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
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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
Oâ&#x20AC;&#x2122;-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)
Oâ&#x20AC;&#x2122;-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
Oâ&#x20AC;&#x2122;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
Oâ&#x20AC;&#x2122;-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
â&#x20AC;&#x2122; 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
â&#x20AC;&#x2DC;Y2
95 SERIES
INTAKE AND EXHAUST SYSTEM
STRUCTURE AND FUNCTION
n
6204F108
A. Air intake B.
Exhaust
95 SERIES
outlet
â&#x20AC;&#x2DC;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
â&#x20AC;&#x153;%Y
95 SERIES
STRUCTURE
AND
FUNCTION
INTAKE
AND EXHAUST
SYSTEM
6206F104
A. B. a.
Air intake Exhaust outlet Dust indicator pickup port
95 SERIES
â&#x20AC;&#x153;-~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
â&#x20AC;&#x153;-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.
â&#x20AC;&#x2122; â&#x20AC;&#x2DC;-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
â&#x20AC;&#x2122;â&#x20AC;&#x2122;-!aâ&#x20AC;&#x2122; 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
â&#x20AC;&#x153;-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)
â&#x20AC;&#x153;-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.
â&#x20AC;&#x153;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
1â&#x20AC;&#x2122;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
heaâ&#x20AC;&#x2DC;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 â&#x20AC;&#x153;valve overlapâ&#x20AC;?.
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
â&#x20AC;&#x153;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
â&#x20AC;&#x2122;â&#x20AC;&#x2122;-: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
â&#x20AC;&#x2122;â&#x20AC;&#x2122;-: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
â&#x20AC;&#x153;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
â&#x20AC;&#x2122;â&#x20AC;&#x2122;-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
â&#x20AC;&#x153;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
â&#x20AC;&#x2122;â&#x20AC;&#x2122;-: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
â&#x20AC;&#x153;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
Vâ&#x20AC;&#x2122;
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.
â&#x20AC;&#x153;: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
Yâ&#x20AC;&#x2122;
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:
â&#x20AC;&#x153;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
â&#x20AC;&#x153;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
â&#x20AC;&#x2122;â&#x20AC;&#x2122;-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
â&#x20AC;&#x2122;â&#x20AC;&#x2122;-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.
â&#x20AC;&#x2122;â&#x20AC;&#x2122;-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.
â&#x20AC;&#x2122;â&#x20AC;&#x2122;-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)
â&#x20AC;&#x153;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.
â&#x20AC;&#x153;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
â&#x20AC;&#x153;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
â&#x20AC;&#x2122;*zol
TESTING
INTAKE
AND
ADJUSTING 1. 2.
INTAKE
AND ADJUSTING
EXHAUST
VALVE
AND
EXHAUST
SYSTEM
SYSTEM
CLEARANCE
â&#x20AC;&#x153;~
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
â&#x20AC;&#x2122;*-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:
180â&#x20AC;?
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.
â&#x20AC;&#x2122;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 - 6Oâ&#x20AC;&#x2122;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 - 6Oâ&#x20AC;&#x2122;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.
â&#x20AC;&#x2122;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. 85â&#x20AC;&#x2122;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 -
40â&#x20AC;? 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
â&#x20AC;&#x2122;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
30â&#x20AC;&#x2122;
from
to 40â&#x20AC;&#x2122;
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.:
â&#x20AC;&#x2DC;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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;2-o&o-2
scale
the standard
the â&#x20AC;&#x2DC;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/cmâ&#x20AC;&#x2122;.
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
â&#x20AC;&#x2122;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
â&#x20AC;&#x153;aâ&#x20AC;?),
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
â&#x20AC;&#x2122;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.
â&#x20AC;&#x2122;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
(0â&#x20AC;?).
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
â&#x20AC;&#x2122;*-OAO-â&#x20AC;&#x2122; *
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
â&#x20AC;&#x2122;2-oAo-â&#x20AC;&#x2122; 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
â&#x20AC;&#x2DC;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.
â&#x20AC;&#x2DC;*-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
â&#x20AC;&#x2DC;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
â&#x20AC;&#x2122;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
â&#x20AC;&#x153;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
â&#x20AC;&#x2DC;[ 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: Manufacturerâ&#x20AC;&#x2122;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)
â&#x20AC;&#x2122;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)
( ): Manufacturerâ&#x20AC;&#x2122;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 30â&#x20AC;&#x2122;
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
(
): Manufacturerâ&#x20AC;&#x2122;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 + 30â&#x20AC;&#x2122;
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
) : Manufacturerâ&#x20AC;&#x2122;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::â&#x20AC;&#x153;, 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: Manufacturerâ&#x20AC;&#x2122;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 yerrtzâ&#x20AC;&#x2122;, 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)
): Manufacturerâ&#x20AC;&#x2122;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)
â&#x20AC;&#x2122;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: Manufacturerâ&#x20AC;&#x2122;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 â&#x20AC;&#x2122; 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
( ): Manufacturerâ&#x20AC;&#x2122;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 â&#x20AC;&#x153;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
â&#x20AC;&#x2122;*-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
â&#x20AC;&#x2122;*-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
â&#x20AC;&#x2122;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 â&#x20AC;&#x2122; 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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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)
â&#x20AC;&#x2122;2-o%-â&#x20AC;&#x2122; 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:â&#x20AC;&#x2DC;:) 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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;
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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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 userâ&#x20AC;&#x2122;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].
â&#x20AC;&#x2122;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.
â&#x20AC;&#x2122;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
â&#x20AC;&#x2DC;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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;
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 â&#x20AC;&#x153;Engine
stops during
I
1
operationsâ&#x20AC;?.
. 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? â&#x20AC;?
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
â&#x20AC;&#x2122;*-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
â&#x20AC;&#x2DC;= 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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2DC;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
IYâ&#x20AC;&#x2122;lâ&#x20AC;?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).
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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 &esâ&#x20AC;?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)
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;*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
â&#x20AC;&#x2122;*-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
â&#x20AC;&#x2122;*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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2DC;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.
â&#x20AC;&#x2122;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.
â&#x20AC;&#x2DC;3-oPâ&#x20AC;&#x2122;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 â&#x20AC;&#x2122;
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+s0â&#x20AC;&#x2122;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
â&#x20AC;&#x2DC;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 â&#x20AC;&#x2122;
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+iâ&#x20AC;?
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-â&#x20AC;&#x2DC;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
Qâ&#x20AC;&#x2122;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).
â&#x20AC;&#x2122;3-o:â&#x20AC;&#x2122; -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
springâ&#x20AC;&#x2122;(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
â&#x20AC;&#x2122;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.
â&#x20AC;&#x2122;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.
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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-ozâ&#x20AC;&#x2122;-3â&#x20AC;&#x2122;
(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
â&#x20AC;&#x2122;3-o&Aâ&#x20AC;&#x2122; -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 180â&#x20AC;?
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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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
360â&#x20AC;? 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
180â&#x20AC;? 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
.â&#x20AC;?
;
,:
6202P504
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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.
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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.
â&#x20AC;&#x2122;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 assâ&#x20AC;&#x2122;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 -
25Oâ&#x20AC;&#x2122;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 180â&#x20AC;&#x2122; 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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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
-
;;;;;fbâ&#x20AC;?,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).
â&#x20AC;&#x2122;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
360â&#x20AC;&#x2122;
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 180â&#x20AC;?
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
Qâ&#x20AC;&#x2122;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.
â&#x20AC;&#x2122;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).
*,~.â&#x20AC;&#x153;< ,,
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.
â&#x20AC;&#x2DC;,,,\,:\ __
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 inâ&#x20AC;&#x2DC;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
â&#x20AC;&#x153;aâ&#x20AC;?) 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 180â&#x20AC;&#x2122;
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 snapâ&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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:
â&#x20AC;&#x2DC;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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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 â&#x20AC;&#x2122; 3-i!to-â&#x20AC;&#x2122;
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
â&#x20AC;&#x2122;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, 120â&#x20AC;&#x2122;
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.
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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
â&#x20AC;&#x2122;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
Iâ&#x20AC;&#x2122;\.
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
â&#x20AC;&#x2122;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 â&#x20AC;&#x2122; 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-iikâ&#x20AC;&#x2122;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-â&#x20AC;&#x2122;
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 -
â&#x20AC;&#x2DC;.
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
â&#x20AC;&#x2DC;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 ,â&#x20AC;&#x2DC;^ 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
â&#x20AC;&#x2DC;,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-$26
0.15
Hole
Shaft
Clearance between piston and piston pin
0.20
1 “.““,,, I
Tolerance
Standard size
0 -0.006
+0.012 +o.oO4
Replace piston or piston ring
0.004 0.018
0.05
95 SERIES
MAINTENANCE
STANDARD
PISTON,
PISTON
RING AND
PISTQN
PIN
SA6D95L-1
6206F709
6207F413 Unit:
No
1
Criteria
Check item
Replace piston (only S size supplied as replacement part)
,o, Measuring point 2
3
Remedy
Outside diameter of piston (at right angle to boss)
2
Standard clearance
Clearance limit
0.28 - 0.38
2.0
0.30 - 0.45
2.0
Top ring
Replace piston ring or liner
Piston ring gap 3
4
mm
4
Oil ring
I
-
I
1.5
0.25 - 0.50
I
I
5
6
Clearance between piston ring groove and piston ring
Replace piston or piston ring 6
Second ring
2.2
-0.01 -0.03
7
Oil ring
4
-0.01 -0.03
Judge using wear gauge
7 +0.04 +0.02
0.03 0.07
0.15
Tolerance
Standard size 8
Clearance limit
Hole
Shaft
Clearance between piston and piston pin
Standard clearance
Replace piston or piston pin
I 30
0 -0.006
+0.012 +0.004
0.004 0.018
0.05
-
95 SERIES
â&#x20AC;&#x2122;4-%6-1
MAINTENANCE
SA6D95L-1
STANDARD
(For PC220-5,
PISTON,
PC220-6,
PISTON
RING AND
PISTON
BR300-1)
6206F709
6207F413 Unit:
No
PIN
Check item
mm
Criteria
Piston size
1
1 Stai$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
â&#x20AC;&#x2122;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
-
-
â&#x20AC;&#x2122;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
-
â&#x20AC;&#x2122;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
â&#x20AC;&#x2DC;* 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):
(â&#x20AC;&#x153;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: