Print D Testing Adjusting

ENGINE ENGINE BODY ‘Adjusting valve clearance .... Measuring compression pressure 12-002 12-003 12-004 Measuring blow-by . FUEL SYSTEM Testing and adjustment of fuel injection timing (with ZEXEL mechanical governor}. (with ZEXEL electronical governor}. Testing and adjustment of fuel injection timing (with KOMATSU electronical governor) ... Adjusting injection pump governor link (with ZEXEL mechanical governor)... (with ZEXEL electronica GOVEFNOT rn Procedure for adjusting ‘engine stop motor cable (applicable for models using engine stop MOtOM) ervnmnes 12-008 Method for installing (adjustment) 12-005 . 12-006-3 621501 . 12-006-6 . 12-007 . 12-008-1 of engine speed SenSOr srnmmnrs 12-010 Adjusting fuel injection pressure .. 12-010-1 Fuel injection pump calibration data . 12-.010-2 12 TESTING AND ADJUSTING COOLING SYSTEM Checking and adjusting V-belt tension 12-011 PERFORMANCE TEST Run-in standard .......ssscsscsesseese 12-013 Performance test criteria .......+.++. 12-014 Testing and adjusting tool list 12.017 Testing and adjusting data .......... 12-018 TROUBLESHOOTING Points to remember when troubleshooting -- 12-025 Method of using troubleshooting chart .. Troubleshooting table . 12-026 12-030 12-001 ®ADJUSTING VALVE CLEARANCE * Adjust clearance between crosshead and rocker arm. ‘Adjusting method of valve clearance 1, Remove the rocker arm housing cover. 2. Rotate the crankshaft in the normal direction. While watching the movement of the intake valve of the R6 cylinder, bring the Rt oylinder into the top dead center position of the compression stroke and align the "R1.6 TOP” line on vibration damper (1) with pointer (2). % Hold with a wrench in position B in the diagram on the right, then crank the engine in the direction of the arrow. * When the R1 cylinder comes near the top dead center of the compression stroke, the R6 intake valve will start to move (open). 3. Loosen locknut (6) of adjustment screw (6) of Ri cylinder, insert the feeler gauge A corresponding to the specified clearance between crosshead (4) and rocker arm (3), and adjust the clearance with the adjustment screw until the thickness gauge can slide lightly. Valve clearance (When engine is cold) 4, Tighten locknut in this position, secure adjustment screw. G>w=1 Locknut: 68.8 2 6.9 Nm (6 + 0.6 kgm) Unit:_mm Intake valve Exhaust valve 56103024) 6215F0001 a \ ferv201068 0.43 0.80 5. Follow the same procedure to align the line with the pointer and adjust the valve clearance of each cylinder according to the firing order. * Firing order: R1—L1— R5— L5— R3—L3 — RG —L6— R2—L2—R4—L4 * The lines and marks shown in the diagram are on the outside circumference of the damper. 12-002 ® 621501621501 MEASURING COMPRESSION PRESSURE Method of measuring compression pressure AX When measuring the compression pressure, be careful not to touch the exhaust manifold or muffler, or to get caught in rotating parts. * Warm up the engine before measuring the compression pressure. (Oil temperature 40 — 60°C) 1. Adjust vaive clearance. % For details, see ADJUSTING VALVE CLEARANCE, 2. Remove the nozzle holder assembly from the cylinder to be measured. 3, Install adapter Ar in the mount of the nozzle holder of cylinder to be measured, then secure with retainer (2). ==) Mounting bolt: 66.2 + 7.4 Nm {6.75 = 0.75 kgm) 4, Connect compression gauge A to the adapter. Crank the engine with the starting motor and measure the compression pressure. Ai ff the fuel contro! lever is not placed in the NO INJECTION position, fuel will spurt out. * Measure the compression pressure at the point where the gauge indicator remains steady, * If the adapter mount is coated with a small amount of oil, it will prevent leakage. * For details of the standard values for compression pressure, see STANDARD VALUE TABLE FOR ENGINE RELATED PARTS. 56109025 56109027 12-003 ®MEASURING BLOW-BY Method of measuring blow-by AX When measuring the blow-by, be careful not to touch the exhaust manifold or muffler, or ‘to get caught in rotating parts. + When measuring the blow-by, warm the engine up thoroughly (water temp.: 70°C), then stop the engine 1) Install the adapter and tool of the blow-by checker to the tip of breather tube (1) of the bank on one side, 2) Install the adapter, tool, hose, and gauge of the blow-by checker to the tip of breather tube (2) of the bank on one side. 3) Run the engine at rated output and measure the pressure indicated by the gauge. * When measuring with the engine mounted on the machine, carry out full stall operation, and read the pressure indicated by the gauge. % If it is impossible to check at rated output or stall speed, measure at high idling. In this case, the blow-by value will be about 80% of the value at rated output. * Blow-by varies greatly according to the condition of the engine. Therefore, if the blow- by value is considered abnormal, check for problems connected with defective blow-by, such as excessive oil consumption, defective exhaust gas color, and prematurely dirty or deteriorated oil 12.004 ® .215F0002| 621501621501 TESTING AND ADJUSTMENT OF FUEL INJECTION TIMING (WITH ZEXEL MECHANICAL GOVERNOR) Test and adjust the fuel injection timing of the fuel injection pump as follows. + When assembling to the same engine without repairing the fuel injection pump, or when replacing with a new fuel injection pump, adjust by aligning the match marks. + When replacing with a disassembled and repaired fuel injection pump, adjust using the delivery valve method, 2 Ifthe delivery valve method is used, the copper gasket and O-ring for the delivery valve must be replaced with new parts, so have new parts available when using this method. If the delivery valve method is used, there is danger of dust getting in from outside, so use this method only if there are no match mark lines a and b. In all other cases use the match mark method. + Testing and adjustment by aligning match marks 1. Set with the right No. 1 cylinder at the TOP position, then rotate the crankshaft 35 - 40° in the opposite direction. 2. Rotate the crankshaft slowly in the normal direc tion, and align the injection timing line on damper (1) with pointer (2) 3. Check that line a on the injection pump is aligned, with line b on the coupling. If No. 6 eylinder is at the TOP position, line may be on the opposite side, so rotate the crankshaft one turn and align the match marks prop- eriy at the No. 1 cylinder TOP position. If the lines are not aligned, loosen bolt (3) and move the coupling to align the lines, then tighten the bolt. ==) Coupling bolt: 88.3 + 4.9 Nm (9 = 0.5 kgm) 86103028 12-005 ©1 Testing and adjusting with delivery valve method Disconnect fuel injection pipe (4) of right No. 1 cylinder. * Before disconnecting the pipe, wipe off all the fuel at the top of the fuel injection pump. to prevent dust from entering. Remove delivery valve holder (5). Remove spring (6) and delivery valve (7) from delivery valve holder (5), then assemble delivery valve holder (5) again. * When doing this, assemble the same O-ring and copper gasket that were removed. (Re- place with new parts after adjusting.) Set with the right No. 1 cylinder at the TOP position, then rotate the crankshaft 35 — 40° in ‘the opposite direction. Set the fuel control lever at the low idling posi tion (FREE condition), then operate the priming pump and rotate the crankshaft slowly in the normal direction. Check the point where the fuel stops flowing from the delivery valve holder. Check that the fuel injection timing line on the vibration damper and the pointer are aligned at the point where the fuel stops flowing. + BEYOND injection timing line: iming RETARDED + BEFORE injection timing line: Timing ADVANCED If the results of the test show that the fuel injection timing is incorrect, adjust the fuel injection timing as follows. 1) Set with the right No. 1 cylinder at the TOP position, then rotate the crankshaft 35 ~ 40° in the opposite direction. 2) Rotate the crankshaft slowly in the normal direction, and align the injection timing line on damper (1) and pointer (2) correctly. 3) Loosen bolt (3) in the oblong hole of the injection pump mounting flange, operate the priming pump, and turn the flange at the pump end a little at a time. Stop at the point where fuel stops flowing from the delivery valve holder. 12-006 ® a20F302A, 621501621601 4) Tighten the bolt in the oblong hole of the injection pump mounting flange. 4 Check the injection timing again to confirm that the injection timing is correctly adjusted. 5) Align with line a on the fuel injection pump, then make line b on the coupling. + Test and adjust the injection timing for the left bank injection pump in the same way as for the right bank injection pump given above. ‘* After adjusting, remove the delivery valve holder, assemble the delivery valve and spring, then install the delivery valve holder again. * Always replace the copper gasket and O- ring of the delivery valve with new parts. If the old parts are used, they may cause fuel leakage. Be careful not to mistake the mounting position of the copper gasket. S35 Order for tightening delivery valve holder Unit: Nm (kgm) ist stop 127.5 — 197.3 (13 - 14) andstep | Return to. 0 ard step | 127.8 - 197.3(13- 14) ____ ath step Return to 0 Sth step 127.5 ~ 137.3(13 ~ 14) Delivery vave holder Spring I petivery vate ql copper gasket qo ‘Tze00013 Be careful to assemble the copper gasket in the correct mounting position. 12-006-1 ®621501 TESTING AND ADJUSTMENT OF FUEL INJECTION TIMING (WITH ZEXEL ELECTRONICAL GOVERNOR) (DCAB00SPK) Test and adjust the fuel injection timing of the fuel injection pump as follows. + When assembling to the same engine without repairing the fuel injection pump, or when replacing with a new fuel injection pump, adjust by aligning the match marks. + When replacing a disassembled and repaired fuel injection pump, adjust using the delivery valve method. Ifthe delivery valve method is used, the copper gasket and O-ring for the delivery valve must be replaced with new parts, so have new parts available when using this method. Ifthe delivery vaive method is used, there is danger of dust getting in trom outside, so use this method only if there are no match mark lines a and b. In all other cases use the match mark method. + Testing and adjustment by aligning match marks 1. Set with the right No. 1 cylinder at the TOP. position, then rotate the crankshaft 35 ~ 40° in the opposite direction. 2. Rotate the crankshaft slowly in the normal direction, and align the injection timing line on damper (1) with pointer (2). 3. Check that line a on the injection pump is aligned with line b on the coupling. If No. 6 cylinder is at the TOP position, line b may be on the opposite side, so rotate the crankshaft one turn and align the match marks prop- erly at the No. 1 cylinder TOP position. %* In the case where the notched lines are not aligned, loosen bolts (3-1) and (3-2), align notched lines by displacing the oval hole in coupling (3-3) and then tighten the bolts. G2] Coupling bolts (3-1), (3-2): 88.3 + 4,9 Nm (9 = 0.5 kgm) alipoe “a aw) 56103024 34, SS “| . RS ££56103028-1| 12-006-3 @2 Testing and adjusting with delivery vatve method Disconnect fuel injection pipe (4) of right No. 1 cylinder. * Before disconnecting the pipe, wipe off all the fuel at the top of the fuel injection pump. to prevent dust from entering. Remove delivery valve holder (5). Remove spring (6) and delivery vaive (7) from delivery valve holder (5), then assemble delivery valve holder (5) again. %* When doing this, assemble the same O-ring and copper gasket that were removed. (Re- place with new parts after adjusting.) Set with the right No. 1 cylinder at the TOP position, then rotate the crankshaft 35 ~ 40° in the opposite direction. Set the fuel control lever at the low idling position (FREE condition), then operate the priming pump and rotate the crankshaft slowly in the normal direction. Check the point where the fuel stops flowing from the delivery valve holder. Check that the fuel injection timing line on the vibration damper and the pointer are aligned at the point where the fuel stops flowing. + BEYOND injection timing line: Timing RETARDED % BEFORE injection timing lin Timing ADVANCED If the results of the test show that the fuel injec- ion timing is incorrect, adjust the fuel injec iming as follows. 1) Set with the right No. 1 cylinder at the TOP position, then rotate the crankshaft 35 ~ 40° in the opposite direction. 2) Rotate the crankshaft slowly in the normal direction, and align the injection timing line ‘on damper (1) and pointer (2) correctly. }osen bolt (3) in the oblong hole of the jection pump mounting flange, operate the priming pump, and turn the flange at the Pump end a little at a time. Stop at the point where fuel stops flowing from the delivery valve holder. 3) 12-006-4 @ 429F3020, 621501621501 4) Tighten the bolt in the oblong hole of the jection pump mounting flange. + Check the injection timing again to confirm that the injection timing is correctly adjusted. 5) Align with line a on the fuel injection pump, then make line b on the coupling + Test and adjust the injection timing for the left bank injection pump in the same way as for the right bank injection pump given above. * After adjusting, remove the delivery valve holder, assemble the delivery valve and spring, then install the delivery valve holder again. + Always replace the copper gasket and O- ring of the delivery valve with new parts. If the old parts are used, they may cause fuel leakage. Be careful not to mistake the mounting position of the copper gasket G32) Order for tightening delivery valve holder Unit: Nm (kgm) Ast step 127.5 ~ 137.3 (13 - 14) 2nd step Return to 0 3rd step 127.5 - 137.3 (13 - 14) aih step | _-Return to0 Sth step, 127.6 ~ 137.3 (13 - 14) Spring —— Delivery valve Copper gasket q ‘Tze00013 Be careful to assemble the copper gasket in the correct mounting position. 12-006-5 @TESTING AND ADJUSTMENT OF FUEL INJECTION TIMING (WITH KOMATSU ELECTRONICAL GOVERNOR) Test and adjust the fuel injection timing of the injection pump as follows, + When assembling to the same engine without repairing the fuel injection pump, or when replacing with a new fuel injection pump, adjust by aligning the match marks. + When replacing with a disassembled and repaired injection pump, adjust using the delivery valve method. + Ifthe delivery valve method is used, the copper gasket and O-ring for the delivery valve must be replaced with new parts, so have new parts available when using this method. Ifthe delivery valve method is used, there is. danger of dust getting in from outside, so Th use this method only if there are no match [| \\ \| mark lines a and b, In all other cases use the match mark method. A 1. Set with the right No. 1 cylinder at the TOP position, then rotate the crankshaft 35 - 40° in | the opposite direction. | + Testing and adjustment by aligning match marks / \ J rection, and align the injection timing line on 2. Rotate the crankshaft slowly in the normal di- | 1 damper (1) with pointer (2). 3. Cheok that line a on the injection pump is aligned With line b on the coupling. If No. 6 cylinder is at the TOP position, line b may be on the opposite side, so rotate the crankshaft one turn and align the match marks prop- erly at the No. 1 cylinder TOP position. If the lines are not aligned, loosen bolt (3) and move the coupling to align the lines, then tighten the bolt. 2x Coupling bolt: 103.0 « 4.9 Nm (10.5 = 0.5 kgm) 12-006-6 @ 621501621501 Testing and adjusting with delivery valve method Disconnect fuel injection pipe (4) of right No. 1 cylinder. + Before disconnecting the pipe, wipe off all the fuel at the top of the fuel injection pump to prevent dust from entering. Remove delivery valve holder (6). Remove spring (6) and detivery vaive (7) from delivery valve holder (5), then assemble deliv- ‘ery vaive holder (5) again. * When doing this, assemble the same O-ring and copper gasket that were removed. (Re- piace with new parts after adjusting.) Set the fuel control lever at the FULL position, Remove rack stopper bolt (8), then tighten rack pusher bolt @ to move the rack. Tighten the rack pusher bolt until it contacts the rack piston, then tighten it a further 8 turns. % Rack pusher bolt part number: 01016-30850 Set with the right No. 1 cylinder at the TOP position, then rotate the crankshaft 35 - 40° in the opposite direction. Operate the priming pump and rotate the crankshaft slowly in the normal direction. Check the point where the fuel stops flowing from the delivery valve holder. Check that the fuel injection timing line on the vibration damper and the pointer are aligned at the point where the fuel stops flowing. BEYOND injection timing line: Timing RETARDED BEFORE injection timing line: Timing ADVANCED 's61F0990 Finn / wt if ‘Lock TzE00014 12-006-7 @If the results of the test show that the fuel injection timing is incorrect, adjust the fuel injection timing as follows. 1) Set with the right No. 1 cylinder at the TOP position, then rotate the crankshaft 35 ~ 40° in the opposite direction. 2) Rotate the crankshaft slowly in the normal direction, and align the injection timing line ‘on damper (1) and pointer (2) correctly. 3) Loosen bolt (3) in the oblong hole of the injection pump mounting flange, operate the priming pump, and turn the flange at the pump end a little at a time, Stop at the point where fuel stops flowing from the delivery valve holder. 4) Tighten the bolt in the oblong hole of the injection pump mounting flange, Check the injection timing again to confirm that the injection timing is correctly adjusted. 5) Align with line a on the fuel injection pump, then make line b on the coupling. * After adjusting, remove the delivery valve holder, assemble the delivery valve and spring, then install the delivery valve holder agai * Always replace the copper gasket and O- ring of the delivery valve with new parts. If the old parts are used, they may cause fuel leakage. Be careful not to mistake the mounting position of the copper gasket. Replace rack pusher bolt @ and rack stopper bolt (8). (If they are not replaced, there is danger that the engine may overrun.) Gwe) Order for tightening delivery valve holder Delivery valve holder Copper gasket ~ vy T2E00016 Unit: Nm (kgm) 1st step 137.3 - 156.9 (14 - 16) 2nd step Return to 0 3rd step 137.3 - 156.9 (14 - 16) 4th step Return to 0 a 5th step 137.3 - 156.9 (14 - 16) 12-006-8 @® Be careful to assembie the copper gasket in the correct mounting position (below the seat). 621501621501 ADJUSTING INJECTION PUMP GOVERNOR LINK (With mechanical governor) © If there is lack of power or excessive power from one bank, and there is a difference in the exhaust color due to an imbalance in the amount of fuel injected in the left and right banks, adjust the governor link. * If the adjustment is carried out on a test bench, use the rated point, if the adjustment is carried out with the engine mounted on the machine, use the stall point. Adjust with the adjustment screw on the left bank side so that the exhaust gas temperature from the left and right banks is within the following standard. © For D475A-2, WAB00-2 Adjust so that the exhaust temperature of the right bank is 10° — 30°C [50° — 86°F] lower than the exhaust temperature of the left bank. (To make the exhaust color from the two muffier pipes the same level.) © For HD785-3, HV700-1 Adjust so that the exhaust temperature for the left and right banks is the same (+ 10°C {+ 50°F). Loosen locknut (1). 2, Measure the exhaust temperature at the position shown in the diagram on the right, and adjust with adjustment screw (2) so that the temperature of the left and right banks is the standard temperature, then tighten locknut (1). ‘* If the adjustment screw is turned in direction A, the rod will become longer: the exhaust temperature of the left bank (with governor} will go down, and the exhaust temperature of the right bank (without gover- nor) will go up. © If the adjustment screw is turned in direction B, the rod will become shorter: the exhaust temperature of the left bank will go up, and the exhaust temperature of the right bank will go down. * After adjusting with the adjustment ‘screw, it will take 5 — 10 seconds for the exhaust temperature to change, so adjust gradually. DA75A-2, WABOO-2 Right bank measurement plug HO785-3, HV700-1, HV700-2 Left Bank measurement plug 152150008) exveron7 12-007 ®y 2 3) If the governor rod is replaced, adjust the governor link as follows. Set the control rack to the STOP position. i) Left bank (with governor) Push in rack (1) fully. ii) Right bank (without governor) Pull out rack (2) fully. The direction to reduce the fuel is ent for the left and right sides: For the LEFT bank move to the REAR For the RIGHT bank move to the FRONT In the condition in Step 1) connect gover- nor rods (3) and (4) of both banks. Follow the procedure in the previous Steps 1 and 2, and adjust with the adjustment screw so that the temperature of the left and right banks is the standard temperature. If the injection pump has been replaced, connect the governor link, and check that there is no variation in the exhaust color of the left and right banks, If there is any variation, measure the exhaust temperature of the left and right banks. Wf the temperature of the left and right banks is not within the standard temperature, follow the procedure in the previous Steps 1 and 2, and adjust with the adjustment screw so that the temperature of the left and right banks is the standard temperature. 12.008-2 @ Left bank x1st 0008 218F0011 621501621501 PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE (Applicable for models using engine stop motor) 1. 2 Stop the engine. Install ball joints to the cable of the engine stop motor, then install this temporarily to the stop lever of the fuel injection pump. Pull the stop lever of the injection pump by hand to the NO INJECTION position, then temporarily install the stop motor cable to the bracket. When doing put the stop lever in contact with the stopper at the engine stop side, and temporarily assemble the cable to the bracket with the locknut. * The engine stop motor is delivered with the cable pulled (engine stop position). * When the lever is free, the stop lever of the fuel injection pump is at the RUN position. (Pulled to the RUN position by a spring). When installing the stop motor (engine stop), adjust to give a clearance of 1 - 2 mm between the stop lever of the fuel injection pump and the stopper at the STOP side. Adjustment is carried out using the nut holding the cable to the bracket. Carry out fine adjustment by adjusting the amount the ball joint is screwed in. Tighten all nuts and bolts, Turn the engine starting switch ON-OFF repeatedly, and check that the stop motor cable moves smoothly, then check the following points ag 1) Check visually that when the engine is running there is slack in the engine stop motor cable, and that the stop lever of the injection pump is fully re- turned to the RUN position. 2) Check again that there is a clearance of 1 - 2 mm between the stop lever and stopper on the STOP position when the engine is stopped. + There are limit switches built into the stop motor at both sides of the cable stroke. + Engine stop motor stroke: 35 mm Fuel injection pump stop lever stroke: 30mm % There is slack in the engine stop motor cable when the engine is running, and it is kept at the RUN position by the action of a spring (this is often built into the fuel injection pump). + There is a loose spring inside the engine stop motor, and this absorbs the tolerance in the stop motor when the engine is stopped. However, when this is absorbed by the stop motor loose spring, pressure is applied to the fuel injection pump side, so this is impossible on some models. On such models, if the clearance between the stop lever and the STOP stopper when the engine is stopped is 0, there is @ risk that problems will occur with the injection pump, + Problems caused by defective adjustment of the engine stop motor cable If there is excessive clearance between the STOP stopper and the stop lever when the engine stop motor cable is pulled: Engine does not stop If there is excessive clearance between the RUN stopper and the stop lever when free: Lack of engine power caused by drop in amount of fuel injection. 12-009 ®METHOD FOR INSTALLING (ADJUSTMENT) OF ENGINE SPEED SENSOR @ Observe the instructions given below at the time of installing of the engine speed sensor (after it was dismounted). 1. Turn the crankshaft in the normal direction and match the position of speed pickup pin (1), which is driven into the external periphery of the flywheel. This pin comes to the position of the speed sensor mounting hole when the L1 oylinder is located at the top position. (There are six pins.) 2. Turn in speed sensor (2) in this position. After it made contact with pin (1) in the flywheel and then back it off by two turns. %* Clearance a at this time: 2mm 3, Tighten lock nut (3). Gram) Lock nut: 49.0 + 4.9 Nm (6 = 0.5 kgm) * Assure that smooth cranking is made on termination of adjustment, 12-010 ® Speed sensor mounting hole 621601621501 ADJUSTING FUEL INJECTION PRESSURE . Remove retaining cap (8). Confirm thickness of adjustment shim (3). Insert correct shim (3) in response to the adjustment value of injection pressure. Tighten retaining cap (8), then confirm the fuel injection pressure, using nozzle tester. Gone] Retaining cap: 83.4 = 4.9 Nm (8.5 + 0.5 kgm) % Fuel injection pressure: (D475A-2, WA800-2, HV700-1, HV700-2) 24.5132 MPa (250 +! kg/cm?) (HD785-3, HD986-3) 27.4} 43 MPa (280 2 kglcm?) Adjustment value per shim thickness of 0.025 mm: 0.34 MPa (3.5 ko/em’) * Prepared shims: 0.5 to 1.975 mm {at intervals of 0.025 mm) Refer to the parts book for part numbers of the prepared shims. == ; oa renzo DATA FOR INJECTION PRESSURE ADJUSTMENT SHIMS THickness] part o, [TICKS] part No. 0.50 | 150530-4000 | 0,525 | 150530-4100 55 | 160590-«200 | 0.575 | 150500-4900 0.60 1505304400 | 0.625 150530-4500 0.65 150530-4600 | 0.675 50530-4700 0.70 150530-4800 | 0.725 150530-4900 075 | 160530-s000 | 0.775 | 150580-5100 0.80 10530-5200 0,825 | 150530-5300 0.85 150530-5400 | 0.875 | 150530-5500 0.90 150530-5600 | 0.925 | 150530-5700 0.95 150530-5800 | 0.975 | 150530-5900 1.00 150530-6000 | 1.025 | 150530-6100 1.05 10530-6200, 1.075 -| 150530-6300 ‘19 _| 150s20-6400 | 1.125 | 150590-6500 1.15 | 10530-6600 | 1.175 | 150530-6700 1.20. | 180530-6900 | 1.225 | 150530-6900 L t + 4 1.95 | 150530-9800 | 1.975 | 10530-9900. 12-010-1FUEL INJECTION PUMP CALIBRATION DATA Engine model [Pump assembly No.| Engine serial No. | Applicable machine | Page 6215-71-1132 WA80O-2 (Left bank) | _12-010-5 6215-71-1142 WA800-2 (Right bank) | _12-010-6 6215-71-1172 DA75A2 (Left bank) 12-0103 6215-71-1181 DA75A-2 (Right bank) = 6215-71-1112 HD785-3 (Left bank) 2001 and up ‘ ! 12.0104 6215-71-1113 HD785-3 (Right bank) 6580.00. HD786-3 (Left bank) 16553-00-1110 HD985-3 (Left bank) savior | HD765-3 (Right bank) 6883-00-1210 H0986-3 (Right bank) 6215-71-1138 WAB00-2 (Left bank) | 12-0105 6215-71-1142 WA800-2 (Right bank) | 12-010-6 5-71-1612 . ez HV700-1 (Left bank) 12.0107 6215-71-1519 HV700-2 (Left bank) a1 HV700-1 (Right banio _ 8215-71-1822 HV700-2 (Right bank) DCABOOSPK (Loft bank) | ag 6215-71-1240 DCABOOSPK (Right bank) is needed. : The fuel injection pump marked * has an electronical governor, so no adjustment of the governor 621501621501 Pump Assembly Number Applicable Machine Applicable Engine 6215-71-1172 (10682-4760) (Left bank) Moder Serial No Moder Serial No (_): Manutacturer’s part No. DATEA? Sataviaon injection | Pump Pump Type | Manufacturer ZEXEL ree? | ose KK) l Injection Timing Engine Specification Rotating direction | Clockwise viewed from drive end] [Rated horsepower ew/tHPyrom] 874 (7702000 Injection order 7—5—3-6-2—4 Maximum torqueiWm kami] 2389 (46/1400 igh idling (rom 2100 2200 Injection interval 60° + 30" Low iaing (rom) 570 ~ 660 Plunger prestroke (mim) 35 +005 Pump tester capacity CEI ae ag mm 150 for Service standard Motor 75 KW Calibration Standard Conditions Service standard Manufacturer standard Service standard | ozzle part no. (10570-0050) 6212-11-3220 (05015-6720) using calibration | Nozzle holder part no. (105780-2080) 6212-11-3211 (15041-7120), BBS tenginy rr! 6 x 3 x 600 6X 22X 725 Testo ‘ASTM D976 No.2 diesel fuel or equivalent. Oil temperature ter 0-45 using factory t28t) orze opening presaredPatigen’ 3721176) 265 (250) Feorreteronce) _[Transar pun presurlPaen 0.16 (18) 0.16 15) Injection volume Rock | Pump | Service standard (cc/ 10st) [Manufacturer standard (cc/ 100s point | Position) speed Magnan Mr ‘rrm)"| (tom |pasis] Allowance | MRSRE"|sasis| Allowance] pea ack eylinder eyinder + Rack positions Bro are the ret-|Basiepoint| 13.1 | 1000 | 29.6 | F8hov.. | 10.888 | 23.0 | Each ev! erence volume when adjusting, [e188 | 760_[ — fe —_|Reaie the injection vol- |—~¢——T-asegs | 300 | 10 |e oas-1as | sais | 29 Te -Marks aro aver! —p We Se ‘age volumes. E be fe Governor performance (300 — 1000 rpm) Boost compensator performance (600 rpm) 20.0" MOT] ack imi: 149° ‘woneae 4012) / fost compen stroke rho ooo 14. % 7” = § 5 2B ns g é § e vei mess Boost proeure (mH) \ tee mon pas 0 an mie - Ure @ :At boot! pressure Omg oo aay, es Mati subapceg st Pump speed (rom) $2 andi a sring et SeBH482401 12-010-3 ®@Pump Assembly Number Applicable Machine ‘Applicable Engine 6216-71-1112 (106681-4026) (Left bank) — 6215-71-1113 (16681-4110) (Right bank) Mode! Serial No. Model Serial No. (_): Manufacturer's part No. HD785-3 2001 andup | SA12V140-1 | 10036 and up Injection | Pump Pump Type_| Manufacturer EXEL PEP (OWSEL Ki Injection Timing Engine specification Rotating direction | Clockwise viewed from drive end Rated horsopower iW (HPVrpm| 753 (1010972100 Injection order_ 1—5—3—6—2—4 Maximum torqua Nm kgmirpm)| 4168 (4251500 12-010-4 @ High iting (om) 2400 2500 Injection interval 60° 490° Low ting pm os — 695 unger preva im) 355 005 = ump tester capacity . TEE aa 0 160 furprememessty | Motor 75 Kw Calibration Standard Conditions Service standard Manufacturer standard + Serie sanded ese pana T0s7a0-050) SHE TTR ONTE.SOT Using calibration | Nozle holder part no (905780-2090) 6212-11-21 (106061-7120) (Eee None | lesion pipe @ 8x 4x 1000 6x22x725 Wome, Nowe | (Spx yBrensty) (mr xax x22x tonsil Testo [ASTM D975 No.2 desl uel or guivatent “Mandard is data | Olltemperature rc) Ba Sshatectory tes | ous css aia waar Fra) {Porteferonce) _ [Tarte pap pean 216 (18) 216 (18) Injection volume ack | pum [Service standard icc 100s) [Manfecturer standard (oc 100 . ck_| Pump Rack | position| speed Masini Nacinam {earn "| pm | Basis| Allowance Basis| Allowance {erates a Sing «Rack positions ach petezito Jesse pone 162 | soso [aon RSE we aH Sree velutne z semen agustng Be | 300 | 20 pe 195-215 20 ieineetor | —G—} age | gen" [ane eae] a Marke ave aver! > te ie metals e be be ‘Governor performance (300 — 1050 mpm) Boost compensator performance ( 600 rem) Race int 7 x het at = ¥e}———— crmettk | / aie Soper ste i a i & % one | zone i owe aa £ lg oem pes ti 2 a4 ‘Automatic timer performance a 74 28405) : imuenvlonmest 3 i i \ 3 i i ‘ Eason —y 0700 70a | 100 Sa LZ). BP ee gi 4e——b Perot ion)” un among psn SEBH 4807.01 621501621501 Pump Assembly Number (6218-71-1133 (108682-4444) (Left bank} Applicable Machine ‘Applicable Engine Model Serial No, Model Serial No. (_}: Manufacturer's part No. ‘wag0o-2 SATIVA ' Injection | Pump. ! Pump Type _| Manufacturer EXEL Peer | (pest Kuch Engine specification Rotating direction _| Clockwise viewed from drive end | [Rated horsepower kw (HPtpm] 680 (780)/2000 injection order 7 pngn6nan4 Maximum torque iN kgeirpm) 3727 (980171400 High idling om) 2200-2200 Injection interval or 2 30 Low ialing rom) 650-700 Plunger pre-suoke (mm) ; Loar rnp tester capacity OEE aE 150 for Service standard Motor 7.5 KW Calibration Standard Conditions Service standard Manufacturer standard \ | Seq standard oa prtaa (705780. 6050) S16 143220 (T0BNTE BT) using calibration | Nozae holder part no. (105780-2090) 6212-11-3211 (10504-7120) (aes Pe any nm) 8x 4x 1000, 6x22%725 tion ipe) Testo ‘ASTM D975 No. 2 diesel fuel or equivalent Manufacture [oi womperature wo a-07 using lectory test none neing serie T7275) 248 (250) Forreterencey | arse puro nessueMFaigion®y i) O10 116) Injection volume on |e Service standard (co/ 100 st) [Manufacturer standard (c/ 100 st) ack | Pump “ “ poim | Postion] speed vorance Seance” imm) | (rpm) | Bosis| Allowance |Setwesn | Basis) Allowance | Sonwaen evindsr eyinder + Rack postions Each oyl Each oyl Sreaeshe rot [Basic point) 138 | 1000 | 3205 S85" 25 | #08615] 207 ‘when adusting 8 15.0 | 700 [S465 [a s425-9505| — | 304 ie theinjecion vol. |-—e—Tsr, Taps | 20 pe 185-215 [F030 | 20 be + Marks + are aver| 0 ie be dpewolumos. | — * E ie ik ‘Governor performance ( 325 — 1000 rpm) Boost compensator performance | 600 rpm} 2 "4 / 06584-2013) /;Boostcompenastr sake c 10 pe i i 4 : g tos} £ no x 4 a é so z a SI ° rg ea Boost pressure (mig) rn RTE Lino © :At Boos pressure 360 mnt or more oa TE IGS NG cartoon ene Omg = spd rom ele sub apring at "2 Lande aub prog et ‘SEBH4968-01 12-010-5 @Pump Assembly Number 6215-71-1142 (106684-4013) (Right bank! Applicable Machine Applicable Engine Model Serial No. Model Serial No. {_} Manutacturer's port No. wae0o-2 ‘SA12V140-1 injection | Bump Pump Type | Manufacturer ZEXEL PEP | (wieseL Kit Injection Timing Engine Specification Rotating direction Clockwise viewed from drive end| [Rated horsepower (kW (HP}/rpm) ‘589 (789)/2000 jection order 1—5—3—6—2-—4 [Maximum torque tim kgmiirpmi| 3727 (3801400 igh iting rpm 7200 - 2300 Injection interval 60° + 30° 2 © mr Low iding em 350-700, Plunger pre-stroke (mm) Pump tester capacity r Dalvery vale nna] for Service standard Motor 7.6 KW Calibration Standard Conditions Service standard Manufacturer standard * Service standard. ozzle part no. (105780-0050) 6215-11-3220 (105015-8070) using cabraten Nozze holder part no (105780-2080) 6212-11-3211 (105041-7120) + Manttortare [TREO BPE gun) mm | @ x 4% 1000 6X22%725 forfactoryt6st. FTogt oi "ASTM 0976 No.2 diesel fual ar equivalent Oit temperature re 0-5 Naas opening pressuralPaliger) 172 1178) 245 (250) “Transfer pum presurePalgie 016.(1.6) 0.18. (1.6) Injection volume Service standard (cc/100st)_ | Manufacturer standard (:/100st) Rack {Rack | Pump speed Maximum Maxum boint (mm) (rpm) |Basis| Allowance |vatiance |Basis| Allowance: variance Sie age 621501 weevotume | | Basic point| 13.5 | 1000 |32,05] Each ey! +40.9615| 23,7 | Each oy sehen ousting the 3180 ~ 32.5 | a = jesion volume, THEO] | 700 |3465|# 3425-508 — | 30a e spe voles. Pegg] 925 | 20 [x res-215 [403 | 20/e * __ Pe E * be 12-010-6 SEBH4869 a621501 Pump Assembly Number Applicable Machine ‘Anoicabie Enaine €216.71-1812 (Let bank) “e " ri 6218.71-1813 (Right bank ‘Medel | Serato. | Model | _ Serial No (i Manufacturer's part No. vv700- saravuoa Pbeebtyo0 | Manbracturer v700-2 saiaviao4 ZexeL | r — PE-6P {DIESEL KIKI) Injection Timing Engine specification Rotating ection | Clockwise vowed tom arive end] [Fated hoceponer tv HPvrpm] WHEE inlestion order yea ea iteximum torque Wm gro ; High iain om) ed Injection iverval coe 20 Cow iaing tom) 70 -e00 Planer pre-sce ) 352005 = rp tester copecty Delivery valve mmist) 160 for Service standard Motor 7.5 KW. Paes Sceme Calibration Standard Conditions Service standard Manufacturer standard + Sandee standard Cisne portro. 60-0050) eee sing eal ration | Nozzle holder part no. (10780-2090) 6212-11-3211 (105041-7120) test par Thjection pipe ~ ~ ~ tout Next ‘rm 6x3 x600 8x22x 728 Waste Nexte BSR nam ¢ | Test oi ASTM D975 No. 2 diesel fuel or equivalent Oitempsowe 1 oo | using factory test ‘Nozzle opening pressureiMPaikgicm’)) 17.2 (175) 26.5 (250) Feorreferencer | Tensor pune proserelPaligtery 0.16 1.6) 016-08) Injection volume | Serve standard (co 100 st) | Manufacturer standard cc 10 et rece | Rack | Pump Rack | position | speed vee” tenon” fram” trom) |Basis| Allowance | S208? | asis| Allowance | fuensh Soa? Sarr eReck postions | Each ol techov. BEES ae sasicpom| 123 | so | 901 IE, | soa | ve | seceiutltg 77 [ae | 28 278-305 [a0 | 20 serneaion’&. —2 i eae x we aver fe * — | im Governor performance (825-1060 rpml Boost compensator performance wi 7 ack ite 4992 / Weesseas “tes z soon compete sola E wah 5 : % vos) E aos] i a eo Taco) wm WAS aso \ Line ® : At boost pressure 300 mmHg or more. af Ss (des) Line G4 At boost pressure 0 min ST ala ut epring st ‘Pump speed (rpm) "2 :2nd idle sub spring sot Boost pressure (mmHg) 12-010-7Pump Assembly Number 6016-71-1290 (Let bank ‘Applicable Machine ‘Applicable Engine 66215-71-1240 (Right bank) Modat Serial No. Mode! ‘Serial No. (__): Manufacturer's part No. DCAEDOSPE ‘SAI2V140-1 Injection | Pump Pump Type_| Manufacturer ZExEL PE-GP | reset kik Injection Timing Engine Specification Rotating direction Clockwise viewed from drive end} [Rated horsepower(kwW(HPlirpmi] faire injection order SEs aba me | [Mercmum torque ten grim) — High idling (rom) Injection interval 60° + 30° ow ting om Plunger prestroke (men) = pnger pes 3.8% 0.08 Pump tester capacity ratraction volume (mm/s) 160, for Service standard Calibration Standard Conditions Service standard Manufacturer standard * Service standard [Nozze part no (105780-0050) {6215-11-3220 (105015-8070) uti ea Nozze holder part no. (105780-2090) 6212-17-3212 (T0504T- 7121) Je Mengiscture | njeetion pipe seers efatn (10/0 XO length) ™™) 8x 4x 1000 622% 725 forfactory test. Presto ‘ASTM D875 No 2 diesel fuel or equivalent Oil temperature vo 0-45 Nozzle opening pessureiNPaaen) 72 078) 27.4 (2601 “Tensfer pam pressraNPalile™y 026 8) 0.16 6.6) Injection volume rock |p Service standard (cc/100st) | Manufacturer standard (cc/ 10st) ack "ump ane Rack | position) speed Maximum point /"imm) | (rom) |Basis| Allowance |arsns"|Basis} Allowance + fact positions ein Biot ere thoret- ~ Bre are the re pont 137 Each ov Each ov = Shon jut hel SSSE POM 139 | 90° so [ura | *°° Injection volume Ta J. igigenon volume, “|e | Ja | 400 I 20] 05-35 | +18 se volumes c T D E ‘Note: nla of < > representa the rack sensor output (VI atthe time when the conitol ui is connected, Rack sensor gradient adjust standard Rack sensor output (V) R2=1121mm R2-R1=620.05mm 18 By (approx. 5) Re approx. 19) Rack position {mm) Pe atoonst SeBHag69 621501621501 ADJUSTMENT OF ELECTRONICAL GOVERNOR MADE BY KOMATSU + Execute control of the rack device and pre-stroke il pressure using an XEP checker at the time of testing of a fuel injection pump with electronical governor. Furthermore, make monitoring of the rack position. Functions of XEP checker + To control the rack position and pre-stroke oil pressure by changing the current in the range of, 0-1,0A by means of the control dial on the panel front face. + To take measurement of current and voltage through terminals for measurement of governor, pre-stroke current and rack voltage. Aciooy a SMT memeremneen tt C Ty ~Pre-stroke current Rack voltage| Governor Display eurrent changeover, switch Preparations + Connect the harness of XEP checker (2} to the electronical governor unit (1) of the fuel injection pump before making adjustment of the electronical governor. ' ‘actoov 2 on, Peby id bPREST: B eo ans. 12-010-9 @ADJUSTMENT OF RACK SENSOR 1. Remove rack stopper bolt (1) and set the rack in position “0” (range in whick motion by the slit on the rear side of the control rack occurs). Make adjustment by shim (3) so that dimension A enters the range indicated below. * Dimension A: 8.5 = 0.05 mm 2. Turn in rack adjust bolt (2) and make adjustment by the shim so that the rack voltage enters the range indicated below. * Rack voltage (when rack position is 14 mmi: 2.80 + 0.01V ‘& Shim thickness: 0.1, 0.3, 0.5 mm 3. Remove rack adjust bolt (2), fit rack stopper bolt (1) and check the rack voltage. * Rack voltage: 0.30-0.41V 4. If the rack voltage is outside of the specified range, replace rack sensor (4) and measure the rack voltage once again. 12-010-10 ® 621501621501 CHECK OF GOVERNOR PERFORMANCE Rotate the fuel injection pump at the specified speed 2. Make adjustment by the pre-stroke control dial so that the pre-stroke oil pressure enters the specified range. 3. Make adjustment by the governor control dial so that the rack voltage enters the specified range. Acrooy Dig meter pre-stroke current control dial Governor eurrent contro! dial Pre-troxs Current Rack votage| _Severnor Display | changeover, Sorts ower switch ° Bed] 4, Measure the fuel injection rate and governor current after the pre-stroke oil pressure and rack voltage were adjusted to the specified ranges. * Governor performance measurement standard Fuel injection valiniecton | ack voltage | Governor current een wi (ay | m5e5 | to root 2| s28 | 22-00 %* Replace the solenoid, if the measured value fails to enter the specified range. * The controller is controlled by current and voltage. But conversion is made to "1A/1V* with the EXP checker so as to permit measurement using a voltmeter. 12-010-11 @CHECK OF PRE-STROKE OIL PRESSURE 1. Remove bolts from the fuel injection pump front face, connect joint @ (8 mm, p=1.25) and then connect oil pressure gauge ©. Rotete the fuel injection pump at the specified speed. 3. Make adjustment by the pre-stroke control dial 0 that the pre-stroke current enters the spe fied range. 4. Check the pre-stroke oil pressure at this time. [Measuring Rom Set point spectied Yanga) Fuclinesion | wPreatvake | Governor | re-svoke pomp 3 ‘current. current | oil pressure Com | MAY TAI" |e tkafem 1) 9525 | 07 2005 O_[arisemn2s0a) 2 255 | 08005 0 oss=nuspr=031 Replace the pre-stroke solenoid if the maximum, value of an item with » mark is outside of the specified range. 12-010-12 @ 621501BENCH TEST ) Engine toa: Lubricating oll temperature 12-010-14 ® 621601621501 1. General The method and criteria for testing of a diesel engine for construction machine after overhaul or rehabilitation are described in this section. 2. Test items 1) Engine foad test (rated output and maximum torque) 2) Engine speed test at the time of unloaded maximum speed 3) Engine speed test at the time of unloaded minimum speed % Be sure to record the conditions for measurement and test data in appended "Engine performance test check sheet”. 3. Measuring items ‘Spocification for Accuracy Measuring tem | Unit] Location | Measuring equipment | Spanien for Engine speed wom |rankshate Multachometer 0 2500 e Engin lad (output) a. [Faywnoe! Syaraulic or eect! apsorbed norsopower| + 1% Cooling water temperature | “© _|Wetor manifold Thertistor 0-160 Lubricating ol temperature| “C_|Main galery or oilpan| __Thermistor 0-160 Air intake temperature | “C [Either ight or et bank] Thermistor 0-100 = Thermostectie Exhaust gas temperature: “Cc | Both of right and left | temperature gauge. 0-800 25 eto frp bank isomsctseone” | Exhavet back pressure Turbocharger bine | Lubricating ol presaure fa Maia gar oF Fer rau eter of Blow-by pressure rio | Breather (abt end | Blow-by checker 0 1.000 12-010-15 )Measuring position + Engine oil pressure Remove plug (1), fit an oil pressure gauge and measure the engine oil pressure. Exhaust gas temperature Remove plugs (2) of right and left banks, fit temperature sensors and measure the exhaust gas temperature. 12-010-16 @ 621501621501 Measurement of fuel consumption ratio + Measure the length of time required for lowering of the fuel level from A to B. + Method for calculation of fuel consumption ratio, £2 x 3600 Fuel consumption ratio (g/kWsh(g/HP+h)) Specific gravity of fuel Fuel consumption (cc) within measuring time P » Shaft output (KWIHP)) t = Fuel consumption time (second) + Typical measurement at test bench + Simple measuring method Fuel tank 3 : 5 i & i Toenoine Fuel tank ‘Manufacturer: Ono Sokki | ‘MODEL F208 | frm | S| Weight towmetr ruatiyaeioe fone?” bigtal equipment onalonntl yea — tuottank Fetun i 0 to fiat ijeion bor Fuel injection | puro ] 12-010-17 ®4. Preparations before start of test Fuel and lubricating oil Use fuel and lubricating oil which satisfy the following conditions for testing an engine. 1) Record the types of fuel and lubricating oil. Example: Fuel: Diesel fuel ASTM D975 No.2 Lubricating oil: Engine oil SAE3O-CD 2) Use fuel that conforms to the specification. Furthermore, measure its specific gravity, cetane number and result of fractional distil- lation test in accordance with regulations. 3). Use lubricating oil that conforms to the spect- fication for SAE30-CD oil. Furthermore, measure its dynamic viscosity in accordance with regulations. Connection of engine to dynamometer 1 Place the engine to be tested on the dynamometer stand, and mount a connection plate to the flywheel of the engine. 12-010-18 Flywheel housing Plate Coupling (yea sided Five Dimensions of plate 30 s128ectes = junem™m ‘e2edrited & 3 . ri 0 621501621501 2 Perform centering of the engine in the following manner (when a tigid coupling is used). 1) Place the engine on the engine stand. 2) Align the engine’s crankshaft with the dynamometer’s shaft by making adjustment in updown, right/lett and fore/att directions. Upidown direction: Make adjustment on the dynamometer side. Make adjustment on the engine side. Forelaft direction: Make adjustment on the engine side. 3) Measure stop difference A of the coupling using a thickness gauge. Standard step difference A: max. 0.13mm % Take measurement at two points, i2., a and b. * The outside diameter of both couplings is identical. 4) Measure clearance B between couplings using a thickness gauge. Standard clearance B: 3 = 1 mm * The differences in the maximum values at four places, i.e, a, b, ¢ and d, should be zero. 5) Positively tighten the mounting bolts of the engine stand on termination of adjustment of centering. Righvieft direction: Wiring and piping 1) Connect the engine cooling system piping (Perform air bleed with the blind plug removed from the water pipe.) 2) Connect the engine fuel system piping. Fill the fuel filter with fuel and perform air bleed 3) Connect a bettery power supply (24V-120Ah) to the key switch, starting motor, APS or preheater. ‘Coupling Contering meacuring points LON. LY B Dynamometer tester] ‘ _{sioamometer sie) 12-010-19 @Min, 200 mm Buterfly valve Pressure measuring point 4) Connect the exhaust pipe, with attention paid to the spacing between pipes so that the air intake temperature will not rise because of the heat from the exhaust pipe. Exhaust pressure: 75 mmHg 5) Mount the fuel control lever holding jig. 5. Run-in Checks before starting the engine 1) Check if mounting bolts for engine components and engine mount are positively fas- tened. 2) Check if the tension of V belts for driving the cooling fan, water pump and alternator is suitable. 3) Check the engine oil level. 4). Check if the cooling water supply and return valve are open. 5) Check if dynamometer components are correctly lubricated, 6) Check if the fuel injection timing of the fuel injection pump is suitable. 12-010-20 @ ‘Min, 1800 - 2700 mm reeteca7 621801621501 Procedure for run-in 1) At start of the engine + Crank the engine without fuel injection for pre-lubrication of engine oil. (Perform cranking for about 15 seconds, and assure that the oil pressure rises to 0.05 MPa (0.5 kg/cm?) or higher.) Check items during run-i 1) Assure that the engine oil level is located between L and H marks on the oil level gauge. 2) During engine idling + Assure that no leakage of oil, water or fuel is observed, Assure that the engine oil pressure is 0.2 MPa (2 kg/cm?) or higher. (When the engine oi! temperature is up to 40°C) + Assure that the exhaust gas temperature is equal between right and left banks. Assure that, even if there is a temperature difference between right and left banks, the difference is not larger than 40°C, adjust the governor link. (See section of ADJUSTMENT OF INJEC- TION PUMP GOVERNOR LINK.) 3) While the engine is running Assure that the engine oil pressure is, kept in the range of 0.1 ~ 0.44 MPa (1.0 ~ 4.5 kg/om’). + Assure that the temperature of the cooling water discharged out of the engine is kept in the range of 70 - 95°C. + Assure that no abnormal noise is produced out of engine components. + Assure that no leakage of water, oil, fuel or gas is observed. + Assure that the joint between the dynamometer and the engine is free of looseness and play. 4) After the engine oil pressure has risen to 60°C, remove the cylinder head cover and make the following checks. + Chock for looseness of the fuel supply pipe and check for fuel leakage. + Check if the valve system of the cylinder head is normally lubricated, 6. Running conditions (see Step 1) Maintain the following conditions during run- ig for test, regardless of engine type and engine speed. Air intake temperature: 20 ~ 30°C (should be as close es possible to 25°C) Cooling water temperature: 70 ~ 85°C Lubricating oil temperature: 80 ~ 110°C 12-010-21 ©7. Testing method * Conduct the test in the following sequence ‘on termination of run-in of the engine. Engine load test 1) Set the fuel control lever in the "FULL THROTTLE" position, 2} Gradually increase the dynamometer oad until the engine speed rises to the rated speed. 3] Hold the engine speed at the rated speed, and take measurement of necessary items. 4) Further increase the dynamometer load until the engine speed rises to the speed at which the maximum torque is produced. 5) Hold the engine speed at the rated speed, and take measurement of necessary items, ‘* Take measurement of speed at 100 rpm intervals as @ rule. However, take measurement of the rated speed and the speed at which the maximum torque is produced at 50 rpm intervals before and after them. Unloaded maximum speed test On termination of engine load test, reduce the dynamometer load to zero and then increase the engine speed to the maximum. Measure the engine speed (unloaded maximum speed test) at this time. Unloaded minimum speed test On termination of unloaded maximum speed test of the engine, reduce the dynamometer load to zero and then decrease the engine speed to the minimum. Measure the engine speed (unloaded minimum speed test) at this time. * In the case where adjustment of the fuel injection pump is made during any of the tests stated above, be sure to start the test sequence all over again from the beginning. 12-010-22 © 621501621501 Adjustment of engine output Carry out checks and readjustment in the sequence indicated below if the test result fails to conform to the specification. Step 1 Recheck the running Abnormal conditions. (See section 6) The engine output nes become normal as a Step 2 ‘Adjust the full load stopper result of adjustment. position of the fuel injection pump. (See section &1) The engine output is still abnormal (too low), Stop 3 ‘Check advancement of the Abnormal timing of the auto timer. (See section 8-2i1HD785-3 only] Stap 4 Check the turbocharger. (See section 8:3) Normat Stop 5 Abnormal ‘Check the after cooler. (See ‘section 8-4) ‘output is tl low after making all of the adjustments stated sbove, contact Komatsu distributor. Conduct a re-test under eorrect conditions. Check the exhaust gas temperature. Replace the auto timer. Roplace the turbocharger. Replace the after cooler. 12.010-23, ®8-1. Adjustment of full load stopper of fuel injection pump (See Step 2) Adjust the full load stopper of the fuel injection pump to obtain rated output. %* Turn the full load stopper clockwise. But do not turn it by more than 90°. 8-2.Check advancement of timing of the auto timer. {Soo Step 3) Measure the fuel injection timing at the low idling speed and rated speed using a timing lights. 1) Timing light sensor mounting positions Mount the sensors on right and left No. 1 fuel injection pipes at points close to the fuel injection pump. Remove paint from fuel injection pipes to positively mount sensors to fuel injection pipes. 2) Criteria for judgment and remedy to be taken on occurrence of abnormalities ‘Sensor mounting position (No. 1 fuel injection pine) Full load stopper Standard value Fel ieeton ming Timing advancing angle of | With or without auto timer wasoo-2 | BTDC30+ 7" — Without 0785-3 | BTOC26a TF BTOCZ7 ~31" (et 2.100 rpm) With parsa2 | BTOCa0= 1 = Without Hv7001 | eTOCT8= 1 = Without Hv7002 | BTOCTB= = a Without Remedy | Check the fuel injection timing again Replace the auto timer = 12-010-24 @ 621501621501 -3.Check the turbo charger. (See Step 4) Measure the intake pressure at the turbo charger outlet. * See the table indicated below for the criteria for judgment. % Replace the turbo charger if it is abnormal. 8-4,Check the after cooler. (See Step 5) Measure the intake temperature at the after cooler outlet. See the table indicated below for the criteria for judgment. Criteria for judgment 7 wessuting point reeo1e20 Fight bank Measuring point Measuring condition Intake pressure at turbo Intake pressure at after Model ‘charger outlet ‘cooler outlet At rated output («W\HPI/rpm) (meg) ic WA800-2 ‘587 (8001/2,000 Min. 700 Max. 102 107853, 768 (1,0301/2,100 Min. 1.000 Max. 110 DATEAZ ‘583 (7811/2,000 Min. 720 Max. 100 HV700-1 ‘560 (750)/2,100 Min. 720 Max. 100 HV700-2 645 (865)/2,100 Min, 720 Max. 100 12-010-25 @®Losize (wid) anoge uet JOO opr us, 1wjod enbog tine ‘op Ieauerevnsi) Warne | (wiByun) | (wida) suneseid sursioapny ndino yeus|anbuoh yey] poeds, no | ait Bunesngn| FON Jabiey90q3n | aimerodusai F 1n216 oytoeds jong FON duind wonoefur jon oye} UoNIDe1I09 Ind FON euibug ‘wp wel 5, eM o, Aig einerodwey wooy POW ~aKq parse, Byun Tainsseid oueydsouny woneoyioeds 433HS NOIHO 1831 3ONVINUOdUad ANION] 12-010-26 @621501 HANDLING OF THROTTLE BOX HD785-3(with electronical governor made by Komatsu) General The following articles are required in addition to a usual test bench to conduct a dynamometer test of an engine of electronical governor type. © Throttle box © Engine control box mounted to the vehicle Precautions for handling A At the time of conduct of a test using a throttle box, assure safety of the surroundings and send a sign to start running of the engine. A Always keep monitoring the engine running conditions during the test. If any abnormality oc curs, immediately stop the engine by turning the key switch to the OFF position, (No automatic stopping device is added to the throttle box.) + Connection and disconnection of a battery Connect @ battery after confirming that all the connections have been completed + On termination of the test, immediately turn the key switch to the OFF position and disconnect the battery. * Make connection of connectors positively. + Make positive connection with each equipment. + Make connection with reference made to the connection diagram so as not to allow occurrence of connector connection abnormalities. + Pay attention to dust, oil, water, etc. 1 dust, oil, water, etc., which is attached to a connector, enter connector pins or interior, faulty connection of the connector will result. There- fore, be sure to remove dust, oil, water, etc. before making connection. + Do not allow the throttle box or the engine control box to be exposed to oil, water, etc. * Be careful in the handling. Handle the checker and harnesses with care. 12-010-27 ®SPECIFICATION AND FUNCTIONS 1. Specification Power supply: DC24V (using a battery) Working temperature: ~10 to 50°C Storage temperature: -20 to 60°C Dimensions: 200mm x 120mm x 80mm. Weight: 1.5kg 2. Functions + Measurement of engine speed Measuring range: 0 to 3,000rpm Accuracy: + 10rpm Display: 4-digit digital display + Measurement of rack sensor output voltage Measuring range: 0 to 9.99V Accuracy: = 0.01V Display: 3-digit digital display Indication of abnormality signals + When an abnormality occurs to the right bank, occurrence of a failure to the electrical system of the fight bank is indicated by a lamp. + When an abnormality occurs to the left bank, occurrence of a failure to the electrical system of the left bank is indicated by a lamp. Engine starting + Power is supplied to various equioment by means of the key switch incorporated in the throttle box, and in addition, start-up of the ‘engine is also achieved. Furthermore, a start signal is directed to the engine control box. 12-010-28 ® 3. Connectors to be connected MIC connector made by AMP Japan (13 pins) Signal arrangement Pin No. Signal narne 1 _| Power supply (0c 2avi : een 3 | Abnoumalty in rack eyatem © __ | Abnormality im rack system 5 | Acceleration power supply (6V) 6 _| Acceleration signal 7 | Acceleration (GND) @ [Crack ouput 0 | Rrack ouput 10 | Engine speed sianal 12 __| Starteignal a3 [eno Automobile connector made by YAZAKI SOGYO (4 pins) Signal arrangement Pin No, ‘Signal name 1 __| Power supply (06 24v) 2 [Star sianet a [eno 621501621501 Components Part No. Part name [Quantity | Weight tkg? Remarks —| 799-605-5000 | Throttle box assembly 1 74 [KT - 1 | 799-608-5010 | - Throttle box 1 18 7 - “2 | 799-605-5020 | Harness 1 | 16 _| Connection of equipment 3 | 799-605-5040 |+ Herness 1 ~ 03 | Connection of battery to throttle box 4 | 799-605-5030 |+ Case - 1 4.0 | Case for accommodation 12-010-29 @Method for use 1. Preparations 1) Set the engine to be tested on the engine bench. 2) Prepare a table (of dimensions approx. 1,000mm x 700mm) for placing equipment, 3) Remove the engine control box from the vehicle, from which the engine was dismounted, and place this engine control box on the table. 4) Prepare a battery (DC24V}. 5) 2 battery cables 12-010-30 @ 2, Method for connection of equipment 1) Connect one end of harness (3) to con- Rector on engine side (2), and connect another end of harness (3) to engine control box (5). 2) Connect the remaining connector (black connector) of harness (3) to throttle box 6). 3) Connect one end of harness (7) to starter connector (10) and battery (8). Connect another end of harness (7) to throttle box (6). 4) Connect cable (8) to battery (8). 1. Engine 2, Connector on engine side 3. Harness (799-605-5020) 4, Table (1,000mm x 700mm) 5. Engine control box (565-06-11641, from the main body) 6. Throttle box (799-605-6010) 7. Harness (799-605-5040) 8. Battery 9. Cable (not included in the kit) 10. Starter connector 621501621501 3, Method for testing dynamometer @ Set the pulse setup at 138. ® Turn the throttle dial to the "MIN" position. Set the select switch (rack sensor output voltage display) in the "RIGHT BANK” position. ® Turn the key switch to the "ON" position. ® Assure that both of right and left bank abnormality indicator lamps are out. © Start the engine. ® Assure that both of right and left bank abnormality indicator lamps are out. if any abnormality indicator lamp lights up, abnormality indication is also mace on the engine control box. Inspect the engine control box. (See the section of self-diagnosis indication and contents of abnormalities with engine control box.) @® Assure that the engine speed rises when the throttle dial is turned toward the "MAX: position. pus SETUP oo @ ENGINE REVOLUTION err sank RACK SENSOR OUTPUT Turn the select switch (rack sensor output voltage display) to the "LEFT BANK™ position as required and measure the output voltage. The work thereafter is same as that in the dynamometer test of a unusual mechanical governor. Measure the engine output using a dynamometer. If the engine output is outside of the specified range as a result of replacement of parts such as pistons during engine overhaul, make adjustment in the following manner. + Make adjustment by Q-tone No. on the engine control box so that the engine output enters the specified range. + The contents of Q-tone resistances are shown in Table 1. + Make adjustment of Q-tone resistances with seals detached, + Stamp a new No. on the engine name plate after adjustment of Q- tone resistances, (Erase the old No.) + Attach seals after adjustment of Q- tone resistances. 2... LEFT BANK ABNORMALITY a RIGHT BANK ABNORMALITY Min THROTTLE, Max S) 2® 12-010-31 ©4, Measures to be taken after the test 1) Run the engine at the low idling speed for about 5 minutes. 2) Turn the key switch on the throttle box to the "OFF" position. 3) Disconnect the battery cabies. 4) Disconnect other harnesses. Table 1 Engine controlier Q-tone resistance adjusting range (Model: JF DDS1) 621501 Engine ouput rao based on Crono] Date (hexadecimal methoa) | Date decimal | resistance No.8 os the stondard No, | 9xon0 [method Ratio Ratio (%) Ena apees | 1400 | coo | 1.400 | 2,000 | 1.400 | 2.000 | 1.400 | 2.000 3 | ei ex | 225 | 225 | 1008 | 1008 | 08 | 98 wie D8 os | 27 | 27 | 10s [1089 | 59 | se 3 | ose | att | 217 | 1029 | 1059 | 20 | 59 2 fe 8 os | a7 | 2 | 1089 | 10 | s9 | 20 nfs) ps_| 2 | 21 | 1020 | 1029 | 29 | 28 wo | A ©. os_| 208 | 2 | 1000 | 102 |. oo | 20 2 | 08 eo | 21 | 205 | 1029 | 1000 | 29 | 00 Standard > [8 | @ co co | 25 | 205 | 1000 | 1000 | oo | 00 7/7 7 co | we | 205 | 097 | 1000 | 20 | 00 «| o cr_| 25 | 12 | x000 | asm | oo 5 | 8 7 cr | 19 | 19 | ost | oan | 20 «|. a o7_| wa | 19 | oo | oo: | 60 3 | 3 7 cr | 19 | 13 [097 | oon | 20 z [2 ot er | 193 | 103 [ oom | oon | 30 7/4 BA er | we [193 | oso7 | 098 | -23 oo BA cr | 16 | 123 [0907 | oon | -o3 | 20 12-010-32Loaiza Bum ou senaang young 91 ot YF pAI0UB 89 he ‘vonesppu Ayeuouge seyeU! J080Es IONS OLR J YORI ION, = Teoidchy 2 on = ousey 018 Ba aecaieg | awe sao sou a OH sang nts ow 012-1020 vom noo m0. oa ~8ea-01090 vem mip vie ao sou oH uyeeny tng) vee] c m0 © pa “bu 10 ws ogg pads BuBu8 we W>UsINs2eL HON Oye (ION susan | sounz0Ta | Fed suneu pal us Woe URBM av © vee] wouoso | ou-oo | So, | Sade) aad | suse nite | cova | vbensea Jnore siuieay o> paul iaisbeion | suemsey [cia 8 8 MB 10 wes 909 paods uve we wowsineousBBeyon OF fCN | Aca wyrew DUE UG YRS URS eouveg0 | pods Joyous yum 'y Josues paods ulus Sur doup so yrasp vad Geran | womemsou [913 & 9 louroneB se owes 2 wosehe soouve ‘noe-c2 APoq auneu poe 193 {dias eae sound jo ue oy perp arctinny @ wess9 ‘njen pupases yes Conse, ‘uw indus sosuse yo unos » penbertinny pou ‘tte an aah joey Oy “worst prouajes sousan08 se owes wasks sO5u96 por Ue ‘NOE~2 Apo autDeW poe BL93 UBeMIAG B8EI0A “L | 20UIaNOB J0 wrshs sosuRE yreH que Teneo smies ieuson Aayeunouge jo S910 Jeruowe XO@ TOHLNOD SNIDNA HLM S3LLITVIONEY 40 SLNSLNOO GNY NOILVSIGNI SISONOVIG-413S ® 12-010-34‘dunnd voxpati Ayes “€ nous sosues oe. peDewea "2 vosuoe ype Aimed 146 40 4600 9 ‘uueey 19 @ v93:9 eusey MOIS @ po an | ee ew = use nois @ 221] = meen ero @ p24 ini ee = soxneu eno @ von Tse ons oei-eaasaonentoroneeverrises t] ana nbs Guperconas| ner eA S13 BEI ~GIL93S) vawwwag yayp-LOYs 10 wraxD UEdO “L | Yalan WNAsIO-WOYs JO yNDB!D Ueda = = 29119 90071 =e 0 6 wa] = anyeey nos pny Soe ATER aoe = = suo nso0 0 & SEN ISALO= FY °| aug mo ~ (2-Ciea-@x99 woweeg ange vows oyna uedD) “t ‘©-Oz93 voowey + uu moIs. v2019| ami ‘oeses eg bu tose ee) me eee e139 ~Ge3-GeI3 veewe yoo vous 20 xMoH19 vedo “L | YIN BINasII-UOYS JO yNAP UedO, a) Mo pay reunion _2yonuod yo vone2ypu eww yon Apes Ayjeuouge eq | 2eyor jeu m0 © vee] souge PUD 0401410 N97 Fz #| 0.6 paul Ona veoweg +, Bnon Acne oad 9204 ‘bateas Ane Jomo mire ree yeuouge yo soo: ucusBpnt 20} eID wonsaipur neve rewon, ‘Anuowne jo ewe uuoieks AouuiouRy jewuaive Losizo 12-010-35 @Harness connection diagram ‘ Rene . bank 8 ee Tae arenas, (ee er SR eee 5 UL ee aan het rere He uu 10 JR governor 1 2 oa pte popes Sapa 4] rack sensor (SV) ~ fr er f on Se a ae teins aot ears ieee Thay Cet papeerd (he Pesce rate AU pret steerer eer ae ise oe ie “ ee Te Sees esas Trae aera = eta eae a ——— a Siero ee ao 51 Se ooseutia tess 5 Eee nT oh Ream sa es seers Le ae eee it 47 | Speed A (AND) J 8 TE rack output Epes — 4 a ‘Acceleration 1GNO! At ——S es — 12-010-36 ® 621501Fuel injection pump connector joint (& bank) | F bank repeating connector 621501 516 Bt 2 Gait Governor + 2 SSS. FL Governor SOL 14} 0 sraa10 - St cover 80x 13| © Prestroke SOL” 12) © a © FPre-stroke SOL aj ° Pre-stroke he io} © Solenoid 4 alo e289. = 81-3210 Blo ack sensor 7° e9 d | ° sic- 7 Speed sensor 5 | 0 Bak sansor SiG+ 3 WF Speed sonora 4] 0 545210 GNO 2 = | Rack sensor 3] ° sv jolt Rack sensor 2] ° 5f2 (yolow) WT Rack sensor ilo E16 Sfx 2 (orange) Speed sensor A Spay 8 Sisters! 7961. ee 92-2330 J op Mt srasooors Foal injection pump connector joint _(L benk) |. bank repesting connector Et Six 2 (oie 7 [Governor + Zook ===, EF GovemerSoL 14 | o 385881 3910 = 1 of S—+t 121 Govenorso.13| © ha | WF preavoke Sou yg| © £10 at Preatole sor 1 | © lo \ 30 (O88 10} ° Prestoke . w 0.58 Esionois 2 $3 9} ° 55981-3210, - qelf2 re @ Flack sensor 71° és 08 8 51x 20d) 3 sie Seg He Sheed snr 5 | 0 sis w 3 ‘Sneed sensor 4 | © Rack sonsor ass3.818210 NO 2 rack sensor ° ov 1 Rack sensor 2] 542 (oreen Rock sensor 1° E12 |g Bfx2 brown ‘Speed sonsor 8; = 2 === 796%-82-2300 = row a= ike naness 561-44-61141 12-010-37 @HANDLING OF XEP CHECKER HD785-3 (with electronical governor made by Komatsu) GENERAL ‘An XEP checker is required to conduct a performance test of a fuel injection pump of an engine of electronical governor type using a test bench. Furthermore, an oil tank, oil pump, etc. are r quired besides an XEP checker. 1. Test contents 1) Check of governor command current and of rack sensor output voltage character: istics + Supply command current from this checker to the fuel injection pump, and measure the command current value at the time when the rack sensor output voltage indicates the specified value. 2) Check of variable pre-stroke characteris- ties + Supply pre-stroke command current from this checker to the fuel injection pump, and measure the pre-stroke oil pressure at this time, Precautions for handling * Use power of AC 100V. Make connection of connectors positively. Positively connect the connectors of the harness to the checker and fuel injection pump. Pay attention to dust, oil, water, etc. If dust, oil, water, etc., which is attached to a connector, enter connector pins or interior, faulty connection of the connector will result. Therefore, be sure to remove dust, oil, water, etc. before making connection. Do not allow the checker to be exposed to oil, water, etc. Be careful in the handling. Handle the checker and harnesses with care. 10-38 ® SPECIFICATION AND FUNCTIONS 1. Specification Power supply: AC 100V (50Hz or 60H2) Working temperature range: -10 to 50°C Storage temperature range: ~20 to 60°C Dimensions: 250mm x 210mm x 102mm Weight: 3.9kg 2. Functions 2) Output signal Governor command current: 0 - 1A (vari able) + Pre-stroke command current: able) + Rack sensor power supply: DCSV ifixed) 2) Signal measurement + Measure the governor command current and pre-stroke command current by the potential difference occurring between both ends a resistance for current measurement (12 + 0.5%). + Measure the rack sensor output voltage. 3}, Indication method + Indication is made by a 1/2 digit digital pane! meter. + Governor command current, pre-stroke ‘command current or rack sensor output voltage is indicated as selected with the select switch. = 1A (vari- 621501621501 Components Part No. Part name _|Q'ty] Weight ka) | Remarks — | 799-608-3000 | Chocker Ase'y | 1 39 | KIT 1 | 799-608-3010 | + Checker 1 37 2 | 799-608-3020 | « Harness 1 0.2 | Sennestion of equipment 3 = ‘AC power cable| Connector Pre-stroke command current set dial Indicator Governor command current set cial 12-010-39 ©METHOD FOR USE 1. 2. Method for connection of checker 1), Install the checker near the test bench. As the angle of the handle can be freely changed as shown, set the checker at an arbitrary position. 2) Set the pre-stroke command current set dial ‘and governor command current set dial at "0" positions. Each one of these dials makes ten turns. The dial value increases and the command current value also increases when the dial is turned counterclockwise. When the dial is turned clockwise, it reaches the stopped and the dial value becomes " * Unlock the dial before turning it. (Keep it unlocked until the test terminates.) 3) Connect the connectors of the harness to the checker and fuel injection pume. 4) Connect the power cable to an AC power outlet (AC 100V). Setup of initial values This measurement is taken for self-diagnosis of the checker main unit. 1) Turn ON the checker's power switch button, and assure that the green lamp lights up. 2) Assure that the checker's maximum value ‘as shown below when the select switch. is located at each of the positions shown in the following table. Maximum value (voltage/current) Max. 0.05 Select switch position GOVERNOR PRE-STROKE RACK SENSER 12-010-40 ® ‘Tho angle of the handle gan.be changod whan but tons on both sides are Lock (Locked when pushod, pushed in, downward, snd untocked ‘nen moved upward) 621501621501 3. Check of governor characteristics 1) Set the input shaft speed of the fuel injec tion pump at 325 rpm. 2). Set the select switch in the "RACK SENSOR" position. 3) Set the pre-stroke oil pressure at 0.64 MPa (6.5kg/em?) by turning the pre-stroke command current set dial counterclockwise, 4) Set the checker's indication at 1.00 by turning the governor command current set dial counterclockwise. 5) Assure that the checker's indication is of the value shown in the following table when the select switch is turned to the "GOVERNOR" position. 6) Return the select switch to the "RACK SEN- SOR" position. 7) Change the checker's indication to 2.20 by turning the governor command current set dial counterclockwise. 8) Assure that the checker's indication is of the value shown in the following table when the select switch is turned to the "GOVERNOR" position. ]Seloot wich postion and maximums Pump speed (rom) [Yate RACK SENSER | GOVERNOR 10200 | 0462010 32528 220x001 | 056: 010 9) Turn the pre-stroke command current set dial and governor command current set dial clockwise to *0" positions on termination of setup. 4, Measurement of pre-stroke oil pressure Take measurement of the pre-stroke oil pressure in the following manner upon termination of check of the governor characteristics of section 3 above. 1) Assure that the input shaft speed of the fuel injection pump is 325 rpm. 2) Set the select switch in the “PRE-STROKE" position. 3) Turn the pre-stroke command current set dial counterclockwise, and measure the pre- stroke oil pressure at the time when the checker's indication becomes 0.70 or 0.80. Set the governor command current set dial at the "0" position Rimpapeed | Prestote command | _Preaiake of pressure Wo ial ‘hie gems weses 070 = 005 071 3 009 (72 + 03) . 80 = 0.05 099 = 009.1203) 12-010-41 @4) Turn the pre-stroke command current set dial clockwise to the "0" position on termination of setup. Measures after termination of test 1) Turn OFF the checker’s power switch button and assure that the green lamp goes out. 2) Set the input shaft speed of the fuel injection pump at 325 rpm 3) Disconnect the power cable from the AC power outlet. isconnect connectors of the harness from the checker and fuel injection pump. 4) 12-00-42 621801621601 CHECKING AND ADJUSTING V-BELT TENSION CHECKING AND ADJUSTING FAN BELT ‘TENSION WA800-2, HD785-3, HD985-3 Lid} HV700-1, HV700-2 Uy tk Lat . Adjustment nut 2. Adjustment bolt 1. Bracket |. Tension pulley Pin Yoke . Clearance between yoke and pin pomawne c2isroca |. Tension spring Adjustment nut 3. Washer |. Adjustment bolt 3. Tension pulley . Protrusion of adjustment bolt PRawNo Engine Mode! Engine Serial No. Dimension A WAg00.2 HO7a5-3 HD985-3 110004 and up With clearance at 0, tighten 3 turns SA12v140-1 HV700-1 HV700-2 10001 and up 90 2 1 mm (V-belt turnbuckle type} 12.011 ‘CHECKING AND ADJUSTING ALTERNATOR BELT TENSION 1. Checking alternator belt tension Push belt (4) at mid-point between the alternator and alternator drive pulley with a force of approx. 58.8 N (6 kg) and measure the distance that the belt sags. 2. Adjusting alternator belt tension Turn the position of the locknut of adjustment bolt (1) in the direction to extend belt (3), then adjust so that the deflection is approx. 20 mm when pushed with a finger pressure of 58.8 N (6 kg) at the midpoint of belt (3). After adjusting, tighten lock bolt (2) and the locknut of the adjustment bolt. 12-012 @ ‘Approx. 20 mm: Approx. 58.8 N (6g) Aiternator pulley 61250182 621501621501 PERFORMANCE TEST * Load are given for the case of dynamometer arm length 716 rom. % This list shows the standard on condition that RUN-IN STANDARD the fan is removed. Order Engine model | APeticable trom a machine 7 2 a 7 3 3 Running time] min. | 5 6 5 5 20 10 Engine speed | rpm | 650 1000 1250 1860) 1800 2000 bers6a2 Load Nig | 0 520,163) | 1069 109) | 215s (220) | 3315 1396) | 4050 ca13) Output lewis] 0 39652) | 1001135) | 281 cen | 487 (608) | 608.826) unaing time | min 5 6 5 5 20 70 Engine speed | rom | 650 +000 1250 1850 eo | 2000 was00.2 Loos Niko | 0 520.63). | 1088 1108 | 2158 (220) | 3315 338) | eras (429) output ene)! 0 06a) _| 00 ra) | 251 ;s¢0 | 447 (60a) | 623 1846) Running me | min 5 6 5 5 20 10 Hores.s [Engine speed | rpm | Low lating | 1080 1300 1630 1900 2100 H09853 |Losd Nu | 0 637 (85) | 1278 130) | 2580 (260) | 2828 (290) | S100 520) Output wiHe)| 0 4368.3) | ras 169 | 310,426 | 555.70) | 615 (1092) Running dine | nin 5 16 5 = 20 0 gine speed | rpm | 7 r 1 evraor [Engine speed | ro 50 1000 1300 1600 900 2100 Hv7002 | Looe Nis} 0 520.2) | 1090 1105) | 2089 (213) | 3198 20) | sot9 (368) santo output wine] o 39637 | roras7) | ze ean | 4a7 608) | 570 0751 Fanning time | min. 5 70 0 20 10 5 peasoo rpm | 8002100 | 1950 1400 1650 1800 1800 PK Load Nag | 0 788,80) | 1869 (160) | s128 (320) | 4707 vasor | 6276 (640) Output weer] o 6992) _| 167 7226) | 394 (620) | 548 (064) | 250 (1982) 12-013 ©‘+ The valuas given for the output and torque ara with the fan removed, so they differ from those of the specification + Values are standardized under the following conditions: Alr cleaner installa alternator idling: and alr compressor (if installed) open, Engine mode! | Appice Test em Specie vak Engine speed | Dynamometer 5433 5166 eri eounrysso0 sors) | re0n=s | S489— S286 Fywheo! horeapower sta2 — 5006 ‘ase tooosPynooeors) | 1g00es |e sea) an tated output DoACOOSEK | Maximum torave - - - ing epoo 1568 § 150K) 1568 «5 _ High idling speed 1881 + 5 (60H2) 1881 2 5 Low iting speed 200 + 100 - saravise-s 12-016 @ 621501621601 4 Dynamometors are given for the case of the arm length 716 mm. + Fuel used: ASTM D975 No.1 or No.2 diesel fuel. 4% Lubreation oll used: CLASS-CD SAEID Cooart | abieang of] lobe a uur | Torwe | Fuel consumption |] otis | sabatg3 asi) | etigmy | "Sectzoosy°” | temporstire | temperature | pressure oro ea 5-028 eee | Min. 108 70-05 0-110 026 - 038 139-705 c2s-as9 ws, | Min. 09 70-45 eo—s10 025-299 | ax ean - - - 10-5 co-110 - - - - - 10-85 sa—m10 - - Win. 08 - - - Min. 70 Min 0 in os - 12-016-1 ®621601 TESTING AND ADJUSTING TOOL LIST Nol| Testing and measuring tem | Feult finding tool__| Part No, Romarks Multétachometer 799-203-8000 | Digital reading: 60 ~ 20,000 rpm 1 | Engine speed Tachometer drive | 6125-81-3500 Gear box | srioa14110 2 | Battery 8.6. 4.100 1.300 7 Resins opr ing | Peer nar tte 738001000 ve | Memes anpotaree | gouge NTPC | 790-500-200 | 0 ~ 200%, 0 - o00'e Exhaust temperature Digital temperature gauge] 799-101-6000 | -60 ~ 1,200°C 5 | Lubrication oil pressure 0 ~ 1.0 MPa (0 - 10 kg/ern”) _ 6 | Fuel pressure 0 20 MPa (0 ~ 20 kglem 7 | intake preseure, exhaust pressure) Engine prsure 799-203-2002 0 ~ 1.500 mmHg @ | Biow-by pressure 0 ~ 1,000 mmHe0 9 | Intake resistance | =1,000 - 0 mmo 10 | compression pressure | Compression gauge | 795-502-1208 | 0-69 MPa (0~ 70 kalem#) + Adapter 795-502-1510 11| Biow-by pressure | Blawsby checker Tee BTAPS 0 — 500 mmHsO 12 | Valve clearance Fooler gauge 795-125-1210] 0.43 mm, 0.80 mm 13 | Exnaust gas color Handy smoke checker | 799-201-9000 | Diminess 0° 701 wilt tenders color 1e| Woter and ful content in ol | Engin ait ehecker | 700-201-0000] ProwGee wih Ot and 0-2 water 15| Publ incon rao pray conction | Nozzle tester CommmiasiaY | fo Mem 16| Coolant quality Water quality tester | 799-202-7001| PH, nitrite ion concentration 17 eee eee tig Sesto Radiator cap tester 799-202-9001 | {o~-"ymrem") 18] Radiator blockage (wind speed) | ALOIS oy 799-202-2001| 1~ aonvs 10| engine caning [ cranking Kit 795-610-1000 | Barring device 6215-21-4500 20 | Electrical eieuit Tester Commercial | Currant, Voltage, Resistance 21 | Fuel injection timing "| pack poston stmt bok | 01076-30860 | For engine with electronic governor 22| inspection of sensor and harness | T-branch adaptor kit__| 789-601-7400 3 fnspeation of electronical governor | Governor tester 796-505-2000 [ - 24 | SgBianieat povemor ype engine | Thottle box 799-5055000 | gine” “Ynemometet test of er 125 | Emergency running equipment for | Engine emergency, 729-606 8000 | the tina wien the angio cont tlestronieal governor type engine running equipment foliar fails 12-017 ®TESTING AND ADJUSTING DATA (12) Engine model sAr2v40-t Applicable machine model Dusae wasoo2 Classi] Item Condition, etc Unit | Standard) Permissible | Standard [Permissible High iting speod 2100-2200 | 2100-2200 | za00-2a00 | 2200-2000 g. | Froine speea rm : Low iting speed 600-690 | 600-690 | es0-700 | 650-700 z —|— 5 oc Min, 110 - in, 110 - Necessary ‘om starting speed -20°C with staring sid) Min 190 - Min, 100 = Intake cesetance | Atal epood Jnmiso) Max. 200 65 Max 200 78 Intake pressure ‘Ax rated output rma} tin. 530 - Min. 520 - Exhaust pressure rated outpu oe _ _ _ g_ | Murino init pressure] At rated output 9 % | Exnaust temperature | All speed 7 & | Fiubinlaicanys | Gnafetrtempcasey |“ | Moers | rap | Max 7eo | 750 gL 5 Quick acceleration Max. 5.0 70 Max. 5.0 70 3 ow ing Hah tog) | | vate coor | ated output Sei] wocz0 | 20 - ~ 2 At high idling Mex. 15 25 Max. 15 20 Valve clearance Intake valve os ~ ous - thon engine i hot mm creer? SM | enause valve 090 - 080 - Compression prssure | Oil temperature: 40 ~ 60° | MPo_| Min. 32 22 Min. 34 22 (SAE30 oi) {Eraine speod160-200rpm) fam] Min. 321 2) (in 3) a E | Blow.y pressure | At rated output ‘nmiso| tax lox (SAED0 oi (ator temperature: Min, 7o1c/™™H0] Mx. 180 300 Me 160 300 osc | os | azs-oa | one Atrated output SAE20 Boas | ey | @erko | te o2s-o2 | 18 | o20-o28 | 0 £ | cit pressure saetowoil) po} aaa | tia | o-sa | ia. & | RASpE Pe) winor | oor | minor | oor 2|"" Atlow iting SAE9O oi citins toy |) | mincSay | to 2 Min. 02 0.07 ino oo 4 SAETOW oi (Min. 1.0), on Min 1.0) on | ott emperature ‘Al'speod cilinottpan) |e | a0-110 120 0-110 va i consumption ratio | AL continuous rated outs me 5 om Olt consumption ratio | feng of fuel consumoton) | % | MAX 0S ° Nox, 05 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. 12-018 ® 621601621501 sanvisos Ho7as-2 Hopes Hv700-1 Hv700.2 ‘ocasoosK Siansard | Pemisabie | Standora | Pomesble | Stnders | Permisie | Standard ] Permissive value ‘value ie Value value ‘value value ‘value - 400 - . . 200 ~ 2500 | 163-17980H | 1888-israsta) ‘2400-2500 | 2400-2800 | 2300-2400 | 2800-2400 | 2400-2860 | 2400 - 2500 | 15TH | 1s sala 65-695 | 605-695 | 750-800 | 750-800 | 750-200 | 750-00 | 7o0-coo | 700-900 Min, 110 - Min. 110 - Min, 110 - Min. 110 - ‘Min, 100 - ‘min, 100 - ‘win, 100 - Min. 100 - Max, 200, 162 Max. 300, ns Max. 300 ns ‘Max. 300 7682 Min. 820 - - - - - - - Max.700 | 700 Max, 700, 700 Max. 700, 700 Max. 620 700 Max. 50 70 Mex. 50 70 Mex. 5.0 19 - - Max. 28 as - - - - Mex. 20 30 Max. 15 25 Max. 15 20 Max. 15 20 Max. 18 28 ou - ous, - oss, - 04s - 020 - 089 - 0.80 - 0.80 — Min. 28 20 Min. 28 20 Min, 28 20 Min, 28 20 (Min, 291 (20) (amin, 28) (20 (Min, 291 (20 (in. 29) 20) Max. 150 200 Max. 180, 300 Max. 150 200 Max. 250 500 075-039 | 018 | o2s-o29 | ors | o2s-o39 | one | o25-om | ae 25-0) fe 125-40) tis 128-40) ts) 128-48) Gi) oz0-034| 015 | 020-038 | ars 20-35 15 022-034 | 018 (20-35) Hs) (20-35) ts) 058} ia) 122-38) a3) Min. 0.1 02 Min. 0.1 0.08, Min. 0. 08 Min. 0.18 oor Imi: 1.0) a) min. 13) oa in, 80 oe (win. 8) on Min. 0.1 08 Min 0. 908 Min. 0 208, Min. 03 oor IMs 0) (at (Min. 0) (03) (Min, 10) (os) (Min 10) o) 90-120 120 0-110 120 0-110 120 0-110 120 Max. 05 10 Max. 05 10 Max. 08 10 Max. 08 10 12-019 ®(2/2) Engine modet saravi40-4 Applicable machine model De7sa2 wason-2 Coat wm contion we Unt | Stondard | Permissive | Sianderd | Pormiabe atom ‘ue ‘ae | PCat — 5 hE 20822 | rut nection pressure | Non tester ra zs zy 5 (20 12 (250 12 = [vet meaionsiming | e.06 lcsree] ao wet 2» woes vainer pana ana Spina posi wa aisonm | oraoom | dorsum | aos om § [esa ve] Baeltsacne lager] toaove | hese | aivsan | wiowk S| ren spose ‘tres engine speea | opm | e122 | oie20 | susan | ousae 3 [Fan por ension | Deft whan pushed with | uy rae cnve tension S| Fan bei force of 88.8N (6 ka) Hvdreut Aut 12-020 © 621601621501 savuor 3 Bs we se veaanosre rar | gee | MEE | gy | me | gy | ME | ay 20:p) | 9 | fasosey | 22 | (asap) | 22 fas spy | Gam oa be woe san Rb aan 60-9 96030 | 96090 | 1670280 | 1670250 | s67=50 | 1670450 hep as \eoHn) 1162 = 35 (60H) 12-021 @621501 TROUBLESHOOTING Points to remember when troubleshooting : vee 12-026 Method of using troubleshooting chart 12-026 S-1_ Starting performance is poor (Starting always takes time) (with electronical governor} nnnnne 12-030 S41 Starting performance is poor (Starting always takes time) (with mechanical governor) 12.031 $2 Engine does not start ® Engine does not tur snmannsnnine 12032 ® Engine turns but no exhaust gas comes out (Fuel is not being injected) (with electronical governor) rence 12.033 ® Engine turns but no exhaust gas comes out (Fuel fs not being injected) (with mechenical governon.. 12.034 ® Exhaust gas comes aut but engine does not start (Fuel is being injected) (with mechanical governor)... $3. Engine does not pick up smoothly (Follow-up is poor) . S-4 Engine stops during operations (with electronical governor) . S-4 Engine stops during operations (with mechanical governor] $5 Engine does not rotate smoothly {hunting} (with electronical governor) S-5 Engine does not rotate smoothly {hunting} (with mechanical governor) $6 Engine lacks output (no power) (with electronical governor! S-6 Engine lacks output (no power) (with mechanical governor)... S-7 Exhaust gas is black {incomplete combustion} (with electronical governor) S-7 Exhaust gas is black {incomplete combustion} (with mechanical governor) . $-8 Oil consumption is excessive (or exhaust gas is blue) nun S-8 Oil becomes contaminated quickly... S-10 Fuel consumption is excessive (with electronical governor) S-10 Fuel consumption is excessive (with mechanical governor) suman S-11 Oil is in cooling water, or water spurts back, or water level goes down. $-12 Oil preseure lamp lights up (drop in oil pressure . ss 12.050 $13 Oil level rises.. cnn 12051 $-14 Water temperature becomes too high (overheating) sn 12.082 $-15 Abnormal noise is made - - 12.083 S-16 Vibration is excessive 12.054 12-023 ©8-17 Diagnosis of electronical governor by diagnosis display {electronical governor made by ZEXEL). Controller system abnormality .. Governor servo system abnormality . |. Rack sensor system abnormality . Overrun abnormality nnn . Ist speed sensor abnorm: 2nd speed sensor abnormality Low idling speed control dial abnormal Droop control dial abnormality wen Diagnosis lamp falls to make indication ..n.un: 10. Normal indication . 11. Memory clear cannot be achieved by pressing the memory clear switch (when failure indication is made by diagnosis lamp). . Seuemnenn AA When carrying out testing and adjusting, or troubleshooting, stop the machine on level ground, fit safety pins, block the wheels, and apply the parking brake Ai wren carrying out operations with two or more workers, always use signals, and do not allow any unau- thorized person near the machine, Bi wren checking the meter love, the redator cap is removed when the engine is hat, Boling water wi Spur out end mey couse bur, 80 always wait forthe engine to cool down before checking the water fev A. Be extremely careful not to touch any hot parts. A Be extremely careful not to get caught inthe fan or any other rotating parts. Ad winen removing the plugs or caps trom places under hydraulic pressure, water pressure, or air pressure, releese the internal pressure first. Fit the meesuring tools securely before carrying out any testing, adjust. ing, or troubleshooting. * When using the standard values table for judgement in testing, adjusting, or troubleshooting, it is necessary to be careful of the following points. 1. The standard values for the new machines in the standard values table are values given as reference from the standards for new machines and machines shipped from the factory. They should be used as values for est ‘mating wear during operation or as target values when carrying out repairs. 2. The failure judgement standard values in the standard value table are values using estimated values based on the results of various tests and standard values for machines shipped from the factory. Use these values for reference together with the repair and operation history of the machine when judging failures. Do not use this standard values table 2s a stendard for judging claims. 12-024 @ 621501621501 POINTS TO REMEMBER WHEN TROUBLESHOOTING Troubleshooting means locating the basic cause of the failure, and carrying out swift repairs, and ensuring that the failure does not occur again. When carrying out troubleshooting, it of course important to understand the structure and function. But to ‘carty out the troubleshooting effectively, a quick method is to carry out troubleshooting using the problems mentioned by the operator as a guide in locating the cause. 1 Do not disassemble the machine simply because there is a failure If the machine is disassembled immediately just because there is 2 fulure: © Unvelated or unnecessary places ere also disassembled © It becomes difficult to locate the cause of the feilure This means that there is not only @ waste of time and money on replacement parts, oll, and grease, but this action will elso lose the confidence of the user and operator. For this reason also, it is important to carry out troubleshooting based on full investigation before starting and troubleshooting following the correct order. Questions to ask the user and operator 1) Are there any problems other than those af ready reported? 2) Did anything unusual happen before the failure occurred? 3) Did the failure occur suddenly, or had the condition of the machine been poor before the failure occurred? 4) What were the conditions when the fallure occurred? 5) Had any repairs been carried ot before the failure occurred? 6) Had any similar failure occurred before? Checks before troubleshooting 1) Chock the oil fevel. 2) Check for any external leakage of oil from the piping and hydraulic equipment, 3) Chack the travel of the control levers. 4) Other maintenance items can also be carried ‘out visually, so carry out any check that ‘considered necessary. 4. Confirming failure Check the degree of the problem to judge for yourselt if itis really a failure, or if there is some problem in the handling or operation of the max chine. * When driving the machine and re-enacting the failure, be sure that the investigation or measurement does not make the failure worse, 5. Troubleshooting Narrow down the causes of the failure from the results of the questions and checks in the above ems 2— 4, then follow the troubleshooting flow chart to locate the failure. + Basic procedure for troubleshooting 1). Start from the simple places. 2}. Start from the most probable places. 3} Investigate related parts also. Basic action to remedy cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will oc- ccur again. To prevent this, t is necessary to investigate why the failure occurred, and to remove the root cause of the feilure, 12-025 ©METHOD OF USING TROUBLESHOOTING CHART This troubleshooting chart is divided into thr sections: questions, check items, and troublesh- ‘coting. The questions and check items are used to pinpoint high probability causes that can be located from the fallure symptoms or simple inspection without using troubleshooting tools. Next, troubleshooting tools or direct inspection ‘are used to check the high probability causes to make final confirmation. [Questions} Sections @ + @ in the chart on the right corze- sponds to the items where answers can be obtained from the user. The items in B ere Items thet can be obtained from the user, depending on the user's level {Check items] The serviceman carties out simple inspection to narrow down the causes. The items under © in the chart on the right correspond to this. The serviceman narrows down the causes trom information ® that he has obtained from the user and the results of © that he has obtained ‘rom his own inspection. {Troubleshooting} Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from (Questions) end [Cheek items}. ] o ° @ 6 e | 7 ° o . 1 2.026 621501621501 The basic method of using the troubleshooting chart is a6 follows. Ntems listed for [Questions] and [Check items} that have a relationship with the Cause items are marked with O, and of these, causes that have a high probebilty ere marked with ©, Check each of the [Questions] and [Check items] in turn, and marked the © or @in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, 0 start troubleshooting for that item to make final confi mation of the cause. 381. For [Confirm recent repair history] in the (Ques- tions] Section, ask the user, and mark the Cause column with 4 to use as reference for locating the cause of the fallure. However, do not use this when making calculations to narrow down the causes. 312. Use the A in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to deter- mine the order for troubleshooting. "ET | Confer recent repair Rstory a2 [Degree ot use [ Operated for tong period 12-027 oO+ Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: (Exhaust gas slowly became black], (Power slowly became weak- fer], end (Dust indicator is red) If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause. -7 Exhaust gas is black {incomplete combustion) 5a eausos why oxhaust gas is black sufelent nike of ait improper conaiton of fuel injection Excessive injection of fu ——— Sree opto 3 5 i Ss a 8g (ee Seco z EE 7 te a TREE ofa tat Hatotetto} | ay RT 2 i EJ i z 5 [Eien ames oH ae pees a hae eooer Be ae H ta | ee S avacwssnaneoame . | 12-028 @621501 Five causes __ | Clarify the relation. in the (Questions} and (Check items] section and the five Cause items in the vertical column. aaa Three symptoms Step 2 ‘Add up the total of © and @ marks where the hori zontal lines for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: 208 {2) Air loakage botwoon turbocharger and head: 00 (3) Clogged, seized injection nozzle: ° (4) Defective contact of valve, vaive seat: O (8) Wom piston ring, cylinder: ° Step 3 ‘The calculations in Step 2 show that the closest relationship is with [Clogged air cleaner element) Follow this column down to the troubleshooting ‘and carry out the troubleshooting item marked @. The Remedy is given es [Clean], so carry out cleaning, and the exhaust gas color should return to normal. 12.929 @TROUBLESHOOTING TABLE ‘$-1 Starting performance is poor (Starting always takes time) (with electronical governor) General causos why starting performance is poor ‘= Poste causes using fom Questions and check toms) «Defective electrical systom Most probebie cause dais fom Cueto a Chek ems Insufficient supply of fuel Res canreeing 1 lena of use used fora tong period! inuficiont intake of air Improper selection of fuel (at ambiont temperature of —10°C [14°F] or below, use ASTM D975 No. 1, and ~10°C [-14°F] or above, use ASTM 875 No. 2 diesel fuel.) + Battery charging rate cer Ta [ae pa [ae fae ociaeeL as par | ts poe | ae ‘hasoeciegravtychovdbe tore chrging Soren [ apemsatomr pg [|e r ; oo HEE | [iiieteesstoce He nda oa ae Ta 5 toutes oto omaToRmEAT| tts sH= or ace a ST ts SHE cay aap - ate Siig arate ee = by pamee = E 2. [ asinine nein pp nema z 4 [tarcoe someone moe - | 1 Une etcomeecutavon nheniaeton rp save ti toaoned . ° Bae tera samnanmna agin z z a Sana or a coer TET = CEE EE Wins soapanin pees mnaoed Voie ——Te T When srcsns arty ey terse dogs || ‘an ear oceans tree oosiseecee = joa noe ovoioanroe = 4 Vote 3¢-2 re sh aE a : x | sbmnestewmmgteetontie o = | Bites oo orca via aay = 4 | Bestntpsere oyna arene Ooms 4 | ste can enw ipa doo ny hong Weal el AS ela alale dle oof] al al lela Welded fem Uelel UST 621501621501 General causes why starting performance is poor + Defective electrical system + Insufficient supply of fuel + Insulficiont intake of air + Improper selection of fuel (At ambient temperature of —10'C [-14°F] or below, use ASTM D975 No. 1, and —10°C [+14 or sbove, use ASTM D975 No. 2 diesel fuel) + Battery charging rate. SBE eee owes | ae | om [roe | oo 20 (BF) ie pie [ia [ae pe oc [32Fl vz | var | az [ie | ve Tage (1930 ae | ae | as |e The seecfe gravity shoul exzeed tho value forthe charging 31 of 70% inte above table In cold woater the spcife gravity must exceed the vale forthe ‘charging at of 73% In te above tbe. +1 Starting performance is poor (Starting always takes time) (with mechanical governor} Legend (G' Possibi couses ging ram Questlons and check ems) Most prosabie eases [judging fom Questons and Chock toms) 15 Rowse causes diet length of ue (ned for long pao’) (© ans conti the couse a z ———— = a a He Se ee EE = {hee z = : - me as : et ee pan TEE - | ee a ots Se = tlie ala 12-031 ®S 2 Engine does not start © Engine does not turn General causes why engine does not turn + Internal parts of engine seized + finternal parts of the engine are seized, carry ‘out troubleshooting for “Engine stops during operations” + Failure in power train + Defective electrical system Legend ° . Posse causes judging from Questions ang check Hams) [Mott probatie causes (udesna For Questions and Check tems) Possible causes due to lngth of ure (ured for long por Degree of we ‘Opera fr lana poo ven em 6668 not soon swteh tena ON Horn sound levis oa When starting switchs Mates erating nove urna to START, pinion ‘Seen disengage a5 Takes rating noise and ing owl tered START, pon doesnot wove Out afo|_6 ‘ihen staring awh i tuned wo ON, Tage dos pol meve Whom banter eeeknd, bat elec found o be ow (e [ Specie graviy of woctynwahage of batty Tow For te following condlens 1) — 5) tum be staring eich OFF, connest he cor, and ary out troubleshooting at ON 1) When te:minal 8 and termina Caf sturtng sate ae connected engine sters 2) Even whan tinal Band ternal © of tring motor ore Connected, engine doer not stat 3 Wn ternal 8 and teil C of safety rely ae connected engine sate {7 When wrminal oF sale Swich and terminal Bot waring mater Be connected engine ea ‘There sno 2V vellage between batery relay terminal B and ‘Viner sing gears hpacted deci, sath surface found 0 be hind ‘erry out woublesiontng for defosive wirha of saring ere [bees noi owe ern wien engine sop ter inage & asconnacted | i ° 1 epee Rosie Td aesicel @ ecto 2.032 ® 621501621501 @ Engine turns but no exhaust gas comes out (Fuel is not being injected) (with electronical governor) {including cases with V-type engine where there is fuel injection for the bank on only one side) General causes why engine turns but no ex- Legere (Ge Possible causes tudaing from Questions and check tems) hhaust gas comes out 12 Most probable causes (veging from uostons and Check ters) Supply of fuel impossible Possible causes due co length of use (used for & lone period) ‘Supply of fuel is extremely small ‘© tems to confi the cause, Improper selection of fuel particularly in win ten) ‘Standards for use of fuel ww -0 0 1 wae, Deel a T Conf reenter ony Dearest use [eesretorona pared TELoE Eshaus gue 600Geny [when arog agin scppedeomingt [0] efettele | Replcerent of irs hat ft ben eae ot azecing to operon ve 8 | mana ™ “ LL | [Fue tance foundvo be omoty z © there is leakage from fuel piping Go Mle suck uel ten a “When fuel fitter is drained, fuel does not come out cr ~ et ‘Whar engine rand wih sing moto, ‘1H Injection pump coupling does nor twrn ° | ite tslcomes out evn when etter arb hgtToomned |e] [lo] = | dno tnt comee out even when icon pump a Died pug 5 | oweea & |_ivotue spurs ou even when risdion pe sens nutztoosened [> [> [> elettele Rust and water ere found when fuel is drained I ote inspect scion sump area = Contra ack doesnot move . Inspect feed pump directly _ . Terri 4 when fl er, einer ae apo Arey toy ar found be son : sages ___{ | | {EP whan polo un Svanar pened aati urd ob | # | eosaee 1 hen fat eap ie inapaied drach, Rie ound be doaaed 2 [soec ee solenoi eewy | CI Tinapect govereer ail pump dest t ae Thiet opvamor soo! vave rely ‘When governor ol supply ple ic specie dros, wie tuna toce | VI stonged | “Wen gov or erate nope Greely sound obo Soya = Remeay || Baa ailals ele 8 \2)2)2 212/55) 5) 1: “Abnormality In servo system” is displayed by troubleshooting function, 12-033 ®® Engine turns but no exhaust gas comes out (Fuel is not being injected) (with mechanical governor) {including cases with V-type engine where there is no fuel injection for the bank on one side) General causes why engine turns but no exhaust gas comes out Legend ‘Supply of fuel impossible (O* Postible causes (judging from Questions and check em ‘Supply of fuel is extremely small Improper selection of fuel {particularly in win- (©: toms to confirm the couse. ter) Standards for use of fuel Ee ee lsat at ‘ASM 0978 No? 18! os probable causes judging from Questions and Check items) 2: Possible causes due to length of use (used fora lang period) Quest (Check tems (Coat recent epai History [Degree of use [Operaedorlongparod Exhaust gos suadaniy jen staring againi eopped coming ut placement of fiters hes net been carried out according to operation Fueltankie found be empty “Tha is oakoga from fuel piping Mu stuck tofu iank con When Wel ites drained fuel does not come out When engine i eanied with etaring motor, ‘Wiejetion pump counting dows nt turn 2)No usl somes out oven when fos itera Basa plug loosened Ne fuel comes out oven when injection pump air bleed plug le leosenad {5 Re tuel spurs out even whan injection pipe leave rats Toosoned ust and water ¢ found when ful craned “Troubleshooting Tnapen rjeoTon pump Great Contre ack dos not move Inspest feed pump droctly ‘wren fue iter, era longed 3 inepactod alestiy, hay are found to bo ‘When priming pump sroiner is inspected directly, i e found to be logged When fit cap is neperted direct, Rs Yound tobe Gagged Inspect fue eut solenola iesiy 12-034 ® Femeey| Repace Replace ‘lesn ‘leer Td Conese Coneet Replace © Replacs 621501621501 Exhaust gas comes out but engine does not start (Fuel is being injected) General causes why exhaust gas comes out but engine does not start + Lack of rotating force due to defective electrical system + Insufficient supply of fuel + Insufficient intake of air + Improper selection of fuel Legend Poni causes tudging from Questions an cack tore) | 2 aos probable causes tugng rom Questions and Chach ems) ‘5 Posubla causes ci fo length of use (use for long period) (© ems to confer ha cause ena aR TO AR eee ofuee [overs tor tong pa Sudo ied wa oo ‘When engine is cranked abnormal noise is heard rom around heed | & Eng i mut be aad ore resin = orspecid fet his ben sed 2 z Teacerent of sha not bon aad uk aecaring To Opa Dua nator red = jester mo dows SGN OP 3 ‘Starting mator cranks engine Swi S Mod's ct oul ak eae [ ‘When fn ean wih ing Wate, vesiona Toutd when hale araned ale ~ | 11 thee el comes outaven whan necton pump seeve tis, || © { loosened 3 Lite fuel comes out aven when fel fiter air Dood plug ‘nd injection pump ar bleed plug ate loosened (Titec siege rom fl png When exaust menial tucned immeclatly afer sering ° engine, tamperatra of some eviner iow Wher il ier ig dined no fal comes out a hk tems Temve bad cover aod chaok recy = T When contolrackis pushed. hisfoundiobe heavy ordosenorreure |_| ‘ier compression pressure Is measured is tund wo be ow . ‘Wien fel iter, saves are inspected recy, tay are found Be ocd ‘Wien Teed puny crn rapastad aaa, rl be coGoea . ‘Winer elament ie hepoced drerty, Ris found tobe eogged . ester mount done not become wan . ier specif gravy of locv te or volage of Baty ow © ‘When foe! pump sapere, her no response. or pump Rea ©. “roublestoating ow. Hitze on ugs hare . [ Wien fol cap is nepated Srey, is Found obs logged . rere Reps epee Repel 12-035 ®S-3 Engine does not pick up smoothly {Follow-up is poor) General causes why engine does not pick up smoothly + Ineutficient intake of air + Insufficient supply of fuel + Improper condition of fuel injection Improper fuel used Legend (O' Possibe couses Gudging fom Questions ana chk itams} 1S: Most probable esses (udging from Questions and Check 13 Poste causes du to longth of oe (used fra long patio |© heme to conto the cause, Tena a Deprctase [onwanareronppeca [sas] | [a = Facer oR RA a ied os coc pro 2 [Nonasocte has ag ued ae [Bess of must br snd mere Famer Z [Ratan water ound whe ld as 1 stent ed z Noes ol wiererence sand ton wand WT Eta Do sari one poor SsCCECEErce com aienesane Taser nd z aio a= oT Te The i or aed go 3 Cig sou etd Fam wood od sd n [rian tom i 9 | Wong sped wd ed art Bt pedal aps i ie ° 2] | fo : i sion wea alate 2 ‘en exaust anf ached ede sh Fans Sa siren fase pda iow ° ° Blow gsi cove z 3 Wen soe Pape drei 1 babe dogged To ‘Whe ltr ane ae iced Ges, ey fun OB ° teats inn ta pany War wineeead ney Wa and wb Sees] |] { [rconsiadiamariaanaateTaeasmaaoe ||| I Te 3 [anarchic by rnd tis ove be Rey 4 © | andor vale : fo ap ac AE, HOP GH Whe ed sump owe pratt Ih 0 ROO reg a ton os = or one set = stelslal Pele ag lansay §) 8! § i af /eél2|e#13 als 12-036 ® 621501621501 $-4 Engine stops during operations (with electronical governor) (including cases with V-type engine where there is fuel injection for the bank on only one side) General causes why engine stops during operations Internal parts of engine seized Insufficiont supply of fuel ‘Overheating + If there is overheating and the engine stops, carry out troubleshooting for overheating, Failure in power train & Ifthe engine stops because of a failure in the power train, carry out troubleshooting for the chassis, Legend (Gr Possibi causes iuaging tom Questions and check items) 1 Mos probable eauses judging rom Questions and Chock items) Possible causes custo length of use lused for along peciod) 18 ams t0 confirm the eau. oppee waden ‘nga sone nyse ovrheted an Repo ae = Engine stooped say Tague oro “Trytotumnbyhand Turns peste sian t = vatenotes!_ [ey nour toa tele ital us ad ws ‘Whe sining erp oie repcted ciety sous oPsconpee = ‘Wen gveror ol rarer cepted ty found oe dogpet = PTs 4: "Abnormality in servo system” is displayed by troubleshooting function, ote 12.037 @S-4 Engine stops during operations (with mechanical governor) (For V type engine, including cases where ‘one bank stops) General causes. why engine stops during operations * Seized parts inside engine + Insufficient supply of fuel + Overheating + If there is overheating end insufficient ‘output, carry out troubleshooting for overheating. + Failure in power train + If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis. Legend (0 Possible causes udging from Questions ana check sms) + Mest probable cause ging fom Questions and Check tems) 2: Possbl eusos due to ena of use (used fo a ong period (© heme to canto the couse Dagan ed ate inden Woops nny som rare ned soi 3[a[e 5 S| Fea gave amo vans ur Faucet a ar tne cw OG ale ‘Nor-specified fuel is boing used ofsle o cont : : E | rvtemmiytand iy Tum meponeooi z | Stnnges Tis sour oe af i a ra ea Spe. i Tana oT ET oT ‘ Tare eS ods = r 4 ire 7 : . i [pecs : onl ack ove ok = TEE Lilslalahalals Perevlplelplate[s/® S)éjaleléis 12-038 ®621501 $5 Engine does not rotate smoothly (hunting) (with electronical governor) Gonaral causes why engine does not rotate smoothiy Air in fuel system Defective governor mechanism Legend (0 Possible caves judging from Quotons and chock ms ng rom Guastons snd Check itera) of se (used for along periog) {© heme 1o cone the couse ‘Desten of Teng pared a= = I in spovd age BG ‘Oenre atlow ng I Condition of hunting ‘eure even when sped = ined ere fete ‘ceure ones Tosi tank Youre o be emp 7 eoloceren of fitrs Ras not beer eed ou according to i © Enoine i somnines cst io #00 ‘Governor lover (cio purge Ht T Spool velve ie st . Ome mi . E | ooo hia i 4 . 12-039 ®S-5 Engine does not rotate smoothly (hunting) (with mechanical governor) Lege ° General causes why engine does not rotate smoothly * Air in fuel system + Defective governor mechanism ed Possible couse Gudging from Questions and chet er) Most prbabie causes (udging from Guostons ard Check tame) 2 | Posie causes de to length of uo (ore fora long pared (© hems to conten the caus Contr resent pat RT T Degree of use ‘pated fr ora peed ala (eco st certain spans ange] 5) [©] 0 (ers ato tng ot fer felefele Cordon of hunting ‘eure aven when speed z raised sets ° a ‘Devore on apa 3 [Falonwtand beens eplacerant of fters hat not Been eariea Bt BESO 1 operation manuat ° ele Rusts found when fel raed oe Leakage om fue pig ale B | 1 Novesponse, he ele 2 | 2) norespontn. ht E [Ergin speed sometimes ries to Nigh SF enaine sometimes citta ost = [7 [Sesemtor ever (eoenaie pionger) eam . ‘Spool vive att - E [When controtracks pchoa tis Yound w beneavy, or does net ratrn . [Werf ap is inopected are, it found tobe sowged . “Te |B [When teea pump strainer inspected avec is ound ob 2 | ccssee . . °° Wnen foie, Svaier are naoactad Graety, they ar Toma to be etoaaee ba aslelslelas Jremec Big] e/a) (3/2 g[2lé|éje}2|é 12-040 ® 621501621501 $6 Engine lacks output (no power) (with electronical governor) (With V-type engine, for cases where there is injection for only one bank, go to troubleshooting S-2-2 or S-4) General causes why engine lacks output ~ Insufficient intake of sir + Insufficient supply of fuel + Improper condition of fuel injection + Improper fuel used (if non-specified fuel is used, output drops) + Lack of output due to overheating + If there is overheating and insufficient output. carry out troubleshooting for over heating, (0° Postini enses judging from Quostons and eek items) 1G: Most probe eauses (udging For Questo 12 Posse causes duet longi of ue (sed for (© Heme wo coi the cause Conn rent rps Fey Deoree af use ‘Gaerne Torlonasaned a] fala la a [ . Ssceniy owes was ost “Gradully = efele @ eplcernt of fRers as nO ren cared out Sosrdeg fo operon "Non-specified fuel is being used [els at Danio ered fears oe Blow by 598 exrereve Engine nice poor and combunten & regu a © oe oe dre rn oe a : ° on exhat marfld tush inmaditly Mer arr aging, tle There is hantng rom engine (otaien & Wegulat BG ole “lanaig sue heard rom around einer head ih ing speed af engine low 3S Leakage eon fue ppg = ‘When oir element is inepected vecty Wm found wo be coggee = TT 7 Wren tubocharger rota by hand, te foune fo be heavy . Wren compression pressre i meszured found obo low . . ‘Wen fl iter, steiner ae wapecteg deci, twy are found . to be clogged _ - When tee pur svar nspeced drach oun wo be Coaded| . Seb enn rca ae hes ana ° 2. [ iwhonaonwol acks pushed, his Tourd tobefenny, or deus Fatah = en vce cnt ety nee ; [ine 6a pum i operate. aperton to ih 100 Peavy . Winen fl cap ic apeciog dec, is found to bo eagoed ° fren) Geen resiee| Reniee Cow aan Gis eniee$-6 Engine lacks output (no power) (with mechanical governor) (With V-type engine, for cases where there is injection for only one bank, go to troubleshooting S-2-2 or S-4) General causes why engine lacks output + Insutfcient intake of air Insufficient supply of fuel + Improper condition of fuel injection + Improper fuel used (if non-specitied fuel is used, output drops) + Lack of output due to overheating + If there is overheating and insufficient ‘output, carry out troubleshooting for overheating, Lasend ( Possible coutes doing rom Questions and check items) 5 Most probable eauseeludging from Questions and Check item) 12: Possible causes due to length af se used fora long period {© hams to cont the cause. Tani rset apa OY Desres of wee ‘persed oriong pores [| [ajala a Power was ost Svsdeniy - 2 Grady of jefelele ° Train a mutt be Sded mare Fema Teplacernet offers has no been carried out acordng Yo person i Novapectied fal being wad ‘olor of exhaust get Tiss of ierovace ie haw Wom aud wrbocharger ‘Slow by 98 excessive = oe ‘Engine pickup le poor end combustion "ig ing speed under noo ie normal but soned dni Grape hon os apne ‘When exhaust manifold touched iniraditely sar ovina enue There Pang om engine roaten ied ote OG ‘langing sounds habe from around inde hes i igh ing speed of engine tw = ‘Laskage fom foelpina Toon oue doaged—‘[@ ‘When wubocherge so i ound 9 . ‘nen compression prassre ix meanred i ound below = . Wien fol ite, sane oe hepecie diet, sey refund . to be clogned [When tod ovo avane i hapcied aici, found Wo be cogoed | - 3 [Septal nein tare cylinder tative ter Inne change nora 4B | soeed tevin: st working * 2 [ithe corral rast oped is founda bs heavy. or dows not eturn . ren valve clesronce checked aire, t fund tobe . ‘hon feed pump is operated, operation oo ght or wo hea ‘Viner at caps inspeced dreety i Ound tebe ele When ina pup tost cempertiriinepetod coos row ‘ean 12-042 @ 621501621501 S-7_ Exhaust gas is black (incomplete combustion) (with electronical governor} General causes why exhaust gas is black Insufficient intake of air + Improper condition of fuel injection + Excessive injection of fuel Legend Possible causes (ung from Questor and check toms ‘Most probable causes doing fom Questions and Ceck tems Possible causes dum length of ute (aed fore fng period) eno Contr cent ree Fay Bere of se ‘Goer long Baro AES Syddenybesame back | = o aI Color ot exhaust gas ‘Graualy Become Bick om = Blo undo ight la ‘uestons gin cil must be seed rave Femanty Sadeany 2 a o ale | Pomer was on Gradual ole ole | Rowspectied tela boing used a tT Noe of ertrenca heard fom arcund Wrbochorgee - /, Bust shetor red ~ 3 Blow-by gas i ecesive Engine pickup por and Corton Wreguar a aL festel Te ‘Wihen exhaust manifolds tuched immediately afer saring angie 7 3 ° ing sur i ar em aourd ede ead = Bossi rise abhome! 3 3 = Mute eushed 3 Teotage ofr bewenn tubocarger and vd bare Game i minder nx wong . ‘When ahaa ada wag dalvery method njsaon Ur i ound 7 tobe noorect Winon valve earance le checked aecly Wis found w be ouside et standard valve ‘When utr ie ernvadsehacat ga clo rir 0 nota . ‘When contoleackis pushed, ound Be Reavy 07 Go0s noT eT t * nto Renteo Resta 12-043 ®'$-7 Exhaust gas is black (incomplete combustion) (with mechanical governor) Goneral causes why exhaust gas is black + Insufficient intake of air + Improper condition of fuel injection Excessive injection of fuel Lngena (0 Possible causes Gudging trom Questions and check ters) 1: Most probebe casos (udging fom Questions end Check tems) 1S: Possible causes duet engi of use (seed for ong period) {© heme cont the sous enti rent rp DRT Degree of ws ‘Operated Tong vevied apeta ‘Sudden become bit |S over of exhaust gas ‘Grecusiy became Baek = ice under ight aed = Engine oF rumt be aaa mare eau Seater z o o = (asealy oe eo Won apeclied fal beng weed or a Toes of nterfaronca ie hese rom around rtacharger = Power was lost Dust nds red e Blonby ores meee = Engin pelub poor and combustion io wreguler = st sfetel te When exhaust manfol i ourhed wnmadaily er Sarg Ona temperature of some eyinders is ow iz heard rom around ender head % Exhaust nie abnormal o a Leakage of ir been tbosharger and Feud, ore comp 3 ‘check toms ‘Sto falineason to ane eye aims Wohewir nochange aS ‘Wan she made ung elvery method, njesion Bran ound tobe ncorect standard valoe — hen miter emoved,oxhaus gs lr Flume ie ror When contolrakie pushed, kis found tobe honey, or does nataiur lnemecy} Renee een 12-044 @ 621601621501 $-8 Gil consumption is excessive (or exhaust gas is blue) + Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling) General causes why oil consumption is excessive ‘Abnormal combustion of oil + External leakage of oil + Wear of lubrication system 4 Judge the oil consumption by comparing it with the fuel consumption during the same period. More than 0.5%: Check the engine More than 1.0%: There is some abnormality 2 Possible cavses due to fongth of use (used fra long period (© tame to contr the exes ‘Confirm recent repair history t | otconsnss sana z = nse ot maton sine moe ean 2 2. [an bene: contin’ eur 3 3 / “Amount of low-by gat ‘Abnormally excessive o oO 2 arent poe ervey i z oe Of veut “ORGPLGW verison daar ae ns 3 Thay ap aT aT eR ano eo —T oT ena ere cn ta ane y aime tga oe zee (rresswetahtes total coner dows ia ane = 2 [Een bration ae 2 [crete etl oreciy z ‘Wien ie mani Se, a a . ‘Wren te mana i reroved. Iona be BY WE = ‘Gills above H level on ei 1] mo Tilsle Ths ay 2/2/88 i pe 22 |8|2 2/8 /2]2/2 12-045 ®$-9 Oil becomes contaminated quickly General causes why oil becomes contaminated auickly * Intake of exhaust gas due to internal wear Clogging of lubrication passege Improper combustion Improper oil used Operation under excessive load 621501 Legend (Q' Possble causes ugg from Questions and check items} 2 : Most probabil causes Wudging fom Questions and Check tems i 6 — cae tes Seiad 6 found to be dirty with oil ne be ow Tone w be clogget remy621501 $-10 Fuel consumption is excessive (with electronical governor) General causes why fuel consumption Is excessive + Leakage of fuel Improper condition of fue! injection Excessive injection of fuel Gone Legere (© Possibie cave udging from Quastione and check tel So Moat © fame ta contr the cave, Desres ef use Goer rl pare ze [ : Mae an ter ae © § | condo of et onsumpton rs a ° Secery nerented 3 ick zc Exhaust gn otor Se Wen exhaust mnie is fovshed rrmedavy sar Having engine temperature of sor eyiees so Match mark on rection pump ie miesignad = cheat tems "Tavs ereral eso ual From enaine = Engine cil lve risa and sre of ase uel o 3 Engine iow ig speeds nah 2 [ eiscon pnp os ows Wat rypon amounts exceseva . | otacienc cect aime Herm aowe nears . 8 +E. [Wen conti rack pushed tis ound obs heavy. or dossnor etm . 3) Wes seis man uno deivey metod, nestor unig sod ; E | oveincorect Remove ad cover 90d hee SCH . {hes akg oon) seri ovale penete md [ . Pielelelalale 2/2] a]slajays renews] 3/2) 2/2) 2/212 HBB 12-047 ®$-10 Fuel consumption is excessive (with mechanical governor) General causes why fuel consumption is exces- + Leakage of fuel + Improper condition of fuel injection Excessive injection of fuel (0 Possible causes judging rom Ovestons and check ems © Most prebabie eases udeing rom Questions and Check ters) 5 Possible causes dua to lengih of une (uted for # long ovis! (© tem to confem the cause [eect ecanrepar Hoy Deseo of se ‘ered ng po : Newer oer msn 3 | conan of fue consumtion steam model | ii mt Gradvaly mereaead ole Sudiy eres oS enust gas clo oes Siete ” White o Trae erg cobasion z | Wher eu montod s warnea mieduy ater sara sore |] « | tporatuin a ome ends ow 3 “Match mark on injection pump is misaligned 2 © ite entra esage of lam engine = nine ova ane and sao isle sere Engrs ow tg and ah 3 t Taian puro at howe at sion aROUNT SSNS . | Septelnpsionteoreopinder sete, Heweienocturasinowee 1 Te] | J tecitrna ovo | § [When serra aie poed ts found oben or does nate . 4 Yretei ers dor ees cr i n ; ‘Remove head cover and check diectly _ * Jaomeo) 32/2 (8/3 12 zielelzlelé 12-048 ® 621501621501 $-11 Cilis in cooling water, or water spurts back, or water level goes down General causes why ols in cooling water Internal leakage in lubrication systom + Internal leakage in cooling system (9 Poutble causes idging om Quoetons and check toms) + Mos peabebia causes judging trom Questions ana Check Rese ' + Possible causes de to length of use lusea for ong ari) (© tems to confi the cause g [Bese fate Oprand rraea—[s z # [ore Ready ewes [5 T5| é Hievel Gradually increased ole Tad wag a a 3 3 Eire ve en oud 3 o[s]s i “Excessive air bubbles inside radiator, spurts back ale 5 [ru au carer rennon of SO wae = 2 | When hydrauiie of torque conwerter, transmission al is drained, 2 | water is found S Fresh nar band ow es ae 3 [Remove evinder read and cece drecty 2 [Remove ol pan ane eneck a Cece se va i aE tamed Zé i 2lele 12-049 ®$-12 Oil pressure lamp lights up (drop in oil pressure) General causes why oil pressure lamp lights up + Leakage, clogging, wear of lubricating system + Defective ol pressure control + Improper oil used {improper viscosity} + Deterioration of oll due to overheating % Standard for use of oil Stig oak SA ery es Tyoeet ot ea es % % & % “oe a L Cones cena ‘satiow “me ens ( aE ia Legena Q's Posse causes ludging hom Questions and check items} 5: Most robatie causes (judging tom Questions and Crock ams) 2 | Posie caueas vo to lang of use (ase for long period) (© hers 0 confirm the cause a aS pS . [Re ania Si ik oda i z ° fo Tarrup a hg = 3 5 conan sero reste Cars atin. nor ai_| | [sts] ofetoloto 2 / | wore iahup one 3 / Sonne ees . Tenyeaie erg xe = i ra a 2 i chetod Ri ound To bao 2 Til ries 0 Fr sat 2 2 t 2 aa oe cp [lemow oi and ceeds efoto £ [toons tans oy ry = 4 eri coming ot it ne rear, oa vle Es gia incen acct Sammars eo Teno pre enrol wr tn seed abe] ni caer pes nao be cen o slat elelslelgialeleig [ é/8/é]s]2)e]e/2 3/3] |2 i le 12-050 ®@ 621501621601 $-13 Oillevel rises S . If there jis oil in the cooling water, carry out troubleshooting for “Oil is in cooling water. General causes why cil level rises + Water in oil (cloudy white) + Fuel in oil (diluted, and smells of diese! fuel) + Entry of oil from other component Possible causes fugng trom Questions ans check ems) Most probabie causes (ding trom Questons and Che Poesble causes duo to lngth of use lused for slong period) hare to eanfer the cou, Dearee of ase [Gara orTong pared a i —_ | [areinotin adoter cooing water & {Emaar ane wane / (Wher engine ret started dopa Ot water carne from muon / | Gabveraaater cop coon. When engine ein ang an ara numberof buble eppear oF water spurte Back exdamper chmbor ‘OT Tove goe3 down Ta Ryo ook 2 Engine oi'emel of dail fel ale) | Przssre tighras: te O01 casar Hone We WAGE Bresurotihtress wat fey Read shows thee i atage ‘When compression possi MBBRUAG, ts found to be low Vien pump auliaryaauipment removed, sale fund io ba broken Remave head cover snd check derby Remove injecton pur and check dresty Theres proper contact of hormone sent valve Tomove ol pan and shack dee Jremeey} ence = peste Rentee Repair Reniee| @ enicel @ 12-051 ®$-16 Vibration is excessi 4 If there is abnormal noise together with the vibration, carry out troubleshooting for “Abnor- ‘mal noise is made” General causes why vibration is excessive + Detective parts (abnormal wear, breakage) + Improper alignment + Abnormal combustion 2 gg Lanena 2/3) Fosse cause aging rom Questions and check tems) §/ 3/9) ‘ow probate causes (uaa om Ovens and Chace Rens) eo angio re ose fr ony pe § eo f eon ‘onfrm recon ropa haioey Degree of se Dpwaied a iorpeenod [a [a pala = Seddeiyinereneed z ° Gradvatynereased conan of vation ‘vestons Nowapecied fa has boon used ‘Metal parses ate fun ino tor Metal portises ar fund when ol a daned (01 aessure sow aow ing a[fe}olo! allel} LL Sn esrare a mi ion Tolows engine spe Esmaust ga nck ale | 9] ef} 5 2 neck tems Rernove oi pan and he ec co Remove Sie ever ard chek dew le ‘heck cre for worn suppor pol Say Cheek cre fr loose engine mountng bli, broken cution ie Check msde of eutpur shat (amper) seecty le ‘Wen dial rundut, fae runout are measured, oy are found to ba ‘outside standard value ie Remove ont cover and shock ares Remove head cover and check cecty ie [Bent writen arr "roubisneotng Jere} Feviae At 12-054 ® 621501621501 $-17 Diagnosis of electronical governor by diagnosis display (electronical governor made by ZEXEL) This electronical governor provides the diagnosis (troubleshooting) function. ‘The following failures can be checked by the indication of diagnosis lamps, ‘Make the following checks before starting diagnosis. (1) The battery is normal. (2) The fuses of the electronical governor controller system are free of blow. (3) The relevant connectors are free of connection abnormalities, + There are cases where the connectors are disconnected and the voltage and resistance value are checked using a T-branch adaptor kit in each step of diagnosis. Therefore, pay sufficient attention not to allow ‘occurrence of short-circuit between connector terminals. ‘* Be sure to reconnect the disconnected connectors before proceeding to the next step on termination of ‘one diagnosis. Items of Abnormalities in controller system Abnormalities in governor servo system Abnormalities in rack sensor system Overrun abnormality ‘st speed sensor abnormality . 2nd speed sensor abnormality Low idling speed control diel sbnormality Droop changeover dial abnormality Failure in lighting of diagnosis tamp . Normal indication ‘a. Failure in changeover between low idling speed and rated speed Failure in changeover between 50Hz and 60Hz ©. Starting failure (the engine cranks, but no exhaust smoke is emitted.) d. Starting failure (the engine fails to start, although but exhaust smoke is emitted.) 2. The engine stalls during running. 11. Memory clear cannot be achieved by pressing the memory clear switch (when failure indication is made by diagnosis lampl, 12-055 @621501 Diagnosis lamp indication @ lit © Out © Quick flashing (0.25 second) @ @ Simuttaneous flashing @ © Alternate flashing ® Slow flashing (2 seconds) © Alternate quick flashing Diagnosis lamp indication Indication type [areon Poa os Controller system ee Governor servo system a © Rack sensor system oe Overrun oe 1st speed sensor (engine) oe @ 2nd speed sensor (Fuel injection pump) o © Low idling speed contro da ; eo Droop changeover dial eo No indication oo Normal indication. eo 12-059 ®1. Controller system abnormality ves, syes ise rack eras in he jection po? check win rack espremoved Sensi ans $5] Eternia) alae wetwean Vemsie i) anc Sitemaiisne 2. Governor servo system abnormality “Power OFF -NO yeg|onasiocttonces andthe eto atsebemvces NO, “Rosita valve baneenElforasi®¥®) ond ‘Evemal)(@h 2083658 2 + Rasitanse vals botwcon feral) 9) and ‘Etieais 075-2250 Disconnect Conve, she eseance YES|voive becveon 1 (es olve beneeon + Resistance value: feratetSiierale®D) 075 za peters, || trae | Bieta O O Heese] ace Lesa eset || eas, Font + Disconnect No ae Electrical circuit diagram related to 1. and 2. above Contrtter 1 @-- 2 12-060 @ 621501Cause Remedy Controller abnormality Faulty controler Faulty harness (between c\-"1)- Band) Foutty harness (between ai~ 1a) Faulty fuel injection pump, fauty harness Replace. Res Replace Repair the hornoss Replace (Fopairtne arose) 12-061 @3. Rack sensor system abnormality ves, SES 4 [iste racceroost [ite easaree —] the jsion puro? sue berewan )_ | [] Chock ith he reck $time | | emer (Twterecstane [| =Powerorr NO ue between El mate ane Nienater Donatz_ || |e*gorasresy eri ior) YES! Shands manares ae between omaty® ena BL aston sin betwen itt) (HO) a Sracmar™* || evemaaerarseazea . 2 comet “Eiemsie® ond ‘Comte 905 385 0 -Resltero va beeen itera eve terwooe * Resistance value ‘GilfemaiekGiChtemalel(Bt 0.75 22 2 feces, || sosee™ | Bree D @ Heese} rareror — Uectaaaan jeercmue T] SSeonec a NS sn iceman aetrraae stase owt NG “Biro aes Electrical circuit diagram related to 3. above [aj Sonnet At t i 7 8 8 - fr | ack sensor @ D @ tlk ; © i | I I I | | i | ! | | \ | | | ! Lt ' q @ L |® 12-062 @ 621601621501 Cause Remedy Feulty fuel injstion pump | Ret Fouty controller Feulty harness (ostwoon c}~ ti -tHlana ity Faulty ful injection pump Faulty harness (between ai -B Faulty ful injction ump, faulty heres Replace. Reploco ai the arose.) Replace Repair the harness Replace [Repair the harness) 12-063 @4. Overrun abnormality Cause Remedy he probate cae ted isthe resletance rs outside of the electronical 03° sewner sem Fauny ee ro oan) no umg.tautyteress | berenes “Disconnect Electrical circuit diagram related to 4. above sn i Hy — r—_# g ro 2 7 {2 Bp | ! I qe Hatt | | | Hy} He | | ta I ie) “bi! He 4-}t 4 \O- © pe ~ @ ® | £ 3 @ 12-064 @ 621601621501 5. Ist speed sensor abnormality Cause Remedy isthe wea 2 ves Faulty controller Replace. Yes value between 1 Pavers? and Tetra rosnanee ] | [221-25 402 Feuny namese oetwoen | Repair or Q @g 3-1. replace. iaty® ora trio 2n ashe ane) Rover OF Faury tstspeedsensor | Replace 6, 2nd speed sensor abnormality aves CS Faulty controller Replace YES vue teeen 1 11 Btemawr ano ae eae | [22-2807 Feuty namess between | Repair or Luveweperreenit Ll powerorr NO ia roplece ismsisxS 228 [] + Disconnect [nr Sonnet
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