

Cylinder head

* *

Direct fuel injection Unitized

type

2 valves

(1 cylinder)

Injection

nozzle:

Assembled Mount:

.

Glow

95 SERIES

outside

Dry type

-

type

Float mount

type

head cover (without

sleeve)

plug installed

’ ’-“;o-3


STRUCTURE

4D95L-1 S4D95L-1

AND

FUNCTION

(Except

ENGINE

PClOO-6, PC120-6,

I

PC128UU-1)

I

t-l

1.

Cylinder head

6. Valve seat insert

2.

Cylinder head cover

7. Blow-by suction pipe (4D95L-1)

3.

Oil filler cap

8. Nozzle holder mounting bracket

4.

Valve guide

9. Nozzle holder

5.

Cylinder head mounting bolt

10. Seat gasket a. Air vent hole

’ ’-“zo-4

95 SERIES

BODY


STRUCTURE AND FUNCTION

ENGINE BODY

Section A -A

6207F112

Cylinder

. * . -

head

For swirl chamber Unitized

structure

2 valves

(1 cylinder)

Injection

nozzle:

Installed

to outside

95 SERIES

type

Valve seat . Exhaust side: Seat insert press fitted (S4D95L-1) . Intake side: Seat insert press fitted (S4D95L-I) Head cover

of head cover

.

Float mount

type

’’-“iio-5


STRUCTURE AND FUNCTION

S4D95L-1

(For PCIOO-6, PCIZO-6,

ENGINE BODY

PC128UU-1)

AME

1.

Cylinder head

6. Valve seat insert

2.

Cylinder head cover

7.

Nozzle holder mounting bracket

3.

Oil filler cap

8.

Nozzle holder

4.

Valve guide

9. Seat gasket

5.

Cylinder head mounting bolt a. Air vent hole

’’-k20-6

95 SERIES


STRUCTURE AND FUNCTION

ENGINE BODY

Y

A-A

SME00229

Cylinder

. . .

head

For swirl chamber

type

Unitized structure

Valve seat . Exhaust side: Seat insert press fitted .

Intake side: Seat insert press fitted

2 valves (1 cylinder) Injection nozzle:

Head cover

Installed to outside of head cover

.

95 SERIES

Float mount type

’’-“;o-7



STRUCTURE

AND

ENGINE

FUNCTION

BODY

View 2

8

Section A - A 6204F114

CYLINDER

. . . .

HEAD

Direct fuel injection type One-piece type

VALVE

. .

SEAT

INSERT

Press-fitted insert for exhaust (4D95L-I) Press-fitted insert for intake (S4D95L-1)

2-valve for one cylinder injection

nozzle assembled in cylinder head

CYLINDER

.

95 SERIES

HEAD

COVER

Floating type seal

’ ‘S2’


STRUCTURE

AND

FUNCTION

ENGINE

4D95L-W-1 4D95SW-1

u

I /

3

6

7

’ ’-:**

1.

Cylinder

head

7. Valve seat insert

2.

Cylinder

head cover

8. Blow-by

3.

Cylinder

head mounting

bolt

suction

9. Fuel injection

4.

Filler cap

IO.

5.

Valve guide

1 1. Nozzle holder

6.

Glow plug lead

12. Hot plug

pipe

nozzle

Glow plug

95 SERIES

BODY


STRUCTURE

AND

FUNCTION

,ENGINE

BODY

View 2

Section A - A

CYLINDER

. . . . .

6204F115

HEAD

Precombustion One-piece

VALVE chamber

(whirl

chamber)

type

SEAT

Press-fitted

INSERT insert for exhaust

type

2-valve for one cylinder Injection

.

nozzle mounted

on cylinder

head

CYLINDER

HEAD

.

type seal

Floating

COVER

With glow plug

95 SERIES

l l -g23


ENGINE BODY

STRUCTURE AND FUNCTION

6D95L-1

6206F991

1. Cylinder

head

2. Cylinder

head cover

3.

Filler cap

4. Valve guide 5.

“z24

Valve seat insert

6. 7. 8. 9.

Cylinder head mounting Bracket Nozzle holder Seat gasket

a.

Blow-by

suction

bolt

pipe

95 SERIES


STRUCTURE

AND

FUNCTION

ENGINE

BODY

8

I Section A-A

6206F

CYLINDER HEAD . Direct fuel injection type

. . .

One-piece type

VALVE

.

IO5

SEAT

INSERT

Press-fitted insert for exhaust

a-valve for one cylinder Injection

nozzle assembled

in cylinder head

95 SERIES

CYLINDER HEAD COVER . Floating type seal

11-825


STRUCTURE

(Without

AND

glow

ENGINE

FUNCTION

plug)

S6D95L-1 SA6D95L-1

4

5

6

1.

Cylinder

head

6.

2.

Cylinder

head cover

7.

Bracket

3.

Oil filler

cap

8.

Nozzle holder

4.

Valve guide

9.

Seat gasket

5.

Cylinder

1’i26

head mounting

Valve seat insert

bolt

95 SERIES

BODY


STRUCTURE

AND

ENGINE

FUNCTION

BODY

-8

Section A - A

6207F112

Cylinder head . For swirl chamber type . Unitized structure . 2 valves (1 cylinder) . Injection nozzle: Installed to outside of head cover

95 SERIES

Valve seat . Exhaust

side: Seat insert press fitted

Head cover . Float mount type

’’-:27


ENGINE BODY

STRUCTURE AND FUNCTION

S6D95L-1

(With

glow

plug)

6206F994

1. 2. 3. 4. 5. 6.

Cylinder head Cylinder head cover Filler cap Valve guide Cylinder head bolt Lead plate

’’-F7-’

7. 8. 9. IO. 11.

Valve seat insert Bracket Nozzle holder Seat gasket Glow plug

(Intake,

exhaust)

95 SERIES


ENGINE BODY

STRUCTURE AND FUNCTION

View Z 6206F995

Section B-B

Section A-A

6206F105

Cylinder

. . *

Valve seat

head

For swirl chamber

type

Unitized structure

Exhaust side: Seat insert press fitted Intake side: Seat insert press fitted

2 valves (1 cylinder) Injection

nozzle:

Installed to outside of head cover

.

. .

Head cover

.

Float mount type

Glow plug installed

95 SERIES

’’-“i7-2


STRUCTURE

AND

ENGINE

FUNCTION

COMBUSTION

CHAMBER

PRECOMBUSTION

(WHIRL)

ON CYLINDER

CHAMBER

TYPE

3D95S-W-1

BODY

HEAD DIRECT

FUEL tNJECTlON

TYPE

4D95L-1 S4D95L-1 6D95L-1 S6D95L-1 SA6D95L-1

4D95L-W-1 4D95S-W-1

F614601005 F614601048

Structure and function

Structure and function

.

Fuel injected

into the precombustion

the

hea‘d to allow

cylinder

chamber

on

20 to 30 percent

of

injected fuel to burn in the precombustion The

resulting

combustion

to

Features . No smoky exhaust is produced. Since no rise in fuel injection

Fuel is directly

injected into each cylinder

through

injection nozzle and burned inside the cylinder.

chamber.

pressure contributes

spurt of remaining fuel into cylinder.

.

.

Features

. . .

Good fuel consumption Excellent startability

ratio

of the engine

Simple structure

pressure is required,

piston top profile is made simple.

11 -t&28

95 SERIES



STRUCTURE

AND FUNCTION

ENGINE

VALVE SYSTEM 3D95S-W-1

6206F527

1. Cam gear (No. of teeth: 2. Thrust

plate

10. Valve

cotter

11. Valve

seat

3. Camshaft

12. Rocker

arm spring

4. Tappet

13. Rocker

arm bracket

14. Rocker

arm shaft

5. Push rod 6. Exhaust

valve

7. Intake valve

’ ’-g30

48)

15. Adjustment

screw

16. Locknut

8. Valve

spring

17. Rocker

9. Valve

guide

18. Valve

arm seal (intake

side)

95 SERIES

BODY


ENGINE BODY

STRUCTURE AND FUNCTION

VALVE TIMING

Top dead center

18

Bottom dead center

Exhaust valve cam

Intake valve cam

6206F528A

.

The

valve timing

indicating intake

Valve lift

-

Intake valve: Exhaust valve:

when the

and exhaust

valves are

opened 10.6 mm

rotary

10.6 mm

in

is given by

the time and

closed

motion

terms

by

the

of the camshaft

of

the

crankshaft

angle (piston.positi0r-r).

.

In the 4-cycle valve timing, the intake

valve

near the stroke.

At

Center), marks

begins

end of TDC where

of

the

to

open

the exhaust (Top the

intake

Ded arrow

and ex-

haust valves overlap each other, both valves open. This is called “valve overlap�.

95 SERIES

11-0~0-1


STRUCTURE

AND

FUNCTION

ENGINE

4D95S-1 4D95L-1 S4D95 L-l 4D95L-W-1 4D95SW-1

1. Valve cotter

10. Cam gear (No. of teeth: 48) (No. of teeth: 52, 4D95S-1)

2. Valve seal (exhaust side) (intake side, without turbocharger only)

11. Spring seat

3. Valve spring

13.

Rocker arm bracket

4.

14.

Rocker arm shaft

5. Exhaust valve

15.

Adjustment

6. .Push rod

16.

Locknut

7. Tappet

17.

Rocker arm

Intake valve

12.

Rocker arm spring

screw

8. Camshaft 9. Thrust plate

’’-k30-2

95 SERIES

BODY


STRUCTURE AND FUNCTION

ENGlNE BODY

VALVE TIMING 4D95L-W-1,4D95S-W-1,4D95L-? Top dead

center

?i? Exhaust close

Bottom dead center

6204F122

4D95S-1 S4D95L-1

Top dead center

-

: open

Bottom dead center

6204F

6206Fl14A

I2 I

Valve lift

-

Intake valve:

-

Exhaust valve:

10.6 mm 9.6 mm (4D95S-1,

S4D95L-1,

SA4D95L-1)

10.6 mm

Camshaft

-

Induction

hardening

95 SERIES

for cam and journal

portion.

“it3’


STRUCTURE AND FUNCTION

6D95L-1,

S6D95L-1,

ENGINE BODY

SA6D95L-1

6206F852

1. 2. 3. 4. 5. 6. 7. 8.

Spring seat Valve spring Intake valve Exhaust valve Push rod Tappet Camshaft Thrust plate

“z3*

9. Cam gear (No. of teeth: 48) 10. Valve cotter 11. Valve seal (exhaust side) (intake side, without turbocharger only) 12. Rocker arm spring 13. Rocker arm bracket 14. Rocker arm shaft

15. 16. 17. 18. 19. 20. 21. 22.

Adjustment screw Locknut Rocker arm Housing Roller bearing Key Plate Bearing

95 SERIES


STRUCTURE AND FUNCTION

ENGINE BODY

VALVE

TIMING Top open

center 12’

close

lift

* *

Intake valve:

9.6 mm

Exhaust valve:

10.6 mm

Camshaft

-

Cam gear bolt tightening

type

hardening cam

6206Fl13A

Cam gear shrink-fit

journal

and bolt tightening

type

19 18 9 Detail

(D31A,

PL,

D37A,

22,

2b

i 6206F898

Cross tip camshaft

SERIES

diagram

“-ii33


ENGINE BODY

STRUCTURE AND FUNCTION

TAPPET AND PUSH ROD

CAMSHAFT

F614601007

6

%

F614601006

1.

Valve

4.

Push rod

1.

Camshaft

2.

Valve spring

5.

Tappet

2.

Camshaft

3.

Rocker

6.

Camshaft

arm

Structure

and function

.

camshaft

The shaft,

Structure

has a camshaft

and camshaft

bearing

gear to

journals

open and close the intake and exhaust

.

The camshaft meshes with

gear is forced

onto

the crankshaft

drive

the

valves.

the camshaft

gear through

The

and exhaust the entire tion-and

.

serves to open

and

the idler

time throughout

cycle of the intake-compression-combusexhaust

The camshaft

strokes.

the intake

and exhaust

for every two revolutions

Intake

c.

Exhaust

journal

cam

and push rods, together

cam

with the camshafts,

arms, and valves, are component

The tappet

serves to c,onvert

the camshaft

.

push

from

the tappet

rod

The tappets lowered

by

the rotary

into linear vertical

The

equivalent

speed is set to l/2

speed by the gear tooth

1 l-$34

.

and close the intake

valves at the optimum

Camshaft

b.

parts of the

valve system.

. camshaft

a.

and function

Tappets rocker

and cams to

gear.

.

.

gear

transmits

motion

the

liner

to the rocker

arm.

vertical

motion

and push rods are raised by cams and valve

springs.

to the amounts

These

movements

of lift of the cam.

of the crankshaft

ratio (24/48).

of

motion.

Consequently,

valves open and close once of the crankshaft.

95 SERIES

are


STRUCTURE

VALVE

AND

FUNCTION

GUIDE

AND

ENGINE

VALVE

SEAT

INSERT

VALVE

SPRING

F614601008

F614601009

1.

Valve guide

1.

Rocker arm

4.

Valve

2.

Valve

2.

Spring seat

5.

Valve guide

3.

Valve seat insert

3.

Valve spring

Structure VALVE

.

and function

Structure

.

GUIDE

and function

A valve spring serves to raise a valve to achieve snug

A valve guide slides against the valve stem which

contact

moves up and down.

when the valve is closed. In addition,

lubricity

between

the same time, accurately

with

For this reason, there must be

the valve guide and stem, but at there

against the exhaust.

must

be sufficient

Thus,

between

quickly

tightness

return

the valve seat face and the valve any

rocker

tappets which are actuated

the guide is machined

original

valves and is made of high wear-

positions

arms,

the spring can push rods, and

by the camshaft to their

without

separating

them

from

each other.

.

resistant material.

.

BODY

When

they

are actuated,

When the sliding surface of the valve guide has worn

“jump”

out, only the valve guide need be replaced. There is

gains speed, “jumping”

no need to replace the cylinder head.

the wear and pitting

because of

push

inertia.

rods and tappets

As the inertial

increases, thereby

force

increasing

of the rods and tappets. The

valve spring serves to prevent such “jumping”. VALVE

.

This

SEAT

INSERT

is a heat-

The valve spring has a large working

and

wear-resistant

forced into the opening-closing

ring which

is

port area of a valve

on the exhaust side of a cylinder head.

.

The valve opening-closing repeated

subjected

to

repeated

loads.

spring must be made of material

force and is

Accordingly, which

the

is high in

both yield point and fatigue.

port area is subjected to

shocks and exposed to high temperature

combustion

gases. Therefore,

and heat-resistant

material

high strength,

wear-

is required for the valve

seat insert.

.

When the valve opening-closing

port area has worn

out, only the valve seat inset need be replaced (on the exhaust valve only).

95 SERIES

l l-$35


STRUCTURE

ENGINE

AND FUNCTION

BODY

CYLINDER BLOCK *

3D95SW-1

There

may be differences

according

to the machine

Section A-A

Section B-B

6206F521B

1.

Main bearing

cap

7.

Bushing

2.

Main bearing

cap bolt

8.

Oil pump

3.

Cylinder

4.

Cam bushing

(Journal

No. 1)

5.

Cam bushing

(Journal

No. 2)

(Engine 6.

drive

drive

shaft

shaft

block

No. 13175 and up)

Cam bushing (Engine

for oil pump

(Journal

No. 3)

No. 13175 and up)

95 SERIES

model.


STRUCTURE AND FUNCTION

ENGINE BODY

Section D-D

t--A Front

Section C-C

Rear

6206F522

Cylinder block

* .

Crankshaft: Camshaft:

4 bearings 3 bearings

Cylinder

* .

95 SERIES

Linerless Inside surface

finishing:

Honing

l l -026-l


STRUCTURE

AND

FUNCTION

ENGINE

4D95L-1 4D95S-1 S4D95L-1 4D95L-W-1 4D95S-W-1 S4D95L-1 SA4D95L-1 a

Section A - A

Section B - B 6206F606A

1.

Main bearing cap

2.

Main bearing cap bolt

3.

Cylinder

4.

Camshaft bushing (No. 1 journal)

5.

Camshaft bushing (No. 2 journal)

block

(Engine No. 33691

.

and up)

6.

Camshaft bushing (No. 3 journal)

7.

Oil pump drive shaft bushing

8.

Oil pump driven shaft

a.

Piston cooling oil jet (S4D95L-1)

(Engine No. 33691

and up)

(SA4D95L-1)

’ ’-“z6-2

95 SERIES

BODY


STRUCTURE

AND

ENGINE

FUNCTION

Section 13 -

BODY

D

Front

Section C -

C

6204FI

CYLINDER

. .

16

BLOCK

Crankshaft: Camshaft:

5 bearings 3 bearings

CYLINDER

. .

Linerless

Inside surface finishing:

95 SERIES

Honing

’ ’-:37


STRUCTURE

AND

ENGINE

FUNCTION

BODY

6D95L-1 S6D95L-1 SA6D95L-1

Section A -A

Section B-B 6206F106B

1.

Cylinder

a.

block

(S6D95L-1,

2.

Camshaft

3.

Main bearing

4.

Main bearing cap

5.

Oil pump drive shaft bushing

6.

Oil pump driven

’ ’-Li3*

Piston cooling

bushing

oil jet

SA6D95L-I)

cap bolt

shaft

95 SERIES


STRUCTURE

AND

FUNCTION

ENGINE

BODY

Section D-D Front

Section C-C

6206F107A

CYLINDER

. .

7 bearings

Camshaft:

4 bearings

FRONT

.

BLOCK

Crankshaft:

SEAL

Single lip with

dust seal

CYLINDER

-

Linerless Inside surface

95 SERIES

finishing:

Honing

’ ‘-39


STRUCTURE

AND

CYLINDER

FUNCTION

ENGINE

LINER

(FOR REPAIR ONLY)

80 mm

F614601010

CYLINDER *

The

LINER 95 series engine

boring

.

cylinder

specified

replacement

Selection

of liners

Two

uses linerless

to recondition

them,

cylinders. use only

When the

liners.

sizes (A and B) of replacement

cylinder

liners

are available. Choose

the

size of

meter of the cylinders * Outside

1 l-$40

diameter

liner

to match

the

inside

dia-

after machining.

of cylinder

liner

95 SERIES

BODY



STRUCTURE

MAIN

AND FUNCTION

CIRCULATION

ENGINE

SYSTEM

3D95SW-1

-

6206F523

1. Crankshaft

10. Top ring

2. Crankshaft

gear (No. of teeth:

3. Main bearing

24)

11. Second

ring

12. Oil ring

4. Connecting

rod bearing

13. Thrust

5. Connecting

rod

14. Connecting

6. Cylinder

block

7. Piston

’ ’-ii42

rod cap bolt

15. Main cap bolt 16. Main cap

8. Connecting 9. Piston

bearing

pin

rod bushing

17. Connecting

rod cap

18. Cam bushing

95 SERIES

BODY


STRUCTURE

AND FUNCTION ENGINE

section A -A

BODY

6206F524

CRANKSHAFT *

Stamp

forging

PISTON .

For precombustion

*

Auto-thermatic,

95 SERIES

(whirl)

chamber

type

offset

’’-Oi2-’


STRUCTURE

AND

ENGINE

FUNCTION

BODY

4D95S-1 4D95L-1 S4D95L-1 SA4D95L-1

15

16

li 6206F525A

10. Top ring

1. Crankshaft 2. Crankshaft

gear

No. of teeth:

24

11. Second ring

No. of teeth:

26

12. Oil ring

(4D95S-1) 3. Main bearing

13. Connecting 14.

rod cap

Main bearing cap

4. Connecting rod bearing

15. Main bearing cap mounting bolt

5. Connecting rod

16.

Connecting

6. Cylinder block

17.

Thrust bearing

7. Piston

18. Camshaft bushing

rod cap mounting bolt

8. Connecting rod bushing 9. Piston pin

1 l-022-2

95 SERIES


ENGINE BODY

STRUCTURE AND FUNCTION

Section A-A

6206F524

Crankshaft . Closed die forging Piston l

.

l

.

Swirl chamber type Auto thermatic piston with steel strut (Suppresses heat expansion and keeps clearance from cylinder small) Center of piston hole offset 1.0 mm (to reduce vibration) Selected mating (When the piston is assembled at the manufacturing plant, an L or S size piston is selected to match the inside diameter of the cylinder, but parts supplied for piston replacement are all assembled with S size pistons.)

95 SERIES

’’-:43


STRUCTURE

AND

FUNCTION

ENGINE

4D95L-W-1 4D95S-W-1

8

1. Crankshaft gear (No. of teeth: 2. Crankshaft

’’-:44

9

24)

10

12

11

IO. Top ring 11. Second ring

3. Main bearing

12. Oil ring

4. Connecting rod bearing

13. Connecting rod cap

5. Connecting rod

14. Main bearing-cap

6. Cylinder block

15. Main bearing cap bolt

7. Piston

16. Connecting

8. Connecting rod bushing

17. Thrust bearing

9. Piston pin

18. Camshaft bushing

rod cap bolt

95 SERIES

BODY


STRUCTURE AND FUNCTION

ENGINE BODY

Section A - A

6204F119A

Crankshaft l

Closed die forging

Piston l

.

.

l

Swirl chamber type Auto thermatic piston with steel strut (Suppresses heat expansion and keeps clearance from cylinder small) Center of piston hole offset 1.0 mm (to reduce vibration) Selected mating (When the piston is assembled at the manufacturing plant, an L or S size piston is selected to match the inside diameter of the cylinder, but parts supplied for piston replacement are all assembled with S size pistons.)

95 SERIES

’’-:45


STRUCTURE

AND

ENGINE

FUNCTION

BODY

4D95S-1 4D95L-1 S4D95L-1 SA4D95L-1

15

16

17 6206F525A

10. Top ring

1. Crankshaft 2. Crankshaft

gear

No. of teeth:

24

11. Second ring

No. of teeth:

26

12. Oil ring

(4D95S-1)

13. Connecting rod cap Main bearing cap

3. Main bearing

14.

4. Connecting rod bearing

15. Main bearing cap mounting bolt

5. Connecting rod

16.

6. Cylinder block

17. Thrust bearing

7. Piston

18. Camshaft bushing

Connecting rod cap mounting bolt

8. Connecting rod bushing 9. Piston pin

“it46

a: b:

Piston cooling oil jet Lubrication hole (S4Dg5L-1,

SA4D95L-1)

95 SERIES


ENGINE BODY

STRUCTURE AND FUNCTION

b

\

18 \

Section A-A 6204F117A

Crankshaft . Closed die forging Piston Direct fuel injection type re-entrant combustion chamber (4D95S-1 only) Direct fuel injection toroidal combustion chamber (all models except 4D95S-1) Auto thermatic piston with steel strut (Suppresses heat expansion and keeps clearance from cylinder small) Center of piston hole offset 1.0 mm (to reduce vibration) Selected mating (When the piston is assembled at the manufacturing plant, an L or S size piston is selected to match the inside diameter of the cylinder, but parts supplied for piston replacement are all assembled with S size pistons.)

95 SERIES

’’-k47


STRUCTURE

AND

FUNCTION

ENGINE

BODY

6D95L-1 S6D95L-1 SA6D95L-1

6

7

8

9

10 11 12

a

6206FllO-1

Crankshaft 2.

12. Oil ring gear (No.

teeth:

24)

13. Connecting rod cap

Main bearing

14. Main bearing cap

Connecting rod bearing

15. Connecting rod cap bolt

5. Connecting rod

16. Main bearing cap bolt

6. Cylinder block

17. Thrust bearing

7. Piston

18. Camshaft bushing

8. Connecting rod bushing 9. Piston pin 10. Top ring

a.

Piston cooling oil jet

b.

Lubrication

hole

11. Second ring

“i4*

95 SERIES


STRUCTURE AND FUNCTION

ENGINE BODY

b

18

Section A-A

6206F108A

Crankshaft l

.

Closed die forging Journal portion fillet portion: Tufftride ment (S6D95L-1, SA6D95L-1)

treat-

Piston Direct injection toroidal combustion chamber Elliptical taper profile thermal flow Auto thermatic piston with steel strut (Suppresses heat expansion and keeps clearance from cylinder small) Center of piston hole offset 1.0 mm (to reduce vibration) Selected mating (When the piston is assembled at the manufacturing plant, an L or S size piston is selected to match the inside diameter of the cylinder, but parts supplied for piston replacement are all assembled with S size pistons.)

95 SERIES

’’-:49


STRUCTURE

AND

FUNCTION

ENGINE

BODY

CRANKSHAFT

F614601011

1.

Vibration

2.

Crankshaft

pulley

3.

Crankshaft

gear

4.

Crankshaft

rotary

5.

Flywheel

power.

damper

Structure

and function

.

crankshaft

The

of a piston

.

The

motor,

while

a

Therefore,

extreme

taken

very

all the

converting

motion.

reciprocating

is then

has

it transmits

into rotary

the

under combustion

which

crankshaft

because power

converts

obtained

the

motion

pressure into off

as engine

complicated engine

shape

output

horse-

reciprocating

care should

be taken

motion about

the

shaft strength.

.

As bearing and crankpin

journals,

the

journals

rod are subjected The load variations

crankshaft

connected

main

journals

by the connecting

to the largest load in the engine. are also severe and their running

speeds are fast. Thus,

conterweights

manufactured

“FO

are

as monoblock

specially

designed

forgings.

95 SERIES

and


STRUCTURE AND FUNCTION

PISTON

AND

ENGINE BODY

CONNECTING

ROD 1. Piston 2. Top ring 3. Second ring 4. Oil ring 5. Piston pin 6. Snap ring 7. Connecting rod bushing 8. Connecting rod 9. Connecting rod bearing 10. Crankshaft 11. Connecting rod cap bolt 12. Connecting rod cap

F614601012

Structure and function

.

Like crankshafts, thepistons and connecting rods are the main moving parts of the engine. The energy of fuel

combustion

motiron motion upper

which

is converted is, in turn,

into

reciprocating

converted

into

by the pistons and connecting portion

of the pistons form

rotary

rods. The

a combustion

chamber with the cylinder and cylinder head.

.

The top end of the connecting the

piston

with

a piston

down. The bottom

rod is connected to

pin and moves up and

end is connected to the crank-

shaft with the connecting

rod cap and makes rotary

motion.

.

The connection

at each end of the connecting

forms a running area which

is subjected

rod

to a very

large load. The upper end (small end) has a bushing forced

in place and the lower end (big end) has a

connecting

rod bushing made of the same material

as the main bearing.

95 SERIES

V’


STRUCTURE

AND

ENGINE

FUNCTION

BODY

PISTON 3D95S-W-1

4D95L-1 S4D95L-1

4D95L-W-1 -Offset Offset

,Trochoidal

6206FlO9 6204F

I20

Structure and function

.

Pistons are directly exposed to the combustion and repeatedly

load of the combustion they

gases

move up and down under the severe

are subjected

pressure. At the same time,

to severe sliding motion

while

being kept airtight with the cylinder.

.

Pistons of 6D95L-1

. . .

Offset

(1.0

Pistons of 3D95S-W-1,

4D95L-W-1

engine have following

features.

. . .

combustion

. .

mm

chamber

between

and 4D95S-W-1

Elliptical taper profile Precombustion Offset

(1.0

(whirl) chamber type

mm between

pin hole center and

piston center)

engine have following features.

Elliptical taper profile Trochoidal

-

Auto-thermatic Two sizes of pistons are available

pin hole center and

piston center) Auto-thermatic (Control thermal expantion

by steel strut which

is build in piston to achieve a smaller clearance between biston and cylinder)

.

Two sizes of pistons (S-mark

and L-mark)

are

available. (Depending

on the dimensions

of the piston

outside diameter. For detail,

see 14. MAINTENANCE

STAND-

ARD.)

ll-0%1

95 SERIES


STRUCTURE

AND

FUNCTION

ENGINE

BODY

PISTON RING

Top ring

Secondring

Oil ring

Structure and function . The piston rings used in 95 series engines are shown

.

The upper two of the three piston rings are called

below.

the top ring and the second ring. They are mainly used to keep the pistons tight against combustion gases. The bottom

ring of the three rings is called the oil

ring which is used to hold the lubricating oil film.

*I:

PCIOO, 120-5,

plating ‘2: PC200-5, *3: PC200-6: *4: PC220-6:

I

S6D95L-1 .._. t-31 SP4fiDg5L-’

Both keystone barrel face, Hard chrome plating

Keystone, barrel face, Hard chrome plating

95 SERIES

PC128UU-1:

PC220-5: Hard chrome Hard chrome plating Hard chrome plating

Hard chrome

plating

lexoander

-4Dg5s_w_, / g$&=

S6D95L-1

PClOO, 120-6,

Y&

jggjj=

I

I

ITapered face inner cut, Parkerizing treatment

/M-shape steel rinq. Hard chrome pIat ing with coil expander

Keystone, inner cut, Parkerizing, Tapered face

M-shape steel ring, Hard chrome plating with coil expander

’’-Oil -2


ENGINE BODY

STRUCTURE AND FUNCTION

PISTON

PIN

F614601015

1.

Piston

4.

Connecting rod bushing

2.

Piston pin

5.

Connecting rod

3.

Snap ring

Structure and function

.

The piston pin serves to join a piston and connecting rod together:

For this reason, the piston pins

are always subjected to the combustion severe repeated

pressure and

loads caused by the inertical

force

of the pistons.

.

The piston pins are made of low carbon special steel with high bending strength and wear resistance. The surface is subjected to hard facing.



STRUCTURE

AND

CONNECTING

ENGlNE

FUNCTION

AND

MAIN BEARING ROD BEARING

ROD

BODY

CONNECTING

A

F614601016 F614601017 1.

Connecting rod bushing

5.

Connecting rod cap

2.

Connecting rod

1.

Crankshaft

3.

Connecting rod cap

A.

Small end

2.

Bearing

bolt

B.

Big end

3.

Back bearing

4.

The connecting the

pressure received

by the

through the piston pin as reciprocating transmits the reciprocating

piston

motion, and

motion to the crankshaft

The

connecting

(surface layer)

Main and connecting

rod bearings are set into the

main and crankpin jounals on the crankshaft.

.

These bearings support the severest running portion of the crankshaft

as the engine bearings and there-

rod

is subjected

to

severe com-

they are subjected to heavy surface pressure \/ and severe high speed running motion.

pressive and hackling loads because of the combus-

Each bearing

tion pressure, and to tensile load and bending load

base metal) but also has a lining (intermediate

because of the inertial force of the connecting

and overlay

itself and the piston. Connecting die-forged

special

high

rod

rods are made of

strength,

high

fatigue

obtain

the

is made of a single material (surface

layer)

high strength

on the

The

connecting

complicated (particularly concentration

rod

alternating

is subjected

to

and break-in

severe and

or scored, the

of stress may break the rod, when

checking.

“:52

layer)

properties

required for bearings shown above.

loads. Be carefull in marred

in the lateral direction)

(as the

base metal to

strength steel. *

layer)

Overlay

fore,

as rotary motion.

.

5.

Structure and function

rods are subjected to the energy of

combustion

Lining (intermediate

(base metal)

Connecting rod bearing

Structure and function

.

4.

95 SERIES


STRUCTURE

THRUST

ENGINE

AND. FUNCTION

OIL

BEARING

SEAL

BODY

OF CRANKSHAFT

F614601019 F614601018

Structure

.

and function

The crankshaft the

flywheel

mounted

to

delivers the engine power through at the

the

shaft is subjected

rear end,

flywheel.

and the clutch

Therefore,

to the thrust

the

3.

Oil seal (Rear)

crankshaft

The

cylinder

gains

the

block and transmits

driving

force

in

the

it outside the cylinder

block.

crank-

Then, the cylinder block is sealed inside and outside

load as the clutch

load on the flywheel

side of the

of the crankshaft.

rod bearings. Therefore, bearing meterial.

.

These seals must be able to withstand speed running motion

bearings is not as

large as that imposed on the main and connecting

95 SERIES

Crankshaft

with the front and rear seals provided on both ends

The load imposed on the thrust

ordinary

Main bearing

5.

housing

and function

is

crankshaft.

.

4.

Flywheel

.

For this reason, three thrust bearings are installed to receive the thrust

Cylinder block

Structure

is operated.

.

1. 2.

thrust bearings are made of

severe, high-

and at the same time form

tight seals to prevent the oil from leaking out. For thss reason, the seal lips are made of rubber material which

is high in heat-, wear-, and oil=resistance

as

well as in tight packing force.

11-$53


STRUCTURE AND FUNCTION

TIMING

ENGINE BODY

GEAR

WITHOUT FRONT PTO TYPE (HELICAL GEAR)

\

--+--I--F

D

--I t-1.

Oil pump drive gear (No. of teeth:

2. 3. 4. 5.

Camshaft gear (No. of teeth: Crankshaft gear (No. of teeth: Idler gear (No. of teeth:

21)

(*)

48) 24)

48)

Injection pump drive gear (No. of teeth:

48)

6.

Thrust plate

7.

Idler gear shaft

8.

Idler gear bushing

9.

Front seal

A, B, C: Match marks for timing gears

(“) PC200-6, PC220-6 (No. of teeth: 20)

’1-:54

95 SERIES


ENGINE BODY

STRUCTURE AND FUNCTION

I

k

I Section D

-

9I

SectionF-F D

Front oil seal

*

95 SERIES

Single lip with dust seal

’ ’-:55


ENGINE BODY

STRUCTURE AND FUNCTION

WITH FRONT PTO TYPE (SPUR GEAR) 4D95S-1 4D90L-1 (WITH BOOSTER PUMP FOR BLADE ON PC60-6, PC60-7,

Section

E-E i

1. PTO gear (No. of teeth:

2. 3. 4. 5. 6.

Oil pump

drive

Injection

pump

(No. of teeth:

’ ’-OZ5-’

drive

52)

22)

8. Thrust

shaft

plate

9. Idler shaft

52)

gear

i

7. PTO drive

26)

gear (No. of teeth:

Idler gear (No. of teeth:

j

i

gear (No. of teeth:

Cam gear (No. of teeth: Crankshaft

PC70-7)

26)

10. Bushing 11. Front seal A, B, C: Gear match

marks

52)

95 SERIES


STRUCTURE AND FUNCTION

ENGINE BODY

6

5

0

9

10

4

11

Section D-D

SectionF-F

6206F112 A

Front seal

*

95 SERIES

Single lip with dust seal

’ ’-Oi5-*


STRUCTURE

AND

FUNCTION

ENGINE

WITH FRONT PTO TYPE (HELICAL GEAR) (Except 4D95S-1 and 4D95L-1, WITH BOOSTER PUMP FOR PC60-6 BLADE) Cam-gear bolt tightening type

Cam-gear shrink fitting type

Section E-E

7

13589

D

E

I

11s56

95 SERIES

BODY


STRUCTURE

AND

FUNCTION

ENGINE

Cam-gear shrink fitting type

Section D-D

BODY

Cam-gear bolt tightening type

Section F-F 6206F112B

Front oil seal

.

Single lip with dust seal

1.

PTO gear (No. of teeth:

2.

Oil pump drive gear (No. of teeth:

24)

3.

Camshaft gear (No. of teeth:

4.

Crankshaft

gear (No. of teeth:

21)

48) 24)

5.

Idler gear (No. of teeth:

6.

Injection pump drive gear (No. of teeth:

7.

PTO gear shaft

95 SERIES

48)

8.

Roller bearing

9.

Idler gear shaft

10.

Front

11.

Housing

seal

12.

Roller bearing

48) A, B, C: Match marks for timing gear

’’-kz57


STRUCTURE AND FUNCTION

FLYWHEEL

AND

ENGINE BODY

FLYWHEEL

HOUSING

WITHOUT REAR PTO TYPE (For PCIOO-3, PC120-3)

1.

Flywheel housing

2.

Starting motor

REAR OIL SEAL . Single lip with dust seal Dry type:

.

3.

Crankshaft

4.

Rear oil seal

5.

Flywheel

6.

Ring gear (No. of teeth: 119) (No. of teeth for 4D95S-1:

’ ’-P8

Wet type:

Double lip

110)

95 SERIES


STRUCTURE AND FUNCTION

ENGINE BODY

1

n

/

6206Fl

95 SERIES

15

’’-Oi8-’


STRUCTURE

WITHOUT S4D95L-1

AND

ENGINE

FUNCTION

REAR PTO TYPE (For PCIOO-6, PC120-6,

BODY

PC128UU-I)

I

2

3

4

SME00230

1. 2. 3. 4. 5. 6. 7.

Starting motor Flywheel housing Rear oil seal (Double lip) Flywheel Ring gear (No. of teeth: 127) Crankshaft Sensor

’’-:8-2

95 SERIES


ENGINE BODY

STRUCTURE AND FUNCTION

WITHOUT REAR PTO TYPE S6D95L-1 (For PC200-61 SA6D95L-1 (For PC220-6)

A-A

SME00231

4.

Starting motor Flywheel housing Rear oil seal (Double Flywheel

5. 6. 7.

Ring gear (No. of teeth: 127) Crankshaft Sensor

1. 2. 3.

95 SERIES

lip)

’’-028-3



LUBRICATION SYSTEM LUBRICATION

SYSTEM

CHART

3D95S-W-1

6206F530

95 SERIES

1. Oil strainer

7. Camshaft

2. Oil pump 3. Regulator valve

8. Piston 9. Intake, exhaust valve

4. Oil filter

10. Rocker arm

5. Safety valve

11. Timing gear

6. Crankshaft

12. Fuel injection

pump

’’-kF9



STRUCTURE

LUBRICATION

AND FUNCTION

LUBRICATION LUBRICATION

SYSTEM

SYSTEM

SYSTEM

CHART

3D95S-W-1

10

s 7

/--i

I

9

f%

/

/

6206F530

7. Camshaft

1. Oil strainer

8. Piston

2. Oil pump 3. Regulator

95 SERIES

valve

9. Intake, exhaust valve

4. Oil filter

10. Rocker arm

5. Safety valve

11. Timing gear

6. Crankshaft

12. Fuel injection

pump

’ ’-“i9-2


STRUCTURE

AND

LUBRICATION

FUNCTION

SYSTEM

4D95S-1 4D95L-1 4D95L-W-1 4D95S-W-1

4D95L-W-1 4D95S-W-1

‘1 6204F131A

1. Oil strainer

8. Camshaft

2. Oil pump

9. Piston

3. Oil cooler

(option)

10.

Intake

4.

valve

11.

Rocker arm

Regulator

and exhaust

5. Oil filter

12. Timing

6. Safety

13.

Fuel injection

W:

Cooling

valve

valve

gear pump

7. Crankshaft

’ ’-EO

water

95 SERIES


STRUCTURE

AND

LUBRICATION

FUNCTION

SYSTEM

S4D95L-1 SA4D95L-1

6206F1003A

1. 2. 3. 4. 5. 6. 7. 8. 9. IO.

Oil strainer Oil pump Oil cooler Regulator valve Oil filter Safety valve Crankshaft Camshaft Piston Intake and exhaust

95 SERIES

11. 12. 13. 14. 15.

Rocker arm Timing gear Fuel injection pump Turbocharger Piston cooling

15A. Piston cooling (For PC1 00-6, PC1 20-6) 16. Low-pressure oil switch 17. High-pressure oil switch (For PCIOO-6, PC120-6) 18. Bypass filter (opt) (For PCIOO-6, PC120-6, PC128UU-1) W.

Cooling

water

valve

Y’


STRUCTURE AND FUNCTION

LUBRICATION SYSTEM

6D95L-1 S6D95L-1 SA6D95L-1

11

6206F1004

1. Oil strainer

8. Camshaft

15.

2. Oil pump

9. Piston

15A. Connecting rod small end greasing (piston cooling) (for PC200-6, PC220-6, LW80-1) 16. Low-pressure oil switch 17. High-pressure oil switch For PC200-6, PC220-6) 18. Bypass filter (opt) (For PC200-6, PC220-6)

3. Oil cooler

10.

4.

11.

Regulator valve

Intake and exhaust valve Rocker arm

5. Oil filter

12. Timing gear

6. Safety valve

13.

7. Crankshaft

14. Turbocharger

Fuel injection pump (S6D95L-1,

SA6D95L-1)

W:

“iF2

Piston cooling (S6D95L-1,

SA6D95L-1)

Cooling water

95 SERIES


STRUCTURE AND FUNCTION

LUBRICATION

SYSTEM

OIL PUMP

i

i”

?

Section

A-A

Section B--B

1. 2. 3. 4. 5. 6. 7. 8. 9. (*)

Bushing Drive gear (No. of teeth: 7) Pump cover Oil pump drive gear (No. of teeth: 21)(*) (No. of teeth: 22 (4D95SI)) Drive shaft Driven shaft Driven gear (No. of teeth: 7) Regulator valve Valve spring PCZOO-6, PCZZO-6 (No. of teeth: 20)

95 SERIES

6206F117

OIL PUMP . Type: . Pump speed:

Gear type Engine speed x 1.143 Engine speed x 1.182 (4D95S-I) Engine speed x 1.20 (PCZOO, 220-6)

REGULATOR VALVE . Set pressure 3D95SW-1, 4D95L-1, 4D95L-W-1, 4D95S-W-1: 490 2 49 kPa (5.0 f 0.5 kg/cm*) S4D95L-1, 6D95L-1, S6D95L-1, SA6D95L-1: 588 f 49 kPa (6.0 -c 0.5 kg/cm2)

’’-F3


STRUCTURE AND FUNCTION

LUBRICATION

SYSTEM

OIL FILTER

D-

Section A-A

Section B-B 6206Fl

1. 2. 3. 4. C. D.

Safety valve Cartridge Bracket (Installed on some machines) Filter caution sensor (Installed on some machines) Oil inlet Oil outlet

OIL FILTER . Filtration

area: 0.20 m2 0.29 m2 (Large capacity)

SAFETY VALVE

.

Set pressure:

FILTER CAUTION

.

Operating

196_‘~& kPa (2.01;;:

kg/cmz)

SENSOR

pressure:

147’39, kPa (Difference

’’-E3-’

IBA

( 1.5’t4 kg/cm?) pressure)

95 SERIES


LUBRICATION SYSTEM

STRUCTURE AND FUNCTION

OIL FILTER MOUNT

(Engine No. up to 833501

(For PCZOO, 220-5)

(Engine No. 83351 and up)

From oil filter

To oil filter View A i

View B

6206F876

1. 2. 3. 4.

Cartridge Head Oil cooler Safety valve (cold spec.)

95 SERIES

’’-%3-2


STRUCTURE

AND

FUNCTION

LUBRICATION

SYSTEM

OIL COOLER 4D95S-1 (OP) 4D95L-1 (OP) S4D95L-1 (STD) 4D95L-W-1 (OP) 4D95S-W-1 (OP)

Section

A -

Section B -

A

B

6204F

1.

Cooler element

OIL COOLER

2.

Cooler cover

3.

Water drain plug

. .

C.

Oil inlet (From oil pump)

D.

Oil inlet (To element)

E.

Oil outlet (From element)

F.

Oil outlet (To filter)

G.

Oil outlet (From filter)

H.

Cooling water inlet

I.

Cooling water outlet

’’-iF4

Stages Stages

of element: of element:

3 stages 6 stages (For PCIZO-6, PC128UU-I)

95 SERIES

132


STRUCTURE AND FUNCTION

LUBRICATION

SYSTEM

6D95L-1 (OP) S6D95L-1 (STD) SA6D95L-1 (STD)

Section B-B

Section A -A 6206F119B

2.

1.

Cooler Cooler

C.

Oil inlet

D. E. F.

Oil outlet (To oil filter) From oil filter To engine

G. H.

Oil (inside cooler) Cooling water inlet

.I. a.

Cooling water outlet Water drain plug

95 SERIES

element cover

OIL COOLER . Effective area:

0.273

mz

’’-F5


STRUCTURE

AND

FUNCTION

FUEL SYSTEM

FUEL SYSTEM FUEL SYSTEM

CHART

3D95S-W-1

6206F533

’ ’-P

1.

Fuel tank

2.

Feed pumd

3.

Fuel filter

4.

Fuel injection pump

5.

Fuel injection nozzle

95 SERIES


FUEL SYSTEM

STRUCTURE AND FUNCTION

3D95S-W-1

(With automatic

air bleed mechanism)

6206F003A

1.

Fuel tank

2.

Feed pump

3.

Fuel filter

4. 5.

Air bleed plug Overflow valve

6.

Fuel injection

7.

Fuel injection nozzle

95 SERIES

pump

11-t&67


STRUCTURE AND FUNCTION

4D95S-W-1, 4D95L-W-1, 4D95L-1, S4D95L-1 (With automatic air bleed mechanism)

FUEL SYSTEM

(*), SA4D95L-1

6204F220A

1.

Fuel tank

2. 3. 4. 5. 6. 7. 8.

Gauze filter Priming pump Feed pump Fuel filter Overflow

valve

Fuel injection pump Fuel injection nozzle

(“) Except PC1 00-6, PC1 20-6

’’-Og7-’

95 SERIES


STRUCTURE AND FUNCTION

FUEL SYSTEM

4D95S-W-1,4D95S-1,4D95L-W-1,4D95L-l,

S4D95L-1,

SA4D95L-1

4D95.sw-1 4D95L-W-1

6204F1336

1.

Fuel tank

2.

Gauze filter

3.

Priming

4.

Feed pump

pump

5.

Fuel filter

6.

Air bleed plug

7.

Fuel injection

pump

8.

Fuel injection

nozzle

95 SERIES

’’-“g7-2


STRUCTURE AND FUNCTION

4D95S-W-1

(With automatic

6

-

4D95S-W-1 4D95L-W-1

FUEL SYSTEM

air bleed mechanism)

9-s

\

r

6204F133-1

1.

Fuel tank

2.

Gauze filter

3.

Priming

4.

Feed pump

pump

5.

Fuel filter

6.

Air bleed

7.

Fuel injection

pump

8.

Fuel injection

nozzle

9.

Overflow

’ ’-“ii7-3

plug

valve

95 SERIES


FUEL SYSTEM

STRUCTURE AND FUNCTION

4D95L-1

(With

automatic

air bleed mechanism)

(For PC60-7,

PC70-7)

6206F1020

1. 2. 3. 4. 5. 6. 7. 8.

Fuel tank Gauze filter Priming pump Feed pump Fuel filter Overflow valve Fuel injection pump Fuel injection nozzle

95 SERIES

’’-“g7-4


FUEL SYSTEM

STRUCTURE AND FUNCTION

S4D95L-1 (For PClOO-6, PC120-6, PC128UU-1) (With automatic air bleed mechanism)

8

7

I i

6206F1005

1. 2. 3. 4. 5. 6. 7. 8. 9.

Fuel tank Gauze filter Priming pump Feed pump Fuel filter Air bleed plug Fuel injection pump Fuel injection nozzle Overflow valve

’’-k67-5

95 SERIES


STRUCTURE AND FUNCTION

FUEL SYSTEM

6D95L-1, S6D95L-1 (“l), SA6D95L-1 (*2) (With automatic air bleed mechanism)

6206Flzo-1

1.

Fuel tank

2.

Gauze filter

3.

Priming pump

4.

Feed pump

5.

Fuel filter

6.

Air bleed plug

7.

Fuel injection pump

8.

Fuel injection nozzle

9.

Overflow

valve

(*I) Except PC200-6 (“2) Except PC220-6

95 SERIES

’’-“ii7-6


FUEL SYSTEM

STRUCTURE AND FUNCTION

6D95L-1 (With automatic (D37A-2, D37P-2A)

air bleed mechanism)

6206F631

.I.

Fuel tank

2.

Gauze filter

3. 4. 5. 6. 7. 8.

Priming Fuel filter Overflow

valve

Fuel injection

pump

Fuel injection

nozzle

’’-tf7-7 1

pump

Feed pump

95 SERIES


STRUCTURE AND FUNCTION

6D95L-1, S6D95L-1,

FUEL SYSTEM

SA6D95L-1

i’; /// :.. i./:, :. :..:: :/:/: ////

iii .:: .::. . ....

j////

(i:i/

6206F12OC

1.

Fuel tank

2. 3. 4. 5. 6. 7. 8.

Gauze filter Priming pump Feed pump Fuel filter Air bleed plug Fuel injection pump Fuel injection nozzle

95 SERIES

’’-Ot7-*


FUEL SYSTEM

STRUCTURE AND FUNCTION

6D95L-1 (For D31A, P, PL, S, Q-20, D37A, (With automatic air bleed mechanism)

P-5)

6206F955

1. 2. 3. 4. 5. 6. 7. 8.

Fuel tank Gauze filter Priming pump Feed pump Fuel filter Air bleed plug Fuel injection pump Fuel injection nozzle

’’-:7-9

95 SERIES


FUEL SYSTEM

STRUCTURE AND FUNCTION

S6D95L-1 (For PC200-6) (With automatic air bleed mechanism) SA6D95L-1 (For PC220-6) (With automatic air bleed mechanism)

8

6206F1006

1. 2. 3. 4. 5. 6. 7. 8. 9.

Fuel tank Gauze filter Priming pump Feed pump Fuel filter Air bleed plug Fuel injection pump Fuel injection nozzle Overflow valve

95 SERIES

“-06i-‘o


FUEL SYSTEM

STRUCTURE AND FUNCTION

FUEL INJECTION

PUMP

3D95S-W-1

6206F534

1. Fuel injection

nozzle

8. Feed pump 9. Oil tube

2. Spill tube 3. Fuel injection

pipe (No. 1)

IO.

4. Fuel injection

pipe (No. 2)

11. Pump holder

Drive shaft

5. Fuel injection pipe (No. 3)

12. Pump drive gear (No. of teeth:

6. Fuel filter

13. Fuel injection

7. Fuel injection

“-“i!i7-”

48)

pump (pump body)

pump (governor)

95 SERIES


FUEL SYSTEM

STRUCTURE AND FUNCTION

6206F535 \

View2

A.

Fuel inlet port

Fuel injection pump

B.

To fuel filter

C.

From fuel filter

* .

D.

To fuel injection

E.

To fuel tank

F.

From oil pump (oil)

95 SERIES

Type:

Yanmar

Lubrication

Diesel in-line type YPES-3CL

method:

Forced lubrication

using

engine oil

nozzle

Governor

*

Type:

Yanmar

Diesel centrifugal

all-speed

type

“-06i-‘2


STRUCTURE

AND

FUNCTION

FUEL SYSTEM

4D95L-1 (PC60-3)

1. Lubricating tube Drive shaft

2.

5.

Il.

Fuel injection pump drive gear 48)

12.

Fuel injection pipe (No. 1) Fuel injection pipe (No. 2) Fuel injection pipe (No. 3)

13.

Fuel injection pipe [No. 4)

14.

Governor

pick-up

(No. of teeth: 6. Pump holder 7.

’ ’-E8

Fuel filter

Feed pump

3. Tachometer 4.

8.

9. Priming pump

Fuel injection pump

10.

15. Spill tube

95 SERIES


STRUCTURE

AND

FUEL

FUNCTION

SYSTEM

Ij

J-

1

ViewZ

A.

Fuel inlet

B.

To fuel filter

C.

From fuel filter

D.

To fuel injection

6204F141

(From fuel tank)

E.

To fuel tank

F.

From oil pump

nozzle

FUEL

. . .

INJECTION

PUMP

Maker:

DIESEL

Type: Lubrication

Bosch type method:

Forced

KIKI PES-A

lubrication

with

engine oil. (oil) GOVERNOR

.

Type:

Bosch RSV Centrifugal,

95 SERIES

all-speed type

11-869


STRUCTURE

AND

FUNCTION

FUEL SYSTEM

4D95L-W-1 (For WA40-1) 4D95S-W-1 (For ECSOZ(S)-5)

1. Governor Lubrication

3.

Fuel injection

pump drive gear

10.

Fuel injection

(No. of teeth:

48)

11.

Fuel injection pipe (No. 2)

12.

Fuel injection pipe (No. 3)

pick-up

13.

Fuel injection pipe (No. 4)

14.

Fuel injection nozzle

4.

tube

Drive shaft

5. Tachometer

’ ’-ii70

8. Priming pump

2.

6.

Feed pump

7.

Fuel injection

9.

Fuel filter pipe (No. 1)

pump

95 SERIES


STRUCTURE

AND

View Z

A.

Fuel inlet

B.

To fuel filter

C.

From fuel filter

D.

To fuel injection nozzle

E.

To fuel tank

F.

From oil pump (oil)

95 SERIES

FUEL SYSTEM

FUNCTION

6204F

I 42 FUEL INJECTION . Maker:

. .

PUMP DIESEL

Type: Lubrication

GOVERNOR . Type:

KIKI

Bosch PES-A method:

Forced lubrication

with engine oil

Bosch RSV Centrifugal,

all-speed type

1571


STRUCTURE

S4D95L-1

AND

FUNCTION

(For PCIOO-6, PC120-6,

FUEL SYSTEM

PC128UU-1)

SME00232

1. 2. 3. 4. 5. 6. 7. 8.

Lubrication tube Drive shaft Feed pump Injection pump drive gear (No. of teeth: 48) Pump holder Fuel injection pump Fuel filter Priming pump

‘l-oi’-’

9. 10. 11. 12. 13. 14. 15.

Fuel injection pipe Fuel injection pipe Fuel injection pipe Fuel injection pipe Spill tube Overflow valve Governor

(No. (No. (No. (No.

1) 2) 3) 4)

95 SERIES


STRUCTURE

FUEL SYSTEM

AND FUNCTION

SME00233

A. Fuel inlet B. To fuel filter C. From fuel filter D. To fuel injection nozzle E. To fuel tank F. From oil pump (oil) G. To fuel tank

95 SERIES

FUEL INJECTION PUMP . Maker: Type: . Lubrication method: l

GOVERNOR . Maker: . Type:

ZEXEL Bosch PES-A Forced lubrication engine oil

with

ZEXEL Bosch RSV Centrifugal, all-speed type

’’-Oil -2


FUEL SYSTEM

STRUCTURE AND FUNCTION

6D95L-1 (FLANGE S6D95L-1

TYPE) (FOR PCIOO-3, PC120-3)

6206F1007

1. Lubrication tube 2. Tachometer pick-up 3. Drive shaft 4. Injection pump drive gear (No. of teeth: 48) 5. Feed pump 6. Priming pump 7. Fuel injection pump 8. Fuel filter

“g7*

9. IO. 11. 12. 13. 14. 15.

Fuel injection Fuel injection Fuel injection Fuel injection Fuel injection Fuel injection Governor

pipe pipe pipe pipe pipe pipe

(No. (No. (No. (No. (No. (No.

1) 2) 3) 4) 5) 6)

95 SERIES


STRUCTURE

AND

FUEL SYSTEM

FUNCTION

View Z 6206F

A.

Fuel inlet

B.

To fuel filter

C.

From fuel filter

D.

To fuel injection nozzle

E.

To fuel tank

F.

From oil pump (oil)

95 SERIES

FUEL INJECTION . Maker:

. .

I2 I

PUMP DIESEL

Type: Lubrication

GOVERNOR . Type:

KIKI

Bosch PES-A type method:

Forced lubrication with engine oil.

Bosch RSV Centrifugal,

all-speed type.

1 l-g73


STRUCTURE

AND

FUEL SYSTEM

FUNCTION

FLANGE TYPE S6D95L-1 (For PC200-6) SA6D95L-1 (For PC220-6)

14

-15

SME00234

1. 2. 3. 4. 5. 6. 7. 8.

Lubrication tube Drive shaft Injection pump drive gear (No. of teeth: 48) Feed pump Priming pump Fuel injection pump Fuel filter Fuel injection pipe (No. I)

’’-Oi3-’ 1

9. 10. 11. 12. 13. 14. 15.

Fuel injection pipe Fuel injection pipe Fuel injection pipe Fuel injection pipe Fuel injection pipe Overflow valve Governor

(No. (No. (No. (No. (No.

2) 3) 4) 5) 6)

95 SERIES


STRUCTURE AND FUNCTION

FUEL SYSTEM

SME00235

A. B. C. D. E. F. G.

Fuel inlet To fuel filter From fuel filter To fuel injection nozzle To fuel tank From oil pump (oil) To fuel tank

FUEL INJECTION PUMP . Maker: ZEXEL l

.

GOVERNOR . Maker: .

95 SERIES

Type: Lubrication

Type:

method:

Bosch PES-A Forced lubrication engine oil

with

ZEXEL Bosch RSV Centrifugal, all-speed type

’’-“i3-2


FUEL SYSTEM

STRUCTURE AND FUNCTION

6D95L-1 COUPLING S6D95L-1

TYPE (For PW150-I)

lY

I--

19

18

17

\ lb

1. Lubrication

tube

11.

Fuel injection pipe (No. 4)

2. Tachometer

pick-up

12.

Fuel injection pipe (No. 5)

13.

Fuel injection pipe (No. 6)

3. Drive shaft 4.

Injection pump drive gear (No. of teeth:

48)

6206F1008

14. Governor 15.

Air compressor connector hose

6.

Fuel injection pump

16.

Priming pump

7.

Fuel filter

17.

Lubrication tube

8.

Fuel injection pipe (No. 1)

18.

Coupling

9.

Fuel injection pipe (No. 2)

19.

Air compressor

10.

Fuel injection pipe (No. 3)

5. Feed pump

’ ’-$74

95 SERIES


STRUCTURE AND FUNCTION

FUEL SYSTEM

I View Z

View Y

A.

Fuel inlet

B.

To fuel filter

C.

From fuel filter

D.

To fuel injection nozzle

E.

To fuel tank

F.

To fuel injection pump (oil)

G.

To oil pan (oil)

H.

To air compressor (air)

95 SERIES

6206F122A

FUEL INJECTION PUMP . Maker: DIESEL

. .

Type: Lubrication

GOVERNOR . Type:

KIKI

Bosch PE-A type method:

Forced lubrication

with engine oil.

Bosch RSV Centrifugal,

all-speed type

’’-:75


STRUCTURE

AND

DCA85SPK

(With

FUEL SYSTEM

FUNCTION

electronical

governor)

SDE00165

7

1. Fuel injection pipe (No. 2. Fuel injection pipe (No. 3. Fuel injection pipe (No. 4. Fuel injection pipe (No. 5. Fuel injection pipe (No. 6. Fuel injection pipe (No. 7. Oil outlet pipe 8. Fuel injection pump 9. Oil inlet pipe IO. Feed pump

’’-OF’

1 2 3 4 5 6

cylinder) cylinder) cylinder) cylinder) cylinder) cylinder)

FUEL INJECTION PUMP . Maker: . Type: . Lubrication method:

GOVERNOR . Maker: . Type:

ZEXEL Bosch PES-A Forced lubrication engine oil

ZEXEL Electronical system

with

governor

95 SERIES


STRUCTURE AND FUNCTION

OUTLINE

FUEL SYSTEM

OF ELECTRONIC GOVERNOR

SYSTEM

The electronic governor system consists of the injection pump governor portion (actuator drive), electronic governor controller, and switches, volumes, and sensors. The electronic governor controller has a built-in microcomputers. It operates the engine and drives the governor actuator according to the operating conditions specified by the volumes, external switches, and nature of the controls set by the microcomputer. The structure of the electronic governor system is as shown in the diagram below, and it has the functions given in Table 1. In addition, it is possible to install a load detector to this system as an option. This detects the change in the alternator load current and allows the governor correspond to these changes. This reduces the momentary changes in speed when there is a sudden change in the load.

Overall structure diagram

Electronic governor controller

SDEOOl67

95 SERIES

’’-Oi5-*


FUEL SYSTEM

STRUCTURE AND FUNCTION

ELECTRONIC GOVERNOR SYSTEM CONTROL ITEMS (for alternator) Model: Power source machine (S6D95LI

Table 1

NO./

Item Keeps engine speed constant even when there is change in load (50 Hz and 60 Hz)

1

lsochronous

control

2

Low idling/rated changeover

3

Rated speed

4

Frequency (50 Hz/60 Hz) changeover

5

Low idling isochronous (constant low idling)

This switches rated speed

operation

between

low idling and

It is possible to adjust external volume

adjustment

Switches

rated speed

rated speed with

50 Hz/60 Hz

Keeps low idling speed constant even when there is change in load at low idling

control

6

Sudden acceleration limit function (soft boost compensator)

Restricts full rack position at sudden acceleration to prevent emission of black smoke

7

Low idling speed

Possible to adjust external volume

8

Emergency (Common electronic

adjustment

for

I

1

Fuel adjustment starting

2

Rack pre-actuation

3

Overrun prevention (hardware)

4

Diagnosis

5

Memory

clear function

6

External disolav

output

7

Stops engine when there is drop in oil pressure, rise in water temperature, or overrun

stop function functions aovernor)

function

This increases the starting fuel amount when starting and increases the amount of fuel when the water temperature is low to improve the ease of starting

when

This moves rack before temoeratures to reduce

function

This cuts fuel when above set value

function

’’-i75-3

starting in low slidina resistance

engine

speed

is

This carries out specified action if any abnormality should occur in electronic governor system

function

Load detection

low idling speed with

This clears trouble

data from

memory

of failure

I function

(option)

This improves response to changes load by detecting load current

in

95 SERIES


STRUCTURE AND FUNCTION

FUEL SYSTEM

CONTROLLER

2

SEE00127

1. Case Connector 3. Mounting bolt

2.

95 SERIES

Function l

The controller produces signals for controlling the fuel injection pump for the engine with signals received from sensors and switches which are installed on the panel and externally located. The controller possesses a self-diagnostic function, and abnormalities are displayed on the LED.

’’-tF4


FUEL SYSTEM

STRUCTURE AND FUNCTION

SYSTEM DCA85SPK

ELECTRICAL CIRCUIT DIAGRAM with

electronic

governor)

E Alternator .% Dust indicator 762i56mmH10

% Water temperature gauge switch

% Oil pressure

switch

9+1 9. 6kPa 0. 5+0. 2ka/cm’)

Battery

12v

% Fuel injection

E Speed

70AHX2

Battery

switch

pump

10

sensor

Controller

E : Parts installed

’’-OF5

to engine

SDEOD168

95 SERIES


STRUCTURE

AND

Electronical

FUEL SYSTEM

FUNCTION

governor

main unit

1. 2. 3. 4. 5. 6. 7.

Housing Actuator Control rod Connector Copper plate Cover Lubrication outlet eyebolt

6

615OFl76

. .

.

.

.

.

The electronical governor is roughly composed of housing, actuator and cover. The actuator is composed of linear DC motor, link and control rod position sensor. It operates in accordance with signals from the control unit. The linear DC motor causes the coil assembly to make up/down motions in accordance with signals from the control unit and causes the coil assembly to become still so that the control rod reaches the target position. (It is because arithmetic processing is executed in the control unit.) The motion of the linear DC motor is further transmitted to the connector through the link, and the fuel injection rate is increased/ decreased when the control rod moves rightward/leftward. That is, the injection rate increases when the coil assembly moves upward, and the injection rate decreases when the coil assembly moves downward. The copper plate at the connector end is the control rod position sensor. It senses the control rod position and feeds it back to the linear DC motor.

95 SERIES

.

.

.

l

The actual injection rate is controlled by these series of motions. That is, the injection rate is controlled at the optimum level that corresponds to the machine running conditions as a result of arithmetic processing executed in the control unit. The linear DC motor is composed of magnet unit that supplies magnetic field, pole unit that leads the magnetic field and coil assembly that makes up and down motions. The operating principle of the DC motor is based on Fleming’s left-hand rule, as it is related to the force applied to current leads in a magnetic field. When the current fed to the coil is of direction A, the magnetic force is applied in direction C. When the current fed to the coil is of direction B, the magnetic force is applied in direction D. When the direction and magnitude of the current fed to the coil are controlled, therefore, the coil assembly can be moved up/down, and it is possible to cause the control rod to be still at an arbitrary position by the feedback from the position sensor.

’’-“i5-6


FUEL SYSTEM

STRUCTURE AND FUNCTION

1) Actuator Control rod position sensor

Copper plate

Connector.

Connect

\

Copper plate

j

Link

r DC motor

uinea

615OFl78

615OFl77

2) Linear DC motor

Pole 615OF179

(Upper side sectional view)

’’-OF7

95 SERIES


STRUCTURE

Control Structural

AND

FUNCTION

rod position

FUEL SYSTEM

sensor

view

l

Operation

diagram

Inductance

615OFl62 6150F161

1. 2. 3. 4. 5. 6.

Copper plate (fixed) Compensator coil E-core Copper plate (movable) Sensing coil Copper plate

This position sensor is located at the center of the governor top for sensing if the control rod is actually located at the correct position with respect to the target position instructed from the control unit. This position sensor is composed of E-core shown above and sensing coils and copper plates of two sets. One of copper plates is installed to the end of the control rod, and another copper plate is fixed to the E-core. This position sensor senses changes in the coil inductance (may be considered as impedance changes) as changes in the counter electromotive force generated in the coil. When a copper plate is placed in a position to intersect the magnetic field generated by the coil as shown above, the magnetic field beyond the copper plate is canceled.

95 SERIES

.

That is, the counter electromotive force generated in the coil changes when the position of the copper plate changes. Another coil and copper plate are provided for compensation. They compensate for impedance changes such as temperature changes. The sensing accuracy is increased by absorbing the abnormality caused by the influence of temperature, etc. through sensing of the control rod position by the ratio (ratio of counter electromotive force) of impedances of two sensing coils.

’’-Oi5-*


FUEL SYSTEM

STRUCTURE AND FUNCTION

LOAD DETECTION

SYSTEM

(OPTION)

Name

plate

SDEOOl69

External

wiring

diagram

Electrical (VI

characteristics

,

_z 320. 05

161 I42 I03

2 s

2+0.05

I&O. 05 H&L

0 -6 LOAD IN

6 SDE00170

’’-OF9

95 SERIES


STRUCTURE

AND

FUNCTION

FUEL SYSTEM

LOAD DETECTOR SYSTEM

(OPTION)

r

r

lrTfi

1 Primary

2 Secondary

Load detector device

Current transformaer

Generator

Load Current transformer SDE00171

Fig. 1

System system

diagram

i

for load detection

Purpose If the system only uses feedback of the speed from the speed sensor, the control will be carried out only after the speed changes when there is a sudden change in the load. As a result, there will be an excessive delay in the response, and it will be difficult to keep the momentary change ratio low. The load detection system detects the change in load with an electric signal, and sends the signal to the control unit, so it is possible to control the injection pump instantaneously. Therefore, it is possible to keep the momentary change ratio to the minimum.

95 SERIES

SDE00172

L Fig. 2

Current

transformer

Operation At the primary side of the current transformer, the load current is always flowing. If the load. increases or decreases, the load current changes, so an electric current is generated at the secondary side of the current transformer. This current is converted to a voltage by the shunt resistance. The change in this voltage is detected and is sent as the load feedback signal to the control unit.

“-“z--‘o


STRUCTURE AND FUNCTION

SYSTEM

STRUCTURE

FUEL SYSTEM

DIAGRAM

(3-PHASE CURRENT)

Shunt resistance

+5v VP’

Load detector

To control unit

SIG

GND Bus 1 Shunt resistance

Bus 2 Shunt resistance

I’

Bus 3

SDEOOl73

’’-“i?-’ ’

95 SERIES



STRUCTURE AND FUNCTION

FUEL

INJECTION

FUEL SYSTEM

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 Its

injection

pump

pump

housing,

is a Bosch type

governor

housing

PES-A.

are forced

lubricated with the engine oil.

.

The fuel injection pump is driven by the pump drive gear

in

the

timing

tion of its rotation driving (flywheel)

’ ’-:76

gear cluster

and

the

direc-

is clockwise as viewed from the side.

95 SERIES


STRUCTURE

AND

STRUCTURE 1.

Structure The

AND

FUNCTION

of injection pump

Bosch

plunger (lo),

FUEL SYSTEM

FUNCTION

type

barrels

tappets

(5),

(II),

the same quantity serve, together

fuel

injection

plunger

pump

(6).

and tappet

contains;

plunger

5. Plunger barrel

17\

6. Plunger

springs

9. Control sleeve

rollers (18), each in

as the engine cylinders, and these

with the camshaft

giving rise to the fuel injection

(12),

as the parts

10.

Plunger spring

Il.

Tappet

12. Camshaft

pressure.

17.

Fuel outlet and inlet port

18. Tappet roller 2. 1)

Pumping action Each plunger makes a vertical piston movement deliver feel under pressure by the combined

to

action

of the cam on the camshaft and plunger spring.

F614601020

2)

If the plunger discharge opened flow

ports

(6) is lowered (17)

by the tip of plunger,

into

the

barrel

Plunger

so that the inlet and

in the plunger barrel fuel will

and stop flowing

(5) are

barrel

17

6. Plunger

begine to when

17.

the

Fuel outlet and inlet

plunger comes into its lowest position. 5

port (suction and discharge port)

t “it

F614601021

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

(19) in the plunger comes in line with the inlet and discahrge ports, fuel will flow back to the inlet and discharge ports through the helix from the plunger center, causing the fuel pressure to drop rapidly.

t !!I Increaseof pressure

Under transfer

Completion of transfer

Withdrawal (no oil transfer) F614601022

5. Plunger barrel 6. Plunger

95 SERIES

17.

Suction and discharge ports

19.

Helical relief (Helix)

’’-z77


STRUCTURE

AND

FUEL

FUNCTION

3.

Effective stroke

.

Distance

from

a position

where the rising plunger

(6) closes the suction and discharge ports (17) the

plunger

barrel

SYSTEM

(5) with

its tip from

in

a point

where the helical relief (19) in the plunger comes in line with the inlet and discharge ports is called the efective stroke (20). varies in proportion

.

The with

helical

relief

reference

Quantity

of fuel to be injected

to this effective stroke.

Effective stroke is short

Effective stroke is long

in the plunger is cut diagonally

to the upper surface.

plunger causes the effective

Rotating

F614601023

the

stroke or the quantity

of fuel to be injected to vary as desired.

5. Plunger barrel

19.

Helical relief

6. Plunger

20.

Effective stroke

17. Suction and discharge port 4.

Adjustment

.

In the lower

mechanism for fuel injection capacity part of plunger

(6) is provided

chaped flange (21). when is fitted

a T-

into the helix in

the control sleeve (9).

.

In the control

sleeve is mounted

the control pinion

(22) which is meshed with the control rack (8).

.

The control

rack is connected to the governor and

fuel control

lever. The

rack

rotates

quantity

the

movement

plunger,

of the control

thereby

adjusting

the

of fuel to be injected.

F614601024

5. Plunger barrel

5.

.

9. Control sleeve

6. Plunger

21.

Plunger flange

8. Control rack

22.

Control pinion

Switching of fuel injection On the top of plunger is installed the delivery valve holder (1) in which the delivery valve (3) and spring

1. Delivery valve holder

(2) are set.

.

Fuel highly

pressurized

overcoming

delivery

valve,

delivery

valve spring,

2. Delivery valve spring

by the plunger opens the and

the

tension

is discharged

of

the

into

the

3. Delivery valve

injection pipe.

F614601025

1 l-g78

95 SERIES


STRUCTURE

.

AND

FUNCTION

The piston

section

of delivery

valve (3).

fuel discharge

FUEL SYSTEM

(23) is provided

at the lower end

by the plunger

is completed,

(2), causing the piston

close

the

prevent

fuel

port

at first,

the reverse flow

6.

Retraction

.

The

valve

will

The above valve action

The

of injection,

RETRACTION

be pushed injection

2

:;

valve

will,

in turn,

down

further,

through

95 SERIES

pipe to flow

at its tapered

stroke prevents

a satisfactory

seat. stroke

of

(24). dribbling

cut-off

F614601026

back,

is called the RETRACTION

and such a working WORK,

assists in producing injection

0 0

in the valve to

which

the valve is called the retraction

.

:

of fuel.

and the valve will be stopped WORK

: :

: 0

work

delivery

causing fuel in the fuel

.

section

:

: 0

the deli-

very valve will be pushed down by the delivery spring

:

I fthe fuel pressure drops after

2. Delivery

valve spring

3. Delivery

valve

23.

Piston

24.

Retraction

stroke

or

of fuel

the nozzle.

1 l-Z79


FUEL SYSTEM

STRUCTURE AND FUNCTION

GOVERNOR Tension lever Start spring

3. Floating lever 4. Guide lever

5. Idling sub-spring 6. :Shifter 7. ISleeve 8. Adapter spring 9. Flyweight 10.

Full-load

stopper

11. Control rack 12. Swivel lever 13. Governor spring 14. Control lever 15. Camshaft

GOVERNOR

.

Bosch RSV Centrifugal all-speed type

11 F033A

GENERAL

DESCRIPTION

1.

Functions of governor

.

The governor

is a Bosch RSV mechanical

type and serves to control

by changing the position of the control fuel

injection

pump

all-speed

the engine output power rack in the

(by adjusting the quantity

of

A flyweight governor

rotational an

to the above, the angleich unit adjusting

maximin

fuel

inejction

speeds, the torque

injection

quantity

change in load during

fuel injected).

.

In addition the

actuated

by the centrifugal

force in the

serves to move the sleeve depending

change in the rotational

on

speed and adjust the move-

such-spring

to

quantity

at

corresponging

to

engine operation,

maintain

an

various

spring unit to obtain

idling

spring to as the engine starting,

a sharp an idling

speed,a

in the governor.

ment of control rack through the guide lever. On the other the

movement

hand, of

the fuel control the

control

lever adjusts

rack through

the

tension lever for the governor spring.

1 l-$80

start

etc. are installed

95 SERIES

.


STRUCTURE

AND

FUEL

FUNCTION

SYSTEM

Function of the governor 1.

.

Engine starting If the fuel control

lever (14)

is pushed to START

position, the governor spring (13) connected swivel lever (12)

integrated

with

to the

the control

lever

will be pushed until the tension lever (1) is brought into contact

with the full-load

stopper (10) at the

lower end.

.

Then,

the sleeve (7) will be shifted to the left, and

the control spring

(2)

quantity,

rack

(11)

will

in the direction

be pulled

by the start

of increasing the fuel

making ease the engine starting.

i

1. Tension lever

.

I IF034

13. Governor spring

2. Start spring

14. Control lever

7. Sleeve

A.

Start position

B.

Full-load position

10.

2.

1’0

Full-load stopper

11. Control rack

C.

Idling position

12. Swivel lever

D.

Stopping position

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 (I) to a point tension.

where the idling sub-spring (5) applies

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 and move-the idling

tension

increases, the flyweight

sub-spring operates

volution.

opens

lever to the right, then the

If the revolution

to adjust the

idling

re-

decrease excessively, the

start spring (2) works to keep the idling revolution.

i 1. Tension lever

I I F035

9. Flyweight

2. Start spring

11. Control

3. Floating lever

13. Governor spring

rack

4. Guide lever

14. Control lever

5. Idling sub-spring

C.

Idling position

7. Sleeve

95 SERIES

“i?*’


FUEL SYSTEM

STRUCTURE AND FUNCTION

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 (IO).

The flyweight

same time, direction

the control

.

If

the

rack will

be moved in the

of increasing the fuel quantity.

the maximum

stopper

(9) will be closed and at the Thereby,

speed will be obtained.

engine

revolutions

range, the centrifugal

exceeds

the

specified

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)

decreasing the fuel quantity.

in the Thereby,

direction

of

the excessive

increase in the revolutions will be prevented. I I F036

I

4.

.

Tension lever

11. Control rack

Sleeve

13. Governor spring

Flyweight

14. Control lever

Full-load stopper

B.

Full-load position

Angleich unit In the engine, if the revolution

increases excessively,

the intake aire resistance will increase, deteriorating the air suction

efficiency.

In the injection

pump,

in proportion

to the

fuel is injected approximately revolutions

and therefore,

the complete combustion

over the shole range of revolution

.

.

will be difficult.

The angleich unit serves to prevent the torque

re-

duction due to the trend of LOCK

IS FUEL

speed, while aiming at COMPLETE

COMBUSTION

at high speeds, thereby

the above un-

satisfactory

conditions.

Where

revolutions

the

improving are low

with

at low

the tension

lever (1) in contact with the full-load

stopper (10)

and the centrifugal

(9) is smaller

than

the

tension

force of flyweight of

the

adapter

spring

(8),

the

adapter spring will shift the sleeve (7) to the left, causing the control tion

110

i

rack (11) to move in the direc-

of increasing the fuel quantity.

Thereby,

I I F037

the

torque at low speeds will be increased.

.

9. Flyweight

As the engine speed increases, the centrifugal force

1. Tension lever

of

7. Sleeve

IO.

8. Adapter spring

11. Control rack

the

flyweight

through

the

contact

with

will

push

sleeve. When the

tension

increasing the fuel quantity

11 -g82

the

adapter

spring

the spring comes into lever,

the

function

Full-load stopper

of

will be terminated.

95 SERIES


5.

Engine stop

.

The swivel lever (12) has a protrusion. lever

(14) is pushed

lever

protrusion the

the

If the control

STOP position,

intergrated

will come into contact Then,

into

with

with

the swivel

the control

lever

the guide lever (4).

lever will position

the control

to

the floating

(3).

I I

1. Tension

lever

11.

rack

11283


FUEL SYSTEM

STRUCTURE AND FUNCTION

FEED PUMP

3

5

4

1. Check valve (Suction) 2. Piston (Priming) 3. Priming pump 4. Tappet 5. Camshaft

2

B

6. Check valve (Discharge) 7. Piston 8. Oil seal 9. Piston (Feed)

1

10. Piston spring

‘6

11.

Nut

A.

Suction port

B.

Discharge port

F614601027

.

The fuel pump is driven by the cam on the fuel injection

pump

camshaft

sure of approx.

and delivers

1.5 kg/cm2.

fuel under pres-

When removing

the air,

you can feed the fuel by pushing the priming pump by hands.

Function Preparation

for fuel delivery

The piston (9) in the feed pump is pushed in by the cam on the camshaft

(5) causing the fuel in the lower

section below the piston to open the check valve (6) on the discharge side and flow into the upper section of the piston. Atthis time, the checkvalve

(1) on the suction side is

closed under the pressure

of fuel pushed in by the

piston, thereby

the reverse flow of fuel.

preventing

Suction and discharge If the camshaft

F614601028

(5) is rotated, bringing the cam out of

the piston, the piston (9) will be pushed upward the piston spring (IO).

The resultant

while fuel is delivered

to the discharge

side,

port (B).

In the section below the piston will be generated pressure,

causing

the suction side to open’s0

by

fuel pressure

will close the check valve (6) on the discharge

negative

6

the check valve

the

(1) on

as to draw in fuel.

F614601029

’ ’-ii84

95 SERIES


FUEL SYSTEM

STRUCTURE AND FUNCTION

3.

*

Control fuel supply Fuel in the section above the piston is through rectly to the passage on the discahrge fuel pressure on the discharge

side.

side increases,

di-

If the itwill

become impossible to push the piston (9) upward by the piston spring (10).

Thus, the suction and dis-

charge of fuel will be stopped until the fuel pressure on the discharge

side drops by controlling

the fuel

quantity to be delivered. F614601030

4.

-

Function of the priming The priming

pump

pump

discharges

fuel in the section

below the piston when the piston (2) is pushed in by hand, and sucks in fuel when the piston is drawn up

B

B

by spring (10).

*

The check valves on the suction and the discharge sides (I) and (6) are used in common

6

with those in

6

the feed pump body. When delivery fuel, the 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.

A Fuel discharge

Fuel suction F614601031

95 SERIES

l l-;85


STRUCTURE

FUEL SYSTEM

AND FUNCTION

FUEL INJECTION

NOZZLE

FOR DIRECT FUEL INJECTION TYPE 4D95S-1,4D95L-1, S4D95L-1, SA4D95L-1 6D95L-1. S6D95L-1, SA6D95L-1

%I 6206F124

6

%I : Shape of spring seat and needle valve Tip is rounded

(Use 5 and 8 as a oair)

-----6

I

JJYY .

B

1.

Connector

2.

Nozzle holder

Diesel Kiki

I

-

Diesel Kiki

I

Nihon Denso

6206F123

Fuel iniection nozzle Type: Diesel Kiki multiple-hole cylindrical type Injection pressure (cracking pressure): 19.6 MPa (200 kg/cm*) PCIOO-5 (106984 and up) PCIOOL-5 (106984 and up) : 22.1 MPa (225 kg/cm? PC120-5 (106984 and up) PC200-5 (83373 and up) PC220-5 (86473 and up) I

. .

3.

Adjustment

4.

Nozzle spring

5.

Spring seat (there are two types)

6.

Retaining

7.

Nozzle body

8.

Needle valve (there are two types)

A.

Ful inlet port (from injection

B.

Fuel spray (inside cylinder)

C.

Fuel return port (to fuel tank)

“ii86

Tip is flat

shim

cap

pump)

1 .

Cracking pressure adjustment:

shim adjustment

95 SERIES


STRUCTURE

AND FUNCTION

FUEL SYSTEM

FOR SWIRL CHAMBER TYPE 3D95S-W-1

6206F538

6206F537A

1.

Nozzle holder

2.

Adjustment

3.

Nozzle spring

4.

Spring

5.

Nozzle valve

6.

Nozzle body

Fuel injection

body

* . . *

shim

seat

A.

Fuel inlet port (from

B.

Fuel spray

C.

Fuel return

95 SERIES

(inside

injection

Model:

nozzle Yanmar

Nozzle type:

Diesel YKCA-S

YDN-0SD177

Injection

pressure

(cracking

Cracking

pressure

adjustment:

pressure):

120 kg/cm*

Shim adjustment

pump)

swirl chamber)

port (to fuel tank)

’ ’-:87


STRUCTURE

FUEL SYSTEM

AND FUNCTION

For swirl chamber type 4D95S-W-1 4D95L-W-1

6204F144A

1.

Nozzle holder

2.

Adjustment

3.

Nozzle spring

4.

Spring

Fuel injection

* . *

shim

seat

5.

Retaining

6.

Nozzle body

7.

Needle

A.

Fuel inlet port (from

B.

Fuel spray

C.

Fuel return

Type:

nozzle

Diesel Kiki throttle

nozzle type

Injection

pressure

(cracking

Cracking

pressure

adjustment:

pressure):

120 kg/cm*

Shim adjustment

cap valve

’’-OZ7-’

(inside

injection

pump)

swirl chamber)

port (to fuel tank)

95 SERIES


STRUCTURE

AND

FUEL SYSTEM

FUNCTION

FUEL CUT SOLENOID SOLENOID A contact

(electricity

flows when stopped)

1

method

2

3

0

4

BR terminal

(AV2LW)

6206F703

1.

Starting

Inner

Plunger

2.

Return spring

3.

Coil

4.

Timer

SOLENOID

switch

. . . . . .

wiring

Maker:

NIKKO

Type:

Sealed

Rated voltage:

D C24V

Pull-in force:

Min. 5.0 kg

Holding force: Performance

Min. 15.0 kg

of timer: Current flows for

FUNCTION

* When stopping the engine, the solenoid is energized, the solenoid plunger is electrically

attracted,

17 seconds after BR terminal

and the

the stop (non-injection)

circuit is

opened (OFF)

stop lever of the injection pump is moved by a rod to position. As a result, the fuel

Stroke:

20 mm

is cut off and the engine is brought to a stop. Accord-

Weight:

2.0 kg

ingly, this solenoid

DENKI

is used only when the engine is

being stopped; it is in free condition

during ordinary

operations.

- When installing the solenoid,refer

to TESTING

AND

ADJUSTING.

95 SERIES

’ ’-Oz7-*


STRUCTURE

AND

FUEL

FUNCTION

SYSTEM

SOLENOID B contact

(electricity

flows in ordinary

1.

Plunger

6.

Solenoid

2.

Coil

7.

Fuel control

3.

Moving

Cl

: Pull-in coil

4.

Stop lever

5.

Return

contactor

C2:

Holding

operation)

Inner

lever

Starting

wiring

6206F607

Solenoid

coil

spring

.

Maker:

NIKKO

* .

Type:

Sealed

Rated voltage:

DC1 2V

*

Coil current

* -

FUNCTION *

method

DENKI DC24V

Maximum:

Max. 55A

Max. 40A

Continuity:

Max. 4A

Max. 2A

Stroke:

20+5mm

Weight:

3.3 kg

engine

When the starting

key

is turned

on, the solenoid

is

energized. Solenoid

shaft

(6)

injection

pump

stop

is electrically lever

(4)

attracted, and fixing

pulling it in the

RUN position. *

Stopping

engine

When the starting

key

is turned

off,

the solenoid

is

de-energized. Injection position -

During controlled

-

pump

operation,

lever

(4) is returned

position)

the

by fuel control

When installing referring

stop

(ncn-injection

amount

’’-“:7-3

of fuel

to STOP spring (5). injection

is

clearance

A

lever (7).

the fuel solenoid,

to TESTING

by return

adjust

AND ADJUSTING.

6162F151

95 SERIES

A


STRUCTURE AND FUNCTION

B CONTACT

SYSTEM

FUEL SYSTEM

(CONSTANT

CURRENT)

4D95L-1

(PC60,70-7)

S4D95L-1

(PC128UU-1)

AUX

6206F972 1. Case Return spring 3. Stop lever 4. Fuel control lever 5. Solenoid

Solenoid

2.

l

l

.

.

Cl. Attraction coil C2. Holding coil

When the engine is started, electricity passes through the solenoid and the solenoid plunger is actuated. This extends return spring (2) (built into the solenoid) and pulls it to the engine run position, and holds it in position. When stopping the engine, the key is turned to the STOP position and the flow of current through the solenoid is stopped. The magnetic force of the solenoid disappears, so the force of the return spring moves the injection pump stop lever to the engine STOP position (no injection). The solenoid plunger is also pulled back at the same time, and the engine stops. The fuel injection amount is controlled by fuel control lever (4) when the engine is running. Adjust clearance A when installing the fuel solenoid valve (see TESTING AND ADJUSTING).

95 SERIES

Type: SYNCHROSTART drip-proof Rated voltage: DC24V Actuating current: When starting to pull: Approx. When finishing pulling: 0.5A Stroke: 25.4 mm Weight: 1 kg

type

25A

4

/3

‘5

6162F151

A

’’-“:7-4


STRUCTURE AND FUNCTION

FUEL SYSTEM

ENGINE STOP MOTOR

-

6

Shape of cable tip (threaded stopper type)-

Section A-A

7

I +onoseal /

Made by AMP Co., cy8P

male

Stroke i,,4. 6 (AV 0.85LR, 2. Not used (filler plug added) 1. Not used (filler plug added)

,3.

P, (AV 0.85LY)

6. Not used (filler plug added) A (AV 0.85L)

/

\

6

1. Motor

9

assembly

2. Cover 3. Cable assembly 4. Cable clamp 5. Coil spring 6. Cable 7. Screw

ENGINE STOP MOTOR * Maker: Jidosha Denki Kogyo Co. Ltd

- Rated voltage: - Operating force: - Stroke:

35:;::

* Weight:

1.2 kg

DC24V Min. 147 N (15 kg) mm

8. Breather 9. Bracket

assembly

10. Cover assembly

’’-“:7-5

95 SERIES


STRUCTURE AND FUNCTION

STRUCTURAL

DRAWING

FUEL SYSTEM

(1)

1.

Gear cover assembly

2.

Slider assembly

3.

Armature shaft

4.

Contactor assembly

5.

Roller

6.

Worm wheel asserribly

7.

Motor assembly

8.

Gear case assembly

95 SERIES

’’-F7-6


STRUCTURAL

1.

DRAWING

(2)

Gear cover assembly

2.

Motor

3.

Cable clamp

4.

Cable assembly

5.

Gear case assembly

’’-07-7

assembly

95 SERIES


STRUCTURE

AND

FUNCTION

FUEL SYSTEM

DESCRIPTION

Contact plate on

plus side

P2_

1 I

I

The above drawing shows the stopped condition has been formed.

I

Auto-stop position on P2 side

Auto-stop position on P, side

closed circuit

E,

when a

The slider assembly is

stopped at the auto-stop position on the PI side. 2.

When switch is turned (when starting the motor) Battery

I

P2_ E, Al

ln7

When the switch is moved to the Pz side (starting switch

starting the motor.

ON),

an electric

contact switch 3.

plate

current

through

and into

the

flows

(90’

the

Pz auto-stop

the armature

Turning Condition

from

plus

side

the direction

terminal

and

starts to move.

The slider assembly starts to move in

of the arrow at the same time as the roller

shaft assembly, thereby

in the drawing) attery I-i I7

Electric current continues to pass through the armature

the

assembly and the motor

continues to move in the direction of the arrow.

95 SERIES

continues

to turn. Because of

rotation

of

the

roller,

the

slider

assembly

also

’’-k87-8


STRUCTURE

4.

A

FUNCTION

FUEL SYSTEM

When stopped (180°)

closed

terminal

5.

AND

circuit

is formed

when

the

P2

rides on the minus-side contactor

auto-stop

plate, and the

motor comes to a sudden stop. The slider assembly also stops.

When switch is turned (when starting the motor)

When the switch is moved to the PI side (starting switch

motor.

OFF),

tion of the arrow at the same time as the roller starts to

an electric current

flows from the plus contactor

plate through the PI auto-stop terminal into

the armature

Turning condition

6.

and switch and

shaft assembly, thereby

(270°

The slider assembly starts to move in the direc-

move.

starting the

in the drawing) Batterv +--1 2

Electric current continues to pass through the armature

of the arrow. Then the circuit

shaft

1.

assembly

and the

motor continues

to turn. The

returns to stop condition

slider assembly also continues to move in the direction

’-07-9

95 SERIES


FUEL SYSTEM

STRUCTURE AND FUNCTION

FUEL FILTER

I

6206F125

Fuel filter

*

Filter area:

0.093 m2

Filter area:

0.2 m2

Filter area:

0.3 m*

6202FOO7

Fuel filter . Filter area: 0.15 m* Filter area: 0.18 m* 1.

Overflow

2.

Filter bracket

1.

Air bleed plug

3.

Cartridge

2.

Filter bracket

4.

Water

3.

Cartridge

A.

Fuel inlet port

B.

Fuel outlet port

C.

To fuel tank

95 SERIES

valve

level sensor

(installed according

to models)

“-“:7-‘o


STRUCTURE AND FUNCTION

FUEL SYSTEM

WATER SEPARATOR

TA

Section A-A F614601032

1.

Bracket

WATER

2.

Ring nut

3.

Baff leplate

. .

4.

Body

5.

Float

6.

Drain plug

A.

Fuel inlet (from fuel tank)

B.

Fuel outlet (to feed pump).

11 -k88

SEPARATOR

Separation

performance:

Pressure loss:

Min. 99% (at 0.7Qlmin.) Max

. 20 mmHg (at 0.7Q/min.)

95 SERIES


COOLING

SYSTEM

COOLING SYSTEM CHART 3D95S-W-1

‘8

6206F539

1.

Radiator

2.

Thermostat

3.

Water

temperature

4.

Water

pump manifold

5.

Water

6.

Cylinder

7.

Piston

8.

Cylinder

95 SERIES

sensor

head block

’’-$89


STRUCTURE AND FUNCTION

4D95S-1 4D95L-1 S4D95L-1 4D95L-W-1 4D95S-W-1

1

COOLING

2

3

4

5

6

'8

6204F151A

1.

Radiator

2.

Thermostat

3.

Water temperature

4.

Water pump

5.

Water manifold

6.

Cylinder head

7.

Piston

8.

Cylinder block

9.

Oil cooler (option)

’’-ii90

A.

From oil pump (oil)

gauge

95 SERIES


STRUCTURE AND FUNCTION

COOLING SYSTEM

6D95L-1 S6D95L-1

.8

F614601037

1. Radiator

7. Cylinder head

2. Thermostat

8. Piston 9. Cylinder block

3. Water pump 4. Water temperature

gauge

10.

Oil cooler

A.

Lubrication

5. Water manifold 6. Corrosion resistor (Option)

95 SERIES

oil

1 l-$91


STRUCTURE AND FUNCTION

COOLING SYSTEM

WATER PUMP l

WITH SEPARATE TYPE WATER SEAL, INTEGRATED BEARING, SHAFT FOR CONSTRUCTION EQUIPMENT, GENERATORS t Ring assembled water

to

Seat assembled

pump bodv

c(\

The shape may differ according

to the machine

model.

to

imoeller

\

Detail P

\

6206F 127-l

1.

Pump cover

2.

Impeller

3.

Water

4.

Pump body

Water pump

*

Type:

Centrifugal

type (V-belt drive)

seal

5.

Boss

6.

Drive shaft

A.

Water

B.

Water

inlet port (from thermostat)

C.

Water

outlet port (to engine)

D.

Water

outlet port (to radiator)

inlet port (from radiator)

F614601033 .

The water

pump has a simple structure and uses a

highly reliable centrifugal-type

.

Vortex-shaped impeller.

guide

Based on the

the centrifugal-type fugal force

which

vortex pump.

vanes are rotation

vortex

pump

attached of the

to

uses the centri-

works in the external

direction

to send out the cooling water.

“if9*

the

impeller,

95 SERIES


STRUCTURE AND FUNCTION

l

COOLING SYSTEM

UNITIZED SEAL WITH ONE PIECE WATER SEAL, INTEGRATED BEARING, SHAFT FOR CONSTRUCTION EQUIPMENT, GENERATORS *

The shape may differ according to the machine

model.

Ring

1

Seat

\

/,

Portion where shG impeller

of

/

has been changed

6206F127-2

1.

Pump cover

2. 3. 4. 5. 6.

Impeller Water

Water pump

*

Type:

Centrifugal

type (V-belt drive)

seal

Pump body Boss Drive shaft

A.

Water

B.

Water

inlet port (from thermostat)

C.

Water

outlet port (to engine)

D.

Water

outlet port (to radiator)

95 SERIES

inlet port (from radiator)

’’-Og2-’


COOLING SYSTEM

STRUCTURE AND FUNCTION

(BEARING, SHAFT SEPARATED TYPE, UNITIZED SEAL WITH INTEGRATED WATER SEAL) FOR CONSTRUCTION EQUIPMENT, GENERATORS t

The shape may differ according to the machine

model.

Ring eat

1

2 \\\__\\__

-A

6206F877

1.

Pump cover

2.

Impeller

3.

Water seal

4.

Pump body

5.

Boss

6.

Drive shaft

7.

Ball bearing

A.

Water inlet port (from radiator)

B.

Water inlet port (from thermostat)

C.

Water outlet port (to engine)

D.

Water outlet port (to radiator)

’’-z2-2

Water pump . Type: Centrifugal

type (V-belt drive)

95 SERIES


STRUCTURE AND FUNCTION

COOLING SYSTEM

CORROSION RESISTOR (OPTION)

Section

Section

1.

Bracket

2.

Body

F614601034

CORROSION RESISTOR . Filtration area: 0.13 m2

3.

Element

(Paper)

4.

Element

(Chemicals)

5.

Spring

6.

Valve

A.

Water inlet

EL

Water outlet

95 SERIES

A-A

B-B

1793


COOLING SYSTEM

STRUCTURE AND FUNCTION

THERMOSTAT

AND

S4D95L-1 (For PClOO-6, PC120-6, 6D95L-1 S6D95L-1 SA6D95L-1

Wind

FAN

DRIVE

PC128UU-I) +

The shape may differ according to the machine

model.

0

/

L View 2

6206F

1. Fan (PC120-6, PC128UU-1: Bent axis flow fan) 2. Fan belt 3. Water pump 4. Fan spacer 5. Fan pulley 6. Vibration damper (6-cylinder engine only) 7. Crankshaft pulley 8. Crankshaft 9. Thermostat case cover 10. Thermostat (PC100,120-6, PC128UU-1: with jiggle valve) 11. Thermostat case 12. Alternator

6. To radiator (cooling water) C. From engine (cooling water) D. Direction of wind a, b, c: Outside diameter of pulley d. Heater pickup port e. Therm0 sensor (installed on some models) f. Water temperature gauge pickup port

95 SERIES 11:94

I28


STRUCTURE AND FUNCTION

COOLING

PClOO,

120-6.

SYSTEM

PCl28UU-I

,

l i

i

6206F129.1

Outer diameter Engine

Applicable

of pulley (mm)

machine a

b

C

3D95S-W-1

EC35Z, ZS-2

139

65

141.4

4D95S-1

WA50-1

150

74.2

150

4D95L-W-1

WA40-1,

150

95

150

135

95

150

165

75

150

PC60-6 (Up to 102170)

165

95

150

PC60-3,

150

95

150

GU60-1

WA70-1 PC60-6 (102171

4D95L-1

PC60-5,

and up)

PW60-3

1 PC80-3

S4D95L-1

95 SERIES

I

169

I

95

I

150

CD35-1

150

95

150

PC1 00, 120-5, PC1 00-6

150

95

150

PC1 20-6

150

95

169

PC128UU-1

189

95

150


STRUCTURE AND FUNCTION

COOLING SYSTEM

6206F129-1

Outer diameter

Engine

6D95L-1

Applicable

a

b

C

TP95S-1

150

85

150

PC1 00-3, PC1 20-3

185

95

150

PW150-1

202

95

150

165

95

150

PC200-5, S6D95L-1

SA6D95L-1

of pulley (mm)

machine

BR200-1

I PWIOO-3,

PC150-3

WA150-1,

WT150-1

PC220-5,

’’-k95-1

BR300-1

I

165

I

95

I

150

185

95

150

165

95

150

95 SERIES


STRUCTURE AND FUNCTION

COOLING SYSTEM

6206F899

Note:

The diagram

shows the D31-18,

20, and D37-2, 5.

Outer diameter Engine

Applicable

of pulley (mm)

machine (Fan 1 a

(Alternator)

b

(Crankshaft)

D20-6,

D21-6

139

95

150

D20-7,

D21-7

165

95

150

D31-18

187

95

150

D31-20

202

95

150

037-2

187

95

150

4D95S-1

6D95L-1 1 D37-5

I

187

I

95

I

150

95 SERIES ’ ’ -Or2

c


STRUCTURE AND FUNCTION

COOLING SYSTEM

6206F1021

Note:

The diagram

shows the PC60, 70-7.

Outer diameter Engine

Applicable

(Fzn) 4D95L-1

’’-OF3

of pulley (mm)

machine (Altekator)

(Crankhaft)

PC60, 70-7

152

77

150

PC60, 70-7 (Blade specification)

152

95

150

95 SERIES


COOLING SYSTEM

STRUCTURE AND FUNCTION

S6D95L-1 (For PC200-6) SA6D95L-1 (For PC220-61

L-A

SME00.236

'C

/----5

1-s

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. A: 6: C:

Alternator Fan belt (poly V-belt) Fan (bent axis flow fan) Water pump Crankshaft Crankshaft pulley Vibration damper Fan pulley Fan spacer Thermostat (cracking temperature: Connector (water outlet port) Thermostat case To radiator From radiator Heater pickup port

82°C)

A-A

Outer diameter Engine

S6D95L-1 SA6D95L-1

95 SERIES

Applicable

machine (Fzn)

b (Tension)

185

95

of pulley (mm) (Crankshaft)

d (Water pump)

PC200-6 148

115

PC220-6

11-095-4 0


STRUCTURE AND FUNCTION

THERMOSTAT

7

8

COOLING SYSTEM

(WITH JIGGLE VALVE)

9

10

11 6206F1009

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Piston Case Pellet Seat Valve Case Spring Bypass spring Bypass valve Bypass seat E-ring Jiggle valve

’’-OF

%: The jiggle valve allows air to flow but stops water from flowing. It allows the engine water temperature to rise in a short time.

95 SERIES


ACCESSORY

STRUCTURE AND FUNCTION

EXHAUST BUTTERFLY

BRAKE

VALVE

TYPE

From exhaust brake valve

11 12

6206F973

8. Air

1. 2. Bushing Spindle 4. 5. Valve 6. Spindle Bushing

9. 10. 11. 12. 13.

Insulator Stopper (fully open position) Yoke Lever Stopper (fully closed position)

Outline The exhaust by the valve,

is installed between the and muffler. is actupressure from the the passage from to the to reduce

engine speed. exhaust brake mechanism and the the valve.

95 SERIES

cylinder

of valve which oper-

’’-OF6


COOLING SYSTEM

STRUCTURE AND FUNCTION

SOLENOID

VALVE

6206F974

2. 3. 4. 5. 6. 7. 8. 9. 10.

Connector Case Core Coil assembly Spring Plunger Spring Valve Rod Body

’’-OF7

A. B. C.

From air tank To exhaust brake Exhaust outlet port

95 SERIES


STRUCTURE

AND

FUNCTION

ACCESSORY

Operation 1. Exhaust brake switch OFF When the switch is at the OFF position, solenoid (I) of the exhaust brake valve is deenergized. In this condition, the passage between ports A and B of the exhaust brake valve is closed, and the passage between ports B and C is open. Therefore, the air entering cylinder (5) of the butterfly valve returns from port B to port C and is released to the atmosphere. The passage from the turbocharger to the muffler through butterfly valve (7) is fully open. 2.

Exhaust brake switch ON When the switch is ON, solenoid (1) of the exhaust brake valve is excited, so plunger (3) and valve (4) move up in the direction of the arrow. This closes the passage between ports B and C, and opens the passage between ports A and B. The air from the dry tank enters port B and flows to cylinder (5) of the butterfly valve. When this happens, the cylinder extends and lever (6) moves down in the direction of the arrow. The passage from the turbocharger to the muffler through butterfly valve (7) is fully closed. As a result, the engine speed drops and the travel speed is restricted when the machine is traveling downhill. Even if the switch is at the ON position, if the accelerator pedal is depressed, the low idling detection limit switch is actuated and prevents the engine brake from taking effect.

95 SERIES

“OFF”

To muffler

From dry tank 22X

F459

?? ,4 -Exhaust

t t

To muffler

From dry tank 22XF460

’ -OF*


STRUCTURE

AND

FUNCTION

ELECTRICAL

SYSTEM

ELECTRICAL SYSTEM ALTERNATOR 3D95S-W-1

6206F543

1.

Collar

2.

Flywheel

3.

Bolt

4.

Plate

5.

Stator

6.

Plate washer

7.

Spring washer

8.

Nut

9.

Coupler

6206F855

Alternator

wiring diagram

Pulley Engine

3D95S-W-1

Machine

EC35Z, ZS-2

model

Type

Specification

Nikko Denki, open type

12 V, 14A

.

No. of pulleys

Outside diameter (mm)

1

65

Weight (kg)

1.4

95 SERIES


STRUCTURE

BUILT-IN

ELECTRICAL

AND FUNCTION

SYSTEM

REGULATOR TYPE (35A) (PC40-5, PC40-6, PCSOUU-1)

1.

Alternator

2.

Alternator

pulley

B, E, F, IG, L: Terminals

Internal

wiring

diagram

6206F606

Pulley Engine

3D95S-W-1

95 SERIES

Machine

model

PC40-5, PC40-6 PC5OUU-1

Specification

Type

Nihon

Denso,

open type

12 V, 35 A

No. of pulleys 1

Outside diameter (mm) 72

Weight (kg)

3.6


STRUCTURE AND FUNCTION

BUILT-IN

REGULATOR

ELECTRICAL SYSTEM

TYPE (25A) (PC60, 70-7 OP, PCIOO, 200-6, (BR200-1) (304 (PC200-6, PC220-6)

PC128UU-1,

PC200, 220-5)

n

6206F856

1. 2.

Alternator Alternator

pulley

Internal

wiring

diagram 6206F857

Machine model

95 SERIES


STRUCTURE AND FUNCTION

BUILT-IN

ELECTRICAL SYSTEM

REGULATOR TYPE (35 A)

6202FOO5

1.

Alternator

2.

Alternator

pulley

6, IG, L, E: Terminals

6206F858

Internal wiring diagram

Pulley Engine

Machine

4D95S-1

WA50-1 L

95 SERIES

model

Specification

Type

Nihon Denso, open type

12 V, 35 A I

1 1

Weight (kg)

Outside diameter (mm)

No. of pulleys

I1

74.2

2.7 ,

11-096-3


STRUCTURE

ELECTRICAL

AND FUNCTION

SYSTEM

BUILT-IN REGULATOR TYPE (22A, 25A)

E B.R

Single

I

Alternator

1.

Regulator

2.

Alternator

3.

Alternator

Regulator

I Inner

Double pulley WPe

pulley type

I

6206F131

wiring

B, E, F, R: Terminals pulley

Pulley Engine

Machine

4D95L-W-1

WA40-1,

4D95L-1

PC60-3

S4D95L-1

PC1 00-5, PCIOO-3,

model

WA70-1

20-5 PC120-3 WAIOO-1

Specification

Type

Nikko Denki,

type

24V,

_

of pulleys

Outside

1

95

Nikko

open type

V, 25

1

95

Nikko

open type

V, 25

1

95

Nikko

open type

V, 25

2

95

24 U, 25 A

2

95

Weight (kg)

GD313A-1 S6D95L-1

00-3, PC1 WA150-1, GD461A-1

’’-:96-4

Nikko Denki, open type

7.3

95 SERIES


ELECTRICAL SYSTEM

STRUCTURE AND FUNCTION

BUILT-IN

REGULATOR TYPE (15 A)

Regulator 1.

Regulator

2.

Alternator

3.

Alternator

pulley

ET1

6206F544

Alternator

Pulley Engine

Machine

model

Type

Specification

Nikko Denki, open type

24V,15A

Outside diameter (mm)

No. of pulleys

95

D20-6, D21-6 4D95S-W-1

4.0

1 77

ECSOZ, ZS-5 PC60-5, PC80-3,

PC75UU-1 PC75UU-2

1

95

7.5

24V,15A

1

77

4.0

Nikko Denki, open type

24V,15A

1

77

4.0

Nikko Denki, open type

24V,

1

77

4.0

Nikko Denki, open type

24V,

EC75Z, ZS-3

Nikko Denki, open type

6D95L-1

D31A, P, S-18, D31-20 D37-5, EGGOB, BS-1

S6D95L-1

EG85B, BS-1

4D95L-1

95 SERIES

Weight (kg)

15A

15A

I


STRUCTURE

AND

ALTERNATOR

FUNCTION

ELECTRICAL

WITH REGULATOR

AND VACUUM

SYSTEM

PUMP

6206F545

1.

Vacuum pump

2.

Regulator

3.

Alternator

4.

Alternator

A.

Air inlet

B.

Air and oil outlet

C.

Oil inlet

B., E, R: Terminals

pulley

Pulley Engine

Machine

4D95L-1

model

PW60-3 I

’’-“J6-6

Specification

Type

Nikko Denki, open type I

24 V, 25 A I

1 I

Weight (kg)

Outside diameter (mm)

No. of pulleys

95

I

11

I

95 SERIES


STRUCTURE AND FUNCTION

ELECTRICAL SYSTEM

BUILT-IN REGULATOR TYPE

Double

Internal 1. 2. 3.

Regulator Alternator Alternator

wiring

pulley

Single

diagram

pulley

6206F976

pulley

Pulley Engine

S6D95L

95 SERIES

Machine

LW80-1

model

Type

Sawafuji Denki, Open type

Specification

24 U, 50 A

No. of pulleys 2

Outside

Weight (kg)

diK%er 77

10

11-096-7


STRUCTURE AND FUNCTION

BUILT-IN

REGULATOR

ELECTRICAL SYSTEM

TYPE

SDE00174

1.

2. 3.

Regulator Alternator Alternator

pulley

B, E, F, R: Terminals

Pulley Engine

Machine

S4D95L-1

D21A-7T (Trimming)

’’-oP-8

model

Type Nikko Denki Drip-proof type (Sealed)

Specification

24 V, 13 A

No. of pulleys 1

Weight (kg)

Outside diK%er 95

7.6

95


STRUCTURE

AND

FUNCTION

STARTING

ELECTRICAL

SYTEM

MOTOR

WITH SAFETY

RELAY

TYPE

Starting

1. Yoke

motor Starting

2. Armature

c&z

3. Ball bearing

8

9

10

wiring

diagram

switch ,\

50

4. Pinion 5. Pinion 6. Starting

pinion

7. Shaft 8. Housing 9. Brush 10. Starting

switch

07BFl93A

Engine

Machine

model

Specification

I 3D95S-W-1

95 SERIES

PC40-5, PC40-6 PC5OUU-1, EC35Z, ZS-2

Hitachi sealed type, reduction type

12V,2

kW

1 pin%:1 9

5.4


STRUCTURE AND FUNCTION

ELECTRICAL SYSTEM

WITH SAFETY RELAY TYPE

6206F832

Safety relay

Starting

motor

:@q-J

Inner wiring

3.

C, F,

Pinion gear Magnetic switch motor

Machine

model

D21-6,

EC502,

4D95S-W-1

4D95L-W-l

WA40-1,

4D95L-1

PC60-3, PC80-3,

ZS-5

D21-7 WA70-1 PC60-5, PW60-3, PC75U U-l, -2 D21A-7T

Pefeth

wlt$ht

Nikko

sealed

type

V, 2.8

9

7

Nikko

sealed

type

V, 2.5

9

8.9

I

EC75Z, ZS-3,

11$98

pinyot

Type

WA50-1 D20-7,

R: Terminals

Nikko

Denki,

sealed

type

24 V, 2.8 kW

9

7

Nikko

Denki,

sealed

tvDe

24 V. 2.8 kW

9

7.5

Nikko

Denki,

sealed

type

24 V, 2.8 kW

9

7.5

Nikko

Denki,

sealed

type

24 V, 2.8 kW

9

7

95 SERIES


STRUCTURE

AND

FUNCTION

ELECTRICAL

Terminal

R

SYSTEM

Termin

Drip-proof 2-pin connector (X connector)

6206F959

Safety relay

Starting

motor

;eaq

Wiring connection

diagram

B, C. F, R, S: Terminals

1. 2. 3.

Pinion gear Magnetic switch Starting motor (body)

V, 2.8 kW

95 SERIES

9

7.3


ELECTRICAL SYSTEM

STRUCTURE AND FUNCTION

Terminal

R

2-pin connector (drip-proof

Safety

relay

Starting

Terminal

S

(male)

X connector)

motor

l&qq--.

L. #

Internal

wiring

connection

diagram 6206F977

1. 2. 3.

Pinion gear Magnetic switch Starting motor (body)

Engine

S4D95L-1

Machine model PC1 00, 120-5, PCIOO, 120-6 PC128UU-1

Specification

Type

Nikko Denki (water-proof, oil-proof

type)

pinyo:

Efeth

Weight (kg)

24 V, 5.5 kW

11

12

S6D95L-1

PC200-5,

PC200-6,

BR200-1

Nikko Denki (water-proof, oil-proof

type)

24 V, 5.5 kW

11

12

SA6D95L-I

PC220-5,

PC220-6,

BR300-1

Nikko Denki (water-proof, oil-proof

type)

24 V, 5.5 kW

11

12

’’-“g8-2

95 SERIES


STRUCTURE

AND

FUNCTION

ELECTRICAL

SYSTEM

SEPARATELY LOCATED SAFETY RELAY TYPE

Internal wiring connection diagram 6206F976

1. 2. 3.

Pinion gear Magnetic switch Starting motor (body)

Engine

S6D95L-1

Machine

LW80-1

model

Type

INihon

Denso,

sealed type

Specification

1 24 V, 4.5 kW 1

No. of pinion teeth 11

Weight (kg) 1

8.5

95 SERIES ’ ’ -“g8-3


ELECTRICAL SYSTEM

STRUCTURE AND FUNCTION

rI

_-_-_

Drip-proof

X connector type

\

Terminal

R

1

/

Terminal

r

S

e-s

Open type

5

Safety relay Starting

1

motor

;@@q

Wiring connection

diagram 6206~133

1. 2. 3.

Pinion gear Magnetic switch Starting motor (body)

Engine

Machine

model

D31A, P, S-18, -20 PCIOO-3, PC120-3 PW150-1, WAIOO-1 6D95L-1

D37-2,-5,

Safety relay Connector

I

B, C, F, R, S: Terminals

Type

Specification

No. of pinion teeth

Weight (kg)

Nikko Denki, sealed type

24 V, 5.5 kW

12

11

Nikko Denki, sealed type

24 V, 2.8 kW

11

7

Nikko Denki, sealed type

24 V, 5.5 kW

12

11

Nikko Denki, sealed

24 V, 2.8 kW

11

GD313A-1

EGGOB-1 EGGOBS-1 PC150-3, WA150-1,

4. 5.

PWIOO-3 GD416A-1

S6D95L-1 EG85-1 EG85BS-1

’’-“i8-4

type

I

7

95 SERIES


ELECTRICAL

INTAKE

AIR HEATER

ELECTRICAL HEATER (DIRECT FUEL INJECTION TYPE)

1.

Heater coil

2.

Housing

Specification

. .

Rated voltage:

DC24V

Rated current:

11 OA (when 22 V)

Wiring diagram

6136FO25

(BIMETAL TYPE GLOW PLUG)

I

12 V (Blue) 24 V (Red)

1.

Sheath

2.

Coil (Fe)

3.

Insulator

Quick type

(Fe-Cr)

1 Birnetai =I

F614601049

95 SERIES

“if99


STRUCTURE AND FUNCTION

ELECTRICAL SYSTEM

CONTROLLER (QUICK GLOW SYSTEM)

Round

8-pin

1.

Connector

2.

Lead wire

3.

Case

4.

Bracket

1

Pin No.

I

I

(round

8-pin),

(Short

1 Color of lead wire

1

1 Blind plug

I

5

1 Red/yellow

I

6204F200

WATER TEMPERATURE SENSOR (QUICK GLOW SYSTEM)

6204F201

1

1.

Water

I

2.

Lead wire

(blue/red)

Connector

(round

3.

Width

temperature

across flats:

sensor l-pin) 22 mm

F614601098

GLOW RELAY (QUICK GLOW SYSTEM) 1.

1.

Controller

2.

Ground

(WR:

(B:

Glow relay

2.

Lead wire

3.

Connector

white

with

(round

2-pin)

red)

black)

6204F202

’’-Oi!i9-’

8-pin)

95 SERIES


ELECTRICAL SYSTEM

STRUCTURE AND FUNCTION

CONTROLLER 1.

Connector

2.

Lead wire

(round &pin)

3.

Case

4.

Bracket

1

Pin No.

I

7

( Blind plug

r

8

I White

)

Color of lead wire

1

6204F200

WATER TEMPERATURE

SENSOR

Connector type 1.

Water

2.

Lead wire (blue/red)

3.

temperature

Connector

sensor

(round l-pin)

Width across fiats:

22 mm

6204F201

Terminal type 1.

Water temperature

2.

Terminal Width

\

across flats:

sensor 22 mm

M16xP1.5 F614601098

95 SERIES

’ ’-Oi9-*


STRUCTURE

AND FUNCTION

ELECTRICAL

SYSTEM

GLOW RELAY 1.

!

Glow relay

2.

Lead wire

3.

Connector

(round

2-pin)

3

1.

Controller

2.

Ground

(WR:

(B:

white

with

red)

black)

6204F202

’ ’-“g9-3

95 SERIES



STRUCTURE

ACCESSORY

AND FUNCTION

ACCESSORY AIR COMPRESSOR

1. Oil seal

12. Cylinder head

A.

Air inlet

2. Crankshaft

13.

Unloader valve spring

B.

Air outlet

3. Ball bearing

14.

Unloader valve

C.

Unloader

4.

15.

Unloader valve guide

Front cover

5. Connecting rod

16.

Inlet valve

6. Oil ring

17.

Inlet valve spring

7. Piston pin

18. Spring seat

8. Piston

19. Outlet valve

9. Second ring

20.

Outlet valve spring

IO. Top ring

21.

Crankcase

11. Cylinder block

22.

Rear cover

11200

95 SERIES


STRUCTURE

AND

ACCESSORY

FUNCTION

AIR COMPRESSOR . Maker:

DIESEL

KIKI

. .

Type:

Single cylinder,

Discharge volume:

150 cc/rev

.

Air pressure

8.5 kg/cm*

-

Weight:

Rotating

speed:

95 SERIES

double

acting

Engine speed x 0.5 6.5 kg

11201



INTAKE

AND

EXHAUST

SYSTEM

.... .. .. ....

Adjusting valve clearance Measuring exhaust gas color ENGINE

. 12-002 . 12-004

BODY

...... ......... Adjusting engine speed sensor .......

Measuring compression pressure

12-005

Measuring blow-by pressure

12-006 12-007

FUEL SYSTEM Checking and adjusting

... . . . . . 12-008 ..... . . . . . 12-01 O-6

fuel injection timing Adjusting

governor

Testing and adjusting fuel cut solenoid Procedure

engine stop motor cable Adjusting

. . .

fuel injection pressure.

LUBRICATION

..

Measuring oil temperature

12-011

.

. . . . . . 12-014 . . . . . . . 12-015

SYSTEM

Measuring water temperature

...

Testing and adjusting fan belt tension FUEL

. 12-010-l 1 . .

SYSTEM

Measuring oil pressure

COOLING

12-010-9

for adjusting

INJECTION

PUMP

CALIBRATION PERFORMANCE

.. 12-016 . . . 12-017

...

DATA

.

.

12-018

TEST

................. ........... Testing and adjusting tool list ...... Testing and adjusting data ........ Run-in standard

Performance test criteria

12-023 12-030 12-030-21

12-030-22

TROUBLESHOOTING Method of using troubleshooting Troubleshooting

95 SERIES

table

table

..

...... . ..

. . . 12-032 . . 12-037

’*zol


TESTING

INTAKE

AND

ADJUSTING 1. 2.

INTAKE

AND ADJUSTING

EXHAUST

VALVE

AND

EXHAUST

SYSTEM

SYSTEM

CLEARANCE

“~

Remove cylinder head cover Rotate

the crankshaft

watching cylinder engine)

in the

the movement (3-cylinder

engine),

or No. 6 cylinder

No. 1 cylinder

normal

direction.

of the intake valve No. 4 cylinder

(g-cylinder

into Compression

While

of No. 3 (Ccylinder

engine),

bring the

Top Dead Center posi-

tion and align the TOP engraved

mark on crankshaft

pulley (1) with pointer (2). Sr

*

TOP engraved

mark to be aligned with pointer

4-cylinder

engine:

1.4 TOP mark

6-cylinder

engine:

1.6 TOP mark

When

the No. 1 cylinder

Top Dead Center (3-cylinder engine)

comes near Compression

position,

engine),

the No. 3 intake valve

No. 4 intake valve

or No. 6 intake

valve

(Ccylinder

(6-cylinder

engine)

will start to move (open).

3.

Adjust

the valve clearance for valves marked

valve arrangement 4.

Rotate

the crankshaft

revolution

l

in the

*

Valve arrangement 3-cylinder

chart. in the normal

direction

Cylinder

by one

chart

engine No.

1

I

and adjust the valve clearance for the remain-

I

2

I

I

3

I

I

ing valves marked 0.

4cylinder

engine

Valve clearance (Engine at hot or cold) e

G-cylinder engine

8. =

Cylinder

No.

Intake valve

Exhaust valve

’*-kio2

1

2

l

3 0

l

l

4

0

5 0

l

l

6

0

0 l

95 SERIES

0


TESTING

*

To

AND

adjust

ADJUSTING

the

adjustment ding

valve

screw

clearance,

(41, insert

to the specified

and rocker

arm

adjustment

screw

INTAKE

loosen

feeler

clearance

between

(6). and adjust until

the

lock

nut

(3) on

gauge A corresponvalve

3

EXHAUST

6

SYSTEM

5

stem (5)

the clearance

thickness

4

AND

with

the

gauge can slide

lightly.

6206F202 5.

After

the clearance

is properly

nut to secure the adjustment m

*

Lock nut:

Intake shaft

with

*

valve

clearances

in a firing

following

direction. * Crankshaft

rotating

angle

engine:

240

4-cylinder

engine:

180�

6-cylinder

engine:

120

may

be adjusted

order by rotating at

a time

in

the crankthe

normal

order

3-cylinder 4-cylinder

engine: engine:

1 - 3 - 2 1- 2 - 4 - 3

6-cylinder

engine:

1- 5 - 3 - 6 - 2 - 4

95 SERIES

the lock

angle

3-cylinder

Engine firing

tighten

4.5 + 0.5 kgm

and exhaust

for each cylinder

adjusted, screw.

’2-;03


TESTING

MEASURING

A

When

EXHAUST

measuring

not to touch

*

Measure

the

Insert

exhaust

probe

to exhaust

2.

Connect

the exhaust

the exhaust

(Oil temperature: 1.

INTAKE

AND ADJUSTING

AND

EXHAUST

SYSTEM

GAS COLOR

gas color,

be careful

pipe.

gas color

while

engine

is warm.

40 - 6O’C)

A in outlet

pipe with

probe

of exhaust

pipe (1) and secure

clip.

hose and connector

switch to smoke checker B. * The pressure of air

hose for accelerator

supply

should

be

under

15 kg/cm2. 3.

Connect *

power cable to AC1 OOV socket.

Check

that

connecting

the

power

4.

Loosen cap nut of suction

5.

Turn power switch

ON.

Accelerate

engine

suddenly.

accelerator

pedal, operate

6.

gas color on filter 7.

Lay filter of unused

is

OFF

pump and insert filter

before

At the same time,

filter

depress

paper.

papers

reference AND

gas color

(10 sheet or more)

and read indicated

see TESTING

paper.

relief valve and catch exhaust

paper used to catch exhaust

paper holder, * For the

12-gO4

switch

the code.

value

on top

inside filter

value. of the exhaust

ADJUSTING

gas color,

DATA.

95 SERIES


TESTING

AND

ENGINE

COMPRESSION

MEASUREMENT

burn

the compression

yourself

muffler, *

PRESSURE

PROCEDURE

While measuring not

BODY

BODY

MEASURING

L!l

ENGINE

ADJUSTING

and

on

the

be careful

not

revolving

part of the engine.

Measure

the compression

pressure, take care

exhaust

manifold

to get caught

pressure while

or

in any

the engine

is warm. (Oil temperature:

1.

Adjust

the

valve

ADJUSTING 2. 3.

40 - 6O’C)

clearance

VALVE

properly.

Remove spill tube and disconnect For machines

with

For

details,

see

CLEARANCE.

a key stop

fuel injection system,

pipe.

remove

the wir-

ing of the fuel cut solenoid. (For machines wiring 4.

with

a stop

motor

installed,

remove

the

of the connector.)

Remove nozzle holder assembly for each cylinder. * Remove the nozzle holder assembly by prying with the spill tube mounting *

Take

it

bolt.

care not to let any dirt

or foreign

matter

get

into the cylinder. 5.

6. 7.

Install

adapter

to

the

nozzle

holder

of the cylinder

to be measured,

to the specified

torque.

m

Torque:

Connect

compression

the engine

gauge A to the adapter. lever in NO INJECTION

with

the starting

gauge when the pointer

is stabilized.

motor,

If you do not put the fuel control A *

INJECTION Most

compression

applying section *

For

the

a small

position,

lever in NO

fuel will blow out.

leakage amount

position,

and readthe

can of

oil

be prevented to

the

by

mounting

of the adapter. reference

sure, see TESTING

95 SERIES

section

the adapter

4.5 i- 0.5 kgm

Place the fuel control crank

mounting

and tighten

values of the compression AND

ADJUSTING

pres-

DATA.

’2-iio5


TESTING

AND ADJUSTING

MEASURING *

Measure

BLOW-BY

blow-by

pressure

(Oil temperature: 1.

Remove suction

3.

4.

engine

is warm.

and

install

blind

plug

in blow-by

(1). then install head cover.

(For 4D95L-1, 2.

while

PRESSURE

Min. 85’C)

head cover tube

ENGINE

4D95L-W-1,

4D95SW-1,

6D95L-1)

Install adapter to oil filler.

Connect

adapter to pressure gauge A with tube.

Run the engine at high idling,

and measure the blow-by

pressure. * Blow-by

greatly

condition

if

abnormal,

check blow-by,

tion,

defective

or deteriorated

blow-by for such

exhaust

reference

see TESTING

12-gO6

the

dirty

For the

varies

according

to the

of the engine.

Therefore, defective

*

pressure

AND

value

problem

is

as excessive gas color,

considered

connected

with

oil consump-

and prematurely

oil. value

of the

ADJUSTING

blow-by

pressure,

DATA.

95 SERIES

BODY


TESTING

AND ADJUSTING

ADJUSTING

ENGINE

BODY

ENGINE SPEED SENSOR

PCIOO-6, PC120-6 PC200-6, PC220-6 1.

install engine speed sensor (I) to flywheel housing (2), then screw in by hand until sensor (I) contacts ring gear (3) lightly. 6 Thread of engine speed sensor: Sealant (LG-6)

2.

After sensor contacts ring gear l/6 turns and secure in position + When this is done, clearance +. 0.25 mm. w Locknut: 58.8 f 9.8 Nm Ir After adjusting, check that carried out smoothly.

(31, turn back lwith locknut (4). a should be 1.5

TME00104

(6 + 1 kgm) cranking can be

DCA85 When the engine speed sensor has been removed and is assembled again, do as follows. Set the piston at top dead center and align the pointer with the crankshaft pulley 1, 3, 4, top line. When this is done, pin (I) knocked into the flywheel is immediately in front of the pickup mounting hole. In this position, tighten speed sensor (3) until it contacts pin (I) in the flywheel, then loosen one turn. * Clearance a when this done: 1 f 0.2 mm Tighten locknut (3). w Locknut: 49.0 - 4.9 Nm (5 f 0.5 kgm) * After adjusting, check that cranking can be carried out smoothly.

95 SERIES

V

TOE00086


TESTING

AND

FUEL SYSTEM

ADJUSTING

FUEL SYSTEM CHECKING INJECTION There

AND ADJUSTING TIMING

FUEL

are two methods for checking and adjusting the fuel

injection timing of an injection pump. l

The “MATCH

MARK

ALIGNMENT”

used when the injection

method,

which is mark

pump is installed to the original

C

engine and the pump is not being repaired. l

The “DELIVERY

VALVE”

method, which is used when

a repaired or replaced injection

pump is installed to the

engine. *

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.

614OF107 (View

from

flywheel

side)

CHECKING AND ADJUSTING BY THE MATCH MARK ALIGNMENT METHOD 1.

Assemble pump holder and pump drive gear on injection pump.

2.

Set No. 1 cylinder at compression top dead center. (See ADJUSTING

VALVE

Align pointer with IT,

CLEARANCE)

1.4T or 1.6T mark on crankshaft

pulley, then confirm that the mark ‘C’ on idler gear can be seen. If the mark ‘C’ can not be seen, rotate the crankshaft one more turn. 3. 4.

1’

Remove cover (1). Mount 4 -

injection 4.5 mm,

pump on engine, and insert pin (dia: length:

80 mm)

in hole of drive gear

through hole a. Then confirm

a 614OFllO

that mounting

holes of pump holder and

front gear cover are aligned. 5.

Tighten

mounting

bolts, confirm

that lines on injection

pump, pump holder, and front plate are aligned. 6.

If the position cannot be aligned,

7.

After tightening jection

pump,

repeat Step 4.

all bolts, check that the lines on the ininjection

pump

holder,

and front

plate

are aligned.

’2-:08

95 SERIES


TESTING

AND

ADJUSTING

l

With coupling

1.

Turn the crankshaft

FUEL SYSTEM

type injection

pump

back 30 -

40� from

the No. 1 cylin-

der TOP position. 2.

Rotate

slowly

in the normal

jection

timing

mark on the crankshaft

direction

and align damper

the inwith

the

pointer. 3.

Check that the line on the injection on the coupling *

The

injection

chine

model,

justing, t

If the oblong

and the line

timing

differs

so refer

according

to the values

to the

ma-

for testing,

ad-

and troubleshooting. lines hole,

then tighten m

pump

are aligned.

Nut:

are not aligned, move

loosen

the coupling

the

to align

nut in the the lines,

the nut again. 3.25 k 0.25 kgm Coupling

type

612FO82

95 SERIES

’2-o$8-1



TESTING

AND

CHECKING DELIVERY 1.

ADJUSTING

FUEL SYSTEM

AND ADJUSTING VALVE METHOD

BY THE

Disconnect fuel injection tube (1) for the No. 1 cylinder.

Remove delivery valve holder (2). Remove

spring

delivery

(3)

and delivery

valve holder,

valve

(4)

from

the

and reassemble the delivery valve

holder. Place the fuel rotate

the

operating

control

crankshaft the priming

lever in FULL

position,

slowly

in the

direction

while

pump,

when the fuel stops flowing

normal

and observe the position out of the delivery

valve

holder. In the position

where the outflow

of fuel stops, check

s

6150P210A

the injection timing stamp line on the crankshaft pulley (5) to see if it is aligned with the pointer (6). * 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 of adjustment, following

*

After

shows that the injection timing

adjust the fuel

injection

timing

is out in the

manner.

the checking and adjusting, be sure to reassemble

the spring and the delivery valve.

1)

Rotate

the crankshaft

direction,

starting

30’

from

to 40’

TOP

in the reverse

position

in

No. 1

cylinder.

2)

Align the injection timing stamp line on crankshaft pulley

(5) with

pointer

(6) by slowly

rotating the

crankshaft in the normal direction.

95 SERIES

12-gO9


TESTING

3)

FUEL SYSTEM

AND ADJUSTING

Loosen nut

(7) 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

flange slot. * Recheck

the

injection

pump mounting

timing

to

see if it is

properly adjusted. 5)

Align

match

mark

a with

mark

b and stamp the

marks.

After adjusting, be sure to assemble delivery valve again. *

Always replace the copper gasket delivery valve with new parts.

the spring

and O-ring

and

on the

TESTING AND ADJUSTING AN INJECTION PUMP HAVING PLUNGERS WITH HELIX * Injection pump (with plungers with helix) This

pump

responds

to

an auto-timer

to

auto-

matically vary the injection timing depending on the engine speed. *

An engine equipped with an injection plungers

with

helix

injection

timing

is constructed

in a low

speed

pump having to

delay

the

range from

the

activation of the start spring. For this reason, it is difficult

to obtain the normal

injection

adjustment

timing

by

making

with

the

conventional fuel delivery method. Injection delays on pumps at engine rotation, 400 rpm, are as shown in the table on next page. *

The

only

difference

in adjustment

by the

ventional delivery method and the adjustment this injection

pump is that in this injection

rack cap pushes in the

control

dimension before adjustment adjustment

of

the

conwith

pump a

rack by a given

in order to prevent the

injection

timing

from

being

affected by the start spring. Thus, an injection

pump having plungers with helix

must have an adjustment 1.

rack cap.

Injection timing adjustment

rack cap

Replace the present rack cap in the injection pump with an adjustment

rack cap.

The subsequent adjustment steps are the same as the standard adjustment procedure.

/ Part No.:

‘2-Fo

6204F202-3

D K155404-6400

95 SERIES


TESTING

AND

ADJUSTING

TABLE OF INJECTION

Engine

Machinemodel

FUEL

PUMPS

D20,21E-6 4D95S-1

4D95L-1

PLUNGER

njectior Injection pump part No. delay

D20,21A-6 4D95S-W-1

USING

WITH

Engine

6202-72-1210 4"

STEPPED

LEAD

Machinemodel

njectior delay

Injection pump part No. 6206-71-1210

PCIOO-3 4"36'

6D95L 6202-72-1230

PC120-3

6206-71-1220

WA50-1

6202-73-1130

PWIOO-3

6207-71-1240

PC60-3

6204-71-1210

6207-71-1241

PC60-5

6204-71-1220

6207-71-1242

PC60-6

6204-73-1210

6207-71-1270

PW60-3

6204-71-1230

PC80-3

6204-71-1240

6207-71-1331

PC75UU-1

6204-71-1280

6207-71-1332

PC90-1

6204-73-1220

D20-6

6204-71-1260

WA150-1

S6D95L

PCIOO-5

S4D95L PC120-5

6207-71-1330

4"36'

6207-71-1333 6207-71-1334

6204-71-1270

6207-71-1260

PC200-5

6205-71-1230

6207-71-1261

6205-71-1231

6207-71-1262

6205-71-1232

6207-72-1260

6205-71-1240

6207-71-1230

6205-71-1241

6207-71-1251

6205-71-1242

PC150-3

6207-71-1320

PW150-1

6206-71-1240

PC150-5

6207-71-1220

r/VAlOO-1

6206-71-1330

S6D95L-1

6206-71-1331

PWIOO-3

4"36

4"36'

6D95L

6207-71-1333 X220-5

6206-71-1333

6209-71-1260 6209-71-1261

6206-71-1334 NA120

6206-71-1360

137A. P-2

6206-71-1370

131-18

6206-71-1250

6207-71-1240 6207-71-1332

v'lA150-1

6206-71-1332

95SERlES

SYSTEM

SA6D95L

4"36'

6209-71-1262 6209-72-1260

’2-oio-1


FUEL SYSTEM

TESTING AND ADJUSTING

ADJUSTMENT (3D95S-W-1)

OF FUEL INJECTION

AMOUNT

Special tools No.

Part Name

Part No. YM

158090-51010

Pump installation stand for Yanmar test stand

YM

158090-51020

Pump installation stand for Robert Bosch test stand

1 YM

158090-51500

A

078P241

B

Using

pump

1 Rack indicator

installation

stand

A, set injection

pump

(1)

on the test stand. Remove

control

rack blind

plug

(2), and install

rack in-

B.

dicator

Rack indicator

Rotate

pinion

the injection

(4) so that pump

at the drive

078F241

control

rack

(3) moves

side face to the maximum

side, then

set the standard

from

a

position

position

(a) on

indicator

slide

position

in the

the scale of the rack indicator. It

Check

that

the

control

rack

and

smoothly. Move

the control

direction

the rack is within Control

lever to the maximum

of operation

and

the standard

check

that

the

position

078F243

rack stroke: 12 + 0.5 mm on the indicator

If the control value,

of

value.

replace

rack stroke

is not within

the link connecting

lever and control The link is provided

’2-o&o-2

scale

the standard

the ‘governor

rack. with

marks every

1 mm.

95 SERIES



FUEL SYSTEM

TESTING AND ADJUSTING

TESTING

FUNCTION

OF PLUNGER

(3D95S-W-1)

Special tools No.

1

A

Part No.

YM

1.

Install

2.

Drive the injection control the

0 - 1000 kg/cm2 gauge

121820-92540

pressure

pump

lightly

direction

for

*

the

amount

rises to above

pressure

move

of fuel,

the in and

078F247

500 kg/cm’.

does not reach

After

the

pressure

rises,

check

does

not

suddenly

drop

and

After

holder.

500 kg/cm2,

the plunger.

leakage *

valve

200 rpm,

the side face of the pump

increasing

If the plunger replace

at approx.

from

check that the pressure *

pressure

A to the delivery

gauge

pinion

Part Name

I

from

that

that

the

there

pressure is no oil

any part.

the pressure

immediately

rises, release

the control

pinion

and set it to NO INJECTION.

078 P243

TESTING VALVE

AIR-TIGHTNESS

1.

the

Follow plunger reaches

2.

same

function,

procedure and

120 kg/cm*,

Measure

OF DELIVERY

when

return

as the

when

testing

plunger

the

pressure

it to NO INJECTION.

the time taken for the pressure

to change

100

+ 90 kg/cm*. Ir

If the time than

taken

5 seconds,

for wash

the

pressure

the delivery

to drop valve

is less and test

again. If the drop

in pressure

is still too quick,

replace

the

plunger. 3.

After

4.

w Delivery valve holder: 3.75 L- 0.25 kgm Test the plungers of the other cylinders in the same way.

adjusting,

install the delivery

’2-oAo-4

valve

holder.

95 SERIES


TESTING

AND

MEASURING (3D95S-W-1) Special

TOP CLEARANCE

Part Name

Part No.

A

OF PLUNGER

tools

No.

1.

FUEL SYSTEM

ADJUSTING

YM

158090-51300

Top clear&ce

Place top clearance

gauge

gauge

A on a flat surface

and set

the zero point. 2.

Remove

the delivery

spring, 3.

Turn

valve

holder,

delivery

then install the top clearance the pump

gauge

camshaft,

indicator,

watch

valve,

and

gauge.

the movement

and set the cam exactly

of the

to top

dead

center. 4.

in this condition, dicator

(top

plunger

barrel

read the position clearance (2):

plunger

check that it is within *

Plunger

of the dial gauge

between top

the standard

top clearance:

plunger clearance

in-

(1)

and

“a�),

and

a

value.

0.5 + 0.05 mm

078F251

5.

If the plunger

top clearance

value,

adjust

the

fitted

between

the roller *

is not within

thickness

adjustment

of screw

shim

(4) of tappet

(5)

(3) and

guide.

Plunger

top clearance

adjustment

shim

Shim thickness

Shim part No.

6.

the standard

adjustment

YM

129156-51750

1.45

YM

129156-51760

1.55

YM

129156-51770

1.65

YM

119865-51610

1.70

YM

119865-51670

1.75

YM

119865-51620

1.80

+

Standard

*

Prestroke:

Assemble

shim thickness:

(mm)

078F252

1.7 mm

2.0 mm

the delivery

valve

spring,

valve,

and holder

again. m

Delivery

95 SERIES

valve

holder:

3.75 i

0.25 kgm

12-O&O-5 J


TESTING

AND

FUEL

ADJUSTING

ADJUSTING

GOVERNOR

SYSTEM

(3D95S-W-1)

1. Adjusting

fuel limit bolt (adjusting full load stopper)

Full load position

1) Keep the pump speed at the rated speed N,, and move the fuel

control

the amount

lever

2) In this condition, fuel

limit

value 3) 4)

adjust

the amount

of tightening

measure

the amount

of fuel

and check that it is within

the standard

value.

Tighten

Keep

the locknut

the

pump

speed

control

the amount

Adjust

the

within

at the lever

078F253

rated

fully

speed,

and

in the direction

move to in-

of fuel.

amount

of tightening

from

Raise the speed,

N, b Pump speed (rpm)

idling speed

of maximum

bolt (1) at the point where

starts to move

injected,

of the fuel limit bolt.

maximum

crease

tion

of the

is the standard

N, %

position,

adjustment 3)

to increase

(R,).

In this

the governor 2)

in the direction

bolt so that the rack position

2. Adjusting 1)

fully

of fuel.

R,.

and check that the speed

R, corresponding the standard

speed

the rack position

to the maximum

at rack posi-

idling

speed

is

value.

078 F255

’2-oho-6

95 SERIES


FUEL SYSTEM

TESTING AND ADJUSTING

3. Adjusting 1) 2)

idling

Hold the pump speed at idling speed N,. Move the governor while

measuring

injection

amount

control

lever to the idling position

the injection

amount.

is the standard

When

the fuel

value, fix the position

of lever (1) with the idling adjustment

bolt.

.

4.

Checking

1)

From the idling speed

injection

amount gradually

when

078F256

starting

raise the speed

and

check that the control rack moves smoothly. 2)

Set the pump speed at the starting speed N,, and hold the governor

3)

control lever at the full load position.

Check that the control rack position is at the maximum rack position,

then measure

the fuel injection

to check that it is within the standard

95 SERIES

amount

value.

’2-oAo-7


TESTING

AND

ADJUSTING

5. Adjusting *

The

torque

injection

FUEL SYSTEM

rise

pump

includes

torque

spring

as

amount

of fuel.

Adjust

amount

of fuel (increase

1.

Adjusting

*

Adjust

the

an Angleich

mechanism

to

the torque

spring

and

increase

the

rise to increase

the torque)

the

as follows.

Angleich the Angleich

after

adjustng

the

high

as part

of the

idling

speed. *

Use the

Angleich

spring

Angleich

assembly.

1) Place the governor position,

and

maximum

control

hold

torque

2) Remove

the

speed

governor

Angleich

speed

at

the

(Ns).

case

assembly

lever in the full load pump cover

(3) into

(I),

and

the thread

screw of ten-

sion lever (2). 3)

Put the Angleich governor begins

lever to move),

the specified 4)

Check

that

Tighten *

screw

the Angleich

Angleich

Raise the

injection

injection

amount

7)

rise stroke

the lever by

is within

torque.

078 F257

locknut. turn

together

with

tightening. locknut:

2.75 + 0.25 kgm

pump

to the

(N,), and check that the control torque

with the

it in further

at maximum

Do not let the Angleich

w 6)

where

(0�).

value

the nut when

in contact

position

then

angle the fuel

the specified 5)

assembly (the

rated

speed

rack moves

the

Check that rack position

(R,) and the fuel injec-

tion

the standard

amount

rated speed

Torque rise stroke

P

N,

N,

(1) smoothly.

are within

value

at

(N,).

Pump speed (rpm)

12-OAO-8

N, 078F258

95 SERIES


TESTING AND ADJUSTING

FUEL SYSTEM

TESTING AND ADJUSTING SOLENOID

FUEL CUT

3D95S-W-1 l

With

this type,

17 seconds

electricity

to actuate

is passed it when

to the solenoid

the

engine

for

is stopped

(no injection). 1.

Push stop

lever

run position turn spring

2.

fully,

Do not tighten

*

Mark the thread

Turn

the

*

rod

When

engine

when

in the re-

rod (2).

doing

this.

in the

direction

for

making

it

the rod locknut. 0.5 times,

the rod becomes

1 mm shorter.

Pass electricity the

fully

a built-in

of rod (2).

the rod is turned

approx.

with

assemble

the rod locknut

0.5 turns

then tighten

pump

the solenoid

then temporarily

*

shorter,

3.

(1) of the injection

to extend

through

stops

the

correctly.

solenoid Carry

out

and this

check test

that three

times. 6206F548

95 SERIES

12-O&O-9


TESTING

AND

ADJUSTING

FUEL SYSTEM

4D95L-W-1, 4D95L-1 6D95L-1, S6D95L-1 If the solenoid is not actuated smoothly, an excessive current will flow and the solenoid coil will burn out, or there will be a drop in output because of the reduction in the injection amount. To avoid this, check the clearance between the stopper and lever, check the stroke of the solenoid, and adjust the length of the rod as follows. 1.

2.

3.

Pull the rod by hand towards the solenoid so that the stop lever is actuated when the solenoid is actuated. Adjust the length of the rod so that the clearance between the stop lever and the stopper is 0.3 - 0.5 mm. Pass electricity through the solenoid and check the solenoid stroke (12 mm) and the clearance between the stop lever and stopper (0.3 - 0.5 mm), and make final adjustment. Start and stop the engine 2 or 3 times and check that the solenoid is actuated smoothly and that the engine stops.

Note:

2

3

5

4

6204~203

1. 2. 3. 4. 5.

Fuel injection Stopper Stop lever Rod Solenoid

pump

The diagram above shows the system for the WA70-1. The mounting position of the fuel cut solenoid and the shape of the stop lever for the WAIOO-1, WA150-1 are different from the diagram above, but the method for testing and adjusting is exactly the same. The D21A-7T (trimming specification) has no stop lever.

4D95S-W-1 1.

Confirm

that the stop lever of the fuel injection

is in the injection position (ordinary

2.

Adjust ween

the length of rod the

lever

pump

operation side).

(1) so that the clearance bet-

and stopper

is less than

1 mm,

then

tighten locknut (2).

3.

Push the

rod

and confirm

(stroke:

20 mm)

towards

the solenoid

that there is a clearance between the stop

lever and stopper. 4.

Start the engine, actuate the solenoid, and confirm that the

engine

comes to

a complete

stop.

Repeat

three

times. 5.

This

solenoid

is a type

in which

an electric

current

passes (for 17 set) when the engine is stopped.

12-OAO- 10

95 SERIES


FUEL SYSTEM

TESTING AND ADJUSTING

4D95L-1 (PC60, 70-7) S4D95L-1 (PC128UU-1) Install ball joint (2) to solenoid locknut (3). + a: Approx. 1 mm (I thread)

(I)

and tighten

Portion P

6206F1022

Assemble rod (4) and rod end (5) temporarily to ball joint (2). * Depth b for screwing rod into ball joint: Approx. 12.5 mm * Depth c for screwing rod end into rod: Approx. 10.0 mm

6206F1023

3.

Pass electricity through solenoid (1) to make it attract. * When doing this, if rod end (5) and stop lever (6) of the injection pump are connected before the solenoid is actuated, the solenoid will not be pulled away (the actuating current will continue to flow) when the solenoid is actuated, and the coil will burn out. To prevent this, do not connect the rod end and stop lever.

Solenoid held I)

I 4.

6206F1024

Check that solenoid (I) is attracted, then connect rod end (5) to stop lever (61, and adjust the length of rod (4) so that the stop lever contacts the end of the lever at the constant end.

Solenoid held b

6206F1025

95 SERIES

’2-oiF’ ’


FUEL SYSTEM

TESTING AND ADJUSTING

Stop lever (6) contacts the end of the lever at the constant end. (Contacts inside the injection pump) * Play: 0 mm

Constant

RUH

;;

Detail of stop lever angle

stopper

6206F1026

1

6206F1030

* Do not pull beyond stop lever end

When adjusting the length of rod (4), do not apply any excessive force to pull stop lever (6) beyond the lever end. The method for adjusting the rod length is as shown in the diagram on the right.

* To make rod shorter

* To make rod longer 6206F1027

5.

Tighten nut (7) at the connection of stop lever (6) and rod end (5), then install a split pin. Ir Install the rod end so that greasing port (8) is at the top. & Rod end: Grease (G2-LI)

Solenoid

I

6.

Make rod (4) longer to give play at the constant end of the stop lever. * Play d: 1.0 - 2.0 mm (loosen the rod l/2 - 1 turn)

held *

6206F1026

Play from constant

end

Stop lever constant

Solenoid

end

held

l

4 6206F1029

’*-OAO-’ *

95 SERIES


TESTING

AND ADJUSTING

7.

Tighten locknut (8). Ir When doing this, be careful that rod (4) does not turn together with locknut (9). Be careful also not to twist stop lever (6) with excessive force.

8.

Stat-t and stop the engine 2 or 3 times and check that solenoid (6) is actuated smoothly and that the engine stops.

FUEL SYSTEM

6206F1031

95 SERIES

’2-o’z-’ 3


TESTING

AND ADJUSTING

FUEL SYSTEM

PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE Engine stop motor

4D95S-1 6D95L-1 (D31-20, S6D95L-1

D37-5)

/b

6206F900

6206F1032

Temporarily install a ball joint to the cable of the engine stop motor (screw in fully, then turn back approx. l/2 turns). Install a ball joint to the stop lever of the injection pump also. Clearance between stopper and STOP stopper

6206F901

Pull the injection pump stop lever by hand to the ENGINE STOP position (NO INJECTION) position, and temporarily assemble the cable to the bracket. When doing this, keep the stop lever in contact with the ENGINE STOP stopper, and temporarily install the cable to the bracket with the locknut. + The engine stop motor is delivered with the cable pulled (engine stop). Sr The stop lever of the fuel injection pump is at the operating position when the lever is free (it is pulled to the operating position by a spring). 3.

Adjust so that clearance a between the fuel injection pump stop lever and the STOP stopper is 1 - 2 mm when the engine stop motor is installed (when the engine is stopped). Adjustment can be carried out using the nut holding the cable to the bracket or by carrying out fine adjustment of the amount that the ball joint is screwed in.

Engine STOP stopper

ClearaAce between siop lever and STOP stopper

’2-oAo-’ 4

6206F999

95 SERIES


TESTING AND ADJUSTING

4.

Tighten

5.

Turn the engine starting switch ON/OFF several times to check that the engine stop motor and cable operate smoothly, then check the following points again. 1) Check visually that there is slack in the engine stop motor cable when the engine is running, and that the stop lever of the fuel injection pump has returned fully to the RUN side. 2) Check again that the clearance between the stop lever and the STOP stopper is 1 - 2 mm when the engine is stopped. * Limit switches are built into the engine stop motor at both ends of the cable stroke. * Stroke of engine stop motor: 35 mm Stroke of fuel injection pump stop lever: 30 mm * The action of the spring (this is usually built into the fuel injection pump) ensures that there is slack in the engine stop motor cable when the engine is running and that it is kept in the operating position. * There is a loose spring inside the engine stop motor and when the engine is stopped, this absorbs the tolerance of the stop motor. However, if this is absorbed by the loose spring of the engine stop motor, force is applied at the injection pump end, so depending on the model, this is made impossible. With such models, if the clearance between the STOP stopper and the stop lever is set at zero when the engine is stopped, there is danger that problems may arise with the injection pump.

95 SERIES

FUEL SYSTEM

all nuts and bolts.

*

Problems caused by defective adjustment of the engine stop motor cable

l

l

Clearance between stop lever and STOP stopper is too lame when engine stop motor cable is pulled. Clearance between stop lever and RUN stopper is too large when cable is free.

l

l

Engine does not stop

Engine output drops because of drop in amount of fuel injected

‘2-oF5 1


TESTING AND ADJUSTING

FUEL SYSTEM

ADJUSTING FUEL INJECTION (CRACKING PRESSURE) 1.

Remove

retaining

PRESSURE

For swirl

cap (1).

chamber

type

For swirl chamber

3D95S-W-1

2.

Remove

nozzle

(2), spring

seat

type

4D95S-W-1 4D95L-W-1

(3), and nozzle spring

(4).

3.

Adjust

thickness

of shim

ure (cracking

pressure).

*

adjustment

Pressure

3D95S-W-1 4D95S-W-1 4D95L-W-1 4D95S-1 (S)(SA)4D95L-1 (S)(SA)6D95L-I m

Retaining

(5) to adjust

injection

press-

for 0.1 mm of shim thickness

: : : : : :

Approx.

Q

10.6 kg/cm2

Approx.

9.5 kg/cm*

Approx.

9.5 kg/cm2

Approx.

15 kg/cm2

Approx.

15 kg/cm*

Approx.

15 kg/cm2

cap

3D95S-W-1 4D95S-W-1 4D95L-W-1 4D95S-1 (S)(SA)4D95L-1 (S)(SA)6D95L-1

: : : : : :

7.5 + 0.5 kgm 7.5 f 0.5 kgm 7.5 + 0.5 kgm 4.5 f 0.5 kgm 4.5 + 0.5 kgm 4.5 + 0.5 kgm

6204F202.1

6206F547

For direct

injection

type

4D95S-1 (S)(SA)4D95L-1 (S)(SA)6D95L-1

6204F202

95 SERIES

‘*i?’


TESTING

SHIM *

AND

FUEL

ADJUSTING

DATA FOR ADJUSTING

Always

use sets of shims

the injection Enaine

made

adjustment

a= 4.0 mm b=11.5 mm

0.8 -

Thickness

Part No. YMI 23325-53800

0.800

YMI 23325-53810

0.95

YMI 23325-53820

1 .oo

YMI 23325-53830

1.05

YMI 23325-53840

1.20

Engine

for

shims.

Range of shim thickness

Shape

3D95S-W-1

PRESSURE

by the same maker

nozzle and pressure

I

INJECTION

SYSTEM

1.2 mm

Range of shim thickness

Shape

Thickness

Part No.

(mm)

(mm)

Range of shim clearance

a

4D95S-1 (S)(SA)4D95L-1

a=2.1

mm

(S)(SA)6D95L-1

b-7.2

mm

Part No.

Thickness

DKI 50534-3600

0.100

DKI 50534-3700

0.200

DKI 50534-3800

0.300

DK150534-3900

0.400

DKI 50534-4000

0.500

DKI 50534-4100

0.520

DKI 50534-4200

0.540

DKI 50534-4300

0.560

12%12

0.1 -

(mm)

0.58 mm

0.025 mm

Part No. DKI 50534-4400

Thickness

(mm)

0.580

95 SERIES


TESTING

AND

ADJUSTING

FUEL

Engine model

Shim a

4D95L-W-1 4D95SW-1

thickness

(Range)

a = 4.5 mm b=

Part No.

Shim

contour

0.50

11.5mm

Thickness

-

1.54

Shim thickness (Interval)

0.02

mm

(mm)

Part No.

mm

Thickness

DK150523-5000

0.50

DK150523-7900

1.08

DK150523-5100

0.52

DKI

1.10

DK150523-5200

0.54

DK150523-8100

1.12

DK1505235300

0.56

DK150523-8200

1.14

DKI

0.58

DK150523-8300

1.16

DK150523-5500

0.60

DK150523-8400

1.18

DK150523-5600

0.62

DK 150523-8500

1.20

DK150523-5700

0.64

DK150523-8600

1.22

DK150523-5800

0.66

DK150523-8700

1.24

DKI

0.68

DKI

50523-8800

1.26

DK150523-6000

0.70

DK 150523-8900

1.28

DK150523-6100

0.72

DK 150523-9000

1.30

DK150523-6200

0.74

DK150523-9100

1.32

DK 150523-6300

0.76

DK150523-9200

1.34

DK150523-6400

0.78

DKI

50523-9300

1.36

DK150523-6500

0.80

DKI

50523-9400

1.38

DK150523-6600

0.82

DK150523-9500

1.40

DK150523-6700

0.84

DK150523-9600

1.42

DK150523-6800

0.86

DK150523-9700

1.44

D K150523-6900

0.88

DK 150523-9800

1.46

DK150523-7000

0.90

DK 150523-9900

1.48

DK150523-7100

0.92

DKI

1.50

DK150523-7200

0.94

DK150530-0100

1.52

DK1505237300

0.96

DK150530-0200

1.54

DK150523-7400

0.98

DK150523-7500

1 .oo

DK150523-7600

1.02

DK150523-7700

1.04

DKI

1.06

50523-5400

50523-5900

50523-7800

95 SERIES

SYSTEM

50523-8000

50530-0000

(mm)

12-gl3


TESTING

AND

LUBRICATION

ADJUSTING

LUBRICATION MEASURING

A

the oil pressure,

get caught in rotating Always with

SYSTEM

OIL PRESSURE

When measuring

A

be careful

not to

parts.

remove or install plugs or oil pressure gauges

the engine stopped.

*

Measure the oil (Oil temperature:

1.

Remove plug

pressure while Min. 80°C)

engine

is warm.

(1).

2.

Install oil pressure gauge A.

3.

Start the engine, and measure the oil pressure. * For reference value of oil pressure, see TESTING AND

12;14

SYSTEM

ADJUSTING

DATA.

95 SERIES


TESTING

AND

ADJUSTING

MEASURING 1.

2.

Remove dipstick

insert

LUBRICATION

SYSTEM

OIL TEMPERATURE (1).

sensor of thermistor

temperature

gauge in dipstick

guide. 3.

Connect

sensor to thermistor

measure temperature * For reference TESTING

95 SERIES

AND

temperature

gauge A and

of oil in oil pan. value

of

ADJUSTING

oil

temperature,

see

DATA.

12-p


TESTING

AND

COOLING

ADJUSTING

COOLING

SYSTEM

MEASURING

WATER

n

sensor

When measuring not

to

rotating 1.

Disconnect

get the

the water

TEMPERATURE

temperature,

cable

SYSTEM

be careful

or clothes

caught

in

part. wiring

of

water

temperature

gauge,

then

remove sensor (1). 2.

Install

adapter

and

sensor

gauge in water temperature

3.

Connect

of thermistor pick-up

sensor cable to thermistor

temperature

port.

temperature

gauge A,

and measure water temperature.

‘*-P

95 SERIES


TESTING

AND ADJUSTING

TESTING TESTING

COOLING

AND

FAN

BELT

ADJUSTING

SYSTEM

FAN BELT TENSION

TENSION Approx. 6 kg

Check the amount the fan belt deflects when pushed with a force of 6 kg at a point midway the altqnator * For the

between the fan pulley and

pulley. reference

TESTING

AND

values of the fan belt tension,

ADJUSTING

see

Alternator

pulley (

)

DATA.

21 KF102

ADJUSTING 1)

Loosen

FAN mounting

tension adjustment 2)

BELT bolt

of

adjustment

alternator

pulley

and belt

bolt (1).

Using a bar, raise alternator Tighten

TENSION

bolt

and adjust fan belt tension. (I),

then

tighten

mounting

bolt.

95 SERIES

12X$7


FUEL INJECTION PUMP CALIBRATION DATA

TESTING AND ADJUSTING

FUEL INJECTION

PUMP CALIBRATION

DATA

3D95S-W-1

4D95S-W-1

6202-73-I

160

6204-71-1560

4D95L-W-1

95 SERIES


TESTING AND ADJUSTlNG

Engine model

Pump

FUEL INJECTION PUMP CALIBRATION DATA

assembly

No.

Engine serial No.

6205-71-1232~I~~~

I PCIOO-5

Page

I

12-022-18

6205-71-1240

31713 and up

PC120-5

12-022-19

6205-71-1241

48811 and up

PC120-5

12-022-20

6205-71-1242

48811 and up

PC120-5

12-022-21

PC120-5

12-022-22

6205-71-1243 S4D95L-1

Applicable machine

1 6205-71-1271

PCIOO-5

)

I

12-022-23

6205-71-1510

PCIOO-6

12-022-80

6205-71-1520

PC120-6

12-022-81

1 6205-71-1320

1

PC128UU-1

I 6205-71-1290

1

JV70DW-1

1 6206-71-1310

1

WA120-1

6206-71-1320

10018 and up

6206-71-1335

I-6206-71-1361 6206-71-1420

26324 and up

I I

GD300-2 WAIOO-1,

6206-71-1360

I

23424 and up

12-022-107 12-022-24 12-022-25

WRII-1

12-022-26

WA120-1 WA120-1

I

12-022-81

12-022-27

I

12-022-85

EG60-1, EG65S

12-022-28

D31E, P, S, Q-18

12-022-36

6D95L-1

6206-71-1251

D31E, P, PL, PLL-20(A)

6206-71-1252

12-022-65

D31S,Q,AM,SM-20 6206-71-1331 6206-71-1333

22592 and up

6206-71-1334 6206-71-1370 6206-71-1371

95 SERIES

29245 and up

WAlOO-1

12-022-37

WAIOO-1

12-022-38

WAlOO-1

12-022-39

D37E-2

12-022-40

D37E-2

12-022-86

’2-oA8-’ 1


TESTING AND ADJUSTING

FUEL INJECTION PUMP CALIBRATION DATA

SL6D95L-1

6207-71-1242

PWIOO-3

12-022-90

6207-71-1243

PWIOO-3

12-022-91

6207-71-1250

PC200-5

12-022-92

6207-71-1251

PC200-5

12-022-93

6207-71-1252

PC200-5

12-022-93

6207-71-1262

S6D95L-1

I

I

6207-71-1271

PWIOO-3

12-022-48

6207-71-1281

PC150-3c

12-022-94

6207-71-1320

10001 and up

PC150, LC-3

12-022-49

6207-71-1320

32941 and up

PC150-3

12-022-50

6207-71-1331

13460 and up

WA150-1

12-022-51

1 WA150-1

1~ ~~12-022-52

1 6207-71-1332

1 23243and

up

I

1 6207-71-1335

WA150-1

6207-71-1510

WA180-3

12-022-108

6207-71-1520

WA250-3

12-022-109

6207-71-1360

12-022-53

1

27750 and up

PC150-3C,PC18OLC,

LLC3

12-022-54

PC150-3, PC180-3

12-022-55

WA180-1

12-022-56

6207-71-1381

WA180-1

12-022-95

6207-71-1390

PC18OLC,

6207-71-1410

EG85-1

12-022-96

6207-71-1420

EG85-1

12-022-96

6207-71-1421

EG85-1

12-022-96

6207-71-1430

EG85-1

12-022-96

6207-71-1540

DCK85SPK

12-022-97

6207-71-1690

EG85-1

12-022-96

GD461A-1

12-022-58

6207-71-1361 6207-71-1380

6207-71-1811

‘T 8-2

12-022-47

PC200-5, BR200-1

26330 and up

24866 and up

LLC-3

12-022-57

95 SERIES


TESTING

FUEL INJECTION

AND ADJUSTING

Engine model

Pump

assembly

No.

Engine serial No.

6207-71-1910

S6D95L-1

SAA6D95LE-1

95 SERIES

CALIBRATION

Applicable machine

26244 and up

GD511,513A,

DATA

Page

R-l

12-022-59

6207-71-1930

GD510R-1

12-022-60

6207-71-1941

WA150-1

12-022-98

6207-71-1950

GD511A,

R-l

12-022-99

6207-71-1951

GD511A,

R-l

12-022-99

6207-71-1960

GDSIOR-1

12-022-61

6207-71-1961

GDSIOR-1

12-022-100

6207-72-1210

PC200-6

12-022-101

6207-72-1270

PWIOO-3

12-022-102

1 6207-71-1211

SA6D95L-1

PUMP

I

1 PC220-5

I

12-022-103

6209-71-1230

PC220-5

12-022-62

6209-71-1250

PC220-5

12-022-104

6209-71-1251

PC220-5

12-022-105

6209-71-1252

PC220-5

12-022-105

6209-71-1262

PC22OLC-5,

6209-71-1210

PC220-6

6209-71-1110

WING100

I

1

12-022-63

BR300-1

12-022-106 12-022-110

(LWIOO-I, LWIOOM-I)

I

’2-28-3



Pump Assembly 6201-72-I

Number

Applicable

110 (771353-51

Machine

Applicable

Engine

iO0) Model

( ) : Manufacturer’s

part No.

Model

Serial No.

EC35Z-2

Serial No.

3D95SW-1

EC35ZS-2

Injection

Timing

Engine specification ,

Rotating direction injection

order

Injection

interval

Clockwise view from drive end 1-2-3

HP/rpm

3512,650

Maximum

kgm/rpm

13/l ,800

torque

High idling

rpm

2,750 to 2,850

Low idling

rpm

650 to 750

120”+30’

Plunger pre-stroke

mm

2.0 i 0.05

Delivery valve retraction volume mm3/st

Calibration

1

Rated horsepower

I

I

Pump tester capacity for Service standard

36

Motor

7.5

KW

Standard

Conditions

Service standard

Service standard indicates data using calibration test parts. Manufacture standard is data for factory test.

Nozzle part no.

Injection ipe (O/D x I/g x length)

6 x 2 x 450

mm

ASTM

Test oil

Rack positions

40 to 45

Nozzle opening pressure kg/cm’

120 0.3 Service standard

(cc/lOOOst)

Rack position (mm)

Pump speed

[ 14.41

1,325

B

L15.21

1,300

52.7

*51.65

C

L16.51

900

60.0

350

15.0

200

80.0 *75.0 to85.0

-

B to E are the refer-

ence volume when adjusting the injection volume. Marks l are average volumes.

D975 No. 2 diesel fuel or equivalent

OC

Transfer pump pressure kg/cm2

Rack point

point

Basic

D E

standard

(771353-5305O)(YKCA-S)

Nozzle holder part no.

Injection volume

Manufacturer

(171353-53000)(YDN-0SD177)

Oil temperature

Approx. 17.8

[19.01

(wm)

Manufacturer

standard (cc/

Maximum

Basis

Allowance Each cyl.

1451

[451

“b”df’$$ cylinder *I .35

Basis

Allowance Each cyl.

?I ,054

*

*57.60to62.40

+2.4

*

*12.75to17.25

k2.25

to 53.75

*

*

(16.5) 7

(15.2) (14.4) =12.8 *Il.8

I 0

200

350

900*50

1130 / 1300+;0

\ \ 1325

st

Maximum variance between cylinder

sovernor performance ( 350 - 1,325rpm)

z .C z a Y 8 u

I

1400*25

Pump speed (rpm) SEBH4525-01 95 SERIES

12219


Pump Assembly Number 6201-72-1120

Applicable Model

( ): Manufacturer’s

Engine Serial No. 10467 and up

3D95S-W-1

Engine specification Clockwise viewed from drive end

Injection order

1-2-3

interval

~t~~~~~~$$?ume

Model

Serial No.

PC40-5

Rotating direction

Plunger pre-stroke

Applicable

part No.

Injection Timing

Injection

Machine

(771353-51200)

120” ? 30’ mm

2.0 * 0.05

mm3/st

36

Rated horsepower

HP/rpm

38.4I2.600

Maximum

kgm/rpm

12.5/1,800

torque

High idling

rpm

2,800 t0 2,900

Low idling

rpm

900 to 950

Pump tester capacity for Service standard

Motor

7.5

KW

Calibration Standard Conditions

- Service

standard indicates data using calibration test parts. - Manufacture standard is data for factory test.

Service standard

standard

(171353-53000)(YDN-0SD177)

Nozzle part no.

(771353-53050)

Nozzle holder part no. Injection ipe (O/D x I/6 x length)

mm

Oil temperature

(YKCA-S)

6x2~450 ASTM

Test oil

“C

D975 No. 2 diesel fuel or equivalent 40 to 45

Nozzle opening pressure kg/cm2

120

Transfer pump pressure kg/cm*

0.3

I

Manufacturer

I

Injection volume

* Rack

positions B to E are the reference volume when adjusting the injection volume. * Marks * are average volumes.

Governor performance

( 450 - 1300 rpm)

Pump

’*-8*O

speed (rpm)

SEBH4524-1

95 SERIES


Pump Assembly Number 6201-72-1121

Applicable

( ): Manufacturer’s

part No.

Injection

interval

Plunger pre-stroke

Engine

Model

Serial No.

PC40-6

10001 and up

Serial No.

3D95SW-1

10467andup

Engine specification

Rotating direction order

Applicable

Model

Injection Timing

Injection

Machine

(771353-51201)

Rated horsepower

Clockwise viewed from drive end

HP/rpm

38.512.600

1

1-2-3 1 2o” f 30’ mm

2.0 f 0.05

Delivery valve retraction volume mm3/st

Pump tester capacity for Service standard

36

Motor

7.5

KW

Calibration Standard Conditions Service standard indicates data using calibration test parts. Manufacture standard is data for factory test.

Service standard

ipe

(O/D x l/g x length)

ASTM

40 120

Transfer pump pressure kg/cm2

0.3

Basic

Marks * are aver-

age volumes.

point

(rpm)

Basis

Allowance

14.0

1300

4. o .

Each cyl. 39.0 to 41 .o

Approx.

C

L15.11

( 450 -

kc/l 000 st)

Pump speed

12.4

L19.01

E Governor performance

Service standard

Rack position (mm)

B

D

D975 No. 2 diesel fuel or equivalent

OC

Nozzle opening pressure kg/cm2

Rack point

1300

490

8.9

900

47.5

200

*

7.4 to 10.4

*46.0

to 49.0

to 45

Manufacturer

Maximum TerE’,$, Basis cylinder

standard (ccl

Allowance

st

Maximum variance between cylinder

Each cyl. k1.0 t1.78

*

k1.9

*

*75.0 to 85.0

*

*

*

rpm)

Pump speed (rpm)

95 SERIES

6x2~450

mm

Test oil Oil temperature

Rack positions B to E are the reference volume when adjusting the injection volume.

(771353-53050)(YKCA-S)

Nozzle holder part no.

Injection volume

standard

(171353-5300)(YDN-OSD177)

Nozzle part no.

Injection

Manufacturer

SEBH470C

’*-iii*’


Pump Assembly 6201-72-1210

Number

Applicable

(771353.51220)

( 1: Manufacturer’s

Injection

part No.

Serial No.

Model

Serial No.

PC5OUU-1

1001 andup

3D95SW-1

12209 and up

Clockwise view from drive end 1-2-3

I

I

Rated horsepower

HP/rpm

38.5/2,500

Maximum

kgm/rpm

12.2/1,800

torque

High idling

rpm

Low idling

rpm

120° 2 30’

interval

950 to 1,000

Pump tester capacity for Service standard

36

J

I

r

2.0 If 0.05

mm

Delivery valve retraction volume mm3/st

Calibration

Engine

Engine specification

Injection order

Plunger pre-stroke

Applicable

Model

Timing

Rotating direction

Injection

Machine

I Motor

7.5 KW

Standard

Conditions

- Service

standard indicates data using calibration test parts. * Manufacture standard is data for factory test.

Service standard

Injection

ipe (O/D x l/g x length)

ASTM

40 to 45

120

Transfer pump pressure kg/cm’

0.3

Governor performance

B

C

Service standard

Rack position (mm)

Pump speed b-n)

Basis

14.0

1,250

40.0

900

47.5

(cc/l 000 st)

l15.11 Approx. 12.4

Manufacturer

standard (cc/

Allowance

“b”,:$$ cylinder

490

8.9

D

t19.01

200

80.0

E

115.71

400

39.0 *45.6 *

to 41 .o to 49.4

7.4 to 10.4

variance between cylinder

Allowance

Basis

Each cyl. k1.0 k1.9

*

k1.78

*

*75.0 to 85.0

*

*Min.

*

44.0

( 450 - 1,300 rpm)

400

750+50

Pump speed (rpm)

stl

Maximum

Maximum

Each cyl.

point

Basic

D975 No. 2 diesel fuel or equivalent

“C

Nozzle opening pressure kg/cm2

Rack positions

’2-ih22

6 x 2 x 450

mm

Test oil Oil temperature

B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

(771353-5305O)(YKCA=S)

Nozzle holder part no.

Rack point

standard

(171353-530OO)(YDN-0SD177)

Nozzle part no.

Injection volume

Manufacturer

1250’; SEBH4807

95SERlES


Machine Model

Engine Model

D20A,P,S-6 D21 A,P,S-6

4D95S-W-1 S/N 233 18 and up

Injection Pump Type

Pump Manufacturer

PES-A

DIESEL KIKI

I

Pump Assembly

Number

6202-72-1210

(101452-3051).

1

,

Injection

Timing Unit

Basis

Allowance

I

I

Specification

for engine with fan (reference only)

Rated horsepower: Plunger pre-stroke Delivery valve retraction volume

Calibration

mm

1.5

1.45 to 1.55

mm3

Standard Manufacturer standard (with nearly the same actual machine parts)

Unit

Nozzle part no.

6202-l

Nozzle holder part no.

6202-12-3110

I’ c”d%t%%?fenqthI

6x2~550

mm

2-3130

(105000-1770)

(105780-0000)

(105071-1450)

(105780-2080) 6x2~600

Oil temperature

“C

40 to 45

40 to 45

Nozzle opening pressure

kg/cm2

120

175

Transfer pump pressure

kg/cm2

1.6

1.6

Rack. . Pump osltlon ~g;? Pmm)

Basis

A

11.0

1225

35.4

B

approx.

410

8.0

Allowance

Maximum variance between cylinder

Basis

Each cyl.

Rack positions B to E are the reference volume when C adjusting the injecD tion volume. Marks * are averE age volumes.

Governor

Injection volume (cc/l OOOstJ for service standard

Injection volume (cc/l OOOst) for manufacturer standard

1: Reference data

Calibration basic point

l

Service standard (with calibration test parts)

ASTM D975 No. 2 diesel fuel or equivalent

Specifications

l

I

I

Test oil

[

39.5/2450

35

Conditions

l

HP/rpm

performance

8.4

32.4 t

l

8.0

Maximum variance between cylinder

Allowance

Each cyl. 31.4t033.4 *

*

*

*

*

*

*

7.0 to

kO.81 9.0

z!I 1.2

Marked *: Rack position approx. 9.3 mm

(41 o - I 225 rpm) ack cap: approx. 17.5 mm

Pump

speed

(rpm)

Numbers in parentheses

SEBH4526 are pump manufacturer

part numbers.

95 SERIES ’ 2-oz2-’


Machine Model

Engine Model

Injection Pump Type

Pump Manufacturer

.Pump Assembly

D21 E-6

4D95S-W-1 S/N 24252

PES-A

DIESEL KIKI

6202-72-I

Injection

Basis

I

Allowance

Counterclockwise viewed from drive end

Rotating direction

Specification

I Delivery valve retraction volume

~auoraaon

HPlrpm

6202-l

Nozzle holder part no.

2-3130

6202-12-3110 mm

(105000-I

770)

(I 05780-0000)

(105071-1450)

(I 05780-2080) 6x2~600

ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature

“C

40 to 45

40 to 45

Nozzle opening pressure

kg/cm2

120

175

Transfer pump pressure

kg/cm2

1.6

1.6

Specifications

Injection volume (cc/l OOOst) for manufacturer standard

1 : Referencedata

A

performance

Maximum variance between cylinder

Injection volume (cc/l OOOst) for service standard

Rack Pump osition speed Pmm) (rpm)

Basis

Allowance

E11.31

1225

38.0

Each cyl. 37.0 to 39.0

20.95

l34.81

410

8.0

*

21.2

‘[ 8.01

B approx. Rack positions 8.4 B to E are the reference volume when C adjusting the injection volume. D Marks * are average volumes. E

Governor

1

44.4/2450

Service standard (with calibration test parts)

6x2~550

Test oil

Calibration basic point

fan (reference only)

I

Manufacturer standard (with nearly the same actual machine parts)

Unit

In ectron rpe (d/D x l/$x lenqth)

l

Rated horsepower:

with

I

aranaara

Nozzle part no.

l

for engine

35

mm3

Conditions

[

0

and up

Timing Unit

l

Number

230 (101452-3070).

(410

- 1225

7.0 to

9.0

Basis

Eachc I. [33.& to L35.81 *[

*

*

*

*

*

* Marked

rpm)

Maximum variance between cylinder

Allowance

7.01 to 1 9.01

LkO.871 [*I.21

Rack

mm

410

670t20

-10

Pump speed in parentheses

are 95 SERIES


Pump Assembly Number 6202-72-1230

Applicable

(101452-3071)

Model (

): Manufacturer’s

part No.

Machine

Applicable

Serial No.

I

I

Injection Timing

1 I

Model

I

1 4D95SW-1

D21 E-6

Engine Serial No.

(

I

44.412.450

I

Engine specification

Rotating direction

Rated horsepower

Clockwise viewed from drive end

1 Maximum

Injection order

1-2-4-3

Injection

9o” f 30’

interval

Plunger pre-stroke

mm

1.5 * 0.05

Delivery valve rptrartinn Vn~llmP mm3/st

torque

HP/rpm kgm/rpm

High idling

rpm

1 Low idling

rpm

2,530 to 2,630

I

800 to 850

I

I

Pump tester capacity for Service standard

35

1

Motor

7.5

KW

I I

Calibration Standard Conditions

Service standard

* Service

standard indicates data using calibration

test parts.

standard is data for factory test.

Nozzle part no.

( 105780-0000)

6202-l 2-3130

(105000-1770)

(105780-2080)

6202-12-3110

(105071-1450)

6x2~600

mm

Test oil

6x2~550

ASTM

Oil temperature

D975 No. 2 diesel fuel or equivalent

“C

43 to 47

Nozzle opening pressure kg/cm2

175

120

Transfer pump pressure kg/cm’

1.6

1.6

Injection volume Rack point

t Rack

positions B to E are the reference volume when

standard

Nozzle holder part no.

Injection ipe (D/D x l/g x length)

* Manufacture

Manufacturer

Basic

adjusting the injection volume.

point B

sMarks * are average volumes.

Governor performance

Service standard (CC/I OOOst)

Rack position (mm)

Pump speed (rpm)

Basis

Allowance

11.3 Approx.

1225

34.6

Each cyl. 33.6 to 35.6

to.865

410

8.0

*

k1.2

84

_

7.0 to

9.0

Manufacturer

Maximum $rgE”, Basis cylinder

standard (cc/lOOOs~ Maximun

Allowance

variance between cylinder

Each cyl. 38.0 8.0

t

C

*

*

D

*

*

E

*

*

( 410 - 1225 rpm) Rack cap: approx. 17.5 mm

t 0

95 SERIES

y!\ 400

j.!lI (11801~40 ‘*go**5 1225::: Pump speed (rpm)

(590) 650 410

SEBH460:

’2-oi2-3


Pump Assembly 6202-72-1610

Number

Applicable

Machine

Model

(

1: Manufacturer’s

Injection

Applicable

part

Rotating

direction

Injection

order

Serial

No.

Model

Serial

No.

No. EC502 (S)-5

Timing

4D95S-W-1

Engine

specification

Clockwise viewed from drive end l-2-4-3

~1

I

Pump tester capacit for Service standar J

Calibration

Engine

(101452-3020,3021,3022)

I

Motor

7.5 KW

Standard

holder and injec-

Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are aver-

Governor performance (400-1400

rpm)

ackcap:approx.17.5mm

1270+50/ 15400r1ess 1400*5

Pump speed(rpm)

’2-022-4

SEBH4527-01 95 SERIES

I


Pump Assembly Number 6202-73-l

Aoolicable

130 (101492-3700)

( ): Manufacturer’s

1

Model

part No.

I

Machine

WA50-1

Serial No.

Applicable Model

I_

10001 and up

Engine Serial No.

4D95S-1

40337andup

WA55-1

Injection Timing

Engine specification

r 1 Rotating direction 1 Injection

order

I

interval

Injection

Plunger pre-stroke I I FZZY?Zkl(f

I

Clockwise viewed from drive end I-2-4-3

I

l

90” f 30’ mm

I

3.6 * 0.05

Pump tester capacity for Service standard

51

Imp mm3/st

Motor

7.5

KW

Calibration Standard Conditions

Service standard

*Service

standard indicates data using calibration test parts. * Manufacture standard is data for factory test.

Nozzle part no.

(105780-0000)

Nozzle holder part no.

(105780-2080)

Injection

ipe

(O/D x l/g x length)

ASTM

43 to 47 175

Transfer pump pressure

1.6

Rack position (mm)

Rack point

D975 No. 2 diesel fuel or equivalent

“C

Nozzle opening pressure kg/cm’

Injection volume

standard

6 x 2 x 600

mm

Test oil Oil temperature

Manufacturer

kg/cm’

Pump speed bm)

Service standard

(cc/l 000 st)

Allowance

Basis

Manufacturer

Maximum rer&2”, Basis

standard (cc/

Maximum variance between

Allowance

cylinder Rack positions B to E an? the reference volume when

Basic point

adjusting the injecage volumes.

Governor performance

1,250

Approx.

B

tion volume.

- Marks l are aver-

9.0

400

33.4

10.5

Each cyl. 32.4 to 34.4

kO.835

to 11.5

k1.575

* 9.5

cylinder

Each cyl. *

C

*

D

*

*

E

*

*

( 400 - 1250

*

rpm)

Rack cap.: approx. 17.5 mm

L 0

I 350 \ 6Ti0 400

900*50

/I350125 I250$::

Pump speed irpm)

95 SERIES

st

SEBH4699


Pump Assembly Number 6202-73-l

Applicable

Machine

Applicable

Engine

131 (01495-3160) Model

( ): Manufacturer’s

part No.

Model

Serial No.

WA50-1

Serial No.

4D95S1

WA55-1

Injection Timing

Engine specification 7

Rotating direction

Clockwise view from drive end l-2-4-3

Injection order Injection

HP/rpm

Maximum

kgm/rpm

torque

16.6/1,600

High idling

rpm

2,650 to 2,750

Low idling

rpm

800 to 850

90” * 30’

interval

Plunger pre-stroke

5512,500

Rated horsepower

mm

3.6 * 0.05

Del ivery valve retraction volume mm3/st

Pump tester capacity for Service standard

51

Motor

7.5

KW

Calibration Standard Conditions

Service standard

’ Service

standard indicates data using calibration test parts. 5Manufacture standard is data for factory test.

Nozzle part no.

(105780-0000)

Nozzle holder

(105780-2080)

part no.

Injection ipe (O/D x l/6 x length)

injection

ASTM

(105048-3300) 6x

1.6x600

D975 No. 2 diesel fuel or equivalent 43 to 47

OC 175

225

Transfer pump pressure kg/cm2

1.6

1.6

Rack position (mm)

Rack point

Basic

tion volume.

* Marks

* are average volumes.

Governor performance

point B

9.7 Approx. 8.1

standard

(105017-0840)

Nozzle opening pressure kg/cm2

volume

Rack positions B to E are the reference volume when adjusting the injec-

6202-13-3530

6 x 2 x 600

mm

Test oil

Oil temperature

Manufacturer

Pump speed (rpm)

1,250 400

Service standard

Basis

(cc/l OOOst)

Allowance

40,4 Each cyl. 39.4 to 41.4 8.0

*

7.0 to

9.0

Manufacturer

Maximum ~“,:‘~$ Basis cylinder

standard (cc/lOOOst

Allowance

Maximur* variance between cylinder

tl.O1

4. 8 Each cyl. .

t1.2

10.5

*

C

*

*

D

*

*

E

*

*

( 400 - 1,250 rpm)

18’:

ck limit : Approx. 13’E’mm

-C E S E

10.5 9.7

B 6 B

7.5 5.8

Pump speed (rpm)

SEBH4808 95 SERIES


Pump Assembly Number 6204-71-1210

( ):

Applicable

(101492-3411)

Manufacturer’s

Machine

Model

Serial

Applicable No.

Engine

Model

part No.

Serial

No.

4D95L-1

PC60-3 PC6OL-3 1

1

PC6OU-3

injection Timing

Engine specification I

Rotating

direction

Injection

order

Injection

interval

Plunger

pre-stroke

Rated horsepower

viewed from drive end

Clockwise

kgm/rpm

1

High idling

rpm

I

1 Low idling

rpm

I

1 Maximum

l-2-4-3

I mm

3.6 + 0.05

Delivery valve retraction volume mm3/st

HP/rpm

torque

I

51

5912,400

I

20/I ,500

I

2,590

I

to 2,690

800 to 850

Motor

7.5

KW

I

I I

Calibration Standard Conditions

8 data using calibration test parts. - Manufacture standard is data for factory test.

Service standard (105780-0000)

6207-I

I-31 30 (105017-0090)

Nozzle holder part no.

(I 05780-2080)

6207-I

l-3110

Injection ipe (O/D x I/g x length)

6 x 2 x 600

mm

Test oil

ASTM

Rack point

kg/cm2

Rack

Pump

position (mm)

speed

(rPm)

6x1.6x600 No. 2 diesel fuel or equivalent

175

200

1.6

1.6

Service standard

(cc/l OOOst)

Manufacturer

standard (cc/l OOOst

Maximum Basis

Allowance

~er$$~

Basis

Allowance

cylinder

point

Basic

Governor performance

B

10.3

35.5

400

10.5

Each cyl. 34.5 to 36.5

20.8875

38.0

*

fl.575

10.5

9.5t011.5

Maximum variance between cylinder

Each cyl.

*

C

*

*

D

*

*

E

*

*

( 425 - 1200 rpm) ack cap:

Pump

95 SERIES

1200

A?EOs”.

(105048-3060)

43 to 47

Nozzle opening pressure kg/cm’

volume

D975

OC

Transfer pump pressure

Rack positions 6 to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

standard

Nozzle part no.

Oil temperature

Injection

Manufacturer

17.5mm

speed (rpm)

+30 ‘2%20

SEBH4685

’2-o;2-7


Machine Model

Engine Model

PC60-5 54 HP

4D95L S/N 16084

Injection Pump Type

Pump Manufacturer

PE-S4A

DIESEL KlKl

Pump Assembly 6204-71-l

Number 0

220 (101492-3490).

and up

(

1: Manufacturer’s par-t No.

Injection Timing Unit

Basis

Allowance

Rotating direction

Clockwise viewed from drive end

Injection order

l-2-4-3

Injection interval

90”

89”30’

3.6

3.55 to 3.65

Plunger pre-stroke

mm

Delivery valve retraction volume

mm3

Calibration

Specification to 90”30’

51

for engine with fan (reference only)

Rated horsepower:

HPlrpm

5412 100

Maximum torque:

kgm/rpm

20.411500

High idling:

rpm

2250 to 2350

Low idling:

rpm

Standard

Conditions

Unit

Manufacturer standard (with nearly the same actual machine parts)

Nozzle part no.

6207-l

l-31 30 (105017-0090)

Nozzle holder part no.

6207-I

l-31 10 (105048-3060)

Injection pipe (O/D x I/D x length)

mm

Test oil

850 to

900

Service standard (with calibration test parts)

6x1.6x600 ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature

“C

40 to 45

Nozzle opening pressure

kg/cm2

200

Transfer pump pressure

kg/cm2

1.6

jpecifications

m[

Calibration basic point

’ Rack positions

Injection volume (cc/l OOOst) for manufacturer standard

1 : Reference data

B B to E are the reference volume when C adjustingthe injection volume. D Marks * are average volumes. E

Governor

performance

Maximum variance between cylinder

Rack Pump osition speed Pmm) (rpm)

Basis

Allowance

[I 0.91

45

Each cyl. 44 to46

k1.125

10.5

*

a1.575

8.4

(425

1050 400

- 1050

9.5 to 11.5

.

St)

Injection volumebY for service standard

Basis

Allowance

Maximum variance between cylinder

Each cyl. *

*

*

*

*

*

*

rpm)

Rack hm,ter set 17.5 mm

Pump speed (rpm)

SEBH4517 95 SERIES


r

Pump Assembly Number 6204-71-1220

Applicable

(101492-3491)

( ): Manufacturer’s

Model

part No.

Machine Serial No.

Applicable Model

Engine Serial No.

4D95L-1

PC60-5

/I

injection Timing

Engine specification

Rotating direction Injection

order

Injection

interval

Plunger pre-stroke

Clockwise view from drive end 1-2-4-3 9y mm

f 30’

3.6 * 0.05

Del ivery valve retraction volume mm3/st

51

Pump tester capacity for Service standard

Motor

7.5

KW

Calibration Standard

standard is data for factory test.

Injection volume

- Rack

positions 6 to E are the reference volume when adjusting the injection volume. * Marks * are average volumes.

Governor performance

( 450 - 1050 wn) ack cap: Approx. 17.5mm

0

450

750

1050/ 115oC25 1050::

Pump speed (rpm)

95 SERIES

(1120)

SEBH4517-01

12-022-9



v

Pump Assembly Number 6204-71-1230

Applicable

Machine

Model

( ): Manufacturer’s part No.

Serial No.

Engine Serial No.

Model 4D95L-1

PW60-3

Engine specification

Injection Timing Clockwise viewed from drive end

Rotating direction

~1

Injection

order

l-2-4-3

Injection

interval

90” f 30

Plunger pre-stroke

Applicable

(101492-3510)

3.6 + 0.05

mm

Delivery valve retraction volume mm3/st

Pump tester capacity for Service standard

51

Motor

7.5

KW

Calibration Standard Conditions

*Service

standard indicates data using calibration test parts. * Manufacture standard is data for factory test.

Service standard

standard

Nozzle part no.

(I 05780-0000)

6207-l

l-3130

Nozzle holder part no.

(105780-2080)

6207-I

l-31 10 (I 05048-3060)

Injection ipe (O/D x l/g x length)

6 x 2 x 600

mm

ASTM

Test oil

Oil temperature

6x

(105017-0090)

1.6x600

D975 No. 2 diesel fuel or equivalent 43 to 47

OC

Nozzle opening pressure kg/cm2

175

200

Transfer pump pressure kg/cm2

1.6

1.6

Injection volume Rack point

pRack positions 6 to E are the reference volume when adjusting the injection volume. - Marks * are average volumes.

Manufacturer

Basic

Governor performance

point

B

Service standard (cc/lOOOst)

_ Manufacturer

Rack position

Pump speed

(mm)

(rpm)

Basis

Allowance

10.5 Approx. 7

1250

37.5

Each cyl. 36.5 to 38.5

kO.9375

40.0

450

10.5

*

21.575

10.5

9.5to

11.5

Maximum yert$$E Basis cylinder

Allowance

Maximun variance between cylinder

Each cyl. *

C

*

*

D

*

*

E

*

*

( 450 - 1250

standard (~~/10OOsl

rpm)

Rack cap: arqxox. 17.5 mm

Pump speed (rpm)

95 SERIES

SEBH461(

’*-O;*-’ ’


Pump Assembly 6204-71-1281

Number

Applicable Model

( 1: Manufacturer’s part No.

Injection

Applicable

Engine

Model

Serial No.

4D95L-1

Engine specification Clockwise view from drive end

Rotating direction Injection order

l-2-4-3

Injection

90” f 30’

interval

Plunger pre-stroke

Serial No.

PC75UU-1

Timing

mm

~1

3.6 +_0.05

Delivery valve retraction volume mm3/st

Calibration

Machine

(101492-3971)

Pump tester capacity for Service standard

51

Motor

7.5

KW

Standard

Conditions

Service standard

~Service standard indicates data using calibration test parts (Nozzle, Nozzle holder and iniec-

Nozzle part no. Nozzle holder part Injection

"0.

ipe

(O/D x I/g x length)

I

Manufacturer 6207-l

I-3130

(105017-0090)

(105780-2080)

6207-l

I-3110

(105048-3060)

6 x 2 x 600

mm

standard

(105780-0000)

6;

1.6x600

Injection volume

when adjusting the injection volume. ‘Marks Sr are average volumes. Governor performance

rat

*

D

1

E

( 475 - 950

I*

* l

rpm)

h

LAY Rack limit

: 153.2

Pump speed (rpm)

’2-os?1 *

,,,,,,

SEBH4809-01 95 SERIES


Pump Assembly

Number

Applicable

Machine

Applicable

Engine

6204-71-1290 Model

( ): Manufacturer’s

part No.

Serial No.

Model

PC75UU-2

Serial

No.

4D95L-1

/

Injection

Timing

Rotating

Engine specification

direction

1 Injection

Clockwise

viewed

order

from drive end

I

1-2-4-3

I Calibration

Motor 7.5 kW

Standard

Conditions

Service

Service standard indicates data using calibration test parts (Nozzle,

Pump tester capacity for Service standard

Nozzle

Manufacturer

(105780-0000)

6207-I

Nozzle holder part no. Injection pipe

(I 05780-2080)

6207-11-3110

(O/D x IiD x length)

holder and injection pipe)

Test oil

Manufacturer standard is data using factory test parts (For reference)

Oil temperature

mm

6 x 2 x 600 ASTM

Nozzle opening Transfer

6x

1.6x600

MPa(kg/cm*)

Pump speed (rpm)

Service Basis

17.2

(175)

19.6

(200)

0.16

(1.6)

0.16

(1.6)

standard Allowance

(cc/lOOOst)

Manufacturer

Maximum “b”,$:ifi Basis cylinder

Each cyl.

standard (cc/1OOOsi

Allowance

Maximum “b”,ztE’, cylinder

Each cyl.

Basic point

10.6

950

49

.

(105017-0090) (105048-3060)

43 - 47

MPa(kg/cm2)

Rack position (mm)

Rack point

I-3130

standard

D975 No. 2 diesel fuel or equivalent

“C pressure

pump pressure

njection volume

Rack positions B to E are the refsrence volume Nhen adjusting :he injection volJme. blarks * are aver3ge volumes.

standard

~~~~~~ part “,,,

B

11.5

750

60.5

C

8.0

515

10.5

D

15

100

80

E

Governor

performance

(100 - 950 rpm)

(900)

950::;

Pump speed (rpm)

6206F960

95 SERIES ’ *-*%-’

3

I


Pump Assembly Number 6204-72-1310

Applicable

(101452-3000)

Model

( 1: Manufacturer’s part No.

WA40-1

injection Timing

90” 2 30’

Model

Serial No.

1001 and up

4D95L-W-1

10001 and up

mm

Low idling

1.5 f 0.05

Pump tester capacity for Service standard

35

mm3/st

800 - 850

rpm

I

4

v~III~~

Serial No.

1-2-4-3

Injection interval

Delivery valve

Engine

Clockwise viewed from drive end

Injection order

wtnrtinn

Applicable

Engine specification

Rotating direction

Plunger pre-stroke

Machine

I

Motor

7.5

1

KW

Calibration Standard Conditions

Service standard

Manufacturer

standard

) Service standard

Nozzle Part no.

indicated data using calibration test parts. 1 Manufacture standard is data for factory test.

(105780-0000)

6202-I 2-3130

(105000-I

Nozzle holder part no. Injection ipe (O/D x l/g x length)

(I 05780-2080)

6202-12-3110

(105071-1450)

Test oil

ASTM

Oil temperature

6 x 2 x 457

D975 No. 2 diesel fuel or equivalent 43-47

“C

Nozzle opening pressure Mpa(kg/cmz)

17.2

(175)

11.8

(120)

Transfer pump pressure Mpa(kg/cmz)

0.16

(1.6)

0.16

(1.6)

Injection volume Rack point

Pump

Rack position (mm)

speed

11.7

1100

(rPm)

1 Rack positions B to E are the reference volume when adjusting

6 x 2 x 600

mm

Basic Point

the injection volume. 1 Marks * are average volumes.

3overnor performance

B

AP,Porynx

400

Service standard

(cc/l OOOSt)

Manufacturer

Basis 33 8

.

11.0

Allowance

yertE”, cylinder

Maximum

Basis

Each cyl. 32.8 - 34.8

kO.845

39.0

* 10.0-12.0

*I .65

11.0

Allowance

variance between cylinder

Each cyl. *

*

*

D

*

*

E

*

*

- 1100

standard (cc/ 1 OOOst

Maximum

C

(400

770)

rpm)

1100::8

Pump speed (rpm)

SEBH4566-01 95

’ 2-o;2-’

4

SERIES

I


Pump Assembly Number

I

I Applicable

330 (101452-3010)

6204-72-l

Model

(

): Manufacturer’s

part No.

WA70-

direction

Injection

order

lniection

interval

Plunger

10001

Applicable No.

Engine Serial

Model 4D95L-W-1

and up

11437

No. and up

Engine Specification Clockwise

viewed

Rated horsepower kW(HP)/rpm

from drive end

900 + 30’

I I 1

mm

1.5

mm3/st

41.2 (55.2)/2200

Maximum torque Nm(kgm)/rpm

1-2-4-3

pre-stroke

Delivery valve retraction volume

Serial 1

Injection Timing Rotating

Machine

* 0.05 35

High idling

rpm

1 Low idlinq

rpm

Pump tester capacity for Service standard

204(20.8)/l

500

2320 - 2420

I

800 --- - 8!irl ___ Motor

7.5 KW

Calibration Standard

using calibration test parts. Manufacture standard is data for factory

test.

1 Rack positions 6 to E are the reference volume

I

volume. Marks * are aver-

age volumes.

Governor performance (400 Rack limit

1100 rpm) 17 5 mm

(1165) Pump speed (rpm)

95 SERIES

SEBH4506-01


Pump Assembly Number

I

(101492-3641)

6205-71-1230

Applicable

I

I

1

Model

Injection Timing

Machine

I

Serial No.

Applicable

1

Engine

1

Model

Serial No.

Clockwise viewed from drive end

Injection order

l-2-4-3

Rated horsepower

HP/rpm

78.912100

Maximum

kgm/rpm

30.5/1500

torque

High idling

rvm

idling

rpm

Low

I

2240 to 2360 900 to 950

Pump tester capacity for Service standard

Motor

7.5

KW

Calibration Standard Conditions

Service standard

I

Manufacturer

standard

Nozzle part no.

(105780-0000)

6206-l

l-3130

Nozzle holder part no.

(105780-2080)

6207-l

l-31 10 (105048-3060)

Injection ipe (O/D x l/g x length)

ASTM

43 175

Transfer pump pressure

1.6

Injection volume

Rack position (mm)

Rack point

D975 No. 2 diesel fuel or equivalent

“C

Nozzle opening pressure kg/cm* kg/cm*

Pump speed (rpm)

Service standard

Basis

(105017-0090)

6X 1.6x600

6 x 2 x 600

mm

Test oil Oil temperature

to

47 200

1.6 h/l

Allowance

OOOst)

Manufacturer

Maximum Tey$f”, Basis

standard (cc/lOOOst Maximum

variance

Allowance

between cylinder

cylinder Rack positions B to E are the reference volume when adjusting the injection volume. * Marks l are average volumes.

Basic point

9.9

1050

69.5

Each cyl. 68.5 to 70.5 *

68.6 to 72.6

*

9.5 to 11.5

B

10.7

750

70.6

C

Apt.7~.

475

10.5

Each cyl. fl.7375 Al.575

66.0 76.2

*

10.5

*

D

*

*

E

*

*

( 400 - 1050 rpm)

Governor performance

Rack limit 17.5mm

0

I:

1 475

/

750

96C

600t50 Pump

105o::g speed

(rpm)

SEBH4720 95 SERIES

’ 2-o$2-’

6

1

Engine specification

Rotating direction

* Service standard indicates data using calibration test parts. - Manufacture standard is data for factory test.

I

1


Pump Assembly Number

Applicable

(101492-3710) (101492-3712) Manufacturer’s part No.

Machine

Applicable

Engine

6205-71-1231

( ):

Model

Serial No. 28001

PC1 00-5

Injection Timing

order

Injection

interval

Plunger prestroke

and up

Serial No.

S4D95L-1

31710

and up

Engine specification Clockwise viewed from drive end

Rotating direction Injection

Model

1-2-4-3 90°a30’ mm

3.2 f 0.05

Delivery valve retraction volume mm3/st

Rated horsepower

HP/rpm

78.912100

Maximum

kgm/rpm

30.5/1500

torque

High idling

rpm

Low idling

rpm

2240 to 2360 900 to 950

Pump tester capacity for Service standard

51

Motor

7.5

KW

Calibration Standard Conditions

Service standard

* Service

standard indicates data using calibration testparts. - Manufacture standard is data for factory test.

Nozzle part no. Nozzle holder part no. Injection ipe (O/D x I/6x length)

B to E are the reference volume when adjusting the injec-

(105780-2080)

6207-I

I-3110

(105048-3060)

ASTM

6x

1.6x600

D975 No. 2 diesel fuel or equivalent 43

“C

to

47

175

200

Transfer pump pressure kg/cm2

1.6

1.6

Rack point

- Rack positions

(105780-0000)

(105017-00901

Nozzle opening pressure kg/cm2

Injection volume

tion volume.

- Marks * are average volumes.

Governor performance

Service standard

(cc/l OOOst)

Rack position

Pump speed

(mm)

(w-n)

Basis

Allowance

1050

66.4

Each cyl. 65.4 to 67.4

(66.4)

* (64.4 to 68.4)

Basic point

9.5

B

10.3

750

C

AP~~x.

450

10.5

*

standard

I-3130

6 x 2 x 600

mm

Test oil

Oil temperature

Manufacturer 6206-I

9.5to

11.5

Manufacturer

Maximum Fer$$e, Basis cylinder

standard (cc/lOOOsl

Allowance

Maximun variance between cylinder

Each cyl. k1.66

63.2

-

74.4

*

?I.575

10.5

*

D

*

*

E

*

*

( 450 - 1050 rpm)

18+; Rack cap: 15.0 i

1 mm

0 970f50 Pump

95 SERIES

speed

Irpm)

SEBH4721-01

’2-02-17


Pump Assembly Number 6205-71-1232

Applicable

Machine

Model (

Applicable

Engine

(101492-3801)

) : Manufacturer’s

part No.

Serial No. 28001

PC1 00-5

Injection Timing

Model

and up

Serial No.

S4D95L-1

Engine specification .

Rotating direction Injection

order

Injection

interval

Plunger pre-stroke

Clockwise viewed from drive end l-2-4-3

Rated horsepower

HP/rpm

78.912100

Maximum

kgm/rpm

30.5/1500

torque

High idling

rpm

2240 to 2360

Low idling

rpm

900 to 950

90”+30’ mm

3.2kO.05

Delivery valve retraction volume mm3/st

Pump tester capacity for Service standard

51

Motor

7.5

KW

Calibration Standard Conditions

’ Service

standard indicates data using calibration test parts. * Manufacture standard is data for factory test.

Injection

Service standard

Manufacturer

Nozzle part no.

(105780-0000)

6206-l

I-3130

(105017-0090)

Nozzle holder part no.

(105780-2080)

6207-I

l-3110

(105048-3060)

Injection ipe (O/D x l/g x length)

6x

6x2~600

mm

Test oil

ASTM

Oil temperature

“C

Nozzle opening pressure

kg/cm2

1.6x600

D975 No. 2 diesel fuel or equivalent 43 to 47

175

200

Transfer pump pressure kg/cm2

1.6

1.6

Rack position

Pump speed

Service standard

(mm)

(rPm)

volume Rack point

(cc/l 0OOs.t)

Manufacturer.

standard (cc/l OOOst:

Maximum Basis

Allowance

r:gz”,

Allowance

Basis

cylinder Rack positions B to E are the reference volume when adjusting the injection volume. Marks l are average volumes.

standard

Basic point

Governor performance

9.7

B

10.0 APT?.

C

1050

67 4 Each cyl. . 66.4 to

68.4

750

(57.4)

*

(57.4)

450

10.5

*

9.5 to 11.5

21.685 ?I.575

(66.6)

Maximum variance between cylinder

Each “I’

(76.9)

*

(10.5)

*

D

*

*

E

*

*

( 450 - 1050 rpm)

18+: ackcap:

Pump

’2-o&2-1 *

15flmm

speed (rpm)

SEBH4786

95 SERIES


Pump Assembly Number

Applicable

Machine

Applicable

Engine

6205-7 l-l 240 (101492-3651) Model (

): Manufacturer’s

part No.

Serial No. 30001

PC1 20-5

Rotating direction order

Injection

interval

Plunger pre-stroke

31713

S4D95L-1

and up

and up

Engine specification

injection Timing

Injection

Serial No.

Model

Clockwise viewed from drive end 1-2-4-3 90°?30’ mm

3.2 f 0.05

Del ivery valve retraction volume mm3/st

Rated horsepower

HP/rpm

83.812200

Maximum

kgm/rpm

30.5/1500

torque

High idling

rpm

2340 to 2460

Low idling

rpm

900 to 950

Pump tester capacity for Service standard

51

Motor

7.5

KW

Calibration Standard Conditions Service standard indicates data usingcalibration test parts. Manufacture standard is data for factory test.

Service standard

Manufacturer

Nozzle part no.

(105780-0000)

6206-I

I-3130

(105017-0090)

Nozzle holder part no.

(105780-2080)

6207-I

I-3110

(105048-3060)

Injection ipe (O/D x l/g x length)

ASTM

43

Nozzle opening pressure kg/cm*

Injection volume Rack point

kg/cm2

Rack position

speed

Pump

(mm)

(rpm)

1.6x600

D975 No. 2 diesel fuel or equivalent

“C

Transfer pump pressure

6x

6 x 2 x 600

mm

Test oil

Oil temperature

to

47

175

200

1.6

1.6

Service standard

(cc/l OOOst)

Manufacturer

standard (cc/lOOOst:

Maximum

Allowance

Basis

Fe’$$‘,

Basis

Allowance

cylinder Rack positions 6 to E are the reference volume when adjusting the injection volume. Marks * are aver-

standard

Basic

age volumes.

Governor performance

point

75.4

10.8

750

76.8

* 74.8 to 78.8

p64r40x.

475

10.5

* 9.5

10.2

B C

1100

Each cyl. 74.4 to 76.4

A

to 11.5

Maximum variance between cylinder

Each cyl. *I.885

70

-

-

*

t1.575

10.5

*

D

*

*

E

*

*

( 400 - 1100 rpm) Rack limit

17.5mm

11oo::g

Pump speed (rpm)

95 SERIES

SEBH4722


Pump Assembly Number

Applicable

( ): I

(101492-3720) (101492-3722) Manufacturer’s part No.

Machine

Applicable

Engine

6205-71-1241

Model PC1 20-5

Injection Timing

Model

Serial No. 30001

Serial No.

S4D95L-1

and up

48811andup

Engine specification I

Rotating direction

Clockwise viewed from drive end 1-2-4-3

Injection order Injection

interval

9o”*30n

Plunger pre-stroke Del ivery valve retrsctinn

I~-.II~~~

Rated horsepower

HP/rpm

83.812200

Maximum

kgm/rpm

30.5/1500

torque

High idling

rpm

1 Low idling

rpm

1

2340 to 2460 900 to 950

I

Pump tester capacity for Service standard

51

mm3/st

Motor

7.5

KW I

Calibration Standard Conditions

Service standard

* Service

standard indicates data using calibration test parts. * Manufacture standard is data for factory test.

Manufacturer

standard

Nozzle part no.

(105780-0000)

6206- ‘1I-3 130

( 105017-0090)

Nozzle holder part no.

(105780-2080)

6207-l

(105048-3060)

Injection

ipe

(O/D x l/E x length)

ASTM

I-3110

6x1.6x600

6 x 2 x 600

mm

Test oil Oil temperature

D975 No. 2 diesel fuel or equivalent 43

“C

to

47

Nozzle opening pressure kg/cm’

175

200

Transfer pump pressure kg/cm’

1.6

1.6

Injection volume

Rack position hnm)

Rack point

* Rack positions B to E are the refer-

Basic

9.8

point

ence volume when

adjusting the injection volume. * Marks * are average volumes.

Governor performance

B

Pump speed

(cc/l OOOst)

(rpm)

Basis

Allowance

1100

70.8

Each cyl. 69.8 to 71.8

750

(66.8)

* (64.8 to 68.8)

450

10.5

10.4 A~yy.

C

Service standard

*

9.5to

11.5

Manufacturer

Maximum Te!$$“, Basis cylinder

Allowance

Maximun variance between cylinder

Each cyl. Y.77

65.6

-

75.4

*

k1.575

10.5

*

D

*

*

E

*

*

( 450 -

standard (cc/l 000~1

1100 rpm)

18+; ckcap:15ilmm

-E .E c .p C 5 a. :: it

c

3.2 f 0.05

mm

9.8 9.3

6.3 5.6

0 1Cmi5o

,l@g:z

0

Pump speed (rpm)

SEBH4723-01

’*-O;*-*O

95 SERIES


Pump Assembly Number 6205-71-1242

Applicable

1

Model (

): Manufacturer’s

h

Machine

Applicable

Engine

(101492-3811)

Injection Pump Type

part No.

4

I

1

I

Pump Manufacturer

/ DIESEL

PES4A

KIKI

1

Model

1 30001 and up 1 I I

PC1 20-5

I

Injection Timing

Serial No.

1 48811 and up I

S4D95L-1

I

I

Engine specification Clockwise viewed

Plunger prestroke

Serial No.

mm

from

drive end

3.2 kO.05

Delivery valve retraction volume mm3/st

Pump tester capacity for Service standard

51

Motor

7.5

KW

Calibration Standard Conditions

Service standard

- Service

standard indicates data using calibration test parts. * Manufacture standard is data for factory test.

(105780-0000)

6206-I

I-3130

Nozzle holder part no.

(I 05780-2080)

6207-I

I-31 IO (105048-3060)

Injection ipe (O/D x l/g x length)

6x

6 x 2 x 600

mm

ASTM

Test oil

(105017-0090)

1.6x600

D975 No. 2 diesel fuel or equivalent 43

OC

to 47

Nozzle opening pressure kg/cm*

175

200

Transfer pump pressure

1.6

1.6

volume Rack point

Rack position (mm)

kg/cm’

Pump speed

Service standard

h/l

OOOst)

Manufacturer

standard (cc/l 000~1

Maximum

(rpm)

Basis

9.9

1100

7l 8 .

Each cyl.

AP;,~.

450

10.5

*

Allowance

rerg$,

Basis

Allowance

cylinder

- Rack

positions B to E are the reference volume when adjusting the injection volume. - Marks l are average volumes.

standard

Nozzle part no.

Oil temperature

injection

Manufacturer

Basic point

Governor performance

B

70.8

to 72.8

9.5 to 11.5

21.795

(67.8)

21.575

10.5

Maximum variance between cylinder

Each cyl. *

C

*

*

D

*

*

E

*

*

( 450 - 1100 rpm)

18+; ackcap: 15f

-z L .-6 It: :: 0 :: 2

lmm

0 set pressure 9.9 9.1

6.1 5.1

0 1100::: Pump speed (rpm)

SEBH4787 95 SERIES ’ *-O$*-*’


Pump Assembly 6205-71-I (

243

Number

Applicable

(101492-3880)

): Manufacturer’s

Machine

Applicable

Engine

part No.

-1

Injection

Timing

Engine specification

Rotating direction

Clockwise view from drive end

Injection order Injection

1-2-4-3

I

I

Rated horsepower

HP/rpm

Maximum

kgm/rpm

torque

83.812.200 30.5/1,500

High idling

rpm

2,340 to 2,460

Low idling

rpm

900 to 950

interval

Plunger pre-stroke

mm

3.2 * 0.05

Delivery valve retraction volume mm3/st

Calibration

Pump tester capacity for Service standard

51

Motor

7.5

KW

Standard

Conditions

Service

* Service

standard indicates data using calibration test parts. - Manufacture standard is data for factory test.

Manufacturer

Nozzle part no.

(105780-0000)

Nozzle holder part no.

(105780-2080)

Injection ipe (O/D x l/g x length)

Nozzle

ASTM

Rack point

Basic point

Marks l are average volumes.

Governor performance

B C

Rack position (mm)

Pump speed

10.0

1,100

"""qfs".

(rPm)

450

10.45

750

Service

standard (105017-0630)

6x

1.6x600

D975 No. 2 diesel fuel or equivalent 43

opening pressure kg/cm’

3-3330

(105048-3300)

OC

Transfer pump pressure kg/cm* Injection volume

6202-l

6 x 2 x 600

mm

Test oil

Oil temperature

Rack positions B to E are the reference volume when adjusting the injection volume.

standard

to 47

175

225

1.6

1.6

standard

(cc/l 000 st)

Manufacturer

standard (cc/1OOOst Maximum variance between cylinder

Maximum

Basis 73,5 10.5 (63.2)

Allowance

~“,:‘$$. cylinder

Basis

Each cyl. 72.5 to 74.5

21.8375

65.2

*

+I ,575

10.5

*

-

(77.5)

*

9.5 to 11.5

f(61.2

to 65.2)

Allowance Each cyl.

D

*

*

E

*

*

( 450 - 1,100 rpm)

cklimil:12.5’~’ mm

0

450

(580) 750 930+50

Pump speed (rpm)

’2-o,2-22

\ i2OOk30 1 100::;

SEBH4810 95 SERIES

I


Pump Assembly 6205-71-1271

Number

Applicable

(101492-3870)

Model

( ) : Manufacturer’s

injection

Timing

Rotating

direction

1 Injection

Machine

part

No.

Serial

Applicable Model

No.

Serial

S4D95L-1

PC1 00-5

Clockwise

view

from

drive

end

1-2-4-3

I

hi

I

90” * 30’ 1 Low idling mm

3.2 * 0.05

Delivery valve rntrIPtir\n ,,n~,,mO mm3/st

Calibration

Motor

to 950

7.5

I

KW

Standard Service standard

standard

indicates data

using calibration test parts. * Manufacture standard is data for factory test.

Nozzle part no.

(105780-0000)

Nozzle holder part no.

(105780-2080)

Injection

(O/D

ipe

x l/g x length)

ASTM

(105017-0630) (105048-3300)

6x1.6x600

D975

No. 2 diesel

fuel or equivalent

OC

opening pressure

kg/cm2

175

225

pump pressure

kg/cm’

1.6

1.6

* Rack

point

Basic

- Marks * are average volumes.

Governor performance

95 SERIES

3-3330

Oil temperature

Rack point

0

6202-I

standard

Nozzle

volume

positions B to E are the reference volume when adjusting the injection volume.

Manufacturer

6 x 2 x 600

mm

Test oil

Transfer injection

900

I

rpm

Pump tester capacity for Service standard

51

Conditions

- Service

No.

Engine specification

order

Plunger pre-stroke

Engine

B C

Rack position (mm)

43 to 47

Pump speed

Service standard

(cc/l 000 st)

(rpm)

Basis

9.9

1,050

6g g Each cyl. . 68.9 to 70.9

10.35

750

(63.2)

450

10.5

Approx. 7.8

Allowance

*(61.2 *

9.5to

to 65.2) 11.5

Maximum $~~~~~ cylinder

Manufacturer Basis

standard (cc/l 000 si

Allowance

Maximum variance between cylinder

Each cyl.

+I .7475

63.6

-

(77.5)

*

?I ,575

10.5

*

D

*

*

E

*

*

( 450 - 1,050 rpm)

I ll.,L

, 450 (680)750 1 1050% ,,50*30 9OOk50 Pump speed (rpm)

SEBH4811

’2-o2-23


Pump

Assembly

6206-71-1310

I

Number

Applicable

(101692-3661)

Machine

Model

( ): Manufacturer’s part No.

Applicable

Serial No.

Engine Serial No,

Model

WA120-1

6D95 L-l

(For altitude spec.)

Injection

Timing

Engine

Rotating direction Injection

order

Injection

interval

Plunger pre-stroke

Clockwise

viewed from drive end

l-5-3-6-2-4

Rated horsepower

HP/rpm

Maximum

kgm/rpm

torque

8512500 32.1/1600

High idling

rpm

2700 to 2800

Low idling

rpm

800 to 850

60” + 30’ 3.6 & 0.05

mm

Delivery valve retraction volume mm3/st

Calibration

specification

51

Pump tester capacity for Service standard

Motor

7.5

KW

Standard

Conditions

Service standard

* Service

standard indicates data using calibration test parts. - Manufacture standard is data for factory test.

Manufacturer

standard

Nozzle Dart no

(105780-0000)

6207-l

I-3130

(105017-0090)

Nozzle holder part no. Injection ipe fO/Dx I/ E x lenathl

(105780-2080)

6207-I

I-3110

(105048-3060)

1Test

mm

6 x 2 x 600

ASTM

oil

Oil temperature

Transfer pump pressure

kg/cm*

injection volume

1.6x600

D975 No. 2 diesel fuel or equivalent

OC

Nozzle opening pressure kg/cm’

6x

43 to 47 175

200

1.6

Service standard

1.6

(cc/l 000st)

Manufacturer

standard (cc/l 000s

* Rack positions B to E are the reference volume when adjusting the injection volume. - Marks l are average volumes.

Governor performance

1 400 - 1250rpm) Rack limit

0

1 w&o) T 400 62Oi20 850130 1:250 Pump speed (rpm) SEBH473E

12-022-24

95 SERIES


Pump Assembly 6206-71-1320

Number

Applicable

Machine

Model

( 1: Manufacturer’s

Injection

Timing

Rotating

direction

part No.

Clockwise

viewed

from

drive end

Serial No. 10018andup

8412,550

Rated horsepower

HP/rpm

Maximum

kgm/rpm

torque

1

31/1.400

High idling

rpm

2,700 to 2,800

Low idling

rpm

800 to 850

60/O f 30’ mm

3.6 f 0.05

Pump tester capacity for Service standard

51

Motor

7.5

KW

Standard

Conditions

* Service

-

Model 6D95L-1

1-5-3-6-2-4

I

Delivery valve . retraction volume mm3/st

Calibration

Serial No.

G D300A-2

interval

Plunger pre-stroke

Engine

Engine specification

Injection order Injection

Applicable

(101692-3001)

standard indicates data using calibration test parts. Manufacture standard is data for factory test.

Service standard

Manufacturer

Nozzle part no.

(105780-0000)

6207-I

l-3130

(105017-0090)

Nozzle holder part no.

(I 05780-2080)

6207-I

I-3110

(105048-3060)

Injection ipe (O/D x l/g x length)

6x2~600

mm

Test oil

ASTM

Oil temperature

6x

1.6x600

D975 No. 2 diesel fuel or equivalent

OC

43 to 47

Nozzle opening pressure kg/cm*

175

200

kg/cm’

1.6

1.6

Transfer pump pressure

Injection volume

Rack position (mm)

Rack point

Service standard

Pump speed

(cc/lOOOst)

Manufacturer

standard (cc/lOOOst

Maximum

(wm)

Basis

Allowance

Fe’$$E

Basis

Allowance

cylinder

* Rack

positions B to E are the reference volume when adjusting the injection volume. * Marks l are average volumes.

standard

Basic

Governor performance

Each cyl.

g8

point

A?$??.

B

1275

31.5

400

10.5

30.5 *9.5to

Each cyl.

to 32.5

20.7875

34.3

11.5

*I .575

10.5

*

C

*

*

D

*

*

E

*

*

(400 - 1275

Maximum variance between cylinder

rpm) Rack capapprox. 17.5mm

0

400

700

1850)

/

1375525

127538

Pump speed (rpm) SEBH4598

95 SERIES

12-0%2-25 d


Pump Assembly 6206-71-1335

Number

Applicable

1

Model (

Machine

Applicable

Engine

(101695-3340)

) : Manufacturer’s

1

Model

Serial No.

part No.

Serial No.

6D95L-1

WAIOO-1 WRII-1

injection

Timing

Plunger pre-stroke

Engine specification

mm

3.6 f 0.05

Del ivery valve retraction volume mm3/st

Calibration

Pump tester capacity for Service standard

51

7.5

KW

Standard

Conditions

Service standard

8Service

standard indicates data using calibration test parts. - Manufacture standard is data for factory test.

Manufacturer

(I 05780-0000)

6207-I

I-3130

Nozzle holder part no.

(105780-2080)

6207-I

I-31 10 (105048-3060)

Injection ipe (O/D x I& x length)

6 x 2 x 600

mm

Test oil

ASTM

6x

(105017-0090)

1.6x600

D975 No. 2 diesel fuel or equivalent 43

“C

to 47

Nozzle opening pressure kg/cm2

175

200

Transfer pump pressure

1.6

1.6

volume

Rack position (mm)

Rack point

kg/cm*

Service standard

Pump speed (rpm)

(cc/lOOOst)

Manufacturer

standard (cc/lOOOst

Maximum

Basis

Allowance

3l .3

Each cyl. 30.3 to 32.3

kO.7825

34.5

11.575

10.5

*

-

48.3

*

reysE”,

Basis

Allowance

cylinder Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

standard

Nozzle part no.

Oil temperature

Injection

Motor

Basic point

Governor performance

B

C

10.0

1,200

Approx. 107

11.1

350

10.5

*

800

36.3

*

9.5to

11.5

34.3 to 38.3

Maximum variance between cylinder

Each cyl.

D

*

*

E

*

*

( 350 - 1,200 rpm)

ack limit: 13’:’ mm

g E 6 :z B Y s a

12.2 10.0 9.2

6.0

0

350

850+30 / 1150f50 Pump speed (rpm)

\

‘1325i25 1240::

SEBH4813 95 SERIES


Machine Model

Engine Model

WA1

6D95L-1 S/N 26324

20-I

Injection

Injection Pump Type

Pump Manufacturer

Pump Assembly

PES-A

DIESEL KIKI

6206-71-l

Basis

Rotating direction Injection order

1-5-3-6-2-4

Injection interval

60”

59”30’

3.55 to 3.65

Plunger pre-stroke

mm

3.6

Delivery valve retraction volume

mm3

51

Calibration

Unit

Specification to 60”30’

for engine

I Rated horsepower:

with

8512500

Maximum torque:

kgm/rpm

32.111600

High idling:

rpm

2700

Low idling:

rpm

Manufacturer standard (with nearly the same actual machine parts)

Nozzle part no.

6207-l

l-31 30 (I 05017-0090)

6207-I

I-31

I

to 2800

800to

850

mm

Service standard (with calibration test parts) (105780-0000)

10 (I 05048-3060)

(105780-2080)

6x1.6x600

6x2~600

Test oil

ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature

“C

40 to 45

40 to 45

Nozzle opening pressure

kg/cm2

200

175

Transfer pump pressure

kg/cm2

1.6

1.6

Specifications

Injection volume (cc/l OOOst) for manufacturer standard

Injection volume kc/l OOOst) for service standard

1 : Reference data

Calibration basic point Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

Governor

fan (reference only)

HP/rpm

Nozzle holder part no. I. c”d%%C?!%ngth)

l

0

Standard

Conditions

l

.

Allowance

Clockwise viewed from drive end

[

360 (I 01692-3450).

and up

Timing Unit

l

Number

Rack Pump osition speed Pmm) (rpm)

Basis

10.7

L41.51

Allowance

Maximum variance between cvlinder

Basis

Each cyl A

1250 400

B a%p.?x~

36.7

110.51 *

‘10.5

Allowance

Each cyl. 35.7 to 37.7

co.91

*

k1.57

C

*

*

D

*

*

E

*

*

performance

(400

- 1250

Rackcap:

Maximum variance between cvlinder

9.5 to 1 1.5

Marked l: Rack position approx. 10.5 mm

rpm)

approx. 17.5 mm

Pump speed (rpmj Numbers in parentheses

SEBH4545 are pump manufacturer

part numbers.

95 SERIES ’ 2-o&2-27


Pump Assembly

Number

Applicable

6206-71-1420 (101692-3161) 6206-71-1421 (101692-3800) ( 1: Manufacturer’s part No.

Model

Machine

Applicable

Serial No.

Engine

Model

EG60-1

Serial No.

6D95L-1

23424

and up

EG65-S

Injection

Timing

Engine specification

Rotating direction

Clockwise viewed from drive end l-5-3-6-2-4

Injection order Injection interval Plunger pre-stroke

60” * 30’ 3.6 * 0.05

mm

Delivery valve retraction volume mm3/st

Calibration

Pump tester capacity for Service standard

51

Motor

7.5

KW

Standard 1

Conditions

* Service standard indicates data using calibration test parts. * Manufacture standard is data for factory test.

Service standard

Manufacturer

standard

Nozzle part no.

(105780-0000)

6207-I

I-3130

(105017-0090)

Nozzle holder part no.

(105780-2080)

6207-l

I-3110

(105048-3060)

Injection

ipe

6 x 2 x 600

mm

(O/D x I/g x lenath) Test oil

ASTM

Nozzle opening pressure kg/cm2

175

Transfer pump pressure kg/cm*

1.6

I

I

D975 No. 2 diesel fuel or equivalent 43 to 47

OC

Oil temperature

6 x 1.6 x 600 1

4.

I

200 1.6

I

Injection volume

Rack positions 6 to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

Governor performance

( 400 - 900 ,Rxk

75&10

rpm)

limit

;00+5

Pump speed (rpm)

SEBH4732-01 95 SERIES

’ 2-o&2-28


Pump Assembly Number

Applicable

6206-71-1940(101692-3860)

Injection Timing

order

Injection

interval

Plunger prestroke

Applicable

Engine

I

Engine specification

Rotating direction Injection

Machine

I

Clockwise viewed

from

drive end

l-5-3-6-2-4

Rated horsepower

HP/rpm

Maximum

kgm/rpm

torque

8512500 31.7/1500

High idling

rpm

2700 to 2800

Low idling

rpm

750 to 850

60”*30’ mm

r

3.6kO.05

Delivery valve retraction volume mm3/st

I

Pump tester capacity for Service standard

51

I

Motor

7.5

KW

I

Calibration Standard Conditions

Service standard

standard indicates data using calibration test parts. ) Manufacture standard is data for factory test.

’ Service

Manufacturer

Nozzle part no.

(105780-0000)

6207-l

I-3130

Nozzle holder part no.

(105780-2080)

6207-I

I-31 IO (105048-3060)

Injection ipe (O/D x l/g x length)

6x

6 x 2 x 600

mm

Test oil

ASTM

Oil temperature

D975

1.6x600

No. 2 diesel fuel or equivalent 43 to 47

“C 175

200

Transfer pump pressure

1.6

1.6

Rack

point

kg/cm’

Rack position

Pump speed

(mm)

(rpm)

Service standard

(cc/l OOOst)

Manufacturer

standard (cc/l OOOst

Maximum Basis

Allowance

rergE”,

Basis

Allowance

cylinder Basic point

10.0 AWF.

B

4clo

30.7 10.5

*

to 32.7

9.5 to 11.5

kO.7925

35.8

21.575

10.5

Each cyl.

*

C

*

D

*

*

E

*

*

Rack limit

L

1250

31 ,7 Each cyl.

Maximum variance between cylinder

*

( 400 - 1250 rpm)

Sovernor performance

0

(105017-0090)

Nozzle opening pressure kg/cm*

Injection volume

Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

standard

I 400

I, 560+30

17.5

I

mm

,/,I

8OOf30 / 11 OOf50

/ -i&17.50::;

Pump speed (rpm) SEBH4793

95 SERIES

’2-062-29


Machine

Engine Model

Injection Pump Type

Pump Manufacturer

6D95L

PES-A

DIESEL KlKl

Model

PC1 00-3

Pump Assembly

Number

6206-71-1210

1

(101692-3020).

PC1 OOL-3

Injection

Timing Unit

Rotating

Allowance

Basis

Clockwise viewed from drive end

direction

Specification

Injection order

l-5-3-6-2-4

Injection interval

60”

59”30’

3.6

3.55

Plunger pre-stroke

mm

Delivery valve retraction volume

mm3

Calibration

to 60”30’ to 3.65

51

for engine

with

fan

(reference

Rated horsepower:

HP/rpm

7912100

Maximum

kgm/rpm

30.5/l

High idling:

rpm

2250

Low idling:

rpm

800

torque:

only)

400 to 2350 to 850

Standard

Conditions

Unit

Nozzle

part no.

Nozzle

holder part no.

In ectron pope (d/D x I/D x length)

Manufacturer

standard

(with nearly the same actual machine l-31

30(105017-0090)

(

1

6207-I

I-31

10(105048-3060)

(

1

mm

6x1.6x600

“C

43 to 47

kg/cm2

200

kg/cm2

1.6

ASTM

Nozzle opening Transfer

pressure

pump pressure

Service standard (with calibration test parts)

6207-I

Test oil Oil temperature

parts)

D975

No. 2 diesel fuel or equivalent

ipecifications Injection volume (cc/l OOOst) for manufacturer standard Rack Pump position speed (mm) kpm) Calibration basic point Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

B

Basis

Allowance

Maximum variance between cylinder

10.5

1050

40.5

Each cyl. 39.5

to 41.5

k1.01

8.4

400

10.5

*

to 11.5

k1.57

9.5

St)

Injection volume(cc/ for service standard

Basis

Allowance

Maximum variance between cylinder

Each cyl.

*

C

*

*

D

*

*

E

*

*

iovernor performance

0 5

g

Pump speed

:gz; _.- r (rpm) Numbers

in parentheses

are pump manufacturer

part numbers. 95 SERIES

’ 2-o;2-30


Pump Assembly Number 6206-71-1210

Applicable

(101692-3022)

( 1: Manufacturer’s

Machine

Model

part No.

Applicable

Serial No.

Model

PC 1003

18001 and UD

PC1 OOL-3

18001 and up

Injection Timing

Engine Serial No. 10001 and up

6D95L-1

Engine specification

~~

Plunger prestroke

mm

3.6 f 0.05

Delivery valve retraction volume mm3/st

Pump tester capacity for Service standard

51

Motor

7.5

KW

Calibration Standard Conditions

Service standard

Service standard indicates data using calibration test parts. Manufacture standard is data for factory test.

Manufacturer

Nozzle part no.

(105780-0000)

Nozzle holder part no.

(105780-2080)

Injection ipe (O/D x l/g x length)

6 x 2 x 600

mm

ASTM

Test oil Oil temperature

No. 2 diesel fuel or equivalent 43

Nozzle opening pressure kg/cm2

175 1.6

Rack point

0975

“C

Transfer pump pressure

Injection volume

Rack position (mm)

kg/cm’

Pump speed (rpm)

Service standard

to 47

(cc/l OOOst)

Manufacturer

standard (cc/

Maximum Basis

Allowance

$gE!,

Allowance

Basis

cylinder Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

Basic point

Governor performance

B

9.8

1050

APBF

400

standard

3. 4

.

10.5

Each cyl. 29.4

to 31.4

*9.5to11.5

si

Maximum variance between cylinder

Each cyl. +0.76 fl.57

*

C

*

D

*

*

E

*

*

*

( 425 - 1050 rpm)

11.4 z .z E ._ C

9.6 6.4 6.4

2 0 Y P LT

Pump speed (rpm)

95 SERIES

SEBH4557

’2-oi2-3 ’


Machine Model

Engine Model

Injection Pump Type

Pump Manufacturer

PC1 20-3

6D95L

PES-A

DIESEL KIKI

Injection

Pump Assembly 6206-71-I

Number

. 1

220 (101692-3030).

Timing Unit

Basis

Allowance

Rotating direction

Clockwise viewed from drive end

Injection order

l-5-3-6-2-4

Injection interval

60”

59”30’

3.6

3.55 to 3.65

Plunger pre-stroke

mm

Delivery valve retraction volume

mm3

Calibration

Specification to 60”30’

51

for engine

with

fan (reference only)

Rated horsepower:

HP/rpm

82

Maximum torque:

kgm/rpm

31.5/1400

High idling:

rpm

2350 to 2450

Low idling:

rpm

800 to 850

/2200

Standard

Conditions

Unit

Nozzle part no. Nozzle holder part no. In ectron pope (d/D x I/D x length)

mm

Manufacturer standard (with nearly the same actual machine parts)

Service standard (with calibration test parts)

6207-I

l-31 30(105017-0090)

(

1

6207-I

I-31 1 0(105048-3060)

(

1

6x1.6x600

Test oil

ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature

“C

43 to 47

Nozzle opening pressure

kg/cm2

200

Transfer pump pressure

kg/cm2

1.6

Npecifications Injection volume (cc/l OOOst) for manufacturer standard Rack Pump position speed (mm) (rpm) Calibration basic point Rack positions B to E are the reference volume when adjustingthe injection volume. Marks * are average volumes. iovernor

B

Basis

Allowance

Maximum variance between cylinder

10.4

1100

40.5

Each cyl. 39.5 to41.5

21.01

8.4

400

10.5

*

* 1.57

9.5

to 11.5

St)

Injection volume&/ for service standard

Basis

Allowance

Maximum variance between cylinder

Each cyl. *

C

*

*

D

*

*

E

*

*

performance

Pump speed (rpm) . Numbers In parentheses are pump manufacturer part numbers. 95 SERIES ’ 2-o;2-32


Pump Assembly Number

Applicable

6206-7 l-l 220 (101692-3032)

( 1: Manufacturer’s

part No.

Machine

Applicable

Model

Serial No.

PC1 20-3

18001 and up

Injection Timing

Engine

Model

Serial No. 10001 and up

6D95L-1

Engine specification

Rotating direction

Clockwise viewed from drive end

Rated horsepower

HP/rpm

8512200

Injection

order

l-5-3-6-2-4

Maximum

kgm/rpm

31.5/1400

Injection

interval

Plunger pre-stroke Delivery valve

retmrtinn

V~II~.O

605 + 30’ mm

3.6 2 0.05

High idling

rpm

2350 to 2450

Low idling

rpm

800 to 850

I

Pump tester capacity for Service standard

51

mm3/st

torque

I

Motor

7.5

KW

Calibration Standard Conditions

Service standard

* Service

standard indicates data usingcalibration test parts. * Manufacture standard is data

for factory test.

Nozzle part no.

(105780-0000)

Nozzle holder part no.

(105780-2080)

Injection

ipe

(O/D x l/g x length)

Injection

ASTM

Transfer pump pressure kg/cm*

1.6

Rack position

Pump speed

Service standard

(mm)

(rpm)

9.9

1100

Appjox

400

* Rack positions 6 to E are the reference volume when adjusting the injection volume.

43 to 47

175

Rack point

Basic

* Marks * are average volumes.

Governor performance

point B

D975 No. 2 diesel fuel or equivalent

OC

Nozzle opening pressure kg/cm*

volume

Basis

(cc/l OOOst)

Allowance

3, 8 Each cyl. .

10.5

30.8 to 32.8 * 9.5to

11.5

Manufacturer

Maximum reTGEE Basis cylinder kO.795 +I .575

st

Maximum variance between cylinder

Each cyl. *

C D

*

*

E

*

*

- 1100

standard (cc/

Allowance

*

(425

standard

6 x 2 x 600

mm

Test oil Oil temperature

Manufacturer

*

rpm)

11.4 9.9 7 2 6 ._ c x Q Y P u

8.4 6.4

Pump speed (rpm)

95 SERIES

SEBH4558

’2-oi2-33


Machine Model IPWl50-1

Injection

Engine Model

Injection Pump Type

Pump Manufacturer

6D95L

PE-A

DIESEL KIKI

Pump Assembly 6206-71-I

I

Number 1

240 (101692-3010).

Timing Unit

Basis

Allowance

Clockwise viewed from drive end

Rotating direction

l-5-3-6-2-4

1Injection order

Specification

I

I

1

1Injection interval I 1Plunger pre-stroke I Delivery valve retraction volume

Calibration

60” mm

59’3O’to

3.6

60”30’

3.55 to 3.65

1 I I

with

fan (reference only) ,

) Rated horsepower: HP/rpm

87

/2400

kgm/rpm

32

/1600

High idling:

rpm

2600 to 2700

Low idling:

rpm

800 to 850

I

I

I

I Maximum torque:

I

II

I

51

mm3

for engine

1

I

Standard

Conditions

Unit

Manufacturer standard (with nearly the same actual machine parts)

Service standard (with calibration test parts)

Nozzle part no.

6207-l

l-31 30(105017-0090)

(

1

Nozzle holder part no.

6207-I

I-31 1 0(105048-3060)

(

)

In ectron pope (d/D x I/D x length)

mm

6x1.6x600

Test oil

ASTM D975 No. 2 diesel fuel or equivalent “C

43 to 47

Nozzle opening pressure

kg/cm2

200

Transfer pump pressure

kg/cm2

1.6

Oil temperature

ipecifications Injection volume (cc/l OOOst) for manufacturer standard Rack Pump position speed (mm) (rpm) Calibration basic point ’

Rack positions B B to E are the reference volume when C adjustingthe injection volume. D Marks +r are average volumes. E

Basis

Allowance

Maximum variance between cylinder kO.96

10.3

1200

38.5

Each cyl. 37.5 to 39.5

8.4

400

10.5

*

9.5

to 11.5

Injection volume&/ for service standard

Basis

Allowance

St) Maximum variance between cylinder

Each cyl. * 1.58

*

*

*

*

*

*

*

jovernor performance

Pump speed (rpm) Numbers in parentheses are pump manufacturer part numbers. 95 SERIES ’ 2-o&2-34


Pump Assembly

Number

6206-71-1250

(101692-3532)

( ): Manufacturer’s

Applicable Model

part No.

/I

Injection

Injection

interval

Plunger pre-stroke

and up

6D95L-1

29222

and up

D31S. Q-18

40001

and up

6D95L-1

29222

and up

l-5-3-6-2-4

Rated horsepower

HP/rpm

Maximum

kgm/rpm

torque

7012350 26.6/1400

High idling

rpm

2600 to 2700

Low idling

rpm

650 to 750

60’ + 30’ 3.6 f 0.05

mm

Pump tester capacity for Service standard

51

Motor

7.5

KW

Standard

standard

indicates data using calibration test parts. Manufacture standard is data

for factory test.

Service standard

Manufacturer

Nozzle part no.

(105780-0000)

6207-11-3130

Nozzle holder part no.

(105780-2080)

6207-I

Injection ipe (O/D x l/g x length)

ASTM

(105017-0090)

1-31 IO (105048-3060)

D975 No. 2 diesel fuel or equivalent 43 to 47

OC

Nozzle opening pressure kg/cm2

175

200

Transfer pump pressure kg/cm*

1.6

1.6

volume

Rack position (mm)

Rack point

Pump speed

Service standard

(cc/l OOOst)

(wm)

Basis

Allowance

10.0

1175

34 6 .

Each cyl. 33.6 to 35.6

B

11.1

650

(36.4)

C

APP~:;.

350

10.5

Manufacturer

Maximum rert$$“, Basis

standard (cc/lOOOst) Maximum

Allowance

cylinder Rack positions B to E are the reference volume when adjusting the injection volume. sMarks * are average volumes.

standard

6x1.6x600

6 x 2 x 600

mm

Test oil Oil temperature

Injection

Serial No.

40001

Conditions Service

Model

D31 E, P-18

Clockwise viewed from drive end

Delivery valve retraction volume mm3/st

Calibration

Engine

Engine specification

Rotating direction order

Applicable

Serial No.

Timing

Injection

Machine

Basic point

Governor performance

kO.865

36.0

Each cyl.

*(34.4

to 38.6)

-

(45.2)

*

*

to 11.5

51.575

(10.5)

*

9.5

D

*

*

E

*

*

( 350 - II75

variance between cylinder

rPm)

/Racklimit

/ 1300+;0 180) Pump speed (rpm)

SEBH4596-02

95 SERIES ’ 2-o;2-35


Pump Assembly 6206-71-1251

Injection

I

Number (101695-3260)

Timing

Calibration

60” f 30’ mm

I

3.6 f 0.05

I

51

mm3h

I

Pump tester capacity for Service standard

I

Motor

7.5

KW

Standard

Conditions

* Service

-

Engine

~~

1-5-3-6-2-4

interval

Plunger pre-stroke

Aoolicable

Clockwise view from drive end

Injection order

Delivery valve retraction volume

Machine

Engine specification

Rotating direction,

Injection

Applicable

standard indicates data using calibration test parts. Manufacture standard is data for factory test,

Service standard (105780-0000)

6207-I

Nozzle holder part no.

(105780-2080)

6207- 1 l-31 10

Injection

ipe

(O/D x l/g x length)

ASTM

l-3130

6x

6 x 2 x 600

mm

Test oil Oil temperature

(105017-0090)

1.6x600

D975 NO. 2 diesel fuel or equivalent

“C

43 to 47 175

200

Transfer pump pressure kg/cm’

1.6

1.6

Rack point

Rack position (mm)

standard

(105048-3060)

Nozzle opening pressure kg/cm’

injection volume

Pump speed (rpm)

Service standard

(cc/lOOOst)

Manufacturer

standard (cc/lOOOst

Maximum

Basis

Allowance

“d’,:ggR

Maximum

Basis

variance between

Allowance

cylinder

* Rack

positions B to E are the reference volume when adjusting the injection volume.

Manufacturer

Nozzle part no.

Basic

- Marks * are average volumes.

Governor performance

point B

88 Approx. 9.3

1,175

28.8

350

8.0

cylinder

Each cyl. 27.8 to 29.8

+0.72

28.7

*

21.2

10.5

7.0 to

9.0

Each cyl. *

C

*

D

*

*

E

*

*

*

( 350 - 1,175 rpm)

ck limit: 13’1’ mm

Pump speed (rpm)

’2-062-36

SEBH4812 95 SERIES

I


I

Machine Model

Engine Model

WA1 00-l 73 HP

6D95L-1 S/N 14287

Injection Pump Type

Pump Manufacturer

PE-S6A

DIESEL KIKI

Pump Assembly 6206-71-1331

1: Manufacturer’s part No.

Timing Unit

I

(101692-3191)....2

and up

(

Injection

Number

Allowance

Basis

I

Rotating direction

Counterclockwise viewed from drive end

Injection order

l-5-3-6-2-4

Injection interval

60”

59”30’

3.6

3.55 to 3.65

Plunger pre-stroke

mm

Delivery valve retraction volume

mm3

Calibration

I Specification

to 60”30’

51

for engine

with

fan (reference only)

Rated horsepower:

HP/rpm

7312400

Maximum torque:

kgm/rpm

29/l

High idling:

rpm

2600 to 2700

Low idling:

rpm

600

800to

850

Standard

Conditions

Unit

Nozzle part no.

Manufacturer standard (with nearly the same actual machine parts) -

Nozzle holder part no.

I t 8% ?l%%ngth)

Service standard (with calibration test parts)

(I 05017-0090~

(I 05780-0000)

(105048-3060)

(I 05780-2080) 6x2~600

mm

6x1.6x600

Oil temperature

“C

40 to 45

40 to 45

Nozzle opening pressure

kg/cm2

200

175

Transfer pump pressure

kg/cm2

1.6

1.6

ASTM D975 No. 2 diesel fuel or equivalent

Test oil

specifications Injection volume(cc/l for service standard

Injection volume (cc/l 000s.t) for manufacturer standard Rack Pump osition speed Pmm) (rpm)

Basis

Allowance

Maximum variance between cylinder

Basis

Allowance

Maximum variance between cylinder

9.3

1200

28.6

Each cyl. 27.6 to 29.6

a0.72

27.4

Each cyl. 26.4 to 28.4

kO.69

B 10.5 B to E are the reference volume when C adjustingthe injecD tion volume. Marks * are averE age volumes.

400

10.5

*

&I.58

10.5

*

* 1.58

Calibration basic point

) Rack positions

1

OOOst)

9.5 to 1 1.5

*

*

*

*

*

*

9.5 to 11.5

jovernor performance

95 SERIES

’2-o?-37


Machine Model

Engine Model

WA1

6D95L-1 S/N 22592

00-l

Injection

Injection Pump Type

Pump Manufacturer

PES-A

DIESEL KIKI

I

Pump Assembly 6206-71-I

333 (I 01692-3480).

0

and up

Timing Unit

Allowance

Basis

Rotating direction

Clockwise viewed from drive end

Injection order

1-5-3-6-2-4

Injection interval

60’

59”30’

3.6

3.55 to 3.65

Plunger pre-stroke

mm

Delivery valve retraction volume

mm3

Specification

for engine with fan (reference only)

to 60”30’

51 Low idling:

Calibration

675 to

rpm

725

Standard

Conditions

Manufacturer standard (with nearly the same actual machine parts)

Unit

Service standard (with calibration test parts)

6207-ll-3130(105017-0090)

Nozzle part no.

6207-I

Nozzle holder part no. I’ . (nd%t%%?!ngth)

mm

l-31

(I 05780-0000)

10 (I 05048-3060)

(I 05780-2080) 6x2~600

6x1.6x600

ASTM D975 No. 2 diesel fuel or equivalent

Test oil Oil temperature

“C

40 to 45

40 to 45

Nozzle opening pressure

kg/cm2

200

175

Transfer pump pressure

kg/cm2

1.6

1.6

jpecifications

B[

Number

Injection volume (cc/l OOOstj for manufacturer standard

Injection volume (cc/l OOOst) for service standard

1 : Reference data Rack Pump osition speed (rpm) Pmm) Calibration basic point Rack positions B to E are the reference volume when adjustingthe injection volume. Marks * are average volumes.

sovernor

Basis

Allowance

Maximum variance between cylinder

Basis

Each cyl. A 9.3

1200

f28.61

350

[IO.51

B %Yox.

27.4 ‘10.5

*

Each cyl. 26.4 to 28.4

kO.68

*

a1.57

*

*

D

*

*

E

*

*

C

performance

(400

- 1200

Rackcap:

9.5 to 11.5

Marked l: Rack position approx. 10.7 mm

rpm)

a~r~~17.5

Maximum variance between cylinder

Allowance

mm

6.0

o--350

800

105OSC )l 315*25 12(IOt40 t30

+

Pump speed (mm)

12-022-38

Numbers in parentheses

SEBH4544 are pump manufacturer

part numbers. 95 SERIES


Pump Assembly Number 6206-71-1334

Applicable

I

Injection Timing

Plunger pre-stroke

,

Machine

Applicable

Engine

(101692-3780)

Engine specification

mm

3.6 * 0.05

Del ivery valve retraction volume mm3ht

Pump tester capacity for Service standard

51

Motor

7.5

KW

Calibration Standard Conditions

Service standard

* Service

standard indicates data using calibration test parts. * Manufacture standard is data for factory test.

(105780-0000)

6207-l

I-3130

Nozzle holder part no.

(I 05780-2080)

6207-l

l-31 10 (I 05048-3060)

injection ipe (O/D x l/6 x length) Tat

6x1.6x600

6 x 2 x 600

mm

oil

ASTM

D975

(I 05017-0090)

No. 2 diesel fuel or equivalent 43

to

47

Oil temperature

“C

Nozzle opening pressure

kg/cm’

175

200

Transfer pump pressure

kg/cm2

1.6

1.6

Rack point

Rack position

Pump speed

(mm)

(rPm)

Service standard

(cc/l 000 St)

Allowance

Basis

Manufacturer

Maximum TerE$ Basis

standard (cc/l OOOst

Allowance

cylinder

t Rack

positions B to E are the reference volume when adjusting the injection volume. bMarks * are average volumes.

standard

Nozzle part no.

volume

injection

Manufacturer

Basic point

(9.5)

B

A~$yx.

Governor performance

1200 350

2g 6 Each cyl. . 28.6 to 30.6

‘o.74

10.5

kl.575

*

9.5to

11.5

31 o

Maximum variance between cylinder

Each cyl.

’ 10.5

*

C

*

*

D

*

*

E

*

*

( 350 - 1200 rpm) Rackcap: a~~rox. 17.5mm

0

/ (330)350

800

Pump speed (rpm)

95 SERIES

1200_$o\ 1325t25 1200~;

SEBH 4708

’2-oi2-39


<

Pump Assembly Number 6206-71-1370

Applicable

(101692-3541)

( 1: Manufacturer’s

Model

part No.

Applicable

Serial No.

Engine

Model

Serial No. 29245

6D95L-1

D37 E-2

Injection Timing

and up

Engine specification Clockwise viewed from drive end

Rotating direction Injection order

1-5-3-6-2-4

Injection interval Plunger pre-stroke

Machine

60” f 30’ 3.6kO.05

mm

Delivery valve retraction volume mm3/st

Pump tester capacity for Service standard

51

Motor

7.5

KW

Calibration Standard Conditions

’ Service

standard indicates data using calibration

test parts.

* Manufacture standard is data for factory test.

Service standard Nozzle part no.

ASTM

(105017-0090)

6 x 1.6 x 600

D975 No. 2 diesel fuel or equivalent 43 to 47

“C

Nozzle opening pressure kg/cm’

175

200

1.6

1.6

Rack position (mm)

Pump speed

Service standard

10.0

1175

B

10.9

650

(33.6)

C

“““go.

350

10.5

Rack point

(vm)

Rack positions Basic point

ence volume when adjusting the injection volume. Marks * are average volumes.

Governor performance

standard

1-31 IO (105048-3060)

Transfer pump pressure kg/cm’ Injection volume

B to E are the refer-

6207-I

6 x 2 x 600

mm

Test oil

Oil temperature

6207-11-3130

(105780-0000) (105780-2080)

Nozzle holder part no. Injection ipe (O/D x l/g x length)

Manufacturer

Basis 35.6

(cc/l 000 St)

Allowance Each cyl. 34.6 to 36.6 k31.6 *

to 35.6

9.5 to 11.5

Manufacturer

Maximum ce’$$‘, Basis cylinder

Allowance

20.89

37.6

-

(43.7)

*

10.5

*

?I ,575

standard (cc/l 000~1 Maximun variance between cylinder

Each cy’.

D

*

*

E

*

*

( 350 - 1175 rpm) Rack limit

Pump speed (rpm)

SEBH4597-01

’2-oi2-4o

95 SERIES


Pump Assembly Number ‘6206-71-1550

Applicable

(101692-3670)

( ): Manufacturer’s

Model

part No.

Injection

interval

1 Clockwise viewed from drive end 1 l-5-3-6-2-4

Plunger pre-stroke retrartinn

vnlllmo

Model

Serial No.

SL6D95L-1

Rated horsepower

HP/rpm

Maximum

kgm/rpm

torque

1 High idling

rpm

Low idling

rpm

7012350 26.611400 2600 to 2700

I

60; f 30’

I Delivery valve

Serial No.

Engine

Engine specification

Rotating direction order

Applicable

D31 E, P-18

Injection Timing

Injection

Machine

mm

3.6 f 0.05

mm3/st

51

700 to 750

Pump tester capacity for Service standard

Motor

7.5

KW

Calibration Standard Conditions

- Service

standard indicates data using calibration

test parts.

- Manufacture standard is data for factory test.

Service standard

6207-11-3130

(105017-0090)

Nozzle holder part no.

(105780-2080)

6207-11-3110

(105048-3060)

Injection ipe (O/D x I/g x length)

6 x 2 x 600

mm

ASTM

Test oil

6x1.6x600

D975 No. 2 diesel fuel or equivalent 43 to 47

“C

Nozzle opening pressure kg/cm’

175

200

Transfer pump pressure kg/cm2

1.6

1.6

Injection volume Rack point

Pump

Rack position

speed

(mm)

(rPm)

- Rack

Basic point

tion volume.

- Marks

standard

(I 05780-0000)

Oil temperature

positions B to E are the reference volume when adjusting the injec-

Manufacturer

Nozzle part no.

are average volumes. l

Governor performance

9.7

1175

Service standard

(cc/lOOOstj

Manufacturer

standard (cc/lOOOst Maximum

Maximum

Basis

Allowance

34 , Each cyl. . 33.1 to 35.1

B

10.6

650

32.5

t

30.5 to 34.5

C

Apprgq$

350

10.5

*

9.5 to 11.5

~e~~~“, cylinder

Basis

kO.8525

36.1

-

44.8

*

10.5

*

f1.575

Allowance

variance between cylinder

Each cyl.

D

*

*

E

*

*

( 350 - 1175 rpm) Rack limit

Pump speed (rpmj

SEBH4737

95 SERIES ’ 2-062-41


Pump Assembly Number 6206-71-l

( ): Manufacturer’s

I

Applicable

570 (101692-3680)

Injection Pump Type

DIESEL

Serial No.

1

Model

Serial No.

SL6D95L-I

I

(For altitude

spec.)

KlKl

Engine specification

Rotating direction

Clockwise viewed from drive end l-5-3-6-2-4

Injection order

60” * 30’

interval

1 Low idling Plunger pre-stroke

Engine

I

injection Timing

Injection

Applicable

D37 E-2

Pump Manufacturer

PES-GA

/

Model

part No.

Machine

mm

3.6 + 0.05

I

Delivery valve retraction volume mm3/st

I

Pump tester capacity for Service standard

51

700 to 750

I

rpm

Motor

I

7.5

KW

Calibration Standard Conditions Service standard indicates data using calibration

test parts. Manufacture standard is data for factory test.

Service standard

Manufacturer

(105780-0000)

6207-I

I-3130

Nozzle holder part no.

(105780-2080)

6207-l

I-31 10 (105048-3060)

Injection ipe (O/D x l/g x length)

6 x 2 x 600

mm

ASTM

Test oil

Oil temperature

175 1.6

Rack position (mm)

Pump speed b-pm)

(105017-0090)

1.6x600

D975 No. 2 diesel fuel or equivalent 43 to 47

Transfer pump pressure kg/cm’

Rack point

6x

OC

Nozzle opening pressure kg/cm2

Injection volume

Service standard

200

1.6 (CC/I OOOst)

Allowance

Basis

Manufacturer

Maximum ye’tEE”, Basis

standard (cc/lOOOst

Allowance

cylinder Rack positions B to E are the reference volume when adjusting the injection volume. Marks l are aver-

standard

Nozzle part no.

Basic

age volumes.

3overnor performance

point

10.4

B

C

1175

38 6 Each cyl. . 37.6 to 39.6

11.1

650

35.4

*

33.4 to 37.4

““3

350

10.5

*

9.5 to 11.5

A

Maximum variance between cylinder

42.4

Each cyl.

+-‘.‘EJ~ k1.575

47.1

*

10.5

*

D

*

*

E

*

*

( 350 - 1175 rpm) Rack limit

Pump speed (rpmj

’2-o62-42

SEBH4736

95 SERIES

I

I


Pump Assembly 6207-71-I

Number Applicable

210 (101692-3890)

Machine

Model

(

): Manufacturer’s

Serial

Applicable No.

Engine

Model

Serial

No.

part No. (CUSTOM) BR200_,

Injection Rotating

Timing

Engine Specification

direction

Injection

order

Injection

interval

Clockwise

viewed

from

drive

end

Rated horsepower

Maximum

l-5-3-6-2-4

High

Low idling Plunger

pre-stroke

Delivery valve retraction volume

Calibration

mm

torque Nm(kgm)/rpm

idling

60° + 30’

kW(HP)/rpm

94.5

(126.7)/2050

475 (48.5)/1560

rpm

2205 - 2325

rpm

875 - 925

3.6 -t 0.05

mms/st

51

Pump tester capacity for Service standard

Motor

7.5 KW

Standard

standard indicates data using calibration test parts. Manufacture standard is data for factory test. Service

Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

Governor performance

(450

-

1025

rpm)

ck limit159’mm

930 * 50 , 025z$ Pump speed (rpm) SEBH 95 SERIES

’ 2-o2-43

4775


Pump Assembly

Number

6207-71-1211

(101695-3050)

Applicable

Machine

Model (

I

) : Manufacturer’s Injection Pump Type

DIESEL

I

KlKl

S6D95L-1

BR200-1

Engine specification

mm

3.6 f 0.05

Delivery valve retraction volume mm3/st

Calibration

Serial No.

CUSTOM

Timing

Plunger pre-stroke

Pump tester capacity for Service standard

51

Motor

7.5

KW

Standard

Conditions

* Service

standard indicates data usingcalibration

test parts.

- Manufacture standard is data for factory test.

Service standard

Manufacturer

(105780-0000)

6202-I 3-3330

(105017-0630)

Nozzle holder part no.

(105780-2080)

6202-I 3-3110

(105048-3300)

Injection ipe (O/D x l/g x length)

6 x 2 x 600

mm

ASTM

Test oil

6 x 2 x 600

D975 No. 2 diesel fuel or equivalent 43 - 47

OC

Nozzleopening pressure Mpa(kg/cmz)

17.2 (175)

22.1 (225)

Transfer pump pressure Mpa(kg/cmz)

0.16 (1.6)

0.16 (1.6)

Injection volume Rack point

Rack position (mm)

Pump speed (rpm)

Service standard

Allowance

Basis

(CC/I OOOst)

Manufacturer

Maximum Fey::“, Basis

standard (cc/l OOOst Maximurr

Allowance

cylinder Rack positions B to E are the reference volume when adjusting the injection volume. * Marks * are average volumes.

standard

Nozzle part no.

Oil temperature

Basic point

Governor performance

Each cyl. 68.7 - 70.7

10.1

1,025

69.7

8

10.7

750

68.2

*66.2-70.2

C

Approx. 8.0

475

12.5

*11.5-

13.5

variance between cylinder

Each cyl. fl.7425

65.1

-

76.1

*

21.875

12.5

*

D

*

*

E

*

*

( 475 - 1,025 rpm)

960 +50 Pump speed (rpm)

12-022-44

Engine

Model

Serial No.

PC200-5

Pump Manufacturer

PES-GA

Injection

part No.

Applicable

SEBH4814 95 SERIES


Pump Assembly Number

Applicable

Machine

Applicable

Engine

6207-7 l-l 230 (101692-3820) Model

( ): Manufacturer’s part No.

I

Injection Pump Type

DIESEL

and up

KlKl

l-5-3-6-2-4

I

interval

60’+30’ mm

I

I Low - idling

875 - 925

rpm

3.6 f 0.05

Delivery valve ~nhrme

48356

S6D95L-1

and up

Clockwise viewed from drive end

Injection order

retractinn

Serial No.

Engine specification

Rotating direction

Plunger pre-stroke

Model

BR200-1

I

Injection Timing

Injection

45001

PC200-5

Pump Manufacturer

PES-GA

Serial No.

Pump tester capacity for Service standard

51

mm3/st

Motor

7.5

KW

Calibration Standard Conditions

*Service

standard indicates data using calibration test parts. pManufacture standard is data for factory test.

Service standard

Manufacturer

Nozzle part no.

(105780-0000)

6206-11-3130

(105017-0140)

Nozzle holder part no.

(105780-2080)

6207-I

(I 05048-3060)

Injection

ipe

(O/D x I/g x length)

I-3110

6 x 2 x 600

mm

Test oil

ASTM

Oil temperature

6x

1.6x600

D975 No. 2 diesel fuel or equivalent 73.0 - 75.0

OC

Nozzle opening pressure Mpalkgicmz)

17.2 (175)

22.1 (225)

Transfer pump pressure Mpa(kg/cm*)

0.16 (1.6)

0.16 (1.6)

Injection volume

Rack position (mm)

Rack point

Pump

Service standard

(cc/l OOOst)

speed

b-pm)

Manufacturer

standard (cc/l OOOst Maximurr

Maximum

Basis

Allowance

74.0

Each cyl. 73.0 - 75.0

ybaer$re!$ Basis

Allowance

cylinder Rack positions B to E are the reference volume when adjusting the injection volume.

standard

Basic

Marks l are average volumes.

Governor performance

point

10.5

1025

B

11.2

750

C

*yyx.

450

(74.0) (* 12.5

t

72.0 - 76.0) 11.5-13.5

variance between cylinder

Each cyl. fl.85 +I.875

73.6 (81.4) * 12.5

t

D

*

*

E

*

*

( 450 - 10% rpm)

18’3

-G 2 .-6 C g a Y z [r

10.5 9.7

6.7 5.7

1 0

450

750 950*50 (670)

Pump speed (rpm)

II1135?30 1025:::

SEBH4711

95 SERIES ’ 2-02-45


Machine Model

Engine Model

PWl OO-3

S6D95L-1 S/N 15060

Injection Pump Type

Pump Manufacturer

PE-A

DIESEL KIKI

Pump Assembly

Number

6207-71-1240

(101692-3221).

1

and up

Injection Timing Unit

Basis

Allowance

-1

Clockwise viewed from drive end

Rotating direction

Specification

Delivery valve retraction volume

Calibration

51

mm3

rpm

850 to

900

Service standard (with calibration test parts)

6207-I

l-31 30 (105017-0090)

(105780-0000)

Nozzle holder part no.

6207-I

l-31 10 (105048-3060)

(I 05780-2080)

mm

6x1.6x600

6x1.6x600 ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature

“C

40 to 45

40 to 45

Nozzle opening pressure

kg/cm2

200

175

Transfer pump pressure

kg/cm2

1.6

Specifications

Rack Pump osition speed (rpm) Pmm)

Basis

11.2

950

55.0

Injection volume (cc/l OOOstI for service standard

B atyp

425

12.5

Allowance

Maximum variance between cylinder

Basis

Allowance

Maximum variance between cylinder

44.5

Each cyl. 43.5 to 45.5

21.11

ll 2.5

* 11.5 to 13.5

k1.87

Each cyl. A

Rack positions B to E are the reference volume when adjustingthe injection volume. Marks * are average volumes.

Governor

1.6 Injection volume kc/l OOOstI for manufacturer standard

1 : Reference data

Calibration basic point

l

Low idling:

2050 to 2150

Nozzle part no.

Test oil

l

rpm

Manufacturer standard (with nearly the same actual machine parts)

Unit

I’ ;d%t?l%%anqth)

[

High idling:

Standard

Conditions

l

for engine with fan (reference only)

t *

*

D

*

*

E

*

C

performance

* Marked l: Rack position approx. 10.4 mm

(425 - 950 rpm) Rack cap:

approx.

17.5 mm

Pump speed (rpm ) Numbers in parentheses

SEBH4528 are pump manufacturer

part numbers. 95 SERIES

’ 2-o&2-46


Pump Assembly

Number

6207-71-1262

(101692-3880)

( 1: Manufacturer’s

Applicable

Machine

Model

part No.

Applicable

Serial No.

Engine

Model

PC2005

Serial No.

S6D95L-1

BR200-1

injection

Timing

Engine specification

Rotating direction

Clockwise viewed from drive end

Injection order Injection

interval

Plunger pre-stroke

60” f 30’ mm

3.2 + 0.05

Delivery valve _ retraction volume mm3/st

Calibration

~1

1-5-3-6-2-l

Pump tester capacity for Service standard

51

Motor

7.5

KW

Standard

conditions Service standard indicates . data . uarn9 cafrbratron test parts (Nozzle, Nozzle holder and injection pipe)

Manufacture siandard is data using facton/ teat parts (For reference)

Service standard Nozzle part no Nozzle holder part no.

.

Injection ipe (O/Ox l/g x length)

6206-11-3130 6207-l

6 x 2 x 600

mm

ASTM

standard

(105017-0140)

1-31 IO (105048-3060) 6x

1.6x600

D975 No. 2 diesel fuel or equivalent 43-47

OC

NO~ZI~ openingPressureMpa(kg/cmz)

17.2 (175)

19.6 (200)

Transfer pump pressureMpa(kg/cmz)

0.16 (1.6)

0.16 (1.6)

njection volume Rack point

Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

(I 05780-0000) (105780-2080)

Test oil Oil temperature

Manufacturer

Rack position (mm)

Basic point B C

(rPm

9.9

1025

10.2

750

““692.

450

A

Service standard

Pump speed

)

Basis

Allowance

6g o Each cyl. . 68.0 - 70.0 12.5

* *11.5-

(d1000st)

+I.725 -

13.5

Manufacturer

Maximum yert$!$“, Basis cylinder

fl.875

68 2

.

12.5

standard (cc/t OOOst

Allowance

Maximum variance between cylinder

Each cyl. * +

D

*

*

E

*

*

Zovernor performance ( 450 - 1025 rpm)

Pump speed (rpmj

95 SERIES

SEBH4733-01

’2-oE-47


Pump Assembly Number 6207-71-1271

(101695-3020)

Service standard

* Service

standard indicates data using calibration test parts. - Manufacture standard is data

for factory test.

Nozzle part no.

(105780-0000)

6207-11-3130

Nozzle holder part no.

(105780-2080)

6207-I

Injection ipe (O/D x l/g x length)

mm

ASTM

(105048-3060) 1.6x600

D975 No. 2 diesel fuel or equivalent 43

OC

to 47

Nozzle opening pressure kg/cm*

175

200

Transfer pump pressure kg/cm2

1.6

1.6

Injection volume Rack point

Rack position (mm)

Pump speed

Service standard

(cc/lOOOst)

Manufacturer

standard (cc/lot)~)st

Maximum Basis

Allowance

1,050

49.9

Each cyl. 48.9 to 50.9

+I .2475

55.4

425

12.5

t

21.875

12.5

(rpm)

~e~~~‘,

Basis

Allowance

cylinder

* Rack

Basic point

adjusting the injection volume. * Marks * are average volumes.

Governor performance

8

11.3 Approx. 10.4

standard

(105017-0090)

I-3110 6x

6 x 2 x 600

Test oil Oil temperature

positions 6 to E are the reference volume when

Manufacturer

11.5 to 13.5

Maximum variance between cylinder

Each cyl. *

C

*

*

D

*

*

E

*

*

( 425 - 1,050 rpm) Rack limit: Approx. 15’:’ mm

Damper spring set 7.510.1 mm

Pump speed (rpm)

’2-o$2-48

SEBH4815

95 SERIES


Machine Model

Engine Model

Injection Pump Type

Pump Manufacturer

PC1 5O(LC)-3

S6D95L-1

PE-S6A

DIESEL KIKI

99 HP

S/N 10001

I

Pump Assembly 6207-71-1320

(101692-311

I).

3

and up

(

Injection

Number

1: Manufacturer’s part No.

Timing Basis

Unit

Allowance

Rotating direction

Clockwise viewed from drive end

Injection order

l-5-3-6-2-4

Injection interval

60” mm

Delivery valve retraction volume

mm3

Calibration

,59”30’

3.6

Plunger pre-stroke

Specification to 60”30

3.55 to 3.65

51

for engine

with

fan (reference only)

Rated horsepower:

HP/rpm

9912200

Maximum torque:

kgm/rpm

38/I 400

High idling:

rpm

2350 to 2450

Low idling:

rpm

850to

900

Standard

Conditions

Unit

Manufacturer standard (with nearly the same actual machine parts)

Service standard (with calibration test parts)

Nozzle part no.

(I 05017-0090)

(I 05780-0000)

Nozzle holder part no.

(I 05048-3060)

(I 05780-2080)

I t 8% ?l%?%ngth)

mm

6x1.6x600

6x 1.6x600

ASTM D975 No. 2 diesel fuel or equivalent

Test oil Oil temperature

“C

40 to 45

40 to 45

Nozzle opening pressure

kg/cm2

200

175

Transfer pump pressure

kg/cm2

1.6

1.6

specifications Injection volumekcll for service standard

Injection volume kc/l OOOst) for manufacturer standard Pump Rack osition ye$d r Pmm) Calibration basic point l

l

Rack positions B to E are the refer-

B

Basis

Allowance

Maximum variance between cylinder

Basis

Allowance

Maximum variance between cylinder

10.7

1100

49.5

Each cyl. 48.5 to 50.5

k1.24

41

Each cyl. 40 to42

f 1.03

10.4

425

12.5

* 11.5 to 13.5

* 1.88

12.5

* 1 1.5 to 13.5

* 1.88

ence volume when C adjusting the injec-

*

*

D

*

*

E

*

*

tion volume. Marks * are average volumes.

OOOst)

sovernor performance 18+B

95 SERIES

’2-oi2-49


Pump Assembly Number

Applicable

Machine

Model

( I: Manufacturer’s

part No.

Applicable

Serial No.

Model

PC1 50-3

Injection Timing

Engine Serial No. 32941andup

S6D95L-1

Engine specification

Rotating direction

Clockwise viewed from drive end l-5-3-6-2-4

Injection

order

Injection

interval

60” + 30’

Plunger prestroke

mm

3.6 f 0.05

Pump tester capacity for Service standard

51

F%ZXr;v,,V~~~ ,mp mm3/st

Motor

7.5

KW

Calibration Standard Conditions

Service standard

Service standard indicates data using calibration test parts. Manufacture standard is data for factory test.

standard

(105780-0000)

6207-I

l-3130

(105017-0090)

Nozzle holder part no.

(105780-2080)

6207-I

13110

(105048-3060)

Injection ipe (O/D x l/g x length)

6x

6 x 2.0 x 600

mm

ASTM

Test oil

1.6x600

D975 No. 2 diesel fuel or equivalent

Oil temperature

“C

Nozzle opening pressure

kg/cm2

175

200

Transfer pump pressure

kg/cm’

1.6

1.6

Injection volume Rack point

Rack positions 6 to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

Manufacturer

Nozzle part no.

Basic

Governor performance

point B

Rack position (mm)

43 to 47

Pump speed (rPm)

Service standard (cc/l 000 st)

Manufacturer

standard (cc/lOOOsl Maximun

Maximum

Basis

Allowance

10.8

1100

42.5

Each cyl. 41.5 to 43.5

A???

425

12.5

*

11.5t013.5

T$!$i”, cylinder

Basis

Allowance

variance between cylinder

Each cyl. +I .0625

51.3

k1.875

12.5

*

C

*

*

D

*

*

E

*

*

( 425 _ 1100 rpm)

1gc3 0

-C

11.5

L

10.8

: Z .0” a Y z cc

8.5

6

Pump speed Irpm)

12-0$2-50

SEBH4579-’

95 SERIES


Machine Model

Engine Model

WA1 50-I 94 HP

S6D95L-1 S/N 14360

Injection Pump Type

Pump Manufacturer

PE-S6A

DIESEL KIKI

Pump Assembly 6207-71-1331

(101692-3201).

__1

and up

(

Injection

Number

1: Manufacturer’s part No.

Timing Unit

Basis

Allowance

I

Clockwise viewed from drive end

Rotating direction

Specification

Delivery valve retraction volume

Calibration

mm3

51

for engine with fan (reference only)

High idling:

rpm

Low idling:

rpm

2600

to 2700

800 to

850

Standard

Conditions

Unit

Manufacturer standard (with nearly the same actual machine parts)

Service standard (with calibration test parts)

Nozzle part no.

(105017-0090)

(105780-0000)

Nozzle holder part no.

(105048-3060)

(105780-2080) 6x1.6x600

6x1.6x600

ASTM D975 No. 2 diesel fuel or equivalent

Test oil Oil temperature

“C

40 to 45

40 to 45

Nozzle opening pressure

kg/cm2

200

175

Transfer pump pressure

kg/cm2

1.6

1.6

Specifications Injection volume (cc/l OOOst) for manufacturer standard Rack Pump osition speed (rpm) Pmm) Calibration basic point l

l

32.5

10.5

400

12.5

Allowance

Each cyl. 31.5 to 33.5

CO.81

32.5

Each cyl. 3 1.5 to 33.5

a0.81

* 1 1.5 to 13.5

* 1.88

12.5

* 1 1.5 to 13.5

f 1.88

Rack positions

B

B to E are the reference volume when

C

*

*

adjustingthe injection volume. D

*

*

Marks * are average volumes.

*

*

Governor

E

Maximum variance

Basis

Allowance

1200

OOOst)

Maximum variance between cylinder

Basis

9.6

Injection volume(cc/l for service standard

between cylinder

performance

SEBH4507 95 SERIES ’ 2-o;2-51


Pump Assembly Number 6207-71-1332

Applicable

Machine

Applicable

Engine

(101692-3330) Serial No.

Model

( 1: Manufacturer’s part No.

Model

WA150-1

Serial No. 23243

S6D95L-1

and up

-1

Injection Timing

Engine specification

Rotating direction

Clockwise viewed from drive end

Injection order Injection

l-5-3-6-2-4

interval

Plunger prestroke Delivery valve

retractinn

vnlllme

I

Rated horsepower

HP/rpm

9412,400

Maximum

kgm/rpm

36/l ,600

torque

High idling

rpm

2,600 to 2,700

Low idling

rpm

800 to 850

60’ + 30’ mm

3.6 2 0.05

mm3/st

51

I

Pump tester capacity for Service standard

Motor

I

7.5

KW

Calibration Standard Conditions

Service standard

* Service

standard indicates data using calibration

test parts.

* Manufacture standard is data for factory test.

Manufacturer

(105780-0000)

6207-11-3130

(105017-4090)

Nozzle holder part no.

(105780-2080)

6207-l

(105048-3060)

Injection ipe (O/D x l/g x length)

ASTM

l-3110 6x

6 x 2.0 x 600

mm

Test oil Oil temperature

1.6x600

D975 No. 2 diesel fuel or equivalent

OC

43 to 47

Nozzle opening pressure kg/cm*

175

200

Transfer pump pressure kg/cm2

1.6

1.6

Rack position

Pump speed

Service standard

(mm)

(rPm)

Injection volume Rack point

(cdl

000st)

Manufacturer

Maximurr

Maximum rer$$“, Basis

Basis

Allowance

1,200

36.6

Each cyl. 35.6 to 37.6

kO.915

42.6

400

12.5

*

21.875

12.5

standard (cc/l OOOst

Allowance

cylinder Rack positions B to E are the reference volume when

standard

Nozzle part no.

Basic

adjusting the injection volume. Marks * are average volumes.

Governor performance

point B

10.1 Approx. 8.6

11.5 to 13.5

variance between cylinder

Each cyl. *

C

*

D

*

*

E

*

*

*

( 400 - 1200 rpm) ck limit 17.5 mm

18+:

z z. 5 ..% x Y m” oz

11.6 10.1 8.6

5.6

0

400 620+20

850 1000 + \1325125 1170+30 1200%

Pump speed (rpm)

’2-062-52

SEBH4799 95 SERIES


Pump Assembly

Number

6207-71-1335

(101695-3070)

Applicable

Machine

Model

( ): Manufacturer’s part No.

Injection

Clockwise view from drive end l-5-3-6-2-4

Injection order

Calibration

3.6 f 0.05

mm

Rated horsepower

HP/rpm

9412.400

Maximum

kgm/rpm

36/l ,600

torque

High idling

rpm

2,600 to 2,700

Low idling

rpm

675 to 725

Pump tester capacity for Service standard

51

mm3/st

Motor

7.5

KW

Standard

Conditions

Service standard

- Service

standard indicates data using calibration test parts. - Manufacture standard is data for factory test.

(105780-0000)

6207-11-3130

Nozzle holder part no.

(105780-2080)

6207-l

Injection ipe (O/D x l/g x length)

ASTM

standard

(105017-0090)

‘l-3110 (105048-3060)

6 x 2 x 600

mm

Test oil

6x

1.6x600

D975 No. 2 diesel fuel or equivalent 43 to 47

OC

Nozzle opening pressure kg/cm*

175

200

Transfer pump pressure

1.6

1.6

Injection volume

* Rack positions B&c

Governor performance

kg/cm*

Service standard

(cc/l 000 st)

Rack position (mm)

Pump speed (rpm)

Basis

10.9

1,200

45.3

Each cyl. 44.3 to 46.3

B

11.5

800

46.2

*44.2

C

APW;.

350

12.5

Rack point

8 to E are the reference volume when adjusting the injection volume. - Marks * are average volumes.

Manufacturer

Nozzle part no.

Oil temperature

point

Allowance

to 48.2

*I 1.5 to 13.5

Manufacturer

Maximum rerts’$, Basis cylinder

standard (cc/lOOOsi

Allowance

Maximun variance between cylinder

Each cyl. +1 .I325

53.4

-

60.2

*

+I.875

12.5

*

D

*

*

E

*

*

( 350 - 1,200 rpm)

ack

zE

S6D95L-1

60” + 30’

interval

~&~~~~$$me

Serial No.

Engine specification

Rotating direction.

Plunger pre-stroke

Engine

Model

Serial No.

WA1 50-l

Timing

Injection

Applicable

limit: 1s:’

mm

11.7

; .o s

10.9

g

0.7

5 d

6.8

1200-L

Pump speed

95 SERIES

(rpm)

1200:9

SEBH481E

12-022-53


Pump Assembly

Number

6207-71-1360

(101692-3430)

Applicable

Machine

Model

( 1: Manufacturer’s part No.

Applicable

Serial No.

Engine

Model

PC150-3c

Serial No.

S6D95L-1

27750

and up

PC180(L)LC-3

Injection

Timing

Engine specification

Rotating direction

Clockwise viewed from drive end

Injection order

1-5-3-6-2-4

Injection interval Plunger pre-stroke

60” f 30’ mm

3.6 + 0.05

Delivery valve retraction volume mm3/st

Calibration

Low idling

Pump tester capacity for Service standard

51

800 - 850

rpm

I

Motor

7.5

KW

Standard

Conditions ) Service standard indicated data calibration test parts.

Manufacture standard is data for factory test.

Service standard Nozzle part no.

6207-11-3130

(I 05780-0000) (I 05780-2080)

part no.

Injection ipe (O/D x l&x length)

13110 6x

6 x 2 x 600

mm

Test oil

ASTM

Oil temperature

0975

standard

(105017-0090) (105048-3060) 1.6x600

No. 2 diesel fuel or equivalent 43 - 47

“C

Nozzleopening pressure Mpa(kg/cmz)

17.2 (175)

19.6 (200)

Transfer pump pressure Mpa(kg/cmz)

0.16 (1.6)

0.16 (1.6)

Injection volume Rack point

sovernor peIfOrmanCe

Manufacturer

(

425

-

Rack

Rack position

Pump speed

(mm)

(rPm)

1100

Service standard (cc/l 000 st) Basis

Allowance

Manufacturer standard (cc/l 000 si

Maximum rerzE”, Basis cylinder

Allowance

Maximun variance between cylinder

rpm)

limit apprcx 17.5 mm

18+3 0

L/

0’

I’

425

700 (990)?50

Pump speed (rpm)

\ +20 “00,lO

12OOi25

SEBH4580-01

’2-oi2-54

95 SERIES

I

I


Pump Assembly Number 6207-71-1361

(101692-3990)

( ): Manufacturer’s part No. injection Pump Tvpe

Pump Manufacturer

PES-GA

ZEXEL (DIESEL KIKI)

Injection Timing

Engine specification

Rotating direction Injection

1 Maximum

1-5-3-6-2-4

order

Injection interval Plunger pre-stroke

Rated horsepower

Clockwise view from drive end

kW(HP)/rpm

torque

78.3

Nm(kgm)/rpml

389(39.7)/l

3.6 * 0.05

rpm

2,350 - 2,450

Low idling

rpm

800 - 850

I

I

Pump tester capacity for Service standard

51

,490

High idling 60” + 30’

mm

(105)/2,200

Motor

7.5

KW

Calibration Standard Conditions

Service standard

l

~d’.$e.$ay$rd

Nozzle part no.

(105780-0000)

Nozzle holder part no.

(105780-2080)

l

using calibration test parts. Manufacture standard is data for factory test.

.

Injection ipe (O/D x I& x length)

ASTM

1.6x600

43 - 47 17.2

0.16 (1.6)

Rack position (mm)

(105048-3060)

1 l-3 110

6x

“C

Nozzle opening pressure Mpa(kg/cmz)

Rack point

6207-

D975 No. 2 diesel fuel or equivalent

Transfer pump pressure Mpa(kg/cmz)

Injection volume

Pump

(175)

Service standard

speed (rPm)

19.6

l

Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

Basic

Governor performance

point

(cc/l OOOstj

Manufacturer

standard (cc/lOOOst

Maximum Basis

Allowance

perE$,

Basis

B

Each cyl. 11.1

1,100

Approx. 10.4

425

Allowance

45.1 12.5

44.1 t

11.5-

Maximurr variance between cylinder

Each cyl.

- 46.1 13.5

+I.1275

54.4

t1.875

12.5

*

C

*

*

D

*

*

E

*

*

( 400 - 1,100

(200)

0.16 (1.6)

cylinder l

standard

(105017-0090)

6 x 2 x 600

mm

Test oil

Oil temperature

Manufacturer 6207-11-3130

rpmj

ck limit: Approx. 1st’ mm

Pump speed (rpm) SEBH4817-01

95 SERIES ’ 2-ozz-55

1

I


Machine Model

Engine Model

WA1

S6D95L-1 S/N 26330

80-I

Injection Pump Type

Pump Manufacturer

PES-A

DIESEL KIKI

Pump Assembly 6207-71-I

Number

380 (101692-3460).

0

and up

Injection Timing Unit

Basis

Allowance

Rotating direction

Clockwise viewed from drive end

Injection order

l-5-3-6-2-4

Injection interval

60”

59’30’

3.6

3.55t03.65

Plunger pre-stroke

mm

Delivery valve retraction volume

mm3

Calibration

Specification to 60”30’

Rated horsepower:

1

51

HP/rpm

11 O/2500

kgm/rpm

40.5/l

High idling:

rpm

2700 to 2800

Low idling:

rpm

1 Maximum torque:

I

600

I

Standard

Conditions

Unit

Manufacturer standard (with nearly the same actual machine parts)

750to

850

Service standard (with calibration test parts)

Nozzle part no.

6207-I

I-3130

(105017-0090)

(I 05780-0000)

Nozzle holder part no.

6207-I

I-31 IO (I 05048-3060)

(I 05780-2080)

In ectron rpe (d/D xl/$x length)

mm

6x1.6x600

6x2~600

Test oil

ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature

OC

40 to 45

40 to 45

Nozzle opening pressure

kg/cm2

200

175

Transfer pump pressure

kg/cm2

1.6

Specifications [

for engine with fan (reference only)

1.6 Injection volume (cc/l OOOst) for manufacturer standard

Injection volume (cc/l OOOst) for service standard

1 : Reference data

Calibration basic point

Basis

A

11.0

1250

L54.01

8

aYq;iox.

400

112.51

positions 8 to E are the reference volume when adjustingthe injection volume. Marks * are average volumes.

Maximum variance between cylinder

Basis

‘12.5

*

Each cyl. 44.7 to 46.7

f1.14

* 11.5 to 13.5

k1.87

*

*

D

*

*

E

* (400

- 1250

Rack cap: /

45.7

approx.

Maximum variance between cylinder

Allowance

C

performance

1a+;

Allowance

Each cyl.

Rack

Governor

Rack Pump osition speed Pmm) (mm)

* Marked l: Rack position approx. 10.5 mm

rpm) 17.5 m,,,

,I//,

17.5’

62OQO

1200+50

Pump speed

1250:;0,

SEBH4546

(rpm)

Numbers in parentheses

are pump manufacturer

part numbers. 95 SERIES

I


Pump Assembly Number 6207-71-I

Applicable

Machine

Applicable

Engine

390 (101692-3550) Model

( ): Manufacturer’s

part No.

Model

Serial No.

PC1 80LC-3

Serial No.

S6D95L-1

PC180LLC-3

Injection Timing

Engine specification Clockwise viewed from drive end

Rotating direction

Rated horsepower

HP/rpm

1

Maximum

kgm/rpm

I

High idling

rpm

I

Low idling

rpm

torque

39.7/1,500 2,350 to 2,450 750 to 850

Pump tester capacity for Service standard

Delivery valve retraction volume mm3/st

105/2,200

Motor

I

7.5

KW

1 I 1 I

I

Calibration Standard Conditions

- Service

standard indicates data using calibration test parts. - Manufacture standard is data for factorv test.

Service standard (105780-0000)

6207-I

l-31 30 ( 105017-0090)

Nozzle holder part no.

(105780-2080)

6207-I

I-3110

Injection ipe (O/D x l/g x length)

6x

mm

1.6x600

ASTM

Test oil

6x

( 105048-3060)

1.6x600

D975 No. 2 diesel fuel or equivalent

“C

43 to 47

Nozzle opening pressure kg/cm*

175

200

Transfer pump pressure

1.6

1.6

volume

pRack

Basic

tion volume. - Marks * are average volumes.

Governor performance

kg/cm*

Service standard

Rack position

Pump speed

(mm)

(w-4

Basis

11.1

1100

45.1

B

12.3

700

C

Approx. 8.5

425

Rack point

positions 6 to E are the reference volume when adjusting the injec-

standard

Nozzle part no.

Oil temperature

Injection

Manufacturer

point

(cc/l 000st)

Manufacturer

standard (cc/ 1 OOCkt Maximum

Maximum

Allowance Each cyl. 44.1 to 46.1

* 12.5

* 11.5 to 13.5

rergzF cylinder

Basis

kl .I275

54.4

Allowance

variance between cylinder

Each cyl.

21.875

174.21 t 12.5

*

D

*

*

E

*

*

( 425 - 1100 rpm) Rack cap: approx. 17.5 mm

1100::;

Pump speed (rpm)

95 SERIES

SEBH4611

’2-o;2-57


Machine Model GD461A-1

Injection

Injection Pump Type

Engine Model S6D95L-1 S/N 24866

PES-A

Pump Manufacturer DIESEL KlKl

Basis

Allowance

Clockwise viewed from drive end

Injection order

l-5-3-6-2-4

Injection interval

60”

59”30’

3.6

3.55 to 3.65

Plunger pre-stroke

mm

Delivery valve retraction volume

mm3

Calibration

Specification to 60”30’

51

Rated horsepower:

HP/rpm

113/2500

Maximum torque:

kgm/rpm

42.811500

High idling:

rpm

2700

Low idling:

rpm

Manufacturer standard (with nearly the same actual machine parts)

Unit

to 2800

750to

850

Service standard (with calibration test parts)

Nozzle part no.

6207-I

l-31 30 (I 05017-0090)

(I 05780-0000)

Nozzle holder part no.

6207-I

l-31 IO (105048-3060)

(105780-20801

In ectron rpe (d/D xl/$x lenqth)

mm

6x1.6x600

6x2~600

Oil temperature

“C

40 to 45

40 to 45

Nozzle opening pressure

kg/cm2

200

175

Transfer pump pressure

kg/cm2

1.6

1.6

Test oil

ASTM D975 No. 2 diesel fuel or equivalent

Specifications

Rack Pump osition speed Pmm) (rpm)

Basis

10.7

1250

51.5

400

12.5

Allowance

Maximum variance between cylinder

Basis

B approx. 8.6

performance

*

Maximum variance between cylinder

Allowance

Each cyl. 42.0 to 44.0

f 1.07

‘12.5

* 1 1.5 to 13.5

k-1.87

*

*

*

* *

* (400-

OOOst)

43.0

Each cyl. A

Rack positions B to E are the reference volume when C adjusting the injecD tion volume. Marks * are averE age volumes.

Governor

Injection volume h/l for service standard

Injection volume (cc/l OOOst1 for manufacturer standard

I : Reference data

Calibration basic point

l

for engine with fan (reference only)

Standard

Conditions

l

(101692-3351)....1

and up

Rotating direction

[

Number

6207-71-1811

Timing Unit

l

Pump Assembly

Marked l: Rack position approx. 10.5 mm

1250 rpm)

Rack cap: approx.17.5 mm

/L 0

400 590*20800*30

1170*50\

Pump speed (rpm) Numbers

1375?35

1250::;

in parentheses

SEBH4529 are pump manufacturer

part numbers. 95 SERIES

’ 2-o$2-58


Machine Model

Engine Model

Injection Pump Type

Pump Manufacturer

GD51 lA,R-1 GD513A,R-1

S6D95L-1 S/N 26224

PES-A

DIESEL KIKI

Pump Assembly 6207-71-l

Number

910 (101692-3390).

.

0

and up

Injection Timing Unit

Basis

Allowance

I

Rotating direction

Clockwise viewed from drive end

Injection order

l-5-3-6-2-4

Injection interval

60”

59”30’ to 60”30’

3.6

3.55 to 3.65

Plunger pre-stroke

mm

Delivery valve retraction volume

mm3

Calibration

Specification

51

Standard

Conditions

Unit

Nozzle part no. Nozzle holder part no. I. c”d%t%%?%nqth~

mm

Maximum torque:

kgm/rpm

1 High idling:

rpm

I Low idling:

rpm

l-3 130 (I 05017-0090)

6207-l

I-31 10 (105048-3060)

44/l 3050

600 to 3 150

850to

950

(105780-0000) (105780-2080)

6x1.6x600

6x2~600 ASTM D975 No. 2 diesel fuel or equivalent

“C

40 to 45

40 to 45

Nozzle opening pressure

kg/cm2

200

175

Transfer pump pressure

kg/cm2

1.6

1.6 Injection volume (cc/l OOOst) for manufacturer standard

1 : Reference data

Rack positions E are refer-

135/2900

Service standard (with calibration test parts)

Oil temperature

Calibration basic point l

HP/rpm

6207-l

Specifications

[

Rated horsepower:

Manufacturer standard (with nearly the same actual machine parts)

Test oil

l

1

for engine with fan (reference only)

A

Injection volume (cc/l OOOst) for service standard

Rack Pump osition speed Pmm) (rpm)

Basis

Allowance

Maximum variance between cylinder

11.2

56.8

Each cyl. 55.8 to 57.8

f 1.42

12.5

* 1

f 1.87

1450

a%?F

to 13.5

Basis

156.81

Allowance

Maximum variance between cylinder

Each c I. [55.& to 157.81

[+ 1.421

l: Rack

Rack cap: apjxox. 17.5 mm

1450+20

Pump speed (rpm) Numbers in parentheses

SEBH4530 are pump manufacturer

part numbers.

95 SERIES ’ 2-022-59

I

I


Pump Assembly 6207-71-1930

Number

Applicable

(101695-3120)

Model

( ): Manufacturer’s part No.

Injection

Serial No.

Engine

Model

Serial No.

S6D95L-1

Engine specification

Rotating direction

Clockwise viewed from drive end

Injection order

Rated horsepower kW(HP)/rpm

I

l-5-3-6-2-4

I

Injection interval

93.3 (125)/2,500

Maximum torque Nm(kgm)/rpm

I

431(44)/l

,600

High idling

rpm

I

2,700 - 2,800

Low idling

rpm

I

850 - 950

60’ ? 30’ mm

3.6 f 0.05

Delivery valve retraction volume mm3/st

Calibration

Applicable

GDSIOR-1

Timing

Plunger pre-stroke

Machine

Pump tester capacity for Service standard

51

Motor

I

7.5 KW

Standard

Conditions

Service standard

Manufacturer

standard

’ fn~~c~t~~~a~~~d Nozzle part no.

(105780-0000)

6207-I

I-3130

(105017-0090)

using calibration test parts. 1 Manufacture standard is data for factory test.

(I 05780-2080)

6207-I

I-3110

(105048-3060)

Nozzle holder part no. Injection ipe (O/D x l/g x length)

ASTM

when adjusting the injection volume. 1 Marks * are average volumes.

D975 No. 2 diesel fuel or equivalent 43 - 47

OC 17.2 (175)

19.6 (200)

Transfer pump pressure Mpa(kg/cmz)

0.16 (1.6)

0.16 (1.6)

Rack position (mm)

Rack point

,“,oE,“:~;h;,ref-

1.6x600

Nozzle opening pressure Mpa(kg/cmz)

Injection volume

1 Rack positions

mm

Test oil Oil temperature

6x

6 x 2 x 600

Pump speed

Service standard

(cc/lOOOstj

Manufacturer

Maximum ~er~~~ Basis cylinder

(rpm)

Basis

[56.3] fEa5c5?3cfj7.31

[+I .4071

59.7

Each cyl*

I

Lk1.8751

12.5

*

Basic Point

[11.31

1250

B

[ 8.41

450

Allowance

standard (cc/l OOOst

L12.51 [* 11.5-

13.5

Allowance

C

*

*

D

*

*

E

*

*

Maximum variance between cylinder

jovernor performance ( 450 - 1250 rpm)

cklimlt

15~8’mm

,Lj 1250::: Pump speed (rpm)

12-022-60

SEBH4642-01

95 SERIES


Pump Assembly 6207-71-1960

Number

Applicable

(101695-3110)

Model

( ): Manufacturer’s part No.

Injection

Model

Serial No.

S6D95L-1

3.6 f 0.05

mm

Pump tester capacity for Service standard

51

Motor

7.5

KW

Standard

Conditions

Service standard

1 Service standard

Serial No.

Engine

Engine specification

Delivery valve retraction volume mm3/st

Calibration

Applicable

GD510R-1

Timing

Plunger pre-stroke

Machine

indicated data using calibration test parts. Manufacture standard is data for factory test.

Manufacturer

Nozzle part no.

( 105780-0000)

6207-11-3130

Nozzle holder part no.

(105780-2080)

6207-I

injection ipe (O/D x l/g x length)

6 x 2 x 600

mm

ASTM

Test oil

Oil temperature

Rack position (mm)

Rack point

1.6x600

D975 No. 2 diesel fuel or equivalent 43 - 47

Transfer pump pressure Mpa(kg/cmz)

Injection volume

I-31 10 (105048-3060) 6x

OC

opening pressure Mpa(kg/cmz)

Nozzle

standard

(105017-0090)

Pump speed (rpm

)

17.2 (175)

19.6 (200)

0.16 (1.6)

0.16 (1.6)

Service standard

Basis

(cc/l 000 st)

Allowance

Manufacturer

Maximum ~e~~~“, Basis

standard (cc/lOOOst Maximum variance

Allowance

between cylinder

cylinder Rack positions B to E are the reference volume when adjusting

B

the injection volume.

Marks t are aver-

11.4

Basic point

_

age volumes.

Governor performance

C

12.0 A pK50

54 7 .

Each cyl. 53.7 - 55.7

800

52.4

*

50.4-

450

12.5

*

11.5 - 13.5

1250

54.4

59.7

Each “1.

-

69.2

*

+ 1.875

12.5

*

fl.3675

D

*

*

E

*

*

( 450 - 1250 rpm)

ck limit

15’g2mm

-j :::

Pump speed (rpm)

SEBH4724-01

95 SERIES

’ 2-oF’


I

Pump Assembly Number 6209-7 l-l 230 (101692-3830)

Applicable

Machine

Model

( 1: Manufacturer’s part No. Injection Pump Type

Serial No.

PC220-5

1 DIESEL

I

Enaine

Model

1

Serial No.

SA6D95L-1

and up

I

I

I

1

I

I

I

KIKI

I

I

I

Injection Timing

I Rotating

35001

Pump Manufacturer

PES-GA

Aoolicable

I

Engine specification

direction

Clockwise viewed from drive end

Injection order

I

l-5-3-6-2-4

I

I

Pump tester capacity for Service standard

I

Motor

7.5

KW

1

Calibration Standard Conditions Service standard indicates data using calibration test parts. Manufacture standard is data for factory test.

Service standard Nozzle part no.

(105780-0000)

6207-11-3130

Nozzle holder part no.

(105780-2080)

6207- II-311

Injection

ipe

(O/D x l/g x length)

6 x 2 x 600

mm

Test oil

ASTM

Oil temperature

6x

(105017-0090)

1.6x600

D975 NO. 2 diesel fuel or equivalent

OC

43

to

47

175

225

Transfer pump pressure

1.6

1.6

Rack point

point

Basic

B C

Zovernor performance

Rack position (mm)

10.9 11.2 Approx. 6.7

kg/cm2

Pump speed b-pm)

Service standard

Basis

(CC/j 00G.t)

Allowance

Manufacturer

Maximum yerrtz’, Basis cylinder

Each cyl.

1100

78.2

750

78.6

450

12.5

standard

0 ( 105048-3060)

Nozzle opening pressure kg/cm2

Injection volume

Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

Manufacturer

standard (cc/l OOOst Maximum variance between cylinder

Allowance Each cyl.

77.2

to 79.2

k1.955

81.6

*

76.6

to 80.6

-

85.0

*

11.5t013.5

k1.875

12.5

t t

D

*

*

E

*

*

( 450 - 1100 rpm) Rack limit 1~+8.~

0

Lf I I 450 (590) / 870*50 750 11oo::g Pump speed (rpm)

12-022-62 9

\ 12ooxio

SEBH4712 95 SERIES


Pump Assembly Number 6209-71-1’262

Applicable

Machine

Model (

): Manufacturer’s

part No.

Serial No.

Engine

Model

Serial No.

SA6D95L-1

PC22O(LC)-5 BR300-1

-1

Injection Timing

Engine specification

Rotating direction

Clockwise viewed from drive end l-5-3-6-2-4

Injection order Injection

Applicable

(101692-3910)

interval

Plunger pre-stroke ~~$$$$J$ume

Rated horsepower

HP/rpm

157.212200

Maximum

kgm/rpm

53.711500

torque

High idling

rpm

2355 to 2475

Low idling

rpm

875 to 925

60”+30 mm

3.620.05

Pump tester capacity for Service standard

51

mm3/st

Motor

7.5

KW

Calibration Standard Conditions

Service standard

’ Service

standard indicates data using calibration test parts. * Manufacture standard is data for factory test.

r

standard

(105780-0000)

6207-l

I-3130

(105017-0090)

Nozzle holder part no.

(105780-2080)

6207-l

l-3110

(1050483060)

Injection ipe (O/D x i/g x length)

6x

6 x 2 x 600

mm

ASTM

Test oil

Oil temperature

1.6x600

D975 No. 2 diesel fuel or equivalent 43 to 47

“C

Nozzle opening pressure kg/cm2

175

200

Transfer pump pressure kg/cm*

1.6

1.6

Injection volume Rack point

- Rack positions B to E are the refer-

Manufacturer

Nozzle part no.

point

Basic

ence volume when adjusting the injection volume. bMarks * are aver-

B

Governor performance

Pump speed

10.6

1100

11.05

c

age volumes.

Rack position (mm)

Ap84’20x~

bm)

Service standard (cc/l OOOst)

Basis

Allowance

74 6 Each cyl. . 73.6 to 75.6

750

74.9

*72.9

to 76.9

450

12.5

* 11.5to

13.5

Manufacturer‘standard

Maximum ~e~~~~ Basis cylinder

Allowance

(cc/l OOOst Maximum variance between cylinder

Each cyi.

*I .865

79.4

-

89.8

t

k1.875

12.5

*

D

*

*

E

*

*

( 450 - 1100 rpm)

Rack cap: approx. 15 +:‘mm

F

10.6

E C .P C

9.6

H

66 6.2

“u d

a

450(560)

Pump

750’930i50\1200~30 11CO::;

speed

@pm) SEBH4788

95 SERIES ’ 2-o;2-63


Pump

Assembly

6202-73-I

Number

Applicable

Machine

160 (101495-3262) Model

(

): Manufacturer’s Injection Pump Tvpe

part No.

ZEXEL

Applicable

Serial No.

Ennine

Model

DZOAG, P, PG-7(A)

Pump Manufacturer

PES-A

I

Serial No.

4D95S-1

D20PL, PLL-7 D21A, AG, PG-7(A)

I

D21S, QG-7

Injection

Timing

Engine

Rotating direction

Clockwise viewed from drive end

retractinn V~IIITI.+mm3/st

Calibration

Rated horsepower

HP/rpm

39.512450

Maximum

kgm/rpm

15.5/l 300

torque

High idling

rpm

2530 to 2630

Low idling

rpm

800 to 850

Pump tester capacity for Service standard

I

Delivery valve

specification

I

Motor

7.5 kW

Standard

. Service standard indicates data using calibration test parts. . Manufacturer standard is data for factory test.

. Rack positions B to E are the reference volume when adjusting the injection volume. . Marks * are average volumes.

Zovernor performance

Marked

%: Rack position approx:

Rack cap: approx. 15 +i’ mm 18 ‘0”

15.0

P 11.8 E

: 9.9 ..z i

8.8

0

oz

7.6

1290 * 25 Pump speed (rpm)

95 SERIES

9.2 mm

I


Pump Assembly 6206-71-I

Number

Applicable

Machine

Model

(

Applicable

Engine

252 (10695-3622)

): Manufacturer’s

part No.

Serial

No.

Model

D31 E, P-20(A)

Serial

No.

6D95L-1

D31 PL, PLL, S-20 D310, AM, SM-20

Injection

Timing

Rotating

direction

Injection

order

Injection

interval

Plunger

pre-stroke

Clockwise

viewed

from drive end

l-5-3-6-2-4 60” k 30’

Delivery valve retraction volume

Calibration

Engine specification

mm

3.6 + 0.05

Pump tester capacity for Service standard

51

mm3/st

Service

. Service

standard indicates data using calibration test parts. . Manufacturer standard is data for factory test.

(105780-0000)

6206-I I-3130

(105780-2080)

6207-I I-31 IO (105048-3060)

6 x 2 x 600

mm

Test oil

ASTM “C

Nozzle opening pressure

kg/cm2

175

Transfer pump pressure

kg/cm2

1.6

I Rack point

Basic point

I

I

Rack position

Pump speed

(mm)

(rPm)

Service

1175

29.6 (32)

B

10.3

700

A~g,y.

350

D

Ap&ox.

500

8

Ey8h6cT;.30,6

6x1.6x600

D975 No. 2 diesel fuel or equivalent

200 1.6

I (cc/l OOOst) Maximum ~~$$~ cylinder i2.5

* (30 to 34) *

215

*7to9

?I5

*

E

standard

Allowance

Basis

9.0

C

(105017-0140)

43 to 47

Oil temperature

volume

ence volume when adjusting the injection volume. . Marks * are average volumes.

standard

Nozzle holder part no. Injection pipe in/n x I/n Y Innnthl

. Rack positions B to E are the refer-

Manufacturer

standard

Nozzle part no.

I

Governor

7.5 kW

Standard

Conditions

Injection

Motor

Manufacturer

Basis

standard (cc/l OOOst)

Allowance

Maximur variance :;KY::

30,6

Each cyl.

(43.4)

*

10.5

* * *

performance ,B+;h

RFkcap:

approx.15C~2mm

15.0 1”““’

Pump speed (rpm)

95 SERIES

1 Z-UZZ-63 0


Pump Assembly 6206-71-I

Number

Applicable

Serial

Model

(

): Manufacturer’s

Injection

part No.

Rotating

direction

Injection

order

Injection

interval

Engine

Delivery valve rn+r.,,.+;fin l,~lll_d

Calibration

Model

Serial

6D95L-1

Clockwise

viewed

from drive end

60” k 30’ mm

3.6 k 0.05 51

mm3/st

Rated horsepower

HP/rpm

8012500

Maximum

kgm/rpm

27.5/1400

torque

High idling

rpm

2650 to 2750

Low idling

rpm

700 to 750

I

Pump tester capacity for Service standard

Motor

7.5 kW

Standard

. Service

standard indicates data using calibration test parts. . Manufacturer standard is data for factory test.

Injection

volume

Rack positions B to E are the reference volume when adjusting the injection volume. . Marks * are average volumes.

Governor

performance k cap:

approx.

17.5 mm

1250 _& Pump speed (rpm)

12-022-66 0

No.

Engine specification

l-5-3-6-2-4

pre-stroke

No.

D37E, P-5(A)

Timing

Plunger

Applicable

Machine

480 (101692-3933)

95 SERIES

I


Pump Assembly

Number

6202-72-1211

Applicable Machine

(101452-3131)

Model (

): Manufacturer’s Injection Pumo Tvoe

Injection order

I

1

Serial No.

I

9o” * 30’

1

1.5 f 0.05

29.5 (39.5)/2450

Nm(kgm)/rPm/

152(15.5)/1300

High idling

rpm

2530 - 2630

Low idling

rpm

800 - 850

torque

Pump tester capacity for Service standard

35

mm3/st

kW(HP)/rpm

Rated horsepower Maximum

l-2-4-3

I

Plung& pre-stroke mm

Calibration

Model 4D95.SW-1

I

Clockwise viewed from drive end

Injection interval

vnl~~mP

1

Engine Specification

Rotating direction

wtractinn

No.

ZEXEL (DIESEL KIKI)

Timing

Deliveryvalve

Serial

D20, 21-6

Pump Manufacturer

PES-4A

injection

part No.

1

Applicable Engine

I

I

Motor 7.5 KW

Standard

1Service

standard indicates data using calibration test parts. 1Manufacture standard is data for factory test.

1 Rack

positions B to E are the reference volume when adjusting volume.

1 Marks

* are aver-

Governor performance

(410 cklimit

1225

rpm)

15’8’mm

J->5 +:8

Pump speed (rpm)

95 SERIES

SEBH482i

’2-o%-67


Pump Assembly 6202-72-1231

(

Number

I

(101452-3140)

): Manufacturer’s

Applicable

Machine

I

Applicable

Engine

I

part No.

R

Injection

Timing

Engine Specification Clockwise

viewed

from

drive

end

~1

Plunger

pre-stroke

Delivery valve retraction vnlllme

Calibration

mm

I

Pump tester capacity for Service standard

mm3/st

Motor

7.5 KW

I

Standard

Manufacture standard is data for factory test.

Rack positions B to E are the reference volume when adjusting volume. tare average volumes.

1 Marks

Governor performance

(410

-

1225

rpm)

jjz5

1225 ;:: Pump speed (rpm)

’2-oi2-68

SEBH4828

95 SERIES


Pump Assembly 6204-72-l

Number Applicable

331 (101452-3082)

1

Model (

): Manufacturer’s

Injection

part No.

WA70-

1

Serial 12001

Clockwise

viewed

from drive end

pre-stroke

retraction

volume

Calibration

Model

and up

Rated horsepower Maximum

Plunger

No.

Engine

1

4D95L-W-1

Serial 36216

No. and up

Engine Specification

Timing

Delivery valve

Applicable

Machine

mm

torque

NmCkgmVrpm

41.2

(55.2)/2200

204(20.8)/l

500

High idling

rpm

2320 - 2420

Low idlina

tom

8nO - 850

Pump tester for Service

mm3/st

kW(HP)/rpm

I~

capacity standard

--_

Motor 7.5 KW

Standard

ervice standard indicates data using calibration test parts. Manufacture standard is data for factory test.

Rack positions B to E are the reference volume when adjusting volume. Marks * are aver-

Governor

performance

(400

-

Rack limit

Pump

95 SERIES

speed

1100

rpm)

15 -8’ mm

(rpm)

SEBH4618-01

’2-o%-69


Pump Assembly 6204-71-l

Number

. Applicable

211 (101492-3940)

Machine

Model

( ): Manufacturer’s

Injection Rotating

part No.

Injection

interval

Clockwise

viewed

from

l-2-4-3

drive

end

Rated horsepower

High

pre-stroke

Serial

No.

torque

kW(HP)/rpm

44 (59)/2400

Nm(kgm)/rpm

196(20)/1500

idling

rpm

2590 - 2690

Low idling

rpm

850 - 900

9oV30*1

mm

3.6 + 0.05

~,“,!.$+~~,Va!~ra,mO mm3/st

Calibration

Model 4D95L-1

Maximum

I

Plunger

Engine

Engine Specification

direction order

No.

PC60-3

Timing

Injection

Serial

Applicable

51

I

Pump tester capacity for Service standard

I

Motor

7.5 KW

Standard

1 Service standard indicates data using calibration test parts. 1Manufacture standard is data for factory test.

I

Rack positions B to E are the reference volume

volume. Marks * are average volumes.

Governor performance 18+;

(425

-

Rack limit

/, , , , , , ,

1200

rpm)

15 *8’ mm

, , , ,, , ,

-z z s ._ C H 5 2

Pump

12-022-70

speed @pm)

1200 :::

SEBH4830

95 SERIES


Pump Assembly 6204-71-1221

Number

r

I Applicable

(101492-3950)

Model

(

): Manufacturer’s

Injection

Timing

I Rotating

direction

part No.

Calibration

Serial

Applicable Model

No.

PC60-5

Engine Serial

No.

4D95L-1

Engine Specification Clockwise

viewed

from drive end

I

Delivery valve m+rar+;,Tn*r*l,,mn

Machine

m ms/st

51

1

Rated horsepower kW(HP)/rpm

40.3 (54)/2100

Maximum torque Nm(kgm)/rPm

200(20.4)/l

500

High idling

rpm

2250 - 2350

Low idling

rpm

900 - 950

I

Pump tester capacity for Service standard

Motor 7.5 KW

I

Standard

Service standard indicates data using calibration test pans. Manufacture standard is data for factory test.

B to E are the reference volume volume. Marks * are average volumes.

Governor performance

(450

-

1050

ck limit

Pump speed @pm)

95 SERIES

rpm)

15 ‘8’mm

SEBH4831

’2-o%-7’


Pump Assembly 6204-71-l

Number

I Applicable

231 (101492-3960)

Machine

Model (

): Manufacturer’s

Injection

part No.

Serial

Applicable No.

Model

PW60-3

Timing

Engine Serial

No.

4D95L-1

Engine Specification Clockwise

viewed from drive end al I

Low

Plunger

pre-stroke

Delivery valve retraction volume

Calibration

mm

idling

rpm

900 to 950

3.6 ?c 0.05

mm3/st

51

Standard

u Service standard indicates data using calibration test parts. ) Manufacture standard is data for factory test.

)

Rack positions B to E are the reference volume

volume. Marks t are average volumes.

Governor performance

(450

-

1250

18’8

Rack

limit

15 ‘8’

-z L .-6 .Z :: a

rpm) mm

11.7 10.5 6.7

% a” 5.7

j 0

450

(620)

Pump

’2-o;2-72

800

speed

/L

1130f50\1325125 1256 ‘:: (rpm)

SEBH4832

95 SERIES


Pump Assembly Number 6204-71-1241

Applicable

(1014923980)

Model (

): Manufacturer’s

part No.

Clockwise

viewed

from drive end

Model

Serial

No.

4D95L-1

mmz/st

Rated horseoower

I

HP/mm

Pump tester capacity for Service standard

1

Calibration

No.

Engine

Engine Specification

direction

Delivery valve retraction volume

Serial

Applicable

PC80-3

Injection Timing Rotating

Machine

51

6412400

Motor 7.5 KW

I

Standard

‘Service standard indicates data using calibration (Nozzle, Nozzle holder and injecManufacture standard is data

Rack positions 8 to E are the reference volume when adjusting the injection volume.

Pump speed (rpm)

95 SERIES

+x) SEBH4883

’2-o%f-73


Pump Assembly

Number

Applicable

6204-71-1550 6204-71-1560

(

Model

): Manufacturer’s

part No.

Serial

direction

Injection

order

Injection

interval

Plunger

pre-stroke

Model

Serial

4D95L-1

Clockwise

viewed

from drive end

1-2-4-3 90” t 30’ mm

3.6 + 0.05 Pump tester capacity for Service standard

51

Motor 7.5 kW

Standard

Service standard

indicates data using calibration (Nozzle, Nozzle holder and injec-

Rack positions B to E are the reference volume when adjusting the injection volume. Marks t are aver-

Governor

No.

Engine specification

Delivery valve retraction volume mmVst

Calibration

No.

Engine

spec.)

Timing

Rotating

Applicable

D21A-7T Trimming

Injection

Machine

performance

(100 - 1225 rpm1

IS’:

Racklimit

: 15. O+t’mm

L

4 0

/ 400

(I OSOl/\\

l&70)\ 410

650

(124011270 1310

Pump speed (rpm)

’2-o:2-74

TDE00091

95 SERIES


Pump Assembly Number 6204-73-1210

Applicable

(101492-3730)

Model

( 1: Manufacturer’s part No.

Machine Serial No.

Engine

Model

PC60-6

Injection Timing

Serial No.

4D95L-1

Engine specification Rated horsepower

Clockwise viewed from drive end

1 Low idling Plunger prestroke

Applicable

mm

3.6 + 0.05

Delivery valve retraction volume mm3/st

HP/rpm

950 to 1000

rpm

I

Pump tester capacity for Service standard

51

Motor

7.5

KW

Calibration Standard Conditions

Service standard

- Service

standard indicates data using calibration test parts. * Manufacture standard is data for factory test.

Manufacturer

standard

Nozzle part no.

(105780-0000)

6207-I

I-3130

Nozzle holder part no.

(105780-2080)

6207-I

I-31 IO (105048-3060)

Injection ipe (O/D x l/g x lenath)

6 x 2 x 600

mm

Test oil

ASTM

6x

(105017-0090)

1.6x600

D975 No. 2 diesel fuel or eauivalent

Oil temperature

Injection volume

Service standard

Manufacturer

standard (cc/l

* Rack positions B to E are the reference volume when adjusting the injection volume. - Marks * are average volumes.

*

E Governor performance

( 475 Rack

1050

rpm)

cap approx.

18+$U~,,,,,

I

8.0

*

C

6.4

Pump speed (rpm)

17.5 mm

\ SEBH4745

95 SERIES ’ 2-o%-75

I I


Pump Assembly 6204-73-I

Number

I

I Applicable

211 (101492-3732)

Model

( ): Manufacturer’s

Injection

part No.

direction

Injection

order

Serial

viewed

from

drive

1 Maximum

1-2-4-3~’

I

High Injection

9o”

interval

f

30’

I Plunger

pre-stroke

Delivery valve retraction volume

Calibration

3.6 + 0.05

mm

Model

51

mm3/st

I

Serial

No.

Specification

Rated horseoower

end

Engine

4D95L-1

Engine Clockwise

No.

PC60-6

Timing

Rotating

Applicable

Machine

torque

HP/ram

rpm

Low idling

rpm

Pump tester capacity for Service standard

54.2/2100 23/l

kgm/rpml

idling

I

1

2250

500

950 to 1000

I

Motor

7.5 KW

indicates data using calibration test parts. Manufacture standard is data for factory test.

Rack positions B to E are the reference volume

volume. Marks tare average volumes.

(495 ck limir

1050

rpm)

15 -8’ mm

Pump speed (rpm)

SEBH4834 95 SERIES

’ 2-o;2-76

I

to 2350

Standard

Governor performance

I

I


Pump Assembly

Number

6204-73-1220

(101492-3742)

Applicable

Machine

Model

( 1: Manufacturer’s part No.

Injection

Rated horsepower

Serial No.

mm

64.1/2,300

HP/rpm

/I

1-2-4-3

I

r

3.6 t 0.05

Delivery valve retraction volume mm3/st

Calibration

Model 4D95L-1

Clockwise view from drive end

interval

Plunger pre-stroke

Engine

Engine specification

Injection order

I

Serial No.

PC90-1

Timing

Rotating direction

Injection

Applicable

Pump tester capacity for Service standard

51

Motor

7.5

KW

Standard

Conditions

Service standard

Service standard indicates data using calibration

test parts. Manufacture standard is data for factory test.

Nozzle part no.

(105780-0000)

6207-I

Nozzle holder part no.

(I 05780-2080)

6207-11-3110

Injection ipe (O/D x 1/g x length)

ASTM

6x

(105107-0090)

1.6x600

D975 No. 2 diesel fuel or equivalent 43 to 47

OC

200

Transfer pump pressure kg/cm*

1.6

1.6

Basic

point B

standard

(105048-3060)

175

Rack point

age volumes.

I-3130

Nozzle opening pressure kg/cm’

Injection volume

tion volume. Marks l are aver-

6 x 2 x 600

mm

Test oil

Oil temperature

Rack positions B to E are the reference volume when adjusting the injec-

Manufacturer

Rack position

Pump speed

(mm)

(rPm)

10.8

1,150

AP;‘~x.

475

Service standard

(oC/1OOOSt)

Allowance

Basis

Manufacturer

Maximum ~“,:‘~~~ Basis cylinder

standard (cc/lOOOstj

Allowance

Maximum variance between cylinder

Each cyl.

140.21 ~~“.~~k 41.21 10.5

*

9.5 to 11.5

*I ,005

47.0

k1.575

10.5

*

C

*

*

D

*

*

E

*

*

Governor performance ( 475 - I ,150 rpm) Rack limit: 17.5 mm

Damper spring set 7.3kO.l mm

0

95 SERIES

(1000) 1 ‘124Ok25 1 150% Pump speed (rpm)

475

750

SEBH4746-01

’2-o%-77


Pump Assembly 6204-73-I

Number Applicable Machine

221 (101492-3990)

Model

(

): Manufacturer’s

Injection

part No.

order

Injection

interval

Plunger

pre-stroke

Delivery valve _ retraction volume

Calibration

Clockwise

viewed

from

drive

Specification

~1

9o”

+ 30’

3.6 i

mm3/st

No.

end

1-2-4-3

mm

Serial

Model 4D95L-1

Engine

Rotating direction

No.

PC90- 1

Timing

Injection

Serial

Applicable Engine

0.05

Pump tester capacity for Service standard

51

Motor

7.5 KW

Standard

1 Service standard indicates data using calibration test parts. 1Manufacture standard is data for factory test.

1 Rack

positions B to E are the reference volume when adjusting volume. It are average volumes.

1 Marks

Governor performance

(475 -

cklimit

1185

15

rpm)

8’mm

Damper

spring set

7.3kO.l

Pump speed (rpm)

mm

SEBH4835 95 SERIES

’ 2-o:2-78


Pump Assembly

Number

Applicable

Machine

Applicable

Engine

6204-73-1240 Model

( 1: Manufacturer’s

part No.

Serial No.

Serial No.

Model

PC60-7

4D95L-1

PC70-7

Injection

Timing

Engine specification

Rotating

direction

Injection

order

Injection

interval

Plunger

pre-stroke

Clockwise

viewed

from drive end

1-2-4-3 90” + 30’ mm

Rated horsepower

kW(HP)/rpm

Maximum

Nm(kgm)/rpm

torque

41(54)/1900 225(23)/1500

High idling

rpm

2050-2150

Low idling

rpm

1000 - 1050

3.6 + 0.05

Delivery valve retraction volume mm%

Pump tester capacity for Service standard

51

Motor 7.5 kW

Calibration Conditions Service standard indicates data using calibration test parts (Nozzle,

Nozzle

Service

standard

Manufacturer

~~~~~~ pae no.

(105780-0000)

6207-11-3130

Nozzle holder part no.

(105780-2080)

6207-I

Injection pipe (O/D x l/D x length)

holder and injection pipe)

Test oil

Manufacturer standard is data using factory test parts (For reference)

Oil temperature

ASTM

Nozzle opening Transfer

6 x 2 x 600

mm

pump pressure

njection volume Rack point

Rack position (mm)

43 - 47

MPa(kg/cm*)

17.2

(175)

19.6

(200)

MPa(kg/cm2)

0.16

(1.6)

0.16

(1.6)

Pump speed (t-pm)

Service standard (cc/lOOOst)

Manufacturer standard (cc/1OOOsl

Maximum

Basis

Allowance

‘1”,$:::

Maximum

Basis

Allowance

cylinder

Rack positions B to E are the reference volume when adjusting the injection vol-

ume. Marks t are average volumes.

(105048-3060)

1.6x600

D975 No. 2 diesel fuel or equivalent

“C pressure

(105017-0090)

I-3110 6x

standard

$$?:Ei cylinder

Each cyl.

Each cyl.

Basic point

11.3

950

41

B

12.1

750

44.5

*

C

8.2

495

10.5

Ir

*

D

Ir

*

E

*

*

51.5

62.5

*

Governor performance (495 - 950 rpm)

Pump speed (rpm)

6206F1033

95 SERIES ’ 2-o%-79


Pump Assembly

Number

6205-71-1510 (

1: Manufacturer’s

\

Injection Pumo TvDe I

I.

I

ZEXEL (DIESEL KIKI)

PES-4A

Injection

part No. Pump Manufacturer

Timing

Rotating

direction

Injection

order

I

Engine specification Clockwise

viewed

from drive end

Rated horsepower

1-2-4-3

Maximum

Conditions

Nozzle holder part no. Injection pipe (O/Dx I/D x length1 Test oil

Rack point

(105780-0000)

6206-11-3130 (105017-0140)

(105780-2080)

6207-I

mm

Rack position (mm)

6 x 2 x 600 ASTM

Pump speed (rpm)

299(30.5)/1500

torque Nm(kgm)/rpm

Manufacturer standard

Manufacturer Oil temperature “C standard is data using factory test Nozzle opening pressure MPa(kg/cm*j parts Transfer pump pressure MPa(kg/cmz) (For reference) njection volume

58.9(78.9)/2100

kW(HP)/rpm

Service standard

Servicestandard ~~~~~~part no, indicates data using calibration test parts (Nozzle, Nozzle ~~~~~,“e;” injec-

I

I-3110

(105048-3060)

6x1.6x600

D975 No. 2 diesel fuel or equivalent 43-47

Service

17.2 (175)

19.6 (200)

0.16 (1.6)

0.16 (1.6)

standard Allowance

Basis

(cc/lOOOst)

Manufacturer

Maximum ~“,~~~~ Basis

standard (cc/IOOOS~

Allowance

cylinder

Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

Governor

Each cyl. Basic point

9.9

1050

69.9

B

10.35

750

63.2

C

6.4

450

10.5

performance

Maximum “b”$%, cylinder

Each cyl. 63.6

*

77.5

*

*

10.5

*

D

*

*

E

*

Ir

(450 - 1050 rpm)

L&J&& Pump speed (rpm)

’2-oi2-80

I090

6206FlOll

95 SERIES


Pump Assembly

Number Applicable

6205-71-152O(PC120-6) 6205-71-132O(PC128UU-I)

( ): Manufacturer’s

Serial

Model part No.

Applicable

Machine No.

Model

Engine Serial

No.

S4D95L-1

PC1 20-6 PC128UU-1

Injection

Timing

Rotating

direction

Injection

order

Calibration

Engine specification Clockwise

viewed

from drive end

1-2-4-3

Rated horsepowerkW(HP)rpm

62.5(83.8)/2200

Maximum

299(30.5)/1500

torque

Nm(kgm)/rpm

Standard

Service standard indicates data using calibration (Nozzle, Nozzle holder and injecManufacturer standard is data

Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are aver-

Governor

performance

(450 - 1100 rpm)

18’;

Pump speed (rpm)

6206F1012

95 SERIES ’ 2-o%*’


,

Pump Assembly Number 6206-71-1211

Applicable

(101695-3290)

Machine

Model

( 1: Manufacturer’s part No.

Applicable

Serial No.

Model

PC 100-3

Injection Timing

Engine Serial No.

6D95L-1

Engine specification

Rotating direction

Clockwise viewed from drive end

Injection order

l-5-3-6-2-4

Rated horsepower

HP/rpm

Maximum

kgm/rpm

torque

79/2100 30.5/1400

High idling

rpm

2250 to 2350

Low idling

rpm

800 to 850

I

Pump tester capacity for Service standard

I

Motor

7.5

KW

Calibration Standard Conditions l

Service standard indicated data using calibration test parts.

l

Manufacture standard is data for factory test,

Nozzle part no.

(105780-0000)

6207-I

Nozzle holder part no.

(105780-2080)

6207- 1 l-31 10 (105048-3060)

Injection

ipe

(O/D x l/g x length)

ASTM

1.6x600

D975 No. 2 diesel fuel or equivalent

“C

43 to 47 175

200

Transfer pump pressure

1.6

1.6

Rack point

l

(105017-0090)

Nozzle opening pressure kg/cm*

Injection volume

Rack positions 5 t0 E are the reference volume when adjusting the injection volume. Marks * are average volumes.

I-3130

6x

6 x 2 x 600

mm

Test oil Oil temperature

l

. Manufacturer standard

Service standard

Rack position (mm)

kg/cm*

Service standard

Pump speed (vm)

Basis

(cc/l OOOst)

Allowance

Manufacturer

Maximum rertz?, Basis

standard (cc/

Allowance

cylinder

point

Basic

Governor performance

B

9.8 “Pg.;“”

1050 400

3.

4

.

10.5

Each cyl. 29.4 *

to 3 1.4

9.5 to 11.5

Maximum variance between cylinder

Each cyl. kO.76 k1.57

*

C

*

*

D

*

*

E

*

*

( 425 - 1056 rpm)

Pump speed (rpm)

st

SEBH4837

95 SERIES


Pump Assembly 6206-71-l

Number

221

I

I Applicable

(101695-3300)

Machine

1

Model (

): Manufacturer’s

part No.

No.

Model

PC1 20-3

I

Injection

Timing

Rotating

direction

Injection

order

injection

interval

Plunger

pre-stroke

viewed

from

drive

60° mm

Serial

No.

Specification

end ~1

l-5-3-6-2-4

Delivery valve retraction volume

1

I

I

Engine Clockwise

Engine

6D95L-1

yzJ-z%J

Cal’ibration

Serial

Applicable

f

3.6 f

mm”/st

30’ 0.05

Pump tester capacity for Service standard

51

Motor

7.5 KW

Standard

Conditions

I

1Service

standard indicates data using calibration test parts. Manufacture standard is data for factory test.

Service standard

Nozzle part no.

(105780-0000)

Nozzle holder part no.

(105780-2080)

Injection pipe (O/D X I/D X length) -

mm

Oil temperature Nozzle opening Transfer

Manufacturer

standard

6X2X600 I

ASTM

Test oil

I

D975

No.2 diesel

fuel

or equivalent

40 to 45

OC pressure

kg/cm*

175

pump pressure

kg/cm*

1.6

njection volume

Rack positions B to E are the reference volume when adjusting the injection volume. Marks + are average volumes.

Governor performance

(425 -

1100

rpm)

is%Rack limit : lS,O” mm

0

425

700

1080~\

1200f25 1 loo:5

Pump speed (rpm)

SEBH486t 95 SERIES

’ 2-oz83


Pump Assembly 6206-71-l

Number Applicable Machine

241 (101695-3320)

Model (

): Manufacturer’s

Dart No.

Serial No.

Timing

6D95L-1

order

Injection

interval

Calibration

Clockwise

viewed

from

drive

I

end -~I

l-5-3-6-2-4 60° f 30’

Plunger pre-stroke Delivery valve retraction volume

I

Engine Specification

Rotating direction Injection

Serial No.

I I

Injection

Model

PW150-1

I PUrnD

I lniection

ADDlicable Enaine

mm

3.6 + 0.05

mm3/st

Pump tester capacity for Service standard

51

Motor 7.5 KW

Standard

mService

)

standard indicates data using calibration test parts. Manufacture standard is data for factory test.

1 Rack

positions B to E are the reference volume

volume. * are average volumes.

1 Marks

Governor performance

(425 -

1200

Rack

15 -8’

rpm)

18+;

z E .-6 C :: P

limit

mm

12.0 10.9 9.0 7.4

t: z

L O

425

I-

(720) &o/ 1020150

Pumpspeed

’2-oi2-84

(rpm)

\ 1325125 12OO:g

SEBH483E 95 SERIES

I


Pump 6206-71-1361

Applicable

(101695-3351)

Model

(

): Manufacturer’s

Injection

Timing

Rotating

direction

Injection

order

Injection

interval

Plunger

pre-stroke

Delivery valve retraction volume

Calibration

part No.

Machine Serial

Applicable No.

Engine

Model

WA1 20-I

Serial

No.

6D95L-1

Engine Specification Clockwise

viewed

from drive end

l-5-3-6-2-4

Rated horsepower

HP/mm

Maximum

kgm/rpm)

torque

High idling

rpm

Low idling

rpm

1 I

85/2500

I

32.1 /1600 2700

to 2800

60° + 30’ mm

3.6 + 0.05

mmz/st

Pump tester capacity for Service standard

51

800 to 850 Motor

7.5 KW

Standard

) Service standard indicates data using calibration test parts. ’ Manufacture standard is data for factory test.

B to E are the reference volume volume. Marks

age

t

are

aver-

volumes.

Governor performance

(400

j 0

400

-

rpm)

1250

L/ 570+20

880+30

,,+

340)‘,

375+25

1250::: Pump

speed

(rpm)

SEBH4840 ---

95 SERIES

-_


Pump Assembly Number 6206-71-1371

Applicable

(1016953240)

Machine

Model

Applicable Model

Serial No.

( 1: Manufacturer’s part No.

Serial No.

6D95L-1

Injection Timing

Engine specification Clockwise viewed from drive end

Rotating direction

l-5-3-6-2-4

Injection order Injection interval Plunger pre-stroke

Engine

60’ + 30’ 3.6 f 0.05

mm

Delivery valve retraction volume mm3/st

Pump tester capacity for Service standard

51

Motor

7.5

KW

Calibration Standard Conditions

Service standard

) Service standard indicated data using calibration test parts. ) Manufacture standard is data for factory test.

Manufacturer

( 105780-0000)

6207-l

I-3130

Nozzle holder part no. Injection ipe

(105780-2080)

6207-l

I-31 10 (105048-3060)

(O/D x l/g x length)

ASTM

43 to 47

1.6

Rack position

Pump speed

Service standard

(mm)

(rpm

)

200

I75

Transfer pump pressure kg/cm2

Rack point

D975 No. 2 diesel fuel or equivalent

“C

Nozzle opening pressure kg/cm2

Injection volume

1.6 (cc/l 000 st)

Manufacturer

standard (cc/l OOOst

Maximum Basis

Allowance

Fer$$!,

Basis

Allowance

cylinder

Governor performance

1175

B

10.9

650

[33.6]

C

A?!$?.

350

10.5

/ 3504k

Each cyl. 34.6 to 36.6 +[31.6 *

9.5to

to 35.61 11.5

kO.89 +I .575

37.6

Maximurr variance between cylinder

Each ‘y’.

143.71 * 10.5

*

D

*

*

E

*

*

( 350 - I I75 rpm)

ck limit

0

35.6

10.0

Basic point

erence volume when adjusting the injection volume. 1 Marks * are average volumes.

(105017-0090)

6 x. 1.6 x 600

6 x 2 x 600

mm

Test oil

Oil temperature

) Rack positions 6 to E are the ref-

standard

Nozzle part “o_

(550) 6.;650*20 Pump

’2-oi2-86

15 ‘8’

mm

/ \ 1175 ::: (1350) (1300)

speed (rpm)

22

SEBH4841

95 SERIES


Pump Assembly

Number

Applicable

6206-71-l 422 (101695-3451) 6206-71-1460 (101695-3580) ( ): Manufacturer’s part No.

njection

Model

Model

EG65-S

Serial No.

6D95L-1

Rated horsepower

Clockwise viewed from drive end

I Maximum

l-5-3-6-2-4

torque

65.111500 74.911800

HP/r-pm kgm/rpm

High idling

rpm

Low idling

rpm

II

mm

3.6 + 0.05

mm%t

51

Plunger pre-stroke

(50 Hz) (60 Hzl

-

I

Max. 1575 (50 Hz) Max. 1890 (60 Hz)

60’ * 30’

interval

Calibration

Engine

Engine specification

Injection order

“..&_^^*:^DeliverY Y!!!f.__

Applicable

Serial No.

Timing

Rotating direction

Injection

Machine

700 to 800

I I

I

I

Pump tester capacity for Service standard

I

Motor

7.5

KW

I I I

Standard

Conditions

Service standard

~Service standard indicates data using calibration test parts (Nozzle, Nozzle holder and injection pipe)

~Manufacture standard is data using fectorV teat parts (For reference)

standard

(105780-0000)

6207-I

l-3130

(105017-0090)

nozzle holder part no.

(105780-2080)

6207-l

I-3110

(105048-30601

Injection ipe (O/D x l/g x length) Test oi,

6 x 2 x 600

mm

ASTM Oil temperature

Rack position (mm)

Pump speed

10.3

900

APP~;.

400

Basic point

Governor performance

B

D975 No. 2 diesel fuel or equivalent 43 to 47

I75

(w-n)

200

1.6

Transfer pump pressure kg/cm*

Rack point

6x1.6x600

“C

Nozzle opening pressure kg/cm’

Injection volume

wrack positions B to E are the reference volume when adjusting the injection volume. 1Marks * are average volumes.

Manufacturer

Nozzle part no.

Service standard

10.5

h/l

Allowance

Basis

52.0

1.6

Each cyl. 51 .o to 53.0 * 9.5

to 11.5

000st)

Manufacturer

Maximum ~e~~~“, Basis cylinder 21.3 k1.575

Maximun

Allowance

58 o

Each cyl.

10.5

*

*

*

D

*

*

E

‘*

*

C

( 400 - 900

standard (cc/l 000~ variance between cylinder

rpm)

ack limit approx. 17.5 mm

1. 0

/ 400

k1.k'. 550 \ 9oois 750flO

Pump speed (rpm)

95 SERIES

SEBH4891

’2-oz-87


Pump Assembly Number 6206-71-1940

Applicable

Machine

Model (

Applicable

Engine

(101695-3420)

): Manufacturer’s

part No.

Model

GD313A-1

Injection Timing

Serial No.

6D95L-1

Engine specification viewed from drive end

Clockwise

Plunger pre-stroke

Serial No.

mm

r

3.6 + 0.05

Delivery valve retraction volume mm3/st

Pump tester capacity for Service standard

51

Motor

7.5

KW

Calibration Standard Conditions

Service standard

1 Service standard

1 Manufacture

standard is data for factory test.

.

(105780-0000)

6207-I

I-3130

(105017-0090)

Nozzle holder part no.

(105780-2080)

6207-l

I-3110

(105048-3060)

Injection ipe (O/D x l/g x length)

6x

6x2~600

mm

ASTM

Test oil

Oil temperature

1.6x600

D975 No. 2 diesel fuel or equivalent 43 to 47

OC

Nozzle opening pressure kg/cm2

175

200

Transfer pump pressure kg/cm*

1.6

1.6

Injection volume Rack point

Rack position

Pump speed

(mm)

(Vm)

) Rack positions B to E are the reference volume

standard

Nozzle part no.

indicated data using calibration test parts.

Manufacturer

Basic point

10.0

B

AYF$?.

when adjusting the injection volume. ) Marks * are average volumes.

Governor performance

1250 400

Service standard (cc/l OOOSt)

Maximum Ter&2E Basis cylinder

Basis

Allowance

3l 7

Each cyl. 30.7 to 32.7

20.7925

35.8

*

fl.575

10.5

.

10.5

*

C

Manufacturer

9.5to

11.5

standard (cc/lOOOsl Maximun

Allowance

variance between cylinder

Each cyl. * *

D

*

*

E

*

*

( 400 - 1250 rpm)

18’: cklimit

15’8’mm

F E

11.4

._s f

10.0

x

8.4

a a” 6.0

0

400

56M30 Pump

’2-oi2-88

\ 800f30 speed

1100+50\

1375f25 1250

(rpm)

::8

SEBH4846

95 SERIES


Pump Assembly 6207-71-I

Number Applicable

221 (101695-3030)

Machine

Model

(

): Manufacturer’s

Injection

Timing

Rotating

direction

Injection

order

Injection

interval

Plunger

pre-stroke

Delivery valve retraction volume

Calibration

part No.

Serial

Applicable No.

Model

PC1 50-5

S6D95L-

Engine Clockwise

viewed

from drive end

l-5-3-6-2-4

Engine Serial

No.

I

Specification

Rated horsepower

HP/rpm

Maximum

kgm/rpm

torque

High idling

rpm

Low idling

rpm

98.6/2000 40/ 2140

1400 to 2260

60° * 30’ mm

3.2 & 0.05

mm3/st

900 to 950

Pump tester capacity for Service standard

51

Motor 7.5 KW

Standard

Conditions

Service standard

Service standard indicates data

Nozzle part no,

using calibration test parts. Manufacture standard is data

Nozzle holder part no.

for factory test.

Test oil

Injection pipe (O/D X I/D X length)

Marks k are average volumes.

6207-I

l-31

D975

(105017-0140)

10 (105048-3060)

6X1.6X600 No.2 diesel fuel or equivalent 43 to 47

175

200

Transfer pump pressure

1.6

1.6

Service standard (cc/l OOOst)

Manufacturer standard (cc/lOOOst

kg/cm2

Rack position

Pump speed (rpm)

(mm)

Marimum

Allowance

Basis 55,1

Basic point

9.1

1000

6

9.7

700

[50.0]

C

*%?Y

450

12.5

Each cyl. 54.1 to 56.1 * +

[48.0 to 52.01 11.5t013.5

Maximum

gz;;nE; cylm 3 er

Basis

fl.3775

58.4

+I.875

Allowance

[67.8] 12.5

Each ‘yf. + Ir

*

*

E

*

*

(450 -

ck limit

1000

15’E2

speed

rpm)

mm

s30*50 Pump

vanance

!$x &ee,”

D

Governor performance

95 SERIES

(105780-2080)

standard

Nozzle opening pressure kg/cm2

Rack positions B to E are the ref-

volume.

l-3130

ASTM

Rack point

erence volume

6206-I

DC

njection volume

when adjusting the injection

(105780-0000)

6 X 2 X 600

mm

Oil temperature

Manufacturer

(rpm)

,m

::g

SEBH4847

’2-o%f-89


Pump Assembly 6207-71-I 6207-71-I (

Number

): Manufacturer’s Injection PumD. TvDe ..

part No. Pump

, Manufacturer ZEXEL (DIESEL KIKI)

PE-GA

Injection

Timing

Rotating

direction

Injection

order

lniection

interval

I

Plunger

pre-stroke

Delivery valve retraction volume

Calibration

4

I

241 (101692-3222) 242 (101692-3690)

Engine Specification Clockwise

viewed

from

drive

end

l-5-3-6-2-4

I

60° + 30’

mm

3.6 f 0.05

mms/st

51

I

I

Rated horsepower

HP/rpm

99/l

Maximum

kgm/rpm

42,’ 1400

torque

High idling

rpm

Low idling

rpm

Pump tester capacity for Service standard

2135

900

to 2235

850 to 900

Motor

7.5 KW

Standard

standard is data for factory test.

1 Rack

positions B to E are the reference volume when adjusting volume. Marks t

are aver-

Governor performance

(425

Rack

limit

-

950

rpm)

17.51bO.2

mm

\

(050125 950

Pump speed

_-

---

(rpm)

3

SEBH4849

--

’z-“i2-90

95 SERIES

I


Pump Assembly 6207-71-l

Number Applicable

243 (101695-3010)

Machine

Model

( ): Manufacturer’s

Injection

Timing

Rotating

direction

Injection

order

Injection

interval

Plunger

pre-stroke

part No.

Serial

Calibration

No.

viewed

from

drive

end

l-5-3-6-2-4 60° + 30’

I mm

I

3.6 * 0.05

mm3/st

No.

Specification

Rated horsepower

HP/rpm

99/I

Maximum

kgm/rpml

42/

torque

idling

rpm

Low idling

rpm

Pump tester capacity for Service standard

51

Serial

S6D95L-1

Engine Clockwise

Engine

Model

PWl OO-3

High

Delivery valve retraction volume

Applicable

2135

900 1400 to 2235

850 to 900

I

Motor

7.5 KW

Standard

) Service standard indicates data using calibration test parts. 1Manufacture standard is data for factory test.

Rack positions B to E are the reference volume when adjusting volume. Marks + are average volumes.

Governor performance

(425

-

950

rpm)

mperspring set. 7.7ztO.l mm

425

470140

/ 91oi30

Pump speed (rpm)

I

\ 105oi25 950::;

SEBH4850

95 SERIES

’ *-O%F9’

I


Pump Assembly

Number

Applicable

Applicable

Machine

Engine

6207-71-1250 Model

( 1: Manufacturer’s

part No.

ZEXEL (DIESEL KIKI)

PES-4A

Engine specification

Timing

Rotating

direction

Injection

order

I

Injection Plunger

Clockwise

viewed

I Maximum

60” f 30’

pre-stroke

94.5( 126.7)/2050

Rated horsepowerkW(HP)rpm

from drive end

l-5-3-6-2-4

interval

torque

(

Nm(kgm)/rpm

1 High idling

rpm

1 Low idling

rpm

475(48.5)/1500

I

875 - 925

I

I

Pump tester capacity for Service standard

51

Motor 7.5 kW

Standard Service

Conditions Service standard indicates data using calibration test parts (Nozzle, Nozzle aX%pzd injecManufacturer standard is data using factory test parts

(For reference)

~~~~~~ pae no,

-

Nozzle holder part no. Injection pipe (O/D x I/D x length)

mm

(105780-0000)

6206-11-3130

(105017-0140)

6207-11-3110

(105048-3060)

ASTM

Oil temperature

6x1.6x600

D975 No. 2 diesel fuel or equivalent 43 - 47

.“C

Nozzle opening pressure MPa(kg/cm*)

17.2 (175)

19.6 (200)

Transfer pump pressure MPa(kg/cm?

0.16 (1.6)

0.16 (1.6)

njection volume

Rack position (mm)

Rack point

Service

Pump speed (rpm)

standard

(cc/lOOOst)

Manufacturer

standard (cc/lOOOsl Ma~llllUm

Maximum

Basis

Allowance

“b”$tzi

Basis

Allowance

B to E are the reference volume when adjusting the injection volume. Marks t are average volumes.

Basic point B

Each cyl.

Each cyl.

10.1 <I .99> 7.3<2.5>

1025

68.2

375

12.5

“b”$g,““, cylinder

cylinder

Rack positions

standard

(105780-2080) 6 x 2 x 600

Test oil

-

Manufacturer

standard

65.8 -

-

12.5

r U D E

Note: Inside of < Governor

> represents the rack sensor output (V)

performance

at

the time

when the control

unit is connected.

(450 - 1025 rpm) Rack sensor

gradient

adjust

standard

R2=1 lltlmm R2-R1=61tO. 05mm

\

I

Ri (approx.

5)

Rack position

R2

(approx.

11)

(mm) TAE00061

’2-oi2-92

1

2200 - 2310

3.2 2 0.05

mm

Delivery valve retraction volume mmVst

alibration

S6D95L-1

PC200-5

Pump Manufacturer

Injection Pump Type

lniection

Serial No.

Model

Serial No.

95 SERIES


Pump Assembly

Number

Applicable

Machine

Applicable

Engine

6207-71-1251

6207-71-1252

(

Injection

Model

1: Manufacturer’s

part No.

Serial

Model

No.

PC200-5

Timing

Serial

No.

S6D95L-1

Engine specification Clockwise

viewed

from

drive

end

i

Plunger

pre-stroke

Delivery valve retraction volume

alibration

mm

3.2 + 0.05

Pump tester capacity for Service standard

51

mm%t

Motor

7.5 kW

Standard

Conditions

Service

~d~c~ia”t”,~t~$~rd Nozzlepart

no.

Nozzle holder part no. Injectionpipe

Jsing calibration

:est parts ‘Nozzle, Nozzle iolder and injec:ion pipe) Vlanufacturer standard is data Jsing factory test Iarts

(O/D x I/D x length)

(105780-0000)

6206-11-3130

(I05780-2080)

6207-11-31

ASTM

Oil temperature

Manufacturer

6x2~600

mm

Test oi,

For reference)

standard

standard (105017-0140)

IO (105048-3060)

6 x 1.6 x 600 D975 No. 2 diesel

fuel or equivalent

43 - 47

“C

Nozzle opening pressure MPa(kg/cm*)

17.2 (175)

19.6 (200)

Transfer

0.16

0.16

pump

pressure

MPa(kg/cm2)

I

(1.6)

(1.6)

I

B to E are the ref-

erence volume when adjusting the injection volume. Marks * are aver-

Note: Inside of < Governor

> represents the rack sensor output (V) at the time when the control

performance

rpm)

(450 - 1025 Rack sensor

unit is connected.

gradient

adjust

standard

R2=1 lltl mm R2-R1=6fO. 05mm

\

RI (approx.

5)

Rack position

Rz (approx.

11)

(mm) TAE00061

95 SERIES ’ 2-o:-93


Pump Assembly Number 6207-71-1281

Applicable

Machine

Applicable

Model

Serial No.

Model

( ): Manufacturer’s part No.

Engine specification

Rotating direction

Clockwise viewed

Injection order

I

from

drive end

1-5-3-6-2-4

Rated horsepower

HP/rpm

Maximum

kgmjrpm

torque

1 High idling

rpm

Low idling

rpm

100/2200

mm

3.2 + 0.05

Delivery valve retraction volume mm3/st

2350 to 2450 950 to 1000

I

Pump tester capacity for Service standard

51

38/l 400

I

interval

Plunger pre-stroke

Serial No.

S6D95L-1

Injection Timing

Injection

Engine

(101692-3980)

I

Motor

7.5

KW

Calibration Standard Conditions l

l

Service standard

Manufacturer

Service standard indicated data

bottle part no.

(105780-0000)

6207-11-3130

using calibration test parts.

Nozzle holder part no.

(I 05780-2080)

6207-I

Manufacture standard is data for factory test.

injection ipe (O/D x l/g x length)

6 x 2 x 600

mm

Test oil

ASTM

Oil temperature

6x‘1.6x600

D975 No. 2 diesel fuel or equivalent 43

OC

to

47

175

200

Transfer pump pressure kg/cm*

1.6

1.6

Rack point

Service standard

when adjusting

10.8

1100

42.5

Each cyl. 41.5 to 43.5

k1.0625

51.3

425

12.5

* 11.5to

k1.875

12.5

A

B

volume. 1 Marks * are average volumes.

Governor performance

Manufacturer

Pump speed

Basic point

K

the injection

(cc/l OOOst)

Rack position (mm)

(rpm

)

Basis

1 Rack positions B to E are the reference volume

(105017-0090)

l-31 10 (105048-3060)

Nozzle opening pressure kg/cm*

Injection volume

standard

Allowance

13.5

Maximum yer$$‘, Basis cylinder

standard (cc/l 000s Maximun variance between cylinder

Allowance Each cyl . *

C

*

*

D

*

*

E

*

*

( 425 - 1100 rpm)

ck limit

15 ‘8’ mm

1100:::

Pump speed (rpm)

’2-oi2-94

SEBH4851 95

SERIES


Pump Assembly

Number

6207-71-1381

I

1 Applicable Machine

(101695-3091)

Model

( ): Manufacturer’s

Injection

Timing

Rotating

direction

Injection

order

Injection Plunger

Clockwise

viewed

60° f

pre-stroke

Calibration

No.

Model

WA1 80-I

from drive end

l-5-3-6-2-4

interval

vnlllme

Serial

Serial

No.

S6D95L-1

Engine Specification

I

Delivery valve retractinn

part No.

Applicable Engine

mm

HP/rpm

Maximum

kgm/rpm(

torque

High idling

rpm

Low idling

rpm

)

II O/2500 40.5/l 2700

600 to 2800

30’

3.6 +_ 0.05

Pump tester capacity for Service standard

51

mms/st

Rated horsepower

800 to 850

Motor

7.5 KW

I

Standard

standard indicates data

Service

using calibration test parts. Manufacture standard is data for factory test.

Rack positions 6 to E are the reference volume when adjusting the injection volume. Marks t are average volumes.

Governor performance

(400 -

1250

rpm)

j! 1200f50

Pump speed (rpm)

1375525

SEBH486E

95 SERIES ’ 2-o%95


Pump Assembl

Number

I

6207-71-1410 1016953150) 6207-71-1420 r 101692-3150) 6207-71-1421 101692-3900, 101695-3160 6207-71-1430 I 101692-3260.101695-3170 6207-71-1690 (101695-3190) ( 1: Manufacturer’s part No.

Applicable Model

1

-1

1 GENERATOR

Clockwise viewed from drive end l-5-3-6-2-4

Injection order Injection interval Plunger prestroke

Calibration

I(For ALGERIA)

, 1

1

I

S6D95L-1

\ I

I I

I

I

85.8/1500 99.6/1800

Rated horsepower

HP/rpm

Maximum

kgm/rpm

torque

3.6 + 0.05 51

me mm%t

,

(50 Hz) (60 Hz) -

High idling

rpm

Max 1560 (50 Hz) Max 1877 (60 Hz)

Low idling

rpm

800

60’ + 30’ mm

Pump tester capacity for Service standard

Motor

7.5

KW

Standard

Conditions

Service standard

4ervice standard indicates data uain9 calibration test parts (Nozzle, Nozzle holder and injection pipe)

~Manufacture standard is data

.

Manufacturer

( 105780-0000)

6207-I

I-3130

NO&

(I 05780-2080)

6207-I

I-31 10 (105048-3060)

Injection ipe (O/D x l/g x length)

6 x 2 x 600

mm

Test oil

ASTM

_Oil temperature

(105017-0090)

6x1.6x600

D975 No. 2 diesel fuel or equivalent 43 to 47

OC

uain9 factory teat

Nozzle opening pressure kg/cm’

175

200

YZ%eference)

Transfer pump pressure kg/cm*

1.6

1.6

Injection volume Rack point

) Rack positions B to E are the reference volume when adjusting the injection volume. 1Marks * are average volumes.

standard

Nozz,epart no. holder part "0.

Governor performance

(cc/lOOOst)

Pump speed (rpm)

Basis

Allowance

11.7

750

56.0

Each cyl. 55.0 to 57.0

21.4

Apry.

400

12.5

* 11.5 to 13.5

*I.875

Basic point B

Service standard

Rack position (mm)

Manufacturer

Maximum

Basis

Allowance

76 o

Each cyl.

12.5

*

C

*

*

D

*

*

E

*

*

( 400 - 999

variance between cylinder

rpm)

Rack cap a~!xox.

450

standard (cc/l 000 st

Maximum

Fert$ cylinder

17.5 mm

75ot5

Pump speed (rpm)

SEBH4761-03 95 SERIES

3

’ 2-oZ2-96

I

Serial No.

Engine specification

Rotating direction

I bl re~r%rtX%r

Engine

Model

I

EG85B-IL

Timing

Applicable

Serial No.

EG85-1 I 1

Injection

Machine


Pump Assembly 6207-71-1540

Number

Applicable

Machine Serial

Model

( ): Manufacturer’s Injection Pump Type

part No.

S6D95L-1

Engine specification Clockwise

viewed

from drive end

l-5-3-6-2-4

order

I

~1

Pump tester capacity for Service standard

Calibration

No.

ZEXEL (DIESEL KIKI)

direction

1 Injection

Serial

Model

DCA85SPK

Timing

Rotating

No.

Engine

Pump Manufacturer

PES-GA

injection

Applicable

Motor 7.5 kW

Standard Service standard

Conditions Service standard ~~~~~~part no. indicates data using calibration

test parts (Nozzle, Nozzle holder and injection pipe) Manufacturer standard is data using factory test parts (For reference)

Nozzle holder part no. Injectionpipe (O/Dx I/D x length)

mm

6207-I

(105017-0090)

I-31 10 (I 05048-3060) 6x1.6x600

D975 No. 2 diesel fuel or equivalent 43 - 47

“C

Nozzle opening pressure MPa(kg/cm*)

17.2 (175)

19.6 (200)

Transfer pump pressure MPa(kg/cm2)

0.16 (1.6)

0.16 (1.6)

Rack point

Rack position (mm)

Pump speed (rpm)

Basic point

Service standard (cc/l OOOst) Basis

Allowance

z%% cylinder

Maximum Basis

Each cyl.

Allowance

“b”,E% cylinder

Each cyl. 83.4

750

<I .84>

Manufacturer standard (cc/1OOOs

Maximum

62.7

10.8

B to E are the reference volume when adjusting the injection volume. Marks + are average volumes.

6206-11-3130

ASTM

Injection volume

Rack positions

(105780-0000) (I 05780-2080) 8 x 3 x 600

Test oi, Oil temperature

Manufacturer standard

B

7.1<2.6>

400

-

C

8.6<2.3>

400

12.5

-

12.5

D E

Note: Inside

of <

> represents the rack sensor output W at the time when the control unit is connected. Rack sensor gradient

adjust standard

R2=1 IzLlmm R2-R14fO. 05mm

>

0

Ri (approx.

5)

R2 (approx.

1 I)

Rack position (mm) TAE00061

95 SERIES

’2-oE-97


Pump Assembly Number 6207-71-1941

Applicable

Machine

Applicable

Engine

(101695-3080) Model

( ) : Manufacturer’s part No.

Model

WA1 50-l

Injection Timing

Serial No.

S6D95L-1

Engine specification

Rotating direction

Clockwise viewed from drive end

Injection order

l-5-3-6-2-4

I

Injection interval

I

108.5/2,400

Rated horsepower

HP/rpm

Maximum

kgm/rpm

torque

High idling

rpm

Low idling

rpm

40/l ,600 2,600

to 2,700

60” f 30

I Plunger prestroke

Serial No.

mm

675 to 725

3.2 f 0.05

Delivery valve retraction volume mm3/st

Pump tester capacity for Service standard

51

Motor

7.5

KW

Calibration Standard Conditions

1 Service standard

Service standard

standard

( 105780-0000)

6207-l

I-3130

(105017-0090)

using calibration

Nozzle holder part no.

(105780-2080)

6207-I

I-3110

(105048-3060)

test parts. Manufacture standard is data

Injection ipe (O/D x l/6x length)

indicated data

I

Manufacturer

Nozzle part no.

for factory test.

6 x 2 x 600

mm

Test oil

ASTM

Oil temperature

1.6x600

D975 No. 2 diesel fuel or equivalent

“C

43 to 47

Nozzle opening pressure kg/cm2

175

200

Transfei pump pressure kg/cm’

1.6

1.6

Injection volume

Service standard

Pump speed

(rpm)

Basis

Allowance

10.0

1200

35.4

Each cyl. 34.4 to 36.4

B

[IO.91

800

38.2

*

C

A7gy.

350

12.5

*

1 Rack positions Basic point

erence volume when adjusting the injection volume. 1 Marks *are average volumes.

Governor performance

(cc/l OOOst)

Rack position (mm)

Rack point

B to E are the ref-

6i

Manufacturer

Maximum rerEsE Basis cylinder

Allowance

41.2

36.2 to 40.2

-

52.2

t

11.5 to 13.5

+I.875

12.5

+

*

*

E

*

*

Rack

limit

rpm)

15 ‘8’

mm

Pump speed (rpm)

SEBH4853 95

’ 2-o%?98

Maximum variance between cylinder

Each cyl. kO.885

D

( 350 -1200

standard (cc/l OOOst

SERIES

I


Pump Assembly Number

I

6207-71-1950 (101695-3130) 6207-71-1951 (101695-3700)

Applicable

Machine

Engine

I

I

Model

( ): Manufacturer’s part No. I lniection I Pumo

Applicable

Serial No.

Model

Serial No.

S6D95L-1

GD51lA(R)-1

I

Injection Timing

Engine specification Clockwise view from drive end

Plunger pre-stroke ,“,F~~t%,vd~Furne

mm

3.2 f 0.05

Pump tester capacity for Service standard

51

mm3/st

Motor

7.5

KW

Calibration Standard Conditions

Service standard

~Service standard indicates data using calibration test parts (Nozzle, Nozzle holder and injection pipe) ~Manufacture standard is data using facton/ teat ?to?referenceI Injection

Nozzle part no. Nc221e holder part

B to E are the reference volume when adjusting the injection volume. ‘Marks j, are average volumes.

I-3130

(105780-2080)

6207-I

l-31 10 (105048-3060)

Oc

6x

(105017-0090)

1.6x600

D975 No. 2 diesel fuel or equivalent 43 to 47

N ozzle opening pressure kg/cm*

175

200

Transfer pump pressure kg/cm*

1.6

1.6

Rack point

Rack position (mm)

Basic point

11.7

Governor performance

0

6207-I

ASTM

Oil temperature

B

Approx.

9.5

Pump speed (W’n)

1450 450

Service standard

Basis 67 3

.

12.5

(cc/lOOOst)

Allowance Each c I.

f&$ to 68.3

* 11.5to

13.5

Manufacturer

Maximum ‘gg:i Basis cylinder

standard (cc/1OOOsl Maximum variance between cylinder

Allowance Each cyl.

*I .6825

62.4

+I.875

12.5

*

C

*

*

D

*

*

E

*

*

( 450 - 1450 rpm)

450 Pump

800 800*50

‘450::8:550*25

speed (rpm)

SEBH4893 ~-

95 SERIES

standard

(105780-0000)

6x2~600

mm

Test oil

volume

1Rack positions

no.

Injection ipe (O/D x l/g x length)

Manufacturer

---

--

’2-o%99


Pump Assembly Number 6207-71-1961

Applicable

(101692-3710)

1

Model

( 1: Manufacturer’s part No.

Machine

)

Serial No.

Clockwise view from drive end

Injection order

I

Injection

I

interval

l-5-3-6-2-4

I

I

,

I

1 Rated horsepower

HP/rpm

1

I Maximum

kgm/rpm

I

I High idling

rpm

I

2700 to 2800

Low idling

rpm

I

850 to 950

torque

60’430’

mm

3.6 f 0.05

mm’/st

51

Plunger prestroke

L

Pump tester capacity for Service standard

I

12512500 -44/1600

Motor

7.5

1

KW

Standard

Conditions *Service standard indicates data usin9 calibration test parts (Nozzle, Nozzle holder and injection pipe)

aManufacture standard is data using factory test parts (For reference) Injection

Serial No.

Engine specification

Rotating direction

Calibration

I

S6D95L-1

Timing

~~~~riy,~$~ume

Engine

)

Model

GDSlOR-1

I

Injection

Applicable

I

Service standard (105780-0000)

Nozzle holder part no.

(105780-2080)

6207- 11-3 110 ( 105048-3060)

Injection ipe (O/D x l/g x length)

6x

6 x 2 x 600

mm

Test oil

ASTM

(105017-0090)

1.6x600

D975 No. 2 diesel fuel or equivalent 43

OC

Dir temperature

l-3130

standard

Nozzle part no.

to 47

Nozzle opening pressure kg/cm2

175

200

Transfer pump pressure kg/cm2

1.6

1.6

volume Rack point

‘Rack positions B to E are the reference volume when adjusting the injection volume. 1Marks * are average volumes.

Manufacturer 6207-l

Basic point

Rack

Pump

position (mm)

speed hm)

Service standard (cc/l 000

st)

Manufacturer standard(cc/lOOO St

Maximum

Basis

Allowance

54.7 Each cyl.

11.4

1250

B

12.0

800

52.4

* 50.4 to 54.4

C

Approx. 9.5

450

12.5

*11.5to

53.7 to 55.7

13.5

Allowance

yergs’, cylinder

Basis

+I.3675

59.7

-

69.2

*

12.5

*

f1.875

Maximum variance between cylinder

Each cyl.

D

*

*

E

*

*

Governor performance ( 450 - 1250 rpm)

Rack

Pump speed (rpm)

cap: 15+$'*mm

SEBH4894

95 SERIES

I I


Pump Assembly

Number

Applicable

Applicable

Machine

Engine

6207-72-1210 Serial

Model

( ): Manufacturer’s Injection Pump Type

direction

Injection

order

Injection

interval

No.

S6D95L-1

ZEXEL (DIESEL KIKI)

Clockwise

Plunger

pre-stroke

viewed

from drive end

1-5-3-6-2-4

~1

60” 2 30’ mm

3.2 f 0.05

Delivery valve retraction volume mm%

Pump tester capacity for Service standard

51

Motor 7.5 kW

Standard Service

Conditions Service standard indicates data using calibration test parts (Nozzle, Nozzle ~c$e[paeld injecManufacturer standard is data using factory test parts (For reference)

Manufacturer

standard

(105780-0000)

6206-11-3130

(105017-0140)

Nozzle holder part no.

(105780-2080)

6207-11-3110

(105048-3060)

Injection

pipe (O/D x I/D x length1

mm

ASTM

Oil temperature

6 x 1.6 x 600

6x2~600

Test oil

D975 No. 2 diesel fuel or equivalent 43 - 47

“C

Nozzle opening pressure MPa(kg/cm?

17.2 (175)

19.6 (200)

Transfer pump pressure MPa(kg/cm*)

0.16 (1.6)

0.16 (1.6)

I

I

v”‘ume! ii%

performance

Service

standard

Al,owance

(500 - 1100 rpm)

Rack limit: 12.5+$2mm /

(I Pump speed (mm) 95 SERIES

standard

~~~~~~ pae no.

B to E are the reference volume

Governor

Serial

Engine specification

Rotating

njection

Model

PC200-6

Timing

alibration

No.

Pump Manufacturer

PES-GA

Injection

part No.

14/d 6206F1013

(cc/lOOOst)

Manufacturer

standard WlOOOfi

Allowance


Pump Assembly 6207-72-l

Number Applicable

270 (101692-3641)

Model

( ): Manufacturer’s

Injection

Timing

Rotating

direction

Injection

order

Injection

interval

Plunger

pre-stroke

Delivery valve retraction volume

Calibration

part No.

Machine Serial

Applicable No.

Model

PWl OO-3

Engine Serial

No.

S6D95L-1

Engine Specification Clockwise

viewed

from drive end

Rated horsepower

HP/rpm

108.5/2100

l-5-3-6-2-4 60° f mm

30

3.6 + 0.05 Pump tester capacity for Service standard

51

mm3/st

Motor 7.5 KW

Standard

indicates data using calibration test parts.

1Manufacture standard is data for factory test.

1Rack

positions B to E are the

ence volume when adjusting the injection volume. 1Marks t are average volumes.

Governor performance

(425

-

1050

rpm)

Damper springset 7.7

425 470f40

1050:: Pump speed (rpm)

SEBH482’

’2-oz-’ O2

95 SERIES


Pump Assembly 6209-71-l

Number

I Applicable

211 (101695-3520)

Model

( ): Manufacturer’s

Injection

Timing

Rotating

direction

Injection

order

Injection

interval

Plunger

pre-stroke

Delivery valve retraction volume

Calibration

part No.

Machine Serial

Applicable No.

Engine

Model

Serial

No.

SA6D95L-1

PC220-5

Engine Specification Clockwise

viewed

from drive end

l-5-3-6-2-4 60° mm

HP/rpm

Maximum

kgm/rpm

torque

High idling

rpm

Low idling

rpm

157.2/2200 53.7/l 2355

500

to 2475

+ 30’

3.2 * 0.05

mm3/st

Rated horsepower

Pump tester capacity for Service standard

51

875 to 925

Motor

7.5 KW

Standard

) Service

standard indicates data using calibration test parts. 1Manufacture standard is data for factory test.

) Rack positions B to E are the reference volume when adjusting volume. ) Marks * are aver-

ck limit

12.5’E2

mm

0 550130

Pump speed (rpm)

95 SERIES

1100:::

SEBH4854

’2-02z-’ O3


Pump Assembly 6209-72-I (

Number

250

I

): Manufacturer’s Injection Pump Type

direction

Injection

order

Calibration

Serial

No.

(

PC220-5

Model

(

Serial No.

SA6D95L-1

ZEXEL (DIESEL KIKI)

Timing

Rotating

(

Model

Pump Manufacturer

PES-GA

Injection

part No.

Engine specification Clockwise

viewed

from drive end

1-5-3-6-2-4

Rated horsepower

kW(HP)rpm

117(157.2)/2200

Maximum

Nm(kgmVrpm

526(53.7)/1500

torque

Standard

holder and injecManufacturer standard is data using factory test

Rack positions B to E are the reference volume when adjusting the injection volume.

B

Marks Ir are average volumes.

D

7.3<2.5>

375

12.5

12.5

C

E

Note: Inside of <

> represents the rack sensor output W) at the time when the control unit is connected. Rack sensor gradient

adjust standard

R2=1 lflmm R2-Rl=6fO. 05mm

> 3 5 P s 0 b ? z % 2

1.8

0

RI (approx. 5)

Rz (approx. 11)

Rack position (mm) TAE00061

95 SERIES ’ 2-o%-’

O4


Pump Assembly

Number

Applicable

6209-71-1251 6209-7 l-l 252

(

Model

1:Manufacturer’s

Injection Rotating 1 Injection

Machine

part No.

Applicable

Serial

No.

Model

PC220-5

Timing

Serial

No.

SA6D95L-1

Engine specification

direction

Clockwise

viewed

from drive end

order

~

Pump tester capacity for Service standard

Calibration

Engine

Motor 7.5 kW

Standard

Conditions

Service standard

Service standard indicates data using calibration test parts (Nozzle, Nozzle

Nozzle part no. Nozzle holder part no. Injection pipe (O/Dx I/D x length)

holder and injec-

Test oil

mm

Rack point

Rack position

6209-11-3130

(105017-0880)

(105780-2080)

6202-13-3110

(105048-3300)

ASTM

6x2~600 D975 No. 2 diesel fuel or equivalent 43 - 47

17.2 (175)

22.1 (225)

0.16 (1.6)

0.16 (1.6)

Service standard (cc/lOOOst)

Pump

speed (t-pm)

(mm)

(105780-0000)

6x2~600

tion pipe) Manufacturer Oil temperature “C standard is data using factory test Nozzle opening pressure MPa(kg/cmz) parts Transfer pump pressure MPa(kg/cmz) [For reference)

njection volume

Manufacturer standard

Allowance

Basis

Manufacturer standard (cc/lOOOst

Maximum vba,;:,“‘, Basis

Maximum

Allowance

cylinder

3ack positions 3 to E are the refsrence volume ,vhen adjusting :he injection volJme. Marks * are average volumes.

Note: Inside of <

cylinder

Each cyl. Basic point

1025

B

375

vb%$~

Each cyl. 65.8

*

-

12.5

C

Ir

*

D

*

*

E

*

*

> represents the rack sensor output (V) at the time when the control unit is connected. Rack sensor gradient

adjust standard

RZ=l If1 mm R2-Rl=6fO. 05mm

> 3 S a % : : z Y B (r

1.8

0

RI (approx.

5)

R2 (approx.

11)

Rack position (mm) TAE00061

95 SERIES ’ 2-o%-’

O5


Pump Assembly

Number

Applicable

Machine

Applicable

Engine

6209-72-1210 Model

( ): Manufacturer’s

Injection

part No.

Serial

No.

PC220-6

Timing Clockwise

viewed

1 Rated horsepower

from drive end

torque

High idling

I Low Delivery valve retraction volume

ialibration

No.

SA6D95L-1

Maximum

pre-stroke

Serial

Engine specification

ql Plunger

Model

idlina

kW(HP)/rpm

1 118(157.7)/2300

Nm(kgm)/rpm

554(56.5)/l

600

2470 - 2590

rpm rDm

975 - 1025

I

3.2 + 0.05

mm

I

51

mmY.st

Pump tester capacity for Service standard

Motor 7.5 kW

Standard Service standard

Conditions Service standard Nozzle pan no, indicates data using calibration Nozzle holder part no. test parts Injectionpipe mm (Nozzle, Nozzle IO/D x I/D x length) holder and injec- Test oil tion pipe) Manufacturer “C Oil temperature standard is data using factory test Nozzle opening pressure MPa(kg/cm2) parts Transfer pump pressure MPa(kg/cm*) (For reference)

Manufacturer standard

(I05780-0000)

6209-I

(105780-2080)

6202-13-3110

6x2~600 ASTM

I-3130

(105017-0880) (105048-3300)

6x2~600 D975 No. 2 diesel fuel or equivalent 43 to 47

17.2 (175)

22.1 (225)

0.16 (1.6)

0.16 (1.6)

Rack positions 6 to E are the reference volume

Governor performance (450 - 1100 rpml

Pump

speed

(rpm)

(I

165) 6206F1014

95 SERIES


injection Pump Assembly 6205-71-1290

Number

Applicable Machine Model

1: injection pump manufacturer’s

direction

Injection

order

Injection

interval

Plunger

pre-stroke

No.

Model

1

Serial

No.

Engine Specification Flywheel

Clockwise

89’30’

- 90”30’

3.15 - 3.25

(mm)

horsepower

Maximum

l-3-4-2

Delivery valve (mm3/st) retraction volume

CiPlibration

Serial

part No.

Injection Pump Specification Rotating

1

Applicable Engine

torque

Standard

(Nm {kgm}/

rpm)

55.2 I73.91/2,000

(Net)

299 {30.5)/1,500

(Net)

High idling speed

(rpm)

2,200 - 2,280

Low idling speed

(rpm)

900 - 950

Pump tester capacity for service standard

51

(kW {HP}) / rpm)

1: lniection

Motor

7.5 kW

DumD manufacturer’s Dart number

C onditions . Service standard indicates data using

calibration

Manufacturer standard is data

$3ction

volume

B to E are the

reference volume when

adjusting

Marks * are average volumes.

Governor

Performance

Curve

Rack

-z E .-z

I imi t : 12. 5’8’

(mm)

IO. 5 10.0 9. 4

.z oi *: nf

6.4 5. 4

950+40 Pump speed

(rpm)

I 100+25 TDE00570

’2-o%f-’ O7 I


Injection

Pump

Assembly

Number Applicable

6207-71-1510 1: Injection

Injection

pump

manufacturer’s

part No.

direction

Injection

order

Injection

interval

Plunger

pre-stroke

Clockwise l-3-4-2 89”30’

- 90”30’

(

(kW {HP}) / rpm)

82.0 {I lOY2,400

(Net;

Maximum

torque

(Nm IkgmI/

417 {42.51/1,500

(Net1 I

idling

) Service

I

standard indicates data using calibration test parts. Manufacturer standard is data

for factory test.

holder part

holder

Injection (Outside Test

part

No.

pipe (mm) dia. x inside dia. x length)

Transfer

speed

2,600 - 2,700 750 - 850

pump

Motor manufacturer’s

standard

7.5 kW

part number Manufacturer’s

standard

6207-l

I-31 10

(105780-0000)

6207-l

l-3130

6x

ASTM D975

No.

1.6x600

2 diesel fuel or eauivalent 40 - 50

1°C) 17.2

pressure (MPa{kg/cm2})

pump pressure

I

(rpm)

6 x 2 x 600

(kPa(kg/cm2H

{175}

19.6

157 (I.601

/ njection

(rpm)

(105780-2080)

oil

Oil temperature Nozzle opening

rpm)

No.

Nozzle part No. Nozzle

speed

1: Injection Service

Nozzle & nozzle

No.

horsepower

Pump tester capacity for service standard

Standard

Conditions

Serial

Specification

Low idling

51

Engine

Model

Flywheel

High

3.15 - 3.25

(mm)

No.

S6D95L-1

Engine

Delivery valve (mm3/st) retraction volume alibration

Serial

WA1 80-3

Pump Specification

Rotating

Applicable

Machine

Model

Service

I2001

157 Il.601

standard (cc/1000 St.1

/ Manufacturer

standard

icc/lOOO st.)

volume

Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

(Basic

A

10.8

1,200

*43.5

- 45.5

B

point)

11.3

750

*43.0

- 47.0

C

8.4

385

*11.5

- 13.5

Performance

*52.5 t59.0

3.8

fi12.5

D

I

E Governor

2.2

I

I

I

I

I

Curve Rack

4’60

I imi t : 15.

/li70\ 1230

Pump speed (rpm)

’*-Oi2-’ O8

0’:’

(mm)

1325 TDE00571

95 SERIES

I


Injection

Pump Assembly

Number

Applicab!e Machine

6207-71-1520

Serial

Model ): Injection

pump

manufacturer’s

part No.

direction

injection

order

Injection

interval

Plunger

pre-stroke

No.

WA250-3

Serial

Model

No.

S6D95L-1

Engine Specification

Injection Pump Specification Rotating

Applicable Engine

Clockwise 1-3-4-2 89”30’

- 90”30’

3.15 - 3.25

(mm)

Delivery valve (mm3/st) retraction volume

51 for service I

Motor

standard

7.5 kW

lniartinn

Service standard

indicates data

I Manufacturer standard is data

ijection

volume

B to E are the reference volume

Marks t are average volumes.

Governor

Performance

Boost Compensator

Curve Rack

limit

Performance

Curve

:15. 0':' (mm)

oost compensator strake:l. 2+0. 1 (mm)

E

12.3

c ” ._ UT il. 1 : z --r

0

6 7i2. 7 (50F201

22. 7+6. 7 ~17Oi501

Boost pressure (kPa(mmHsl) 0

385 \ 400

1100 /\

\ 1300

1235 Pump speed (rprn)

TDE00573

1330 TOE00572

95 SERIES ’ 2-oz-’ 1

O9


Injection

Pump Assembly

6209-71-1110

Number

Applicable Machine

(101691-3041)

Model ): injection

pump

manufacturer’s

part No.

1

Serial

Applicable Engine No.

WING100

/

Model

Serial

No.

SAA6D95LE-1

(LWIOO-1, LWIOOM-1) ZEXEL

PES-A

Enaine Snecification

Injection Pump Specification Rotating

direction

Injection

order

Injection

interval

Plunger

pre-stroke

1 Flywheel

Clockwise

1

Maximum

l-5-3-6-2-4

(mm)

horsepower torque

(kW {HP}) / rpm) 1 118 {1581/3,000 (Nm IkgmY

rpm)

457

(Net11

{46.6}/1,800

59”30’ - 60”30’

High idling speed

(rpm)

3,400 - 3,500

3.55 - 3.65

Low idling speed

(rpm)

750 - 850

Delivery valve (mm3/st) retraction volume

Pump tester capacity for service standard

51

Motor

(Net)

7.5 kW

Conditions I Service standard

indicates data

I Manufacturer standard is data

njection

volume

I Rack

positions B to E are the

reference volume when adjusting volume.

Governor

Performance

Curve

# Adjusting the injection pump at 375 (rpm) is as follows: adjust injection volume and variance of injection pump without governor to adapt to the values in the chart above at the rack position on 10.0 (mm), and after coupling with the governor, check if the rack position is 9.0 (mm), checking of injection volume or variance at rack position 9.0 (mm) is not necessary. B.ldle lever set point Boost comvensator

E E

:0.45-O. 65 (mm)

I I. 4

J:Lever limit set Point for increasing injection oiume at engine stariina

E

Il.25 Il. I .v, 10. 23-10. 5 : 6. 66-10. 2 .-z

Pump speed (rpm)

Boost Pressure (kPa(mmHa))

330

400 Pump speed (rpm) lWE00725

‘2-o~2-“o

95 SERIES


TESTING AND ADJUSTING

PERFORMANCE TEST

PERFORMANCE TEST RUN-IN

1

Engine model

Load are given for the case of the dynamometer arm lensth is 716 mm. This list shows the standard on condition that the fan isremoved.

T

Order

Item 1

PC40-5 PC40-6

3D95S-W-1

*

STANDARD

PC5OUU-1

EC35Z-2 EC35ZS2 EC35ZSB-2

D20A, P,S, Cl, PL, PLL-6 D21A, P, S, Q, PL-6

5

3

IO

3

10

1,000

1,600

2,600

147 (15)

147 (15)

17.7 (23.7)

28.7 (38.5)

(“53

Load

0

output

0

3.7 (4.9)

Running time

3

10

2

3

10

Engine speed

950

1,000

1,200

1,600

2,500

:;

(Fz,

147 (15)

147 (15)

Load

0

output

0

3.7 (4.9)

8.8 (I 1.8)

17.7 (23.7)

27.6 (37)

Running time

2

10

2

3

10

Engine speed

700

1,000

1,200

1,600

2,650

(E, (E,

118 (12)

147 (15)

147 (15)

10.6 (14.2)

17.7 (23.7)

29.4 (39.4)

2

3

10

1,600

2,450

147 (15)

166 (17)

Load

0

output

0

Running time

3

10

Engine speed

825

1,000

(“53

Load

0

output

0

3.7 (4.9)

17.7 (23.7)

30.9 (41.4)

3

IO

2,000

2,300

2,800

118 (12)

137 (14)

162 (16.5)

Running time

min.

2

10

Engine speed

rpm

700

1,400

Load

Running time DZOAG, P, PG Engine speed PL, PLL-7(A) D21A. AG, PG Load S, QG-7(A) output

WA50-1

4

950

output

4D95S-1

3

Engine speed

4D95S-W-1

EC50Z-5 EC50ZS-5 EC50ZSB-5

2

Running time

& CK

0 0

(“9”, &,

17.7 (23.7)

:%

$6:

min.

2

10

2

3

Min. 10

rpm

800 - 850

1,000

1,200

1,600

2,450

$,

216 (22)

226 (23)

161 (16.4)

t;:;,

19.1 (25.6)

27.2 (36.5)

29.5 (39.6)

& (k!,

0 0

Running time

min.

2

IO

2

3

10

Engine speed

rpm

800 - 850

Load output

$I, &

6

1,000

1,200

1,600

2,500

0

5,

216 (22)

:%

220 (22.4)

0

7.3 (9.8)

19.1 (25.6)

27.2 (36.5)

41.2 (55.2)

Running time Engine speed Load output

95 SERIES

’2-:23


PERFORMANCE TEST

TESTING AND ADJUSTING

*

Engine model

T

Load are given for the case of the dynamometer arm length is 716 mm. This list shows the standard on condition that the fan is removed. Order

-

WA70-1

Load

2

2

3

10

rpm

1,000

1,600

2,200

0

196 (20)

196 (20)

275 (28)

0

17.7 (23.7)

29.4 (39.4)

33.1 (44.4)

min.

2

2

3

10

rpm

800 - 850

1,200

1,600

2,200

196 (20)

294 (30)

196 (20)

17.7 (23.7)

35.3 (47.3)

32.4 (43.4)

2

2

3

IO

(kNg, &F,

EG33B, BS-1

PC60-3 PC6OL-3 PC6OU-3

?C60-5 ‘C6OL-5 ?C6OU-5

PC60-6 PC70-6

7.3 (9.8)

1,200

1,600

1,800

0

147 (15)

196 (20)

245 (25)

output

0

13.2 (17.7)

23.5 (31.5)

33.1 (44.4)

Running time

min.

2

10

2

3

10

Engine speed

rpm

800 - 850

1,000

1,200

1,600

2,400

196 (20)

275 (28)

255 (26)

17.7 (23.7)

33.1 (44.4)

45.6 (61.1)

Load

&

0

%

7.3 (9.8)

output

CkY,

0

Running time

min.

2

2

3

10

Engine speed

rpm

900 - 950

1,200

1,400

2,100

0

196 (20)

294 (30)

265 (27)

0

17.7 (23.7)

26.5 (35.5)

41.7 (55.9)

Load

(kNg)

Running time

(K, min.

2

10

2

3

10

Engine speed

rpm

350 - 1,000

Load

& (%,

1,000

1,200

1,400

2,100

0

5,

196 (20)

294 (30)

265 (27)

0

7.3 (9.8)

17.7 (23.7)

30.9 (41.4)

41.7 (55.9)

Running time

min.

2

10

2

3

Max. 10

Engine speed

rpm

1,000- 1,05(

1,000

1,200

1,500

1,900

(Z,

196 (20)

294 (30)

284 (29)

0

7.3 (9.8)

17.7 (23.7)

33.1 (44.4)

40.4 (54.2)

min.

2

10

rpm

950 - 1,000

Load output Running time Engine speed

& (“&

(kNg) &Y,

’2z24

0

z,

800 - 850

output

PC60-7 PC70-7

0

1,000

Load

output

4D95L-1

5

800 - 850

(K,

10

4

min.

6%

4D95L-W-1

3

1

0

6

-

0 0

95 SERIES


PERFORMANCE TEST

TESTING AND ADJUSTING

*

Load are given for the case of the dynamometer arm length is 716 mm. This list shows the standard on condition that the fan is removed. Order

Engine model

Applicable machine

‘C75UU-2

Item

2

10

2

3

10

IEngine speed

,000 - 1,051

1,100

1,200

1,600

1,900

196 (20)

294 (30)

275 (28)

I_oad

0

(3utpLlt

0

8.1 (10.8)

17.7 (23.7)

35.3 (47.3)

39.2 (52.5)

2

10

2

3

10

900 - 950

1,000

1,200

1,600

2,400

196 (20)

294 (30)

275 (28)

I%gine

(3lJtput

0

7.3 (9.8)

17.7 (23.7)

36.1 (48.3)

49.7 (66.6)

2

10

2

3

10

50 - l,OO(

1,000

1,200

1,600

2,300

196 (20)

343 (35)

287 (29.3) 49.5 (66.3)

(E,

(zwtput

0

7.3 (9.8)

17.7 (23.7)

41.2 (55.2)

2

10

2

3

900

1,000

1,200

1,600

speed

0

7.3 (9.81

17.7 (23.7)

35.3 (47.3)

52.2 (70)

2

10

2

3

10

825

1,000

1,200

1,600

2,450 206 (21)

time speed

:3904

I_oad

0

f53

(Y!,

147 (15)

(3utput

0

3.7 (5)

(:2,

17.9 (24)

38.4 (51.5)

2

10

2

3

10

BOO - 850

1,500

2,100

2,400

3,000

I_oad

0

118 (12)

167 (17)

204 (20.8)

235 (24)

(3utput

0

13.2 (17.7)

26.5 (35.5)

36.8 (49.3)

(Y,

2

IO

2

3

10

BOO - 850

1,000

1,200

1,600

1,800

196 (20)

245 (25)

294 (30)

17.7 (23.7)

29.4 (39.4)

39.7 (53.2)

IQrnning

time speed

time

IEngine speed

95 SERIES

278 (28.4)

(3utput

Ikgine

BS-1

2,500

%

I3unning

EG40B.

196 (20)

Load

0

output

0

(E, (E,

6

10

0

I%gine

zs-3

time

I_oad

Iknning

x75z.

speed

0

IIngine

121A-7T ‘Trimming)

time

$,

I_oad

IQnning

‘W60-3

speed

0

Iingine

4D95L-1

time

%

I_oad

Ikrnning x90-1

5

Iqunning time

Iqunning

‘C80-3

4

2

’2-:25


TESTING

PERFORMANCE

AND ADJUSTING

*

TEST

Load are given for the case of the dynamometer arm length is 716 mm. This list shows the standard on condition that the fan is removed. Order

Engine model

Applicable machine

item

Running Engine ‘ClOO-5 ‘CIOO-6

time

speed

Load

3

4

5

nin.

10

2

3

10

rpm

1,000

1,200

1,600

2,100

200 (20)

290 (30)

360 (37)

6%

%

:%

7.3 (9.8)

17.7 (23.7)

35.3 (47.3)

57.1 (76.6)

time

nin.

10

2

3

10

speed

rpm

1,000

1,200

1,600

2,200

200 (20)

290 (30)

370 (38)

output Running PC120-5 PC1 20-6 PC128UU-1

Engine Load output Running Engine

JV7ODW-1

7.3 (9.8)

17.7 (23.7)

35.3 (47.3)

61.8 (82.8)

2

3

Min. 10

speed

rpm

1,000

1,200

1,600

2,000

196 (20)

390 (40)

390 (40)

17.9 (24.0)

47.7 (64.0)

59.7 (80.0)

& 6% time

nin.

speed

‘pm

% 7.46 (10.0)

6

&

output

Engine

K

10

Load

Running

$,

nin.

output

Engine

(kNg,

time

Load

Running

1

2

-

&I$ time speed

Load output Running Engine

time speed

Load output Running Engine

time speed

Load output Running Engine

time speed

Load output

1 Z-026

95 SERIES


TESTING AND ADJUSTING

PERFORMANCE TEST

Load are given for the case of the dynamometer

Ir

This list shows the standard

arm length is 716 mm.

that the fan is removed.

Order

Engine model

1

min Engine speec D31A, P, S, Q-18

D31E, P, PL, PLL, S, 0, Ab SM-LO(A)

D37A-2 D37P-2A

2

2

3

10

1,200

1,600

2,350

343 (35)

294 (30)

41.2 (55.2)

51.8 (69.5)

(f,

196 (20)

output

0

7.3 (9.8)

17.7 (23.7)

Running time

2

10

2

Engine speec

700 - 75c

1,000

1,200

343 (35)

294 (30)

41.2 (55.2)

51.8 (69.5)

output

0

Running time

2

2

3

IO

Engine speed

700 - 750

1,200

1,600

2,500

0

196 (20)

343 (35)

323 (33)

196 (20)

392 (40)

392 (40)

47.1 (63.1)

61.8 (82.8)

Load

z, 7.3 (9.8)

Load

17.7 (23.7)

2 rpm

1,200

w$

196 (20)

r”&

17.7 (23.7)

0

nin.

2

IO

2

Engine speed

rpm

850 - 900

1,000

1,200

&

Running time

F, nin.

Engine speed

‘pm

Load

0%

0

z,

0

7.3 (9.8)

17.7 (23.7)

2

10

2

800 - 850

1,000

1,200

0

$,

196 (20)

G,

17.7 (23.7)

output

kW HP)

0

Running time

nit-b

2

10

2

Engine speed

‘pm

850 - 900

1,000

1,200

0

3,

196 (20)

kW HP) nin.

0

7.3 (9.8)

17.7 (23.7)

2

10

2

‘pm

575 - 725

1,000

1,200

Load output Running time Engine speed Load output

+

17.7 (23.7)

Running time

Load

6

-I10

2,350

0

output

‘VAIOO-1 YRII-1

196 (20)

3

1,600

Load

output

‘W150-1

5

IO

0

6D95L-1

X120-3

I

1,000

Load

Engine speed

PC100-3 PClOOL-3 PClOOU-3

4

700 - 75c

Running time

137E, P-5(A)

3

2

output

95 SERIES

on condition

:kNg,

kNg) kW HP) -

0

(Z,

0

7.3 (9.8)

196 (20)

,.:o. 392

392

(40)

(40)

47.1 (63.1)

64.7 (86.7)

392

314 (32)

(40)

17.7 (23.7)

’2-:27


TESTING AND ADJUSTING

PERFORMANCE TEST

Sr

Engine model

GD313A-1

EGGOB, BS-1

PC150-3 PC15OLC3

PC150-5

PCZOO-5 BRZOO-1

2

3

4

5

Running time

2

IO

2

3

10

Engine speed

675 - 725

1,000

1,200

1,600

2,400

196 (20)

392 (40)

363 (37)

Load

0

output

0

7.3 (9.8)

17.7 (23.7)

47.1 (63.1)

65.3 (87.5)

Running time

2

IO

2

3

10

Engine speed

750 - 850

1,000

1,200

1,600

2,500

196 (20)

392 (40)

353 (36)

0

(%

output

0

7.3 (9.8)

17.7 (23.7)

47.1 (63.1)

66.2 (88.7)

Running time

2

10

2

3

10

Engine speed

800 - 850

1,000

1,200

1,600

1,800

(?I,

196 (20)

294 (30)

392 (40)

Load

0

output

0

7.3 (9.8)

17.7 (23.7)

35.3 (47.3)

Running time

2

10

2

3

10

Engine speed

800 - 850

1,000

1,200

1,600

2,200

245 (25)

490 (50)

466 (47.5)

0

output

0

7.3 (9.8)

22.1 (29.6)

58.9 (78.9)

76.8 (103)

Running time

min.

2

10

2

3

10

Engine speed

rpm

900

1,000

1,200

1,600

2,000

196 (20)

490 (50)

519 (53)

Load

6% (F,

0

z,

0

7.3 (9.8)

17.7 (23.7)

58.9 (78.9)

(10748.5,

Running time

min.

2

10

2

3

10

Engine speed

rpm

950

1,000

1,200

1,600

2,050

196 (20)

490 (50)

598 (61)

Load

.

Engine speed Load output Running time Engine speed Load Output

’2z28

%

&

0

%

0

7.3 (9.8)

17.7 (23.7)

58.9 (78.9)

82.6 (110.7)

min.

2

10

2

3

Min. 10

rpm

1,000

1,200

1,400

1,600

2,200

0

147 (15)

294 (30)

588 (60)

637 (65)

0

13.2 (17.7)

30.9 (41.4)

70.6 (94.7)

105.2 (141)

(“Y,

& IF, min.

2

10

2

3

IO

rpm

850 - 900

1,000

1,200

1,600

1,900

c%

196 (20)

392 (40)

529 (54)

7.3 (9.8)

17.7 (23.7)

47.1 (63.1)

75.7 (101.5)

(I% I%

0 0

6

$,

Load

Running time

PWI 00-3 (Engine No. up to 36829)

$,

Load

output

PCZOO-6

Order 1

output

6D95L-1

T

Item

WAIOO-1 WRII-1 (Engine No. 46799 and u,

6D95L-1

Load are given for the case of the dynamometer arm length is 716 mm. This list shows the standard on condition that the fan is removed.

95 SERIES


PERFORMANCE TEST

TESTING AND ADJUSTING

Load This list

Engine model

;D461A-1

2

3

10

Engine speed

rpm

850 - 900

1,000

1,200

1,600

2,100

200 (20)

390 (40)

537 (54.8)

_oad

&

(:,

%

CK?

&

7.3 (9.8)

17.7 (23.7)

47.1 (63.1)

84.6 (113)

3unning time

2

10

2

3

10

Engine speed

JJ5

Load

PC220-5 BR300-1

1,600

2,400

E,

250 (25)

490 (50)

470 (48)

!&

7.5 (IO)

(%,

&

85.8 (115)

10

2

3

10

Engine speed

1,200

1,600

2,400

Load

1%

250 (25)

440 (45)

490 (50)

Qutput

7.5 (10)

(%,

(?I$

$FO,

Running time

2

10

2

3

10

Engine speed

750 - 850

1,000

1,200

1,600

2,500

250 (25)

540 (55)

470 (48)

Ii,

(%

i:

7.5 (9.8)

22.1 (29.6)

64.8 (86.8)

Running time

2

10

2

3

Min. 10

Engine speed

750 - 850

1,000

1,200

1,800

3,000

A

(%

200 (20)

390 (40)

490 (50)

i,

7.5 (9.8)

17.6 (23.7)

(J?O,

110 (148)

Running time

IO

2

3

10

Engine speed

1,000

1,200

1,600

1,800

200 (20)

390 (40)

670 (68)

7.5 (9.8)

17.6 (23.7)

47.1 (63.1)

90.3 (121)

Running time

10

2

3

10

Engine speed

1,000

1,200

1,600

1,800

200 (20)

390 (40)

590 (60)

7.5 (9.8)

17.6 (23.7)

47.1 (63.1)

79.8 (107)

Running time

10

2

3

10

Engine speed

1,000

1,200

1,600

2,200

I%,

200 (20)

590 (60)

710 (72)

7.5 (9.8)

17.6 (23.7)

JO.6 (94.6)

116 (156)

Load

Load

Load

Load

Load output

95 SERIES

1,200

1,000

output

SA6D95L-1

1,000

0 !O)

sunning time

output

DCA85 QAS85

5

10

output

:G85B, BS-1

4

2

output

_W80-1

3

min.

Qutput

NA250-3

arm is 716 fan is removed.

time

3tltput

NA180-3

that

Order 1

‘Wl OO-3 Engine No. 16830 and up

condition

r

Item

bnning

S6D95L-1

for case of the standard

%

%

6

H8188s,

’*-Oi*-’ 1


PERFORMANCE TEST

TESTING AND ADJUSTING

*

Load are given for the case of the dynamometer arm length is 716 mm. This list shows the standard on condition that the fan is removed.

lEngine model

Applicable machine

l-

Item

1

2

3

4

5

time

nin.

2

10

2

3

10

speed

rpm

1,000

1,200

1,400

1,600

2,300

(%

294 (30)

764 (78)

686 (70)

7.3 (9.8)

30.9 (41.4)

91.8 (123)

117.7 (157.8)

Flunning Eingine SA6D95L-1

PC220-6

1.oad

$1

(kItput

WING100 LWIOO-1 1 LWIOOM-1 1

rk!,

0

nin.

10

2

3

E.ngine

rpm

1,000

1,200

1,600 440 (45)

speed

1.oad

FIunning Eingine

Eingine

IK, time

nin.

speed

rpm & rk!,

time

nin.

speed

rpm

1.oad

&

tIutput

E!ngine

$, time

min.

speed

rpm

Load

&

output Running Engine Load output

&

6

&

(XJtput

FIunning

7.5 (10)

rpm

I -

Eingine

K,

speed

1.oad

FIunning

(E,

nin.

(Iutput FIunning

&

250 (25)

time

1.oad

’2-z8-2

0

Fsunning time

(Iutput

SAA6D95LE-’

Order

(!zJ time

min.

speed

rpm & K, -

95 SERIES



PERFORMANCE TEST

TESTING AND ADJUSTING

PERFORMANCE

Engine model

TEST CRITERIA

Applicable machine

Test item

Flywheel PC40-5 PC40-6

Maximum

horsepower torque

Specified value (fully equipped)

Engine speed (rpm)

Dynamometer (kg)

38.5 HP/2,600 rpm

2,595 - 2,605

14.2 - 15.4

1,700 - 1,900

Min. 17.1

12.5 kgm/1,800

rpm

High idling speed

2,800 rpm

2,750 - 2,850

0

Low idling speed

950 rpm

950 - 1,000

0

38.5 HP/2,500 rpm

2,495 - 2,505

14.4 - 15.9

1,700 - 1,900

Min. 17.1

2,650 - 2,750

0

Flywheel Maximum

horsepower torque

12.2 kgm/l,800

rpm

PC5OUU-1 High idling speed

2,700 rpm

Low idling speed

950 rpm

950 -

1,000

0

3D95SW-1 Flywheel EC35Z-2 EC35ZS2 EC35ZSB-2

Maximum

horsepower torque

35 HP/2,650 rpm 13 kgm/l,800

rpm

2,645 - 2,655 1,700 -

1,900

14.8 - 16.2 18.7 -

High idling speed

2,800 rpm

2,700 - 2,900

0

Low idling speed

700 rpm

650 - 750

0

39.5 HP/2,450 rpm

2,445 - 2,455

16.9 - 17.7

1,200 - 1,450

21.3 - 22.6

Flywheel Maximum

horsepower torque

High idling speed Low idling speed Flywheel D20A. P, S, Q, PL, PLL-6 D21A, P, S, Q, PL-6

Maximum

EC50Z-5 EC50Z.55 EC50ZSB-5

’*-g30

torque

15.5 kgm/l,300

rpm

High idling speed

2,850 rpm

2,800 - 2,900

0

Low idling speed

825 rpm

800 - 850

0

45 HP/2,800 rpm

2,795 - 2,805

17.5 - 18.4

1,900 - 2,100

21 - 22.5

-

0

Flywheel

4D95SW-1

horsepower

Maximum

horsepower torque

15 kgm/2,000

High idling speed

-

Low idling speed

1,500 rpm

rpm

1,450 -

1,550

0

95 SERIES


PERFORMANCE TEST

TESTING AND ADJUSTING

The values Values

given

for the output

are standardized

(if installed)

under

and torque the following

are with

the fan removed,

conditions:

Air cleaner

so they differ installed;

from

alternator

those

of the specification.

idling;

and air compressor

open.

Dynamometers

are given

Fuel used:

ASTM

Lubrication

oil used:

for the case

of the arm

length

is 716

mm.

D975 No. 1 or No. 2 diesel fuel. CLASS-CD

SAEBO. Lubrication oil pressure (kg/cm?

Exhaust temperature (“C) (t=lntake temp. - 20°C)

3.0 - 6.0

Max. 650 + 3t

90 - 120

-

Max. 650 + 3t

output 0-W

Torque t&m)

Fuel consumption (sec./l 00 cc)

Coolant temperature (“C)

Lubrication oil temperature (“C)

35.5 - 39.2

-

Min. 19.4

70 - 90

go-

70 - 90

120

-

Min. 12.2

0

0

_

70 - 90

90 - 120

_

-

0

0

-

70 - 90

Min. 90

Min. 1 .O

_

36.5 - 39.4

_

19.4 - 20.9

70 - 90

90 -

3.0 - 6.0

Max. 700 + 3t

Min. 12.2

_

70 - 90

90 - 120

_

Max. 650 + 3t

0

0

-

70 - 90

90 - 120

-

_

0

0

-

70 - 90

Min. 80

36.4 - 42.4

-

Min. 36.4

70 - 90

-

0

40.6 - 43

13.4

70 - 90

0

_

0

-

,,,I,,,

-

70 - 90 70 - 90

0

0

-

0

0

-

48.3 - 50.8

-

29.7 - 33.3

120

Min. 1 .O

-

3.0 - 6.0

Max. 700 + 3t

90 - 120

_

Max. 700 + 3t

90 - 120

-

_

Min. 80

Min. 1.0

-

90 - 120

3.5 - 6.0

Max. 700 + 3t

90 - 120

_

Max. 700 + 3t

-

_

90 -

120

70 - 90

90 - 120

70 - 90

Min. 80

Min. 1 .O

_

3.0 - 6.0

Max. 700 + 3t

_

Max. 700 + 3t

0

_

_

0

Min. 1.5

_

_

95 SERIES

15.0 :‘i’

1

37.9 T.6

’2-020-1


TESTING

Engine model

AND

ADJUSTING

PERFORMANCE

Applicable machine Flywheel D20AG, P, PG. PL, PLL-7(A) D21A, AG, PG. S, QG-7(A)

Specified value (fully equipped)

Test item

Maximum

horsepower

speed (rpm)

39.5 HP/2,450 rpm

torque

15.5 kgm/1,300

rpm

TEST

Dynamometer (kg)

2,445 - 2,455

15.9- 16.9

1,200 -

21.2 - 22.6

1,450

High idling speed

2,530 - 2,630 rpm

2,530 - 2,630

_

Low idling speed

800 - 850 rpm

800 - 850

-

55 HP/2,500 rpm

2,494 - 2,506

21.3 - 23.5

1,500 -

22.4 - 24.5

4D95S1 Flywheel Maximum

horsepower torque

16.6 kgm/1,600

rpm

1,700

WA50-I High idling speed

2,700 rpm

2,650 - 2,750

0

Low idling speed

800 rpm

800 - 860

0

Flywheel

horsepower

41 HP/2,200 rpm

1

2.195-22205

I Maximum

19 kgm/l,400

torque

rpm

1,300 - 1,500

27.0 - 28.3 0

WA40-1 High idling speed

2,400 rpm

2,350 - 2,450

Low idling speed

800 rpm

800 - 850

0

55 HP/2,200 rpm

2,195 - 2,205

25.5 - 27.0

1,400 - 1,600

28.3 - 30.4

2,320 - 2,420

0

Flywheel Maximum

horsepower torque

20.8 kgm/1,500

rpm

WA70-I High idling speed

2,370 rpm

Low idling speed

800 rpm

Flywheel

4D95L-W-I

EG33B, BS-1 Prime

horsepower

High idling speed

EG33B, BS-I Stand-by

horsepower

High idling speed Low idling speed Flywheel Maximum

800 - 850

0

I

(50 Hz) (60 Hz)

34.5 HP/l,500 rpm 41.4 HP/l ,800 rpm

1,495 - 1,505 1,795 - 1,805

22.9 - 24.3 23.2 - 24.6

(50 Hz) (60 Hz)

Max. 1,560 rpm Max. 1,872 rpm

Max. 1,560 Max. I,872

0 0

1 Low idling speed Flywheel

I

I

800 rpm

I

800 -850

1

(50 Hz) (60 Hz)

38.5 HP/l,600 rpm 45.4 HP/I ,800 rpm

1,495 - 1,505 1,795 - 1,805

(50 Hz) (60 Hz)

Max. 1,575 rpm Max. 1,890 rpm

Max. 1,575 Max. 1,890

0

25.4 - 26.8

800 rpm

horsepower torque

High idling speed Low idling speed

’*-O2O-*

95 SERIES


TESTING AND ADJUSTING

PERFORMANCE TEST

*

The values given for the output and torque are with the fan removed,

t

Values are standardized (if installed)

under the following

conditions:

so they differ from those of the specification.

Air cleaner installed;

alternator

idling; and air compressor

open.

*

Dynamometers

t

Fuel used:

ASTM

*

Lubrication

oil used:

(H+) 38.5- 40.8

are given for the case of the arm length is 716 mm. D975 No. 1 or No. 2 diesel fuel. CLASS-CD

SAEBO. Coolant temperature ('C)

1

Lubrication oil temperature ('C)

1

Lubrication oil pressure (ko/cm2)

Torque (k9m)

Fuelconsumption (sec./100cc)

_

Min.40.5

70-90

80-110

15.2- 16.2

-

70-90

80-110

-

_

-

70-90

80-

-

110

3.5- 6.0

-

70-90

52.6- 58

70-90

80-120

_

70-90

80-120

_

0

70-90

80-

-

0

70-90

42.1 - 44.7

70-80

0

0

42.1 - 58.6

-

-

20.2- 21.8

120

Min.80

Max600+3t

Min. 1.0 3.5- 6.0

Max.600 + 3t Max.650 + 3t -

Min. 1.0

80-110

3.0- 6.0

Max.600 + 3t

70-80

80-110

-

Max.650 + 3t

-

70-80

80 -110

-

-

70-80

Min.80

0

Min.80

Exhaust temperature (C) It-lntaketemo.- 2o'CI

1

-

Min.l.O

Min. 25.8

70-80

90-120

3.0- 6.0

Max.650+

3t

_

70-80

90-120

-

Max.650+

3t

-

-

0

0

-

70-80

90 -120

0

0

_

70-80

Min.80

Min. 1.0

33.8 - 35.9 41.1 - 43.6

-

70-85 70-85

80-115 80- 115

2.5- 5.0 3.0- 5.5

Max.700 + 3t Max.700 + 3t

0 0

0 0

-

70-85 70-85

80-115 80-115

_

_ -

0

0

-

70-885

Min.l.5

-

37.7 - 39.3 45.1 - 47.5

_

0 0

0 0

0

0

95 SERIES

-

Min. 46.9 Min. 39.1

Min.80

70-85 70-885

80-115 80-115

_

70-85 70-85

80-115 80-115

-

70-85

Min. 42.1 Min. 35.7

Min.80

2.5 - 5.0 3.0- 5.5 _ _ Min. 1.5

Max.700+3t Max.700+3t _ -

12-O$O-3 I


TESTING AND ADJUSTING

Engine model

PERFORMANCE TEST

Test item

Flywheel PC60-3 PC6OL-3 PC6OU-3

Maximum

horsepower torque

High idling speed Low idling speed Flywheel

PC60-5 PC6OL-5 PC6OU-5

Maximum

horsepower torque

High idling speed Low idling speed Flywheel

PC60-6 PC70-6

Maximum

horsepower torque

High idling speed Low idling speed Flywheel

PC60-7 PC70-7

Maximum

horsepower torque

High idling speed Low idling speed

Specified value (fully equipped) 44 kW (59 HP)/2,400 196 Nm (20 kgm)/1,500 2,640

rpm rpn

rpm

PC75UU-1

Maximum

horsepower torque

High idling speed Low idling speed Flywheel PC75UU-2

Maximum

torque

1,400 - 1,600

267.5 - 293 (27.3 - 29.9)

850 rpm

850 - 900 rpm

2,095 - 2,105

257.7 - 271.4 (26.3 - 27.7)

200 Nm (20.4 kgm)/1,500 rpm

1,400 - 1,600

Min. 284.2 (29.0)

40.3 kW (54 HP)/2,100

2,300

rpm

2,250 - 2,350

900 rpm

900 - 950 rpm

2,095 - 2,105

256.8 - 272.4 (26.2 - 27.8)

225.4 Nm (23 kgm)/1,500 rpm

1,400 - 1,600

Min. 319.5 (32.6)

40.3 kW (54 HPV2,lOO

2,300

rpm

2,250 - 2,350

950 rpm

950 - 1,000 rpm

1,895 - 1,905

284.2 - 300.9 (29.0 - 30.7)

225.4 Nm (23 kgm)/1,500 rpm

1,400 - 1,600

Min. 320.5 (32.7)

40.4 kW (54.2 HP)/1,900

2,050 - 2,150

rpm

2,050 - 2,150

950 - 1,000 rpm

950 - 1,000 rpm

1,895 - 1,905

264.6 - 290.1 (27.0 - 29.6)

200 Nm (20.4 kgm)/1,500 rpm

1,400 - 1,600

Min. 261.7 (26.7)

40.3 kW (54 HP)/1,900

2,100

rpm

2,050 - 2,150

950 rpm

950 - 1,000 rpm

1,895 - 1,905

264.6 - 290 (27.0 - 29.6)

225.4 Nm (23 kgm)/1,500 rpm

1,400 - 1,600

Min. 319.5 (32.6)

40.5 kW (54.2 HP)/1,900

rpm

2,050 - 2,150

Low idling speed

1,000 - 1,050 rpm

1,000 - 1,050

Maximum

horsepower torque

Low idling speed Flywheel Maximum

horsepower torque

High idling speed Low idling speed

’2-020-4

243 - 277.7 (24.8 - 26.3)

2,050 - 2,150

High idling speed

PC90-1

2,395 - 2,405

High idling speed

Flywheel

PC80-3

horsepower

Dynamometer N (kg)

2,590 - 2,690

4D95L-1 Flywheel

Engine speed (rpm)

47.8 kW (64.1 HP)/2,400

rpm

2,395 - 2,405

210 Nm (21.4 kgm)/1,600 rpm

1,500 - 1,700

2,550

rpm

2,500 - 2,600

900 rpm

268.5 - 284.2 (27.4 - 29) Min. 298 (30.4) _

900 - 950 rpm

2,295 - 2,305

278.3 - 295 (28.4 - 30.1)

225.4 Nm (23 kgm)/1,500 rpm

1,400 - 1,600

Min. 319.5 (32.6)

47.8 kW (64.1 HP)/2,300

2,475

rpm

950 rpm

2,425 - 2525 950 - 1,000

95 SERIES


TESTING AND ADJUSTING

t t + Sr *

PERFORMANCE TEST

The values given for the output and torque are with the fan removed, so they differ from those of the specification. Values are standardized under the foilowina conditions: Air cleaner installed: alternator idling; and air compressor (if installed) open. Dynamometers are given for the case of the arm length is 16 mm. Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel. Lubrication oil used: CLASS-CD SAESO.

Outupt kW (HP) 43.9 (58.8

Torque

Nm (kgm)

- 46.5 - 62.3) 192 - 210 (19.6 - 21.4)

Gel consumptior (sec./100

cc)

- 29.1

70 - 80

80 - 110

39.2

- 45.5

70 - 80

80 - 110

70 - 80

80 - 110

- 33.9

Min. 202.9 (20.7)

Min.

31.4

Min. 228.3 (23.3)

70 - 80

Min.

70 - 80

80-110

70 - 80

80 - 110

70 - 80

80 - 110

70 - 80

Min.

Min.

31.0

Min. 229.3 (23.4)

- 41.3 - 55.4)

Min.

32.3

Min. 187.2 (19.1)

90 - 120

70 - 90

90 - 120

- 41.9 - 56.2)

Min.

32.3

Min. 228.3 (23.3)

90 - 120

70 - 90

90 - 120

70 - 90

90 - 120

- 51.1 - 68.5)

25.3

- 28.4

Min. 213.6 (21.8)

Min. Min. 228.3 (23.3)

26.4

80

80 - 110

70 - 80

80 - 110

70 - 80

80 - 110 Min.

80

70 - 80

90 - 120

70 - 80

90 - 120

70 - 80

90 - 120 Min.

80

70 - 80

80 - 110

70 - 80

80 - 110

70 - 80

80 - 110

70 - 80 48.0 - 51 (64.4 - 68.3)

Min.

70 - 80

70 - 80 48.3 (64.8

80

70 - 90

70 - 80 38.3 (51.3

80

70 - 90

Min.

Min.

oil

Lubrication oil pressure MPa (kg/cm*) 0.3 - 0.6 (3.0 - 6.0)

80

70 - 90

90 - 120

70 - 90

90 - 120

70 - 90

90 - 120

70 - 90

Min.

80

Exhaust temperature (“C) [t=lntake temp. -20°C) Max.

650

+ 3t

Max.

650

+ 3t

Max.

650

+ 3t

Max.

650

+ 3t

Max.

700

+ 3t

Max.

700

+ 3t

Max.

600

+ 3t

Max.

650

+ 3t

Max.

650

+ 3t

Max.

650

+ 3t

Max.

650

+ 3t

Max.

650

+ 3t

Max.

650

+ 3t

Max.

650

+ 3t

Max.

600

+ 3t

Max.

600

+ 3t

Min. 0.1 (1.0) 0.3 - 0.6 (3.0 - 6.0)

90 - 120

70 - 90 37.7 (50.6

80

70 - 90

70 - 90 41 - 43.6 (55.0 - 58.4)

Lubrication temperature (“C)

27.5

30.1

40.4 - 43 (54.2 - 57.6)

Coolant temperature (“0

Min. 0.1 (1.0) 0.35 - 0.6 (3.5 - 6.0)

Min. 0.1 (1.0) 0.35 - 0.6 (3.5 - 6.0)

Min. 0.1 (I.01 0.3 - 0.7 (3.0 - 7.0)

0.3 - 0.7 ‘3&;.y c1:o; 0.35 - 0.7 (3.5 - 7.0)

0.35 - 0.7 (3.5 - 7.0) Min. 0.1 (1.0) 0.3 - 0.6 (3.0 - 6.0)

Min. 0.1 (I.01 0.35 - 0.6 (3.5 - 6.0)

Min. 0.1 II .O)

95 SERIES ’ 2-o:o-5


TESTING

Engine model

AND ADJUSTING

PERFORMANCE

Applicable machine

Test item

Flywheel

PW60-3

Maximum

Specified value (fully equipped)

Engine speed (rpm)

Dynamometer N (kg)

rpm

2,495 - 2,505

270.5 - 286.2 (27.6 - 29.2)

2‘15.6 Nm (22 kgm)/1,600 rprr

1,500 - 1,700

300 Min. (30.6)

419.2 kW (66 HP)/2,500

horsepower torque

thigh idling speed

2,650

Low idling speed

TEST

2,600 - 2,700

rpm

900 - 950

900 rpm -

clywheel

EC75Z. ZS-3

Vlaximum iigh

2,995 - 3,005

228.3 - 235.2 (23.3 - 24)

2 01.9 Nm (20.1 kgm)/Z,OOOrpm

1,900 - 2,100

275.4 Min. (28.1)

3 6.8 kW (49.3 HP)/2,450

rpm

2,445 - 2,455

206.8 - 217.6 (21.1 - 22.2)

171.5 Nm (17.5 kgm)/1,300 rpm

1,200 - 1,400

237.2 - 249 (24.2 - 25.4)

417.7 kW (64 HP)/3,000

horsepower torque

rpm

idling speed

_ow idling speed -lywheel

4D95L-1

D21A-7T [Trimming)

Maximum iigh

horsepower torque

idling speed

_ow idling speed

2,530 - 2,630

2,530 - 2,630

800 - 850

800 - 850

-lywheel EG40B, BS-1 ‘rime

iigh

horsepower

1:: !zi

Max. Max.

idling speed

EG40B, BS-1 Stand-by

horsepower

High idling speed Low idling speed Flywheel

PCIOO-5 PClOO-6

Maximum

horsepower torque

High idling speed Low idling speed Flywheel

S4D95L-1

PC120-5 PC120-6 PC128UU-1

Maximum

horsepower torque

High idling speed. Low idling speed Flywheel

JV7ODW-1

Maximum

horsepower torque

High idling speed Low idling speed

’2-oio-6

rpm rpm

1,560 rpm 1,872 rpm

I$

$i

(50 Hz) (60 Hz)

r5.4- 292(28.1- 29.8) ‘5.4- 291.1128.1 - 29.7)

1,560 1,872

800 - 850

35.3 (47.3 HPY1.500 41.2 (55.2 HPY1.800 Max. Max.

1,495 - 1,505 1,795 - 1,805 Max. Max.

800 rpm

LOW idling speed

Flywheel

31.6 (42.4 HP)/1,500 37.5 (50.3 HP)/l,SOO

rpm rpm

1,495 - 1,505 1,795 - 1,805 Max. Max.

1,575 rpm 1,890 rpm

07.7- 325.4131.4 - 33.2) 01.8- 319.5(30.8- 32.6)

1,575 1,890

800 rpm

800 - 850

is.9 kW (78.9 HPY2.100 rpn

2,095 - 2,105

372.4 - 395 (38.0 - 40.3)

198.5 (30.5 kgm)/1,500

1,400 - 1,600

Min. 424.3 (43.3)

2,300

rpn

rpm

2,240 - 2,360

900 rpm

900 - 950

i2.5 kW (83.8 HP)/2,200

rpn

2,195 - 2,205

378.3 - 400.8 (38.6 - 40.9)

198.5 (30.5 kgm)/1,500

rpn

1,400 - 1,600

Min. 424.3 (43.3)

2,400

rpm

2,340 - 2,460

900 rpm

900 - 950

55 kW (74 HP)/2,000

rpm

199 Nm (30.5 kgm)/1,500 rprr Max. 2,200

rpm

900 - 950 rpm

1,995 - 2,005

385 - 409 (39.3 - 41.7)

1,400 - 1,600

Min. 425 (Min. 43.3)

Max.

2,200

900 - 950

95 SERIES


TESTING

PERFORMANCE

AND ADJUSTING

TEST

* t

The values given for the output and torque are with the fan removed, so they differ from those of the specification. Values are standardized under the following conditions: Air cleaner installed; alternator idling; and air compressor

* * t

(if installed) open. Dynamometers are given for the case of the arm length Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel. Lubrication oil used: CLASS-CD SAE30.

Outupt (HP)

kW

Torque

Nm (kgm)

50.7 - 53.7 (68 - 72) Min. 316.5 (Min. 32.2)

:uelconsumption (sec./100cc)

Coolant temperature ("C)

23.4 - 26.2

70 - 80

80-110

Min. 37.4

70 - 80

80-

110

70-80

80-

110

70-80 51.4 - 53 (68.9 - 71) Min. 197 (Min. 20.1)

37.8 - 40.1 (50.7- 53.7)

80-

38 - 43

70-80

80 - 110

70-80

80-110

Min. 42.1 Min. 36.5

-

Min. 37.7 Min. 32.3

_ Min. 22.9 Min. 303.6 (Min. 31.0)

62.4 - 66.2 (83.7 - 88.7)

Min. 21.1 Min. 303.6 (Min. 31.0)

Min. 22.1 Min. 306 (Min. 31.2)

0.3 - 0.6 (3.0- 6.0)

0.3 - 0.6 (3.0- 6.0)

70-90

90 - 120

70-90

90 - 120

70-90

Min. 80

70-85 70-85

8080-

115 115

70-85 70-85

8080-

115 115

80-115 80-115

70-85 70-85

80-115 80-115 Min. 80

70-

80

80-110

70-

80

80-110

70-

80

80-110

70-

80

Min. 80

70- 80

80-

110

70 - 80

80-

110

70-80

80-

110

Min. 80

70-90

80-

120

70-90

80 - 120

70-90

80 - 120

70-90

Min. 80

Max.650 Max.650

90 - 120

70-85 70-85

Max.650

Min. 0.1 (Min. 1.0)

70-90

Min. 80

Exhaust temperature ("C) :=lntake temp. -20°C)

Max.650

Min. 0.1 (Min. 1.0)

70-80 57.7 - 61.4 (77.4- 82.3)

0.3 - 0.6 (3.0- 6.0)

Min. 80

70-80

58.7 - 62.2 (78.7- 83.4)

110

Lubrication oil pressure MPa (kg/cm*)

70-80

70-80 34.6 - 36.6(46.4 - 49.11 37 - 43.1(49.6 - 57.8)

Min. 80

70-80

Min. 33.3

-

Lubrication oil temperature ("0

23-28

169.5 - 178.4 (17.3- 18.2)

31- 32.9(41.5 - 44.11 37.2 - 39.2(49.8 - 52.6)

is 716 mm.

Max.650 Max.650

Min. 0.1 (Min. 1.0) 1.25 - 0.5(2.5- 5.0 1.3 - 0.55(3.0- 5.5

Max.700 Max.700

Min. 0.15 (Min. 1.5) 1.25 - 0.5(2.5- 5.0 I.3 - 0.55(3.0- 5.5

Max.700 Max.700

Min. 0.15 (Min. 1.5) 0.35 - 0.4 (3.5- 6.0)

Max. 650 Max.650

Min. 0.1 (Min. 1.0) 0.35 - 0.6 (3.0- 6.0)

Max. 650 Max.650

Min. 0.1 (Min. 1.0) 0.34 - 0.69 (3.5- 7.0)

_ Max.650 _

Min. 0.1 (Min. 1.0)

-

95 SERIES

1 ’ 2-oio-7


TESTING AND ADJUSTING

Engine model

PERFORMANCE TEST

Applicable machine

Test item

Flywheel Maximum

horsepower torque

I

Specified value (fully equipped)

Engine speed @pm)

Dynamometer (kg)

70 HP/Z,350 rpm

2,345 - 2,355

29.6 - 31.3

1,300 -

38.0 - 40.0

26.6 kgm/l,400

rpm

1,500

D31A, P, S, Q-18 High idling speed

2,700 rpm

2,600 - 2,700

0

Low idling speed

700 rpm

700 - 750

0

70 HP/Z,350 rpm

2,345 - 2,355

29.6 - 31.2

1,300 -

38.0 - 39.9

Flywheel D31 E, P, PL, PLL, S, Q, AM, SM-20(A)

Maximum

27.0 kgm/l,400

rpm

1,500

2,535 - 2,635 rpm

2,535 - 2,635

_

Low idling speed

700 - 750 rpm

700 - 750

-

80 HP/2,500 rpm

2,495 - 2,505

31.7 - 33.6

1,300 - 1,500

37.6 - 39.8

Maximum

horsepower torque

27.5 kgm/1,400

rpm

High idling speed

2,750 rpm

2,650 - 2,750

0

Low idling speed

700 rpm

700 - 750

0

80 HP/2,500 rpm

2,495 - 2,505

31.7 - 33.6

1,300 - 1,500

37.6 - 39.8

Flywheel Maximum 6D95L-1

torque

High idling speed

Flywheel D37A-2 D37P-2A

horsepower

horsepower torque

27.5 kgm/l,400

rpm

D37E, P-5(A) High idling speed

2,650 - 2,750 rpm

2,650 - 2,750

Low idling speed

700 - 750 rpm

700 - 750

79 HP/2,100 rpm

2,095 - 2,105

Flywheel PC1 00-3 PC1 OOL-3 Pc1oou-3

Maximum

horsepower torque

30.5 kgm/1,400

rpm

1,300 -

1,500

38.9 - 41 .I Min. 43.4

High idling speed

2,300 rpm

2,250 - 2,350

0

Low idling speed

850 rpm

850 - 900

0

85 HP/2,200 rpm

2,195 - 2,205

39.3 - 41.6

1,300 - 1,500

Min. 43.4

Flywheel Maximum

horsepower torque

31.5 kgm/1,400

rpm

PC1 20-3 High idling speed

2,400 rpm

2,350 - 2,450

0

Low idling speed

850 rpm

850 - 900

0

87 HP/2,400 rpm

2,395 - 2,405

37.9 - 40.1

1,500 - 1,700

Min. 43.3

Flywheel Maximum

horsepower torque

32 kgm/l,600

rpm

PWI 50-I

’2-20-8

High idling speed

2,650 rpm

2,645 - 2,655

0

Low idling speed

850 rpm

850 - 900

0

95 SERIES


TESTING AND ADJUSTING

PERFORMANCE TEST

*

The values given for the output and torque are with the fan removed,

*

Values are standardized

under the following

conditions:

so they differ from those of the specification.

Air cleaner installed;

alternator

idling; and air compressor

(ifinstalled)open.

*

Dynamometers

*

Fuel used:

ASTM

are given for the case of the arm length is 716 mm.

*

Lubrication

oil used:

D975 No. 1 or No. 2 diesel fuel. CLASS-CD

output (HP)

Torque (kgm)

68.5 - 72.5

-

-

SAE30.

Fuel consumption (sec./100cc) Min.24.3

Coolant temperature ("C) 70-

80

27.2- 28.6

-

0

0

_

70-80

0

0

-

70-80

68.5 - 72.5

-

Min. 23.8

70-

80

Lubrication oil temperature ('C) 90 -110

Lubrication oil pressure (kg/cm?)

Exhaust temperature ("C) (t=lntaketemp.- 20°C)

3.5 - 7.0

Max.650 + 3t

90 -110

_

90-110

-

Min. 80

70- 90

90-110

Max.650 + 3t -

Min. 1.0 3.5- 6.0

Max.650 + 3t

_

27.2- 28.6

_

70-

90

90-110

-

_

0

0

-

70-

90

90-110

_

-

0

0

_

70-90

Min.l.O

_

78.1 - 82.8

-

3.5- 7.0

Max.650 + 3t

_

26.9- 28.5

Min. 21.2 _

70-80 70-80

0

-

70- 80

0

0

_

70- 80

78.1 - 82.8

_

0

-

Min. 20.7

80-

95

Min. 90 80-110 80 -110

-

80-110

_

Min.80 80-110

26.9 - 28.5

-

80-

95

80-

0

0

-

80-

95

80-110

0

0

-

80-

95

80.5- 85.2

_

3.5 - 6.0

Max.600 + 3t

_

-

_

_

Min. 1.0 3.5- 6.0

80-110

28.9- 32.8

70- 80

80-110

-

80-110

_

_

Min.l.5

-

0

0

_

70-

80

0

0

-

70-

80

85.2 - 90.3

_

70-

80

18.6- 22.3 28.9 - 32.8

0

0

_

0

0

_

84.2- 89.3

_

17.3- 20.5

70-80 70-80 70-80 70-80

-

31.0 - 33.0

0

0

-

70-80

0

0

_

70-80

95 SERIES

Min.l.5

70- 80

Min. 31.1

Min. 31.1

Min.80

25.4- 28.8

70-

80

Min. 80 80-110

3t

_

19.8- 23.6

-

-

110

Max.650+

3.5- 6.0

Max.650 + 3t Max.650+

3t

Max.650 + 3t

80-110

_

Max.650 + 3t

80-110

-

-

Min. 80 80-110

Min 1.5 3.5 - 7.0

Max.650 + 3t

80-110

_

Max.650 + 3t

80-110

_

_

Min.80

Min 1.5

’2-020-9


TESTING

AND

Engine model

ADJUSTING

PERFORMANCE

Applicable machine

Test item

Flywheel horsepower WAIOO-1

Maximum torque

WRll-1

WAIOO-1 (Engine No. 46799 and up)

Specified value (fully equipped)

Engine speed frpm)

Dynamometer (kg)

73 HP/2,400 rpm

2,395 - 2,405

31.4 - 33.3

1,500 - 1,700

39.8 - 44.0

2,395 - 2,405

35.9 - 38.0

1,500 - 1,700

44.0 - 48.1

29 kgm0.600

rpm

High idling speed

2,650 rpm

Low idling speed

800 rpm (EngineNo. upto 25582) 700 rpm (EngineNO. 25583 and up)

Flywheel horsepower

84 HP/2,400 rpm

Maximum torque

TEST

32 kgm/l,600

rpm

High idling speed

2,650 rpm

2,600 - 2,700

0

Low idling speed

700 rpm

676 - 724

0

85 HPI2.500 rpm

2,495 - 2,505

35.5 - 37.5

1,400 - 1,600

43.6 - 46.3

Flywheel horsepower Maximum torque High idling speed Low idling speed Flywheel horsepower Maximum torque 6D95L-1

31.7 kgm/l,500

rpm

GD313A-1 High idling speed

2,750 rpm

2,700 - 2,800

0

Low idling speed

800 rpm

750 - 850

0

I

EGGOB, BS-1 Prime

I

(50 Hz) (60 Hz)

65.1 HP/l,500 rpm 74.9 HP/l ,800 rpm

1,495 - 1,505 1,795 - 1,805

44.0 - 46.6 42.6 - 45.2

High idling speed

(50 Hz) (60 Hz)

Max. 1,560 rpm Max. 1,872 rpm

Max. 1,560 Max. 1,872

0 0

800 rpm

800 - 850

0

Flywheel horsepower

(50 Hz) (60 Hz)

72 HP/l,500 rpm 82.8 HP/l ,800 rpm

1,495 - 1,505 1,795 - 1,805

48.6 - 51.4 46.9 - 49.7

High idling speed

(50 Hz) (60 Hz)

Max. 1,575 rpm Max. 1,890 rpm

Max. 1,575 Max. 1,890

0 0

800 rpm

800 - 850

0

Low idling speed

12-0~0-10 i

I

Flywheel horsepower

Low idling speed

EGGOB, BS-1 Stand-by

I

95 SERIES


TESTING

AND

*

The values

*

Values

ADJUSTING

PERFORMANCE

given for the output

are standardized

(if installed)

under

and torque the following

are with

the fan removed,

conditions:

Air cleaner

so they differ installed;

those

of the specification.

idling;

and air compressor

open.

*

Dynamometers

*

Fuel used:

ASTM

*

Lubrication

oil used:

are given

for the case of the arm length

is 716 mm.

D975 No. 1 or No. 2 diesel fuel. CLASS-CD

Output U-W

Torque ikim)

74.2 - 78.8

-

SAE30.

Fuel consumption (sec.000 cc) Min. 22.8

Coolant temperature ("C) 70-

Lubrication oil temperature ("C~

80

80-110

-

28.5- 31.5

-

70- 80

80-110

0

0

-

70-

80-110

0

0

_

70-80

84.8 - 89.9

-

-

31.5 - 34.5

0 0

87.6 - 92.5

from

alternator

TEST

Min. 19.2

80

80-115

_

70-80

80-115

0

-

70-80

80-115

0

_

70 - 80

Min. 19.5

70- 80

80-115

-

I

-

I

Min.80

-

31.2- 33.2

-

70-80

80-115

0

0

_

70- 80

80-115

0

0

-

70-

80

1

Exhaust

Min. 80

70- 80

-

Lubricarion oil

Min. 80

Min. 1.5

_

_

I

65.1 - 68.9 75.5 - 80.2

Min. 27.4 Min. 23.8

7070-

85 80

0 0

_

70-885 70-85

0

-

70-85

71.9- 76.0 84.4 - 88.4

Min. 24.8 Min. 21.6

80-115 80.- 115

80-115 80-115 80-115 80-115

_ -

70- 85 70- 85

0

-

70-

85

-

_

_

-

Min.1.5

_

Min. 80

70-85 70-85

0 0

95 SERIES

80-115 80-115

Min. 80

12-0~0-11 ./


TESTING AND ADJUSTING

PERFORMANCE TEST

Engine model

Specified value (fully equipped) Flywheel

PC150-3

Maximum

horsepower

1Low

torque

idling speed

Flywheel

PC1 50-5

Maximum

1Low

I

horsepower

Flywheel PC200-5 BR200-1

Maximum

I

PC200-6

Maximum

Min. 551.7 (56.3)

1,995 - 2,005

392 Nm (40 kgm)/1,400 rpm

1,300 - 1,500

Min. 262.5 (57.4)

rpm

2,150 - 2,250

900 rpm

17;;:; I ;;f;F

475.3 Nm (48.5 kgmV1.500

1,400 - 1,600

657.6 - 697.8 (67.1 - 71.2)

2,260

2,210 - 2,310

rpm

rpm

900 rpm rpm

490 Nm (50 kgmV1.600 rpm 2,360 - 2,480

Maximum

torque

High idling speed Low idling speed Flywheel

Maximum

horsepower

torque

High idling speed Low idling speed

I

I

-

875 - 925

99.3 kW (133.1 HP)/2,200

rpm

2,195 - 2,205

617.4 - 651.7 (63.0 - 66.5) 682 - 722.3 (69.6 - 73.7)

1,500 - 1,800 2,360 - 2,480 975 - 1,025

rpm

411.6 Nm (42 kgm)/1,400 rpm

horsepower

-

2,045 - 2,055

torque

idling speed

1

rpm

975 - 1,025 rpm

Flywheel

850 -900

504.7 - 534.1 (51.5 - 54.5)

73.9 kW (99 HP)/1,900

1Low

’*-OiO-’ *

1

850 rpm

2,100

LW80-1

2,350 - 2,450

1

) PWIOO-3 (Engine No. 36830 and up)

rpm

91.8 kW (123 HP)/2,050

High idling speed

S6D95L-1

1,300 - 1,500

900 - 950

Low idling speed horsepower

372.4 Nm (38 kgm)/1,400 rpm

I

High idling speed

Flywheel

451.8 - 479.2 (46.1 - 48.9)

2,200

horsepower torque

2,195 - 2,205

73.7 kW (99 HP)/2,000

torque

idling speed

rpm

2,400

High idling speed

I

Dynamometer N (kg)

73.9 kW (99 HP)/2,200

High idling speed

I

Engine speed (rpm)

rpm

1,895 - 1,905

515.5 - 546.8 (52.6 - 55.8) Min. 583.1 (59.5)

1,300 - 1,500 2,050 - 2,150

850 rpm

850 - 900

I

-

rpn

2,095 - 2,105

529.2 - 559.6 (54.0 - 57.1)

411.6 Nm (42 kgm)/1,400 rpm

1,300 - 1,500

Min. 589 (60.1)

80.9 kW (108.5 HP)/2,100

2,400

rpm

2,350 - 2,450

850 rpm

850 - 900

110.4 kW (148 HP)/3,000

rpm

435 Nm (44.4 kgm)/1,800 rpm 3,400 - 3,500

rpm

700 - 800 rpm

2,995 - 3,005

1,700

-

1,900

474.3 - 502.7 (48.4 - 51.3) 594.9 - 629.2 (60.7 - 64.2)

3,400 - 3,500 700 - 800

95 SERIES


PERFORMANCE TEST

TESTING AND ADJUSTING

+ * Ir Ir *

The values given for the output and torque are with the fan removed, so they differ from those of the specification. Values are standardized under the following conditions: Air cleaner installed; alternator idling; and air compressor (if installed) open. Dynamometers 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.

Outupt kW (HP)

Torque

Nm

(kgm)

74.6 - 79.1 (100-106)

:uelconsumption (sec./100cc) Min. 17.0

394.9 (40.3)

Coolant temperature ("C1 70-80

80-110

70-80

80-110

70-80

80-110

70-80 75.8 - 80.2 (101.6 - 107.5)

Min. 17.2 402.8 (41.1)

Min. 14.7 470 - 499.6 (48.0- 51.0)

80-110

70-80

80-110

70-80

80-110

Min. 12.5 488 -517.4 (49.8- 52.8)

80-110

70-80

80-110

70-80

80-110

73.6 - 78 (98.6- 104.5) 417.5 (42.6)

83.4 - 88.3 (111.8- 118.3)

go-

110

70-80

go-

110

70-80

90-110

70-80

80-

110

21.4 - 22.7

70-80

80-

110

70-80

80-

110

Min. 421.4 (43.0)

70-80

Min. 80

70-80

80 - 110

70-80

80-110

70-80

80-110

70-80 106.7- 113.2 (143- 151.8)

Min. 10.2 425-450.8 (43.4 - 46.0)

95 SERIES

Min. 80

17.2 - 18.3

Min. 15.5

0.3 - 0.7 (3.0- 7.0)

Max.650

+ 3t

Max.650

+ 3t

Min. 0.15 (1.5) 0.35 - 0.7 (3.5- 7.0)

Max. 650 + 3t Max. 650 + 3t

1

Max.650

+ 3t

Max.650

+ 3t

Max.650

+ 3t

Min. 80

70-80

70-80

Lubrication oil Exhaust pressure temperature ("0 MPa (kg/cm21 (t=lntaketemp.-20T)

Min.80

70-80

70-80 101.9 - 107.7 (136.6 - 144.4)

Min. 80

70 -80

70-80 89.4 - 94.5 (119.9 - 126.7)

Lubrication oil temperature ("C)

Min. 0.1 (I.01 0.35 - 0.7 (3.5- 7.0)

-i&j-+ Max. 650 + 3t

Min. 80

70-90

go-

70-90

90 - 110

70-85

90 - 110

70-85

Min. 80

110 0.35 - 0.7 (3.5- 7.0)

Max. 650 + 3t

Min. 0.1 (1.0)

’2-o%-’ 3


PERFORMANCE TEST

TESTING AND ADJUSTING

Engine model

Applicable machine Flywheel WA150-1 (Engine No. up to 47624)

I

WAl50-1 (Engine No. 47625 and up)

Specified value (fully equipped)

Test item

Maximum

horsepower

70.1 kW (94 HP)/2,400 rpm

torque

352.8 (36 kgm)/1,600

2,395 - 2,405

I

Maximum

horsepower

392 (40 kgm)/1,600 rpm

torque

I 1,500 - 1,700

2600 - 2700 rpm

2,600 - 2,700

Low idling speed

675 - 725 rpm

675 - 725

84.3 kW (113 HP)/2,500 rpm

2,495 - 2,505

800 rpm

800 - 850

(50 Hz) (60 Hz)

64 kW (85.8 HP)/1,500 rpm 74 kW (99.6 HP)/1,800 rpm

1,495 - 1,505 1,795 1,805

(50 Hz) (60 Hz)

Max. 1,560 rpm Max. 1,872 rpm

Max. 1,560 Max. 1,872

horsepower

High idling speed

horsepower

High idling speed

Fh’whee’ horsepower

High idling speed

I

horsepower

High idling speed Low idling speed

800 rpm

1

800 - 850

(50 Hz) (60 Hz)

71.4 kW (95.7 HP)/1,500 rpm 83.1 kW (111.4 HP)/1,800 rpm

1,495 - 1,505 1,795 1,805

(50 Hz) (60 Hz)

Max. 1,575 rpm Max. 1,890 rpm

Max. 1,575 Max. 1,890

800 rpm

800 - 850

(50 Hz) (60 Hz)

64 kW (85.8 HP)/1,500 rpm 74.3 kW (99.6 HP)/1,800 rpm

1,495 - 1,505 1,795 1,805

(50 Hz) (60 Hz)

Max. 1,560 rpm Max. 1,872 rpm

Max. 1,560 Max. 1,872

800 rpm

800 - 850

(50 Hz) (60 Hz)

71.3 kW (95.6 HP)/1,500 rpm 83.1 kW (111 HP)/1,800 rpm

1,495 - 1,505 1,795 1,805

(50 Hz) (60 Hz)

Max. 1,575 rpm Max. 1,890 rpm

Max. 1,575 Max. 1,890

800 rpm

450 - 500

I

Low idling speed F’ywhee’

456.7 - 482.2 (46.6 49.2)

I- 538 - 570.4 (54.9 - 58.2)

High idling speed

Low idling speed

’2-020-’ 4

485.1 - 514.5 (49.5 - 52.5)

1,700

80.9 kW (108.5 HP)/2400 rpm

Ffywhee’

DCA85 QAS85 (At rated outupt)

-

1,500

Flywheel

1 Low idling speed

(At rated output)

396.9 - 419.4 (485.1 514.5)

2,600 - 2,700 800 - 850 675 - 725

Ffywheef horsepower

EG85B, BS-1 Stand-by

2,395 - 2,405

2,650 rpm 800 rpm (Engine No. up to 23242) 700 rpm (EngineNo. 23243and up)

Low idling speed

EG856, BS-1 Prime

Dynamometer N (kg)

High idling speed Low idling speed

Flywheel

S6D95L-1

rpm

Engine speed hx-n)

456.7 - 484.1 (46.6 49.4)

556- 589(56.7 - 60.1) 541 574(55.2 58.61

1

-

621.3 (63.4 -- 67.21 -- 658.6 604.7641(61.7 65.4)

I

-

555.7 - - 589156.7 - 60.1) 541 574.3 (55.2 58.61

621- 659(63.4- 67.2) 605 641(61.7 65.4)

95 SERIES


TESTING

* t t * *

AND ADJUSTING

PERFORMANCE

TEST

The values given for the output and torque are with the fan removed, so they differ from those of the specification. Values are standardized under the following conditions: Air cleaner installed: alternator idling; and air compressor (if installed) open. Dynamometers 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.

Outupt kW (HP)

Torque Nm (kgm)

71.4 - 75.7 (95.7 - 101.5) 347 - 368.5 (35.4 - 37.6)

82.1 - 87.0 (110.1 - 116.6)

:uel consumption (sec./l00 cc)

Coolant temperature (“C)

Lubrication oil temperature 1°C)

Lubrication oil pressure MPa (kg/cm*)

Exhaust temperature (“0 t=lntaketemp. -20°C)

17.4 - 18.6

70 - 80

80 - 110

0.35 IO.7 (3.5 - 7.0)

Max. 650 + 3t

21.5 - 22.9

70 - 80

80 - 110

70 - 80

80 - 110

70 - 80

Min. 80

Min. 0.1 (1.0)

70-80

90 - 110

0.35 - 0.7 (3.5- 7.0)

70-80

90 - 110

70-80

90 - 110

70-80

Min. 80

Min. 0.1 (1.0)

11.2 - 14.0

70-80

80 - 110

0.35 - 0.7 (3.5 - 7.0)

16.7 - 21.0

70-80

80-

Min. 15.3 385.1 - 408.7 (39.3 - 41.7)

85.7 - 90.9 (114.9 - 121.8) 407.7 - 434.1 (41.6- 44.3)

62.5 - 66.2(83.8 - 88.8 73.0 - 77.5 (97.9 - 103.9

70.0- 74.2(93.8 - 99.4 81.6 - 86.5(109.4 - llf

62.5 - 66.2(83.8 - 88.8 73.1 - 77.5 (97.9 - 103.9

70.0- 74.2(93.8 - 33.4 61.6 - 86.6 1109.4 - 116.1

95 SERIES

Min. 20.8 Min. 17.9

Min. 18.7 Min. 16.0

Min. 20.8 Min. 17.9

Min. 18.7 Min. 16.0

Max. 650 + 3t

110

Max. 650 + 3t

Max. 650 + 3t Max. 650 + 3t

Min. 80

Min. 0.1 (1.0)

70-85 70-85

80 - 115 80 - 115

I.3 - 0.55(3.0- 5.5 I.3 - 0.55(3.0- 5.5

70-85 70-85

80 - 115 80 - 115

_

70-85

Min. 80

Min. 0.15 (1.5)

70-85 70-85

80 - 115 80 - 115

I.3 - 0.55 (3.0 - 5.5 I.3 - 0.55 (3.0 - 5.5

Max. 700 + 3t Max. 700 + 3t

70-85 70-85

80 - 115 80 - 115

70-85

Min. 80

70-85 70-85

80-115 80- 115

1.3 - 0.55(3.0- 5.5 I.3 - 0.55(3.0- 5.5

Max. 700 + 3t Max. 700 + 3t

70-85 70-85

80 - 115 80-115

70-85

Min. 80

70-85 70-85

80-115 80-115

70-85 70-85

80-115 80 - 115

70-85

Min. 80

Max. 700 + 3t Max. 700 + 3t

Min. 0.15 (1.5) 1.3 - 0.55(3.0- 5.5 1.3 - 0.55(3.0- 5.5

Max. 700 + 3t Max. 700 + 3t

12-030-15


TESTING AND ADJUSTING

Applicable machine

PERFORMANCE TEST

Test item

Flywheel Maximum

horsepower torque

VA1 80-3 High idling speed Low idling speed Flywheel

VA250-3

S6D95L-1

Maximum

horsepower torque

High idling speed Low idling speed Flywheel Maximum

Specified value (fully equipped) 32.0 kW (110 HP)/2,400 (Net)

rpr

417 Nm (42.5 kgm)/1,600 rpn (Net) 2,600 - 2,700

lynamometer N (kg)

2,395 - 2,405

456 - 484 (46.5 - 49.4)

1,500 - 1,700

595 - 672 (60.7 - 68.5)

2,600 - 2,700

rpm

750 - 850 rpm

750 - 850

37.0 kW (130 HP)/2,400 (Net)

rpr

441 Nm (45.0 kgm)/1,600 (Net)

wn

2550 - 2,650

Engine speed (rpm)

rpm

2,395 - 2,405

521 - 548 (53.1 - 55.9)

1,500 - 1,700

610 - 644 (62.2 - 65.7)

2,550 - 2,650

750 - 850 rpm

750 - 800

horsepower torque

High idling speed Low idling speed ‘C220-5 With air to air aftercooler) !R300-1 With air to air aftercooler)

Flywheel Maximum

torque

High idling speed Low idling speed Flywheel

‘C220-6 With air to air aftercooler)

horsepower

Maximum

horsepower torque

High idling speed Low idling speed

2,195 - 2,205

648 - 670 (66.1 - 70.4)

1,400 - 1,600

713 - 757 172.7 - 77.2)

118 kW (158 HPV2.300 rpn (Net)

2,295 - 2,305

661 - 703 (67.4 - 71.7)

554 Nm (56.5 kgm)/1,600 rpn (Net)

1,500 - 1,700

750 - 797 (76.5 - 81.3)

114 kW (153 HP)/2,200 (Net)

rpn

527 Nm (53.7 kgmU1.500 rprr (Net) 2,355 - 2,475

rpm

925 - 975 rpm

2,470 - 2,590

rpm

975 - 1,025 rpm

2,470 - 2,590 975 - 1,025

SA6D95L-1 Flywheel Maximum

horsepower torque

High idling speed Low idling speed Flywheel Maximum

horsepower torque

High idling speed Low idling speed

Note:

The SA6D95L engine for the PC220-5 and PC220-6 are equipped with an air-cooled aftercooler, which is installed at the front of the radiator. When carrying out an outupt performance test on the engine as an individual part, install the radiator and air-cooled aftercooler to a stand in the same way as when carrying out a test with the engine installed on the machine, and run with the fan equipped.

12-030- 16

95 SERIES


TESTING

AND ADJUSTING

PERFORMANCE

TEST

Sr *

The values given for the output and torque are with the fan removed, so they differ from those of the specification. Values are standardized under the following conditions: Air cleaner installed; alternator idling; and air compressor

Ir li *

(if installed) open. Dynamometers 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 SAESO. Flywheel horsepower kW (HP)

Torque Nm (kgm)

82.0 - 87.1 (110 - 117)

:uel consumption (sec./100 cc) Min. 14.2

411 - 436 (41.9 - 44.5)

93.6 - 98.8 (125 - 132)

Min. 12.8 373 - 392 (38.0 - 40.0)

107 - 114 (144 - 153) 107 - 114

Min. 11.6 511 - 542 (52.1 - 55.3)

114 - 121 (153 - 163)

Min. 11.0 537 - 570 (54.8 - 58.2)

95 SERIES

Coolant temperature (“C)

Lubrication oil temperature (“C)

Lubrication oil pressure kPa (kg/cm?

70 - 80

90 - 110

0.35 - 0.71 (3.5 - 7.0)

70 - 80

90 - 110

0.35 - 0.71 (3.5 - 7.0)

70 - 80

90 - 110

70 - 80

Min. 80

Min. 0.1 (Min. 1.0)

82 - 95

90 - 120

0.35 - 0.71 (3.5 - 7.0)

82 - 95

90 - 120

82 - 95

90 - 120

82 - 95

90 - 120

70 - 80

80-

110

70 - 80

80-

110

70 - 80

80 - 110

70 - 80

Min. 80

Min. 0.1 (Min. 1.0)

70 - 80

90 - 110

0.35 - 0.70 (3.5 - 7.0)

70 - 80

90 - 110

70 - 80

90 - 110

70 - 80

90 - 110

Exhaust temp(er$ure) 0 Max. 650

Max. 650 Max.

650

Max.

650

Min. 0.1 (Min. 1.0)

0.35 - 0.60 (3.5 - 6.0)

Max. 650

Max.

650

Max.

650

Min. 80

’*-OF’ 7 1


PERFORMANCE TEST

TESTING AND ADJUSTING

Specified

Test item Flywheel WING100 (LWIOO-1, LWlOOM-I)

Maximum

horsepower

. 118 kW {I58

torque

57 Nm i46.6

High idling speed

Flywheel Maximum

HPY3.000 (Net) kgm}/1,800 (Net)

3,400 - 3,500

Low idling speed

Engine speed (rpm)

value rpm

rpm

rpm

Dynamomete (N {kg})

2,995 - 3,005

487 - 520 149.7 - 53.0) (Gross) 447 - 507 148.3 - 51.71 (Net)

1,700 - 1,900

624 - 672 (63.6 - 68.5) (Gross) 619 - 668 (63.1 - 68.1) (Net)

3,400 - 3,500

750 - 800 rpm

750 - 800

horsepower torque

High idling speed Low idling speed Flywheel

Maximum

horsepower

torque

High idling speed Low idling speed Flywheel Maximum

horsepower toraue

SAA6D95LE-1 High idling speed Low idling speed

I

I

I

Long time flywheel horsepower Normal flywheel

horsepower

High idling speed Low idling speed Rated flywheel

horsepower

Maximum flywheel horsepower High idling speed

I

Low idling speed Flywheel

Maximum

horsepower

torque

High idling speed Low idlina speed

’2-oio-’ *

95 SERIES


TESTING

AND ADJUSTING

PERFORMANCE

TEST

* Sr

The values given for the output and torque are with the fan removed, so they differ from those of the specification. Values are standardized under the following conditions: Air cleaner installed; alternator idling; and air comoressor

It * t

(if installed) open. Dynamometers are given for the case of the arm length Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel. Lubrication oil used: CLASS-CD SAE30.

Flywheel horsepower (kW {HP}) 110 - 117 1147- 157) (Gross) 107 - 114 1143 - 153) (Net)

Torque (Nm Ikgm})

:uel consumption (sec./lOOcc)

-

Min. 10.5

446- 481145.5 - 43.11 IGros

is 716 mm.

Coolant temperature (“C)

Lubrication tmperature

82 - 95

90 - 120

82 - 95

90 - 120

a2 - 95

90 - 120

82 - 95

90 - 120

oil (“C)

Lubrication oil pressure (kPa {kg/cm% 340 - 590 13.5 - 6.0)

Exhaust emperature (“0 Max.

700

Max.

650

443-47914% WlNel

95 SERIES

340 - 590 {3.5 - 6.0)

12-030-19 @



TESTING AND ADJUSTING

TESTING AND ADJUSTING

TESTING

AND ADJUSTING

TOOL LIST

TOOL LIST Part No. 799-203-8001

Remarks Digital

reading:

L: 60 - 2,000 rpm H: 60 - 19,999 rpm

799-203-8000 6210-81-4111 1.100 - 1.300 Battery

coolant

795-500-1001

tester

-5 - -50°C

799-101-1500

-99.9

- 1,299”C

0 - 2 MPa (0 - 20 kg/cm? 0 - 4.9 MPa (0 - 50 kg/cm? Engine

pressure

799-203-2000

0 - 1,000 mmHg 0 - 500 mmH,O -100

Compression

gauge

kii

- 0 mmH,O

795-502-1205 - 795-502-1380 (Direct injection 1 0 - 6.9 MPa (0 - 70 kg/cm? 795-502-1370 (Swirl chamber) l

799-201-1504

0 - 500 mmH,O

795-114-1370

0.35,

799-201-9000

Dirtiness 0 - 70% with standard color (Dirtiness % x l/IO = Bosch scale)

799-201-6000

Provided with 0.1 and 0.2 water content standard sample

Commercially available

0 - 29.4 MPa (0 - 300 kg/cm?

799-202-7001

PH, nitrite

799-202-9001

0 - 0.2 MPa (0 - 2 kg/cm*)

Anemometer

799-202-2001

1 - 40 m/s

Cranking

795-61 O-l000

Engine

Nozzle holder ,7

Fuel injection condition

nozzle spray

18

Coolant

19

Pressure

valve

20

Leakage

in cooling

21

Radiator

blockage

22

Engine

Water quality

quality

95 SERIES

ion concentration

function Radiator

cranking

tester

0.50 mm

cap tester

system

kit

with

DC 24 V starting

motor

’2-oio-21


TESTING

AND ADJUSTING

TESTING

TESTING AND ADJUSTING Engine

Applicable

DATA

DATA

model

machine

AND ADJUSTING

3D95SW-1

PC40-5 PC40-6

model

PC5OUU-1

T

Condition,

Item

Engine

Unit

etc.

Standard value

Permissible value

Standard value

Permissible value

High idling speed

rpm

!,750 - 2,850

,750 - 2,850

!,650 - 2,750

1,650 - 2,750

Low idling speed

rpm

950 - 1,000

950 - 1,000

950 - 1,000

950 - 1,000

rpm

Min. 150

speed

0°C (without

starting

aid)

Min. 150

Necessary starting speed -20°C

(with starting

aid)

rpm

Intake resistance

All speed

mmH,C

intake pressure

At rated output

mmHg

Exhaust pressure (Turbine inlet pres.)

At rated output

mmHg

Exhaust temperature (Turbine inlet temp.)

All speed (Intake air temp.:

“C

20°C)

Quick acceleration (Low idling + High idling) Exhaust

gas color

Bosch scale

At rated output

Min. 100 Max.

Min. 100

300

762

Max. 300

762

Max. 650

700

Max. 650

700

Max.

4.0

6.0

Max.

4.0

6.0

Max.

1.5

2.5

Max.

1.5

2.5

At high idling Valve clearance (When engine is hot or cold) Compression (SAE30) Blow-by (SAE30)

pressure

pressure

Oil pressure (Oil temperature: Min. 80°C)

Intake valve

Exhaust

mm

mm

valve

Oil temperature: 40 - 60°C (Engine speed: 320 - 360 rpm

MPa (kg/cm’

Min. 2.9 (Min. 30)

2.1 (21)

Min. 2.9 (Min. 30)

At rated output Water temperature:

mmH,C

Max.

200

Max.

100

MPa (kg/cm’ MPa (kg/cm’ MPa (kg/cm’ MPa (kg/cm’

0.3 (3.0 0.3 (3.0

0.07 (0.7)

0.3 (3.0 0.3 (3.0 Min. (Min.

0.6 6.0) 0.55 5.5) 0.1 1.0)

Min. 70°C

At rated output

(SAE 30)

At rated output

(SAE IOW)

At low idling (SAE 30) At low idling (SAE 1OW)

Oil temperature Oil consumption Fuel injection

Ir

ratic

pressun

100

- 0.6 - 6.0) - 0.55 - 5.5)

Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8)

Min. 0.08 (Min. 0.8) 80 - 110

All speed (oil in oil pan)

“C

80 - 110

At continuous rated output (Ratio to fuel consumption)

%

Max. 0.5

MPa (kg/cm;

Nozzle tester

Fuel injection timing

B.T.D.C.

Radiator pressure valve

Opening pressure (Differential pressure)

Fan speed

At rated engine

Fan belt tension (Alternator to fan pulley

Deflects when pushed a force of 6 kg

with

11.8+‘.3(120”3 +0.5 5 l

10.1 (103)

Max. 0.5 10.1 (103) 11.8+'~3(120+'3 +0.5 5 I

18 + 1

18 + 1

88.3 ? 14.7 (0.9 f 0.15)

88.3 + 14.7 (0.9 + 0.15)

88.3 + 14.7 (0.9 + 0.15)

88.3 + 14.7 (0.9 + 0.15)

rpm

2,390 - 2,53t

!,390 - 2,53(

2,083 - 2,21’

2,083 - 2,211

mm

8

kPa (kg/cm’

speed

1.0

18 + 1

degree

The values given in the Testing and Adjusting Do not use these values as a guide to change

12-030-22 @

0.35

18*

1

6-

10

8

6-

10

Data are NOT for adjustment of the output. the setting of the fuel injection pump.

95 SERIES


TESTING

TESTING

AND ADJUSTING

3D95S-W-1

2,700

Permissible value

- 2,900

650

- 750

Min.

150

Min.

100

Max.

300

DATA

4D95S-W-1 D20A. D21A,

P, Q, PL, PLL-6 P, 0, PL-6

Standard value

Permissible value

EC35Z. ZS-2, EC35ZSB-2 Standard value

AND ADJUSTING

2,700

- 2,900

650

- 750

762

2,530

- 2,630

800 - 850

2,530

EC50Z, ZS-5, EC50ZSB-5

- 2,630

800

- 850

Min.

150

Min.

100

Max.

300

762

I

Permissible value

Standard value

1,450 - 1,550 Min.

150

Min.

100

Max.

300

Standard value

I 1,450

Permissible value

- 1,550

-e-j--

_

Max.

650

700

Max.

700

750

Max.

700

750

6

8

Max.

3.5

5.5

Max.

3.5

5.5

2.5

3.5

Max.

3.0

4.0

Max.

3.0

4.0

2.0

Max.

3.0

Max. Max.

1.0 0.35

0.35

0.50

0.50

0.50

Min. (Min.

2.9 30)

2.1 (21)

Min. (Min.

2.9 30)

Max.

100

200

Max.

50

0.3 - 0.6 (3.0 - 6.0) 0.3 - 0.55 (3.0 - 5.5) Min. 0.1 (Min. 1.0) Min 0.08 (Min. 0.8)

0.25 (2.5) 0.2 (2.1) 0.07 (0.7) 0.07 (0.7)

80 - 110

120

SO-

Max.

1.0

Max.

0.5

11.8:;::(120:‘:) 18 * 1

10.1

18 2 1 49 t 9.8 (0.5 +. 0.1)

2,750

2,750

95 SERIES

6-

100

10

Max.

50

110

120

SO-

110

0.5

1.0

Max.

0.5

16 + 1 88.3 k 14.7 (0.9 t 0.15) - 2,750 8

2.9 30)

0.35 (3.5 0.25 (2.5 Min. (Min.

11.8:;:;(120:';) 10.1

2,620

Min. (Min.

0.25 (2.5) 0.25 (2.5) 0.07 (0.7) 0.07 (0.7)

0.35 - 0.55 (3.5 - 5.5) Min 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8)

49 2 9.8 (0.5 * 0.1)

8

2.1 (21)

0.35 - 0.6 (3.5 - 6.0)

(103)

-+--+-

0.35

16*

6-

- 0.55 - 5.5) - 0.5 - 5.0) 0.15 1.5)

Min 0.12 (Min. 1.2)

(103) 1

88.3 k 14.7 (0.9 t 0.15) 2,620

-iid---

- 2,750 10

=I= 120 1.0

10.1

162

1

16+

(103) 1

88.3 k 14.7 (0.9 + 0.15) 3,080 2.370

(502) (5OZS) 8

6-

10

12-030-23 @


TESTING

TESTING

AND ADJUSTING

Engine

Applicable Classifi. cation

r

model

machine

Item

Condition,

Unit

etc.

E b ‘t a”

Engine

wm

Low idling speed starting

aid)

Necessary starting speed -20°C

(with starting

aid)

800 - 850

rpm

Min. 150

vm

Intake resistance

All speed

Intake pressure

At rated output

mmHg

Exhaust pressure (Turbine inlet pres.)

At rated output

mmHg

Exhaust temperature (Turbine inlet temp.)

All speed (Intake air temp.:

“C

20°C)

Quick acceleration (Low idling + High idling) gas color

Bosch scale

At rated output

At high idling Valve clearance (When engine is hot or cold) F;A;prrion

pressure pressure

Oil pressure (Oil temperature: Min. 80°C)

mm

Intake valve

WA50-1

Standard value

Permissible value

!,650 - 2,75(

‘,650 - 2,750

800 - 850

800 - 850

Oil consumption

ratio

Max.

380

762

Max.

650

700

Max.

650

700

Max. 4.0

6.0

Max.

4.0

6.0

Max. 3.0

4.0

Max. 3.0

4.0

Max.

2.5

Max.

2.5

1.5

At rated output Water temoerature:

nmH,C

Max.

At rated output

(SAE 30)

MPa kg/cm*

At rated output

(SAE IOW)

MPa kg/cm2

At low idling (SAE 30)

(oil in oil pan)

At continuous rated output (Ratio to fuel consumption)

MPa .kg/cm2 MPa :kg/cm*

1.5

0.35

0.35

0.50

All speed

Oil temperature

762

Min. 3.1 (Min. 32)

Min. 70°C

Min. 100

380

mm

valve

Min. 150

Min. 100

MPa Ikg/cm2:

Exhaust

800 - 850

Max.

Oil temperature: 40 - 60°C (Engine speed: 320 - 360 rpm)

At low idling (SAE 1OW)

0.50 2.2 (22)

Min. 3.1 (Min. 32)

50

0.35 - 0.6 (3.5 - 6.0) 0.3 - 0.6 (3.0 - 6.0) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8)

“C

80-

%

Max. 0.5

110

Max. 50 0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

0.35 - 0.6 (3.5 - 6.0)

Min. 0.08 (Min. 0.8)

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

120

80 - 100

120

1.0

Max. 0.5

1.0

0.3 (3.0 Min. (Min.

0.6 6.0) 0.1 1.0)

Nozzle tester

MPa :kg/cm2

Fuel injection timing

B.T.D.C.

degree

Radiator pressure valve

Opening pressure (Differential pressure)

kPa [kg/cm2

88.3 * 9.8 (0.9 * 0.1)

88.3 + 9.8 (0.9 * 0.1)

88.3 + 9.8 (0.9 * 0.1)

88.3 + 9.8 (0.9 * 0.1)

Fan speed

At rated engine

rpm

2,140 - 2,27(

1,140 - 2,27C

2,425 - 2,57!

!,425 - 2,575

Fan belt tension (Alternator to fan pulley

Deflects when pushed a force of 6 ka

mm

8

Fuel injection

*

I‘ermissible value

!,530 - 2,63C 12 ,530 - 2,630

rpm

mmH,O

Blow-by fSAE30)

Standard value

r

speed

0°C (without

Exhaust

DATA

4D95S-1

120AG, P, PG, PL, PLL-7(A) 121A. AG, PG. S, QG-7(A)

model

High idling speed

8 :

AND ADJUSTING

pressure

speed with

The values given in the Testing and Adjusting Do not use these values as a guide to change

12-030-24 @

!2.1:::(225:‘; 14*

1

18.4 (188)

2.1+‘.5(225+‘5 r0.5 +5 14*

6-

1

10

14*

14% 1

7-8

1

7-8

Data are NOT for adjustment of the output. the setting of the fuel injection pump.

95 SERIES


TESTING AND ADJUSTING

TESTING AND ADJUSTING

4D95L-1

4D95L-W-1

WA40-1 Permissible value

Standard value

Permissible value

2,350 - 2,450

2,350 - 2,450

2,320 - 2,420

2,320 - 2,420

800 - 850

800 - 850

800-

850

T

EG336, BS-1

WA70-1

Standard value

800 - 850

DATA

Standard value

Permissible value

lax.l,560(50Hz 2,590 - 2,690 lax.l,872(60Hz 800-

850

850-

900

PC60, 6OL-3 PC6OU-3

Standard value - 2,690

2,590

850 -900

Min. 150

Min. 150

Min. 150

Min. 150

Min. 100

Min. 100

Min. 100

Min. 100

Permissible value 2,590 - 2,690 850-900

Max.380

762

Max.300

762

Max.300

762

Max.380

762

Max.650

700

Max. 650

700

Max.650

700

Max. 650

700

Max. 4.5

6.5

Max. 4.0

6.0

Max. 4.5

6.5

Max. 3.0

4.0

Max. 3.0

4.0

Max. 3.0

4.0

Max. 2.5

3.5

Max. 2.5

3.5

Max. 1.0

2.0

Max. 2.0

3.0

0.35

0.35

0.35

0.50

0.50

Min. 2.9 (Min. 30)

Min. 2.9 (Min. 30)

2.1 (21)

Min. 2.9 (Min. 30)

2.1 (21)

Min. 2.9 (Min. 30)

2.1 (21)

Max. 50

100

Max.50

100

Max. 50

100

Max.50 0.35 - 0.6 (3.5- 6.0) 0.3 - 0.55 (3.0- 5.5) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8) 80-

110

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7) 120

0.3 - 0.6 (3.0- 6.0) 0.3 - 0.55 (3.0- 5.5) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8) 80-

0.50

0.21 (2.1) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

Max. 0.5

11.8+'.3 (120+'3) +0.5 +5

11.8+= +05 (120+'? +5

Min. 0.12 (Min. 1.2) 80-

110

Max. 0.5

0.3 - 0.55 (3.0- 5.5) 0.25 - 0.5 (2.5- 5.0) Min. 0.15 (Min. 1.5)

110

88.3 -c9.8 (0.9 * 0.1)

88.3 k 9.8 (0.9 * 0.1)

2,150 - 2,250

2,150 - 2,250

2,360 - 2,480

2,360 - 2.48C

95 SERIES

6-10

12.5

88.3 k 14.7 (0.9 + 0.15)

110

19.6+'.5 (200"' r0.5 +5 1421

88.3 + 9.8 (0.9 f 0.1)

Min. 0.08 (Min. 0.8)

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

Max. 0.5

1.8+= (120:';) +0.5

88.3 + 9.8 (0.9 * 0.1)

0.35 - 0.6 (3.5- 6.0) 0.3 - 0.55 (3.0- 5.5) Min. 0.1 (Min. 1.0)

80-

Max. 0.5

14tl

8

0.21 (2.1) 0.18 (1.8) 0.07 (0.7) 0.07 (0.7)

88.3 -c 14.7 (0.9 * 0.15)

16 + 1 88.3 2 9.8 (0.9 -c0.1)

,610-1,690(50Hi1,610-1,690(50H. 2,350 - 2,450 ,930-2,030(60Hi1,930-2,030(60H 8-12

8

16.7 (170) 1621 88.3 2 9.8 (0.9 * 0.1) 2,350 - 2,450 6-10

12-030-25 @


TESTING

TESTING

AND ADJUSTING

Engine

Applicable Classifi cation

I

model

machine

model

AND ADJUSTING

DATA

4D95L-1

T

PC60, 6OL-5 PC6OU5 Permissible value

PC60-6 PC70-6

Standard value

High idling speed

rpm

1,250 - 2,35(

,250 - 2,351

Low idling speed

rpm

900 - 950

900 - 950

rpm

Min. 150

rpm

Min. 100

Min. 100

Max. 300

Max.

300

762

etc.

Standard value

Permissible value

Unit

Condition,

Item

,250 - 2,35C

!,250 - 2,350

950 - 1.000

950 - 1,000

Engine speed

0°C (without

starting

aid)

Min. 150

Necessary starting speed -20°C

(with starting

aid)

Intake resistance

All speed

mmH,C

Intake pressure

At rated output

mmHg

Exhaust pressure (Turbine inlet pres.)

At rated output

mmHg

Exhaust temperature (Turbine inlet temp.)

All speed (Intake air temo.:

_

“C

20°C)

Quick acceleration (Low idling + High idling) Exhaust

Bosch scale

At rated output

gas color

At high idling Valve clearance LWzz;engine is hot

CoA;proyion Blow-by (SAE30)

pressure

Intake valve

mm

Exhaust

mm

valve

Oil pressure (Oil temperature: Min. 80°C)

Min. 70°C

At rated output

(SAE 30)

At rated output

(SAE IOW)

At low idling (SAE 30) At low idling (SAE IOW)

Oil temperature

All speed

Oil consumption

Ir

ratio

(oil in oil pan)

At continuous rated output (Ratio to fuel consumption)

Max. 650

700

Max.

650

700

Max.

4.5

6.5

Max.

4.0

6.0

Max. 2.5

3.5

Max. 2.0

3.0

Max.

5.0

Max.

1.0

2.0

2.1 (21)

Min. 2.9 (Min. 30)

2.1 (21)

Max.

4.0

0.35

0.35

0.50

0.50

MPa Oil temperature: 40 - 60°C (Engine speed: 320 - 360 rpm: (kg/cm2 1 At rated output Water temoerature:

pressure

762

Min. 2.9 (Min. 30) Max.

50

100

MPa (kg/cm2 1 MPa [kg/cm* ) MPa lkglcmz ) MPa lkglcm’ )

0.3 (3.0 0.3 (3.0 Min. (Min.

0.6 6.0) 0.55 5.5) 0.1 1.0)

0.21 (2.1) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

0.35 (3.5 0.3 (3.0

Min. (Min. Min. (Min.

0.1 1.0) 0.08 0.8)

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

“C

80-

110

120

80-

110

120

%

Max. 0.5

1.0

Max. 0.5

Min. 0.08 (Min. 0.8)

Fuel injection

pressure

Nozzle tester

MPa 16.7 (170) 19.6+'.5(200+" +0.5 + (kg/cm’ ‘) ,

Fuel injection

timing

B.T.D.C.

degree

Radiator pressure valve

Opening pressure (Differential pressure)

kPa (kg/cm’

Fan speed

At rated engine

Fan belt tension (Alternator to fan oullev

Deflects when pushed a force of 6 ka

speed

rpm with

The values given in the Testing and Adjusting Do not use these values as a guide to change

12-030-26 a4

50

mmH,C 1

mm

16?

‘)

1

16 + 1

-

0.6 6.0) 0.6 6.0)

9.6+'?200+'5 +0.5 + 5 16?

1.0 16.7 (170) 16=

1

1

68.6 + 9.8 (0.7 * 0.1)

68.6 ? 9.8 (0.7 f 0.1)

88.3 ? 9.8 (0.9 -c 0.1)

88.3 =’ 9.8 (0.9 + 0.1)

1,843 - 1,93

1,843 - I,93

1,840 - 1,94(

1,840 - 1,940

8

7 - 10

8

6-

10

Data are NOT for adjustment of the output. the setting of the fuel injection pump.

95 SERIES


TESTING AND ADJUSTING

TESTING AND ADJUSTING

DATA

4D95L-1 PC60-7 PC70-7 Standard value

Permissible value

2,050 - 2,150

2,050 - 2,150

950-

1,000

950-

r

1.000

PC75UU-1 Permissible value

st~~lduaerd

Permissible value

2,050 - 2,150

?,050 - 2,150

2,050 - 2,150

950 - 1,000

950 - 1,000

1,000 - 1,050

1,000 - 1,050

Min. 150

Min. 100

Min. 100

Standard value

2,050 - 2,150

Min. 150

Min. 150

r

PC75UU-2

PCSO-3 Standard value

E.500 - 2,600 850-

Permissible value 2,500 - 2,600

900

850 - 900

Min. 150

Min. 100

Min. 100

Max.300

762

Max. 300

762

Max.300

762

Max. 300

762

Max.650

700

Max.650

700

Max.650

700

Max.650

700

Max. 4.0

6.0

Max. 5.0

Max. 5.0

7.0

Max. 5.0

7.0

Max. 2.0

3.0

Max. 2.5

Max. 2.5

3.5

Max. 2.5

3.5

Max. 1.0

2.0

Max. 2.0

Max. 2.0

3.0

Max. 5.5

6.5

0.35

0.35

0.35 0.50 Min. 2.9 (Min. 30)

0.50 2.1 (21)

Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8) SO-

110

Max. 0.5

16kl

100

Max. 50

100

120

80 - 120

120

SO-

110

120

1.0

Max. 0.5

1.0

Max. 0.5

1.o

80 - 110

1.0

Max. 0.5

19.6:;:;(200:':) 16.7 (170) 1651

2.1 (21)

Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8)

120

1621

_

Min. 2.9 (Min. 30)

0.21 (2.1) 0.18 (1.8) 0.07 (0.7) 0.07 (0.7)

Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8)

16.7 (170) 19.6+'.5(200+'5) *cl.5 f 5

0.3 - 0.7 (3.0- 7.0) 0.3 - 0.65 (3.0- 6.5)

Min. 2.9 (Min. 30) Max.50

0.21 (2.1) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

0.50 2.1 (21)

0.50 2.1 (21)

Max. 50

Max. 50 0.35 - 0.6 (3.5- 6.0) 0.3 - 0.6 (3.0- 6.0)

Min. 2.9 (Min. 30)

0.35

16 + 1

0.3 - 0.7 (3.0- 7.0) 0.25 - 0.65 (2.5- 6.5)

16.7 (170) 19.6+'-5(200"5) r0.5 + 5 14*1

14 + 1

0.3 - 0.6 (3.0- 6.0) 0.3 - 0.55 (3.0- 5.5) Min. 0.1 (Min. 1.0)

0.21 (2.1) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

Min. 0.08 (Min. 0.8)

19.6:;::(200:':) 16.7 (170) 16kl

16 + 1

88.3 k 9.8 (0.9 + 0.1)

88.3 k 9.8 (0.9+ 0.1)

68.6 f 9.8 (0.7 t 0.1)

68.6 + 9.8 (0.7 * 0.1)

68.6 + 9.8 (0.7 * 0.1)

68.6 k 9.8 (0.7 t 0.1)

68.6 k 9.8 (0.7 + 0.1)

68.6 + 9.8 (0.7 + 0.1)

1,840 - 1,960

1,840 - 1,960

1,660 - 1,760

1,660 - 1,76(

1,660 - 1,760

1,660 - 1,760

2,110 - 2,210

2,110 - 2,210

8

7 - 10

8

95 SERIES

6-10

8

6-10

8

1

6-10

’2-oio-27


TESTING

AND ADJUSTING

TESTING

Engine

Applicable

model

machine

AND ADJUSTING

4D95L-1

model

PC90-1

PW60-3

f Classifi cation

Item

Engine

DATA

Condition,

etc.

Standard value

Unit

Permissible value

Standard value

High idling speed

rpm

!,425 - 2,525

Low idling speed

rpm

950 - 1,000

900 - 950

rpm

Min. 150

Min. 150

,425 - 2,525

Permissible value

$600 - 2,700 I i !,600 - 2,700

speed

0°C (without

starting

aid)

900 - 950

Necessary starting speed

-20°C (with starting

aid)

Min. 100

rpm

Intake resistance

All speed

mmH,C

Intake pressure

At rated output

mmHg

Exhaust (Turbine

At rated output

mmHg

pressure inlet pres.)

Exhaust temperature (Turbine inlet temp.)

All speed (Intake air temp.:

“C

20°C)

Quick acceleration (Low idling --f High idling) Exhaust

gas color

Bosch scale

At rated output

762

Max.

300

762

Max.

650

700

Max. 650

700

Max.

4.0

6.0

Max.

5.0

7.0

Max. 2.5

3.5

Min. 2.9 (Min. 30)

2.1 (21)

Max.

Intake valve

mm

1.0

0.35

mm

0.50

F:s”A”E”36”,ssion pressure

Oil temperature: 40 - 60°C (Engine speed: 320 - 360 rpmj

MPa (kg/cm’

Min. 2.9 (Min. 30)

Blow-by (SAE30)

At rated output Water temperature:

mmH,C

pressure

Oil pressure (Oil temperature: Min. 80°C)

Exhaust

valve

Min. 70°C

At rated output

(SAE 30)

At rated output

(SAE IOW)

Oil temperature Oil consumption

ratio

MPa :kg/cm* MPa Ikg/cmz MPa

At low idling (SAE 30)

Ikg/cm2

At low idling (SAE IOW)

*

300

Max. 2.5

At hiah idlina Valve clearance (When engine is hot or cold)

MPa

[kg/cm’

At continuous rated output Ratio to fuel consumption)

%

Max. 0.5

MPa

Vozzle tester

Fuel injection

timing

3.T.D.C.

degree

Radiator pressure valve

Dpening pressure :Differential pressure)

Fan speed

At rated engine

Fan belt tension (Alternator to fan pulley)

3eflects when pushed 3 force of 6 kg

given

in the

use these

values

’2-oo-28

0.35 - 0.6 (3.5 - 6.0) 0.3 - 0.6 (3.0 - 6.0) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8) 80-

pressure

Do not

50

“C

Fuel injection

The values

Max.

411speed (oil in oil pan)

Testing

kg/cm?

speed

and

as a guide

with

Adjusting to change

Min. 100

Max.

0.25 (2.5) 0.21 (2.1)

Max.

50

0.35 (3.5 0.3 (3.0 Min. (Min.

0.6 6.0) 0.5 5.0) 0.1 1.0)

0.25 (2.5) 0.21 (2.1) 0.07 (0.7)

Min. 0.08 (Min. 0.8)

110

80 - 110 1.0

16.7 (170) 9.6+'.5(200+'5) +0.5 + 5

Max. 0.5 9.6+‘~5(200+‘51 +0.5 15

16.7 (170)

16e 1

16? 1

16? 1

16 f 1

kPa kg/cm2:

88.3 ? 9.8 (0.9 * 0.1)

88.3 t 9.8 (0.9 f 0.1)

49 t 9.8 (0.5 f 0.1)

49 + 9.8 (0.5 + 0.1)

rpm

1.020 - 2,120

,020 - 2,120

!,350 - 2,450

1,350 - 2,450

mm

8

7 - 10

8

Data the

are setting

6-

10

NOT for adjustment of the output. of the fuel injection pump.

95 SERIES


TESTING AND ADJUSTING

TESTING AND ADJUSTING

DATA

4D95L-1 D21A-7T (Trimming) Standard value

Permissible value

2,530 - 2,630 800-

r

EC75Z,ZS-3

EG40B, BS-1

Standard value

Permissible value

2,530 - 2,630

3,250 - 3,350

3,250 - 3,35C

800 - 850

750 - 850

850

’

750-

850

Standard value

Permissible value

hlax.l,872(60H Aax.l,872(60Hz 800 - 850

Min. 150

Min. 150

Min. 100

Min. 100

Min. 100

800-

850

Max.380

762

Max.380

762

Max. 400

762

Max. 650

700

Max.650

700

Max. 650

700

4.0

6.0

Max. 5.0

7.0

3.0

4.0

Max. 2.5

3.5

Max. 3.5

4.5

1.5

2.5

0.35

0.35

0.35

0.50

0.50

0.50

2.1 (21)

Max. 50 0.3 - 0.6 (3.0- 6.0) 0.3 - 0.55 (3.0- 5.5) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8) 80-

0.21 (2.1) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

110

Max. 0.5 19.6".5(200+'5) +0.5 + 5 16kl

2,810 - 2,990 8

95 SERIES

1.0 16.7 (170) 16~1

!,810 - 2,990 6-10

Min. 2.9 (Min. 30)

2.1 (21)

Min. 2.9 (Min. 30)

2.1 (21)

Max. 50

100

Max. 50

100

Min. 0.12 (Min. 1.2)

0.21 (2.1) 0.18 (1.8) 0.07 (0.7) 0.07 (0.7)

80 - 110

120

80-

110

120

Max. 0.5

1.0

Max. 0.5

1.0

0.3 - 0.55 (3.5- 5.5) 0.25 - 0.5 (2.5- 5.0) Min. 0.15 (Min. 1.5)

16.7 (170) 19.6+'.5(200+'5) +0.5 + 5 20 k 1

20 + 1

88.3 2 9.8 (0.9t 0.1)

88.3 k 9.8 (0.9+ 0.1)

1,420 - 3,600

8,420- 3,600

8

6-10

Permissible value

lLlax.l,560(50H Aax.l,560(50Hz

Min. 150

Min. 2.9 (Min. 30)

Standard value

0.3 - 0.55 (3.0- 5.5) 0.25 - 0.5 (2.5- 5.0) Min. 0.15 (Min. 1.5) Min. 0.12 (Min. 1.2)

0.21 (2.1) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

l9.6:;:;(200:': 17.6 (180) 1621 88.3 t 14.7 (0.9-c0.15)

16 t 1 88.3 k 14.7 (0.9-c0.15)

,610-1,690(50Hi,610-1,690(50Hz) .930-2.030160H;.930-2.030(60Hz) 10

8 - 12

12-030-29 @


TESTING

TESTING

AND ADJUSTING

Engine

Applicable

machine

model

Condition,

Item

Engine

I

model

etc.

High idling speed

vm

Low idling speed

rpm

PCIOO-5

!,240 - 2,360

PCIOO-6

Permissible value ,240 - 2,360

Standard value

0°C (without

-20°C

starting

aid)

(with starting

aid)

900 -

X,240 - 2,360

1,240 - 2,360

950

900 -

950

900 - 950

900 - 950

vm

Min. 150

Min. 150

vm

Min. 100

Min. 100

Intake resistance

All speed

mmH,C

Max.

300

762

Max.

300

762

Intake pressure

At rated output

mmHg

Min. 500

450

Min. 500

450

Exhaust pressure (Turbine inlet pres.)

At rated output

mmHg

Min. 350

300

Min. 350

300

Exhaust temperature (Turbine inlet temp.)

All speed (Intake air temp.:

Max. 650

700

Max.

Max. 6.0

7.5

Max. 6.0

Max. 3.0

4.0

Max. 3.0

Max.

2.0

Max.

“C

20°C)

Quick acceleration (Low idling + High idling) Exhaust

gas color

Bosch scale

At rated output

At high idling Valve clearance (When engine is hot or cold) Compression (SAEBO) Blow-by (SAE30)

pressun

pressure

Oil pressure (Oil temperature: Min. 80°C)

Oil consumption

ratic

1.0

0.35

mm

0.35

Exhaust

mm

0.50

_

0.50

Oil temperature: 40 - 60°C (Engine speed: 320 - 360 rpm:

MPa (kg/cm2 )

Min. 2.9 (Min. 30)

2.1 (211

Min. 2.9 (Min. 30)

2.1 (211

At rated output Water temoerature:

mmH,C 1

Max. 50

100

Max.

50

100

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

0.35 (3.5 0.3 (3.0 Min. (Min.

0.7 7.0) 0.7 7.0) 0.1 1.0)

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

valve

Min. 70°C

At rated output

(SAE 30)

At rated output

(SAE IOW)

At low idling (SAE 30)

All speed

Oil temperature

1.0

650

Intake valve

At low idling (SAE IOW) (oil in oil pan)

At continuous rated output (Ratio to fuel consumption)

MPa [kg/cm2 1 MPa (kg/cm2 ) MPa [kg/cm’ 1 MPa (kg/cm2 )

0.35 (3.5 0.3 (3.0 Min. (Min.

0.7 7.0) 0.7 7.0) 0.1 1.0)

Min. 0.08 (Min. 0.81

“C

80-

%

110

Min. 0.08 (Min. 0.8)

120

80-

1.o

Max. 0.5

Max. 0.5

110

/kl)

Fuel injection

*

Permissible value

speed

Necessary starting speed

j,

DATA

S4D95L-I

Standard value

Unit

AND ADJUSTING

pressur

MPa 19.6+‘.5(200+‘5 +o.s +5 (kg/cm’ ‘1

Nozzle tester

Fuel injection timing

B.T.D.C.

Radiator pressure valve

Opening pressure (Differential pressure)

Fan speed

At rated engine

Fan belt tension (Alternator to fan pullej

Deflects when pushed a force of 6 kg

18.4 (188)

18 * 1

18 2 1

18 + 1

49 + 9.8 (0.5 + 0.1)

49 -c 9.8 (0.5 * 0.1)

49 -c 9.8 10.5 -c 0.1)

49 e 9.8 (0.5 z? 0.1)

rpm

2,040 - 2,16C

!,040 - 2,16(

2,100

2,100

mm

8

kPa (kg/cm’

with

!2.1:;:;(225:‘:

1 .o

18 + 1

degree

speed

16.7 (170)

120

‘)

6-

10

+ 60 8

6-

+ 60 10

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. (%I) PCIOO-5 (106894 and up): 22.1:::: MPa (225:‘: kg/cm’)

12-030-30 a4

95 SERIES


TESTING

TESTING

AND ADJUSTING

AND ADJUSTING

DATA

S4D95L-1

PC120-6,

PC120-5 Permissible value

Standard value 2,340

- 2,460

2,340

- 2,460

- 2,460

- 2,460

2,200

100

Min.

100

300

762

Max.

300

762

Min.

550

500

Min.

450

400

350

Min.

400

350

Max.

350

315

650

700

Max.

650

700

Max.

650

700

Max.

6.0

7.5

Max.

6.0

7.5

Max.

3.0

4.0

Max.

3.0

4.0

Max.

1.0

2.0

Max.

1.0

Min. (Min.

2.9 30)

2.2 (22)

Min. (Min.

2.9 30)

2.2 (22)

Min. (Min.

3.0 30)

2.1 (21)

Max.

50

Max.

50

100

Max.

50

0.70 7.0) 0.70 7.0) 0.1 1.0)

0.25 (2.5) 0.21 (2.1) 0.070 (0.70)

0.35 (3.5 0.30 (3.0 Min. (Min.

0.080 0.80)

0.070 (0.70)

Min. (Min.

100

Min.

Max.

300

762

Max.

Min.

550

500

Min.

400

Max.

Min.

Standard value

Permissible value

- 2,280

150

150

150

- 950

- 2,280 - 950

Min.

Min.

900

2,200

Min.

900 - 950

- 950

2,340

Permissible value

Standard value

900

900 - 950

900

JV70DW-1

Permissible value

Standard value 2,340

PC128UU-1

900 - 950

T

2.0 1.0

0.35

0.50

0.70 7.0) 0.70 7.0) 0.10 1.0)

0.25 (2.5) 0.21 (2.1) 0.070 (0.70)

0.35 (3.5 0.30 (3.0 Min. (Min.

Min. (Min.

0.080 0.80)

0.070 (0.70)

Min. (Min.

80-

110

120

0.35 (3.5 0.30 (3.0 Min. (Min.

-

80 - 110 Max.

16.7

39 - 59 (0.40 - 0.60) 2,135

- 2,265 8

95 SERIES

(170)

22.6 (230

120

0.5 - 23.6 - 240)

(188)

17 - 19

17 - 19

17 - 19

39 - 59 (0.40 - 0.60)

39 - 59 (0.40 - 0.60)

39 - 59 (0.40 - 0.60)

2,135 6-

- 2,265 10

F12~61 1,910 - 2,031 'ClZo-6) 1,910 - 2,031 3 if C128UU-111,696 - 1.71 - 1.7s 16(PClZWU-111.696

8

0.70 7.0) 0.70 7.0) 0.10 1.0)

0.25 (2.5) 0.21 (2.1) 0.070 (0.70)

0.080 0.80)

0.070 (0.70)

80 - 120

120

Max. 18.4

6-

100

22.6 (230

-

0.5 - 23.6 - 240)

18.4

(188)

17 - 19

1,940

- 2.06C

1,940

- 2,060

10

’2-oio-3’


TESTING AND ADJUSTING

TESTING AND ADJUSTING

Engine

Applicable Classifi cation

machine

D31A,

model

Condition, High

Engine

6D95L-1

model

Item

etc.

idling

speed

Low idling

speed

Standard value

Unit

starting

aid)

Necessary starting speed

Permissible value

D3lE. P, PL, PLL, S, Q, AM, SM-20(A) Permissible value

Standard value

rpm

,600 - 2,700

2,600 - 2,7OC

1,535 - 2,635

$535 - 2,635

rpm

700 - 750

700 - 750

700 - 750

700 - 750

rpm

Min.

150

rpm

Min.

100

nmH,O

Max.

300

762

Max.

650

700

Max.

4.0

Max.

3.0

Max.

2.0

(with

starting

aid)

Intake

resistance

All speed

Intake

pressure

At rated

output

nmHg

output

nmHg

Exhaust (Turbine

pressure inlet pres.)

At rated

Exhaust (Turbine

temperature inlet temp.)

All speed (Intake air temp.:

At rated

gas color

At high Valve clearance I”t,e;ldengine is hot

Intake

Oil pressure (Oil temperature: Min.

80°C)

Oil consumption

valve

mm

150

Min.

100

Max.

300

762

Max.

650

700

6.0

Max.

4.0

6.0

1

4.0

Max.

3.0

4.0

1

3.0

Max.

2.0

3.0

Min. 2.9 (Min. 30)

2.1 (21)

_

0.35

0.35

0.50

mm

valve

Oil temperature: 40 - 60°C (Engine speed: 320 - 360 mm)

MPa kg/cm21

At rated output Water temperature:

nmH,C

Min. 70°C

Max.

50

80 - 110

120

%

Max.

1.0

MPa (g/cm2

0.35 - 0.7 (3.5 - 7.0)

At rated

output

(SAE IOW)

MPa <g/cm2

0.3 (3.0 Min. (Min.

(SAE 30) (SAE

IOW)

(oil in oil pan)

At continuous (Ratio to fuel

rated output consumption)

50

“C

(SAE 30)

idling

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

Max.

Min. 0.08 (Min. 0.8)

output

At low

100

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

At rated

All speed ratic

Bosch scale

idling

At low idling Oil temperature

idling)

output

Exhaust pressure

“C

20°C)

Quick acceleration (Low idling + High

Compression (SAE30)

Min.

i -20°C

*

P, S-18

speed

0°C (without

Exhaust

DATA

MPa <g/cm2 MPa <g/cm2

0.7 7.0) 0.1 1.0)

Min. 0.08 (Min. 0.8)

0.35 - 0.7 (3.5 - 7.0) 0.3 (3.0 Min. (Min.

0.65 6.5) 0.1 1.0)

0.5

Fuel injection

pressurl

Nozzle tester

MPa kg/cm2

Fuel injection

timing

B.T.D.C.

degree

Radiator pressure valve

Opening pressure (Differential pressure)

kPa kg/cm*

68.6 & 9.8 (0.7 * 0.1)

68.6 + 9.8 (0.7 c 0.1)

Fan speed

At rated

rpm

1,687 - 1,79’

1,687 - 1,791

Fan belt tension (Alternator to fan pulle)

Deflects when pushed a force of 6 kg

mm

10

engine

speed with

The values given in the Testing and Adjusting Do not use these values as a guide to change

’2-oio-32

9.6:;,:(200+‘5) +5 162

1

16.7 (170)

9.6+=(200 r0.5

16 + 1

16*

+” +5

16.7 (170)

1

16+

8-

1

12

Data are NOT for adjustment of the output. the setting of the fuel injection pump.

95 SERIES


TESTING

AND ADJUSTING

TESTING

AND ADJUSTING

DATA

6D95L-1

D37A-2. D37P-2A

T

PClOO, IOOL-3

D37E, P-5(A)

Standard value

Permissible value

Standard value

Permissible value

2,650 - 2,750

2,650 - 2,750

2,300 - 2,400

2,300 - 2,400

700-750

700-750

850-

900

850-

900

r

PC120-3

Standard value

Permissible value

2,350 - 2,450

2,350 - 2,450

850 - 900

Min. 150

Min. 150

Min. 150

Min. 100

Min. 100

Min. 100

Max.300

850-900

Max.300

762

Max.380

762

Max.380

762

Max.650

Max.600

700

Max. 650

700

Max.650

700

Max. 5.0

Max. 5.0

7.0

Max. 5.0

7.0

Max. 5.0

7.0

Max. 3.5

Max. 3.5

4.5

Max. 3.5

4.5

Max. 3.5

4.5

Max. 2.5

Max. 1.0

2.0

Max. 1.0

2.0

0.35

0.35

0.35

0.50

0.50

0.50

_

762

Min. 2.9 (Min. 30)

2.1 (21)

Min. 2.9 (Min. 30)

2.1 (21)

Min. 2.9 (Min. 30)

2.1 (21)

Min. 2.9 (Min. 30)

2.1 (21)

Max. 50

100

Max.50

100

Max. 50

100

Max. 50

100

0.35 - 0.7 (3.5- 7.0) 0.3 - 0.65 (3.0- 6.5) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8)

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.06 (0.6)

80-110

120

Max. 0.5

1.0

16.7 (170) 19.6+'.5(200+'5) r0.5 * 5 16kl

0.35 - 0.7 (3.5- 7.0) 0.3 - 0.65 (3.0- 6.5) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8) 80-

110

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7) 120

0.35 - 0.7 (3.5- 7.0) 0.3 - 0.7 (3.0- 7.0) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8)

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

80 - 110

120

80-

110

120

Max. 0.5

1.0

Max. 0.5

1.0

17.6 (180)

19.6+= +I” r0.5 (200+ 5’

16.7 (170)

19.6:;::(200:';

1621

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

16 + 1

16 + 1

68.6 k 9.8 (0.7t 0.1)

68.6 f 9.8 (0.7 2 0.1)

49 f 9.8 (0.5 2 0.1)

49 k 9.8 (0.5f 0.1)

49 2 9.8 (0.5 + 0.1)

49 f 9.8 (0.5 + 0.1)

1,940 - 2,060

1,940 - 2,060

1,640 - 1,72C

1,640 - 1,720

1,720 - 1,800

1,720 - 1,800

10

95 SERIES

8-12

8

16kl

0.35 - 0.7 (3.5- 7.0) 0.3 - 0.7 (3.0- 7.0) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8)

6-10

8

16 + 1

6-10

’2-oio-33


TESTING

TESTING

AND ADJUSTING

Engine

Applicable Classif cation

Item

starting

etc.

Unit

Standard value

Permissible value

rpm

!,600 - 2,700

,600 - 2,700

vm

800 - 850

800 - 850

rpm

Min. 150

Standard value 1,600 - 2,700

Permissible value !,600 - 2,700

100-&350(-25582 00-850(-25582) 75-725(25583-j i75-725(25583Min. 150

speed -20°C

(with starting

aid)

rpm

Intake resistance

All speed

mmH,O

Intake pressure

At rated output

mmHg

Exhaust pressure (Turbine inlet pres.)

At rated output

mmHg

(Turbine

(Intake

inlet temp.)

air temp.:

“C

20°C)

Bosch scale

mm

Compression (SAE30) Blow-by (SAE30)

WAIOO-1 WRl l-l

PW150-1

model

Condition,

I

DATA

6D95L-1

model

machine

AND ADJUSTING

pressure

pressure

Oil pressure (Oil temperature: Min. 80°C)

Max.

Max. 650

650

Max. 5.0

Max.

Max. 3.5

Max. 3.0

Max.

1.0

Max. 2.0

0.35

0.50

0.50 Min. 2.9 (Min. 30)

At rated output Water temperature:

mmH,C

Max. 50

MPa kg/cm2 MPa :kg/cm2 MPa :kg/cm2

0.35 - 0.7 (3.5 - 7.0)

At rated output

(SAE 30)

At rated output

(SAE IOW)

(oil in oil pan)

At continuous rated output (Ratio to fuel consumption)

6.5

4.5

Min. 2.9 (Min. 30)

Min. 70°C

762

_

mm

All speed ratio

Min. 100 Max. 300

762

MPa (kg/cm2

At low idling (SAE 1OW)

Oil consumption

380

Oil temperature: 40 - 60°C (Engine speed: 320 - 360 rpml

At low idling (SAE 30)

Oil temperature

Min. 100 Max.

MPa :kg/cm2

0.3 (3.0 Min. (Min. Min. (Min.

0.7 7.0) 0.1 1.0) 0.08 0.8)

“C

80-

110

%

Max. 0.5 19.6+‘.5(200+‘5 +0.5 +5

0.25 (2.5) 0.21 (2.1) 0.07 (0.7)

Max.

50

0.35 (3.5 0.3 (3.0 Min. (Min.

0.7 7.0) 0.7 7.0) 0.1 1.0)

0.25 (2.5) 0.21 (2.1) 0.07 (0.7)

Min. 0.08 (Min. 0.8) 80-

110

Max. 0.5

Fuel injection

pressure

Nozzle tester

MPa Ikg/cm2

Fuel injection

timing

B.T.D.C.

degree

Opening pressure (Differential pressure)

kPa Ikg/cm2

49 -c 9.8 (0.5 t 0.1)

49 + 9.8 (0.5 * 0.1)

49 2 9.8 (0.5 * 0.1)

49 k 9.8 (0.5 * 0.1)

rpm

1,850 - 1,95C

‘,850 - 1,95(

1,736 - 1,81f

1,736 - 1,816

mm

8

Radiator pressure valve

16*

1

16.7 (170) 16 + 1

19.6+'.5(200 +” r0.5 + 5 16?

16.7 (170) 16 + 1

1

I Fan speed

At rated engine

speed

Fan belt tension Deflects when pushed (Alternator to fan pulley) a force of 6 kg

*

with

The values given in the Testing and Adjusting Do not use these values as a guide to change

’2-oio-34

6-

10

6-

8

10

Data are NOT for adjustment of the output. the setting of the fuel injection pump.

95 SERIES


TESTING

AND ADJUSTING

TESTING

AND ADJUSTING

DATA

6D95L-1 WAlOO-1 (Engine No. 46799 and up) Standard value 2,600 - 2,700 675-725

EGGOB, BS-1

GD313A-1

'ermissible value

Standard value

Permissible value

2 ,600 - 2,700

2,700 - 2,800

2,700 - 2,800

_

-

675-725

800 - 850

800-

850

Min. 100

Min. 150 Min. 100

Standard value

Permissible value

800 - 850

800-

850

Min. 150 Min. 100

Min. 80 Max.300

762

Max. 400

762

700

Max.650

700

Max. 650

700

Max. 4.5

6.5

Max. 5.0

7.0

Max. 3.0

4.0

Max. 2.5

3.5

Max. 3.5

4.5

3.0

Max. 2.5

3.5

Max.650

Max. 2.0

_

_

0.35

0.35

0.35

0.50

0.50

0.50

Min. 2.9 (Min. 30) Max.50

-

2.1 (21)

Min. 2.9 (Min. 30)

2.1 (21)

Min. 2.9 (Min. 30)

2.1 (21)

Max.50

100

Max. 50

100

0.35 - 0.7 (3.5- 7.0) 0.3 - 0.7 (3.0- 7.0) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8)

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

110

80 - 110

120

Max. 0.5

Max. 0.5

0.35 - 0.7 (3.5- 7.0) 0.3 - 0.7 (3.0- 7.0) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8) 80-

19.6:;:;(200 :‘:I 16 k 1

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

16.7 (170) 16kl

16&l

68.6 k 9.8 (0.72 0.1)

68.6 c 9.8 (0.7 2 0.1)

68.6 2 9.8 (0.7* 0.1)

68.6 2 9.8 (0.7 + 0.1)

1,736 - 1,816

1,736- 1,816

1,950 - 2,050

1,950 - 2,050

8

95 SERIES

6-10

0.3 - 0.6 (3.0- 6.0)

0.21 (2.1)

Min. 0.15 (Min. 1.5) Min. 0.12 (Min. 1.2)

0.07 (0.7) 0.07 (0.7)

80-110

180

Max. 0.5

16.7 (170) 19.6+'.5(200+'5) +0.5 + 5 16 k 1

Permissible value

~ax.l,560(50Hzllax.l,560(50Hz ~ax.l,872(60Hzllax.l,872(60Hz

762

Max.300

Standard value

19.6+'-5(200 +“) 4.5 + 5 16kl 49 +. 9.8 (0.5 + 0.1)

16.7 (170) 16 + 1 49 + 9.8 (0.5 -c0.1)

1,462-1,538(50Hz 1,462-1,538(50Hz 1,755-1,845(60Hz 1,755-1,845(60Hz 10

8 - 12

12-030-35 @


TESTING AND ADJUSTING

TESTING AND ADJUSTING

Engine

Applicable Classifi cation

S6D95L-1

model

machine

model

etc.

High idling speed Engine

PC1 50-5

PC150-3

f

Condition,

Item

DATA

Unit

Standard value

rpm

!,350 - 2,45t

‘ermissible value ,350 - 2,450

Standard value

Permissible value

!,I 40 - 2,26( 12 !,I 40 - 2,260

speed Low idling speed 0°C (without

rpm

starting

aid)

rpm

850 -

900

850 -

900

Min. 150

900 - 950 Min.

900 - 950

150

Necessary starting speed -20°C

(with starting

aid)

rpm

Intake resistance

mmH,O

Max.

300

762

Intake pressure

At rated output

mmHg

Min. 280

250

Exhaust (Turbine

At rated output

mmHg

Min. 380

335

Max.

650

pressure inlet pres.)

Exhaust temperature (Turbine inlet temp.)

All speed (Intake air temp.:

“C

20°C)

Quick acceleration (Low idling --f High idling) Exhaust

Bosch scale

At rated output

gas color

At high idling Valve clearance $J;~;engrne is hot

Compression (SAE30) Blow-by (SAE30)

pressure

pressure

Max. 300

762

700

Max. 650

700

Max. 6.0

8.0

Max. 6.0

8.0

Max.

4.0

5.0

Max.

4.0

5.0

Max.

1.0

2.0

Max.

1.5

2.5

2.0 (20)

Min. 2.7 (Min. 28)

2.0 (20)

100

Max. 75

150

0.35

Intake valve

mm

Exhaust

mm

0.50

Oil temperature: 40 - 60°C (Engine speed: 320 - 360 rpm)

MPa [kg/cm2.

Min. 2.7 (Min. 28)

At rated output Water temperature:

mmH,C

valve

Min. 70°C

0.35

Max.

0.50

50

MPa kg/cm2 MPa kg/cm2 MPa :kg/cmz MPa :kglcm2

0.35 - 0.7 (3.5 - 7.0) 0.3 - 0.7 (3.0 - 7.0) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8)

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

“C

80 - 110

120

80-

%

Max. 0.5

1.0

Max. 0.5

Nozzle tester

MPa [kg/cm2

19.6+‘.5(200 +‘!! r0.5 +

16.7 (170)

Fuel injection timing

B.T.D.C.

degree

22 f 1

22 * 1

Radiator pressure valve

Opening pressure (Differential pressure)

kPa

[kg/cm2

49 + 9.8 (0.5 * 0.1)

49 f 9.8 (0.5 +. 0.1)

Fan speed

At rated engine

wm

1,930 - 2,031

1,930 - 2,03(

Fan belt tension (Alternator to fan pulleb

Deflects when pushed a force of 6 kg

mm

8

Oil pressure (Oil temperature: Min. 80°C)

At rated output

(SAE 30)

At rated output

(SAE 1OW)

At low idling (SAE 30) At low idling (SAE IOW) All speed

Oil temperature Oil consumption Fuel injection

*

Min. 100

Min. 100

All speed

ratic

pressurl

(oil in oil pan)

At continuous rated output (Ratio to fuel consumption)

speed with

The values given in the Testing and Adjusting Do not use these values as a guide to change

12-030-36 a9

6-

10

0.35 (3.5 0.3 (3.0 Min. (Min.

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

0.7 7.0) 0.7 7.0) 0.1 1.0)

Min. 0.08 (Min. 0.8) 110

19.6:;::(200:‘;

120 1.0 16.7 (170)

18 -c 1

18 -c 1 34.3 5 14.7 (0.35 2 0.15)

1,940 - 2,06

1,940 - 2,060 6-

8

10

Data are NOT for adjustment of the output. the setting of the fuel injection pump.

95 SERIES


TESTING AND ADJUSTING

TESTING AND ADJUSTING

DATA

S6D95L-1 PC200-5 BR200-1 Standard value 2,200

Permissible value

- 2,320

925

PC200-6

2,200

Min.

150

Min.

100

Max.

300

2,360

- 2,320

925

- 975

Standard value

- 975

975

762

Permissible value

- 2,480

2,360

- 1,025

Min.

150

PWl OO-3 No. up to 36829)

(Engine Standard value

- 2,480

975

2,050

- 1,025

850

Standard value

Permissible value

- 2,150

2,050

- 900

Min.

150

Min.

100

Min.

100

Max.

300

762

Max.

300

Min.

900

800

Min.

380

Min.

1000

900 Max.

650

- 2,150

850

PWI 00-3 No. 36830

(Engine

- 900

2,350

up)

Permissible value

- 2,450

850

and

- 900

Min.

150

2,350

- 2,450

850

- 900

Min.

100

762

Max.

300

762

700

Max.

650

700

Max.

650

700

Max.

650

700

Max.

5.5

7.5

Max.

7.5

8.5

Max.

6.0

7.0

Max.

6.0

8.0

Max.

3.7

4.7

Max.

2.0

3.0

Max.

3.5

4.5

Max.

1.5

2.5

Max.

1.0

2.0

Max.

1.0

2.0

Max.

3.5

4.5

Max.

1.0

2.0

Min. (Min.

2.7 28)

2.0 (20)

Max.

75

150

1

1

0.35

0.35

0.50

0.50

Min. (Min.

2.7 28)

Max.

75

Max.

0.35 - 0.7 (3.5 - 7.0)

0.24 (2.4) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

0.35 - 0.7 (3.5 - 7.0) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8)

100

50

0.35 - 0.7 (3.5 - 7.0) 0.3 (3.0 Min. (Min.

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

0.7 7.0) 0.1 1.0)

Min. (Min.

0.08 0.8)

!

I

I

I

Min. (Min.

0.1 1.0)

Min. (Min.

0.08 0.8)

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

0.35 - 0.7 (3.5 - 7.0) 0.3 - 0.7 (3.0 - 7.0)

I

80-

110

120

80 - 110

120

80-

110

120

80-

110

120

Max.

0.5

1.0

Max.

1.0

Max.

0.5

1.0

Max.

0.5

1.0

&I) 19 .6+=(200 +a5

+‘? +5

a

16.7

(170)

0.5

22.1 +‘.5(225+‘5) +,,5 +5

20

20

18 + 1

49 2 9.8 (0.5 k 0.1)

49 -c 9.8 (0.5 -c 0.1)

49 * 9.8 (0.5 + 0.1)

2,000

- 2,100

2,000

- 2,100

1,710

6-10

8

(~1) pC200-5 (83373 and

up), up),

95 SERIES

(83373

and

(180)

19.6:;::(200:‘:)

18 f 1

16 + 1

49 -c 9.8 (0.5 2 0.1) 1,710

4

(g2)

pc200-5

- 1,810

17.6

- 1,810 3-4

BR200-1: BR200-1:

38.2 (0.39 1,390

k 9.8 -c 0.1) - 1,460

16.7

(170)

16k 38.2 (0.39 1,390

8

6-

1 t 9.8 + 0.1)

- 1,460 10

16.7 19.6+'.5(200+'5) +a5 + 5 16k

1

49 k 9.8 (0.5 k 0.1) 1,640

- 1,720 8

(170)

16k

1

49 k 9.8 (0.5 t 0.1) 1,640 6-

- 1,720 10

22.1 ::::MPa (225:‘: Wcm2) 17.6 MPa (170 kg/cm’ )

12-030-37 @



TESTING AND ADJUSTING

TESTING AND ADJUSTING

DATA

S6D95L-1

GD461A-1 Standard value

Permissible value

Standard value

Permissible value

2,700 - 2,800

2,700 - 2,800

3,400 - 3,500

3,400 - 3,500

800-

850

800-850

750-

800

750 -800

Min. 150

Min. 150

762

Max.300

762

Min. 500

400

Min. 600

550

Min. 550

450

Min. 550

850

Max.650

700

Max.650

700

Max. 7.0

6.0

Max. 6.0

7.0

Max. 2.0

3.0

Max. 2.5

3.5

Max. 1.0

2.0

Max. 1.0

2.0

0.35

0.50 Min. 2.7 (Min. 28) Max.75 0.35 - 0.7 (3.5- 7.0) 0.3 - 0.7 (3.0- 7.0) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8)

800 - 850

Max.700

700

Max. 4.5

5.5

762

Max. 4.5

0.35

0.50

0.50

Min. 2.7 (Min. 28)

2.0 (20)

Min. 2.7 (Min. 28)

2.0 (20)

150

Max.85

150

Max.100

200

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

0.3 - 0.7 (3.0- 7.0) 0.25 - 0.7 (2.5- 7.0) Min. 0.15 (Min. 1.5) Min. 0.12 (Min. 1.2)

0.25 (2.5) 0.18 (1.8) 0.07 (0.7) 0.07 (0.7)

0.35 - 0.7 (3.5- 7.0) 0.3 - 0.7 (3.0- 7.0) Min. 0.1 (Min. 1.0) Min. 0.08 (Min. 0.8) 110

120

80-

Max. 0.5

1.0

Max. 0.5

1.0

Max. 0.5

19.6:;::(200:':) 16.7 (170)

Max.500

_

go-

19.6+'5(200"5) *0.5 5 l

16.7 (170)

22 + 1

22 * 1

16 + 1

49 f 9.8 (0.5 + 0.1)

49 k 9.8 (0.5 + 0.1)

68.6 k 9.8 (0.7f 0.1)

68.6 f 9.8 (0.7* 0.1)

1,950 - 2,050

1,950 - 2,050

2,153 - 2,287

2,153 - 2,287

95 SERIES

,.,

762

120

9

800-850

Max. 400

110

80-

Permissible value

flax.l,560(50Hzlax.l,560(50Hi Aax.l,560(50Hz)Max.l,560(50Hz) Jax.l,872(60Hz lax.l,872(60Hi ~ax.l,872(60Hz)Max.l,872(60Hz)

2.0 (20)

0.25 (2.5) 0.21 (2.1) 0.07 (0.7) 0.07 (0.7)

Standard value

Permissible value

Min. 100

Max.300

0.35

Standard value

Min. 150

Min. 100

Min. 100

DCA85 QAS85

EG85B. BS-1

LW80-1

1621

6-10

110

120

200

80 - 110

120

1.0

16.7 (170) 19.6".5(200+'5) +0.5 I 5 1421 49 + 9.8 (0.5k 0.1)

1421 49 t 9.8 (0.5 + 0.1)

1,462-1,538(50Hz,462-1,538(50Hz 1,755-1,845(60Hz,755_1,845(60Hz 10

8-12

12-030-39 @


TESTING

AND ADJUSTING

TESTING

Engine

Applicable Category

model

machine

High

conditions

speed

5

Low idling

speed

b

0°C (Without

Engine

h

WA1 80-3 Standard value

Unit

12 ,600 - 2,700

750 - 800

starting

(With

starting

Intake

resistance

At all speed

Boost

pressure

At rated flywheel

Exhaust (Turbine

pressure inlet press.)

At rated flywheel

Exhaust (Turbine

temperature inlet temp.)

All speed (Intake air temp.:

Exhaust

At rated flywheel

gas color

Hiah Valve clearance ($:;2lengme is hot

idlina

Intake

aid)

aid)

IPermissible value

$600 - 2,70( 12 ‘,600 - 2,700

750 - 800 Min.

150

Min.

100

750 - 800

7.47 1762)

horsepower

Min. 5.88 (Min. 600)

4.95 (500)

horsepower

Min. 6.86 (Min. 700)

5.88 (600)

20°C) idling)

horsepower

Bosch index

soeed

valve

Exhaust

valve

Max.

3.0

5.0

Max.

3.0

Max.

1.0

2.0

Max.

1.0

1 (

2.0 (20)

Min. 2.7 (Min. 28)

2.0 (20)

kPa nmHzOl

Max. 0.49 (Max. 50)

0.98

(100)

Max. 0.49 (Max. 50)

(100)

MPa kg/cm?

0.35 - 0.70 (3.5 - 7.0)

o il

SAE IOW oil

(Oil in oil pan)

Fuel injection

pressure

Nozzle tester

Fuel injection

timing

B.T.D.C.

Radiator pressure valve

Opening pressure (Differential pressure)

Fan speed

At rated

Fan belt tension

Deflects when pushed with a force of 60 N 16 kg>

12-030-40 @

engine

speed

700

Min. 2.7 (Min. 28)

SAE 1OW oil

At continuous rated horsepower (Ratio to fuel consumption)

5.5

0.50

At rated flywheel horsepoer SAE30 or SAE15W-40 oil

ratio

Max.

0.50

At rated flywheel horsepower (Water temperature: Min. 70°C)

Oil consumption

7.5

i mm

Blow-by pressure (SAE30 or SAE15W-40)

All speed

650

0.35

MPa kg/cm?

Oil temperature

Max.

0.35

Oil temperature: 40 - 60°C (Engine speed: 320 - 360 rpml

At low idling SAEBO or SAE15W-40

700

mm

Compression pressure (SAE30 or SAE15W-40)

Oil pressure (Oil temperature: Min. 80°C)

6

Standard value

Min. 2.94 (Min. 300)

Quick acceleration (Low idling + High

s

value

WA250-3

Necessary starting speed -20°C

x t .-P %

IPermissible

r

speed

E ‘t

I

model

idling

x

DATA

S6D95L-1

Measurement

Item

AND ADJUSTING

%

Max.

0.98

0.25 (2.5) 0.21 (2.1) 0.070 (0.70) 0.070 (0.70)

0.35 (3.5 0.30 (3.0 Min. (Min.

120

go-

110

120

1.0

Max.

0.5

1.0

0.5

0.70 7.0) 0.70 7.0) 0.1 1.0)

0.25 (2.5) 0.21 (2.1) 0.070 (0.70)

Min. 0.080 (Min. 0.80)

0.070 (0.70)

16.7 (170)

20.1 - 21.1 (205 - 215)

16.7 (1701

21 -23

19 - 21

19 - 21

59 - 7.8 (0.6 - 0.8) 3 1,730 - 1,83C 6-

10

1,870 - 1,9713 11,730 - 1,830 8

6-

10

95 SERIES


TESTING AND ADJUSTING

TESTING AND ADJUSTING

DATA

SA6D95L-1

PC220-5 BR300-1 Standard value

Permissible value

2,300 - 2,475

2,355 - 2,475

925 - 975

925 - 975

Min.

r

PC220-6 Standard value

Permissible value

_

Standard value

Permissible value

150

Min. 100 Min. .94 (Min. 300)

7.47 (762)

Min. 2.94 (Min. 300)

7.47 (762)

Min. 5.88 (Min. 600)

5.88 (600)

Min. 6.88 (Min. 700)

5.88 (600)

Max. 650

700

Max.

650

700

Max. 5.5

7.5

Max.

8.0

9.0

Max.

4.0

5.0

Max. 2.0

3.0

Max.

1.0

2.0

Max.

2.0

Min. 2.7 (Min. 28)

2.0 (20)

0.74 (Max. 75)

1.47 (150)

0.35 - 0.70 (3.5 - 7.0)

0.25 (2.5) 0.21 (2.1) 0.070 (0.70) 0.070 (0.70)

0.35 (3.5 0.30 (3.0

120

80-

110

120

1.0

Max. 0.5

1.0

1.0

0.35 0.50

0.30 - 0.70 (3.0 - 7.0) Min. 0.1 (Min. 1.0) Min. 0.080 (Min. 0.80) 80-

110

I

Max. 0.5

0.48 (Max. 50) -

0.7 7.0) 0.70 7.0)

0.98 (100)

Min. 0.1 (Min. 1.0)

0.25 (2.5) 0.21 (2.1) 0.070 (0.70)

Min. 0.080 (Min. 0.80)

0.070 (0.70)

I

Jp to364721 16.7 (170) 6473and up)17.6 1160

20

20

5.9 - 7.8 (0.6 - 0.8) 2,330 - 2,470 8

95 SERIES

2,330 - 2,470 6-

10

8

6-

10

’2-oio-4’


TESTING

TESTING

AND ADJUSTING

Engine

Applicable Category

machine

I

SAA6D95LE-1

conditions

Unit

Standard value

!

rpm

$400 - 3,500

:,400 - 3,500

Low idling speed

rpm

750 - 800

750 - 800

rpm

Min. 150

starting

aid)

Necessary starting speed -20°C

(With starting

aid)

rpm

Min. 100

kPa ImmHzO

Min. 2.94 {Min. 300)

Intake resistance

At all speed

Boost pressure

At rated flywheel

horsepower

imkiig

Min. 66.7 {Min. 500)

Exhaust pressure (Turbine inlet press.)

At rated flywheel

horsepower

ImkJja,g

Min. 126 {Min. 900)

107 18001

Exhaust temperature (Turbine inlet temp.)

All speed (Intake air temp.:

Max. 700

700

Max. 5.5

6.5

Max. 2.5

3.5

Max. 2.0

3.0

“C

20°C)

At rated flywheel

gas color

horsepower

Bosch index

High idling speed Valve clearance f”E,e;dengine is hot

Compression pressurt (SAE30 or SAE15W-40 Blow-by pressure (SAE30 or SAE15W-40

Oil pressure (Oil temperature: Min. 80°C)

Intake valve

mm

Exhaust

mm

valve

2.0 I201

At rated flywheel horsepower (Water temperature: Min. 70°C)

kPa {mmHzO

Max. 0.98 {Max. 100)

2.0

At rated flywheel horsepoer SAE30 or SAE15W-40 oil

MPa (kg/cm2 MPa {kg/cm2 MPa {kg/cm’ MPa {kg/cm2

0.34 - 0.59 (3.5 - 6.01

At low idling SAE30 or SAE15W-40

All speed

Oil consumption

ratic

o il

(Oil in oil pan)

At continuous rated horsepower (Ratio to fuel consumption)

Fuel injection

pressurl

Nozzle tester

Fuel injection

timing

B.T.D.C.

Fan speed

At rated engine

Fan belt tension

Deflects when pushed a force of 60 N (6 kg}

QOO}

I I

1

0.25 l2.51 0.21 12.1) 0.07 IO.701

Min. 0.069 {Min. 0.70) 90 - 120

%

Max. 0.3

degree

Opening pressure (Differential pressure)

0.29 - 0.54 (3.0 - 5.5) Min. 0.098 {Min. 1.0)

“C

MPa {kg/cm2

Radiator pressure valve

’2-oio-42

0.50 Min. 2.7 {Min. 281

SAE 1OW oil Oil temperature

I

0.35

MPa Oil temperature: 40 - 60°C (Engine speed: 320 - 360 rpm) (kg/cm2

SAE 1OW oil

Permissible value

I

Quick acceleration (Low idling --f High idling) Exhaust

Standard value

Permissible value

High idling speed speed

0°C (Without

DATA

WING100 (LWIOO-1, LWIOOM-1)

model

Measurement

Item

Engine

model

AND ADJUSTING

20.1 - 21.1 (205 - 2151 II-

13

MPa {kg/cm2

speed

rpm with

mm

!,150 - 2.29c 8

1,150 - 2,290 6-

10

95 SERIES


TESTING AND ADJUSTING

TESTING AND ADJUSTING

DATA

SAA6D95LE-1

Standard value

95 SERIES

Permissible value

Standard value

Permissible value

’2-oio-43



TROUBLESHOOTING Method

of using troubleshooting

Points to remember S-l s-2

Starting

chart

......................................................................................................

when troubleshooting

performance

................................................................................................

is poor (Starting

always takes time)

..............................................................

12-032 12-036 12-037

Engine does not start @

Engine does not turn ..............................................................................................................

12-038

0

Engine turns but no exhaust gas comes out (Fuel is not being injected)

.....................................

12-039

0

Exhaust gas comes out but engine does not start (Fuel is being injected)

...................................

12-040

s-3

Engine does not pick up smoothly

s-4

Engine stops during operations

s-5

Engine does not rotate smoothly

S-6

Engine lacks output (no power)

s-7

Exhaust gas is black (incomplete

S-8

Oil consumption

s-9

Oil becomes

s-1 0

Fuel consumption

S-l 1

Oil is in cooling water,

S-l 2

Oil pressure lamp lights up (drop in oil pressure)

S-l 3

Oil level rises ...............................................................................................................................

12-051

s-14

Water temperature

12-052

S-l 5

Abnormal

S-l 6

Vibration

s-17

Diagnosis

contaminated

12-043

.....................................................................................................

12-044

combustion)

................................................................................

(or exhaust gas is blue) ... . ................................................................. ................................................................................................

...................................................................................................... level goes down ............................................

...........................................................................

too high (overheating)

.......................................................................

................................................................................................................... governor

made

12-041

...................................................................................................

...............................................................................................................

of electronical governor

....................................................................

12-042

or water spurts back, or water

becomes

is excessive

is poor)

.....................................................................................................

quickly

is excessive

noise is made

(electronical

95 SERIES

is excessive

(Follow-up

by diagnosis

12-045 12-046 12-047 12-048 12-049 12-050

12-053 12-054

display

by ZEXEL) ...................................................................................................

12-055

’2-:31


TESTING

AND

ADJUSTING

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING This

troubleshooting

sections: ing.

The

pinpoint from

questions

and

the

symptoms

to

check

that or

three

are

used

to

can be located

simple

inspection

tools. tools

the

into

troubleshoot-

items

causes

troubleshooting

used

and

check

probability

failure

is divided

items,

using troubleshooting

Next, are

check

high

without

chart

questions,

CHART

or

high

direct

inspection

probability

causes

to

make final confirmation. [Questions] Sections

@ -I- @ in the

sponds

to

obtained items

the

from that

[Check The

the

can

depending

chart

items

on the

where

user.

be

The

in

from

be

@I are

the

user,

level.

items] serviceman

narrow

down

carries the

out

causes.

simple

The

serviceman

information

narrows

@ the

that

he

user

and

results

of 0

from

his own inspection.

to

under

@ in

causes

from

to this.

down has

inspection

items

the chart on the right correspond The

correcan

items

obtained

on the user’s

right

answers

the obtained

that

from

he has

the

obtained

[Troubleshooting] Troubleshooting probability,

is starting

been

marked

from

information

[Check

as

carried with having gained

out

in

the

the

causes

the

highest

from

order that

of have

probability

[Questions]

and

items].

’2-:32

95 SERIES


TESTING

AND

TROUBLESHOOTING

ADJUSTING

The basic method

of using the troubleshooting

chart

is as fol-

lows. items

listed for [Questions]

tionship

and [Check

causes that have a high probability Check

each of the [Questions]

marked number

The vertical of points

are marked

that

For

(Confirm

column the

recent

Section, with

cause

when

repair

ask to

A

of the

making

the

has the highest of the cause.

history)

user,

use

and

the problem

cause, so starttroublesh-

for that item to make final confirmation

tions]

0.

in turn,

where

(Causes)

is the most probable

with

items]

for items

column

that have a rela-

with 0, and of these,

and [Check

the 0 or 0 in the chart

appeared. ooting

items]

with the Cause items are marked

and

as

in

the

mark

reference

failure.

However,

calculations

to

do

[Ques-

the

Cause

for

locating

not

use this

narrow

down

the

causes. Use

the

in the

A

(Degree

of

use

[Questions] use

section

it when

cause,

but

L

A A A A A

When

As a rule,

do not

points

for

if necessary

Degree of use

out

the

to deter-

Operated

A

for long period

A

A

out troubleshooting

testing

out

person

locating

for troubleshooting.

when carrying

out

in the

Confirm recent repair history

and

adjusting,

and apply

or troubleshooting,

the parking

operations

with

two

stop

the

machine

on

level

ground,

fit

safety

allow

any

unau-

brake.

or

more

workers,

always

use signals,

and

do

not

near the machine.

checking

spurt

the

for

period))

%2

carrying

When

as reference

long

%l

carrying

thorized

for

it can be included

pins, block the wheels, When

column

as reference.

calculating

mine the order

Precautions

Cause

(Operated

and

the

water

level,

may

cause

burns,

if the

radiator

so always

cap

wait

is removed

for

the

when

engine

to

the cool

engne down

is hot, before

boiling checking

water the

will water

level. Be extremely

careful

not to touch

Be extremely

careful

not to get caught

Y Y a+ When

removing

release

the

the

internal

plugs

or

pressure

any hot parts. in the fan or any other

caps first.

from

places

Fit the

under

measuring

rotating

parts.

hydraulic

tools

pressure,

securely

before

water

pressure,

carrying

out any

or air testing,

pressure, adjusting,

or troubleshooting. Method l

of using testing,

When

using

the

to be careful 1. The the

standard

values

standards

for

failure

on the

wear judgment

results

for reference

for

the

toghther

95 SERIES

values table

judgment

new

machines and

operation tests values

in the

machine

or as target

values

in the

and standard

with the repair

3. Doo not use this standard

for

machine

standard

of various

table

in testing,

adjusting,

or tourbleshooting,

it is necessary

points.

the

new

during

and troubleshooting

values

of the following

for estimating 2. The

adjusting,

standard

standard shipped

values standard

values

and operation

able as a standard

values from

when value

for history

table

carrying table

machines

They

given should

as reference be used

from

as values

out repairs. are

shipped

of the machine

for judging

are values

the factory. values

from when

using

estimated

the factory. judging

values

based

Use these

values

failures.

claims.

’2-;33


TESTING

AND

ADJUSTING

TROUBLESHOOTING

- Example of troubleshooting Let us assume have

causal

that

[Clogged

relationship

er], and [Dust indicator If we causes,

look

from

these

Let us explain

with

when exhaust gas is black air cleaner] this

is taken

problem:

to

[Exhaust

be the

gas slowly

cause

of black

became

black],

gas.

[Power

Three

slowly

symptoms

became

weak-

is red]. three

symptoms

here the method

to

find

the

causes,

of using this causal

we

find

relationship

I

that

there

to pinpoint

I

is a relationship the most probable

with cause.

I

III

12-034 17 \/7

exhaust

I

95 SERIES

five


TESTING

TROUBLESHOOTING

AND ADJUSTING

v

‘I

Five causes Step 1 Clarify the relationship in the

[Questions]

between

and

the three

[Check

items]

symptoms

section

and

the five Cause items in the vertical column.

r

Three symptoms

L Add

up the total of 0

zontal

Step 2

and 0

lines for the three

marks where

symptoms

the hori-

and the vertical

columns for the causes intersect. (I)

000

Clogged air cleaner element:

(2) Air leakage between

turbocharger

and

head:

00 0

(3)

Clogged,

seized injection

nozzle:

(4)

Defective

contact of valve, valve seat:

0 0

(5) Worn piston ring, cylinder:

Step 3

V The

calculations

in Step

relationship

is with

Follow

column

this

area and carry 0.

The

and

down

air to

that

the

is given exhaust

the

as [Clean], gas

the

cleaner

out the troubleshooting

Remedy

cleaning,

2 show

[Clogged

color

deepest element].

troubleshooting item

marked

so carry should

out

return

to normal.

95 SERIES

’2-:35


TESTING

AND

ADJUSTING

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING Troubleshooting failure

means

locating

the basic

cause

of the failure,

and carrying

out swift

repairs

to ensure

that

the

does not occur again.

When

carrying

carry

out

mentioned 1. Do

out

the

troubleshooting,

troubleshooting

by the operator

not

as a guide

disassemble

because

there

. If the

it is of course

effectively,

the

important

a quick

in locating

machine

method

is

just because

there

- Unrelated

or

simply

4. Confirming

disassembled

some

is a fuilure: unnecessary

places

are

also

to

locate

the

means

time

and

cause

grease,

but

that

there on

this

is

not

only

replacement

action

reason

also,

troubleshooting starting

will

a waste

parts,

also

lose

oil,

the

based

on full

and troubleshooting

confid-

to carry

investigation following

out

before

the

already

any

problems

other

correct

than

the

the

condition failure

in the

driving

to judge or

handling

the

unusual

flow

that

does

the of

and

the

not

2 -

causes

the

4, then

happen

before

the failure

failure

occur

of the

machine

suddenly, been

re-enacting

make

the

of the the

the failure.

the most probable related

places. places.

parts also.

6. Basic action

the

conditions

when

if

to remedy the

failure failure

the

cause

of the

the

failure

will occur

the

failure

To

prevent

why

the

this, failure

’

cause of failure is

repaired,

is not

if

repaired,

the the

it is necessary occurred,

and

to to

been

carried

ot before

6) Had any similar

failure

occurred

before?

the fai-

3. Checks before troubleshooting 1) Check the oil level. for

any

external

and hydraulic

leakage

3) Check the travel

of the control stroke

visually,

considered

12-036 a

so

the

equipment.

4) Check the spool

maintenance

of oil from

items carry

levers.

of the control out

can any

also

valve. be carried

check

that

same

investigate remove

root cause of the failure. repairs

root

again.

lure occurred?

out

in

for troubleshooting

the simple

3) Investigate

from

check

troubleshooting

1) Start from

had

occurred?

5) Had any

5) Other

or

failure

failure

and

2) Start from

before

or poor

occurred?

piping

is of

investigation

inspection follow

chart to locate

Basic procedure

. Even

were

2) Check

for

if there

or operation

machine

be sure

down

results

Items

those

occurred?

4) What

problem

a failure,

reported?

2) Did anything 3) Did

to

5. Troubleshooting

to ask the user and operator

there

but

problems

worse.

of

*

1) Are

When

* Narrow

it is important

the

and

order. 2. Questions

problem

the failure,

of

ence of the user and operator. For this

of the

if it is really

measurement

money

function,

using

the machine. *

difficult

and

failure

yourself

immediately

the failure This

structure

troubleshooting

* Check the degree

disassembled

- It becomes

the

out

the cause.

is a failure

machine

to understand is to carry

is

necessary.

95 SERIES

the


TESTING

S-l

AND

ADJUSTING

Starting General

TROUBLESHOOTING

performance

is poor (Starting

causes why starting performance

Defective

electrical

insufficient

intake of air selection

(At ambient ASTM

system

supply of fuel

Insufficient Improper

always takes time)

is poor

of fuel

temperature

of -10°C

D975 No. 1, and -10°C

or below,

use

or above, use ASTM

D975 No. 2 diesel fuel.) l

Charging

2o’c O’C -10°C The specific the above

Incold

gravity

90%

80%

75%

70% 1.22

1.28

1.26

1.24

1.23

1.29

1.27

1.25

1.24

1.23

1.30

1.28

1.26

1.25

1.24

should

causes Starting aid lllllll

I /lil/L

rate of batterv.

be for the charging

rate of 70% or more

in

table.

weather

the specific

lea?.t 75% in the above

I

gravity

must

be for the charging

rate of at

table.

Confirm

recent

repair hktory I

ODerated

lDQ*e”K

far lono

aeriad

III

I

II

I

III

III

III

Leakaae from fuel him There

95 SERIES

is

hunting from

engine (rotamn

is irregular)

I

I

I

lolol

I

I

I

I

I

I

I

I

lol

I

I

I

lo1

I


TESTING

AND

ADJUSTING

TROUBLESHOOTING

S-2 Engine does not start 0 Engine does not turn General

causes why

. Internal *

engine

parts of engine

If internal

does not turn seized

parts of the engine are seized, carry

out troubleshooting

for “Engine

stops during

I

1

operations�.

. Failure in power train . Defective electrical system

When turned

starting

switch

to START,

is

pinion

moves out, but

1) When terminal

B and terminal

C of starting

switch

are connected,

95 SERIES


TESTING

0

AND

TROUBLESHOOTING

ADJUSTING

Engine turns but no exhaust

gas comes out

(Fuel is not being injected) General comes

causes why engine

turns

but no exhaust

gas

out

* Supply of fuel impossible . Supply of fuel is extremely - Improper selection of

small fuel

(particularly

in

winter) Standards

95 SERIES

for use of fuel

12-039 0


TESTING AND ADJUSTING

TROUBLESHOOTING

0 Exhaust gas comes out but engine does not start (Fuel is being injected) General engine

causes

why

exhaust

gas

comes

out

but

does not start

* Lack of rotating

force

due

to defective

electri-

cal system

* Insufficient supply of fuel - Insufficient intake of air . Improper selection of fuel

loosened

temperature When

12-040 0

of some cylinder

fuel filter is drained,

is low

no fuel comes

out

95 SERIES


TESTING

AND

ADJUSTING

TROUBLESHOOTING

S-3 Engine does not pick up smoothly General

causes

why

engine

does

not

(Follow-up pick

is poor)

up

smoothly

- Insufficient intake of air * Insufficient supply of fuel . Improper condition of fuel injection . Use of improper

1 Non-specified Engine

fuel

fuel has been

oil must

Rust and water Dust indicator

used

be added

more

frequently

are found

when

fuel

I

lolalol-~~

I

lolol

0

is drained

I

of interference

.=

when

load

z _I? �

There

is hunting

When

exhaust

is heard

from

around

Blow-by

I

I

I

is applied from

engine

manifold

(rotation

is touched

of some

cylinders

gas is excessive

95 SERIES

I

turbocharaer

is irregular)

immediately

000 after

starting

0

engine, 0

I

I

is red

Noise

temperature

I

0

is low 8

I

12-041 0


TESTING

AND ADJUSTING

TROUBLESHOOTING

S-4 Engine stops during operations General

causes

why

engine

stops

during

operations

* Seized parts inside engine * Insufficient supply of fuel * Overheating + If

there

is

output,

overheating

carry

out

and

troubleshooting

insufficient for

over-

heating.

* Failure in power train *

If the the

engine

power

stops train,

because

carry

out

of

a failure

in

troubleshooting

for the chassis.

Condition

o

when

engine

urn by hand

using

bar

ring tool

When

I

1

5,n 4

to

fuel filter,

strainer

are inspected

directly,

they

are found

is inspected

directly,

it is found

I

I

I

I

I

I

I

1-l w

I

I

I

I

I

I

I

I

I

I

I

I

IZ

I

I

I

I?

d 2

be clogged

I When

feed

pump

strainer

Check

feed

pump

directly

When

control

does

rack is pushed,

it is found

to be heavy

l-1

or

not return

’*-hi4*

95 SERIES


TESTING

AND

ADJUSTING

TROUBLESHOOTING

S-5 Engine does not rotate smoothly General

causes

smoothly

(hunting)

why

engine

does

not

. Air in fuel system . Defective governor mechanism . Defective electrically controlled

rotate

throttle

mechanism (electrically

controlled

*

is no

If there controlled out

throttle

troubleshooting

tem.

Condition

95 SERIES

of hunting

throttle

hunting rod

type)

when

the

electrically

is disconnected, for

the

electrical

carry sys-


TESTING

AND

ADJUSTING

TROUBLESHOOTING

S-6 Engine lacks output (no power) General

* . .

causes why

Insufficient Insufficient Improper

engine

intake supply

Use of improper

If

there

output,

Ci%W?S

of fuel injection

fuel

(if non-specified l

I //1111111/11/

of fuel

condition

* Lack of output

lacks output

of air

fuel is used, output

drops)

due to overheating is

carry

overheating out

and

insufficient

troubleshooting

for

over-

heating.

Degree

of use

II

Suddenly Power

was

lost Gradually

IIQI I 0

II 0

II

II

0

0

0

8

II 0

II

II

II

II

II

0

II

b

‘= I S

Engine

oil must

Replacement

be added

of filters

more

frequently

has not been

carried

0 out according

to operation 0

manual

Color

of exhaust

gas

95 SERIES

I


TESTING

AND

TROUBLESHOOTING

ADJUSTING

S-7 Exhaust gas is black (incomplete General

causes why

exhaust

combustion)

gas is black

. Insufficient intake of air * Improper condition of fuel injection * Excessive injection of fuel

Color of exhaust

/

gas

When

turbocharger

When

air cleaner

When

compression

Speed

of some cylinders

95 SERIES

I

is rotated is inspected pressure

by hand, it is found to be heavy directly,

it is found to be clogged

is measured,

it is found to be low

does not change when

operating

on reduced

l 0

l

0

l

12-045 0


TESTING

AND

ADJUSTING

TROUBLESHOOTING

S-8 Oil consumption is excessive (or exhaust gas is blue) * Do not run the engine at idling for more than 20

minutes

continuously.

(Both

low

and

high

idling) General

causes why

oil consumption

is excessive

. Abnormal combustion of oil . External leakage of oil . Wear of lubrication system

l

When

intake manifold

is removed,

dust is found

When

intake manifold

is removed,

inside is found to be dirty with oil

inside

0 $

Remedy

’2-:46

g

.h .L .= .= ?j { $ uSBgggmssggg ~ o oagggmw,m $$o=eaec,,EtTE

8

B

.=

.=

.L

95 SERIES


TESTING

AND

TROUBLESHOOTING

ADJUSTING

S-9 Oil becomes contaminated General

causes

why

oil

quickly

becomes

contaminated

quickly

* * f .

Intake

of exhaust

gas due to internal

Clogging

of lubrication

Improper

combustion

Use of improper

oil

Operation

excessive

under

wear

passage

load

Colorof exhaust gas

95 SERIES

12-047 0


TESTING

AND

ADJUSTING

S-l 0 Fuel consumption General

causes

why

TROUBLESHOOTING

is excessive

fuel

‘consumption

is exces-

sive

* Leakage of fuel * Improper condition . Excessive injection

of fuel injection of fuel

I

Condition

When

I

of fuel consumption

check is made

using delivery

method,

injection

timing

is found

95 SERIES


TESTING

AND

ADJUSTING

TROUBLESHOOTING

S-l 1 Oil is in cooling water, or water spurts back, or water level goes down Generl causes why oil is in cooling water

* Internal leakage in lubrication system . Internal leakage in cooling system

95 SERIES

12-049 0


TESTING

S-12

*

causes why

2

TROUBLESHOOTING

oil pressure

Leakage,

clogging,

Defective

oil pressure

Use of improper Deterioration Standards

operation 3

ADJUSTING

Oil pressure lamp lights up (drop in oil pressure)

General

* * * .

AND

Caution

wear

lamp

lights

of lubricating

up

system

control

oil (improper

viscosity)

of oil due to overheating for engine

oil selection

manual lamp lights up

Non-specified

8

fuel has been used

0 Lights up at low idling

Condition

when

Lights up on sl Sometimes

is clogging,

leakage

1 Oil level sensor lame

I

P .Z 8 1

f %

I

12p

Metal

oarticles

When

oil filter

Remove Oil pump There

0

from

hvdraulic

0

000QOOO

Lights up at low, high idli “g

oil pressure

lamp lights up

1 There

0 0

OK3

0

ligt Its up

0

0

0

0

,.“+.,m.l\

liohts UD

are stuck to oil filter E

is inspected

directly,

it is found to be clogged

rotation

is catching

is heavy, there of relief valve,

0

l l

oil pa” and check directly

F ‘Z x gzi ? .t

a

l

is play regulator

l

valve, spring,

11

g-$

1 valve guide is broken

1 When

oil pressure

is measured,

it is found to be within

sti

95 SERIES


TESTING

AND

ADJUSTING

TROUBLESHOOTING

S-13 Oil level rises * If there is oil in the cooling troubleshooting

water,

for “Oil is in cooling

carry

out

water”.

. Water in oil (cloudy white) . Fuel in oil (diluted, and smells of diesel fuel) . Entry of oil from other component

ewe umber

radiator

cap open. When

of bubbles

95 SERIES

appear,

engine

or water

is run at idling.

spurts back

an abnormal


TESTING

AND

ADJUSTING

TROUBLESHOOTING

S-14 Water temperature General

causes

why

becomes too high (overheating)

water

temperature

becomes

too high

. Lack of cooling

water

(deformation,

damage

of

fan)

* Drop in heat dissipation efficiency * Defective in cooling circulation system . Rise in oil temperature of power train *

Carry out troubleshooting

Condition

3

Water

for chassis.

of overheatin

temperature

gauge

Does not go down from

2

I

red ranae Radiator

water

level sensor

Fan belt whines

/I

Cloudy

white

Coolina

water

Excessive

under sudden

oil is floating flows

I

I

I

I

load

on cooling

inside radiator,

I

I

I

I

I

I

I I I 1 I r-~-l

Q

I

I

I

I

I

101 Q

water

out from overflow

air bubbles

I

lights up

I

I

hose water

I

I

I

I

I

I

lo1

spurts back

Engine oil level has risen, oil is cloudy white There

is play when

Temperature

fan pulley

is rotated

difference

between

top and bottom

radiator

tanks is

difference

between

top and bottom

radiator

tanks

l

excessive Temperature

I I I I I I I I I<

I I.1 P ‘Z 8 5 ‘:

F

When

water

filler port is inspected,

When

a function

test is carried

out on the thermostat,

$

a

the core is found to be clogged

z ‘G 8

it does not open 0

even at the cracking When water

temperature

temperature

When

oil cooler

When

measurement

is measured,

is inspected

directly,

is made with

it is found

radiator

cap tester,

set pressure

f

a

to be normal

P a b

0

it is found to be clogged is

0 found to be low When

compression

) Remove

pressure

is measured,

2 ?

it is found to be low

oil pan and check directly

’*-SF*

95 SERIES


TESTING

AND

ADJUSTING

TROUBLESHOOTING

S-l 5 Abnormal noise is made * Judge if the noise is an internal external General

noise

or

an

noise.

causes why

abnormal

noise is made

. Abnormality due to defective parts * Abnormal combustion noise . Air sucked in from intake system

Condition

Metal

of abnormal

particles

Blow-bv Noise

are found

y

in oil filter

of interference pickup

When

exhaust

/ temoerature

is poor manifold of some

c

0)

oas is excessive

Engine

reduced

noise

is heard

from

around

and combustion is touched cvlinders

turbocharger

is irregular immediately

is low

after

starting

engine,

I

I

I

IY’l�l

I

I

I

I

I

I

I

cylinders

95 SERIES

12-053


TESTING

AND

ADJUSTING

TROUBLESHOOTING

S-l 6 Vibration is excessive * If there is abnormal noise vibration,

carry

together

out troubleshooting

with for

the

“Abnor-

mal noise is made”. General

causes

- Defective - improper . Abnormal

Remove

why vibration

parts

(abnormal

is excessive wear,

breakage)

alignment combustion

oil pan and check

Remove side

Remove

head

Injection

pump

cover

cover

directly

and check

and check

test shows

that

11

1.1

I

directly

I.1

11 I I

directly injection

/ I

0 amount

is incorrect

0

Remedy

E $

: $

k$e”$$CcK

12-054

11 I I

I

0” $

8 $

g 2

.& 0

.5 g

B $

6 5

L?

-z

95 SERIES


TROUBLESHOOTING

TESTING AND ADJUSTING

S-17 Diagnosis of electronical governor governor made by ZEXEL) This electronical The following *

governor

failures

Make the following

Sr

(1)

The battery

(2)

The fuses of the electronical

(3)

The relevant

There

(troubleshooting)

by the indication

function.

of diagnosis

starting

diagnosis.

governor

controller

display (electronical

lamps.

is normal. connectors

are cases where

occurrence

the diagnosis

checks before

using a T-branch *

provides

can be checked

by diagnosis

the connectors

adaptor

between

are disconnected connector

the disconnected

are free of blow.

abnormalities. and the voltage

kit in each step of diagnosis.

of short-circuit

Be sure to reconnect

system

are free of connection

Therefore,

and resistance

pay sufficient

value are checked

attention

not to allow

terminals.

connectors

before

proceeding

to the next step on termination

of

one diagnosis.

Items of diagnosis 1. Abnormalities

in controller

system

2. Abnormalities

in governor

servo system

3. Abnormalities

in rack sensor

4. Overrun 5.

1st speed

sensor abnormality

6. 2nd speed

sensor

7.

Low idling speed

8.

Droop changeover

9.

Abnormality

10. 11.

system

abnormality abnormality control

dial abnormality

dial abnormality

in load current

Failure

in lighting

Normal

indication

signal

of diagnosis

(when

equipped

with feed forward

a.

Failure

in changeover

between

low idling speed

b.

Failure

in changeover

between

50Hz and 60Hz

c.

Starting

failure

(the engine

cranks,

d.

Starting

failure

(the engine

fails to start, although

e.

The engine

12. Memory

clear cannot

by diagnosis

95 SERIES

stalls during

controller)

lamp and rated speed

but no exhaust

smoke

is emitted.)

but exhaust

smoke

is emitted.)

running.

be achieved

by pressing

the memory

clear switch

(when failure

indication

is made

lamp).

’2-:55


SYSTEM Low

RELATED ELECTRIC CIRCUIT DIAGRAM idling/rated

50/60

speed

Hz changeover

changeover Table

of terminals

N fl .Name of signal

ller ground

and signals N fl *Name of signal

N n .Name

of signal

terminal

(Tightened

together

controller

bolt)

with

Table

of wirino

harness

connectors

and eauioment

1Awicable 1 Type wire Size IIIL

I __________________________-

_____

I + I

----

II

I -I__

------------------

_I

I

+ 2 4 v Oil pressure

detection

Engine

Chassis

wiriing

ON/OFF

harness

, 0 J 17

Lamp RL.UP8-87-R LED-R. R:3KQlW Lamp GL. UP8-87-G LED-G. R:ZKQlW PB.SB-221 N/O Switch IP. ACl25V3A

-

lzumi Denki

-

lzumi Denki

_

Nihon kaiheiki TDE00094

’2-:58

95 SERIES


TROUBLESHOOTING

TESTING AND ADJUSTING

Diagnosis lamp indication

l

Lit

@

@ Simultaneous

0

out

@

6%)Alternate

flashing

@

@ Alternate

quick flashing

@ Quick flashing

(0.25 second)

@ Slow flashing

(2 seconds) Diagnosis

Indication

type

Controller

system

Governor

servo system

lamp indication &es�Red I 0 0

Q

(>

CD

0

0

@

0

8

No indication

0

0

Normal

l

0

I

Rack sensor system

I

Overrun

1st speed sensor (engine)

2nd speed sensor (Fuel injection

Low idling speed control

Droop changeover

Load

current

indication

dial

dial

signal

_

pump)

I

flashing


TROUBLESHOOTING

1. Abnormality

Green

DIAGNOSIS

OF ELECTRONICAL GOVERNOR

in controller

Red 5YES

2. Abnormality

L

1

Green

Red

3. Abnormz

rES Is there catching inside injection Is resistance between pump? q (female) 8 (0) YES and qfemalel @ - (@I),,. and between q - * Remove rack cap No 3 to check. (female) @ @I and Is resistancebetween W (female) 8 60) 0 (female) 6 and a normal? ySS (female)0 @ (female) *Resistancebetween0 N 0 - (0). and between 0 (female)QI (@I and q(femalei@ @I: 30.5-33.5 R (female) @and 0 -Resistance between Ej (female)@@I and @ (female) (female10 &Z (female) @@,,: 0.75-z?Q 2 (0) normal? . Turn powersource OFF. Is resistance - Resistancebetween D *Disconnect0. (Connectqand qI.) YES between q (female) _ (female) 0 and 0 NO (female)0 @Iffemale) r 0 (8) and @(@I (a,,: 30.5 38.5 n norrnal? 1 -Resistance between q (female) @and 0 Is resistance between * Resistance: (female) 0 l@female) IQ : 0.75- 22 R 9-10.5Q -Turnpower source OFF. (female) t@j and 0 *Disconnect 0 and q. - Turn power source OFF. NO * Disconnect a. * Resistance: (Connect q and q.) 9-10.5R * Turn power I source OFF. NO * Disconnect q and q.

in governor

servo system

ity in rack sensor system

L

J

TDE00095

95 SERIES


TROUBLESHOOTING

DIAGNOSIS

OF ELECTRONICAL GOVERNOR

Cause

-L ibnormality

-c Iefective

Remedy

in controller

Replace

injection pump

Replace

-C )efective controller

IIjefective wiring harness q and q,@I

(Ibetween

Replace

Replace (repair wiring harness)

-C jefective injection pump

jefective wiring harness aetween q and 0)

clefective injection pump, d efective wiring harness

95 SERIES

Repair wiring harness

Replace (repair wiring harness)

’2-F


DIAGNOSIS

TROUBLESHOOTING

OF ELECTRONICAL GOVERNOR

4. Overrun abnormality

1 YES OFF

ON

*z Green (Overrun)

Is resiStance between 0 (female) 8 and 0 (female) @I infinity?

. Turn l

power source OFF. Disconnect q.

NO

Cause is probably outside electronic governor system

Replace

Defective injection pump, defective wiring harness

Replace, repair wiring harness

TDE00095

’*2*

95 SERIES


DIAGNOSIS OF ELECTRONICAL GOVERNOR

TROUBLESHOOTING

in No. 1 speed sensor

5. Abnormality

I

1

resistance between q (male) _ @and q (male) @ 2.1 - 2.5 kR? , * Turn power source OFF. * Disconnect q.

6. Abnormality

2

@ Green

@Red

1

I

Iefective controller

3eplace

I

defective wiring harness between q and q)

3epair or .eplace

c

Iefective engine nstallation, speed sensor

NO

*Turn power source OFF. * Disconnect q. (Connect HI.) NO

in No. 2 speed sensor 2

Slow alternateflashing

YES

Is resistance YES between q 1 (female) @ and @I 2.1 - 2.5 kQ?

Is

Remedy

Cause

YES

jefective controller

Is resistance between q (female) @Iand q (female) s I~.l-2.5M?

(Euikintoinjection pump) * Turn power source OFF. * Disconnect q.

I@

NO

::“[Jg

-------------I

defective wiring harness between q and q)

3epair or ,eplace

Iefective speed sensor nside injection pump

qeplace

/

TDE000915

95 SERIES

’*-iF3


DIAGNOSIS

TROUBLESHOOTING

7. Abnormality

in low idling speed adjustment

OF ELECTRONICAL GOVERNOR

volume Cause

2 YES

Abnormality

resistance YES between q (female) Q and q (female) @ H 1 normal?

rl

in controller

I

Remedy

Replace

Is

;

:Ec

Green

_zzz$~Yrl&l_ normal? * Resistance ;hytt;;prox.

’* Resistance changes: Approx. 0.5 - 10.5 kR *Turn power source OFF. * Disconnect q. *Turnlow idling speed adjustment volume. NO

*Turnpower

source OFF. . Disconnect q. *Turn low idling speed adjustment volume.

Defective wiring harness (between H @ and low idling speed adjustment volume)

Repair wiring harness

Defective low idling speed adjustment volume or defective wiring harness (between L%@ and low idling speed adjustment volume)

Replace or repair wiring harness

I

cl Cl----

TDE00097

’2P4

95 SERIES


TROUBLESHOOTING

8. Abnormality

DIAGNOSIS

in droop adjustment

volume

2

YES

-

Is resistance YES_ between q (female) _ @and q (female) @ 1 normal?

ON

l

Quick flashing

Green

(# Red

_

Is resistance between q (female) _ @and q (female) @I normal? * Resistance

*Turn power source OFF. * Disconnect 0. *Turn droop adjustment

OF ELECTRONICAL GOVERNOR

NO * Resistance changes: Approx. 0.5 - 10.5 kD *Turn power source OFF. * Disconnect k3. *Turn droop adjustment volume.

)

Abnormality

in controller

Replace

Defective wiring harness (between q @and droop adjustment volume)

Repair wiring harness

Defective droop adjustment volume or defective wiring harness (between q @ and droop adjustment volume)

Replace or repair wiring harness

TDE00097

95 SERIES

’*-F5


DIAGNOSIS

TROUBLESHOOTING

9. Abnormality in load current signal (when equipped with feed forward

OF ELECTRONICAL GOVERNOR

controller) Cause

2

OFF Slow flashing 0 Green

@ Red

Is wiring harness -betweenBandH normal?

-

YES

NO * Start engine. * Connect T-adapter to 0. * Voltage between q 0 - @ (@I: 5V (if it is not 5 + 0.25 V, controller is abnormal.) *Voltage between q (4) !@0)- 0 t@): l -3V

*Disconnect conneztofsOand0 - No continuity Load detector output adjustment value between any of Generator load: 0% - 3V q (female) @, @, 8 and chassis [ Generator load: 100% -) IV ground. I\IO Connect each of q (female) @I,@, (@), @I, (8) to chassis ground. * Continuity between each of q (female) @, @, @ and chassis ground.

Remedy

,bnormality in controller

eplace

,bnormality in load etector

eplace

Defective wiring harness (between q and q)

lepair wiring larness

l

’*P

95 SERIES


TROUBLESHOOTING

lO.Diagnosis

OFF

DIAGNOSIS

OF ELECTRONICAL GOVERNOR

lamp gives no display

OFF -

1 YES Is voltage between q (checkterminal) @ and generator body, and between @and generator normal? NO * 0 voltage: +20 - +3ov * 0 voltage: 0 - +2V *Turn power source ON.

Abnormality

in controller

Defective wiring harness (between q @ t@) and r- ACC terminal, or between q @ (I@ @)) and battery ground)

TDE00099

95 SERIES

’2-:67


TROUBLESHOOTING

11. Normal

DIAGNOSIS OF ELECTRONICAL GOVERNOR

display

a. Low idling/rated

does not switch Cause

1

; Green

“6;Red

Is voltage between q @ and q @ normal?

YES

-Abnormality

Remedy

in controller

Replace

Defective wiring harness (between low idling/rated changeover switch and controller)

NO

* Turn power source ON. . At low idling: 20 - 3ov * At rated: 0 - 2V

I

Repair wiring harness

I

TDEOOlOO

b. 50/60

1

Green III

Red

Cause

Hz does not switch

Remedy

YES L

Abnormality

I

Defective wiring harness (between 50/60 Hz changeover switch and controller)

Is continuity between q (female) _ @and q (female) d normal? * Disconnect q. NO * 50 Hz selected: Continuity . 60 Hz selected: No continuity

50/60 Hz changeover

gl

in controller

Replace

Repair wiring harness

& = 0 & F s

TDEOOIOI

’*2*

95 SERIES


TROUBLESHOOTING

c.

DIAGNOSIS

OF ELECTRONICAL GOVERNOR

Defective starting (engine is cranked but no exhaust smoke comes out) Check first for any cause outside the electronic governor system (abnormality in fuel system, etc.) Cause

YES 1 ON

OFF

0

0

Green

Red

Is there short circuit between (female) 8 and (female) @I? -Turn power source OFF. - Disconnect 0.

.

I

q q

2

YES

Is there short circuit between q (female) NO @ (6% and q (female) @ @?

- Turn

power source OFF. - Disconnect a.

NO

Defective injection pump (defective wiring harness)

Remedy

I

Fleplace or r’epair

Defective wiring harness (between 0 and q )

lepair or eplace

Defective controller

leplace

L..

TDE00095

95 SERIES

’*-Lf9


DIAGNOSIS

TROUBLESHOOTING

d.

Exhaust

smoke

comes

out, but engine

OF ELECTRONICAL GOVERNOR

does not start Remedy

Cause

YES

ON

OFF

1

Ilsthereshort

Defective injection pump (defective wiring harness)

leplace or epair

Short circuit in rack sensor wiring harness between 0 and q

lepair or eplace

‘1 : YES

IS mere

* Turn power source OFF. * Disconnect 0.

snort ( Cause is probably outside electronic governor system

___.__ _. F. * Disconnect a. NO *20-3ov (battery voltage) * Disconnect @I. * Turn power source ON. * Start engine.

Defective wiring harness [between starting switch terminal q and q)

lepair or eplace

-2 51

r-

L-

I

I

40

52

•1C

TDE00095

Starting switch C terminal -

TDE00102

’2i?70

95 SERIES


DIAGNOSIS

TROUBLESHOOTING

e.

Engine

stops during

OF ELECTRONICAL GOVERNOR

operation

This electronic governor system is designed to stop the engine following cases. 1. When the emergency stop switch is being pressed 2. When the engine water temperature is abnormal 3. When the engine oil pressure is abnormal

95 SERIES

in the

’*-ii7’


DIAGNOSIS OF ELECTRONICAL GOVERNOR

TROUBLESHOOTING

12.

Memory is not cleared when memory clear switch (when diagnosis lamp displays failure)

is pressed

To clear the memory, keep the memory clear switch pressed for at least memory is not cleared if the switch is pressed only momentarily. If the memory is not cleared when memory clear switch is pressed for more carry out the troubleshooting below.

5 seconds. than

Cause

1

YES

= _ Defective controller

Is continuity between q (female) @ and @J normal?

) NO

- Turn power source OFF. * Disconnect a. * Memory clear switch ON: Continuity * Memory clear switch OFF: No continuity

Memory

Defective memory clear switch or defective wiring harness (between memory clear switch and controller)

The

5 seconds,

Remedy

Replace

Replace switch or repair wiring harness

clear switch

TDE00103

‘2i72

95 SERIES


ENGINE 13 DISASSEMBLY

AND ASSEMBLY

3D95S-W-1 General

disassembly

General

assembly

. . . . . . . . . 13-001-I .

. . . . . . .

. . . .

13-001-9

4D95S-1 General

disassembly

General

assembly

4D95L

disassembly

General

assembly

disassembly

General

assembly

procedure

in which

fundamentally *

95 SERIES

Use the correct

may differ

slightly

the engine is mounted

from

that

of

. . ..

given here depending

and also the particular

. . . . . . . . . . . . 13-036 .... . ..... . . . . 13-050

and assembly

air compressor

The work

. ..... . . . . . 13-002 ..... . . . . . . . . . . 13-016

SERIES

General

Disassembly

chine

. . . . . . . . . . . . 13-001-22 ... . . . . . 13-001-33

SERIES

General

6D95L

*

..

..... .....

13-070

upon the ma-

stand used, however

it is

the same. service tools when performing

disassembly

and assembly.

’3-:01


GENERAL DISASSEMBLY GENERAL

DISASSEMBLY

2. Alternator 3. Starting 5. 6. 7.

.....................

................. Water pump ................... Filter, level gauge .............. Fuel filter, injection tube ........ Nozzle holder ..................

8. Glow

motor

plug

.....................

9. Fuel injection 10. 11. 12. 13. 14.

............ Cylinder head cover ............ Rocker arm .................... Push rods ..................... Cylinder head assembly ........ Flywheel .......................

15. Housing

pump

.......................

16. Crankshaft 17. Oil pan

pulley

..............

........................

.......

13-001-2

1. Tappet 2. Camshaft

....... 13-001-3

3. Crankshaft

....... 13-001-3

4. Main cap

....... 13-001-3

5. Piston,

....... 13-001-3

6. Oil pump

....... 13-001-3

7. Idler gear

....... 13-001-3 ....... 13-001-3

...........................

. 13-001-13 . 13-001-13 13-001-14 . 13-001-14 13-001-14

11. Crankshaft

....... 13-001-4

12. Housing

............................

. 13-001-15

....... 13-001-4

13. Flywheel

. 13-001-15

....... 13-001-5

14.

. 13-001-15

....... 13-001-5

15.

....... 13-001-5

16.

....... 13-001-5

17.

............................ Cylinder head ....................... Push rods .......................... Rocker arm ......................... Adjusting valve clearance ........... Cylinder head cover ................. Fuel injection pump ................. Glow plug .......................... Nozzle holder ....................... Fuel filter, injection tube ............. Oil filter, level gauge ................ Water pump ........................ Starting motor ......................

20.

....... 13-001-6

21.

....... 13-001-6

22.

23. Piston,

....... 13-001-6

23.

....... 13-001-8

24.

....... 13-001-8

25.

....... 13-001-8

26. Alternator

............................. pulley

...................

..........................

27. Fan, fan pulley

‘3-08’-’

. 13-001-11

10. Oil pan

....... 13-001-6

...................... ..................... 25. Crankshaft ........................ 26. Tappet

. 13-001-10

....

....... 13-001-4

18.

24. Main cap

rod assembly

....... 13-001-4

19.

rod assembly

. 13-OOI- 9

...........................

........................... ......................... 8. Gear cover 9. Oil suction pipe .....................

....... 13-001-6

connecting

. 13-OOI- 9

................. ..........................

assembly

connecting

....... 13-001-5

pipe

19. Gear cover

. 13-OOI- 9

.............................

....... 13-001-2

................ .................... 20. Idler gear ...................... ...................... 21. Oil pump ............ 22. Camshaft assembly

18. Oil suction

(3D95S-W-l)

GENERALASSEMBLY

.................

1. Fan, fan pulley

4.

AND ASSEMBLY

......................

. 13-001-14

13-001-17 13-001-17 . 13-001-18 . 13-001-18 . 13-001-18 . 13-001-18 . 13-001-19 . 13-001-19 . 13-001-19 . 13-001-19 . 13-001-19 . 13-001-20 13-001-20

95SERlES


DISASSEMBLY

AND ASSEMBLY

GENERAL

GENERAL DISASSEMBLY Special

No.

l

DISASSEMBLY

(3D95S-W-1)

(3D95S-W-1)

tools

1

Q’ty

Part Name

Part No.

1 795-102-2102

B

I 795-100-4710 I Valve guide remover

C

I 795-100-2800

Preparatory

1 Spring

I

A

pusher

I Piston

1

I 1 I 1

ring tool

work

l

Remove

all dirt and mud from

l

Remove

the drain

plug

around

and drain

the engine.

the oil from

the

engine. I l

:

Engine

Prepare vent

a stable

from

5.0 I!

stand @ which

falling

will pre-

over, then put the en-

on the stand.

Fan, fan pulley Remove Loosen

fan. mounting

then loosen

A

bolts of adjustment

mount

Be careful

not to catch

tor towards fan puley

plate

bolt, and remove

age the alternator

Remove 2.

Approx.

engine

the engine

gine securely

1.

oil:

when

the cylinder

your

(I),

belt. fingers

moving

or dam-

the alterna-

block.

(2).

Alternator Remove remove

adjustment alternator

95 SERIES

plate

and

mount

bolt,

then

(3).

’3-oz’ -*


DISASSEMBLY

3.

4.

AND ASSEMBLY

Starting

motor

Remove

starting

Water

motor

6.

7.

Filter,

filter

2)

Remove

level gauge

3)

Remove

hose (8).

Fuel filter,

pump

(5).

Disconnect

2)

Remove

Nozzle

(6).

injection

1)

(7).

tube

hose (9) and remove

fuel injection

tube

fuel filter

(IO)

(11).

holder spill tube,

Be careful holder

not

when

and remove to

damage

the

of installation. nozzle

when

nozzle holder the

tip

of the

(12). nozzle

removing.

Mark the nozzle holders sition

holder,

with

If there install

tags showing

the PO-

is no abnormality

it in the

same

in

position

assembling.

Glow plug Remove

9.

water

level gauge

Disconnect

8.

then remove

Remove

*

(3D95S-W-1)

(4).

1)

*

DISASSEMBLY

pump

Pull out pilot portion,

5.

GENERAL

glow wire

Fuel injection Disconnect pump

(13), then remove

glow

plug (14).

pump

lubrication

tube,

then

remove

fuel injection

(15).

13-tP3

95 SERIES


DISASSEMBLY

AND

10. Cylinder

GENERAL

ASSEMBLY

DISASSEMBLY

(3D95S-W-1)

head cover

Remove

cylinder

head cover.

11. Rocker arm Remove *

rocker

When

arm (16).

removing

the rocker

and turn the adjustment

arm, loosen

screw

the locknut

back 2 -

3 turns.

12. Push rods Remove *

push rods (17).

Mark the push of

rods with

installation.

push

rod,

If there

install

it in

tags to show is no the

the position

abnormality

same

in the

position

when

assembling.

13. Cylinder

head assembly

Remove

cylinder

head mounting

bolts.

Remove

cylinder

head assembly

(18).

*

Lay cardboard

on the floor

tom face of the cylinder When

disassembling

the

to protect

head from cylinder

the bot-

damage.

head

assembly,

do as follows.

1) Using remove ii)

Release spring

tool

A,

valve

compress

cotter

pressure

on

spring,

seat (20) and valve

iii)

Remove

iv)

Using tool B, remove

95 SERIES

valve

valve

spring,

then

(19). spring

and

remove

(21).

(22).

valve

guide

(23).

P614701Of5

13-og l-4


DISASSEMBLY

AND ASSEMBLY

GENERAL

DISASSEMBLY

(3D96S-W-1)

14. Flywheel Remove

a

flywheel

(24).

If the

flywheel

wheel

may drop suddenly,

comes

out

from

pilot,

so handle

the

fly-

carefully.

15. Housing 1)

Remove

housing

2)

Remove

rear seal (26).

16. Crankshaft

(25).

pulley

1)

Remove

plate (27).

2)

Remove

crankshaft

pulley

(28).

17. Oil pan *

Turn the engine then remove

18. Oil suction Remove

13-O$l-5

over and set the oil pan at the top,

the engine

oil pan.

pipe

oil suction

pipe (29).

95 SERIES


DISASSEMBLY

GENERAL

AND ASSEMBLY

19. Gear cover 1)

Remove

gear cover

2)

Remove

front

seal (31).

(30).

(32).

20. Idler gear 1)

Remove

plate

2)

Remove

idler gear (33).

21. Oil pump 1)

Remove

oil pump

2)

Remove

driven

22. Camshaft 1)

(34).

gear (35).

assembly

Remove

mounting

bolts

(36) through

casting

hole

in gear. 2)

Remove *

camshaft

When

assembly

removing,

and be careful 23. Piston, *

connecting

Taking der,

the

camshaft

lightly

the bushing.

rod assembly stamped

the cylinder

care not to damage

use fine

(37).

not to damage

Check that the number rod cap matches

Sr

rotate

sandpaper

on the connecting

number. the inside

to remove

of the cylin-

the carbon

on

the top wall of the cylinder. *

Measure with

the side clearance

dial gauge

95 SERIES

0.

of the connecting

rod

DISASSEMBLY

(3D95S-W-1)


DISASSEMBLY

AND

Rotate

the

crankshaft

removed

at bottom

Remove

mounting

(38),

then

with

GENERAL

ASSEMBLY

remove

to

set

the

piston

to

DISASSEMBLY

(3D95S-W-1)

be

dead center. bolts

of

connecting

connecting

rod

rod

cap

cap

together

bearing.

Push

piston

and connecting

wooden

bar or hammer

Support

piston

in further

from

connecting

assembly

at cylinder

from

piston

with

a

oil pan side.

head end, then push

oil pan side and remove

rod assembly

Disassemble

rod

handle

piston

bar and

(39).

and connecting

rod

assembly

as follows. Using snap ring pliers, Remove

piston

remove

ing rod (42) and piston *

snap ring (40).

pin (41), and separate

If the pin does

connect-

(43).

not come

out,

soak

in hot

water. Remove

snap

ring

on other

side

in the same

way.

P6 I 470

4)

5)

Using tool C, remove

When

replacing

(outside *

bushing

diameter:

Keep

the

ings,

piston

piston

ring (44).

(45), use push tool

32 mm) to remove

pistons, rings,

for each cylinder

IO28

connecting and

piston

@

bushing.

rods, pins

bearin sets

number.

d2 P61470t031

13-iP7

P634708032

95 SERIES


DISASSEMBLY

AND

ASSEMBLY

GENERAL

24. Main cap *

Measure 0. *

The

end end

judging

1)

play

of crankshaft

play

measurement

wear

of the thrust

mal wear

of the crankshaft,

removing

the crankshaft.

Remove

mounting

bolts

main cap (46) together *

Rubber

seal

using

dial gauge

is necessary bearing

so measure

before

of main cap, then with

lower

for

and abnor-

remove

bearing.

(47) is assembled

to No. 4 main

cap.

25. Crankshaft 1)

Remove *

crankshaft

Be careful cylinder

2)

Remove

(48).

not to hit the crankshaft

block and damage

upper

main

bearing

against

the sliding

the

surface.

(49), and thrust

bear-

ing (50). *

Mark the main bearing tags

or a felt

stallation,

and

number.

26. Tappet Remove

tappet

95 SERIES

(51).

and thrust

pen to show keep

in

the sets

bearing position for

each

with of incap

DISASSEMBLY

(3D96S-W-1)


DISASSEMBLY

AND

ASSEMBLY

GENERAL

ASSEMBLY

(3D95SW-1)

GENERAL ASSEMBLY Special

tools

No.

Part No.

A

795-l 02-2102

Spring

pusher

1

C

795-l 00-2800

Piston

ring tool

1

D

795-l 00-4720

Push tool

2.

795-213-1800

) Piston holder

I

1

G

1

795-100-4700

1 Push tool

I

1

795-l 25-l 370

Coat

the

Feeler gauge

sliding

surfaces

1

of all parts

with

engine

oil

installing.

Tappet Assemble

tappet

(51).

Camshaft

assembly

1) Insert camshaft *

Rotate avoid

2) Tighten

3.

1

)

(EOBO-CD) before 1.

O’ty

F

H

*

Part Name

the

assembly

(37) into cylinder

camshaft

lightly

damaging

mounting

when

block.

inserting

to

the bushing. bolts

casting

hole of gear.

m

Mounting

bolt:

(36) of thrust

plate through

1.4 k 0.5 kgm

Crankshaft 1)

Align

protrusion

of upper

notch

in cylinder

block,

main

then

bearing

assemble

(49) with to cylinder

block. *

Check that there

is no dirt or dust stuck

to the

rear face of the bearing. 2)

Assemble

3)

Assemble t

thrust

crankshaft

Be careful cylinder

t

When

bearing

(48) to mounting

not to hit the crankshaft

position. against

the

block. the crankshaft

heat the crankshaft to 230 shrink

(50).

250°C for

gear

has been

gear in an electric approx.

replaced, furnace

30 minutes,

then

fit the gear.

’3-oz’-9

95 SERIES


DISASSEMBLY

4.

AND ASSEMBLY

GENERAL

ASSEMBLY

(3D95S-W-1)

Main cap 1)

Align

protrusion

in lower

in cap (46), then install Check that there

*

main

bearing

main bearing

with

notch

cap.

is no dirt or dust stuck to the

rear face of the bearing. *

Assemble

rubber

seal (47) and the thrust

bear-

ing to No. 4 main cap.

Rubber

seal IT

L

I L

P

6206F554

&

2)

Rubber

Check same

that

seal groove:

number

as number

stamped

Assemble number

3)

the facing

Tighten

mounting

wrench

as follows.

*

When

cap

then

is the

assemble

bolts.

cap with

the casting

part

the front. bolts

tightening

main

block,

mounting

main

sealant

on main

on cylinder

main cap and tighten t

Gasket

cap, start

of main the

cap with

mounting

in the middle

outside

symmetrically

to

Tighten

in steps to the following

&

Bolt thread,

B

Mounting

a torque

bolts

of the

and work

the

seat face:

left

to the

and

right.

torque. Engine

oil

bolt of main cap kgm

Order

Target

1 st step

11.5

11 -

0

I Loosen completely

13.5

13 -

2nd step

I

3rd step

*

After

tightening

the main

check that the crankshfat

95 SERIES

Range 12

14

cap mounting rotates

bolts,

smoothly.

‘3-oP’o


DISASSEMBLY

4)

AND

Measure

end

ASSEMBLY +

5.

Piston, *

play

crankshaft.

(See

ASSEMBLY

and

assemble

connecting

the piston

DIS-

0.13 - 0.35 mm

rod were

disassem-

and connecting

rod as-

first as follows.

Using

push tool

@ (outside

press fit connecting

diameter:

rod bushing

32 mm),

(45).

P614701032

2)

Using tool C, install *

Set

the

When

fitting

with

ring

the oil ring, assemble

to the piston

the groove

P614705031

ring (44).

mark at the end gap facing

pander into

piston

compression

stamped *

(3D95S-W-1)

rod assembly

piston

sembly

of

range of end play:

connecting

bled,

GENERAL

for details)

Permissible

If the

1)

ASSEMBLY

first,

the up.

the ex-

and fit securely

on the inside

diameter

of

the oil ring. *

The end gap of the ring should

be at 180

to the join of the coil in the expander. 3)

Assemble groove

snap

ring

on one side

in snap

ring

of piston. _

4)

Set

F mark

same ing

rod.

boss

as casting

Insert

connecting 5)

on piston

direction

piston

surface

number

pin

Assemble

snap

ring

in

on connect-

(41), and

rod (42) and piston

facing

PSf4708030

assemble

(43).

(40) and secure

with

pis-

ton pin. *

Assemble

the

snap

ring

securely

in the

ring groove. *

After that

assembling the

forward

the

connecting

snap

rod

rings,

moves

check

smoothly

and backward. P614701028

13-oP1 ’

95 SERIES


GENERAL ASSEMBLY (3D95S-W-1)

DISASSEMBLY AND ASSEMBLY

Position of oil ring end gap

Assemble

the

cylinder

piston

and

Set crankshaft be installed

rings as shown

pin of piston

at bottom

protrusion

rod

rod

in the

block as follows.

Set end gaps of piston

Align

connecting

with

in

rod to Position of top ring end gap

dead center.

in upper

notch

in diagram.

and connecting bearing

connecting

of connecting

rod,

then

install Position of undersize line

bearing. *

Coat the inside

face of the cylinder,

rings

surface

and

bearing

the

with

engine

of the

the piston

connecting

rod

oil. Position ofcsecond ring end gap

4)

Align

direction

face front connecting

5)

When

of F mark on piston

rod (39) from

piston

liner,

push

rings

6)

Align rod

protrusion with

semble f

piston

inside

cylinder

In addition,

pull

rod and fit to crankshaft

pin.

lower

to and

head gnd.

inserted

of piston.

of

notch

cylinder

are

in head

end of connecting

boss surface

Using tool F, insert

of engine.

bearing

in connecting

rod

big

of connecting cap,

then

as-

bearing.

Check that there

is no dirt or dust stuck

to the

rear face of the bearing.

7)

Set with

stamped

mark

at camshaft

stall connecting

rod cap (38).

t

the

Check

that

necting

stamped

end, then

number

rod cap is the same

in-

on the con-

as the number

of

the cylinder.

9)

Tighten

mounting

bolts

of connecting

rod

cap as

follows. a

Bolt thread,

m

Mounting

seat face:

bolt of connecting

1 st stap

Tighten

2nd step

Mark

After bolt

oil

rod

in turn to 4+t2 kgm

bolt head and cap seat with

pen, then turn *

Engine

tightening,

bolt 90+s0’to

make

head to indicate

a punch

a felt

tighten. mark

the number

on the

of times

the

Put a mark on the bolt cap

bolt has been tightened. The times.

bolt

can

Always

has five punch t

After

be

used

replace

a maximum any

bolt

that

of

five

already

marks.

assembling

that the crankshaft

the

connecting

rotates

smoothly.

rods,

check After tightening, stamp mark the tightening time on bolt head by punch

6206F303

95 SERIES

13-og-12


GENERAL ASSEMBLY (3D96S-W-1)

DISASSEMBLY AND ASSEMBLY

9) Measure

side

clearance

(See DISASSEMBLY *

Permissible

of

connecting

rod

cap.

for details.)

range

of side

clearance:

0.20 -

0.40 mm

6.

Oil pump

7.

1)

Install driven

2)

lnstal oil pump

gear (35) of oil pump. (34).

Idler gear Align

match

(33). * Match

marks

of gear,

and

gear and idler gear:

gear

plate (32), then tighten Mounting

Measuring

bolt:

backlash

Align

match

mark

install

temporarily,

“A”

“B”

Cam gear and idler gear:

m

idler

marks

Crankshaft Install

install

mounting

bolts.

110.2 + 12.3 Nm (11.25 + 1.25 kgm)

of gears “C”

of fuel

then

injection

measure

pump

backlash

(15),

of each

P6t4701022

gear. *

When hold

measuring one gear

the other

the

backlash

in position

of each

securely,

gear,

and move

gear to measure.

P614701041

t

Gear backlash (helical gear) (Serial No.: 106425 and below)

j,

Match mark

Position

Gear backlash (helical gear) (Serial No.: 106426 and up)

mm

Range

of measurement

Match mark

Position

Unit:

mm

Range

of measurement

I

I

A -

A

B -

B

C-

C ) Injection

-

Unit:

Crankshfat

gear and idler gear

0.28

A - A

pump gear and idler gear

crear and idler

1 0.08 - 0.19

aear

gear

/ 0.13 - 0.34 0.13 -

0.35

-

13-oP’3

1Crankshaft

/ 0.15 - 0.30

1 Cam gear and idler gear

Cam gear and oil pump

0.14 -

1Cam gear and PTO gear (With PTO)

1 0.15 - 0.30

95 SERIES


DISASSEMBLY

AND

ASSEMBLY

GENERAL

ASSEMBLY

(3D95S-W-1)

8. Gear cover 1)

Using *

push tool,

Fill 40 &

2)

install front

Front seal:

Coat mounting gasket

seal (31).

60% of space at seal lip with Grease

surface

(G2-LI)

on cylinder

block side with

sealant.

a

Gear cover

mounting

surface: Gasket

*

grease.

Coat the gasket

sealant

of approximately

sealent

in a line with

(LG-7)

a width

$1 mm. P6l4701021

3)

Install

4)

Measure

gear cover

(30).

difference

in height

ing oil pan on cylinder +

Permissible mounting

of surface

for mount-

block and gear cover.

difference surface:

in height

of oil pan

Max. 0.15 mm

p6:4701020

9. Oil suction Fit O-ring

pipe and install

oil suction

pipe (29).

10. Oil pan Coat mounting engine t

face with

gasket

sealant,

then install

oil pan.

Coat the gasket approximately

sealant

in a line with

a width

of

sealant

(LG-7)

$1 mm.

a

Oil pan mounting

m

Mounting

face: Gasket

bolt:

1.9 + 0.5 kgm 614701019

11. Crankshaft 1)

Align

pulley with

pulley 2)

crankshaft

key,

Fit plate

(27), then tighten

w

Mounting

95 SERIES

then

install

crankshaft

(28).

bolt:

mounting

bolts.

9.5 + 0.5 kgm


DISASSEMBLY

AND

GENERAL

ASSEMBLY

ASSEMBLY

(3D95SW-1)

12. Housing 1)

Install *

rear seal (26).

Fill 40 -

60% of space at seal lip with

&

2)

Rear seal:

Coat mounting stall housing &

Grease

surface

with

(G2-LI)

gasket

sealant,

and in-

(25).

Housing

mounting

surface: Gasket

*

grease.

When

fitting

diameter

the

of the

not to apply

seal

lip

crankshaft

force

sealant

to

the

flange,

(LG-7) outside

be careful

to the seal lip surface.

13. Flywheel Install

flywheel

(24).

&

Bolt thread:

m

Mounting

Engine

oil

bolt: Unit:

Order

Target

1st step

11.0

IO-

2nd step

19.5

19-20

14. Cylinder *

head assembly

bled, assemble

12

has been

Using

push tool G, install valve valve

stems

valve

Assemble (20), then

‘3-oF

with

guide

engine

(23).

oil,

and

as-

(22).

valve

spring

(21)

and

using tool A, compress

and fit valve *

disassem-

as follows.

Coat semble

iii)

Range

I

head

If the cylinder i) ii)

kgm

cotter

(19) in valve

Tap the top of the valve tic hammer

to check

is completely

fitted.

that

spring valve

seat

22 ’

spring,

stem groove.

stem with the valve

a plascotter

95 SERIES


GENERAL ASSEMBLY (3D9BS-W-1)

DISASSEMBLY AND ASSEMBLY

3)

Tighten

mounting

bolts

of cylinder

head

Exhaust side

in the

order shown in the diagram. Ml

Intake side

*

There

are two methods

bolts:

the

controls

tightening

the tightening

turning

angle

of tightening torque

method.

the head

method

force,

6206F555

which

and the plastic

(See the figure

on the

28

right.) m

Cylinder head mounting bolt 1st step: 68.6 - 88.2 Nm (7 - 9 kgm) 2nd step: 107.8 - 127.4 Nm (II-13kgm)

120

m Tightening by plastic turning angle

Tightening by torque 6206F872

3rd step: 142.1 - 151.9 Nm (14.5 - 15.5 kgm)

&

Bolt thread:

Anti-friction

m

Cylinder head mounting

compound

(LM-P)

bolt Make mark with punch \

1st step: 68.6 + 9.8 Nm (7 * 1 kgm) 2nd step: 107.8 f 4.9 Nm (11 + 0.5 kgm) 3rd step:

Mark with

bolt head

and cylinder

head

Make mark on cylinder

a felt pen, then turn bolt 90+i�

to tighten. *

After

tightening,

make

bolt head to indicate

a punch

the number

mark

on the

of times the

bolt has been tightened. The times.

bolt

can

Always

be

used

replace

a maximum any

bolt that

of five already

F621201067A

F621201061

has five punch marks.

95 SERIES

13-oP6


DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY (3D96S-W-1)

16. Rocker arm

13-oP17

95 SERIES


DISASSEMBLY

AND

17. Adjusting *

GENERAL

ASSEMBLY

ASSEMBLY

(3D95S-W-1)

valve clearance

Adjust

the clearance

between

the valve

and rocker

lever. *

Standard

value for valve clearance

Intake valve: 1)

Rotate

the

0.35 mm, Exhaust valve:

crankshaft

align the pointer

in the

normal

on the gear cover

mark

on

the

check

the

movement

crankshaft

pulley.

0.5 mm

direction

with When

of the intake

to

the 1 TOP rotating,

valve

of No. 1

cylinder.

2)

Insert

feeler

H between

rocker

adjustment

screw

stem

ance

is a sliding

adjustment w 3)

gauge and turn

valve

When shaft

Then

direction,

in the firing

Firing order:

to hold

1 -

3 -

center,

adjust

rotate

the crank-

and adjust

the valves

order.

2

head cover

Fit O-ring m

is at top dead

of No. 1 cylinder.

in the normal

18. Cylinder

locknut

4.5 + 0.5 kgm

No. 1 cylinder

of each cylinder *

tighten

and clear-

in position.

Locknut:

the valves

and install Mounting

19. Fuel injection Tighten fully,

fit. Then

screw

lever until

cylinder

bolt:

head cover.

0.9 + 0.1 kgm

pump

mounting

then fit gasket

bolts

of fuel

and install

injection

lubrication

pump

(15)

tube.

20. Glow plug 1) m 2)

Install

glow

plug (14).

Glow plug: Install

95 SERIES

glow wire

1.25 + 0.25 kgm (13).

13-OiP8


DISASSEMBLY

AND

ASSEMBLY

13-o:1-‘9

GENERAL

ASSEMBLY

(3D95S-W-1)

95 SERIES


DISASSEMBLY

AND

ASSEMBLY

GENERAL

ASSEMBLY

(3D95S-W-1)

26. Alternator Install ment

alternator plate

(3), then

temporarily

tighten

adjust-

(1).

27. Fan, fan pulley 1) 2)

Tighten

fan pulley

(2) together

Fit belt in pulley

groove,

then

insert

a bar or pipe

alternator

and

alternator

to outside

to adjust

fan belt tension.

the

belt

deflects

pushed

with

Adjust given

so that below

when

ure of 6 kg at a point ternator * After

pulley

Deflection adjusting

fully.

95 SERIES

the

cylinder

Fan pulley

fan.

between *

3)

with

midway

block,

belt

the

pulley

raise ‘\

amount

a finger between

and the crankshaft of belt:

and

Alternator

the al-

14 -

17 mm tighten

the

bolts

\\ ‘v

14-

17 mm

pulley.

tension,

‘\

press-

‘\

‘\ ‘\

Q Crankshaft

pulley 614OF301

’3-o&’ -20



GENERAL DISASSEMBLY GENERAL

DISASSEMBLY

1. Unit repair 2. Fan..

stand

GENERAL

...............

. . . 13-001-23

.....................

3. Alternator 5. 7. 8. 9.

..................... Starting motor ................. Fuel injecttion pipe ............. Fuel injection pump ............ ................ Intake manifold Water pump ...................

10. Glow wire,

glow

plug

13-001-23

. . . 13-001-23

..........................

4. Fan pulley 6.

AND ASSEMBLY

. . . 13-001-23 . . . . 13-001-24

8. Camshaft

assembly

...

13-001-25

9. Idler gear

.

13-001-25

................ .............. Crankshaft pulley ............... Gear case cover ...................... Oil pump Idler gear ...................... ............ Camshaft assembly Flywheel ....................... .............. Flywheel housing

19. 20. 21. 22. 23. 24. 25.

pipe

13-001-41

13-001-26

14. Oil pan

13-001-42

. 13-001-26 13-001-27 13-001-27

. . . . 13-001-27 13-001-27 . . . 13-001-28

. . . . 13-001-28 . . 13-001-28

. . 13-001-28

............................. ............... 17. Push rods ............................ 15. PTO shaft

19. Adjusting

22. Glow wire,

. . . . 13-001-29

25.

29. Tappet

. . . . 13-001-30

clearance

.............

................... .........................

glow

plug

.................

.......................... Intake manifold ....................... Fuel injection pump ................... Fuel injection pipe .................... Starting motor ........................

23. Water

27.

pump

13-001-40 13-001-41 13-001-41

13-001-42 13-001-42 13-001-43 13-001-44 13-001-44 13-001-45 13-001-45 13-001-45 13-001-45 13-001-45 13-001-46 13-001-46 13-001-46

28. Fan pulley

............................

13-001-47

29. Alternator

............................

13-001-47

30. Fan..

.................................

31. Lowering

95 SERIES

valve

.................

head cover

21. Nozzle holder

24.

13-001-30

arm assembly

20. Cylinder

. . 13-001-29

..

head assembly

18. Rocker

26.

........................

...............................

16. Cylinder

. . 13-001-29

rod assembly

13-001-39 13-001-39

.............................

11. Gear case cover

. . . . 13-001-30

connecting

27. Main cap

13-001-38 13-001-39

...................

10. Oil pump

...................... ..................... 28. Crankshaft

26. Piston,

13-001-34

13-001-25

..

........................

......

............................. ...................... ..................... pulley 12. Crankshaft 13. Oil suction pipe .......................

..

18. Oil suction

rod assembly

. . . 13-001-24

...

13-001-34

.....................

..............................

13-001-25

17. Oil pan

connecting

7. Flywheel

...

15.

5. Piston,

13-001-33

.............................

4. Main cap

. . . . 13-001-24

12.

16.

13-001-33

stand ...................... ............................... ............................ 3. Crankshaft

housing

. . . 13-001-25

13.

13-001-33

2. Tappet

6. Flywheel

11. Nozzle holder

14.

ASSEMBLY

1. Unit repair

. . 13-001-24

..........

.................. Cylinder head cover ............ .......... Rocker arm assembly Push rods ..................... ........ Cylinder head assembly PTO shaft ......................

(4D95S-1)

engine

......................

13-001-47 13-001-47

’3-o$’ -22


DISASSEMBLY

AND

ASSEMBLY

GENERAL

GENERAL DISASSEMBLY Special

.

(4D95S-1)

(4D95S-1)

tools

No.

Part No.

A

DISASSEMBLY

Part Name

Q’ty

790-501-5000 or

Unit repair stand or

790-501-2000

Engine

Preparatory . Remove . Remove

repair

1

stand

work all dirt and mud from the drain

plug

around

and drain

the engine.

the oil from

the

engine. 4

.

.(.

Engine

Prepare

a stable

the engine

oil:

falling

securely Engine

r?zlkg

engine

from

assembly

Approx.

1.

2.

Setting

Remove

2)

Install

will prevent

assembly:

Approx.

differs

255 kg

according

to the

ma-

model.)

oil filter.

engine

assembly

on unit repair

stand A.

Fan fan (1).

Alternator 1)

Loosen

mounting

and mounting 2)

Move

bolts towards

adjustment

plate

(I),

cylinder

6202P500

block,

and

belt (2).

A Becareful age

the

not to catch alternator

nator towards 3)

of

bolt and nut of alternator.

alternator

remove

4.

which

in unit repair stand

1)

Remove 3.

stand

over, then put the engine

on the stand.

(The weight chine

6 P

Remove

alternator

your

when

the cylinder

fingers

moving

or damthe

alter-

block.

(3).

Fan pulley Remove

fan pulley

13-0(&l-23

(4).

95 SERIES


DISASSEMBLY

5.

AND

Starting

motor

Remove

starting

ASSEMBLY

motor

GENERAL

Fuel injection 1)

Remove

2)

Remove

(4D95S-1)

(1).

_.-.

6.

DISASSEMBLY

;”

6202P504

,,;

pipe clamp

(1).

sleeve

nut,

then

remove

fuel

injection

fuel

injection

pipe (2).

7.

Fuel injection

1) Remove 4 Remove 3)

pump oil supply

(2).

cover

(3),

Remove

pump (4). * Remove

mounting

tion pump *

tube

bracket

To prevent

(1).

then bolts

8.

Intake Remove

(5) from

the fuel injec-

side. dirt or dust

or use tape to cover outlet

remove

from

entering,

the oil and fuel

fit caps inlet

and

ports.

manifold intake

manifold

(1).

1

202P509

95 SERIES ’ 3-oih’

-24


DISASSEMBLY

9. Water

AND

GENERAL

ASSEMBLY

DISASSEMBLY

(4D95S-1)

pump

Remove

water

10. Glow wire, Remove

pump

(1).

glow plug

glow wire

(I), then remove

glow

plug (2).

11. Nozzle holder Disconnect

spill hose (3), and remove

*

Be careful

*

Mark the nozzle

holder sition the when 12. Cylinder Remove

not

when

to

damage

nozzle holder tip

of the

(4).

nozzle

removing. holders

of installation. nozzle

the

holder,

with

If there install

tags showing

the po-

is no abnormality

it in the

same

in

position

assembling. head cover cylinder

head cover

(5).

13. Rocker arm assembly 1)

Remove t

rocker

When locknut 2 -

2)

Remove

arm assembly

removing and

turn

the the

(1).

rocker

arm,

adjustment

loosen screw

the back

3 turns.

stem cap (1).

’3-o:’ -25

95 SERIES


DISASSEMBLY

AND

ASSEMBLY

GENERAL

14. Push rods Remove *

push rods (1).

Mark of

the push

rods with

installation.

push

rod,

tags to show

If there

install

it

the position

is no abnormality

in the

same

in the

position

when

assembling.

15. Cylinder

head assembly

1)

Remove

2)

Fit lifting

cylinder tool

off cylinder *

head mounting

to mount

head assembly

Lay cardboard

Cylinder

kg

on the floor

l

When

head:

disassembling

head,

(1) with

tom face of the cylinder

el

bolts.

on cylinder

then

lift

crane.

to protect

head from

the bot-

damage.

30 kg

the

cylinder

head

assembly,

do as follows. i)

Using

spring

then remove ii)

Release spring

iii)

pusher valve

pressure

B, compress cotter

(2).

on

spring,

seat (3) and valve

Remove

valve

valve and

spring, remove

spring’(4).

(5).

6206F30i

iv)

Using

valve

guide

(6).

95 SERIES

guide

remover

C, remove

valve

DISASSEMBLY

(4D95S-1)


DISASSEMBLY

AND

ASSEMBLY

GENERAL

DISASSEMBLY

(4D95S-1)

16. PTO shaft 1)

Remove

flange

2)

Remove

PTO shaft

(1). (2).

17. Oil pan Remove *

oil pan (1).

If the oil pan is stuck sert a wedge surface

and cannot

be removed,

in-

at the boss on the oil pan mounting

and remove.

6202P519

18. Oil suction Remove

pipe

oil suction

19. Crankshaft

pipe (I)

pulley

1)

Remove

plate (1).

2)

Remove

crankshaft

’3-o2 -27

pulley

(2).

95 SERIES


DISASSEMBLY

AND

GENERAL

ASSEMBLY

DISASSEMBLY

(4095S-1)

20. Gear case cover 1)

Remove

gear case cover

2)

Remove

front

(1).

seal (1).

6206P406

21. Oil pump Remove

oil pump

(1).

22. Idler gear 1)

Remove

plate (2).

2)

Remove

idler gear (3).

*

For machines

with

PTO, a bearing

is used for the

idler gear bushing.

23. Camshaft 1)

Turn

assembly over

mounting 2)

Remove

cylinder

block

face is facing mounting

so

that

cylinder

head

down.

bolts

(1) through

casting

hole in

gear. 3) *

Remove

camshaft

thrust

plate (2).

When

removing,

careful

95 SERIES

assembly rotate

not to damage

(3)

the camshaft

together lightly

with and be

the bushing.

’3-oii1 -28


DISASSEMBLY

AND

GENERAL

ASSEMBLY

DISASSEMBLY

(4D95S-1)

24. Flywheel 1)

Remove

A

flywheel

(1).

The pilot is short, suddenly,

and the flywheel

so be careful

may come

not to get your

off

fingers

caught.

25. Flywheel

housing

1)

Remove

flywheel

2)

Remove

rear seal (1).

26. Piston, 1)

connecting

Checking i)

housing

(1).

rod assembly

connecting

rod cap number.

Turn over cylinder

block,

and set so that cylin-

ders are horizontal. *

Turn

over

tappets ii)

carefully

Check that the number rod cap matches

*

and

If there

make

sure

that

the

do not fall out. stamped

cylinder

is no number

ing rod cap, stamp

on connecting

number.

stamped

on the connect-

a number

at the camshaft

end.

’3-oki1 -29

95 SERIES


DISASSEMBLY

2)

AND

Removing

DISASSEMBLY

(4D95S-1)

carbon

Using

fine sandpaper,

linder

wall.

t

GENERAL

ASSEMBLY

Be careful

remove

not to damage

carbon

at top of cy-

the inside

of the cy-

linder. t

Measure

the end

dial gauge necting

3)

the

crankshaft

at bottom

ii)

Remove

iii)

(I). Tap cap with necting

Piston, Push

rod with

the piston

and con-

rod cap

Rotate removed

4)

of the connecting

removing

rod assembly.

Connecting i)

play

@ before

mounting

bolts

plastic

connecting

rod cap

and remove

with

connectng

wooden

bar or hammer

Support

piston

connecting

to be

con-

bearing.

rod assembly

and

from

piston

of connecting

hammer

rod cap together

piston

in further

to set the dead center.

rod

handle

at cylinder

assembly from

head end, then

oil pan side to remove

rod assembly

with

a

oil pan side. push bar

piston

and

(2).

6206P332

5)

Disassembly i)

Using

of piston and connecting pliers

0,

remove

snap

rod assembly ring

(3) on one

side. ii)

Remove

piston

pin (4), and separate

ing rod (5) and piston *

If the pin does

connect-

(6). not come

out, soak in hot

water. iii)

Remove

snap

ring

on other

side

in the same

way.

95 SERIES

’3-oE -30


DISASSEMBLY

iv)

AND

Using

ASSEMBLY

piston

ring

GENERAL

tool

D, remove

(7), oil ring (9), and expander

piston

(IO) from

DISASSEMBLY

(4D95S-1)

ring

piston.

6202P524

v)

If bushing

(8) is worn,

use push

side diameter:

32 mm) to remove

*

pistons,

Keep

the

ings,

piston

tool

connecting

rings,

piston

pins,

ings in sets for each cylinder

@ (out-

bushing. rods,

bear-

and

bush-

number.

6206P336

27. Main cap 1)

Measuring i)

end play

Turn

over

cylinder

block

so that

oil pan is fac-

of

crankshaft

ing up. ii)

Measure gauge *

end

The

end

play

measurement

for judging

wear

abnormal

wear

measure

2)

play

using

dial

0.

before

is necessary

of the thrust of

the

removing

bearing

and

crankshaft,

so

the crankshaft.

Main cap i)

Remove

ii)

Insert lever

mounting mounting

cap,

bolts bolt

or tap with

and

right,

and

with

lower

main bearing

13-oz’-3’

(1) of main cap.

in bolt

remove

plastic main

hole

in cap,

hammer cap

then

on left

(3) together

(2).

95 SERIES


DISASSEMBLY

*

AND

Thrust cap

bearings

(4) are assembled

(3) at the

mark them

GENERAL

ASSEMBLY

flywheel

to show

end,

the position

on both sides of

so after

removing,

of installation.

28. Crankshaft 1)

Crankshaft Remove *

crankshaft

Be careful cylinder

Upper

against

the sliding

25 kg

upper

main bearing

Mark the main bearing tags to show

(2). and thrust

the position

bearing

of installation,

keep in a safe place in sets for each cap number.

29. Tappet Remove

the

surface.

main bearing

Remove *

block and damage

Crankshaft:

PI kg

2)

(1).

not to hit the crankshaft

tappet

95 SERIES

(1).

with and

DISASSEMBLY

(4D95S-1)


DISASSEMBLY

AND

ASSEMBLY

GENERAL

GENERAL ASSEMBLY Special

1.

Part No.

Part Name

O’ty

Unit repair stand or

790-501-2000

Engine

790-901-I 250

Bracket

B

795-l 02-2102

Spring

pusher

D

795-l 00-2800

Piston

ring tool

1

E

795-213-l

Piston

holder

1

F

795-l 00-4700

Push tool

1

G

795-l 25-l 370

Feeler gauge

1

Setting

800

repair

1

stand 1 1

(KIT)

in unit repair stand block on unit repair

stand A.

Tappet 1)

Turn over is facing

2)

3.

(4D95S-1)

790-501-5000 or

Set cylinder

2.

(4D95S-1)

tools

No.

A

ASSEMBLY

cylinder

block so that cylinder

head side

down.

Coat with

engine

oil and assemble

tappet

(1).

Crankshaft 1)

Upper i)

main bearing

Align with

protrusion notch

cylinder *

of

in cylinder

side

rear face face

(SAE30)

’3-o:’ -33

main

bearing

(2)

then

assemble

to

block,

block.

Check that there the

upper

is no dirt or dust stuck to

of the

of the before

bearing.

bearing

with

Coat the inengine

oil

assembling.

95 SERIES


DISASSEMBLY

ii)

AND

ASSEMBLY

Raise crankshaft

GENERAL

(I),

and assemble

ASSEMBLY

(4D95S-1)

to mount-

ing position. Be careful

*

not to hit the crankshaft

the cylinder

4.

against

block.

Main cap 1)

Lower i)

main bearing

Align

protrusion

in lower

main bearing

notch

in cap, then install

main cap (3).

Check that there

*

(2) with

is no dirt or dust stuck to

the rear face of the bearing.

2)

Main cap i)

Check

that

number

stamped

cap is the same as number ii)

Set casting

number

and assemble iii)

of main

mounting

Align

thrust

install

in main cap (3).

*

bearing

Assemble

two

and bottom

cap facing

(4) with thrust

front,

dowel

bearings

pin, then at the

top

end and one at

end.

Depending there ing

bearing block.

bolts (1).

at the flywheel

the opposite Note:

on main on cylinder

on the

may

be only

at the

bottom

machine

model,

one thrust at the

bear-

flywheel

end. *

iv)

Set

Install

each

groove

on the outside.

casting

number

main bearing *

thrust

Be careful

bearing

facing

with

front,

the

and

oil

install

cap (3). not

to

let the

thrust

bearings

slip out of place. v)

Tighten

cap

bolts

with

torque

wrench

as

follows. *

Coat the bolt thread

and seat face with

en-

gine oil (SAE30).

95 SERIES

’3-o&A’ -34


DISASSEMBLY

AND

*

When

tightening

main

bearing

work

to the

left and lowing *

After bolts,

GENERAL

ASSEMBLY

the mounting cap, start

outside

right.

bolts

in steps

and

check

the that

main

the

w

Mounting

bolt of main cap

to the

Unit:

kgm

to the fol-

torque. tightening

(4D95S-1)

of the

in the middle

symmetrically

Tighten

ASSEMBLY

cap

mounting

crankshaft

rotates

smoothly.

Order

Target

I

1 st step

11.5

I

2nd step

I

cl

Range II-12

I Loosen completely I

3rd step

vi)

Measuring Put probe

13.5

13 -

14

end play of crankshaft of dial gauge

@ in contact

face

of crankshaft.

Read

when

crankshaft

is moved

with

end

movement

of gauge

forward

and back-

ward. *

5.

Piston, 1)

Permissible

range of end play:

connecting

rod assembly

Assembly

of piston

*

piston

If the

sembled, Using

and connecting and

rod assembly.

connecting

assemble

rod assembly i)

0.13 - 0.35 mm

rod were

the piston

disas-

and connecting

first as follows.

push tool @ (outside

press fit bushing

diameter:

(8) to connecting

32 mm),

rod.

6206P336

ii)

Set with

stamped

(compression tool

at end gap facing

only),

D to assemble

and expander *

mark

ring

then

piston

ring

(IO) on piston

Be careful

not

to

use piston (7), oil ring

up ring (9),

(6).

damage

the

piston

or

break the rings. *

Fit expander side diameter

(10) in the groove of oil ring

ing. Check that the expander fitted *

on the in-

(9) before

into the ring groove.

The end gap of the ring should

be at 180�

to the join of the coil in the expander.

13-og-35

install-

is completely

6202P524

95 SERIES


DISASSEMBLY

iii)

AND

Using

ASSEMBLY

pliers

0,

GENERAL

assemble

snap

side only in snap ring groove

iv)

Set F mark rection

on piston

as casting

Insert

piston

in same

pin (4), and assemble (6). to insert

If it is difficult piston

in

diameter

hot

of the

to

hole,

dirod.

6206P421

connecting

the piston

water

pin

on one

on connecting

rod (5) and piston

(4D95S-1)

of piston.

boss facing

number

*

the

ring

ASSEMBLY

pin, put

expand

then

the

insert

the

pin. v)

Assemble

other

snap

ring

on

other

side

of

piston. *

After

assembling

that

the

forward vi)

Align

the

connecting

snap

rod

rings,

moves

check

smoothly

and backward.

protrusion

ing rod with

in upper

notch

bearing

of connect-

in connecting

rod, then

in-

stall. 6206P433

2)

Assemble

piston

cylinder

and connecting

rod

assembly

in

crankshaft

is

block as follows.

1) Turn over cylinder

Oil ring

block

so that

piston

rings

Size mark IS or L)

vertical. ii)

Set

end

gaps

of

as

shown

in

diagram. iii)

Set crankshaft der where

at bottom

piston

and

dead

center

connecting

in cylin-

rod

mark

assem-

bly are to be assembled. *

Coat

the

piston necting

iv)

Align sert

piston cylinder

and

When

piston

push

in head

necting

95 SERIES

of the

cylinder,

the

the

surface

of the

con-

bar.

with

engine

of F on side face

of engine.

from

wooden

face

and

rod bearing

direction

face front

v)

inside

rings

Using

oil.

6206F302

of piston

piston

holder

rod

assembly

connecting

to

E, in(2)

head end. rings are inserted of piston In addition,

rod to align with

with pull

inside palm

cylinder,

of hand

big end

crankshaft

or

of con-

pin.

13-0(&l-36


DISASSEMBLY

vi)

Align

AND

protrusion

of lower

cap, then assemble *

GENERAL

ASSEMBLY

bearing

with

to connecting

Check that there

notch

ASSEMBLY

(4D95S-1)

in

rod cap.

is no dirt or dust stuck to

the rear face of the bearing. vii)

Set with

stamped

mark

install connecting

at camshaft

end, then

rod cap (1).

Coat the connecting

rod

bearing

with

en-

gine oil. Check

that

connecting

the

stamped

rod

cap

number

of the cylinder.

Tighten

the connecting

Coat

the

connecting

seat face with 6J3

Tighten

2nd step

Mark with

on the

same

as the

rod cap as follows. rod

engine

Connecting

1st step

number

is the

bolt

thread

and

oil. rod cap bolt

in turn to 4+:.* kgm bolt

head

and

cap

seat

a felt

pen,

then

turn

bolt

90fi0’ to tighten. After the

tightening, bolt

times

head

the

make

a punch

to indicate

bolt

has

the

been

tightened.

bolt can be used a maximum Always

replace

five punch After

any

that

the the

kgm

Put a mark on the bolt cap

on of The

of five times.

that

already

has

marks.

assembling

check

bolt

mark number

4 ‘i.’

connecting

crankshaft

After tightening, stamp mark the tightening time on bolt head by punch

rods, rotates

smoothly.

6206F303

’3-og’ -37

95 SERIES


DISASSEMBLY

6.

Fhwheel

AND

GENERAL

ASSEMBLY

diameter:

stall rear seal (2) on flywheel After

press fitting

at seal lip with &

3)

(4D95S-1)

housing

1) Using push tool @ (outside 4

ASSEMBLY

rear seal, fill 40 -

with

120 mm), in(1). 60% of space

grease.

Rear seal:

Align

housing

dowel

Grease

(G2-LI)

pin, and install

flywheel

housing

(1). a

Mounting

surface

of flywheel Gasket

*

When

fitting

diameter

the

of the

not to apply m

Measuring

4)

bolt:

difference

mounting

oil pan

to

the

flange,

(LG-7) outside

be careful

to the seal lip surface.

Mounting

distance

lip

crankshaft

force

Measure

seal

housing: sealant

7 f 0.5 kgm

in height

of mounting

in height

between

on cylinder

block

surface

surface

for

and flywheel

housing. *

Permissible mounting

5)

Measure ing with

difference surface:

radial

and face

dial gauge

*

Radial runout:

*

Face runout:

95 SERIES

in

height

of

oil

pan

Max. 0.15 mm

runout

of flywheel

hous-

0. Max. Max.

0.30 mm 0.35 mm

13-O;l-38


DISASSEMBLY

7.

AND

ASSEMBLY

flywheel

housing

GENERAL

(4D95S-1)

Flywheel 1)

Install w

Mounting

(1).

bolt: Unit:

2)

Measure

radial and face runout

Radial runout:

Max.

Face runout:

8.

ASSEMBLY

Max.

Camshaft

assembly

1)

camshaft

Insert *

Rotate avoid

2)

0.20 mm

assembly

damaging mounting

through

casting

of flywheel.

0.15 mm

(3) into cylinder

the camshaft

Tighten

kgm

lightly

when

block.

inserting

to

plate

(2)

the bushing. bolts

hole

(1)

of

of gear

thrust

to secure

camshaft

assembly. w 3)

Thrust

plate mounting

Put dial gauge shaft,

move

@ in contact

camshaft

read movement *

9.

Idler

Camshaft

bolt: with

1.9 * 0.5 kgm

end face of cam-

backward

and forward,

and

of gauge. end play:

0.15 -

0.35 mm

gear Align

match

(3). * Match

marks

of gear,

and

gear (5) and idler gear:

Idler gear and cam gear (4):

gear

“A”

“B”

plate (2).

Tighten

mounting

w

Idler gear mounting

put dial gauge gear, move measure *

idler

marks

Crankshaft Install

install

bolt (1) of idler gear.

in contact

bolt: with

11.25 & 1.25 kgm

end face of idler

idler gear backward

and forward,

and

end play of idler gear.

End play of idler gear:

’3-o&Y -39

0.03 -

0.09 mm

95 SERIES


DISASSEMBLY

AND

GENERAL

ASSEMBLY

ASSEMBLY

(4D95S-1)

10. Oil pump 1)

Install

driven

2)

Install

cover

gear (1) of oil pump.

3)

Mesuring

end play

Measure

end

(2) and drive play

as measuring *

gear (3) of oil pump.

of oil pump

gear

in same

way

0.02 -

0.07

end play of camshaft.

Permissible

range

of end

play:

mm

*

Measuring

backlash

of gears

Install fuel injection use dial gauge

pump

(1) temporarily,

@ to measure

backlash

then of each

gear. *

When hold

measuring one gear

the other

the

backlash

in position

of each

securely,

and

gear, move

gear to measure.

6206F411A

*

Backlash

of gears Unit:

Match mark

Position

of measurement

A -

A

1 Crankshfat

B -

B

1 Cam gear and idler gear

C -

C I Injection

a b

I Cam

gear and idler gear

pump gear and idler gear

gear and oil pump

Cam gear and PTO gear (machines

95 SERIES

with

PTO)

gear

mm

Range IO.08 -

0.31

IO.09 -

0.34

10.08 - 0.31 10.08 - 0.31 0.08 -

0.31

’3-oF&1 -40


DISASSEMBLY

AND

ASSEMBLY

GENERAL

ASSEMBLY

(4D95S-II

11. Gear case cover Using

push tool

(outside

front

seal (1).

After

press fitting

at seal lip with &!?I+

front

Coat mounting

seal, fill 40 -

Grease

surface

sealant

&

72 mm), install 60% of space

grease.

Front seal:

gasket

diameter:

,

(G2-LI)

on cylinder

block

side with

(LG-7).

Cylinder

block:

LG-7 6206P424

4)

install

5)

Measuring

gear case cover difference

assembly in height

Measure

distance

in height

mounting

oil pan on cylinder

(1). of mounting

between block

surface

surface

and gear

for case

cover. *

Permissible mounting

12. Crankshaft 1)

Align pulley

2)

difference surface:

13. Oil suction Fit O-ring

height

of

oil

pan

pulley with

key of crankshaft,

then install

crankshaft

(2).

Fit plate (I), then tighten w

in

Max. 0.15 mm

Mounting

bolt:

mounting

bolts.

9.5 + 0.5 kgm

pipe and install

’3-o& -41

oil suction

pipe (1).

95 SERIES


DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY (4D95S-1)

14. Oil pan 1j

Fit gasket

and install

under-plate.

2)

Fit gasket

and install

oil pan (1).

m

Mounting

bolt:

m

Drain plug:

3.25 + 0.25 kgm

6.0 f 1.0 kgm

6202P51 I9

15. PTO shaft

1) 2)

Align

gear

of PTO shaft

(2) with

camshaft

gear, and install.

Fit O-ring

and install flange

tooth

surface

of

(1).

16. Cylinder head assembly 1)

Assembly

of cylinder

i)

Using

push tool

linder

head.

ii)

Coat stems

head

F, install valve

of intake

inside face of valve iii)

Install valve

iv)

Assemble

v)

Using spring

and exhaust

guide

with

(6) in cy-

valves

engine

spring

pusher cotter

L..,

(4) and spring

B, compress

seat (3).

valve

(2).

-6 6206F301

95 SERIES

and

oil.

(5).

valve

and fit valve

guide

spring,


DISASSEMBLY

AND

2) Installation *

ASSEMBLY

of cylinder

Remove

of

the

Remove

and

all

Install cylinder *

ii)

Fit the

guide,

from

(4D95S-1)

the contact

block

burrs

and

and

cylinder

damage,

and

inside the cylinder

block.

head gasket.

gasket

up. Raise cylinder as

dirt

cylinder

clean out all dirt form i)

ASSEMBLY

head

all carbon

surfaces head.

GENERAL

with

the

TOP

mark

facing

head (1) then using 4 head bolts

install

cylinder

head

to

cylinder

block. 2P516

3)

Tightening

mounting

Coat thread antifriction

bolts of cylinder

of cylinder

head

compound

ing bolts

(LM-P),

of cylinder

head

head

mounting

then tighten

in the

Order for tightening

bolts

order

head bolts

with

mountshown

Exhaust side

in

the diagram. m

Cylinder

head

mounting

bolt

1st step: 68.6 - 88.2 Nm (7 - 9 kgm) 2nd step: 107.8 - 127.4 Nm (11 - 13 kgm) 142.1 - 151.9 Nm

3rd step:

Intake side

(14.5 - 15.5 kgm) *

There

are two

bolts:

the

methods

of tightening

tightening

torque

controls

the

tightening

turning

angle

method.

force,

the head

method

which

and

plastic

the

(See the figure

on the

right.) w

Cylinder

1st step: 2nd step:

head mounting

Make mar< with punch

bolt

Mark

bolt head and cylinder

a felt

pen,

then

turn

head with

bolt

90+zV to

tighten. After bolt

Tightening by torque 6206F672

68.6 2 9.8 Nm (7 + 1 kgm) 107.8 c 4.9 Nm (11 + 0.5 kgm)

3rd Step

*

Tightening by plastic turning angle

tightening,

head to indicate of five

bolt that already

-6@ 90

make

a punch

mark

the number

bolt has been tightened. a maximum

Make mark on cylinder head and bolt

on the

of times

the

The bolt can be used

times.

Always

has five punch

replace

any

marks.

3

.

F621201067A

F621201061

17. Push rods Insert push rods (1) in tappet *

The same

part

guides.

is used for the intake

and exhaust

push rods. *

If there

is no abnormality

the same position

’3-okL1 -43

in the push rod, install

as before

in

disassembly.

95 SERIES


DISASSEMBLY

AND

ASSEMBLY

GENERAL

ASSEMBLY

(4D95S-1)

18. Rocker arm assembly 1)

2)

Install

stem cap (1).

Install

rocker

f

arm assembly

(1).

Check that the ball of the adjustment fitted

properly

then tighten m

into the socket

screw

of the push

is

rod,

the nuts and bolts uniformly.

Mounting

bolt of rocker

arm bracket: 2.5 * 0.5 kgm

*

If the valve rocker

spring

arm,

adjustment strain

19. Adjusting Adjust

tension

loosen screw

the

pushes locknut

against and

back 2 to 3 turns

the

turn

the

to prevent

on the push rod.

valve clearance

clearance

between

valve

and

rocker

arm

as

follows. Standard

value

for

valve

clearance

(both

warm

and cold) Intake valve: Rotate align

the

0.35 mm

Exhaust

crankshaft

pointer

in the

(b) on the gear

0.5 mm direction

case cover

1.4 TOP mark

(a) on crankshaft

rotating,

the movement

check

valve:

normal pulley

to

with

the

(1). When

of the valves

of No.

4 cylinder. When

No. 1 cylinder

center,

adjust

the crankshaft just the vales *

Valve

No.

Exhaust

valve

Intake valve

95 SERIES

is at compression

valves

marked

360� in the normal marked

0.

top Then

direction,

dead rotate

and ad-

0.

arrangement

Cylinder

k-

the

1

2

l

0 0

0

4

3 0 0

0 0

13-og -44


DISASSEMBLY

3)

AND

To adjust, arm

ASSEMBLY

insert

and

feeler

valve

stem

until clearance

4)

After

adjusting

*

rocker

adjustment

screw

fit. Then tighten

locknut

of No. 1 cylinder to turn

adjust

according 1 -

the valve

to the firing 2 -

4 -

at top dead

the

crankshaft

clearance

of

order.

3

head cover

Fit packing

and install

cylinder

head cover

(5).

holder

Fit gasket w

2)

14D95S-1)

in position.

possible

and

Firing order:

20. Cylinder

1)

valves

time

each cylinder

G between

turn

ASSEMBLY

4.5 f 0.5 kgm

it is also

180� each

21. Nozzle

screw

Locknut:

center,

gauge and

is a sliding

to hold adjustment m

GENERAL

and install

Mounting

Connect

nozzle holder

bolt:

(4).

4.5 + 0.5 kgm

spill hose (3).

22. Glow wire, glow plug Install

glow

m

plug (2), then install glow

Glow plug:

Install

mounting

and install water

0.125 f 0.025 kgm

pump

(1).

manifold intake

manifold

(1).

&

Mounting

surface:

m

Mounting

bolt:

*

nut:

pump

Fit gasket

24. Intake

(1).

1.25 + 0.25 kgm

Glow wire

23. Water

wire

Coat the gasket approximately

Gasket

sealant

(LG-7)

4.1 f 0.6 kgm

sealant

in a line with

a width

of

41 mm.

202P509

13-og-45

95 SERIES


DISASSEMBLY

AND

25. Fuel injection 1)

align

match

install fuel injection Check

that

Tighten pump

Install

bracket

Install

oil supply

26. Fuel injection

tube

marks

are aligned,

cover

and

bolts

then

(3).

(5) at the fuel injection

(1).

the fuel injection

air through

Install

fuel

sleeve

injection

clamp

Fully tighten

pipe,

blow

com-

it to clean it. pipes

(2), then

temporarily

nuts at both ends.

clearance

w

gear,

pipe

tighten Align

idler

(2).

installing

tighten

with

(4).

and install

mounting

3)

pressed

(4D95S-1)

end.

2)

Before

marks

pump

the match

fit an O-ring *

ASSEMBLY

pump

Fit O-ring, *

GENERAL

ASSEMBLY

between

fuel

injection

pipes,

then

(1). sleeve

Sleeve

nut:

nuts of injection

pipes.

2.3 + 0.2 kgm

Pi89

27. Starting Fit O-ring

motor and install

starting

motor

(1).

,-._

95 SERIES

.�

;

,:

6202P504

’3-o:1 -46


DISASSEMBLY

AND

GENERAL

ASSEMBLY

ASSEMBLY

(4D95S-1)

28. Fan pulley Install fan pulley (4). 29. Alternator 1)

Install alternator

(3).

2)

Fit

pulley

belt

(2)

in

tighten adjustment 3)

groove,

then

temporarily

plate (1).

Insert a bar or pipe between der block, and raise alternator

alternator

and cylin-

to outside to adjust

fan belt tension. Be careful not to get your fingers caught.

a *

Adjust

so that

the

given below when

belt

deflects

ure of 6 kg at a point midway ternator * 4)

After adjusting

amount

betwen

pulley and the crankshaft

Deflection

the

pushed with a finger

of fan belt:

7 -

pressthe al-

pulley.

10 mm

belt tension, tighten

bolts fully.

30. Fan install fan (1). 31. Lowering

engine

1)

Remove

2)

Install oil filter.

*

unit repair stand A from engine assembly.

Clean the filter holder,

then coat the cartridge

surface with engine oil or grease *

Tighten

by hand approx.

ing surface

contacts

6202P500

seal

(G2-LI).

2/3 turns after the pack-

the seal surface

of the filter

holder.

13-og-47

95 SERIES



DISASSEMBLY

GENERAL

AND

GENERAL

ASSEMBLY

DISASSEMBLY

(4D95L

DISASSEMBLY

(4D95LSERIES)

SERIES)

a

I I

I (4D95L-W-1

only)

4D95L SERIES Engine

14

’3-:02

15

16

95 SERIES


DISASSEMBLY

95 SERIES

AND

ASSEMBLY

GENERAL

DISASSEMBLY

(4D95L

SERIES)


DISASSEMBLY

AND

GENERAL

ASSEMBLY

DISASSEMBLY

(4D95L

SERIES)

Special tools

AI

1

790-901-1250

1 Bracket

B

1

795-102-2102

1 Spring pusher

l

Preparatory 1) 2)

I 1

work

Remove all dirt and mud from around the engine. Remove

the drain

plug and drain the oil from

the

engine. 3)

:

Engine oil:

Approx.

9.5 R

Prepare a stable stand which will prevent the engine from

falling

over, then

put the engine securely

in

the stand. Engine assembly: (The weight to

the

Approx.

300 kg

of the engine differs according

model

of

machine

on which

it is

mounted.) 1.

Setting in unit repair stand I.) 2)

Remove starting motor (1). Install bracket A1 to engine.

3)

Install engine assembly (2) in repair stand A.

’3-:04

95 SERIES


DISASSEMBLY

2.

Muffler Remove muffler

3.

GENERAL

AND ASSEMBLY

(1) together with bracket.

Fan Remove fan (1).

4.

Fan pulley

1)

Loosen mounting mounting

2)

bolt of adjustment

plate

(I),

and

bolt and nut of alternator.

Move alternator

towards cylinder

block, and remove

belt (2). A

Be careful damage alternator

3)

5.

to

catch

alternator

your

when

fingers moving

towards the cylinder block.

Remove fan pulley (3).

Alternator Remove adjustment

6.

not

the

plate, then remove alternator

Oil filter, dipstick guide 1)

Remove oil filter

2)

Remove dipstick guide (3).

95 SERIES

(2).

(1).

or the

DISASSEMBLY

(4D95L

SERIES)


DISASSEMBLY

AND ASSEMBLY

GENERAL

DISASSEMBLY

(4D95L

SERIES)

7. Water pump Pull out pilot portion, then remove water pump (1).

8.

Exhaust manifold Remove exhaust manifold

(I 1.

9. Fuel injection pipe 1)

Remove clamp (1).

2)

Remove sleeve nut, then remove fuel injection

pipe

(2).

10. Intake manifold Remove intake manifold

’3-:06

(I 1.

95 SERIES


DISASSEMBLY

AND

ASSEMBLY

GENERAL

11. Glow wire, glow plug (4D95L-W-1 1)

Remove glow wire (1).

2)

Remove glow plug (2).

DISASSEMBLY

(4D95L

SERIES)

only)

12. Spill tube Remove spill tube

(1).

13. Nozzle holder Remove nozzle holder (2). * When removing the nozzle nozzle

holder

dirt from *

holder,

and fit a blind

clean around

plug to prevent

the

dust or

entering.

Be careful

not to damage the tip of the nozzle holder

when removing. *

Mark

the

cylinder

tags

showing

the

No. and keep in a safe place.

nozzle

holders

If there

is no

abnormality

in

same position

when assembling.

14. Cylinder

nozzle

holder,

install

in

the

head cover

Remove cylinder 15. Rocker

the

with

head cover (3).

arm assembly

Remove rocker arm assembly (1). * When removing the rocker arm, and turn the adjustment

loosen

the

locknut

screw back 2 - 3 turns.

16. Push rods Remove push rods (1) from f

Mark

cylinder

the push rods with

installation abnormality position

95 SERIES

and keep in

the

head.

tags to show the places of

in a safe place. push

rod,

install

If there in

the

is no same

when assembling.

’3-:07


DISASSEMBLY

AND

ASSEMBLY

GENERAL

DISASSEMBLY

(4D9!5L SERIES)

17. Cylinder head assembly 1)

Remove mounting bolts of cylinder head assembly.

2)

Fit lifting

tool to hanger of cylinder

head, then lift

off cylinder head assembly (1) with crane. * Lay cardboard on the floor to protect

the

bottom face of the cylinder head from damage.

*

When

disassembling the cylinder

head assembly,

do

as follows.

i)

Using

spring

pusher

B, compress valve spring,

then remove valve cotter (2). ii)

Loosen spring, and remove spring seat (3) and valve spring (4).

iii)

Raise cylinder head and remove valve (5). *

Mark

the

valves with

place of installation

tags to

show

the

and keep in a safe place.

For 4D95L-1

\.$-A 6206F301

iv)

13-$08

Using remover C, remove valve guide (6)

95 SERIES


DISASSEMBLY

AND

ASSEMBLY

GENERAL

18. Fuel injection pump 1)

Remove lubrication

2)

Remove bracket (2).

3)

Remove mounting

tube (1). bolts (3) of fuel injection

pump,

then remove fuel injection pump (4). *

There

is one bolt installed from

the fuel injec-

tion pump side, so do not forget to remove it. *

To prevent dirt or dust from entering, fit caps or use tape to cover the oil and fuel inlet and outlet ports.

*

Remove cover (5) so that the match marks can be

aligned

when

installed.

19. PTO shaft 1)

Remove flange (I ).

2)

Remove PTO shaft (2).

20. Oil pan Remove oil pan (1).

95 SERIES

the

fuel

injection

pump

is

DISASSEMBLY

(4D95L

SERIES)


DISASSEMBLY

AND ASSEMBLY

GENERAL

DISASSEMBLY

(4D95L

SERIES)

21. Oil suction pipe Remove oil suction pipe (1).

22. Crankshaft pulley 1)

Remove plate (I).

2)

Set flange puller D in position,

then pull out crank-

shaft pulley (2).

62OW322

23. Gear case cover 1)

Remove gear case cover (I).

2)

Remove front oil seal (I).

13-go

95 SERIES


DISASSEMBLY

GENERAL

AND ASSEMBLY

24. Oil pump Remove oil pump (1). 25.

Idler gear 1)

Remove plate (2).

2) *

If a PTO

Remove idler (3). is installed,

the idler gear bushing uses a

bearing.

26. Camshaft assembly 1)

Turn

over

cylinder

block,

so that

cylinder

head

mounting face is facing down. 2)

Remove mounting

bolts (1) through

casting hole in

gear. 3)

Remove camshaft

assembly

(3) together

with thrust

plate (2). *

When removing,

rotate the camshaft

lightly and

be carefuel not to damage the bushing.

27.

Flywheel 1)

Remove coupling (1).

2)

Remove flywheel A

The

(2).

pilot

is short,

come off suddenly.

28.

Flywheel housing 1)

Remove flywheel

95 SERIES

housing (1).

so the

flywheel

may

DISASSEMBLY

(4D95L

SERIES)


DISASSEMBLY

2)

29.

AND

GENERAL

ASSEMBLY

DISASSEMBLY

(4D95L

SERIES)

Remove rear oil seal (I).

Piston, connecting rod assembly 1)

Checking connecting rod cap number. i)

Turn over cylinder

block, and set with cylinders

horizontal. * Turn the cylinder prevent

the

block

tappets

over carefully

from

coming

to

out

of

position. ii)

Check that number

stamped

on connecting

rod

cap matches cylinder number. *

If

there

is no

connecting

number

stamped

on

the

rod cap, stamp a number at the

camshaft end. 2)

Removing carbon Using

fine

sandpaper,

cylinder. * Be careful

not

remove

to

carbon

damage

the

at

inside

top

of

of the

cylinder. *

Measure the end play of the connecting

rod with a

dial gauge before removing the piston and connecting rod assembly. 3)

Connecting rod cap i)

Rotate

crankshaft

to set piston at bottom

dead

center. ii)

Remove

iii)

(I). Tap

13-$12

mounting

cap with

bolts of connecting

plastic hammer

rod cap

and remove con-

95 SERIES


DISASSEMBLY

4)

AND

ASSEMBLY

GENERAL

Piston, connecting rod assembly Push a wooden bar or hammer handle through from oil pan side. Support then push bar in further

piston at cylinder

head end,

from oil pan side to remove

piston and connecting rod assembly (2).

5)

Disassembly of piston and connecting rod assembly i)

Using pliers 0,

ii)

Remove

piston

remove snap ring (3) on oneside. pin (4),

and separate connect-

ing rod (5) and piston (6). * If the pin does not come out, leave in hot water, then try again. iii)

iv)

Remove snap ring on other side in the same way.

Using piston ring tool E, remove piston ring (7) from piston.

v)

If bushing (8) is worn,

remove using push tool

@ (outside diameter: 32 mm). * Keep the pistons, connecting piston

rings, piston

sets for each cylinder number.

95 SERIES

rods, bearings,

pins, and bushings in

DISASSEMBLY

(4D95L

SERIES)


DISASSEMBLY

AND

ASSEMBLY

GENERAL

DISASSEMBLY

(4D95L

SERIES)

30. Main bearing cap 1)

Measuring end play i)

Turn

over cylinder

block,

so that

oil

pan

is

facing up. ii)

Measure end play of crankshaft

using dial gauge

0. *

is necessary for

The end play measurement judging abnormal

wear

of

the

thrust

bearing

wear of the crankshaft,

and

so measure

before removing the crankshaft.

2)

Main i) ii)

bearing

cap

Remove mounting bolts (1) of main bearing cap. Insert mounting

bolt

in bolt hole in cap, then

lever cap, or tap with

plastic

hammer

on left

and right sides, and remove main bearing cap (3) together with lower bearing (2).

*

Thrust

bearings (4) are assembled on both sides

of cap (3) at the flywheel

end, so after removing,

mark to show the place of installation.

31.

Crankshaft 1)

Remove crankshaft (1). * Be careful not to hit the crankshaft

against the

cylinder block and damage the sliding surface.

13-:14

95 SERIES


DISASSEMBLY

2)

AND

Rel move upper * Mark the

main

bearing

main

bearing

tags to show the place a safe place

32.

GENERAL

ASSEMBLY

DISASSEMBLY

(4D95L

SERIES)

(2). and

thrust

bearing

of installation,

with

and keep

in

in sets for each cap number.

Tappet Remove

tappet

95 SERIES

(1).

13-g15


DISASSEMBLY

GENERAL

AND

ASSEMBLY

ASSEMBLY

GENERAL

(4D95L

ASSEMBLY

(4D95L

SERIES)

SERIES) a

13-p

95 SERIES


DISASSEMBLY

AND

GENERAL

ASSEMBLY

i-i

19

18

Push rods

16 Fuel injection pump

< /

H

Rocker arm ass’y

H

20

Adjusting valve clearance

H

ASSEMBLY

(4D95L

SERIES)

21

Cylinder head cover

1

\

Alternator I

33 Muffler

95 SERIES

13-g 7


DISASSEMBLY

GENERAL

AND ASSEMBLY

ASSEMBLY

(4D95L

SERIES)

Special tools

>

AI

1.

2.

1

1 Bracket

790-901-1250

I 1

B

795-102-2102

Spring pusher (KIT)

1

E

795-100-2800

Piston ring tool

1

F

1

795-213-1800

1 Piston holder

G

)

795-100-4720

) Push tool

I 1

Ii

1

795-125-1370

( Feeler gauge

I 1

~

r

Setting in unit repair stand 1)

Install bracket AI to cylinder block.

2)

Set cylinder block in unit repair stand A.

Tappet 1)

Turn

over cylinder

block so that cylinder

head side

is at bottom. 2)

3.

Coat with engine oil and assemble tappet (1).

Crankshaft 1)

Align

protrusion

notch

in cylinder

of

upper

block,

main

bearing

(2)

with

then assemble to cylinder

block. *

Check that there

is no dirt or dust stuck to the

rear face of the bearing. Coat the inside face of the

bearing

with

engine

oil

(SAE30)

before

assembling.

13-$18

95 SERIES


DISASSEMBLY

2)

AND

ASSEMBLY

GENERAL

Taking care not to hit crankshaft block, set crankshaft *

heat

at

230

(4D95L

SERIES)

(1) against cylinder

in mounting position.

If the crankshaft the crankshaft

ASSEMBLY

gear has been replaced,

gear in an electric -

25O’C

for

about

insert

furnace 30

and

minutes,

then shrink fit the gear.

4.

Ma lin bearing cap 1)

Align protrusion

in lower main bearing (2) with notch

in cap, then install main bearing cap (3). * Check that there is no dirt or dust stuck to the rear face of the bearing. Coat the inside face of the

bearing

with

engine

oil

(SAE30)

before

assembling.

2)

Check that

number

stamped

on main bearing cap is

the same as number on cylinder block. 3)

Set casting number of main bearing cap facing front, and assemble with mounting bolt (1).

4)

Align

lower thrust

bearing (4) with dowel pin, then

install in main bearing cap (3). * Assemble two pieces at the top and bottom the flywheel

at

end, and one piece at the opposite

end.

*

Install each thrust bearing with the oil groove on the outside.

5)

Set casting

number

facing

front,

and install

main

bearing cap (3). * Be careful not to let the thrust bearings slip out of place.

95 SERIES

13-g19


DISASSEMBLY

6)

AND

Tighten

GENERAL

ASSEMBLY

mounting

ASSEMBLY

(4D95L

SERIES)

bolts of main bearing cap with a

torque wrench as follows. *

Coat the bolt thread and seat face with engineoil.

*

When tightening

the mounting

bolts of the main

bearing cap, start in the middle and work to the outside. Tighten to the following Mounting

w

torque.

bolt of main bearing cap Unit:

Target

Order

*

1 st step

11.5

2nd step

0

3rd step

13.5

After

tightening

kg

Range II-12 Loosen completely 13 -

I

the mounting

14

bolts, check that

the crankshaft rotates smoothly.

7)

Measuring end play of crankshaft Put probe of dial gauge @ in contact with end face of crankshaft.

Read movement

of gauge when crank-

shaft is moved forward and backward. * Permissible range of end play: 0.13 - 0.35 mm

5.

Piston, connecting rod assembly 1)

Assembly of piston and connecting rod assembly. *

If the been

piston and connecting disassembled,

assemble

rod assembly has the

piston

and

connecting rod assembly first as follows. i)

Using

push tool

@

(outside

diameter:

32 mm),

press fit bushing (8) on connecting rod.

6206P336

13-020

95 SERIES


DISASSEMBLY

ii)

GENERAL

AND ASSEMBLY

Set rings with (compression

stamped

mark at end gap facing up

ring only),

then use piston ring tool

ASSEMBLY

(4D95L

SERIES)

E to assemble piston ring (7) on piston (6).

Be careful

not to damage the piston

or break the

piston rings. Fit expander

(IO) in the groove on theinsidediameter

of

(9)

oil

ring

before

expander is completely

installing.

Check

that

the

fitted into the ring groove.

The end gap of the ring should be at 180’ to the join of the coil in the expander.

Using pliers

iii)

0,

assemble snap ring on one side in

snap ring groove of piston.

iv)

Set F mark on piston pin boss facing in same direction as casting number

on connecting

pin (4), and assemble connecting (6). * If

it

is difficult

rod.

Insert piston

rod (5) and piston

to insert the

piston

pin,

put

the piston in hot water to expand the diameter of the pin hole, then insert the pin.

VI

Assemble other snap ring on other side of piston, * After assembling the snap rings, check that the connecting

rod

moves smoothly

forward

and

backward. vi)

Align

protrusion

in upper bearing of connecting

rod

with notch in connecting rod, then install.

95 SERIES

’3-:21


DISASSEMBLY

AND

ASSEMBLY

GENERAL

2)

Turn over cylinder block so that crankshaft

3)

Set end gaps of piston rings as shown in diagram.

4)

ASSEMBLY

(4D95L

SERIES)

isvertical. Oil ring

Size mark (.Sor L)

Set crankshaft pin at bottom dead center. *

Coat the inside face of the cylinder, rings and

the

surface

of the

the piston

connecting

rod

Over size mark

bearing with engine oil. 5)

Align direction face front

of F mark on side face of piston to

of engine.

Using piston holder

F, insert

Size mark (S or L)

piston and connecting rod assembly (2) from cylinder 6206F302

head end. 5)

When piston rings are inserted inside cylinder,

push in

head of piston with hand or wooden bar. In addition, pull big end of connecting

rod to align with crankshaft

pin. 7)

Align protrusion

of lower bearing with notch in cap,

then assemble to bearing cap. *

Check that there

is no dirt or dust stuck to the

rear face of the bearing. 8)

Set with stamped mark at camshaft end, then install connecting rod cap (1). *

Check

the connecting

rod bearing with

engine

oil. *

Check that the stamped number on the connecting cap is the same as the number of the cylinder.

13-$22

95 SERIES


DISASSEMBLY

AND

GENERAL

ASSEMBLY

*

Tighten the connecting rod cap as follows.

Ir

Coat

the connecting

rod bolt thread

and seat

ASSEMBLY

(4D95L

SERIES)

Put a mark on the bolt cap

face with engine oil. m

Mounting

go0 +30° 0

bolt of connecting rod Unit:

kgm

Order

Target

Range

1 st step

4.0

4.0 - 4.2

2nd step

After tightening, stamp mark the tightening time on bolt head by punch

Mark bolt head and cap seat with felt pen, then tighten to following angle. 6206F303 9o” -

9o” *

The

connecting

times.

Make

rod

a punch

bolts may mark

120°

be reused five

on the

bolt

head

each time the bolts are used. If there are already five marks

on the bolt head, replace with

new

bolts. *

After

assembling

the

that the crankshaft

9)

connecting

rods,

check

rotates smoothly.

Measuring side clearance of connecting rod cap. i)

Turn over cylinder block so that oil pan faces up.

ii)

Using dial gauge 0,

measure side clearance

of

connecting rod cap. *

Permissible range of side clearance: 0.20 - 0.40 mm

6.

Flywheel 1)

housing

Using push tool

@

(outside

diameter:

install rear oil seal (2) on flywheel 2)

After

press fitting

120 mm),

housing (1).

rear oil seal, fill 40 - 60% of space

0 -

r

at seal lip with grease. &

95 SERIES

Rear seal: Grease (G2-LI)

13-$23


DISASSEMBLY

AND ASSEMBLY

GENERAL

Align with dowel pin (3). and install flywheel

3)

ASSEMBLY

(4D95L

SERIES)

housing

(1). a,,

Mounting surface of flywheel

housing:

Gasket sealant (LG-7) *

When fitting of

the

the seal lip to the outside diameter

crankshaft

flange,

be careful

not

to

apply excessive force to the seal lip surface. Mounting

m

Measuring

4)

bolt:

difference

6.75 f 0.75 kgm

in height of mounting

surface

Measure distance in height betweensurfacefor

mount-

ing oil pan on cylinder block and flywheel housing. * Permissible difference in height of flywheel housing mounting surface:

5)

Measure

radial and face runout

with dial gauge 0. * Radial runout: * Face runout:

Max. 0.15 mm

of flywheel

housing

Max. 0.30 mm Max. 0.35 mm

614OF286

7.

Flywheel

1)

Install flywheel w

(2).

Mounting

bolt:

12.0 f 0.5 kgm Unit:

kgm

)

2)

Install coupling (1).

3)

Measure radial and face runout of flywheel. * Radial runout: Max. 0.15 mm * Face runout: Max. 0.25 mm

’3-:24

95 SERIES


DISASSEMBLY

8.

AND ASSEMBLY

GENERAL

ASSEMBLY

(4D95L

SERIES)

Camshaft assembly

1)

Insert camshaft assembly (3) into cylinder block. *

Rotate

the camshaft

lightly

when

inserting to

avoid damaging the bushing.

2)

Tighten mounting bolts (1) of thrust plate (2) through casting hole of gear to secure camshaft assembly. m

Mounting bolt of thrust Plate: 1.9 f 0.5 kgm

3)

Put dial gauge 0 shaft.

in contact

Read movement

with end face of cam-

of gauge when

camshaft

is

moved backward and forward. *

9.

End play of camshaft:

0.15 - 0.35 mm

Idler gear

II

Align

match

marks

of

gear, and install

idler gear

(3). * Match marks Crankshaft gear (5) and idler gear:

“A”

Idler gear and cam gear (4):

“9”

2)

Install plate (2).

3)

Tighten mounting bolt (1) of idler gear shaft. m

4)

Mounting bolt:

Put dial gauge @ gear.

11.25 f 1.25 kgm

in contact

Read movement

with

end face of idler

of gauge when

idler gear is

moved backward and forward. *

End play of idler gear: 0.03-0.09

95 SERIES

mm

’3-ii25


DISASSEMBLY

AND ASSEMBLY

GENERAL ASSEMBLY (4D95L SERIES)

10. Oil pump 1)

Install driven gear (1) of oil pump.

2)

Install cover (2) and drive gear (3) of oil pump.

3)

Measuring end play Measure end play of oil pump gear in same way as measuring end play of camshaft. *

Permissible range of end play:

*

Measuring backlash of gears Temporarily (I),

and

fit

fuel

measure

0.02 - 0.07 mm

injection

backlash

of

pump

assembly

gears with

dial

gauge 0. When measuring the backlash of the gears, hold

*

one gear securely, then move the other gear and measure the backlash.

Ir

Backlash (Serial

D_ C

of gears (helical

No.: 106425

gear)

and below)

Unit:

mm

,lnjection pump gear and Idler gear

0.13 - 0.34

-

Camshaft gear and oil oumo clear

0.13 - 0.35

-

;;;;;fb�,i;;r

0.15 - 0.30

13-ii26

and PTo gear

95 SERIES


DISASSEMBLY

*

GENERAL ASSEMBLY (4D95L SERIES)

AND ASSEMBLY

Backlash of gears (helical gear) (Serial No.: 106426 and up) Unit:

Match mark

1 t

Position

Camshaft

Backlash (with

Range

of measurement

gear and oil pump

of gears

(spur

gear)

for PC60-6 Unit:

1

-measurement

B - B

o.07 _ o.2g

blade)

A _ ,,+ Crankshaft gear Camshaft

mm

gear and idler

mm

Range

0.08 - 0.31

gear and idler gear

0.09 - 0.34

gear and idler

1o.08 _ o.3,

6206F411A

q;tionFp _

i;;shaft

-

Camshaft gear and PTO gear (with PTO)

95 SERIES

gear and oil pump

o,08 _ o,3,

0.08 - 0.31

’3-F-’



DISASSEMBLY

AND

ASSEMBLY

GENERAL

ASSEMBLY

(4D95L

SERIES)

11. Gear case cover 1)

Using push tool

(outside

diameter:

72 mm),

install

front oil seal (1). 2)

After

press fitting

front

oil seal, fill 40 -

60% of

space at seal lip with grease. a 3)

Front oil seal: Grease (G2-LI)

Coat

mounting

surface on cylinder

block side with

gasket sealant. a

Mounting surface:

Gasket sealant (LG-7)

4)

Install gear case cover assembly (1).

5)

Measuring Measure

difference distance

mounting

in height of mounting

in

height

between

oil pan on cylinder

block

surface

surface

for

and gear case

cover. *

Permissible difference ing surface:

12. Crankshaft 1)

Align

in height of oil pan mount-

Max. 0.15 mm

pulley with

crankshaft

key,

then

install

Fit plate (l), then tighten mounting

bolts.

crankshaft

pulley (2). 2)

m

13.

Mounting

bolt:

9.5 * 0.5 kgm

Oil suction pipe Fit O-ring and install oil suction pipe (1).

95 SERIES

1%_027


DISASSEMBLY

14.

GENERAL

AND ASSEMBLY

ASSEMBLY

(4D95L

SERIES)

Oil pan Coat

mounting

face with

gasket sealant, then

install oil

pan (1). w

Mounting

m

Drain plug:

6.0 + 1 .O kgm

Mounting face:

Gasket sealant (LG-7)

& *

bolt:

1.9 + 0.5 kgm

Coat the gasket sealant in a 1 mm wide film.

15. PTO shaft 1)

Align

gear of PTO shaft (2) with surface of teeth of

camshaft gear. 2)

16.

Fit O-ring and install flange (1).

Fuel injection pump 1)

Turn

over cylinder

block

so that

cylinder

head is

at top. 2)

Fit

O-ring,

install

fuel

injection

align match injection

Tighten mounting

4)

Install bracket (2). Install lubrication +

idler gear, and

(4) together

with

fuel

pump.

3) 5)

marks with

pump

Check

that

bolts (3). tube (1). the match

marks are aligned, then

fit O-ring and install cover (5).

’3-:28

95 SERIES


GENERAL ASSEMBLY (4D95L SERIES)

DISASSEMBLY AND ASSEMBLY

17. Cylinder head assembly 13 Assemble cylinder head assembly as follows. i)

Using push tool G, install valve guide (6) in cylinder head (1).

ii)

Coat

stems of

intake

and

exhaust

valves and

inside face of valve guide with engine oil. iii)

Install valve (5).

iv)

Assemble valve spring (4) and spring seat (3).

6206F301

For 4D95L-1 VI

Using spring

pusher

B, compress valve spring,

and fit valve cotter (2) in valve stem groove. * After releasing the valve spring, tap the top of the valve stem with a plastic hammer to check that the cotter is completely

fitted.

For 4D95L-W-1

6206P396

95 SERIES

13-829


DISASSEMBLY

2)

AND

GENERAL

ASSEMBLY

ASSEMBLY

(4D95L

SERIES)

Install cylinder head assembly. Remove

all carbon

surfaces head.

of the

Remove

and dirt from

cylinder all

block

burrs

the contact and

and

cylinder

damage,

clean out all dirt from inside the cylinder Install cylinder t

head gasket.

Fit the gasket

up. Raise cylinder as

guide,

and block.

with

the TOP

mark facing

head (1) then using 4 head bolts

install

cylinder

head

to

cylinder

block. 3)

Tighten

mounting

Coat thread compound,

bolts

of the mounting

bolts with antifriction

then tighten mounting

bolts as shown in

Tightening order of cylinder head mounting bolt

diagram. m

*

Cylinder head mounting bolt 1st step: 68.6 - 88.2 Nm (7 - 9 kgm) 2nd step: 107.8 - 127.4 Nm (11 - 13 kgm) 3rd step: 142.1 - 151.9 Nm (14.5 - 15.5 kgm)

There

are

two

methods

bolts: the tightening the tightening

of tightening

torque method

force,

the

Front 11

Intake side head

which controls

and the plastic turning

angle

method.

(See the figure on the right.)

m

Cylinder head mounting bolt 1st step: 68.6 -c 9.8 Nm (7 +_ 1 kgm) 2nd step: 107.8 f 4.9 Nm (11 + 0.5 kgm) 3rd step: Mark bolt head and cylinder head with a felt pen, then turn bolt 90’“8’ to tighten.

*

After

tightening,

head to indicate been tightened.

make a punch the number

Rear

mark on the bolt

of times the bolt has

Tightening by torque

Tightening by plastic turning angle

6206F872

Make mark with punch

Make mark on cylinder head and bolt

The bolt can be used a maximum

of five times. Always

replace

any bolt that already

has five punch marks.

F621201067A

18.

F621201061

Push rods

Insert push rods (1’) in tappet guides. *

The

same part

is used for the

intake

and exhaust

push rods. *

If there

is no abnormality

in the push rod, install

in the same position as before disassembly. 19.

Rocker

1)

arm assembly

Install rocker arm assembly (2).

’3-:30

95 SERIES


DISASSEMBLY

2)

AND

GENERAL

ASSEMBLY

Check that ball of adjustment into

ASSEMBLY

(4D95L

SERIES)

screw is fitted properly

socket of push rod, then tighten

the nuts and

bolts uniformly. m

Mounting

bolt of rocker arm bracket: 2.5 f 0.5 kgm

*

If

the

valve spring tension

rocker

arm,

adjustment

loosen

the

pushes against the

locknut

and turn

the

screw back to prevent strain on the

push rod.

20.

Adjusting valve clearance Adjust clearance between valve and rocker arm as follows. *

Valve clearance (hot or cold) Unit: Intake ~~ valve

1)

Rotate

Exhaust ~ valve

7

0.35

0.5

I

the

crankshaft

align pointer

mm

in the

normal

direction

to

(b) on the gear case cover with the 1.4

TOP mark (a) on crankshaft check the movement

pulley (1). When rotating,

of the intake valves of No. 4

cylinder. 2)

When

No.

1 cylinder

is at compression

center, adjust the valves marked crankshaft

360’

in the normal

0. Then direction,

top

dead

rotate the and adjust

the valves marked 0. *

Valve arrangement

,

I

3)

To

Cylinder No.

adjust,

chart

1

I11213141

insert tool

H between

valve stem and turn adjustment is a sliding fit.

Then tighten

rocker

lever and

screw until clearance

locknut to hold adjust-

ment screw in position. w 4)

Locknut:

After

adjusting

4.5 + 0.5 kgm No.

1 cylinder

at compression

top

dead center, it is also possible to turn the crankshaft 180�

each time

and adjust the valve clearance

of

each cylinder according to the firing order. *

Firing order:

*

After

1- 2 - 4 - 3

tightening

the locknut, check the clearance

again.

95 SERIES

13-031 0


DISASSEMBLY

AND

ASSEMBLY

GENERAL

(For precombustion 21.

22.

Cylinder

ASSEMBLY

(4D95L

SERIES)

chamber type (4D95L-W-1))

head cover

1)

Fit O-ring to cylinder head cover.

2)

Install cylinder head cover (3).

Nozzle holder For 4D95L-1 i)

Install gasket (5).

ii)

Install nozzle holder (2).

m

Mounting

bolt:

4.5 + 0.5 kgm

For 4D95L-W-1 i)

23.

Install gasket (4). * Install the gasket with the blue mark facing

ii)

up. Install nozzle holder (2).

B

Nozzle holder:

7 k 1.0 kgm

Spill tube Install spill tube (1). w

Mounting

bolt:

4.5 f 0.5 kgm (4D95L-W-1

24. Glow plug, glow lead (4D95L-W-1 1)

Install glow plug (2).

2)

Install glow lead (1).

w

25.

Glow plug:

only)

1.75 + 0.25 kgm

Intake manifold Install intake manifold a * w

(1).

Mounting surface:

Gasket sealant (LG-7 ‘1

Coat the gasket sealant in a 1 mm wide film. Mounting bolt:

’3-;32

4.1 * 0.6 kgm

95 SERIES


DISASSEMBLY

26.

AND

ASSEMBLY

GENERAL

Fuel injection pipe * Before installing the fuel injection

pipe, blow com-

pressed air through to clean it. 1)

Install

fuel

injection

pipe

(21,

then

temporarily

tighten sleeve nuts at both ends. 2)

Align fuel injection pipes, then tighten clamps (1).

3)

Fully tighten sleeve nuts of injection pipes. w

27.

Sleeve nut:

2.3 f 0.2 kgm

Exhaust manifold .Fit gasket and install exhaust manifold w

28.

Mounting

bolt:

(I)

4.5 f 1 .O kgm

Water pump Assemble

O-ring

on pilot,

then

fit

gasket and

water pump (1).

29.

Oil filter, gauge guide 1)

Install gauge guide (21, then secure with clamp.

2)

Install oil filter (1).

95 SERIES

install

ASSEMBLY

(4D95L

SERIES)


DISASSEMBLY

30.

AND ASSEMBLY

ASSEMBLY

(4D95L

SERIES)

Alternator install alternator

31.

GENERAL

(1 j.

Fan pulley 1)

2)

Install fan pulley (3).

Fit belt (2) in pulley groove, then temperarily adjustment

3)

Insert a bar or pipe between alternator block,

tighten

plate (1).

and raise alternator

and cylinder

to outside to adjust fan

belt tension.

A *

Be careful not to get your fingers caught. The belt should deflect 14 -

17 mm when pushed

with a finger pressure of 6 kg at a point midway between the alternator

pulley and the crankshaft

pulley. *

After

adjusting the belt tension, tighten the bolts

fully.

Crankshaft

pulley

614OF301

32.

Fan Install fan (1).

13-$34

95 SERIES


DISASSEMBLY

33.

ASSEMBLY

GENERAL

Muffler Install

34.

AND

muffler

Lowering 1)

engine

Sling unit

(I 1.

engine

assembly

repair stand A, then

(2).

disconnect

lower

stand.

2)

Remove

3)

Fit O-ring and install starting

95 SERIES

bracket

AI

from

engine

from

engine on to a stable

engine.

motor

(I).

ASSEMBLY

(4D95L

SERIES)


DISASSEMBLY

AND

GENERAL

ASSEMBLY

GENERAL DISASSEMBLY

(6D95L

DISASSEMBLY

(6D95L

SERIES)

SERIES) 3

4

Oil cooler

P

13

13236

14

15

95 SERIES


DISASSEMBLY AND ASSEMBLY

95 SERIES

GENERAL DISASSEMBLY (6D95L SERIES)


DISASSEMBLY

AND

GENERAL

ASSEMBLY

DISASSEMBLY

(6D95L

SERIES)

Special tool Part name

Part No. A Al

a

Q’ty

790-501-5000

Engine repair stand

1

790-901-l

Bracket

1

250

B

795-102-2102

Spring pusher

1

C

795-100-4710

Valve guide remover

1

D

795-240-2801

Flange puller

1

E

795-l 00-2800

Piston ring tool

1

Prepartory

1) 2)

work

Remove all dirt and mud from around the engine. Remove drain plug and drain oil from engine. _ :

3)

Engine oil:

Approx.

10.5 II

Prepare a stable stand which will prevent the engine from

falling

over, then put the engine securely

in

the stand. Engine assembly:

Approx.

410 kg.

(The weight of the engine differs according to the model

of machine

on which

it is

mounted.) 1.

Starting motor Remove starting motor (1).

2.

. .

Setting engine onto repair stand I) Install bracket Al to engine assembly (I), 2) Install engine assembly (1) onto engine stand A using bracket Al.

repair

For the engine, install Al to the engine first. For the transmission, install Al to the stand first.

’3-838

95 SERIES


DISASSEMBLY

3.

AND

GENERAL

ASSEMBLY

Alternator 1)

Loosen mounting

2)

mounting

bolts of adjustment bolt and nut of alternator.

Move alternator

towards

cylinder

plate (I), and

block,

and remove

belt (2).

Q

t

Be careful damage alternator

3)

4.

Remove alternator

not

the

to catch

alternator

towards

your

when

the cylinder

fingers moving block.

(3).

Oil cooler

_Remove oil cooler (1).

5.

6.

Exhaust

manifold Remove exhaust manifold

(1).

Water pump Pull out pilot

95 SERIES

portion,

then remove water

pump

(1).

or the

DISASSEMBLY

(6D95L

SERIES)


DISASSEMBLY

7.

AND

GENERAL

ASSEMBLY

DISASSEMBLY

(6D95L

SERIES)

Fuel filter 1)

Disconnect

hose (1)

between

pump

and filter

at

hose (2)

between

pump

and filter

at

pump end. 2)

Disconnect pump end.

3)

8.

Remove fuel filter (3).

Fuel injection pipe 1)

Remove clamp (1).

2)

Remove

sleeve

nut,

then

remove

fuel

injection

pipe (2).

9. Spill tube Remove spill tube (1). *

When removing the nozzle holder, the inserted part is easier to pull out if the spill tube is removed after the nozzle holder is removed.

IO.

Fuel injection pump 1)

Remove oil supply tube (1).

2)

Remove fuel injection pump holder bolt (2).

3)

Remove gear and nut (3), then remove fuel injection pump (41. * There is one bolt installed from the fuel injection *

pump side, so do not forget to remove it.

To prevent dirt or dust from entering, fit caps or use tape to cover the oil and fuel inlet and outlet ports.

13-$40

95 SERIES


DISASSEMBLY

11.

AND

GENERAL

Intake manifold Remove intake

12.

ASSEMBLY

Nozzle -1)

manifold

(1).

holder

Remove nozzle holder (I). * When removing the nozzle holder, the nozzle holder

and fit a blind

clean around

plug to prevent

dust or dirt from entering. *

Be careful holder

*

Mark

not to damage the tip of the nozzle

when removing. the nozzle

cylinder

holders

is no abnormality in the same position

13. Cylinder

tags showing

in the nozzle

holder,

the

If there install

when assembling.

head cover

Remove cylinder

14.

with

No. and keep in a safe place.

head cover (1).

*,~.“< ,,

Rocker arm assembly Remove rocker *

When

arm assembly

removing

the rocker

and turn the adjustment

95 SERIES

(1). arm, loosen the locknut

screw back 2 to 3 turns.

‘,,,\,:\ __

DISASSEMBLY

(6D95L

SERIES)


DISASSEMBLY

AND

GENERAL

ASSEMBLY

DISASSEMBLY

(6D95L

SERIES)

15. Push rods Remove push rods (1) from cylinder head. * Mark the push rods with tags to show the places of installation

and keep in‘a

abnormality position

16. Cylinder

in the

safe place.

push

rod,

install

2)

Fit lifiting

tool

bolts of cylinder

in mount

bottom

face of the cylinder

Disassemble the cylinder Using

spring

loosen

pusher

spring,

iii)

Mark

B, compress

protect

the

,,

valve spring,

(2).

and remove head.and

the valves with

of installation iv)

to

head from damage.

spring

seat (3) and

(4).

Raise cylinder *

head, then lift crane.

head assembly as follows.

then remove valve cotter

valve spring

head assembly.

on cylinder

off cylinder head assembly (1) with * Lay cardboard on the floor

ii)

same

head assembly

Remove mounting

i)

is no

in the

when assembling.

1)

l

If there

Using remover

remove valve (5). tags to show the place

and keep in a safe place.

C, remove valve guide (6).

6206F301

13$42

95 SERIES


DISASSEMBLY

17.

AND ASSEMBLY

GENERAL

DISASSEMBLY

(6D95L

SERIES)

Flywheel Remove mounting bolts, then remove flywheel (1). * The pilot is short, so the flywheel may come off suddenly.

18.

Flywheel

housing

1)

Remove flywheel

2)

Remove rear oil seal (2).

19. Vibration

housing (1).

damper

Remove vibration damper (1).

20.

Crankshaft 1) 2)

pulley

Remove plate (1). Set flange puller D in position, then pull out crankshaft pulley (2). *

The tapered collar is press fitted, so hit the bolt portion

of the flange puller with a hammer to

remove it.

6206P322

95 SERIES

13-$43


DISASSEMBLY

21.

22.

AND

GENERAL

ASSEMBLY

DISASSEMBLY

(6D95L

SERIES)

Gear case cover 1)

Remove gear case cover

2)

Remove front

(1).

oil seal (2).

Oil pan Remove oil pan (1).

23.

Oil pump Remove oil pump

13344

(1).

95 SERIES


DISASSEMBLY

24.

25.

AND

GENERAL

ASSEMBLY

Idler gear (1), then remove plate (2).

1)

Remove bolts

2)

Remove gear (3).

Camshaft assembly I)

Turn

over

mounting 2)

cylinder

block,

Engine No. 10001 -

.

so that

cylinder

head

face is facing down.

Remove

10036

mounting

bolts

(I)

through

hole in gear, then remove thrust

casting

plate (2).

Engine No. 10037 and up

.

Remove

mounting

bolts

(1)

through

casting

hole in gear. 3)

Engine No. 10001 -

.

10036

Remove camshaft

assembly

(3).

Engine No. 10037 and up

. *

Remove

camshaft

thrust

plate (2).

When

removing,

and be careful

26.

95 SERIES

rotate

the

(3) together

camshaft

not to damage the bushing.

Oil suction pipe Remove oil suction

assembly

pipe (1).

with

lightly

DISASSEMBLY

(6D95L

SERIES)


DISASSEMBLY

27.

AND

Piston, connecting 1)

Checking i)

GENERAL

ASSEMBLY

DISASSEMBLY

(6D95L

SERIES)

rod assembly.

connecting

rod cap number.

Turn over cylinder

block,

and set with

cylinders

horizontal. ii)

Check that the number

stamped

on connecting

rod cap matches cylinder number. * If there is no number stamped connecting camshaft 2)

Removing Using

on

rod cap, stamp a number

the

at the

end.

carbon

fine

sandpaper,

cylinder. * Be careful

not

remove

to

carbon

damage

at top

the

inside

end

play

of

of the

cylinder. *

If

necessary,

connecting

measure

rod with

the

ing the piston and connecting 3)

Connecting i)

Rotate

the

dead center.

crankshaft

mounting

to

ii)

Remove

iii)

cap (I). Tap cap

with

connecting

rod cap together

Be careful

Piston, connecting Push a wooden

not

rod assembly.

to

set of

the

piston

connecting

hammer

and

with

damage

at rod

remove

bearing. the

thread

of

bolts.

rod assembly

bar or hammer

oil pan side. Support then

bolts

plastic

the mounting

4)

the

rod cap

bottom

*

of

a dial gauge before remov-

piston

push bar in further

piston and connecting

from

handle through at cylinder

from

head end,

oil pan side to remove

rod assembly

(2).

6206P332

l

Disassemble

piston

and

connecting

rod

assembly

as follows. i)

Using pliers

0,

remove

snap ring

(3) on one

side. ii)

Remove

piston

pin (4), and separate connecting

rod (5) and piston (6). * If the pin does not come out, soak in hot water. iii)

Remove

snap

ring

on

other

side

in the

same

way.

13-$46

96 SERIES


DISASSEMBLY

AND

iv)

Using piston from

v)

GENERAL

ASSEMBLY

ring tool

E, remove piston

(6D95L

SERIES)

ring (7)

piston.

Using

push

tool

@_I, remove

connecting rod. * Keep the pistons, piston

rings,

bushing

connecting

piston

(8) of

rods, bearings,

pins, and bushings

sets for each cylinder

28.

DISASSEMBLY

in

number.

Main bearing cap 1)

Measuring

end play

i)

over

Turn

cylinder

block,

so that

oil

pan

is

facing up. ii)

Measure

end

play

of

crankshaft

using

dial

gauge 0. *

The end play measurement judging abnormal

wear

of

the

wear

of

is necessary for

thrust the

measure before removing

bearing

and

crankshaft,

so

the crankshaft.

2)

Remove mounting

bolts (1) of main bearing cap.

3)

Insert

bolt

mounting

lever cap, or tap with right with

and

remove

in

main

lower main bearing

bolt

plastic

hole hammer

bearing

cap

in

cap, on left

then and

(3) together

(2).

95 SERIES

0


DISASSEMBLY

AND

*

ASSEMBLY

Thrust

GENERAL

(6D95L

SERIES)

bearings (4) are assembled on both

sides of cap (3) at the flywheel after

DISASSEMBLY

removing,

mark

end, so

to show the place

of installation.

29.

Crankshaft 1)

Remove crankshaft (1). * Be careful not to hit the crankshaft the

cylinder

block

and

damage

the

against sliding

surface.

2)

Remove upper main bearing (2). * Mark the main bearing and thrust bearing with tags

to

show

the

place of

installation,

and

keep in a safe place in sets for each cap number.

30.

Tappet Remove tappet (1)

13$48

95 SERIES



DISASSEMBLY

GENERAL

AND ASSEMBLY

GENERAL ASSEMBLY

(6D95L 2

ASSEMBLY

(6D95L

SERIES)

SERIES) 6 15

I

9

Cylinder block

13-$50

95 SERIES


DISASSEMBLY

AND

ASSEMBLY

GENERAL

ASSEMBLY

(6D95L

SERIES)

16 Vibration damper

--

31

32

2

2 Fuel filter

21 Exhaust manifold

95 SERIES

13F


DISASSEMBLY

AND

GENERAL

ASSEMBLY

ASSEMBLY

(6D95L

SERIES)

Special tool Part No.

1.

A

)

A1

1 790-901-1250

Part name

790-501-5000

) Engine repair stand

1 Bracket

Q’W / 1 I ’

Setting in engine repair stand 1)

Install bracket

2)

Set cylinder

AI

to engine repair stand A.

block

in engine repair stand A.

96 SERIES


DISASSEMBLY

2)

AND

Raise

crankshaft

position. * Be careful cylinder

4.

GENERAL

ASSEMBLY

(l),

and

assemble

to

not to hit the crankshaft

mounting against the

block.

Main bearing cap 1)

Lower i)

main bearing

Align

protrusion

notch *

in

Check that there the

rear face

side

face

bearing

(2)

main bearing

with

cap.

is no dirt or dust stuck

of the

of the

(SAEBO) before 2)

lower

in cap, then install

bearing.

bearing

to

Coat the in-

with

engine

oil

assembling.

Main cap

1) Check that number

stamped

cap is the same as number ii)

Set casting

number

and install with iii)

Align

lower

*

iv)

Set

(4) with cap (3).

is one upper thrust these

t

each

(portion

thrust

bearing

pin,

but two

Be careful

not

to

bearing

with

the

oil

facing

front,

and

install

cap (3). not

slip out of place.

95 SERIES

dowel

“a�) on the outside.

number

Be careful

front,

bearings.

Install

main bearing

thrust

bearings.

groove

casting

cap facing

bearing

lower

bearing block.

bolt (1).

in main bearing

There mistake

*

of main

mounting

thrust

then install

on main on cylinder

to

let the

thrust

bearings

ASSEMBLY

(6D95L

SERIES)


DISASSEMBLY

5)

GENERAL

AND ASSEMBLY

Tighten

mounting

bolts

of

Coat the bolt

thread

main

bearing

cap

ASSEMBLY

(6D95L

SERIES)

as

follows. *

and seat face with

engine

oil. *

When

tightening

main bearing to the outside. w

the

mounting

bolts

cap, start in the middle Tighten

Mounting

of

to the following

torque.

bolt of main bearing cap

Unit:

*

Order

Target

I

1st step

11.5

I

2nd step

0

3rd step

13.5

After

tightening

Measuring

Range 11-12

13-

mounting

14

bolts,

check

rotates smoothly.

end play of crankshaft

Put probe of dial gauge @ in contact of

kgm

Loosen completely

the

that the crankshaft 6)

the

and work

crankshaft.

Read

movement

with

of

end face

gauge

when

crankshaft is moved forward and backward. * Permissible range of end play: 0.13 - 0.35 mm

5.

Piston, connecting 1)

Assemble

rod assembly

piston

and connecting

rod

assembly

as

follows. i)

Set piston facing

ring with

up, then

stamped

use piston

mark at end gap

ring tool

E to assem-

ble piston rings (7) on piston (6). * Be careful not to damage the break the piston *

Fit

expander

inside

*

piston

or

rings. (10)

diameter

installing.

Check

completely

fitted

in the

of

oil

that

groove ring

the

on the

(9)

before

expander

is

into the ring groove.

The end gap of the ring should

be at 180’

to the join of the coil in the expander.

13-854

95 SERIES


DISASSEMBLY

ii)

AND

ASSEMBLY

GENERAL

ASSEMBLY

(6D96L

SERIES)

Using pliers (1), assemble snap’ring on one side in snap ring groove of piston.

iii)

Using

push

tool

0,

press fit

bushing

(8)

on connecting rod.

iv)

Set arrow direction

on head of piston

facing

in same

as casting number on connecting rod.

Insert piston pin (4), and assemble connecting rod (5) and piston (6). * If it is difficult to insert the piston pin, put the piston in hot water to expand the diameter

of

the

pin

hole,

then

insert

the pin. v)

Assemble

other

piston. * After that

assembling

Align the

the

the connecting

forward vi)

snap ring

on other snap

rings,

side of check

rod moves smoothly

and backward.

the protrusion connecting

rod

in the with

upper bearing of the

notch

in the

connecting rod, then install.

95 SERIES

13255


DISASSEMBLY

2)

Turn

AND

over

GENERAL

ASSEMBLY

cylinder

block

so that

crankshaft

ASSEMBLY

(6D95L

SERIES)

is

vertical. 3)

Set end gaps of piston rings as shown in diagram.

4)

Set crankshaft-pin *

Oil ring

Size mark (S or L)

at bottom dead center.

Coat the inside face of the cylinder, rings and the

the piston

of the connecting

surface

rod

bearing with engine oil.

Over size mark

Size mark (S or L)

6206F302

5)

Align

direction

of F (Front)

mark on side face of

piston to face front of engine. Using piston holder F, insert piston

and connecting

rod assembly

(2)

from cylinder head end. 6)

When piston rings are inserted inside cylinder, in head addition,

of piston pull

Align

hand or wooden

big end of connecting

with crankshaft 7)

with

protrusion

push

bar.

In

rod to align

pin. of lower

bearing with

notch

in

cap, then assemble to bearing cap.

81

Set with stamped mark at camshaft end, then install connecting rod cap (1). * Coat the connecting

rod bearing

with engine

oil. *

Check that the stamped number on the connecting rod cap is the same as the number of the cylinder.

13356

95 SERIES


DISASSEMBLY

9)

AND

Tighten

GENERAL

ASSEMBLY

mounting

bolts

of

connecting

SERIES)

Put a mark on the bolt cap

Coat

the connecting

face with w

rod bolt

thread

and seat

engine oil. Mounting

bolt of connecting

rod

Unit:

After tightening, stamp mark the tightening time on bolt head by punch

kgm

Order

Target

Range

1st step

4.0

4.0 - 4.2

Mark bolt head and cap seat with felt pen, then tighten to following angle.

2nd step

1 *

(6D95L

rod cap as

follows. *

ASSEMBLY

The

connecting

times.

Make

rod

bolts

a punch

9o"-120°

may

mark

6206F303

be reused five

on the

bolt

head

each time the bolts are used. if there are already five

marks

on the bolt

head, replace with

new

bolts. *

After

assembling

that crankshaft

10)

Measuring

the

rotates

connecting

rods,

check

smoothly.

side clearance of connecting

rod cap.

over cylinder

oil pan faces

i)

Turn

ii)

up. Using dial gauge 0,

block

so that

measure side clearance

of

connecting rod cap. * Permissible range of side clearance: 0.20 - 0.40 mm

6.

Camshaft 1)

assembly

Insert camshaft *

Rotate

assembly

the camshaft

avoid damaging *

2)

When

inserting

plate (2) from

mounting

lightly

when

the

bolts

camshaft

Mounting

to

assembly,

insert

the side to install. (1) of thrust

plate through

casting hole of gear to secure camshaft m

block. inserting

the bushing.

thrust Tighten

(3) into cylinder

bolt of thrust

assembly.

plate: 1.9 + 0.5 kgm

95 SERIES

’3-:57


DISASSEMBLY

AND

(When tightening insert *

avoid

assembly

into cylinder

the camshaft damaging

Use sleeve

ASSEMBLY

(6D95L

SERIES)

cam gear bolts)

camshaft

Rotate

GENERAL

ASSEMBLY

lightly

block.

when

inserting

to

the bushing.

inserted

into

block

as a pilot,

and in-

stall housing. press sleeve,

fit

Tighten bolts

gear

finally

bearing,

so

that

all

shoulders

of

and gear are in contact.

housing through

to block casting

assembly hole

of

with

mounting

gear

to

secure

assembly. w

Mounting

Mesh

cam

gear

then tighten m

Mounting

Insert

camshaft

Rotate avoid

1.9 k 0.5 kgm PTO gear

mounting

(When shrink fitting *

bolt: with

bolt:

‘18 -

idler

gear,

20 kgm

cam gear and tightening) assembly

the camshaft damaging

Use sleeve

and

bolts of cam gear fully.

into cylinder

block.

lightly

inserting

when

to

the bushing.

inserted

into

block

as a pilot,

and in-

stall housing. Press

fit

gear

finally

sleeve,

bearing,

Tighten

housing

bolts through

so

that

all

shoulders

of

and gear are in contact. to block

casting

assembly

with

mounting

hole of gear to secure

cam-

shaft assembly. m

Mounting

’3-t?7-1

bolt:

1.9 k 0.5 kgm

95 SERIES



DISASSEMBLY

3)

AND

Measuring

end play of camshaft

Put probe

of dial gauge @ incontact

of camshaft.

Read movement

shaft is moved. * Permissible

7.

GENERAL

ASSEMBLY

with

ASSEMBLY

(6D95L

SERIES)

end face

of gauge when cam-

range of end play:

0.15 - 0.35 mm

Idler gear 1)

Align match marks of gear, and install * March marks Crankshaft

gear (4) and idler gear:

Idler gear and cam gear (5): 2)

Install

3)

Tighten m

13-058

idler gear (3). “A”

“B”

plate (2). lock bolt

(1) of idler gear shaft.

Lock bolt:

11.25 f 1.25 kgm

95 SERIES


DISASSEMBLY

8.

AND

GENERAL

ASSEMBLY

ASSEMBLY

(6D95L

SERIES)

Oil pump 1)

Install driven gear (1) of oil pump.

2)

Install cover (2) and drive gear (3) of oil pump.

3)

Measuring

backlash

Measure

backlash

measuring *

of oil pump

backlash

Standard

gear in same way as

of idler gear.

backlash:

Cam gear and oil pump gear: 0.13 - 0.35 mm 4)

Measuring

end play

Measure

end play of oil pump

gear in same way as

measuring end play of camshaft. * Permissible range of end play: 9.

Fuel injection

.

Fuel injection 1)

Turn

0.02 - 0.07 mm

pump pump

over

cylinder

block

so that

cylinder

head is

at top. 2)

Fit

O-ring,

align

match

install fuel injection 3)

.

marks

pump

with

idler

Fit gasket and install oil supply

tube.

Measuring gear backlash Measure the backlash of each gear with Backlash of gears (helical gear) (Serial No.: 106425 and below)

*

gear, and

(1).

a dial gauge.

Unit: Match mark

Position

A - A

Crankshaft

B - B

Cam gear

C - C 1Injection

-

gear

and idler

and idler pump

gear

Range 0.14 - 0.28 0.15 - 0.30

gear

gear and idler gear

Cam gear and oil pump

-

*

of measurement

mm

gear

1Cam gear and PTO gear (With PTO)

0.13 - 0.34

I 0.13 - 0.35 1 0.15 - 0.30

Backlash of gears (helical gear) (Serial No.: 106426 and up) Unit:

Match mark A - A B - B

Position Crankshaft

-

gear and idler

gear

ICam

gear

pump

gear and idler gear

and oil pump

gear

Cam gear and PTO gear (With PTO)

95 SERIES

/..

--I

6206F41

I

Range 0.08 - 0.19

1 0.08 - 0.19

/Cam gear and idler gear

C - C 1Injection

-

of measurement

mm

1 0.07 - 0.29 I 0.07 - 0.29 0.15 - 0.30

’3ii59


DISASSEMBLY

10.

GENERAL

AND ASSEMBLY

ASSEMBLY

(6D95L

SERIES)

Gear case cover

1)

Using push tool H, install front

2)

After

3)

press fitting

front

at seal lip with

grease.

a

seal:

Front

Coat mounting

oil seal (1).

seal, fill 40 - 60% of space

Lithium

grease

surface on cylinder

block

side with

gasket sealant. 6

4) 5)

Mounting

surface:

Gasket sealant (LG-7)

Install gear case cover assembly Measuring Measure mounting

difference distance

(2).

in height of mounting in

height

between

oil pan on cylinder

block

surface

surface

for

and gear case

cover. *

Permissible mounting

10A. Gear case cover

. 1) 2)

3)

4) 5)

6)

difference surface:

in

height

of

oil

pan

Max. 0.15 mm

(front cover)

For camshaft with bearing support at both ends (D31-20, D37-5) Using push tool H, install front seal (1). After press fitting front seal (I), fill 40 - 60% of space at seal lip with grease. & Front seal: Lithium grease Coat mounting surface at cylinder block end with gasket sealant. 6 Cylinder block: LG-7 Install gear case cover (front cover) assembly (3). Measure stepped difference at mounting surface. Measure stepped difference at oil pan mounting surface of gear case cover and cylinder block. * Repair limit for stepped difference at oil pan mounting surface: 0.15 mm

6206F950

Assemble outer race (6) of bearing (5) to bearing case (4), then coat bearing case mounting surface of front cover (3) with gasket sealant, and install bearing case to front cover. *

Insert outer tom surface

race (6) until it contacts the botof the bearing case pilot.

6206F951

’3iYo

95 SERIES


DISASSEMBLY

AND ASSEMBLY

Ir

Center

&

shaft, then secure the bearing case to the front cover. Bearing case mounting surface of front cover: Gasket sealant (LG-7) Bearing case mounting bolt:

m

the inner

GENERAL DISASSEMBLY

(6D95L SERIES)

race at the tip of the cam-

18.6 + 4.9 Nm (1.9 f 0.5 kgm) If the bearing case is installed to the front cover and then installed to the engine, it will not be centered with the shaft and there will be excessive force brought to bear on the

t

cam bushing. This may cause seizure of the bushing. To make it possible to center the bearing and camshaft when assembling the bearing case, always install the bearing case 7)

after installing the front cover. Install sound-suppressing cover (8) to front cover (3). Ir This sound-suppressing quire the use of any

cover does not regrommet as a blind

plug. m

Sound-suppressing

cover mounting

bolt:

7.8 + 2 Nm (0.8 i: 0.2 kgm)

6206F952

11.

Flywheel

housing

Using

push tool

J (outside

diameter:

install rear oil seal (2) on flywheel Outside circumference

&

120

mm),

housing (1).

of rear seal: Gasket sealant (LG-1)

After press fitting rear seal, fill 40 - 60% of space at seal lip with grease. &

Rear seal: Grease (G2-LI)

Coat

mounting

surface of flywheel

housing with

gasket sealant. a

Mounting surface:

Align

with

dowel

pin

Gasket sealant (LG-7)

(3),

and

install

flywheel

housing (1). *

When fitting the seal lip to the outside diameter of

the

crankshaft

flange,

be careful

not

to

apply force to the seal lip surface. w

Mounting bolt: 66.2 + 7.4 Nm (6.75 + 0.75 kgm)

95 SERIES ’ 3-i!to-’



DISASSEMBLY

5)

AND

Measuring difference Measure

distance

mounting

GENERAL

ASSEMBLY

height

between

difference

surface

Face runout:

for

height

of

flywheel

Max. 0.15 mm

Measure radial and face runout of flywheel with dial gauge 0. * Radial runout:

SERIES)

block and flywheel

in

housing mounting surface:

6)

(6D95L

in height of mounting surface in

oil pan on cylinder

housing. * Permissible

ASSEMBLY

housing

Max. 0.30 mm Max. 0.35 mm

614OF286

12.

Flywheel 1)

Install flywheel m

(1).

Mounting bolt: Unit:

2)

Measure

radial

and face runout

dial gauge. * Radial runout: *

Face runout:

of flywheel

kgm

with

Max. 0.30 mm Max. 0.35 mm

13. Oil suction pipe Fit O-ring and install oil suction pipe (l), with bracket.

95 SERIES

then secure

~

13-06 a

1


DISASSEMBLY

AND ASSEMBLY

GENERAL

ASSEMBLY

(6D95L

SERIES)

14. Oil pan

15.

1)

Install under plate with gasket.

2)

Install oil pan (1) with gasket.

Q~z

Mounting

m

Drain plug:

Crankshaft 1)

bolt:

3.25 + 0.25 kgm

6.0 f 1.0 kgm

pulley

Insert tapered

collar, then install crankshaft

pulley

(2). 2)

Fit plate (I), then tighten mounting bolts. w

16. Vibration

Mounting bolt:

38.0 -+ 3.0 kgm

damper

Install vibration damper (1). m

Mounting

17. Cylinder 1)

bolt:

3.1 t 1.1 kgm

head assembly

Assemble cylinder head assembly as follows. i)

Using push tool cylinder head

’3-kL62

G, install

valve guide

(6) in

(1).

95 SERIES


DISASSEMBLY

ii)

AND

Coat

GENERAL

ASSEMBLY

stems

of

intake

and

exhaust

inside face of valve guide with iii)

Install valve (5).

iv)

Assemble

valve spring

ASSEMBLY

(6D95L

SERIES)

valves and

engine oil.

(4) and spring seat (3).

6206F301

v)

Using

spring

pusher

B, compress

valve spring,

and fit valve cotter (2) in valve stem groove. * After releasing the valve spring, tap the top of the to

valve

check

stem

that

with

the

a plastic

cotter

hammer

is completely

fitted.

2)

Install cylinder head assembly. * Remove all carbon and dirt surface

of the cylinder

Remove

Install *

from

the contact

and cylinder

head.

all burrs and damage, and clean out all

dirt from i)

block

inside the cylinder

cylinder

Fit the

block.

head gasket.

gasket

with

the

TOP

mark

facing

up. ii)

Raise cylinder as

guide,

head (1) then

install

cylinder

using 4 head bolts head

to

cylinder

block.

Tightening order of cylinder head mounting bolt

3)

Tighten t

mounting

Coat

the

thread

antifriction *

There bolts:

bolts. of the

compound

are two the

methods

tightening

controls

the

turning

angle

tightening method.

mounting

bolts

with

(LM-P).

Front mi

of tightening torque force,

Rear

the head

method

which

and

plastic

the

(See the figure

Intake side

6206F40

on the

right.)

Tightening by plastic turning angle

Tightening

by torque 6206F872

95 SERIES

13-063 @

I


DISASSEMBLY

AND

GENERAL

ASSEMBLY

Cylinder

w

head mounting

Make

Order

Target

Range

1st step

7

6-8

2nd step

11

3rd step

90”

After

tightening,

of five times.

mark

with

punch

\

Make mar.k on cylinder and bolt

head

9o”-120°

I a punch

the number

been tightened.

kgm

10.5-11.5

make

head to indicate

(6D95L-1)

bolt Unit:

*

ASSEMBLY

mark

of times

on the

bolt

the bolt

has

F621201067A

F621201061

The bolt can be used a maximum Always

has five punch

replace

any bolt that already

marks.

18. Push rods Insert push rods (1) in tappet guides. *

The

same part

is used for

the intake

and exhaust

push rods. *

If there

is no abnormality

in the same position

19.

in the

push rod, install

as before disassembly.

Rocker arm assembly

1)

Install

2)

Check that ball of adjustment into

rocker socket

arm assembly

(1). screw is fitted

of push rod, then tighten

properly

the nuts and

bolts uniformly. m *

Mounting

bolt:

2.5 f 0.5 kgm

If the

valve

spring

tension

rocker

arm,

loosen

the

adjustment

pushes against

locknut

and turn

screw back 2 to 3 turns

the the

to prevent

strain on the push rod.

20.

Adjusting valve clearance a Adjust clearance between

valve and rocker

arm as

follows. *

1)

Valve clearance

Rotate

the

align pointer TOP

mark

rotating,

(hot or cold)

crankshaft

in the

Unit:

normal

direction

(b) on the gear case cover with (a)

on

crankshaft

check the movement

pulley

mm

(1).

to

the 1.6 When

of the valves of No. 6

cylinder.

’3-E4

95 SERIES


DISASSEMBLY

2)

AND

When

No.

center, the

GENERAL

ASSEMBLY

1 cylinder

adjust

the

crankshaft

is at compression

valves

marked

in the normal

No. 6 cylinder

0.

top

direction,

is at compression

dead

Then

top

rotate

and when dead center,

adjust the valves marked0. *

Valve arrangement

8=

Cylinder

Intake

2

l 0

To adjust,

3

l

valve

4

5

l

0 0

0

0

adjustment

until

fit.

to hold adjustment

m After

Locknut: adjusting

dead center, 120’

is a sliding

No.

0 0

insert feeler gauge H between

clearance

6

0

arm and valve stem and turn locknut

*

1

valve

Exhaust

*

No.

chart

Then

0

rocker screw tighten

screw in position.

4.5 f 0.5 kgm 1 cylinder

at compression

top

it is also possible to turn the crankshaft

each time

and adjust

the valve clearance

of

each cylinder according to the firing order. * Firing order: 1 - 5 - 3 - 6 - 2 - 4

21.

Cylinder

head cover

Fit O-ring and install cylinder

22.

Nozzle

head cover (I).

holder

Fit gasket and install nozzle holder w

* *

Mounting When

bolt:

remove

the

nozzle

gasket with

new one.

Insert

spill

holder.

95 SERIES

the

(1).

4.5 * 0.5 kgm

tube

holder,

before

replace

installing

the

the seat nozzle

ASSEMBLY

(6D95L

SERIES)


DISASSEMBLY

23.

GENERAL

AND ASSEMBLY

ASSEMBLY

(6D95L

SERIES)

Spill tube Install spill tube (1).

24.

Fuel injection pipe * Before installing

the

fuel

injection

pipe,

blow

compressed air through it. 1)

Install

fuel

injection

pipe

(2),

then

temporarily

tighten sleeve nuts at both ends. 2)

Align fuel injection pipes, then tighten clamps (1).

3)

Fully tighten sleeve nuts of injection pipes. w

25.

26.

Sleeve nut:

2.3 f 0.2 kgm

Intake manifold Coat mounting

surface with

intake manifold

(1).

&,s

Mounting surface:

m

Mounting bolt:

gasket sealant, then install

Gasket sealant (LG-7)

3.0 f 1 .O kgm

Fuel filter 1)

Install fuel filter (3) to bracket.

2)

Fit gaskets to both

faces of joints

of fuel

hoses

(2) and (I), then connect with joint bolts. w

13-p

Joint bolt:

2.3 f 0.2 kgm

95 SERIES


DISASSEMBLY

27.

AND

ASSEMBLY

Water pump Fit gasket and install water

28.

pump

&I&

Both faces of gasket:

Exhaust

manifold

Fit gasket and install exhaust m

Mounting

29. Oil cooler, Install

*

Be careful

m 2)

bolt:

(1).

Gasket sealant (LG-1 )

manifold

(1).

4.5 * 1.5 kgm

oil filter

1)

oil cooler

sealant

on the mount-

of the filter.

Mounting Oil filter

(1).

not to get gasket

ing surface

bolt:

3.2 f 0.5 kgm

(for PC200, 220-5)

Fit O-ring

30.

GENERAL

to mounting

surface

of oil filter

then install

bracket.

If there

with

sealant

(LG-7) and install

gasket

bracket,

is no oil groove,

coat

bracket.

Alternator 1)

Install alternator

2)

Fit

belt

plate (1).

95 SERIES

(2),

(3).

then

temporarily

tighten

adjustment

ASSEMBLY

(6D95L

SERIES)


DISASSEMBLY

3)

AND

GENERAL

ASSEMBLY

Insert a bar or pipe between block,

and raise alternator

alternator to outside

fan

Alternator

Pullev

belt tension.

A

Be careful

*

The

belt

should

pushed with midway the

not to get your deflect

a finger

between

crankshaft

belt tension,

fingers caught.

14 -

17 mm

when

pressure of 6 kg at a point the

alternator

pulley.

tighten

After

pulley

and

adjusting

the

the bolt fully.

(6D95L

\\ w

SERIES)

Fan pulley

and cylinder to adjust

ASSEMBLY

‘\J

14-17mm

‘\ \\ ‘,

_

Crankshaft pulley

31.

Lowering Sling

engine

engine

bracket

614OF301

AI

assembly

(11,

disconnect

engine

from

and engine repair stand A, then lower engine

on to a stable stand.

32. Starting

motor

Install. starting

0

Refilling

with

1)

Tighten

2)

Add

motor

(1).

oil drain plug.

engine

oil

through

oil

filler

to the specified

level.

Q

13868

Engine oil:

Approx.

10.5 II

95 SERIES



DISASSEMBLY

AND

ASSEMBLY

DISASSEMBLY

AIR

AND ASSEMBLY

COMPRESSOR

OF AIR COMPRESSOR

Specifications The air compressor compressed Komatsu Maker

is used

as a source

air to the air brakes,

6206-91-I

Part No.

Engine

100

(S)6D95L-1

Model

Air-cooled, single cylinder, double acting type

Tvw Cylinder

diameter

70 x 40

x stroke

1,450

Usual max. speed

The stroke

Operation of unloader valve

8.5

Usual max. pressure

table

of

DK408717-0300

Part No.

Applicable

of supply

etc.

volume

at each

speed

is as shown

in the

below.

Speed

(rpm)

Discharge

amount

(Illmin)

250

500

1,000

1,500

38.5

77

154

231

Air intake port *

Actuation This equipment gine

timing

driven the

gear.

so the

the engine

automatically cylinder.

the

and the

valve

delivery

valve

air. On the

closes

and intake

valve

is provided

air tank

the compressed the

reaches air inside

air governor

loader

valve

this reason,

and

down while

if the air pressure of the tion,

the unloader

unloader

ting condition,

opens

to draw

the amount

the air pressure specified the

the

in-

pressure, through

rod

of the

intake

valve.

valve

inside valve

valve

is being

the air tank

goes

of the air governor, returns returns

and air is force

Air pressure from air governor

de-

unFor actu-

in is not compressed.

pressure

the intake

the

the tank passes

pushes

to open

ated, the air sucked the specified

the

valve

to discharge

to control

the air tank. When

6206F910

the

the air in-

intake

down-stroke,

An air governor the

the opens

the air cleaner.

side

rotating

inside

of the piston,

is compressed,

in more air from of air inside

is to

open and close

to the pressure

On the up-stroke

valve

and

directly

is always

and delivery

according

compressed

livery

the en-

pump,

It is connected

air compressor

the cylinder

closes

between

injection

is running.

The intake valve

side

installed

and the fuel

by the timing

engine,

when

is generally

gear

to its original to the normal

Air intake port e

below the rod posiopera-

fed again.

6206F911

13g70

95 SERIES


DISASSEMBLY

3.

AND

Structure 1)

Engine

is jointed with

four

The

is made

are

in the

is installed

valve.

The delivery be installed

the

The

with

the

with

the bolts, tighten too

The

head

four

uniformly

much

on

in

holes are provided

is an aluminium

holes

for

the

oil

there

is an overflow flows

supply

in the

face with

holes

propriate

face

casting,

joint.

engine

the

1)

excess

crankcase.

is put in contact of the timing

with

gear

with

the

balance

weight.

by two

ball bearings:

a taper

shaft to the timing

end is connected

that

forms

Remove

ii)

Tap

Two

piston

are rings

made

of

iii)

are installed

one oil ring is installed the

heat

moving,

the

outside

expansion

smaller

than

the

when

the

diameter outside

gasket

head

cross-sectional

4 bolts cylinder

Remove

cylinder

head.

bottom

with

from

a

to remove. inserted

between

cylinder

head.

connecting

Remove

rod, piston tightening from

cylinder,

then

crankcase.

2 bolts tightening

big end of con-

rod.

Remove

piston

Using

a tool,

oil ring from

alloy.

at the top,

at the bottom.

is

and

connecting

rod from

crankcase.

pump.

aluminium

Remove

necting

by

gear, and the other

of the cylinder head

head

hammer

remove

iv) pistons

is

compressor

4 bolts tightening

cylinder

wooden

Cylinder,

ii)

It is supported

Piston The

The

numbers

cylinder

and cylinder

one

one end is connected

to the fuel injection

piston

head

i)

iii)

the ap2)

is a forging

and

the compressor

of compressor part

the

Cylinder

i)

part

of

see

case when

the compressor.

crankshaft

engine.

com-

crankcase.

as follows.

of the

The

Crankshaft The

rod,

unless

main

and

drawing.

Furthermore, for

of three

cylinder,

connecting

the

disassembly

portion,

and

are also mounting

installed

the over-

end.

one

on the side face to inThere

out through

consists head,

head,

from

overhauled

For details

four

in the

up by the

and the big end of the

at the engine

be disassembled

removed

bolts;

Partial crankcase

weight

cylinder

cylinder

Crankcase The

joint

is splashed

and flows

air compressor

ponents:

valve

cannot

tightening

rod,

The oil force

Disassembly

un-

of the intake

and unloader

head is installed

avoid

installing

balance

holes provided

side.

oil that

5)

and

on top

removed

stall the compressor.

4)

of the crankcase

lubricant.

to the oil supply

and delivery

head,

valve

and

tightening to

side face

flow

casting,

to the body.

The cylinder

3)

fins. Both intake

installed

valve

turn

is an aluminium

as the

the engine

connecting head

still installed

oil is used

fed from crankshaft

loader

when

it is installed

bolts.

and has cooling

can

and

the bottom

head

cylinder

vales

of cast iron;

to the crankcase

Cylinder

COMPRESSOR

Lubrication

of parts

Cylinder The cylinder

2)

AIR

ASSEMBLY

remove

2 piston

rings

and 1

piston.

and

Because piston

at the

diameter

top at

is is the

bottom. 6)

Connecting

rod

The

big

steel

back split

adjust

the

bearing The

end

must

match

made

95 SERIES

of the

connecting

bearing.

tightening

by

be replaced mark

used

rod

uses

As it is impossible using

shims,

if it becomes when

a to the

worn.

assembling

is

on the side face.

’3-:71


DISASSEMBLY

v)

Remove

AND ASSEMBLY

AIR

COMPRESSOR

2 snap rings from piston pin hole,

then remove

pistn pin and disconnect

ton from connecting

pis-

rod.

Unload n

Air intake Dart

6206F912

’3-ii72

9. Rod

1.

Intake valve guide

2.

intake valve spring

IO. Unloader

3.

Plate valve

11. Delivery

valve body valve body

4.

Intake valve seat

12. Spring guide

5.

Snap ring

13. Delivery

6.

Washer

14. Plate valve

7.

Unloader

8.

O-ring

valve spring

15. Delivery

valve spring valve seat

16. Gasket

95 SERIES


DISASSEMBLY AND ASSEMBLY

3)

Bearing i)

cover

ii)

Remove

4 bolts

installed

to crankcase,

crankcase ii) 4)

together

Remove

crankshaft

with

remove

bearing

ball

valve

pair

from

snap

loader

valve

(6), spring

valve

body

body

in-

of

un-

(IO),

then

iii)

delivery

valve

spring

(13) and valve

body

then

(14) from

(1) is screwed and

caulking

Remove

guide

all the

is

before (I),

inside. of cylin-

caulked,

removing

then

(3), and

easy.

measurement, dards 1)

and

at the

ring

end

gap

ex-

Unit: mm Standard clearance

Carry

0.10 0.25

2.0

Clearance at oil ring end gap

0.10 0.50

1.5

Table 3

spring same

in flushing

oil,

of disassembly

to

out

the

inspection

maintenance

Repair limit

Clearance at piston ring end gap

3)

Wear of piston If the fitting

pin and piston

between

pin hole

the piston

pin hole is loose,

and exceeds

(Table 4), replace

the piston

pin and piston the repair

or piston

limit

pin. Unit: mm

Nominal dimension

and

Standard clearance

Repair limit

stan-

if parts can be used again or if

must be replaced. Table 4

Cylinder Check

for

any wear

age to the inside or if there

Measure and

the

if

the

diameter pair part.

wall.

cylinder,

or dam-

If any damage

is found,

Measure

than

pin and the inside

wear

of more

0.1

cylinder.

Piston and piston i)

of the

is eccentric

mm, replace 2)

0.20

limit (Table 3), replace.

so

(4) at the

parts

use

to determine

clearance

guide.

remove

seat

out in the order

assembly

If the

remove

into bottom

thread

disassembled

lay them

I

(11) installed

assembly

remove

/ 0JyG5

4

head.

(15) to remove,

head

1

ceeds the repair

Inspection and maintenance

make

Repair limit

remove

time.

then

Standard clearance

or

Table 2

assembly

(2), valve

Wash

Nominal dimension

the piston

head.

(7), and rod (9).

seat

Guide

(10)

(5) in middle

Lever

der ii)

2), replace

crankshaft

&Y$G,

ring

washer

Intake valve

i)

(Table

ring

the re-

Unit: mm

of bearing

from

valve

to top of cylinder ii)

the

still installed.

bearings

to top of cylinder

Remove

Remove

i)

they

limit

between

and if it exceeds

cover.

in direction

unloader

stalled

Delivery

clearance

ring.

assembly

Remove

ii)

the

a hand press.

Unloader i)

6.

Measure

and ring groove,

cover

oil seal.

2 ball bearings

Remove with

7)

bearing

then

with

oil seal from

Remove cover

ii)

6)

tightening

Crankshaft i)

5)

AIR COMPRESSOR

Wear of piston

rod

outside

diameter

clearance

(Table

I),

from

of piston, the

small

exceeds

replace

with

the

outside

end,

diameter

diameter

and

(Table

if the

rod of the

piston

of the connecting clearance

5), replace

with

exceeds the con-

rod. Unit: mm

re-

Nominal dimension

a new Unit: mm

Standard clearance

necting

pin and connecting

inside

b Nominal dimension

the

the standard

rings

of the cylinder

limit

4)

Clearance between piston pin and inside diameter of small end

16

Standard clearance 0.006 0.022

Repair limit

0.1

Repair limit

Table 5

%

Measure

the outside

diameter

of the piston

at

the skirt. Table

95 SERIES

1

’3-$73


DISASSEMBLY AND ASSEMBLY

5)

AIR COMPRESSOR

Wear of connecting

rod and crank

Measure

diameter

the inside

bearing

at the connecting

the outside

diameter

the clearance replace

pin

ii)

of the crank rod small

pin

end and

of the crank

pin, and if

the standard

(Table 6),

exceeds

the connecting

Repair limit

30

0.020 0.060

0.15

Clearance between crank pin bearing and crank pin

iii)

7)

Bearing

portion cover

Check 8)

of oil seal

and replace

Intake valve Check

Check the valve

Unloader

and

to cylinder

for

spring

damage

iv)

also, and re-

to the O-ring.

doing spring

seat

(15)

thread

of delivery

operation.

v)

replace.

2)

Cylinder

head bolt:

ii)

Cylinder

iii)

Bearing

Unloader

iv)

Connecting

v)

Guide

vi)

Delivery

vii)

Unloader

bolt:

tightening

O-ring

rounding

area

phide

grease

body

(10).

intake valve: valve valve:

i)

vi)

of the part numbers,

3)

and spring

(2) on top in turn,

guide

(1) temporarily.

check

that

smoothly. (1) to

After

the

protrudes head, the

valve

from

there top

tremely

the

is danger

face careful

caulk at three

13-l&74

doing

specified

of

the when

this,

the piston

the

small

end

of the

sert

the

piston

pin,

bottom that

face it may

piston,

so

tightening.

places with

a punch.

(1)

of the

then

rings and oil ring

Install

the top

of the

in in-

at both

rings

ring place.

upside

There

down,

with

facing

so that the end gaps

of the rings

oil will

careful

the

up. As-

If the rings

are

leak up,

to assemble

is no difference

cor-

between

the

of the oil ring.

Oil seal and bearing press fitting

ing

cover,

the

oil

coat

seal

Overall

the oil seal to the bearthe

with

outside

Three

Press fit both with

diameter

Bond

1360

ball bearings

of ad-

to the

a press.

assembly from

cover.

Coat

the

and

case

with

cover packing

agent,

the

crankcase,

then

area

install

between

Three tighten

bearing

then

the

Bond

1104

to the speci-

fied torque. Insert

the connecting

the crankcase

be

the

cap

that

the connecting

Finally,

rod,

secure

and second

face

contact ex-

and the hole

connecting

Piston

the

guide

spe-

a bar, and

snap rings.

doing

If guide

ring (5).

rod

pin hole

crankshaft

tighten

torque.

and

(3) moves.

Piston and connecting

of the

(2) move

in

(7)

snap

Push rod (9) with

the

this,

assemble

spring

to head with

torque.

surdisul-

with

end

(3)

(9), coat

and

valve

cover

(3) and spring

specified

molybdenum

insert

and tighten

When

to

(8) to rod

Insert

put valve

Bond

unloader

crankshaft

then

coat

Three

(6), and secure

hesive.

see the cylin-

drawing.

seat (4) in head,

a punch. head,

Tighten

When

1500 kgcm

Intake valve Insert

tighten

with

top and bottom

250 kgcm

500 kgcm

der head cross-sectional

(14) Caulk

washer

rectly.

1200 kgcm

body:

in

with

(LM-G),

so be extremely

60 kgcm

Assembly For details

valve

Next,

300 kgcm bolt:

valve

with

(16)

and

bolt:

rod tightening

that

smoothly.

valve

assembled

300 kgcm

tightening cover

fit

places

are not at the same

torques

i)

check

gasket

Assemble

semble

Tightening

(15).

press

move

adhesive,

ends with

Assembly 1)

seat

at three

stamped 7.

(14)

and

this,

insert

(11).

valve

(13)

Next,

(12) in body

(13) and plate

in turn,

and

Align

Then as-

head and check

is poor,

guide

check that valve

seat

valve

If operation

spring

top

cified

part.

Check for any damage semble

scratches

valve

and valve

place any defective 9)

for

if necessary.

and delivery

the valve

and wear.

replace.

and oil seal

surface

roughness,

is damaged,

put spring

1360

Crankshaft If rotating

Then

torque.

Table 6 6)

fit

When

Unit: mm Standard clearance

valve

Press on

rod.

Nominal dimension

Delivery

to

rod from

(cylinder the

the top of

end), then

specified

tighten

torque.

rod match

Check

marks

aligned.

95 SERIES

are


DISASSEMBLY

iii)

AND

When

ASSEMBLY

AIR

assembling

the

the

crankcase

Three

Bond

piston

ring compressed,

correctly,

cylinder,

adhesive

coat

surface

1104 packing

then

first

agent,

COMPRESSOR

with , Outside of oioe

keep the

mate the cylinder

tighten

to

the

specified

torque. iv)

Lay the gasket cylinder,

then

sembly

on top

the

out

carry

formance

bolts

as-

and tighten

gradually

and

uni-

(2) If carbon

disassembly,

the carbon

test and per-

compressed (3)

If there

air pressure

at 7 kg/cm2 valve

the amount

tank,

to the delivery

at the same time,

of leakage

from

Standard

for leakage:

Charging

performance

The amount capacity

stuck

the

with

seat

Remove taken

to charge

of 35 liter between

the tank

a tank pressure

shall be as shown

of

the

head

cylinder

Charging time (set)

1,100

Max. 158

the

cylinder

head,

condition.

pipe

at the

run the

Check

delivery

engine

that

port

there

*

of the

and check

and there

doing

out the air

the delivery

following

maintenance

every

4000

pipe

(between

air

compressor

and

(3)

wet tank) the delivery

than

on the blow

to clean

inside

ment

oil

out the

end)

for

cannot

(for circuit

stuck

remove

so check these

the pipe

following in the

to the top

the carbon with

from

a sharp

tool.

not to let the carbetween

the

where

scratches

enough

to

catch

piston

the cylinder,

in the cylinyour

finger-

piston,

and pis-

If there

is carbon

of the

head

holes,

remove

the carbon

with

and blow with

compressed

air to clean.

If there

ele-

(See the

to en-

of use.)

at joints, the flow

(4)

or

with

valve

*

to the bottom

air

stuck

seat,

intake

surface

and

delivery

a screwdriver

to the delivery

guide,

valve,

or spring,

a screwdriver

remove

and blow

with

air to clean.

is carbon

and spring, (If the

stuck the

is carbon valve,

If there driver

KO: Part

it is possible this.

to stick

points

diagram

be removed,

agent

for the method

carbon

and other

with

are vertical

compressed

accu-

at oil cooler

is available, carbon

(see

air through

If washing

explanations

It is easy

95 SERIES

surface

it. If the carbon

No. 600-311-3310

stricted,

1.5 mm of carbon

compressed

the piping.

clean

the

scratches

is carbon

the gap

deep

the carbon

air pipe and do as follows.

is more

mulated

valves,

the

ton ring kit.

port.

intake

closed

(If the

replace

out

of the piston

nails, replace

is no abnormal

hours.

replace

broken,

this, be careful

If there der

the

inspection

below),

a screwdriver

and cylinder.

of oil from

If there

valve

and wet

air to clean.

carry

of the piston,

When

(2)

(1)

is

and

the top surface

up

Remove

Remove

with

(1) If there are no deep vertical

below.

Speed (rpm)

Oil leaking

9.1 Delivery

the check

maintenance.

bon fall through

Carry

carbon

compressed

valve

surface

Periodic

inside

the air compressor

9.2 Air compressor

Max. 450 cc/min

of time

0 and 7 kg/cm2

9.

with

valve.)

take port.

spray

remove

and blow

air to clean.

remove

rubber

the in-

joints,

a screwdriver

between

and blow

and

with

is carbon

installed

test

port and unloader measure

is stuck to connecting

and

inspection,

test as follows.

Apply

6206F913

torque.

out the air-tightness

Air-tightness

If X+X exceeds 1.5 mm, the pipe must be cleaned or

of the

head

test after assembly

carrying

assembly,

surface

cylinder

to the specified

Performance After

the

of the gasket

4 mounting

formly 8.

on the top put

stuck

remove

and blow with O-ring

to the unloader

the carbon compressed

is worn,

with

valve

a screw-

air to clean.

replace

the

unloader

the carbon

with

a screw-

assembly.)

When driver,

removing be careful

not to scratch

the sur-

face.

check is re-

places carefully.

13g75


DISASSEMBLY

AND

9.3 Tightening

torques

and air compressor

’3-:76

AIR

ASSEMBLY

when

piping

COMPRESSOR

to air compressor

has been disassembled.

95 SERIES


14

ENGINE MAINTENANCE

STANDARD

Turbocharger ............................................ 14-002 Cylinder head ........................................ 14-003-2 Valve and valve guide ............................. 14-008 Rocker arm shaft, push rod and tappet.. ........................ 14-009 Cylinder block.. ......................................... 14-010 Crankshaft ................................................. 14-012 Camshaft ................................................... 14-014 Timing gear .............................................. 14-018 Flywheel and Flywheel housing ............. 14-019 Piston, piston ring and piston pin.. ........ 14-020 Connecting rod ......................................... 14-027 Oil pump ................................................... 14-028 Regulator valve ........................................ 14-030 Water pump and thermostat .................. 14-031 Fuel system ............................................... 14-034

95 SERIES

14-001 0


MAINTENANCE

STANDARD

TU RBOCHARGER

TURBOCHARGER

(S4D95L-1,

SA4D95L-1, S6D95L-1, SA6D95L. ml)

T-31

I--

6207F402

1 3

5

4

6207F401

A

Unit: mm

No -

Remedy

Radial play of rotor Repair or

Retighten

Thickness of thrust bearing

6

Outside diameter wheel shaft

of

Bend of wheel sha

8

Inside diameter back plate

of

inside diameter center housing

of

14202

qeplace

C

15.80

15.81

D

18.03

18.08

95 SERIES


MAINTENANCE

STANDARD

TURBOCHARGER

T04B 3

I

5

\

4 I4F036A

I’\.

I4FO36-

I

I4FO36-2

Unit: mm

No

Check item

Criteria Standard

1

Radial play of rotor

size

Remedy Repair limit

0.075 - 0.150

0.18 Replace

2

End play of rotor

3

Tightening torque of blower housing mounting bolt

4

Tightening torque of turbine housing mounting bolt

-

0.025 - 0.075

0.10

Target Nm (kgm)

Range Nm (kgm)

17 (1.3)

16.4 - 18.6 (1.15 - 1.5) 17.6 - 21.6 (1.8 - 2.2)

I

Tightening torque of back plate mounting bolt

Standard L

5

Thickness of thrust bearing

of

Repair limit

size

4.36 Measuring

Outside diameter wheel shaft

8.4 - 10.2 (0.86 - 1.04)

9.3 (0.95)

4.35

point

Standard

size

Repair limit

A

17.34

17.25

B

10.16

10.15

6

Repair limit: 0.010 (Total indicated runout)

Bend of wheel shaft

Standard 7

Inside diameter back plate

Inside diameter center housing

95 SERIES

Repair limit

of 12.70 Measuring

8

size

Replace

of

point

12.73 Standard

size

Repair limit

C

15.80

15.81

D

18.03

18.08

14-003 0


MAINTENANCE

STANDARD

TURBOCHARGER

S2D (SCHWITZER)

6206F954

Unit: mm

No

1

Check

Criteria

item

Remedy

Play of rotor in radial direction

2

Play of rotor in axial direction

3

Tightening torque of turbine housing VEE clamp

Target Nm (kgm)

Range Nm (kgm)

6.9 (0.7)

6.9 (0.7)

Standard 4

Thickness of thrust bearing

Repair limit

size

4.35 l

4.30

Outside diameter Measuring

point

1 I

Standard

size

5

Repair limit

I 10.152

Outside diameter, of wheel shaft

Tighten

10.130

I

curvature B

17.32

17.25

I

-1

- Curvature Repair limit: 0.0076 (Total indicator runout) Replace

Standard 6

Inside diameter

of insert

size

Repair limit

12.71

12.71

Measuring

7

Inside diameter housing

of center

C

D

14-003-l 0

point

1

I

Standard

size

1

15.80

Repair limit 15.82

I 18.06

I

18.06

95 SERIES


MAINTENANCE

STANDARD

CYLINDER HEAD

CYLINDER HEAD 3D95S-W-1

i

6206F558

Exhaust side

6206F557

Intake side

Unit: mm No.

Check item

Distortion surface

Protrusion

of cylinder

Criteria

Remedy

Tolerance

Repair limit

0 - 0.05

0.30

head mounting

of swirl chamber

Standard:

insert

Sequence Tightening torque of cylinder head mounting bolt [Coat bolt seat surface and thread with molybdenum disulphide (LM-P)]

Tightening

torque of nozzle holder

5

Tightening

torque of glow plug

6

Tightening

torque of terminal

7

Tightening torque of head cover mounting bolt

0 - 0.08

Nm (kgm)

Replace insert

Range Nm (kgm)

1st Step

68.6 (7)

58.8 - 78.4 (6 - 8)

2nd Step

107.8 (11)

102.9 - 112.7 (IO.5 - 11.5)

3rd Step

4

Target

Grind to correct, or replace

90

go’-

.

Tighten

120

100 + 2.5 Nm (10.25 + 0.25 kgm)

12 t 2.5 Nm (1.25 * 0.25 kgm)

-

Tighten

-

1.5 + 0.49 Nm (0.15 * 0.05 kgm)

nut

I

8.8 f I Nm (0.9 + 0.1 kgm)

95 SERIES ’ 4-oii3-2


MAINTENANCE

STANDARD

4D95S-1 4D95L-1 (For PC60-6,

CYLINDER

PC60,70-7,

HEAD

PC90-I)

6202FOO26

i

6202F002A

Tightening order of cylinder heat mounting bolt

Front r

Rear

Intake side 6204F403 6206F401

A Unit:

No

1

Distortion of cylinder head mounting surface

2

Protrusion of hot

3

Tightening torque of cylinder head mounting bolt (Coat bolt threads and washers with molybdenum disulphide)

-

4

tening torque of nozzle

5 6

Tightening torque of terminal nut

7

Tightening torque of head cover mounting bolt

1.2 + 0.2 Nm (0.125 + 0.025 kgm)

8.8 L 1 Nm (0.9 + 0.1 kgm)

95 SERIES

mm


MAINTENANCE

CYLINDER

STANDARD

HEAD

4D95L-1 S4D95L-1

1

6204F401

Tightening order of cylinder heat mounting bolt

I

Ir

Intake side

6206 F401 A Unit: No.

1

2

Distortion of cylinder head mounting surface

Protrusion of nozzles

and washers with molybdenum disulphide)

I 4

Tightening torque of nozzle holder mounting bolt

5

Tightening torque of head cover mounting bolt

Standard size

Repair limit

0 - 0.05

0.30

2.7 - 3.5

3.12 + 0.28

Tightening torque of cylinder head mounting bolt (Coat bolt threads 3

Remedy

Criteria

Check item

I

Target Nm (kgm)

Range Nm (kgm)

1st step

68.6 (7)

58.8 - 78.4 (6 - 8)

2nd step

107.8 (11)

102.9 - 112.7 (10.5 - 11.5)

3rd step

I

90”

I

44.1 + 4.9 Nm 14.5 + 0.5 kgm)

-

95 SERIES

I

mm

8.8 f 1 Nm (0.9 + 0.1 kgm)

90” - 120”

Reljair by grinding or replace

I

Replace nozzle gasket

1 Retighten


MAINTENANCE

STANDARD

CYLINDER

HEAD

4D95L-W-1 4D959-W-1

i

6204F404

Tightening order of cylinder head mounting bolt .

I/

Rear

Intake side

6204F405

6204F403

Unit: No

Check item

Criteria

Standard 1

Remedy

Repair limit Repair by grinding or replace

Distortion of cylinder head mounting surface o-0.05

0.30

2

Protrusion of hot plug

Standard:

Order

3

Tightening torque of cylinder head mounting bolt (Coat bolt threads and washers with molybdenum disulphide)

4

Tightening torque of nozzle holder

I

5

Tightening torque of injection pipe nut

I

6

Tightening torque of glow Plug

7

Tightening torque of terminal nut

8

Tightening torque of head cover mounting bolt

-

14-006 0

I

Target Nm (kgm)

1st step

68.6 (7)

2nd step

107.8 (II)

3rd step

Replace hot plug

0 - 0.08

90”

Range Nm (kgm) 58.8 - 78.4 (6 - 8) 102.9 - 112.7 (10.5 - 11.5) 90” -

120”

88.2 + 9.8 Nm (9 t 1 kgmj

Retighten

44.1 k 4.9 Nm (4.5 + 0.5 kgm)

17.2 k 2.5 Nm (1.75 + 0.25 kgm)

I

1.2 f 0.2 Nm (0.125 + 0.025 kgm)

8.8 + 1 Nm (0.9 t 0.1 kgm)

95 SERIES

mm


MAINTENANCE

STANDARD

CYLINDER

HEAD

6D95L-1 S6D95L-1 SA6D95L-

Tightening order of cylinder head mounting bolt

Intake side

I

6206F401A

+--2

Unit: NC

Check item

Criteria

mm

Remedy

-

1

2

Standard

Repair limit

0 - 0.05

0.30

Distortion of cylinder head mounting surface

Protrusions of nozzles

I

3.12 f 0.28

I

Repair by grinding or replace

2.7 - 3.5

Order Tightening torque of cylinder head mounting bolts

Target (kgm)

Replace nozzle gasket

Range (kgm)

1st step

7

6-8

2nd step

11

10.5-11.5

3rd step

9o”

9o” - 120”

3 (Coat bolt threads and washers with molybdenum disulphide)

Retighten 4

Tightening torque of nozzle holder mounting bolt

4.5 + 0.5 kgm

5

Tightening torque of head cover mounting bolt

0.9 t 0.1 kgm

95 SERIES

14-007 0


No.

1

Criteria

Check item

Sinking of valve

2

Thickness of valve head

3

Valve seat angle

Applicable engine

Tolerance

Repair limit

3D95S-W-1 4D95S-W-1 4D95L-W-1

0.8 + 0.18

1.80

4D95S-1 (SA)4D95L-1

0 f 0.18

1 .oo

3D95S-W-1 4D95S-W-1 4D95S-1 4D95L-W-1 (SA14D95L-1

1.40 - 1.60

1 .oo

Tolerance

Repair limit

Standard

45

4

Free length of valve spring

5

Installed load of valve spring

18 /

~~:‘~~

I I

6204414410 (Peach color) 6204-41-4431 (Red)

1

+i’015

1 ““~~&

Correct valve or valve seat, or replace

1

1

0.20

Repair limit

Standard size

I

I 49.2

I

48.5

I

56.0

I

55.0

I

Part No. (distinguishing feature)

Installed length

Standard load (kg)

Load limit (kg)

6204-41-4410 (Peach color)

40.5

18.5 f 0.9

16.5

6204-41-4431 (Red)

40.5

15.6 * 1.5

13.0

Replace

Repair limit: 1.85

Out-of-square of valve spring

*

Replace

Judge contact surface condition with vacuum

f 15

Part No. (distinguishing feature)

*

Replace valve or valve seat

Clearance between valve guide and valve stem

/ Exhaust

6

Remedy

Standard size

Tolerance

14.5

* 0.2

Correct

Driving-in height of valve guide

4D95S1 engine: no valve seat insert (EX) 4D95L-1 engine for PC60-6, PC90-1: No valve seat insert (EX, IN)

’4-:08

95 SERIES


MAINTENANCE

STANDARD

VALVE, VALVE GUIDE

6D95L-1,

6

6206F403

2

IN

I

No

Check item

Criteria

Applicable Sinking of valve

2

Thickness

of valve head

engine

6D95L-1 S6D95L-1 SA6D95L-1

Remedy

Tolerance

Repair limit

0 f 0.18

1 .oo

6D95L-1 S6D95L-1 SA6D95L-1

1.40 -

Standard 3

Unit: mm

1.60

1.oo

Tolerance

Replace

Repair limit

Valve seat angle 45

Replace valve or valve seat

Correct valve or valve seat, or replace

Judge contact surface condition with vacuum test

f 15

Tolerance Standard

4

Clearance between valve guide and valve stem

size

Intake

Exhaust

8

I

8

1

Shaft

Hole

Standard clearance

Clearance limit

-0.035 -0.050

+0.015 0

0.035 0.065

0.20

-0.065 -0.050

0 f0.015

0.080 0.050

0.20

Part No. (distinguishing feature)

Free length of valve spring

6204-41-4410 (Peach color)

Installed

load of valve spring

Driving-in

48.5

56.0

55.0

I

I

Installed length

Standard load (kg)

Load limit (kg)

6204-41-4410 (Peach color)

40.5

18.5 * 0.9

16.5

of valve spring

40.5

15.6 + 1.5 I

13.0 I

Replace

I

Repair limit: 1.85 size

Tolerance

height of valve guide

Correct 14.6

95 SERIES

!

Part No. (distinguishing feature)

Standard 6

Repair limit

I

I

I

I

I 49.2

6204-41-4431 (Red) Out-of-square

size

I I

6204-41-4431 (Red) 5

Standard

Replace either valve or valve guide or both

* 0.2

’4-oz8-1


MAINTENANCE

VALVE, VALVE GUIDE

STANDARD

S4D95L (PCIOO-5, P&20-5, PCIOO-6, PC120-6, S6D95L (PC200-5, PC200-6, BR200-1) SA6D95L (PC220-5, PC220-6, BR300-1)

PC128UU-I)

6

6206F403 IN

I

I

Unit: mm

No.

Criteria

Check item

Remedy

-

1

2

Applicable engine

Tolerance

Repair limit

S4D95L

0 f 0.18

1.00

S6D95L SA6D95L

0 f 0.18

1 .oo

Replace valve or valve seat

Sinking of valve

S4D95L S6D95L

Thickness of valve head

1.40 - 1.60 (Exhaust) 1.90 - 2.10 (Intake)

1.OO (Exhaust) 1.50 (Intake)

Replace

SA6D95L Standard 3

i/alve seat angle

Tolerance

“CD,cxrKiusq ,T__L_.__~L 43 7r-P,ln+~tn\ “” ,..“..,.W,

I

1Judae I

* 15

contac condition with vacuum

Correct valve or valve seat, or replace

I

4

Clearance between valve guide and valve stem

Intake

8

-0.035 -0.050

+0.015 0

0.035 0.065

0.20

Exhaust

8

-0.050 -0.065

+0.015 0

0.050 0.080

0.20

Replace either valve or valve guide or both

Standard size

Repair limit

Free length of valve spring

31

5

Replace

Out-of-square of valve spring

6

Repair limit: 1.85 Standard size

Tolerance

14.5

f 0.2

Driving-in height of valve guide

’4-ooo8-2

Correct

95 SERIES


MAINTENANCE

ROCKER

STANDARD

ARM SHAFT,

PUSH ROD AND

TAPPET

ROCKER

6206F405 Unit: No

Check item

Criteria

Remedy

Standard

Tolerance

_

Outside diameter of rocker arm shaft

19

Inside diameter of rocker arm shaft hole

mm

Replace rocker arm shaft

-:.020 Replace rocker arm

19

+0.030 +0.010

Standard clearance

Clearance limit

1

Clearance between rocker arm and rocker arm shaft

0.010 - 0.050

Bend of rocker arm shaft

Replace rocker arm or rocker arm shaft

0.12

Repair limit:

0.20 (Total indicated runout)

Repair limit:

0.30 (Total indicated runout)

I

Replace rocker arm shaft

I 2

3

Bend of push rod

Valve clearance (at cold)

I

Valve

Standard

Intake

0.35

Exhaust

0.50

Replace push rod Tolerance

*

I

0.02

1

Adjust

* 0.02

Standard

Tolerance Replace tappet

Outside diameter of tappet -0.015 -0.030

16

Inside diameter of tappet hole 4

I I

+0.018 0

16

Standard clearance Clearance between tappet and tappet hole

Tightening torque of adjustment nut of rocker arm

Replace cylinder block I

Clearance limit

0.015 - 0.090

0.12

4.5 + 0.5 kgm

Replace tappet or cylinder block

Retighten

95 SERIES ’ 4-:09


MAINTENANCE

CYLINDER

STANDARD

CYLINDER

BLOCK

BLOCK

6206F407

6206F406 Unit: No.

Remedy

Criteria

Check

size

Standard

I

Repair

Tolerance

I

I

Repair by using over

Inside diameter of cylinder

1

Roundness of cylinder

14-010 a

Repair limit:

0.02

Repair limit:

0.02

95 SERIES

mm


MAINTENANCE

CYLINDER

STANDARD

BLOCK Unit:

No

Check

When using the Standard (STD) piston, use the size of pistons indicated by the stamped mark (S or L) on the top surface of the cylinder block. When using the Over Size (0.S.) piston, measure inside diameter of cylinder at points 40 mm, 100 mm and 160 mm from the cylinder block top face. Then select S-size or L-size piston according to the smallest of the three inside diameters.

l

l

/

Piston size 1

Standard size

1 ~~~~t~~~

;“‘inder~~~~~e~iameter

Selection of pistons

I 0.25 O.S.

L

95.25

95.25+0.011 O (95.250

S-size piston

- 95.261)

95.25 +O.O’ ’ +0.022 (95.261

0.50 0,s.

L-size piston

O +0.011

(95.500

95.50

S-size piston

- 95.511)

95.50 +O.O’ ’ +0.022 (95.511

L-size piston

- 95.522)

Standard

Distortion of cylinder head mounting surface

When changing the piston size, correct the stamped mark (S or L) on the cylinder block top face

- 95.272)

95.50

2

mm

Repair limit

Repair by graiding

Inside diameter of main bearing lole Repair or replace cylinder block

3

-

Roundness of main bearing hole

Repair limit:

0.005

Fitraighteness of main Jearing holes

Repair limit:

0.010

Standard size

4

STD

70.00

70.20

0.25 U.S.

69.75

69.95

0.50 U.S.

69.50

0.75 U.S.

69.25

69.45

1 .oo U.S.

69.00

69.20

nside diameter of cam bushing lole ournal

6

Repair limit

Inside diameter of main bearing

5

Tolerance

+0.103 +0.058

69.70

Standard

Tolerance

53.5

+0.030

I

nside diameter of cam lushing

No.

1

50.5

Inside diameter of cylinder block

No. 2 No. 3

50.5

Rapair or replace cylinder block

n

I

Standard

/

Tolerance

+ 0.030 I

Replace main bearing

-0.040 -0.031 -0.050

Repair limit 50.60

Replace

50.60

Press fit bushing

Order

I

Target (kgrn)

rightening torque of main bearing :ap mounting bolts

1st step

Coat bolt threads and washers with engine oil)

2nd step

0

3rd step

13.5

7

95 SERIES

I

11.5

Range ikgm)

I

11-12 Fietighten Loosen completely 13 -

14

14-p


MAINTENANCE

STANDARD

CRANKSHAFT

CRANKSHAFT 3D95S-W-1

6206F558

Unit: NC

1

Check Item

mm

Criteria

End play

Outside diameter of main journal

2

Repair limit:

0.020

_ Replace main bearing

Clearance of main journal 0.043 - 0.103

0.25

Outside diameter of crankpin journal

I

I

I Standard size

Tolerance

Repair limit

0.50 U.S.

56.50

+0.015 0

56.41

0.75 U.S.

56.25

56.16

1 .oo U.S.

56.00

55.9 1

Repair by using under size bearing or replace

3

Roundness of crankpin journal

Repair limit:

0.020

Standard clearance

Clearance limit

0.029 - 0.089

0.22

Replace connecting rod bearing

0.09 (Total indicated runout)

Repair by using under size bearing

Clearance of crankpin journal 4

Bend of crankshaft

14-iik’2

Repair limit:

95 SERIES


MAINTENANCE

STANDARD

CRANKSHAFT

4D95L-1 S4D95L-1 4D95L-W-1 4D95SW-1

6204F405

/

Unit:

No

Check Item

Criteria

Remedy

Standard 1

End - olav

Repair by using over size thrust bearing or replace

Repair limit

I

-7-,

I

0.131 - 0.351

0.40

II

I

Standard size STD

70.00

0.25 U.S.

69.75

0.50 U.S.

69.50

0.75 U.S.

69.25

1.00 U.S.

69.00

mm

I

Repair limit

Tolerance

Repair by using under size bearing or replace

Outside diameter of main journal

2

Roundness of main journal

Repair limit:

0.020

Standard clearance

Clearance limit

0.043 - 0.103

0.25

Replace main bearing

Clearance of main journal

Standard size

Tolerance

Repair limit

STD

57.00

56.91

0.25 U.S.

56.75

56.66 Repair by using under size bearing or replace

Outside diameter of crankpin iournal 3

1 .oo U.S.

56.00

I

1 qoundness of crankpin journal

Repair limit: 0.020

I

I Clearance limit

Standard clearance

0.22

Replace connecting rod bearing

0.09 (Total indicated runout)

Repair by using under size bearing

Clearance of crankpin journal I

4

send of crankshaft

95 SERIES

0.029 - 0.089

Repair limit:

I


MAINTENANCE

CRANKSHAFT

STANDARD

S4D95L-1 SA4D95L-1

6204F405

Unit: mm No

Criteria

Check item

Remedy

Standard

Repair limit

0.131 - 0.351

0.40

Repair by using over size thrust bearing or replace. Note: The tufttride crankshaft cannot be corrected.

End play

Standard

size

Tolerance

Dutside diameter

Repair limit

I

I STD

70.00

0.25 U.S.

69.75

0.50 U.S.

69.50

69.86

Repair by using under size bearing or replace. Note: The tufttride crankshaft cannot be corrected.

of main journal 69.61

+0.015 0

69.36

2 qoundness

of main journal

Repair limit: 0.020 I

I

Standard

clearance

Clearance

limit Replace main bearing

Clearance of main journal 0.25

0.043 - 0.103 -

I Outside diameter

Standard STD

57.00

0.25 U.S.

56.75

0.50 U.S.

56.50

size

Repair limit

tolerance

56.91

of crankpin journal 56.66

+0.015 0

56.41

3 Roundness

of crankpin journal

Repair by using under size bearing or replace. Note: The tufttride crankshaft cannot be corrected.

Repair limit: 0.020

Standard

clearance

Clearance

Clearance of crankpin journal 0.22

0.029 - 0.089

limit Replace connecting rod bearing.

I 4 -

Bend of crankshaft

Repair limit: 0.09 (Total indicated

runout)

Repair by using under size bearing or replace. Note: The tufttride crankshaft cannot be corrected.

95 SERIES


MAINTENANCE

CRANKSHAFT

STANDARD

6D95L-1 SA6D95L-1

6206F408 *

Marked

% are applied

only for 6D95L-1

Criteria

Check item

Repair limit

0.130 - 0.350

0.40

Reoair by using over size thrust bearing or replace. Repair by using over size thrust bearing or replace. Note: The tuftbide crankshaft cannot be corrected.

Engine

I

Outside diameter of main journal

I Repair limit

Tolerance

STD

70.00

69.86

0.25 U.S.

69.75

69.61

0.50 U.S.

69.50

0.75 VS.”

69.25

69.11

1 .oo U.S.”

69.00

68.86

+0.015 0

Repair limit:

Roundness of main journal

69.36

Repair by using under size bearing or replace. Repair by using under size bearing or replace. Note: The tufttride crankshaft cannot be corrected.

0.020

Clearance limit

Standard clearance

Replace main bearing.

Clearance of main journal 0.043 ‘,.

mm

Remedy

Standard

Standard size

Unit:

- 0.103

0.25

-

Outside diameter of crankpin journal

3

Repair limit

Tolerance

Standard size STD

57.00

56.91

0.25 U.S.

56.75

56.66

0.50 U.S.

56.50

0.75 U.S?

56.25

56.16

1 .oo U.S.%

56.00

55.91

+0.015 0

Repair limit:

Roundness of crankpin journal

56.41

Repair by using under size bearing or replace. Repair by using under size bearing ore replace. Note: The tufttride crankshaft cannot be c,orrected.

0.020

Standard clearance

Clearance limit

0.029 - 0.089

0.22

Clearance of crankpin journal

Replace connecting rod bearing.

I

-

4

Bend of crankshaft

95 SERIES

Repair limit:

0.09 (Total indicated runoutj

Repair by using under size bearing or replace. Repair by using under size bearing or replace. Note: The tufttride crank-

14-O 13-2


MAINTENANCE

STANDARD

CAMSHAFT

CAMSHAFT 3D95S-W-1 (without

bushing for No. 2 and No. 3 journals)

6206F559

Unit: T

No.

Check item

Criteria

Standard 1

Repair limit Replace thrust plate

End play 0.150 - 0.350

0.50

I

-

Journal

Tolerance

Standard size

Shaft 2

3

Clearance between camshaft and bushing

Standard clearance

Clearance timit

Hole

Replace bushing

No. 1

50.5

-0.080 -0.110

+0.030 -0.040

0.040 0.140

0.25

No. 2 No. 3

50.5

-0.080 -0.110

-0.031 -0.050

0.030 0.079

0.25

Bend of camshaft

Repair

limit:

Press-fitt insert bushing

0.03 (Total indicated runout)

Cam

Standard size

Tolerance

Repair limit

1

4

Cam height

Intake

Replace camshaft

42.7

43.24 to.10

Exhaust

43.44

42.9

95 SERIES

mm


MAINTENANCE

STANDARD

CAMSHAFT

3D95S-W-1 (with bushing for No. 1, No. 2 and No. 3 journals)

SectionA-A

6206F559

Unit:

I

I

No

Check item

Criteria

Remedy

Standard 1

0.150 - 0.350

Journal Clearance between camshaft and bushing

-

4

Tolerance

Standard size

Standard clearance

Shaft

Hole

50.5

-0.080 -0.110

+0.030 -0.040

Repair limit:

Bend of camshaft

Cam height

0.50

I

No. 1 No. 2 No. 3

3

Replace thrust plate

End play

I

2

Repair limit

Clearance limit Replace bushing

0.040 0.140

0.25

0.03 (Total indicated runout)

Cam

Standard size

intake

43.24

Tolerance

Repair limit 42.7

20.10 Exhaust

95 SERIES

43.44

42.9

Replace camshaft

mm


MAINTENANCE

CAMSHAFT

STANDARD

4D95S-1 4D95L-1 (without for PC60-6 and PC90-1) S4D95L-1 SA4D95L-1 4D95L-W-1 4D95S-W-1 (without bushing for No. 2 and NO. 3 journals)

6204 F406

Unit:

Remedy

Criteria

Check item

No.

Repair limit

Standard 1

Replace thrust plate

End play 0.50

0.150 - 0.350 Journal

/

.Stasn;:rd

I

2

Clearance between camshaft and bushing

No. 1

/

,hal’“a,nceHo,e

I

50.5

I

-0.080 -0.110

1 .Sta;;;;

/ Cl;E;ce

I

I

II -0.040 +0’030 1o.~&

1

Replace bushing 0.25 Press-fitt insert bushing

3

Bend of camshaft

Repair

limit:

0.03 (Total indicated runout)

Cam 4

Cam height

Intake

Exhaust

14-g 6

Standard site 43.24 14D95S-1 S(A)4D95L: 42.69 43.44 4D95S1 ( S(A)4D95L: 43.04 1

Tolerance

*0.10

Repair

Replace camshaft

limit

42.7 4D95S-1 ( S(Aj4D95L:

42.2 )

42.9 4D95S-1 C S(A)4D95L:

42.5 1

95 SERIES

mm


MAINTENANCE

4D95L-1 (without

STANDARD

CAMSHAFT

(for PC60-6 and PC90-1) busing for No. 2 and No. 3 journals)

-fzzz36204F406

Unit: No.

Criteria

Check item

/

Remedy

Repair limit

Standard 1

Replace bushing

-0.080 -0.110

50.5

Repair limit:

Bend of camshaft

Cam 4

0.50

I

Clearance between camshaft and bushing

No. 2 No. 3

3

Replace thrust plate

End play 0.150 - 0.350

2

mm

-0.03 1 -0.050

0.030 0.079

0.25

Press-fitt insert bushing

0.03 (Total indicator reading)

Standard size

Tolerance

Repair limit

Replace camshaft

Cam height

,’ 95 SERIES

’4-?A &’


MAINTENANCE

CAMSHAFT

STANDARD

4D95S-1 4D95L-1 S4D95L-1 SA4D95L-1 4D95L-W-1 4D95SW-1 (with bushing for No. 1, No. 2 and No. 3 journals)

6204F406

‘Init: No

Check item

Criteria

Remedy

Standard

I

Repair limit

1

End play

Replace thrust plate

2

Clearance between camshaft and bushing

Replace bushing

3

Bend of camshaft

-

Repair limit:

0.03 (Total indicated runout)

Cam 4

Cam height

’4-% 6-2

Standard size

Tolerance

Repair limit 42.7 4D95S-1 t S(A14D95L.1: 42.2 1 42.9 4D95S-1 ( S(A)4D95L-1: 42.5 1

Replace camshaft

95 SERIES

mm


MAINTENANCE

STANDARD

CAMSHAFT

6D95L-1 S6D95L-1 SA6D95L-1

6206F409

Unit: 1~

No.

Check item

Criteria

Remedy

-

Standard

Repair limit

I

1

End play

Replace thrust bearing

2

Clearance between camshaft and bushing

Replace bushing 50.5

3

4

Bend of camshaft

Cam height

-0.080 -0.110

+0.020 -0.050

Reapir limit:

0.030 0.130

0.25

0.03 (Total indicated runout)

Cam

Standard size

Intake

42.7

Tolerance

Repair limit 42.2

to.10 Exhaust

95 SERIES

43.4

42.9

Replace camshaft

mm


MAINTENANCE

TIMING Serial

TIMING

STANDARD

GEAR

GEAR (HELICAL GEAR)

No. 106425

and below

(Except for 4D95S-1)

6206F412A

6206F4llA

Unit: mm No

Measuring point

1

Standard

Gears

A

Crankshaft gear and idler gear

0.14 - 0.28

B

Idler gear and camshaft gear

0.15 - 0.30

C

Idler gear and fuel injection pump gear

0.13 - 0.34

a

Camshaft gear and oil pump gear

0.13 - 0.35

b

Camshaft gear and PTO gear (with PTO)

0.15 - 0.30

sacklash of each gear

Tolerance Standard size 2

Iearance between idler gear bushing snd shaft 45

3

Remedy

Criteria

Check item

Shaft

Hole

0 -0.015

+0.035 +0.015

0.4

Standard clearance

Clearance limit

0.015 0.050

0.10

Standard

Repair limit

0.03 - 0.09

0.20

ind play of idler gear

14-:18

Repair limit

Replace bushing or gear

Replace bushing (Supplies are semi-fabricated) or gear

Replace idler shaft, thrust plate or gear

95 SERIES


MAINTENANCE

Serial

TIMING

STANDARD

No. 106426

GEAR

and up

6206F412A

6206F411A

Unit: mm No.

Measuring point

I 1

Remedy

Criteria

Check item

Gears

Standard

I

A

Crankshaft gear and idler gear

Repair limit

0.08 - 0.19

Replace bushing or gear

Backlash of each gear

Camshaft gear and oil pump

Camshaft gear and PTO gear (with PTO)

b

Tolerance Standard size 2

Shaft

Clearance between idler gear bushing and shaft 45

3

-:.015

Hole +0.035 +0.015

0.15 - 0.30

Standard clearance

Replace bushing or gear 0.015 0.050

Standard

Repair limit

0.03 - 0.09

0.20

End play of idler gear

95 SERIES

Clearance limit

0.10

Replace idler shaft, thrust plate or gear

14-Z8-’


MAINTENANCE

TIMING GEAR

STANDARD

WI ‘HOUT FRONT PTO TYPE s41 195L-1 (For PClOO, 120-6, PC128UU-I) S6l 195L-1 (For LW80-I)

2

3

\

\

,:p======

mm No.

Remedy

Criteria

Check item

Repair limit

1

Backlash of each gear

2

Clearance between idler gear bushing and shaft

3

End play of idler gear

C

Idler gear and fuel injection pump gear

0.07 - 0.29

a

Camshaft gear and oil pump gear

0.07 - 0.29

0.4

Replace bushing or gear

Replace bushing or gear

Standard

Repair limit

Replace idler shaft, thrust plate or gear

-

’4-% *-*

95 SERIES


MAINTENANCE

TIMING GEAR

STANDARD

WITH FRONT PTO (SPUR GEAR) 4D95S-1 (For PC60-6 BLADE SPEC.1 4D95L-1

6206F412A

6206F411A

Unit: mm No.

Remedy

Criteria

Check item

Standard

!

0.14 - 0.28

1

Repair limit

0.15 - 0.30 1

3acklash of each gear 0.13 - 0.34

a

Camshaft gear.and oil pump gear

b

Camshaft gear and PTO gear (with PTO)

0.4

Replace bushing or gear

1

0.13 - 0.35

0.15 - 0.30

Standard clearance 2

Clearance limit

;;daFhnc; between idler gear bushing

““b’,;,/

Replace bushing or gear

Repair limit

Standard 3

End play of idler gear 0.03 - 0.09

-

95 SERIES

I

0.20

Replace idler shaft, thrust plate or gear

1

“-od8-3



FLYWHEEL AND FLYWHEEL HOUSING

6206F4

6206F4

I5

I6

Unit: mm

No -

‘.

Remedy

Criteria

Check item

1

Face runout of flywheel housing

Repair limit: 0.30

2

Radial runout of flywheel housing

Repair limit: 0.35

3

Face runout of flywheel

Repair limit: 0.15

4

Radial runout of flywheel

Repair limit: 0.20

-

Repair by reassembling

Target Nm (kgm)

Range Nm (kgm)

1st step

107.8 (11)

98 - 117.6 (IO - 12)

2nd step

191.1 (19.5)

186.2 - 196 (19 - 20) Retighten

Order

5

Tightening torque of flywheel mounting bolts (Coat bolt threads and washers with engine oil)

3D95S-W-1 6

Tightening torque of flywheel housing mounting bolts

95 SERIES

Except 3D95S-W-1

Repair limit: 53.9 2 19.6 Nm (5.5 + 2.0 kgm) (IO mm) 24.5 2 9.8 Nm (2.5 2 1.0 kgm) (8 mm) Repair limit: 68.6 2 4.9 Nm (7 * 0.5 kgm)

14-019 0


MAINTENANCE

STANDARD

PISTON,

PISTON

PISTON,

RING AND

PISTON

PISTON

RING AND

PISTQN

PIN

PIN

3D95S-W-1 4D95S-W-1

1

.6206F708

6706F413-1

Unit:

No.

1

Criteria

Check item

Remedy

Piston size

Standard size

Size mark

Tolerance

Repair limit

STD

95.00

L

-0.130 -0.145

94.76

0.25 O.S.

95.25

0.50 O.S.

95.50

Xrtside diameter of piston

,o, Measuring point

Replace piston 95.01

~ -0.145 -0.t60

S

95.26

Standard clearance

Clearance limit

2

Top ring

0.30 - 0.45

2.0

3

Second ring

0.30 - 0.45

2.0

0.25 - 0.45

1.5

IReplace

‘iston ring gap

I

mm

piston

Iping

I

4

Tolerance uo, Measuring point

Clearance between piston ring groove and piston ring

5

7

Standard size

/Top ring 1

2.2

4

Oil ring

1 1::‘;

I 1

30

Clearance limit

0.03 0.07

Replace piston or piston ring

0.15

Standard clearance

Clearance limit

Hole I

I

Standard clearance

Judge using wear gauge

+0.04 +0.02

-0.01 -0.03

Shaft

Clearance between piston and piston pin

Piston

Tolerance

Standard size

8

Ring

Replace piston or piston pin

I

I

I

0 -0.006

i6.012 iC.004

0.004 0.018

0.05 -L

’4-Fk20

95 SERIES

‘_


MAINTENANCE

4D95S-W-1

STANDARD

PISTON,

PISTON

RING

AND

PISTON

PIN

(D20,21-6)

6 7 f

28mm

6206F708 6206F413.1

Unit:

mm

T Check item

Criteria

Piston size

1

1 Sta$:rd

STD

95.00

0.25 O.S.

95.25

0.50 0,s.

95.50

1

Size mark

1

Tolerance

L

1

I;:cm;

Outside diameter of piston

1 Repair 1

limi

94.76 Replace piston

-

~

95.01 -0.145 -0.160

s

95.26

rJo.

Measuring point

Standard clearance

Clearance limit

2

Top ring

0.30 - 0.45

2.0

3

Second ring

0.30 - 0.45

2.0

Replace piston ring

Piston ring gap

I

I

I

Oil ring

4 I

0.25 - 0.45

1.5

I Tolerance

Jo, Measuring point

5

I\

5 6

2.2

Clearance between piston ring groove and piston ring

7

8

Top ring

Standard size

Clearance between piston and piston pin

95 SERIES

Ring

Piston

Standard clearance

Clearance limit

-0.01 -0.03

Judge using wear gauge

Judge using wear gauge

6

Second ring

2

-0.01 -0.03

7

Oil ring

4

-0.01 -0.03

+0.04 +0.02

0.03 0.07

‘o., 5

Replace piston or piston ring


MAINTENANCE

STANDARD

PISTON,

PISTON

RING

AND

PISTON

PIN

4D95L-W-1 4D95S-W-1

I

25

6202FOO6

6206F413- 1

Unit:

No

Check item

Criteria Standard size

Piston size

1

Size mark

Remedy

Tolerance

Repair limit

Outside diameter of piston

No, Measuring point

Piston ring gap

Standard clearance

Clearance limit

2

Top ring

0.30 - 0.45

2.0

3

Second ring

0.30 - 0.45

2.0

4

Oil ring

0.25 - 0.45

1.5

I

I Clearance between piston ring groove and piston ring

5

I Top

ring

1 Oil

1

2.2

I

ring

I

4

I

Replace piston ring

I

I

I I

7

8

mm

I

I

1 1::‘:

1

I I

I I

I

I

I 1:::;

I 2::;

1 “‘““,,,

/

1

Judge using wear gauge

0.15

I

Replace piston or piston ring

1

Clearance between piston md piston pin

95 SERIES


MAiNTENANCE

4D95S-1 4D95L-1 6D95L-1

PISTON, PISTON RING AND PISTON PIN

STANDARD

1 \

8

5mm7 8 ,‘^ I

6206F4 Unit: No

1

Check item

Criteria Standard size

Size mark

STD

95.00

L

0.25 O.S.

95.25

Outside diameter of piston (at right angle to boss)

,o. Measuring point

Tolerance

Repair limit 94.85

-0.045 -0.060 ~

95.10 -0.050 -0.075

S

Standard clearance

Clearance limit

Top ring

0.30 - 0.45

2.0

3

Second ting

0.30 - 0.45

2.0

Piston ring gap

t

0.25 - 0.45

Jo. Measuring point

Clearance between piston ring groove and piston ring

Standard size

Ring

Replace piston ring or liner

1.5

I

Tolerance Piston

Standard clearance

Clearance limit

5

Top ring

2

-0.01 -0.03

+0.07 +0.05

0.05

0.10

0.15

6

Second ring

2

-0.01 -0.03

+0.04 +0.02

0.03

0.07

0.20

7

Oil ring

4

-0.01 -0.03

+0.04 +0.02

0.03

0.07

0.15

I

8

I

I

I

Replace piston ring or piston

1 Replace piston or piston pin

Clearance between piston and piston pin 30

95 SERIES

Replace piston (only S size supplied as replacement part)

95.35

2

I

mm

Remedy

-

95.50

0.50 O.S.

I3

-00.006

+0.012 +0.004

0.004 0.018

0.05

‘,4-:23


MAINTENANCE

S4D95L-1 S6D95L-1

STANDARD

(PC200-5,

PC200-6,

PISTON,

PISTON

RING

AND

PISTQN

PIN

4

BR200-1)

1 \

8 3.6mm 7

8

6206F413

6207F413

Unit: NC

Check item

Criteria

Piston size I

1

STD

Outside diameter of piston (at right angle to boss)

Standard size

Remedv

Size mark I

Tolerance I

95.00

Repair limit I

-0.045 -0.060

I L

mm

Replace piston (onlv S size supplied as replacement

94.85

No. Measuring point

2

3

2

Top ring

3

Second ring

Standard clearance

Clearance limit

0.28 - 0.38

2.0 Replace oiston ring or liner

Piston ring gap

I 4

4

Clearance between piston groove and piston ring

5

ring

6

Top ring

1 ‘,;;’

2.5

)

2.2

8

2.0

0.25 - 0.50

1.5

-0.06 -0.08

( 1;:;;

Shaft

I

Judge using wear gauge Replace piston or piston ring

(

Tolerance

Standard size Clearance between piston end piston pin

0.40 - 0.50

I

Judge using wear gauge

Standard clearance

Clearance limit

Hole

Replace piston or piston pin

I 30

0 -0.006

+0.012 +0.004

I

0.004 0.018

0.05

L

’4-ii24

95 SERIES


MAINTENANCE

PISTON. PISTON RING AND PISTON PIN

STANDARD

SA4D95L-1

6 ‘mm

ii 8

6206F413

6207F413

Unit: No.

Check item

Piston size

1

1 Staitfrd

1

Size mark

)

Tolerance

)

Repair limit

Outside diameter of piston (at right angle to boss)

Replace piston

,o Measuring . ooint

2

3

mm

Standard clearance

Clearance limit

Piston ring gap

Replace piston ring or liner

Clearance between piston ring groove and piston ring

Replace piston or piston ring

\. 4 -

5

6

7 7

1 Oil

ring

Sta;;zrd 8

Clearance between piston and piston pin 30

95 SERIES

1

4

1

ShafTo’er,ce

I

I 0 -0.006

/ ~~:~~ 1 2::: Hole

/ o.“~,~7 1

z;$;‘pe

I

+0.012 +0.004

1 /

0.15

Ck?arma;ce Replace piston or piston pin

I

0.004 0.018

0.05

’4-i25


MAINTENANCE

PISTON,

STANDARD

PISTON

RING

AND

PlSTCjN PIN

S6D95L-1

6 5mm 7 8

6207F413

Unit: No.

1

Remedy

Criteria

Check item

Piston size

Standard size

STD

95.00

0.25 OS.

95.25

Outside diameter of piston (at right angle to boss)

Size mark

Tolerance

Repair limit

-0.045

94.85

L

-0.060 ~ -0.060 -0.075

S 0.50 OS.

mm

95.50

95.10

.

Replace piston (only S size supplied as replacement part)

95.35

,o, Measuring point

2

3

Piston ring gap 3

I 4

Second ring

I

5

0.30 - 0.45

2.0

Replace piston ring or liner

I

I

1.5

0.25 - 0.45

I

(Top ring (

6

7

Clearance limit

Oil ring

4

Clearance between piston ring groove and piston ring

Standard clearance

Second ring

1 Oil

ring

I

1

2.5

( Ii:::

2

1

4

I

1

-0.01 -0.03

Judge using wear gauge

) _~:~~ 1 $:zi I

I

0.04 0.08

+0.05 +0.03

)

I

I

8

I

Standard clearance

Clearance limit Replace piston or piston pin

I 30

’4-$26

0.15

Hole

Shaft

Clearance between piston and piston pin

0.20

1 “.““,,, I

Tolerance

Standard size

0 -0.006

+0.012 +o.oO4

Replace piston or piston ring

0.004 0.018

0.05

95 SERIES


MAINTENANCE

STANDARD

PISTON,

PISTON

RING AND

PISTQN

PIN

SA6D95L-1

6206F709

6207F413 Unit:

No

1

Criteria

Check item

Replace piston (only S size supplied as replacement part)

,o, Measuring point 2

3

Remedy

Outside diameter of piston (at right angle to boss)

2

Standard clearance

Clearance limit

0.28 - 0.38

2.0

0.30 - 0.45

2.0

Top ring

Replace piston ring or liner

Piston ring gap 3

4

mm

4

Oil ring

I

-

I

1.5

0.25 - 0.50

I

I

5

6

Clearance between piston ring groove and piston ring

Replace piston or piston ring 6

Second ring

2.2

-0.01 -0.03

7

Oil ring

4

-0.01 -0.03

Judge using wear gauge

7 +0.04 +0.02

0.03 0.07

0.15

Tolerance

Standard size 8

Clearance limit

Hole

Shaft

Clearance between piston and piston pin

Standard clearance

Replace piston or piston pin

I 30

0 -0.006

+0.012 +0.004

0.004 0.018

0.05

-

95 SERIES

’4-%6-1


MAINTENANCE

SA6D95L-1

STANDARD

(For PC220-5,

PISTON,

PC220-6,

PISTON

RING AND

PISTON

BR300-1)

6206F709

6207F413 Unit:

No

PIN

Check item

mm

Criteria

Piston size

1

1 Stai$rd

1

1

Size mark

1 Repair

Tolerance

limit Replace piston (only S size supplied as replacement part)

Outside diameter of piston (at right angle to boss)

Standard clearance

2 Piston ring gap 3

4

Top ring

0.28 - 0.38

ring

2.0

I

I Replace piston ring or liner

Second ring

1 Oil

Clearance limit

0.40 - 0.50

1

2.0

0.25 - 0.50

1.5

I

I

Tolerance do. Measuring point

Standard size

Ring

Piston

Standard clearance

Clearance limit

Clearance between piston ring groove and piston ring

7

8

Oil ring

4

-0.01 -0.03

+0.04 +0.02

0.03 0.07

0.15

Clearance between piston and piston pin

Replace piston or piston pin 30

’4-if6-2

-0.006 0

+0.004 +0.012

0.018 0.004 -

0.05

I

95 SERIES


MAINTENANCE

STANDARD

CONNECTING

CONNECTING

ROD

ROD 1

2

3

5

7

6

4

6206F414A Unit: NO

Check item

Criteria

mm

Remedy

I

Clearance between connecting rod bushing and piston pin (carry out reaming after press fitting)

2

Standard

Tolerance

33

+0.025 0

Inside diameter of connecting rod bushing hole

Replace connecting rod

I

Standard size

3

Inside diameter of connecting rod bearing

Tolerance 57.20

STD

57.00

0.25 U.S.

56.75

0.50 U.S.

56.50

56.70

0.75 U.S.

56.25

56.45

1.00 U.S.

56.00

56.20

Inside diameter of connecting rod bearing hole

Replace connecting rod bearing

Tolerance

Standard 4

56.95

+0.095 +0.045

+0.025 0

61

Replace Connecting rod

Bend

5

Bend and twist of connecting rod

6

Tightening torque of connecting rod cap mounting bolts (Coat bolt threads and washers with engine oil)

95SERIES

-wist

Order

Target Nm (kgm)

Range Nm (kgm)

1st step

39.2 (4)

37.2 - 41.2 (3.8 - 4.2)

2nd step

Retighten with 90”

90” - 120”

’4-:27


MAINTENANCE

STANDARD

01 L PUMP

OIL PUMP 3D95S-W-1 4D95L-1, S4D95L-1 4D95L-W-1, 4D95S-W-1 6D95L-1, S6D95L-1

17

6206F4

Unit:

mm

I NO.

Criteria

Check item

Engine

Standard size

Tolerance Gear width

1

Remedy

Body depth

Standard clearance

Clearance limit

(End play)

fEnd play)

Axial clearance of pump gear

Replace gear

2

Radial clearance of pump gear

38

+0.115 +0.065

+0.245 +0.205

0.045 0.090

3

Interference between pump drive gear and drive shaft

4

Clearance between drive shaft and cover

13

-0.024 -0.042

+0.018 0

0.024 0.060

5

Interference between pump gear and drive shaft

13

-0.024 -0.042

-0.065 -0.086

0.025 0.061

6

Clearance between drive shaft and bushing

13

-0.024 -0.042

+0.048 +0.004

0.028 0.09

7

Clearance between driven shaft and cylinder block

16

+0.064 +0.046

M.018 0

0.028 0.064

8

Clearance between driven shaft and gear

13

-0.110 -0.125

-0.065 -0.086

0.024 0.060

9

Interference between drive shaft bushing hole and cylinder block

+0.087 +0.060

+0.018 0

0.042 0.087

0.13

I

Replace bushing

-

Replace

-

I

-

-

’4-$28

16

-

Replace bushing Replace cylinder block Replace shafr or gear

-

Replace cylinder block

95 SERIES


MAINTENANCE

STANDARD

01 L PUMP

S4D95L-1 (For PCIOO, 120-5, PCIOO, 120-6) S6D95L-1 (For PC200-5, PC200-6, BR200-1) SA6D95L-1 (For PC220-5, PC220-6, BR300-1)

J

v’

6206F4

I7 Unit:

NO

mm

Check item

-

1

Axial clearance of pump gear

S6D95L-1 SA6D95L-l

1

32

1 _:.0,5

1 _‘:::;;

1 “‘“$&j

1 O.‘O

1:::‘aCe

-

2

Radial clearance of pump gear

-

3

nterference between pump drive ear and drive shaft

4

Xearance between drive ;haft and cover

5

nterference between pump ear and drive shaft

6

Clearance between drive shaft nd bushing

7

Clearance between driven haft and cylinder block

8

Clearance between driven haft and gear

9

nterference between drive shaft bushinghole and cylinder block

cylinder block 13

-0.110 -0.125

-0.065 -0.086

0.024 0.060

Replace shaft or gear

+0.087 a.060

+0.018 0

0.042 0.087

Replace cylinder block

-

95 SERIES

16

’4-229


MAINTENANCE

REGULATOR

STANDARD

VALVE

REGULATOR VALVE

6206F4

I8

Unit:

NO.

Criteria

Check item

I

Clearance between valve and body

olerance

_.._..

I

I 11

Hole

mm

Remedy

Standard clearance

Clearance limit

I -0.077 -0.050

-0.020 +0.020

0.030 0.097 -

Standard

Repair limit

Free length

Installed length

Installed load

33.1

27.8

2.44 kg

30.1

27.8

2.02 kg

Free length

Installed load

-

2.3 kg

Replace

3D95S-W-1 Regulator valve spring

2

~~~~~:~_, 4D95S-W-1 Except above models

3

Regulator valve set pressure

14-030 8

Standard:

5.0 * 0.5 kg/cm* (3D95S-W-1,4D95L-1,4D95L-W-l, 6.0 f 0.5 kg/cm2 (except above models)

1.92 kg

4D95S-W-1)

Repair or replace spring

95 SERIES


MAINTENANCE

WATER

STANDARD

PUMP,

THERMOSTAT

WATER PUMP, THERMOSTAT (WITH SEPARATE TYPE WATER SEAL, INTEGRATED BEARING, SHAFT)

6206F419

Unit:

No.

Check

Clearance

of impeller

Remedy

Criteria

item

Standard

body

Interference between and fan pulley boss

shaft

3

Interference and body

between

shaft

4

Interference between and impeller

shaft

5

Curvature

12

clearance:

Standard interference

Hole

Shaft

I

4.013

Repair limit:

of shaft

0.30 - 1.00

Tolerance

Standard size

0.030 - 0.070

-0.043 -0.070

Runout

mm

at face A: 0.1 qeplace

6

Wear of seal of water seal ring

Repair limit:

l

Thermostat (For WA50, WA55, and generators) l

7 l

l

-

95 SERIES

A: 0

Cracking temperature:

76 + 1.5”C (Fully open: Shall open fully when immersed in hot water bath at temperature between 95°C and 71°C for 4 - 5 minutes) Fully open temperature: 90°C (when immersed in hot water bath Fully open lift: Min. 8 at 90°C for 4 - 5 minutes) Cracking temperature:

82 + 2°C

Thermostat l

Dimension

Fully open temperature: Fully open lift Min. 8

(Fully open: Shall open fully when immersed in hot water bath at temperature between 95°C and 77°C for 4 - 5 minutes)

95°C (when immersed in hot water bath at 95°C for 4 - 5 minutes)

14-031 0


MAINTENANCE

STANDARD

WATER PUMP, THERMOSTAT

(BEARING, SHAFT SEPARATED STRENGTHENED WITH INTEGRATED WATER SEAL)

TYPE, UNITIZED

SEAL

6206F877

-1

Unit:

NC -

Check item

1

Clearance of impeller body

Criteria

Standard

Interference between and fan pulley boss

shaft

3

Interference between and impeller

shaft

4

Curvature

5

Wear of seal of water seal ring

2

20

12

of shaft

Remedy

clearance:

0.77 - 1.92

Tolerance

Standard size

I

Standard interference

Shaft

Hole

+0.015 +0.002

-0.027 -0.049

0.029 - 0.063

-0.070 -0.043

0.030 - 0.070

1

4.013

Repair limit:

Runout

mm

at face A: 0.1

Repair limit:

Dimension

A: 0

l

Thermostat (For WA50, WA55, and generators)

* l

6 l

Cracking temperature:

76 2 1.5”C (Fully open: Shall open fully when immersed in hot water bath at temperature between 95°C and 71°C for 4 - 5 minutes) Fully open temperature: 90°C Fully open lift: Min. 8 (when immersed in hot water bath at 90°C for 4 - 5 minutes) Cracking temperature:

82 + 2°C

Thermostat

* Fully open temperature: 95°C * Fully open lift: Min. 8

14-032 0

(Fully open: Shall open fully when immersed in hot water bath at temperature between 95°C and 77°C for 4 - 5 minutes) (when immersed in hot water bath at 95°C for 4 - 5 minutes)

95 SERIES


MAINTENANCE

STANDARD

WATER PUMP, THERMOSTAT

(BEARING, SHAFT INTEGRATED TYPE, UNITIZED SEAL WITH INTEGRATED WATER SEAL)

6206F419

Unit:

NC 1

Criteria

Check item

Clearance

of impeller

Standard

body

clearance:

Standard size 2

interference between and fan pulley boss

mm

Remedy

0.40 - 1.30

Hole

shaft

3

Interference and body

between

shaft

4

Interference between and impeller

shaft

5

Curvature

6

Wear of seal of water seal ring

12

I

-0.066 -0.082

I

I

I

I

-0.022

- 0.043

I

-0.043 -0.070

0.030 - 0.070

I

4.013

Repair limit:

of shaft

Runout

0.053

at face A: 0.1

Replace 0

k 15°C Thermostat (For WA50, WA55, and generators)

4 l

7

Fully temperature: Fully open lift: Min. 8

. Cracking temperature:

(when immersed in hot water bath at 90°C for 4 - 5 minutes) 82 k 2°C

Thermostat l l

95 SERIES

Fully open temperature: Fully open lift: Min. 8

5 minutes)

90°C

(Fully open: Shall open fully when immersed in hot water bath at temperature between 95°C and 77°C for 4 - 5 minutes)

95°C (when immersed in hot water bath at 95°C for 4 - 5 minutes)

14-833


MAINTENANCE

FUEL SYSTEM

STANDARD

FUEL SYSTEM INJECTION 3D95S-W-1

PUMP

078~420 Unit: mm

-

Standard 1

Outside diameter

Remedy

Criteria

Check item

No.

size

Tolerance

Repair limit

-

-

of plunger 7.5 I Standard

2

Function of plunger

3

Function of delivery valve

4

Clearance at top of plunger

I

I

generated

pressure:

Replace plunger ass’y I

Min. 49 MPa (500 kg/cm’)

Replace plunger ass’y

(at 200 rpm)

Standard

time for drop in pressure:

9.8 MPa (100 kg/cm’)

Correct or

--t Min. 5 sec.

replace

Standard

Clearance limit

clearance

0.45 - 0.55

I Sliding resistance

of control

rack

I

I

Correct

Repair limit: 60 g

I

I

Standard

size

Repair limit

I

I

Free length of plunger spring

I I

5

I

I Standard

Installed length

Load limit

load

load of plunger spring

-

11.59 kg

29.5

I

-

35.5

Installed

Replace plunger guide

Cam lift 7mm

-

Replace Standard size

Repair limit

19.5

-

Free length of delivery valve spring

6 Installed length Installed load of delivery

Tightening holder

load

valve spring 16.3

7

Standard

torque of delivery valve

2.34 kg

Load limit -

36.8 -c 2.5 Nm (3.75 2 0.25 kgm) Tighten

Tightening torque of injection mounting bolt

’4-:34

pump

63.7 + 4.9 Nm (6.5 + 0.5 kgm)

95 SERIES


MAINTENANCE

FUEL SYSTEM

STANDARD

FUEL INJECTION 3D95S-W-1

NOZZLE

6206F560

Unit: mm Check item

No. I

Remedy

Criteria I

I

I

I

I

Standard

Spray angle

Replace nozzle

size: 15

-,,.s(,20,

Standard

l --

Repair limit

MPa (kg/cm?

Standard

MPa (kg/cm? Adjust or replace

+ 0.5 (5)

Repair limit

size

Free length of nozzle spring -

22.0

Replace

2 Installed length Installed

Standard

load

Load limit

load of nozzle spring 21.06

95 SERIES

28.04 kg

-

’4-835



15

ENGINE REPAIR AND REPLACEMENT

CYLINDER HEAD SECTION Grinding cylinder head mounting surface . . . . . . .. . . . . . . .. .. . . .. . . .. . . . .. . . 15-003 Replacing valve seat insert . .. . . . .. . . .. .. .. .. . .. . . 15-003 Replacing valve guide . .. . .. . . . . . .. . . . . . .. . . . . .. . . . . . 15-008 Grinding valve . . .. .. . .. . . . .. . . . .. . . . .. . .. . . . . .. . . .. .._.... 15-009

CYLINDER BLOCK SECTION Replacing camshaft bushing . . .. . .. . . . . .. . . . . . . .. 15-010 Replacing gears . . . . . .. .. . . . .. . . . . . . .. .. . . . . . .. . . . . .. . . . . . 15-012 Procedure for pressure test . .. . . . . .. . .. . . . .. . . . .. 15-014 Cylinder liner (special restoration part) .. 15-015 Machining drawing for cylinder block bore . . . . .. . . . . . . .. . . . . . .. . . . 15-016 Additional machining of cam journal . . . . . . 15-017 Grinding crankshaft . . . . . . .. .. . .. . . . . . . .. . . . . . .. . .. . . . . . 15-018

95 SERIES

15-00 1 0


REPAIR

AND

REPLACEMENT

OF PARTS

TABLE

OF SPECIAL

TOOLS

TABLE OF SPECIAL TOOLS Operation

Replacing

valve seat

Replacing

valve guide

Grinding

Replacing

Pressure

iymbol

Part No.

Part Name

Q’ty

Remarks

valve

cam bushing

test

H

1 J

’%02

I

l

795-215-1120

l

Push tool

1

l

795-215-l

l

Collar

1

l

795-215-1150

l

Guide

1

140

790-513-4200

Coolant

79A-471-1050

Pump ass’y

tester

kit

I

1

I

1

95 SERIES


REPAIR AND

REPLACEMENT

OF PARTS

GRINDING

CYLINDER

HEAD MOUNTING

SURFACF

GRINDING CYLINDER HEAD MOUNTING SURFACE 1.

2. l

Grinding Grind the bottom surface of the cylinder head with a surface grinding machine to remove deformation or corrosion. Do not exceed the repair limit of cylinder head height H. After grinding, make an R mark at the rear on the left side (intake side) of the cylinder head. + Standard dimension of cylinder head height H: 90 - 0.: mm Repair limit: 89.5 mm * Amount to remove per grinding: 0.10 - 0.15 mm * Surface roughness of grinding surface: Within 6s * Flatness (deformation): Within 0.05 mm * Grinding limit: 0.3 mm + Difference in head height per unit: Within 0.15 mm * For details of the surface grinding machine, see the operation manual. Ir For engines with a swirl chamber, leave the swirl chamber insert (port plug) in position when grinding.

6202FOlOA

Checking after grinding Check that the insertion depth of the valve is within the standard value. Insertion depth of valve (mm)

I

I 0.8 + 0.18

3D*4D95S-W-1 4D95L-W-1 4D95S-1

0 2 0.18

(SKSA) 4D95L-1 (S)(SA) 6D95L-1

Check the protrusion of the swirl chamber insert (port plug) from the bottom of the cylinder head and check that it is within the standard value. Rrotrusion : 0 - 0.08 mm

t 6204F405A

95 SERIES

Protrusion

15203


REPAIR AND REPLACEMENT

GRINDING

OF PARTS

CYLINDER

HEAD MOUNTING

SURFACE

REPLACING VALVE SEAT INSERT Ir When correcting the valve seat insert and not re*

placing it, use tool A and finish 0.5 mm of the insert seat face. Insertion depth after machining:

at a range

within

Insertion depth of valve Correction limit: 0 - 0.5 mm Insertion depth of valve

I Seat angle

_-

P __-

__ fl

:-

I

I 6202FOll

15to4

Applicable engine 3D95S-W-1 (Swirl chamber 4D95S-W-1 type) 4D95L-W-1 4D95S-1 S4D95L-1 SA4D95L-1 S6D95L-1 SA6D95L-1

(Direct injection type)

S4D95L-1 (PCIOO, 120-A, PCIOO-6, PC120-6, PC128UU-1) S6D95L-1 (PCZOO-A,WA1 50-3, WA200-3) SA6D95L-1 (PC220-A)

angle

Standard size

Repair limit

45” Both intake

0.8 + 0.18

1.80

0 + 0.18

1.00

0 k 0.18

1.00

Seat

Ind exhaust)

45” Both intake Ind exhaust)

45” Exhaust 60’ Intake

95 SERIES


REPAIR AND REPLACEMENT

OF PARTS

1.

Removal

a

When using a grinder to carry out this work, carry out a test run for one minute before starting the operation to check that there is no abnormality. . If the grindstone has been replaced, carry out the test run for 3 minutes.

A

Check that there is no damage to the grindstone, fit it to the grinder spindle so that there is play, and wear safety glasses when using the grinder.

.

When removing with a valve seat puller 1) Install grindstone @ to grinder 0. 2) Align the groove of sleeve @ with holder 0, and insert. * Adjust the position of the grinder with set screw 0.

REPLACING

VALVE

SEAT INSERT

of valve seat

6162F504

3)

4) 5)

Adjust the position of the grinder so that the center of grindstone @ is at the center of valve seat (I), then tighten the set screw to fix the grinder in place. Rotate the grindstone and move it slowly until it contacts valve seat (I). Press the grindstone lightly against the inside face of the valve seat and make a groove around the whole circumference of the inside face of the valve seat. * Depth of groove: Approx. 1 mm

I 6)

7)

8)

6162F505

Push three claws @ of puller head @ of tool B inwards by hand, and fit into valve seat (I). Tighten screw @ to push the three claws into the groove on the inside face of the valve seat. * When the claws are completely in contact with the groove, stop tightening. Insert bridge @ on the outside of the puller head, set plates @ and 0 on top of the bridge, and tighten nut @ to pull out the valve seat.

95 SERIES

6162F506

15005 0


REPAIR AND REPLACEMENT

.

2.

OF PARTS

REPLACING

When welding a bar to the valve seat to remove 1) Weld bar (2) (length: 0.1 - 0.5 mm shorter than inside diameter of valve seat, diameter: approx. 10 mm) to inside of valve seat (1). * Be careful not to deposit any of the welding metal on the head itself. of the weld has 2) When the temperature dropped to around room temperature, insert a used valve (3) in the opposite direction, and hit the face of the valve with a small hammer to remove the valve seat. * Be careful not to hit too hard, as any excessive shock may cause the weld to break off. Machining mounting hole for valve seat insert + When no valve seat insert is used, and the seat face is damaged or worn, follow the same procedure and use tool A to grind, then press fit the insert.

1) Using tool A, grind the hole to a onelevel larger oversize. * Machine within an oversize range of 0.5 mm. If it is more than 0.5 mm, replace the cylinder head.

.

Method of machining ing hole

insert and mount-

VALVE

SEAT INSERT

I

6127F205

!n_take.,valve

0.50 0.S

045.50 ;;:;;;

8.62 _o”,, 045.50 +;020

3.0 _i,2

11.62 too’2

(Direct injection) Insert seal

Unit Insert

Dia(n&;ter

1

Insert mounting H&hg)ht

1

Diameter (dz)

Height thzl

Chamfer (Cl) 2.2 :,2

2.0 -“.2

2.2 _;,2

2.0 -00.2

2.2 _;,2

2.0 _“o.,

S.T.D.

045.00 :I;;;

8.50 _o”,, 045.00 tgoo20 ,o,70 $2

0.25 0.S

045.25 :;:;;;

8.50 _o”,, 045.25 +;02’

0.50 0.S

045.50 ;;:A;;

8.62 _;,, 045.50 +;020

l 10.82 l y 10.70 ;’

Insert seal

Insert m[‘h

Intake

valve

LAL_l

Diameter (d,)

Insert mounting H:e:tI

Diameter (dz)

6202FO12 *

* *

Roughness

Within Roughness at bottom of mounting Within Concentricity with inside surface of guide: Within 0.05 mm

15-006 0

of inside surface: 6.3s hole: 12.5s valve (TIR)

Chamfer (Cl) 3.0 0 -0.2

S.T.D.

039.00 :t;;;

6.50 -o”.,

039.00 to.020 o

0.25 0.S

039.25 ;t;;;

6.50_;,,

039.25 +;020

9.50 +i.2

3.0 4.2

0.50 OS

039.50 $1;;;

6.62-i,,

039.50 +;o25

9.62 +;‘2

3.0 j.2

Insert seal valve

: mm

hole

2 H&Ag:’ 9.50 *o.2 0

Unit

(Direct iniection)

Exhaust

Chamfer (CA

Unit Insert

: mm

hole

Exhaust valve (Swirl chamber)

h

2.0 i.2

Insert DiaI?Yer 1

Insert mounting H?hg; 1

DiafZ?er 2

Height

hz)

: mm

hole Chamfer

(Cl)

S.T.D.

039.00 +o,070 to.080

6.50 ;,,

039.00 +ZO2O

8.70 +I2

3.0 _:.2

0.25 0.S

+o,070 039.25 to.080

6.50 ;,,

039.25 +ZO2O

8.70 +i2

3.0 j.2

0.50 0,s

039.50 $f;;

6.62 _;,,

039.50 +zo2’

8.82 +i2

3.0 j.2

95 SERIES


REPAIR AND

3.

REPLACEMENT

REPLACING

OF PARTS

Press fitting valve seat insert 1) Using tool C or tool D, press fit insert (2) of a size that matches the oversize of the mounting hole. * Use the inside diameter of valve guide (4) as a guide, and press fit, taking care that the insert is not fitted at an angle. * To check that insert bottom face (C) is completely sealed, tap with a hammer and listen to the change in sound, or judge from the springing back of the push tool. 2) Check the insertion depth of the insert from the mounting surface of the cylinder head. + Insertion depth of insert Standard

VALVE

SEAT INSERT

615FOO4

t

h3: 3.0 + t” mm (Swirl)

1

h3

2.2 + t” mm (Direct injection) 1 4.

Finishing insert seat surface 1) Using tool A, finish the surface of the insert seat to the dimension shown in the diagram below. Sr When selecting a pilot to insert into the valve guide, choose one that leaves no clearance when it is inserted.

Intake

6206F1017

valve

6202FO14

a 1 %

b

1

Swirl

Direct injection

3.8 + 0.1

3.0 + 0.1

3.8 + 0.1

1

3.0 + 0.1

Direct injection,

intake only seat angle 60” + O”15 % 2.835 + 0.1

1

3.0 + 0.1

I

Applicable machines for seat angle 60” + O”15 PC100,120-A, PC100,120-6, PC128UU-1 PC200, 220-A WA1 50, 200-3

95 SERIES

15007 0


REPAIR AND REPLACEMENT

OF PARTS

REPLACING

VALVE

GUIDE

REPLACING VALVE GUIDE 1.

Removing Insert tool head, put hit with a

2.

Press fitting valve guide I) Press fit the valve guide until the tip of tool F contacts the cylinder head. * After press fitting, insert the valve, and if the valve does not enter smoothly, machine the hole with a reamer (0 8 + $015). 2) *

valve guide E from the top surface of the cylinder it in contact with the valve guide, then hammer to remove the valve guide.

Measure the protrusion of the valve guide and check that it is within the standard range. Valve guide protrusion Tolerance:

15008 0

14.5 + 0.2 mm

95 SERIES


REPAIR AND

REPLACEMENT

GRINDING

OF PARTS

REPLACING

VALVE

GUIDE

VALVE

Grinding seat face After using tool G to adjust the valve seat angle, grind the seat face. Ir For details of the angle of the valve seat, see the Maintenance Standard Table. Checking after grinding Measure the thickness of valve head, insertion depth of the valve and the contact of the valve seat face to check that they are within the standard range. * Thickness of valve head: 1.40 - 1.60 mm 1.90 - 2.10 mm (PCIOO-5, PC120-5, PC200-5, PC220-5 intake only) * Insertion depth of valve Unit: mm r

3D*4D95S-W-1 4D95L-W-1

*

*

Contact width of valve Standard Intake valve: 2.0 mm 2.2 mm (PCIOO-5, PCl20-5, PC200-5, PC220-5 (seat angle 29”45’ - 30”15’) Exhaust valve: 2.0 mm For details of handling the valve refacer, see the operation manual.

95 SERIES

1709 1


REPAIR AND

REPLACEMENT

OF PARTS

REPLACING

CAM BUSHING

REPLACING CAM BUSHING 1.

Removing front and rear bushings As shown in the diagram, assemble push tool (2), collar (31, and push bar (I) of push tool H, then hit the push bar to knock bushing (6) out from cylinder block (5). 6202FO15

2.

Removing center bushing Assemble push bar (I), push tool (21, collar (31, and guide (4) of push tool H, then hit the push bar to knock bushing (6) out from cylinder block (5).

3

2

4

1

c

6202F016

*

Cam bushing

After removing the bushing, remove any burrs or dirt from the mounting hole of the bushing.

assembly

drawing

Oil hole Bushing

6 I27F242

3.

Press fitting center bushing Assemble bushing (6) to tool H, and press fit the bushing until the oil hole in cylinder block (5) is aligned with the oil hole in the bushing.

36

2

1

4

6202FO17

‘%‘O

95 SERIES


REPAIR AND REPLACEMENT

4.

OF PARTS

REPLACING

Press fitting front and rear bushings Assemble bushing (6) to tool H, and press fit the bushing until the oil hole in cylinder block (5) is aligned with the oil hole in the bushing.

36

2

CAM BUSHING

1

6202FO18

5.

After press fitting bushing . Using inside gauge 0, measure the inside diameter of the bushing. Check the clearance between the bushing and shaft, and if the clearance is not within the specified range, or the shaft does not pass through smoothly, correct the inside diameter of the bushing with a reamer. . When correcting the inside diameter of the bushing with a reamer, clean all chips from the oil hole and oil groove. l

*

Inside diameter

of cam bushing: 050.5 +Jiii

*

95 SERIES

Clearance

6202FO19

mm

of camshaft journal: 0.030 - 0.130 mm

15211


REPAIR AND REPLACEMENT

OF PARTS

.

REPLACING

CRANKSHAFT

GEAR, CAM GEAR

REPLACING CRANKSHAFT GEAR

REPLACING CAM GEAR

1.

Removal of gear Remove the gear with a gear puller.

1.

2.

Press fitting gear 1) Check the gear mounting surface, key groove, and flange surface, and if there are any scratches, correct them with an oilstone. 2) Knock the key into the key groove of the shaft. 3) Heat the gear for the specified time at the specified shrink-fitting temperature. * Crankshaft gear shrink-fitting temperature: 230 - 250°C Heating time: 30 minutes 4) Put the timing mark on the outside, then use a hitting tool to press fit until the side face of the gear is in tight contact with the shaft flange. * Knock in quickly before the gear becomes cool.

When using only shrink fitting 1) Check the gear mounting surface, key groove, and flange surface, and if there are any scratches, correct them with an oilstone. 2) Knock the key into the key groove of the shaft. 3) Heat the gear for the specified time at the specified shrink-fitting temperature. Sr Cam gear shrink-fitting temperature: 250 - 270°C Heating time: 30 minutes

2.

When combining shrink fitting and tightening with bolt 1) Press fit with the bearing installed to the camshaft. Leave no Put the inner race of J/-Z-Y the bearing in contact with the shoulder of the No. 1 journal.

2) Knock the key (6206-

3) 4)

5)

sr

*

15i12

41-1380) into the cama Camshaft shaft. When doing this, check that the key is below the surface of the tip of the camshaft. (See diagram on right) Heat the cam gear in a furnace at 220°C - 240°C for approx. 35 minutes. When press fitting the cam gear to the camshaft, use a press to apply a force of approx. 2 tons to the outer shoulder of the gear so that the bearing inner race is Position for oushing pressed against with press the end of the inside of the I---I cam gear. When the cam gear has cooled to \! room temperature, push with a press to press fit Cam.shaft’support po~lon * it fully. Insert the bolts in the plates and coat the thread with LT-2, then tighten to the camshaft. After tightening to the specified torque, loosen the bolts, then tighten again to the specified torque. Tightening torque of bolt: 98 - 122.5 Nm (IO - 12.5 kgm) After press fitting, tighten the bolts fully within 2 minutes, and be sure that the cam gear temperature has not gone down. 95 SERIES


REPAIR AND

REPLACEMENT

REPLACING GEAR

REPLACING

FLYWHEEL

RING GEAR

FLYWHEEL RING

a

Be careful you.

1.

Removal of ring gear 1) Prepare a support for on the support with facing down. 2) Heat the area around torch lamp, then hit remove it.

2.

OF PARTS

not to let the flywheel

fall and injure

the flywheel, and set the ring gear surface the ring gear with a it with a hammer to

Press fitting ring gear 1) Check the ring gear mounting surface, and if there are any scratches, correct them with an oilstone. 2) Heat the ring gear for the specified time at the specified shrink-fitting temperature. * Ring gear shrink-fitting temperature: Max. 200°C Heating time: 45 minutes 3)

Set the chamfered face of the ring gear facing the flywheel, and press fit until the side face of the gear is in tight contact with the flywheel.

95 SERIES

15-013 0


REPAIR AND REPLACEMENT

PRESSURE

OF PARTS

TEST

PRESSURE TEST .

When corrections have been made head, test the pressure as follows.

1.

Water pressure test I) Tighten the nozzle holder assembly to the specified torque. 2) Assemble tool I and tool J, and connect the hose to flange (1). 3) Apply water pressure 0.25 - 0.6 MPa (2.5 6.0 kg/cm*) for approx. 10 minutes, and check that there is no leakage from around the head. When carrying out this test, heat the whole * cylinder head and carry out the test with hot water (82 - 93°C).

2.

Air pressure test 1) Tighten the nozzle holder assembly to the specified torque. 2) Connect the compressor hose to flange (I). 3) Put the head in the container of water, apply air pressure 0.2 MPa (2.0 kg/cm? for approx. 30 seconds, and check that there is no leakage in the water.

*

*

around

the

6202FO20

If the above test shows any cracks in the nozzle holder or around the plate plugs, replace the cylinder head. If cracks are found in any other places, weld to repair.

15-t14

95 SERIES


REPAIR AND

REPLACEMENT

OF PARTS

CYLINDER LINER (SPECIAL RESTORATION

CYLINDER

LINER

PART)

:::,_ 30mm

; 0

I

:

40mm

F614601010

Cylinder liner . The 95 Series engine has a liner-less cylinder, so if the cylinder bore exceeds 95.40 mm because of wear, the cylinder is bored, and this cylinder liner is used to restore the cylinder. Selection of liner There are two sizes of cylinder liner: A and B. After machining the cylinder bore, select the size of liner to match the bore. l

Outside

diameter

of cylinder

liner

Unit: mm

Line

0

@

0

[Remark] Machined dimension of cylinder

I

+0.020 g8 +0.005

g8 +0.025 -0.010

g8 +0.025 -0.020

gB +0.0125 0

Measurement

Category mark Part No.

Letter

6207-21-2110 % 6354-21-2210

A

6207-21-2120 % 6354-21-2220 I

%: For alcohol

95 SERIES

engine

I

g8 +0.040 +0.005

+0.035 g8 +0.020

II

B I

I

location

I

g8 +0.040 -0.005 I

‘* I

+0.0250 +0.0125


REPAIR AND

REPLACEMENT

OF PARTS

MACHINING

DRAWING

FOR CYLINDER

BLOCK BORE

MACHINING DRAWING FOR CYLINDER BLOCK BORE .

Honing At this position, measure the diameter into two directions as shown in the diagram below, and stamp at the position in Fig. 2 according to the average diameter.

I r face

Too surface of cylinder

block

Note, bench mark C is the center of the crankshaft A honing droop is permissible if it is within at the diameter between 20 mm from the bottom end and 15 mm from the top face.

,0.005mm

‘Aj

d

+0.0125 o

.-

d 9B +0.025 to.0125

B

c-2

98

Right side face

’ c_ There must be no burrs or flashes at these corners

499io.04 Stamp A or B (6 places) Detail of portion

6206F904

15-g 6

Erase stamp mark S or L Fig. 2

R

6206F904-1

95 SERIES


ADDITIONAL

REPAIR AND REPLACEMENT OF PARTS

ADDITIONAL MACHINING CAM JOURNAL

MACHINING

OF CAM JOURANL

OF

Carry out additional machining of the cam journal, and install a cam bushing (Part No.: 6206-21-1420) to correct the damage. 1. To carry out the additional machining, disassemble to make the cylinder block into an individual part. * To clean out the metal particles after machining, remove the taper plug from the oil hole, the p-plug, and the oil pressure caution switch. Remove parts a - e in the diagram.

6206F874

2.

Center with an undamaged cam journal and carry out additional machining. (Cross-sectional diagram No. I) Inside diameter 0 after machining: 53.5 +‘.‘i mm (Surface roughness: Max. 12.5 S)

3.

Align the oil hole in the cam bushing with the oil hole in the cylinder block, and press fit. After press fitting, insert a 0 3.5 check bar through the oil hole in the main journal and check that it passes through the oil hole. (Diameter of bushing oil hole: 0 4)

4.

After press fitting, check the inside diameter of the bushing. (Cross-sectional diagram No. 2) Inside diameter

of bushing:

0 50.5 $,“,’ mm

5.

Clean thoroughly and check that there are no metal particles remaining in the oil hole.

6.

To check the alignment of the journal at three places, insert the cam shaft and check that it rotates smoothly by hand.

7.

Remove the cam shaft, then install the taper plug for the oil hole, the p-plug (replace with a new part), and the oil pressure caution switch to the cylinder block.

15217


REPAIR AND REPLACEMENT

GRINDING

OF PARTS

GRINING

CRANKSHAFT

CRANKSHAFT

Applicable crankshaft . It is possible to correct by grinding and rebuild so that undersize bearings can be used only with crankshafts which have received induction hardening. This method of repair may not be used for crankshafts that have received tufftride treatment. (*I) . It is possible to distinguish these two types of crankshaft from the engine serial number(*2), but check the crankshaft as follows to ensure that there is no mistake. (New)

crankshaft given induction hardening (possible to correct by grinding)

(Old) crankshaft (not permitted

given tufftride treatment to correct by grinding)

Temper color caused by No temper color can be

harge symbol (PI) on

t No. 6204-31-3410 mped on rear face)

art No. 6207-31-3310 tamped on rear face) The counterweight and arm have the black skin from forging

The counterweight and arm are a grey color from the tufftride treatment

6206F890

(*I):

(“2):

6206F891

With tufftride treatment, the hardened layer is thin, so if additional grinding is carried out, the hardened layer will be removed and it will be impossible to ensure the strength and wear resistance. The part number does not change when there is change in the surface treatment of the crankshaft, but as shown above, the crankshaft pin bearing is changed at the same time.

15t18

95 SERIES


Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186

PROPOSAL

1

FOR MANUAL

REVlslON

FOR INTERNAL USE ONLY -- No. PMR 2

NAME OF COMPANY:

:

PHONE NO:

: S

DEPARTMENT:

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

LOCATION:

DATE:


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