16357490-KP1MAEWM-Komatsu 95 Series Engine Service Manual PDF

SEBE61460114
Shop
Manual
!!i SERIES
DIESEL ENGINE
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
January 1998 Copyright 1998 Komatsu America International Company OO@-1

CONTENTS
No. of page
01 GENERAL . . . . ..‘...............................,..........‘..,..................... 01-001
11 STRUCTURE AND FUNCTION . . . . . ..n................................ 11-001
12 TESTING AND ADJUSTING ,....,.,.,....................m..,.......... 12-001
13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 13-001
14 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-001
15 REPAIR AND REPLACEMENT .. ..... . .. ... ..... ... .... ..... ..... ... . .. 15-001
95 SERIES
LIST OF REVISED PAGES LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary actions Mark Indication Action required
be taken to these pages according to the table below.
0 Page to be newly added Add
0 Page to be replaced Replace
Page to be deleted Discard

1 1
Pages having no marks are those previously revised

or made additions.
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95 SERIES
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95 SERIES 00-2-3
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12-043 13-001-11 @ 13-006 13-045 14-007
12-044 13-001-12 @ 13-007 13-046 14-008
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12-046 13-001-14 @ 13-009 13-048 14-008-2
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95 SERIES
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95 SERIES
0°Z5
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for welding signs on them.
ing work.
9. When disassembling or assembling, support
When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11 When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit. tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21 When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-1 terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane. rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: ((iJo@....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
Attachments volume: volume to cover all REVISIONS
1 models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
Special safety precautions are
2. Following examples
page number.
show how to read the
Example 1 (Chassis volume):

a Safety necessary when performing
the work.
Special technical precautions

10 -3 + or other precautions for pre-
* Caution serving standards are neces-
Item number (IO. Structure sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
lecting hoisting wire, or when
Example 2 (Engine volume): working posture is important,
etc.
Places that require special at-

I
Unit number (1. Engine) tention for the tightening
Item number (2. Testing and torque during assembly.
Adjusting) Places to be coated with ad-
Consecutive page number for hesives and lubricants, etc.
each item.
Places where oil, water or fuel
must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-1 and number after the
Places where oil or water
page number. File as in the example. must be drained, and quan-
Example: tity to be drained.
1o-4 12-203
10-4-I -
> Added pages ---c~~:~~~I~
1O-4-2
1o-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAD00479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
A Slinging with one rope may cause

turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-

(Standard “Z” or “S” twist ropes ing a wide hanging angle from the hook.
When hoisting a load with two or more
without galvanizing)
ropes, the force subjected to each rope
Rope diameter 1 Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg) when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN (1000 kg) vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2 to 19.6 kN (2000 kg} of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 (1000 kg} when two ropes make a 120”
20 43.1 4.4 hanging angle. On the other hand, two

ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN (4000 kg1 if they sling
30 98.1 10.0
a 19.6 kN {2000 kg) load at a lifting angle
40 176.5 18.0 of 150”.
50 274.6 28.0
60 392.2 40.0
Ir The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.
I I I I I I
2) Sling wire ropes from the middle portion 30 60 90 120 I 60
of the hook. Liftina ankle [detree) SAD00480
00-7
FOREWORD COATING MATERIALS
COATING MATERIALS
Ir The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
+ For coating materials not listed below, use the equivalent of products shown in this list.
Category Q’W Container Main applications, features
l Used to prevent rubber gaskets, rubber

790-129-9030 150 g Tube cushions, and cock plug from coming out.
l Used in places requiring an immediately

effective, strong adhesive. Used for plas-
790-129-9050 20 g Polyethylene
LT-IB tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
l Features: Resistance to heat and chemi-

Polyethylene cals
LT-2 0994040030 50 g container l Used for anti-loosening and sealant pur-
pose for bolts and plugs.
790-129-9060 Adhesive: l Used as adhesive or sealant for metal, glass

(Set of adhe- 1 kg and plastic.
LT-3 sive and lardeniny I Can
hardening agent:
agent) 500 g
Adhesives
IPolyethylene . Used as sealant for machined holes.
250 g
container
l Used as heat-resisting sealant for repair-

75 g Tube
ing engine.
l Quick hardening type adhesive

Three bond Polyethylene l Cure time: within 5 sec. to 3 min.
1735 790-129-9140 50 g Used mainly for adhesion of metals, rub-
container l
bers, plastics and woods.

I
l Quick hardening type adhesive

l Quick cure type (max. strength after 30 min-
Polyethylene
Aro;;;pha 790-129-9130 29 container
utes)
l Used mainly for adhesion of rubbers, plas-
tics and metals.
I
l Features: Resistance to heat, chemicals

Loctite Polyethylene
79A-12991 IO 50 cc l Used at joint portions subject to high tem-
646-50 container
peratures.
l Used as adhesive or sealant for gaskets

790-129-9010 200 g Tube
and packing of power train case, etc.
Features: Resistance to heat

Used as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant LG-3 to prevent seizure.
1 kg
Used as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.
00-8
FOREWORD COATING MATERIALS
Category (omatsu code Part No. Q’ty Container Main applications, features
. Features: Resistance to water, oil

. Used as sealant for flange surface, thread.
. Also possible to use as sealant for flanges
LG-4 790-129-9020 200 g Tube
with large clearance.
. Used as sealant for mating surfaces of fi-
nal drive case, transmission case.
. Used as sealant for various threads, pipe
‘olyethylene joints, flanges.
LG-5 790-129-9080 1 kg . Used as sealant for tapered plugs, elbows,
container
nipples of hydraulic piping.
. Features: Silicon based, resistance to heat,

Gasket cold
sealant 0994040011 250 g Tube . Used as sealant for flange surface, tread.
. Used as sealant for oil pan, final drive case,
etc.
. Features: Silicon based, quick hardening

type
LG-7 09920-00150 150 g Tube . Used as sealant for flywheel housing, in-
take manifold, oil an, thermostat housing,
etc.
Three bond . Used as heat-resisting sealant for repairing

790-129-9090 100 g Tube
1211 engine.
. Used as lubricant for sliding portion (to pre-

Molybde-
LM-G 09940-00051 60 g Can
vent from squeaking).
num
disulphide . Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
. Used as lubricant for linkage, bearings, etc.
SYG2-4OOLI . General purpose type

SYG2-350LI
G2-LI SYG2-4OOLI-A Various Various
SYG2-160LI
SYGA-16OCNLl
. Used for normal temperature, light load

SYG2-4QOCA bearing at places in contact with water or
Grease
SYG2-350CA steam.
GZ-CA SYG2-4OOCA-A Various Various
SYG2-16OCA
SYGA-16OCNCI
Vlolybdenum 400 g . Used for places with heavy load

disulphide SYG2-400M (IO per 8elows type 1
lubricant case)
00-9
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

Use these torques for metric bolts and nuts. (Always use torque wrench).
Thread diameter Width

of bolt across flats
mm mm Nm bm
6 10 13.2f 1.4 1.35kO.15

8 13 31f3 3.2f0.3
10 17 66f7 6.7kO.7
12 19 113flO 11.5+1
14 22 177f19 18+2
16 24 279+30 28.5?3
18 27 382+39 39+4
20 30 549+59 56+6
22 32 745k83 76f8.5
24 36 927f103 94.5f 10.5
27 41 1320+140 135+15
30 46 1720f190 175+20
33 50 221Ok240 225+25
36 55 2750f290 280f30
39 60 329Ok340 335+35
Thread diameter Width

of bolt across flats
mm mm Nm bm
6 10 7.85+ 1.95 0.8kO.2
8 13 18.6f 4.9 1.9f0.5
10 40.2+ 5.9 4.1f0.6
12 :7" 82.35k7.85 8.4f0.8
TIGHTENING TORQUE OF HOSE NUTS

Use these torques for hose nuts.
Thread diameter Width across flat Tightening torque

Nominal No.
mm mm Nm kgm
02 14 19 24.5+ 4.9 2.5+ 0.5
03 18 24 49+ 19.6 5+2
04 22 27 78.5f 19.6 8f2
05 24 32 137.3f29.4 14f3
06 30 36 176.5f29.4 18f3
10 33 41 196.lf 49 2055
12 36 46 245.2f49 25f5
14 42 55 294.2f 49 3055
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

mm mm Nm k9m
10 14 65.7f6.8 6.7f0.7
12 17 112k9.8 11.5*1
16 22 279k29 28.5?3
00-l0
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Use these torques for O-ring boss connector

Nominal No.
mm mm Nm kgm
02 14 34.3f4.9 3.5kO.5
03,04 20 Variesdepending on 93.1f9.8 9.5+1
05,06 24 type of connector. 142.1f19.6 14.5f2
IO,12 33 421.4f58.8 43f6
14 42 877.1f132.3 89.5f 13.5
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Nominal No.
Thread diameter Width across flat Tightenil ns1 torque
mm mm Nm kgm _
08 8 14 7.35f1.47 0.75kO.15
10 10 17 11.27f 1.47 1.15+0.15
12 12 19 17.64f1.96 1.8kO.2
14 14 22 22.54? 1.96 2.3f 0.2
16 16 24 29.4+ 4.9 3f0.5
18 18 27 39.2f 4.9 4f0.5
20 20 30 49f4.9 5kO.5
24 24 32 68.6f9.8 7+1
30 30 32 107.8f14.7 llf1.5
33 33 - 127.4k 19.6 13f2
36 36 36 151.9f.24.5 15.5f2.5
42 42 - 210.7k29.4 21.5f3
52 52 - 323.4rf:
44.1 33* 4.5
- - -
TIGHTENING TORQUES OF FLARE NUT

_
mm mm Nm kgm
14 19 24.5k4.9 2.5kO.5
18 24 49f 19.6 5+2
22 27 78.5f19.6 8+2
24 32 137.3k29.4 14+3
30 36 176.5k29.4 18+3
33 41 196.1+49 20f5
36 46 245.2f 49 25f5
42 55 294.2f 49 30f5
00-l 1
TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS)

Use these torques for metric bolts and nuts of 102 Series Engine.
Thread diameter Tightening torque

mm Nm kgm
6 IO f 2 1.02 f 0.20
8 24 f 4 2.45 f 0.41
10 43 f 6 4.38 zk0.61
12 77 f12 7.85 + 1.22
TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS)

Use these torques for metric eye joints of 102 Series Engine.

mm Nm kgm
6 8f2 0.81 f 0.20
8 10+2 1.02 I?0.20
10 12 f2 1.22 + 0.20
12 24 f 4 2.45 + 0.41
14 36 k 5 3.67 f 0.51
TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS)

Use these torques for inches tapered screws of 102 Series Engine.

inches Nm kgm
1 / 16 3+1 0.31 ?r:
0.10
118 8+2 0.81 + 0.20
114 12+2 1.22 * 0.20
318 15 f 2 1.53 zk0.41
l/2 24 f 4 2.45 f 0.41
314 36 + 5 3.67 f 0.51
1 60 + 9 6.12 + 0.92
00-12
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
::$ Number of Dia. of strands Cross section

CurreMrating
12
Applicable
Starting, lighting,
circuit
signal etc.
20 Lighting, signal etc.
5 I 65 I 0.32 I 5.23 I 4.6 37 Charging and signal
15 84 0.45 13.36 7.0
40 85 0.80 42.73 11.4 :,
60 I 127 I 0.80 I 63.84 I 13.6
100 I 217 I 0.80 109.1 I 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Charging Ground Starting Lighting Instrument Signal Other

C
W R Y G L
Green Blue
GW LW
2
IG Ireen & Whitc llue &White
GR LR
3
:C ireen & Red Blue & Red
GY LY
4 ;
IG reen & Yellov lue & Yellow
/Code1 WG 1 - 1 - RG YL GB LB
5
Color White & Green - - Red & Green Yellow & BlurtG Ireen & Blacl %lue & Black
Code - - - RL YW GL
6
/Color1 - I - I - I Red 8~ Blue bellow & White?Gireen & Blue
00-l 3
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.
EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(I) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line
down from @.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(I) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10,so multiply2.165 inches by 10 (movethe decimal
point one place to the right)to returnto the originalvalue. This gives 550 mm = 21.65 inches.
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5: 6 7 8 9
9
0 0 0.039 0.079 0.118 0.157 0.197; 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591! 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984; 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378: 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772; 1.811 1.850 1.890 1.929
0 i
a... .,................1.969
50 ..............2.008 ...............
..............2.047 ..............
2.087 ............12.1651
2.126 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-14
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
. 0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
IO 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-M
FOREWORD CONVERSIONTABLE
Literto U.S. Gallon

It = 0.2642 U.S. Gal
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

If! = 0.21997 U.K. Gal
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-16
kgm to ft. lb
1 kQm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
\
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-17
kg/cm* to lb/in*
1kg/cm2 = 14.2233 lb/in2
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-18
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8”F
“C “F 1 “C I OF I “c I “F “C “F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 65 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 96 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 166 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 146 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 IO 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-19
ENGINE
01 GENERAL
General view ...................................................... 01-002

Specifications ..................................................... 01-004
General assembly drawing ........................... 01-005-21
Engine performance curve ................................ 01-026
Weight table ....................................................... 01-077
95 SERIES
O’zol
GENERAL VI
EW
GENERAL VIEW
* The general views may differ depending on the
product on which the engine is mounted.
4D95L-W-1
1. Crankshaft pulley
2. Fan
3. Fuel filter
4. Intake manifold
5. Fuel injection pump
6. Starting motor
7. Oil filter
8. Alternator
9. Dipstick
IO. Exhaust manifold
11. Oil filler
12. Thermostat
6204POO4
0902 95 SERIES
GENERAL GENERAL VIEW
6D95L-1
4 5 6 7 8 1. Vibration damper
2. Fan
3. Water pump
4. Thermostat
5. Fuel filter
7. Electrical intake air heater
8. Intake manifold
9. Muffler
10. Starting motor
6206POOl
11 12 13 14 15 11. Oil filter

12. Exhaust manifold
13. Oil cooler
14. Dipstick
15. Alternator
6206POO2
95 SERIES 01203
GENERAL SPECIFICATIONS
SPECIFICATIONS
Engine model 3D95S-W-1
PC40-5 EC35Z-2
Applicable machine model PC5OUU-1
PC40-6 EC35ZS-2
Number of cylinder - Bore x Stroke (mm) 3 - 95 x 95
Total piston displacement (cc) 2,020
Firing order 1-3-2
Overall length (mm) 763 763 689
Overall width (mm) 539 539 623
Overall height
(mm) 689 689 756
(Excluding exhaust pipe)
Overall height - - -
(mm)
(Including exhaust pipe)
Flywheel horsepower (HP/rpm) 38.5/2,600 ’ 38.5/2,500 35/2,650
Maximum torque (kgmjrpm) 12.5/l ,800 12.2/l ,800 13/I ,800
High idling speed 2,750 - 2,850 2,650 - 2,750 -

(rpm)
Low idling speed @pm) 950 - 1,000 950 - 1,000 700
Minimum fuel consumption ratio (g/HPh) 193 193 192
Dry weight (kg) 234 I 234 205
Fuel pump YPES9CL type
Governor Centrifugal, all speed type
Lubricating oil capacity (Q)
(Refill capacity) (Q)
Coolant capacity (C)
Alternator 12V,35A 12V,35A 12V. 14A
Starting motor 12 V. 2.0 kW 12 V, 2.0 kW 12 V, 2.0 kW
Battery 12V,70Ahxl 12V,70Ahxl 12V,65Ahxl
- -
Air compressor
Others
01Z04 95 SERIES
3D95S-W-1
EC35ZSB-2
I
3 - 95 x 95
2,020
1-3-2
689
622
756
35/2,600
13/l ,800
700
192
205
YPES3CL type
Centrifugal, all speed type
5.0 (4.6) (up to 17145)
7.8 (7.0) (17146 and up)
7.0
12V,14A
12 V. 2.0 kW
12V.65Ahxl
95 SERIES
O’-go5
Engine model 4D95S-W-1
DPOA,P,S,Q,PL,PLL-6
Applicable machine model EC50Z, 25-5
DPlA,P,S,Q,PLB I
Number of cylinder - Bore x Stroke (mm) 4 - 95 x 95
Firing order l-2-4-3
Overall length (mm) 782.5 767
Overall width (mm) 598.2 529
Overall height
(mm) 972.5 750
Overall height -
(Including exhaust pipe) (mm)
Flywheel horsepower (HP/rpm) 39.512.450 4512,800
Maximum torque (kgm/rpm: 15.5/1,300 15/2,000
High idling speed 2,800 - 2,900 -

(rpm)
Low idling speed (rpm) 800 - 850 1,450 - 1,550
Minimum fuel consumption ratio (g/HPh) 188 185

_
Dry weight (kg) 285 270
Fuel pump Bosch PES-A type
Governor Bosch RSV centrifugal, all speed type
Lubricating oil capacity (Q) 8.0 7.5
(Refill capacity) (a) (7.0) (7)
Coolant capacity (a) 10 13
Alternator 24V,15A 24V, 15A
Starting motor 24 V, 2.8 kW 2.4 V, 2.8 kW
Battery 12V,45Ahx2 12V,45Ahx2
Turbocharger - - I
Air compressor -
- -
Others I
O’-Og5-’ 95 SERIES
4D95S-1 4D95L-W-1
DPOAG, P, PG, D21A, AG, PG,

WA50-1 WA40-1 WA70-1
PL, PLL-7 (A) S, QG-7 (A) I
4 - 95 x 95 4-95x115
2,690 3,260
1-2-4-3 1-2-4-3
871.5
600
871.5
600
744
556
767
550
l- 746
593
972.5 972.5 781 763 921
- - - - -
39.5/2,450 39.5/2,450 55/2,500 41/2,200 55/2,200
15.5/1,300 15.5/1,300 16.6/ 1,600 19/1,400 20.8/1,500
2,530 - 2,630 2,530 - 2,630 2,650 - 2,750 2,350 - 2,450 2,320 - 2,420
800 - 850 800 - 850 800 - 850 800 - 850 800 - 850
165
300
I
165
303
I
170
255
I
180
305
I 180
275
Bosch PES-A type
Bosch RSV centrifugal, all speed type
8 8 6.0 8 8
(7) (7) (5.0) (7) (7)
10 10 9 9 12
12V, 15A 12V,15A

24 V, 25 A 24 V, 25 A 12V,35A 24 V, 25 A 24 V, 25 A
24 V, 2.8 kW 24 V, 2.8 kW 12 V, 2.5 kW 24 V, 2.8 kW 24 V, 2.8 kW
12V,45Ahx2 12V,45Ahx2 12V,BOAhxl 12V,70Ahx2 12V,65Ahx2
- - - - -
- - - - -
- - - -
95 SERIES
O’-F2
Engine model 4D95L-1

I
Applicable machine model

I PC60, 6OL-3
PC6OU-3 I
PC60, 6OL-5
PC6OU-5 I
PC60, 6OL-6
PC70-6
Number of cylinder - Bore x Stroke (mm) 4-95x 115
Firing order I 1-2-4-3
Overall length (mm) 797 768 931.0

z Overall width 622 647
542 (excluding
.o (mm)
mount bracket)
2 Overall height
(mm) 750 771 -
E (Excluding
.- exhaust pipe)
I
n Overall height
(mm) - - 1.047.1
(Including exhaust pipe) I
Flywheel horsepower (kW(HP)/rpm) 44(59)/2,400 40.3(54)/2,100 40.3(54)/2,100
Maximum torque (Nm(kgmhpm) 196(20)/1,500 200(20.4)/1,500 225.5(23)/1,500
High idling speed (rpm) 2,590 - 2,690 2,250 - 2,350 2,250 - 2,350
Low idling speed (rpm) 850 - 900 800 - 850 950 - 1,000
Minimum fuel consumption ratio (g/kWh(g/HPh)) 217(160) 217(160) 217(160)
292
I I (excluding muffler)
Governor I Bosch RSV centrifugal, all speed type
Lubricating oil capacity @I 8 9 7
(Refill capacity) (e) (7) (7.5) (6.5)
Coolant capacity (e) 9 9 10
Alternator 24 V, 25 A 24V, 15A 24 V, 15 A
Starting motor 24 V, 2.8 kW 24 V, 2.8 kW 24 V, 2.8 kW
Battery 12 V, 65 Ah x 2 12 V, 65 Ah x 2 12 V, 65 Ah x 2
Turbocharger - - -
Air compressor - - -
Others - - -
O’-“:5-3 95 SERIES
4D95L-1
PC60-6, PC6OL-6F PC60-7 PC70-7

PC60-7 PC70-7
(Blade spec.) (Blade spec.) (Blade spec.)
4-95x115
3,260
l-2-4-3
931.0 931 931 931 931

542 (excluding
752 752 752 752
mount bracket)
- - -
1,047.l 1,093 1,093 1,093 1,093
40.3(54)/2,100 41(54)/1,900 41(54)/1,900 41(54)/1,900 41(54)/1,900
225.5(23)/1,500 225.5(23)/1,500 225.5(23)/1,500 225.5(23)/1,500 225.5(23)/1,500
2,250 - 2,350 2,050 - 2,150 2,050 - 2,150 2,050 - 2,150 2,050 - 2,150
950- 1,000 950 - 1,000 950 - 1,000 950- 1,000 950- 1,000
225(166) 224(165) 224(165) 224(165) 224(165)
292
320 325 320 325
(excluding muffler)
Bosch PES-Atype
Bosch RSV centrifugal,allspeed type
8 11 11 11 11
(7) (10.5) (10.5) (IO.51 (10.5)

I I
12.5 12.5 12.5 12.5
10
(4.5:excluding radiator)(4.5:excluding radiator)(4.5:excluding radiator)(4.5:excluding radiator)
24V,25A 24V.15A 24 V,25 A 24V,15A 24 V,25 A
12 V,60 Ah x 2 12 V,65 Ah x 2 12 V.60 Ah x 2 12 V,60 Ah x 2 12V,60Ahx2
- - - - -
- - - - -
- - - - -
95 SERIES
O’-o:5-4
Applicable machine model PC75UU-1 PC75UU-2 PC80-3

I-
Overall length (mm) 1,001 1,001 769
Overall height
(mm) 802 802 771
Overall height - - -
(mm)
Flywheel horsepower (kW(HP)/rpm 40.3(54)/l ,900 41(54)/l ,900 47.8l64.1 I/2,400
Maximum torque (Nm(kgm)hpm 200(20.4)/1,500 225.5(23)/1,500 210(21.4)/1,600
Low idling speed (rpm) 950 - 1,000 1,000 - 1,050 900 - 950
Minimum fuel consumption ratio (gbWh(g/HPh) 217(160) 217(160) 217(160)
Dry weight (kg) 270 295 270
Lubricating oil capacity (e) 9 9 9
(Refill capacity) (e) (7.5) (7.5) (7.5)
Coolant capacity (e) 9 10 9
Alternator 24V, 15A 24 V, 15 A 24 V, 15 A
Battery 12V,65Ahx2 12 V, 60 Ah x 2 12 V, 65 Ah x 2
Turbocharger - - -
Others - - -
O’-OF 95 SERIES
4D95L-1
D21A-7T
PC90-1 PW60-3 EC75Z, ZS-3
(Trimming spec.)
4-95x115
3,260
l-2-4-3
928 760 753 871.5

542 (excluding
693 636 600
mount bracket)
- 7 (including muffler)
740 972.5
960
- !S (excluding muffler) -
1,047.l
745
47.8l64.1 j/2,300 49.2(66)/2,500 47.7(64)/3,000 37(49)/2,450
225.5(23)/l ,500 209.8(21.4)/l ,600 197(20.1)/2,000 171.6(17.5)/1,300
2,425 - 2,525 2,600 - 2,700 - -
950 - 1,000 900 - 950 - 2,530 - 2,630
224(165) 224(165) 217(160) 217(160)
295
270 270 287
(including muffler)
Bosch PES-A type
7 8 8 8
(6.5) (7) (7) (7)
4.5
11.5 13
(excluding radiator)
24 V, 25 A
24V, 15A 24V, 15A
(with vacuum pump)
24 V, 2.8 kW 24 V, 2.8 kW 24 V, 2.8 kW 24 V, 2.8 kW
12V,60Ahx2 12V,65Ahx2 12V,65Ahx2 12 V, 45 Ah x 2
- - -
- - -
- -
95 SERIES
O’-“z5-6
Engine model S4D95L-1
Applicable machine model PC1 00-5 PC1 00-6 PC1 20-5
Overall length (mm) 769 998 769

Overall height -
(mm) 877 877
Overall height - -
(mm) 1,133
Flywheel horsepower (kW(HP)/rpm) 58.9(78.9)/2,100 59(79)/2,100 62.5(83.8)/2,200
Maximum torque (Nm(kgm)/rpml 299(30.5)/1,500 299(30.5)/l ,500 299(30.5)/l ,500
Low idling speed (rpm) 900 - 950 900 - 950 900 - 950
Minimum fuel consumption ratio (g/kWh(g/HPh)l 210(155) 210(155) 210(155)
Lubricating oil capacity ce, 12.0 12.0 12.0
(Refill capacity) @I (11.0) (11.0)

I (11.0)
Coolant capacity (e) 10.3 15.7 10.3

I
Alternator 24 V, 25 A 24 V, 25 A 24 V, 25 A
Battery 12 V, 80 Ah x 2 12 V, 80 Ah x 2 12V,80Ahx2
Turbocharger GARRET CO. T31 GARRET CO. T31 GARRET CO. T31
Air compressor -
Others -
O’
-OF7 95 SERIES
S4D95L-1
PC1 20-6
JV70DW-1
PC128UU-1
4-95x 115
3,260
l-2-4-3
995 797
641 618
- 847
1,133 -
63.0(84.0)/2,200 55.2(73.9)/2,000
299(30.5)/1,500 299(30.5)/l ,500
2,340 - 2,460 2,200 - 2,280
900 - 950 900 - 950
208( 155) 210(157)
355 318
Bosch PES-A type

T-
12.0 9.5
(11.0) (8.8)
15.7 12.0
(engine only: 4.5)
24 V, 35 A 24 V, 35 A
24 V, 5.5 kW 24 V, 5.5 kW
12V80Ahx2 12 V 110 Ah x 2
GARRET T31 type GARRET T31 type
- -
- -
95 SERIES
O’-Oi05-*
Applicable machine model D31A, P, S, Q-18 D31E F, FL, FLL, S, D3,A_2 D3,F_2A
Q, AM, SM-20(A)
Firing order ‘t-5-3-6-2-4
Overall length (mm) 1,056 1,056 1,075

Overall height
(mm) 1,093 1,093 1,100
Overall height
(mm) - - -
Flywheel horsepower (kW(HP)/rpm) 52.2(70)/2,350 52.2(70)/2,350 59.7(80)/2,500
Maximum torque (Nm(kgm)/rpm) 265(27)/1,400 265(27)/1,400 270(27.5)/1,400

I I
Lubricating oil capacity (e) 12.5 13 13
(Refill capacity) @I (10.5) (11) (11)
Coolant capacity ce, 22 22.3 22

I
Alternator
Starting motor
Battery
Turbocharger - - -
Others - - -
O’-OF9 95 SERIES
6D95L-1
D37E-2 D37E, P-5 (A) PCIOO-3 PC120-3 PC150-3
6-95x115
4,890
l-5-3-6-2-4
1,075 1,075 1,043 1,043 1,043
625 625 619 619 619
1,100 1,100 862 862 862
- - - - -
56(75)/2,350 60(80)/2,500 59(79)/2,100 63(85)/2,200 66(88.7)/2,200
267(27.2)/1,400 270(27.5)/1,400 300(30.5)/1,400 309(31.5)/1,400 300(30.5)/1,400
2,600 - 2,700 2,650 - 2,750 2,250 - 2,350 2,350 - 2,450 2,350 - 2,450
700-750 700-750 850- 900 850-900 850-900
217(160) 217(160) 217(160) 217(160) 217(160)
439 405 405 405
Bosch PES-Atype
11.5 13 12.5 12.5 12.5
(9.5) (11) (10.5) (10.5) (10.5)
22 22.3 16 16 16
24V,15A
24V.15A 24 V,25A 24V,25A 24V.25A
24V,24 A
12 V,70Ah x 2 12 V,70Ah x 2 12 V, IlOAh x2 12 V, 110 Ah x 2 12V,llOAhx2
- - - -
- - - -
- - - -
95 SERIES 01-005-10
WAIOO-1 WAIOO-1
Applicable machine model PW150-1
WRI l-l (Engine No. 46799 and up)
Firing order l-5-3-6-2-4
2
.-o Overall width (mm) 619 809 809
g Overall height
(mm) 862 1,081 1,081
i (Excluding exhaust pipe)
.-
n Overall height -
(mm) 1,142 1,142
Flywheel horsepower (kW(HP)/rpm) 65(87)/2,400 54(73)/2,400 63(84)/2,400
8 Maximum torque (Nmhm)/rpm) 314(32)/1,600 284(29)/1,600 314(32)/l ,600

:
E High idling speed (rpm) 2,600 - 2,700 2,600 - 2,700 2,600 - 2,700
‘t 300 - 850 (up to 25582)
$ Low idling speed (rpm) 850 - 900 675 - 725
$75- 725 (25583 and up)

I
Fuel pump Bosch PE-A type Bosch PES-A type
Governor Bosch RSV centrifugal, Bosch RSV centrifugal,

all speed type all soeed tvoe
Lubricating oil capacity (Q) 12.5 13.0 13.0
(Refill capacity) (Q) (10.5) (11.0) (11.0)
Coolant capacity (Q) 16 17 17

I
Alternator 24 V, 25 A 24 V, 25 A 24 V, 25 A
Battery 12 V, 110 Ah x 2 12 V, 110 Ah x 2 12 V, 110 Ah x 2
Turbocharger - - -
Air compressor - -
Made
Single bJouble
cylinder, ZExEL
actingvp~
Others - -
O’-OF-’
’ 95 SERIES
6D95L-1
WA120-1 GD313A-1 EGGOB, BS-1
6-95x115
4,890
l-5-3-6-2-4
1,029 1,041 1,133
809 809 620
1,081 1,160
1,142
63(85)/2,500
315(32.1)/1,600
-
63(85)/2,500
311(31.7)/1,500
&ii+
56(74:9)/1:800 (60 Hz)
- I
Max. 1,560 (50 Hz)

2,700 - 2,800 2,700 - 2,800
Max. 1,872 (60 Hz)
800-850 750 -850 800- 850
217(160) 224(165) 224(165)(at

ratedoutput)
413 402
I
Bosch PES-A type
12.5 11 12.5
(IO.51 (9) (10.5)
20 17
24V.25A 24V,25A 24V,15A
24 V, 2.8 kW
24 V, 5.5 kW 24 V, 5.5 kW
i!4V,4.5kW (48720and up)
12 V, 110 Ah x 2 12V.80Ahx2 12V,70Ahx2
- -
- -
- -
95 SERIES
PC150-3
Applicable machine model PC1 50-5 PC1 80-3
PC1 5OLC-3 I I

-r
1,043 (excluding muffler:
Overall length (mm) 1,043
1,212 (including muffler)
Overall width (mm) 610 612
Overall height
(mm) 873 928
Overall height - -
(mm)
Flywheel horsepower (kW(HP)/rpm) 74(99)/2,200 74(99)/2,000 78(105)/2,200
Maximum torque (Nm(kgml/rpml 373(38)/1,400 392(40)/1,400 389(39.7)/1,400
Minimum fuel consumption ratio (glkWh(g/HPh)) 217(160) 217(160) 217(160)
Lubricating oil capacity (e) #80273 -: #81773 -: 12.5

12.5 19.5 12.5 19.5
(Refill capacity) @I (10.5) (18.5) (10.5) (18.5) (10.5)
Coolant capacity (E) 19 15.9 18.5
Alternator 24 V, 25 A 24 V, 25 A 24 V. 25 A
Battery ’ 12 V, 110 Ah x 2 12 V, 80 Ah x 2 12 V, 110 Ah x 2
Turbocharger GARRET CO. T31
Air compressor
Others - - -
O’-OF-’
3 95 SERIES
S6D95L-1
PC200-5 PWI 00-3 PWI 00-3

PC200-6
BR200-1 (Engine No. up to 36829) (Engine No. 36830 and up)
6-95x115
4,890
l-5-3-6-2-4
1,391 1,340 1,044 1,044
727 822 660 660
818 - 873 873
1,095 1,264 - -
92( 123)/2,050 99(133)/2,200 74(99)/l,900 81(108.5)/2,100
476(48.5)/1,500 490(50)/1,600 412(42)/1,400 412(42)/1,400
2,190 - 2,310 2,360 - 2,480 2,050 - 2,150 2,350 - 2,450
875 - 925 975 - 1,025 850 - 900 850 - 900
202(149) 214(158) 217(160) 227(167)

I
432 522 420 420
I
Bosch PES-A type Bosch PE-A type
Bosch RSV centrifugal,
aff soeed tvDe
,,
I_
19.5 23.5
(18.5) (22.5)
19.7 20.7
24 V. 25 A 24 V, 30 A 24 V, 25 A 24 V. 25 A
24 V, 5.5 kW 24 V, 5.5 kW 24 V, 5.5 kW 24 V, 5.5 kW
12 V, 110 Ah x 2 12 V, 110 Ah x 2 12 V, 120 Ah x 2 12V,llOAhx2
GARRET CO. T04B SCHWITZER S2D GARRET CO. T31 GARRET CO. T31
- - Made by ZEXEL Made by ZEXEL

ingle cylinder, double acting type Single cylinder, double acting type
- - -
95 SERIES
O’-ot2-‘4
Applicable machine model WA180-1 WA1 80-3 WA250-3

-
ii?
.o Overall width (mm) 761 761 701
ii Overall height
(mm) 1,220 1,220 1,214
.-i (Excluding exhaust pipe)
n Overall height
(mm) - - -
Flywheel horsepower (kW(HP)/rpml 82.0(1 lOY2.500 82.0(110)/2,400 97.0(130)/2,400
Maximum torque (NmlkgmIhpm: 397(40.5)/1,600 417(42.5)/1,600 441(45.0)/1,600
High idling speed (rpm) 2,700 - 2,800 2,600 - 2.700 2,550 - 2,650
Minimum fuel consumption ratio (g/kWh(g/l-lPh) 217(160) 217(160) 217(160)

I
Lubricating oil amount ce, 12.5 12.5 12.5
(Refill capacity) (U (10.5) (10.5) (10.5)
22.5
Coolant capacity (J?) 20 (engine only: 8.5)
(engine only: 7.5)
Alternator 24 V, 25 A 24 V, 35 A 24 V. 35 A
Battery 12VllOAhx2 12 V 110 Ah x 2 12 V 110 Ah x 2
Turbocharger GARRET T31 type GARRET T31 type GARRET 131 type
Others - - -
O’-oF’5 95 SERIES
S6D95L-1
I
GD511A, R-l
GD461A-1 GD510R-1 LW80-1 EG85B, BS-1
I GD513A. R-l I I
6-95x 115
4,890
l-5-3-6-2-4
1,041 1,042 1,153
809 676 620
1,151 1,002 942
- - 1,150
64(85.8)/1,500 (50 Hz)

84( 113)/2,500 93(125)/2,500 101(135)/2,900 11 0(148)/3,000
74(99.6)/1,800 (60 Hz)
420(42.8)/1,500 431(44)/l ,600 431(44)/1,600 435(44.4)/l ,800
Max. 1,560 (50 Hz)

2,700 - 2,800 2,700 - 2,800 3,050 - 3,150 3,400 - 3,500
Max. 1,872 (60 Hz)
750 - 850 850 - 950 850 - 900 750 - 800 750 - 850
231(170) 217(160) 217(160) 224(165) 224(165) (at rated output)
435 410 450 420
Bosch PES-A type Bosch PE-A type Bosch PES-A type

3osch RLD centrifugal, Bosch RSV centrifugal,
Bosch RSV centrifugal, all speed type half all speed type all speed type
11 11 11 12.5 12.5
(10.5) (9) (9) (10.5) (10.5)
18.7
17 34 34 30
8.5: excluding radiator1
24 V, 25 A 24 V, 25 A 24 V, 25 A 24 V, 25 A 24V.15A
24 V, 5.5 kW 24 V, 5.5 kW 24 V, 5.5 kW 24 V. 5.5 kW 24 V, 2.8 kW

I !4 V, 4.5 kW (45334 and up)
12V,80Ahx2 12A95E41RAh x 2 12 V, 70 Ah x 2
GARRET CO. T31 GARRET CO. T31 GARRET CO. T31

(With waist gate)
- - - Made by ZEXEL
ngle cylinder,doubleactingtype
- - - - -
95 SERIES
O’-002-’
6

-
z Overall width (mm) 727 620 620

.o
2 Overall height
(mm) 818 942 942
E
.- (Excluding exhaust pipe)
a Overall height
(mm) 1,095 1,150 1,150
64{85.8}/1,500 (50 Hz) 71.3{95.6)/1,500 (50 Hz)

Flywheel horsepower (kWIHPVrpm 92(123)/2,050
74{99.6}/1,800 (60 Hz) 33.1{111.4}/1,800 (60 Hz)
Maximum torque (Nm(kgml/rprr 476(48.51/l ,500 - -
Max. 1,560 (50 Hz) Max. 1,570 (50 Hz)

High idling speed (rpm) 2,200 - 2,320
Max. 1,872 (60 Hz) Max. 1,872 (60 Hz)
Minimum fuel consumption ratio (gntWhIg/HPh 202I1491 223{165)(At rated output) 223{165I(At max. output)
420 (STD) 420 (STD)

Dry weight (kg) 432
435 (Elect. governor, opl 435 (Elect. governor, op)

Electronical governor type or
Lubricating oil capacity ce, 18.5 12.5 12.5
(Refill capacity) U?) (17.5) (11.3) (11.3)
Coolant capacity (e) 15.6 7.5 7.5

I I
Alternator 24 V, 25 A 24V, l5A 24 V, 15 A
I
Starting motor 24 V, 5.5 kW
Battery
Turbocharger c
Air compressor
Others
O’-OF-’
7 95 SERIES
SA6D95L-1
PC220-5, BR300-1 PC220-6

(With air to air (With air to air
aftercooler) aftercooler)
6-95x 115
4,890
l-5-3-6-2-4
1,391 1,340
813 822
818 -
1,095 1,264
114{153}/2,200 118{158Y2,300
527{53.7}/1,500 554{56.5}/1,600
2,355 - 2,475 2,470 - 2,590
925 - 975 975 - 1,025
202{149} 214{158}
448 525
Bosch PES-A type

Bosch PES-A type
Electronical govern01
Bosch RSV centrifugal,
type or Bosch RSV
all speed type
centrifugal, all speed type
#81676 -
19.5 18.5 23.5

(18.5) (17.5) (22.5)
16 20.7
24 V, 25 A 24 V. 30 A
24 V, 5.5 kW 24 V, 5.5 kW
12 V 110 Ah x 2 12 V 110 Ah x 2
GARRET CO. T04B SCHWITZER S2D
- -
I I I
Aftercooler Aftercooler
95 SERIES 01 -OO_S-18
Engine model SAA6D95LE-1
WING100
Applicable machine
_WlOO-1, LWlOOM-1) I
Number of cylinder - Bore x Stroke mm 6-95x 115
Total piston displacement e ICC} 4.89 {4,8901
Overall length mm 1,042
Overall width mm 736
Overall height mm 1,189

(excluding exhaust pipe)
Overall height mm -
(including exhaust pipe)
Flywheel horsepower kW/rpm 118/3,000 (Net)

IHP/rpmI {158/3,000} (Net)
Maximum torque Nm/rpm 457/l ,800 (Net)

kgm/rpmI {46.6/1,8001 (Net)
High idling speed rpm 3,400 - 3,500
Low idling speed rpm 750 - 800

g/kW.h 215 (Net)
Minimum fuel consumption ratic {I 60) (Net)
{g/HP-h}
Dry weight kg 489
Fuel injection pump BOSCH PES-A type
Governor BOSCH RLD centrifugal, half all speed type
Lubricating oil amount 12.5

e
(refill capacity) I (10.5) I I
Coolant amount I e (engine only: 85)
Alternator 24 V, 50 A
Starting motor 24 V, 4.5 kW
12 V 100 Ah x 2
Battery
(95E41R x 2)
GARRET T31 Type

Turbocharger
Jvith waist gate valve)
ZEXEL reciprocation,
Air compressor
jingle cylinder type
With air cooled

Others
aftercooler
O’-Og5-’
9 95 SERIES
95 SERIES
O’-oo2-20
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING

3D95S-W-1 LEFT SIDE VIEW (For EC35Z,ZS-2)
Crankshaft center F
t
\ Flywheel housing
‘\ rear surtace
6206F500
01-005-21 95 SERIES
a3
3D95S-W-1 RIGHT SIDE VIEW (For EC35Z,ZS-2)
Coolant (drain)
-
II
-
Crankshaft center
\ / i
324.5 )
Flywheel housing
rear surface
6206F501
95 SERIES 01-005-22
@
3D95S-W-1 FRONT VIEW (For EC35Z,ZS-2)
L 509.5
285 Water temperature switch
/
Water temperature
gauge pick-up port
/
8
-I
Crankshaft
-~
center
6206F502
95 SERIES
O’
-oiF23
3D95S-W-1 REAR VIEW (For EC35Z. ZS-2)
Crankshaft center
6206F503
95 SERIES 01-005-24
@a
34.8
Flywheel housing rear surface
_-
~ t-l
u 34.8
4D95S-W-1 RIGHT SIDE VIEW (For D20,21-6)
-
-
-
.I
03
- 0
-
6204F207
95 SERIES 01-005-26
@
GENERAL
4D95S-W-1 FRONT VIEW (For D20,21-6)
289.5
I *
Crankshaft center
245 225
6204 F208
01-005-27 95 SERIES
a3
GENERAL GENERALASSEMBLY DRAWING
4D95S-W-1 REAR VIEW (For D20,21-6)
1
,
7
Crankshaft center
IO-10x1.5
Depth I8
(239) (259) I
6204FZG9
95 SERIES 01-005-28
@
4D95L-1 LEFT SIDE VIEW (For PC60-3)
Out let for heater
Xrection of wind Water temperature gauge pick-up

/
Crankshaft center
n!
2 4 - 10x1.5
O’-go6 95 SERJES
4D95L-1 RIGHT SIDE VIEW (For PC60-3)
rankshaft center
4 - 10 x’1.5 Oil pressure switch

15
6204FOO2
95 SERIES Ol-go7
GENERAL
4D95L-1 FRONT VIEW (For PC60-3)
312
4
Dust indicator pick-up
ankshaft center
6204FOO3
0 l-$08 95 SERIES
4D95L-1 REAR VIEW (For PC60-3)
i’
/
6 - 12x1.75
6204 FO04
95 SERIES 0 1-go9
4D95L-1 LEFT SIDE VIEW (For PC60-5, PC6OU-5)
+ 760.0 .-P
-;
2
Direction z
of wind
Crankshaft center
Depth 18
F614601051
Ol-g9-1 95 SERIES
4D95L-1 RIGHT SIDE VIEW (For PC60-5, PC6OU-5)
208.2
Coolant (To radiator)
Crankshaft center
4-12x1.75, 3
Depth 21
I
pl_ ’ a
15.4- z
N
479.4 45
F614601052
95 SERIES 0 l -0;9-2
4D95L-1 FRONT VIEW (For PC60-5, PC6OU-5)
270.7\_j
F614601053
0 l -0;9-3 95 SERIES
4D95L-1 REAR VIEW (For PC60-5, PC6OU-5)
11-10~~~_. .._
I
I
225 225
I 1
F614601054
95 SERIES
Ol-0$9-4
4D95L-W-1 LEFT SIDE VIEW (For WA40-1)
Direction of wind
Tachometer pick-up
Crankshaft center
6204FOO5
Ol-$lO 95 SERIES
4D95L-W-1 RIGHT SIDE VIEW (For WA40-1)
Coolant (to radiator)
6204FOO6
95 SERIES Ol-gll
4D95L-W-1 FRONT VIEW (For WA40-1)
Outlet for heater

_ a307.1 f
Water temperature gauge pick-up
/
ft center
6204FOO7
01-$12 95 SERIES
4D95L-W-1 REAR VIEW (For WA40-1)
Crankst
6204FOO8
i
/
6--12X I .75
01-$13
GENERAL
S4D95L-1 LEFT SIDE VIEW (For PCIOO-5, PC120-5)
Dire
3 Of \I\
.4-10X 1.5 Depth 18
Cranl aft center
u!
4-10 X 1.5 Depth18
95 SERIES
o’-oi3-1
S4D95L-1 RIGHT SIDE VIEW (For PC1 00-5, PC120-5)
‘\ 4-10X I .5Depth 18
15.4
: 226.4336.4 -I 1
419.4
6206F901 A
95 SERIES
o’-G
3-2
S4D95L-1 FRONT VIEW (For PC1 00-5, PC1 20-5)
605 I
H
radiator)
shaft center
6206F902 A
01-023-3 95 SERIES
S4D95L-1 REAR VIEW (For PCIOO-5, PC1 20-5)
6-12Xl.75Depth20
eJ PI I-lOXl.sDepth 18
240 240
b-
6206F903A
95 SERIES
O’-“A3-4
S4D95L-1 (PClOO-6) * There may be differences according to the

machine model.
View from left
Water temperature
gauge pickup pot-t
4- 10 x 1.5 depth 18
Center of crankshaft
479.4 ’ . SME00211
View from right
1. Engine cooling
z water drain plug
Ill -
Center of crankshaft
‘Oil pressure switch (low pressure)
Oil pressure switch (high pressure)
479.4 . 1451_ SME00.212
95 SERIES
*’-“k3-5
S4D95L-1 (PClOO-6)
View from front
From radiator
- Center of cranksh laft
SME00213
View from rear
drill hole
IO x 1.5 drill hole
‘crankshaft
4 - 12 x 1.75 depth 20
depth 18
SME00214
95 SERIES
o’-%3-6
6D95L-1 LEFT SIDE VIEW (For PC1003, PClOOL-3, PC120-3)
Direction
,f wind
c3
c
:
6206FOO I
oy14 95 SERIES
6D95L-1 RIGHT SIDE VIEW (For PClOO-3, PClOOL-3, PC120-3)
ant :
adiatol r)
I-
Crankshaft centel
- - - I I I I r ,_ ,-
\I/1 I
6206FOO2
95 SERIES 01-p
GENERAL
6D95L-1 FRONT VIEW (For PClOO-3, PClOOL-3, PC12031
6206FOO3
01-p 95 SERIES
6D95L-1 REAR VIEW (For PClOO-3, PClOOL-3, PC120-3)
,- 655 /
_
center
_
A \-?c-I I
12- IOX 1.5’
CL
95 SERIES 01-$17
S6D95L-1 LEFT SIDE VIEW (For PC150-3, PC15OLC-3)
Coolant (from radiator)
Water temperature gauge pick-up
e \
jirectio
If wind
_l5.4
Crankshaft center
,”
z
37
6-10X
\:
z 4-‘2x ‘.75
z
m
.E
654.4 z
2
6207F001
Ol-$18 95 SERIES
S6D95L-1 RIGHT SIDE ‘VIEW (For PC150-3, PC15OLC-3)
Crankshaft center
/ 1.5
4-12X 1.75
15.4
s
_m
654.4 45 45
)T-
6207~002
95 SERIES 01g19
S6D95L-1 FRONT VIEW (For PC150-3, PC15OLC-3)
Cra
6207FOO3
01 g20 95 SERIES
GENERAL
S6D95L-1 REAR VIEW (For PC150-3, PC15OLC-3)
12- IOX 1.5

’ ) 240 ) 240 1
6207FOO4
95 SERIES
01g21
S6D95L-1 (PC200-6) * There may be differences according to the

machine model.
View from left
-Center of crankshaft
SME00215
View from right
Oil cooler cooling

_ water drain plug
- Engine cooling water

drain plug
Oil pressure switch
Cenl :er of crankshaft
SME00216
95 SERIES
o’-02-’
S6D95L-1 (PCZOO-6)
View from front -
Center of crank
SME00217
View from rear I-
IO x 1.5 drill hole - of crankshaft
2 - 8H8 depth 20-
SME00218
95 SERIES
o’-02’-2
1
SA6D95L-1 LEFT SIDE VIEW (For PC220-5)
1127 128.4
45 145I_ 654.4
cl
6206F848
O’-k822 95 SERIES
SA6D95L-1 RIGHT SIDE VIEW (For PC220-5)
Crankshaft center
\ 5-10x1.5
Depth 20
c
654.4 145 I 45 -
6206F649
95 SERIES
01:23
SA6D95L-1 FRONT VIEW (For PC220-5)
6206F850
95 SERIES
SA6D95L-1 REAR VIEW (For PC220-5)

164
4 -
6206F851
95 SERIES 0 1-g25
SA6D95L-1 (PC220-6) + There may be differences accol *ding to the

machine model.
View from left
1140
1
Center of
crankshaft
c
3-10x 1.5
depth 18
70
/II 4545
i Orll d
SME00219
View from I
1&Y
654.4 ’ I45l45l
SME00220
c 881.4
O’-OF 95 SERIES
GENERAL
SA6095L-1 (PC220-6)
View from front
Center of CrankshaftI,,
SME00221
View from rear
8-lOx1.5depth18
enter of crankshaft
11 -10 x 1.5 depth 18
SME00222
95 SERIES
O’-“z5-2
GENERAL ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE

3D95S-W-1 (For PC40-5, PC40-6)
Flywheel horsepower: 38.5 HP/2,600 rpm
Maximum torque: 12.5 kgm/l,800 rpm
Minimum fuel consumption ratio: 193 g/HPh
20
30
25
c
I
5
a 20 220
2
210 2
h
15 200 p
.o
190 ;i;
L
s
180 'g
E
170 :
1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
Engine speed (rpm)
F614601070
O’-:26 95 SERIES
3D95S-W-1 (For PC5OUU-1)

15
Torque
-z
--
z
10 ;
/-
z
b
+
5
220
210 g
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
'Enginespeed (rpm)
F614601071
95 SERIES
O’-ki27
GENERAL
3D95S-W-1 (For EC35Z,ZS-2, EC35ZSB-2)

Flywheel horsepower: 35 HP/2,650 rpm
Maximum torque: 13 kgm/l,800 rpm
Engine speed (rpm)
6206F508
O’-:** 95 SERIES
4D95S-W-1 (For D20A. P, S-6)

(For D21A, P, S-6)
Maximum torque: 15.5 kgm/1,300 rpm
25
230
20 220
Z
210 Et
9
15 200 .p
E
190 s
._
E
10 180 E
zi
- 170 :
0
5 160 3
I.&
- 150
0
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
Engine speed (y-W

F614601072
95 SERIES
O’-ki29
4D95S-W-1 (For EC502, ZS-5)

Flywheel horsepower: 45 HP/Z,800 rpm
Maximum torque: 15 kgm/2,000 rpm
.55
5
50
0
/ Y
45
5-
0
1400 I600 I800 2000 2200 2400 2600 2800 3000 3200
Engine speed (rpm)
6206F618
O’-ki30 95 SERIES
4D95S-1 (For DZOAG, P, PG. PL, PLL-7(A))

(For D21 A, AG, PG. S, QG-7)
20
15
10 z?
J
P
:
5
45
40
35
30
25
6
E.
S
g 20
0
15
10
0 1000 1200 1400 1600 1800 2000 2200 2600 2800
Engine speed @pm)
F614601101
95 SERIES 01-030-l
0
4D95S-1 (For WA50-1)

20.
-210
15 200
-,I90
lo--. e’ consumpti0n ratio 180

- --
- 170
5 160
- 150
0 IO00 I200 I400 I600 1800 2000 2200 2400 2600 2800
Engine speed (rpm)

6202FOOl
95 SERIES
01:31
4D95L-W-1 (For WA40-1)

Flywheel horsepower:. 41 HP/2,200 rpm
Maximum torque: 19 kgmD.400 rpm
50
40
30
z
I
;
a
;
0
20
10
0
1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine speed (rpm)

F614601040
O’-ki32 95 SERIES
4D95L-W-1 (For WA70-I)

Torque
50 / 0
20 220
- 210
200
190
10 180
170
160
150
0 800 1000 1200 1400 1600 1800 2000 2200 2400
Engine speed ham)
F614601073
95 SERIES
O’-6i33
(For PC6OL-3,
Maximum 20 kgm/l,500 rpm

20
60
z
200 4
190 B
.z
180 2
6
170 'E
160 :
.,=
8
150 =
I=
0 1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine speed (rpm)
F614601050
01 -c&34 95 SERIES
4D95L-1 (For PC60-5, PC6OU-5)

50 -
40 -
5
;
a
;
0
30 -
20
180
10
60
100 1600 1800 2000 2200 2400
Engine speed (rpm)
F614601055
95 SERIES
O’ -;35
4D95L-1 (For PC60-5, PC6OL-5, PC6OU-5)

70 20
65 15
-z
60 m
- Y
10 a,
$
b
I-
55
50
45
25
5
T
-150 ,'
O- 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
Engine speed hrn)
F614601074
95 SERIES
O’-ki36
4D95L-1 (For PC60-6, PC70-6)

20
10 ~- --
0. 600 800 1000 1200 1400 1600 1800 2000

2200 2400
Engine speed (rpm)
F614601075
95 SERIES
01-z37
4D95L-1 (For PC60-7, PC70-7)

Flywheel horsepower: 40.3 kW (54 HP)/1,900 rpm
226 Nm (23 kgm)/1,500
Minimum fuel consumption
60
50
40
30
/
/
I \
20
IO
0
600 800 IO00 I200 1400 1600 1800 2000 2200
Engine speed (rPm)

6206F1018
95 SERIES
O’-Oi7-’
4D95L-1 (For PC75UU-1)

Flywheel horsepower: 54 HP/l ,900 rpm
35
E 30
E
S
P
05 25
20
15
600 800 1200 1400 1600
Engine speed (rpm)
F614601076
95 SERIES
O’-OZ7-*
GENERAL ENGINE PERFORMANCE CURVE,
4D95L-1 (For PC75UU-2)

Maximum torque: 226 Nm (23 kgmV1,500 rpm
Minimum fuel consumption ratio: 217 g/kWh (160 g/HPh)
15
z
m
Y
60 IO sj
a-
b
l-
55 5
50 0
45
25
600 800 1000 1200 1400 1600 1800 2000 2200 2400
Engine speed (rpm) 6206F957
O’-if8 95 SERIES
4D95L-1 (For PC80-3)

20
210 2
!?
200 5
190 -@
180 ,E
'L
170 E
z
160 6
o
1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine speed (rpm)
F614601077
95 SERIES
01-$39
GENERAL
4D95L-1 (For PC90-1)

60
0
800 1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine speed (rpm)
F614601078
O’-ii40 95 SERIES
4D95L-1 (For PW60-3)

Flywheel horsepower: 66 HP/2,500rpm
Maximum torque: 2 1.4kgm/ 1,600rpm
Minimum fuel consumption ratio: 165glHph
-
_ Fuel consumption ratio
0 1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine speed (rpm) F614601079
95 SERIES
0'-ii4'
4D95L-1 (For EC752, ZS-3)

Flywheel horsepower: 48 kW (64 HPV3,OOO rpm
Maximum torque: 197 Nm (20.1 kgm)/2,000 rm
Engine speed (rpm)
o’-“iY 95 SERIES
4D95L-1 (For D21A-7TI

Flywheel horsepower: 37 kW (49 HP)/2,450 rpm
Maximum torque: 172 Nm (17.5 kgmV1,300 rpm
20
15
-z
102
2
e
5r-o
50, 0
40
0 600 1000 1200 1400 1600 1800 2000 2200 2400 2600 2600
Enginespeed (rpm)
SDEOOl62
95 SERIES
O’-Oil-*
S4D95L-1 (For PCIOO-5, PCIOO-6)

40
Torque
/---- 30
-z
m
Y
20 sj
P
z
10
90
80
70
/ II
60 -
50 -
40 220
/ r
210 z
F
30 - 200 B
0
190 '5
\
E
20 180 ';'a
E
170 2
c
Qti, 160 x
lO--p--w
5
150 I=
0
1000 1200 1400 1600 1800 2200 2400 2600
Engine speed (rpm)
F614601080
O’-:42 95 SERIES
S4D95L-1 (For PC120-5, PC120-6, PC128UU-1)

Flywheel horsepower: 83.8 HP /2,200 rpm
10 -_ 160
/
- 150
800 1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine speed (rPm)
F614601081
95 SERIES
O’-:43
S4D95L-1 (For JV7ODW-1)

Flywheel horsepower: 55.2 kW (73.9 HPY2,OOO rpm
Maximum torque: 299 Nm (30.5 kgm)/1,500 rpm
L 60- 60
:
0 40
a 50-
a, 50
v)
z
_c 40- 30 40
-
aI
a,
1I 30- 30
3
x 20
-
IL I
20- 20
10
10- lo-
o- 0 o ::
600 1000 1200 1400 1600 1600 2000 2200 2400
Ens i ne speed (rpm) SDE00921
O’-Oi3-’ 95 SERIES
GENERAL
6D95L-1 (For D31A. P, S, Q-1 8)

10
80
60
220
210 f
z
200 c"
.P
190 P
6
180 ‘g
E
170 :
z
160 z
zl
150 IL
1000 1200 1400 1600 1800 2000 2400
Engine speed (rpm)
F614601082
*’-li44 95 SERIES
6D95L-1 (For D31E. P, PL, PLL, S, Q, AM, SM-20(A))

25
20
60
50
K
11
40 220 =
5
n
S 210 %
0
2
30 200 .P
190 E
6
180 'g
E
170 2
160 5
~
150 z
0 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
Engine speed (rpm)
F614601102
95 SERIES
O'-%f4-'
6D95L-1 (For D37A-2, D37P-2A)

40
IO
60 .
200
190 g
?
180 p
.P
z
170 L
s
160 'g
E
150 2
6
140 _"
2
130 u
0
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
Engine speed (rpm)
F614601083
O’-z4-* 95 SERIES
6D95L-1 (For D37E. P-5(A))

80
60
50
r
E
5
%a 40
30
20
Fuel consumption ratio

lO---------'
0
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
Engine speed @pm)
F614601103
95 SERIES Ol-$45
GENERAL
6D95L-1 (For PClOO-3, PClOOL-3)

Flywheel horsepower: 79 HP/2,100 t-pm
Maximumtorque: 30.5 kgm/l,400 rpm
I I
1600 1800 2000 2200 2400 2600
0 800 1000 1200 1400
Enginespeed (rpm)
F614601041
O’-r
95 SERIES
6D95L-1 (For PC120-3)

Maximum toqrue : 31.5 kgm/l,400 rpm
80
60
220
210
200
.C
E
180
E
I I I 2
Fuel consumotion ratio
0 1000 1400 1800 2200 2600
SERIES
O’
6D95L-1 (For PW150-1)

80
60
z 50
E
z
a
S
0 40
30
20
10
0 1600 1800 2000 2200 2400 2600 2800
Engine speed (rpm)
F614601043
O’-ii4* 95 SERIES
6D95L-1 (For WA1 00-1, WRI I-l)

Flywheel horsepower: 73HP/2,400 rpm
Maximum torque: 29kgm/l,600 rpm
90
80
70
60
50
40
30 200
190
20 180
170
10 160
150
0 1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine speed (rpm)
F614601051
95 SERIES 01$49
6D95L-1 (For WAIOO-1, Engine No. 46799 and up)

40
- - T%ue
-- -
\
60
Lz
F
n
.P
20 F
\ 6
- consumption ratio ';a
E
10 :
5;
"
s
O-
1400 1800 2200 2600 3 IO
Engine speed (rpm)
O’ 95 SERIES
6D95L-1 (For WA1 20-I)

r35
\
\ - 30
\
I 25
80
60
/ u
50
30
/
20
Fuel consumption ratio
10
800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
Engine speed (rpm)
F614601085
95 SERIES 01p
6D95L-1 (For GD313A-1)

40
190 .g
'80 5
._
FM consumption ratio 'a
170 E
2
160 z
5
150 2
1600 1800 2000 2200 2400 2600 2800
Engine speed (rpm)
F614601086
0 1-t&52 95 SERIES
6D95L-1 (For EG60-1, EG65-1)

Flywheel horsepower: 65.1 HP/l,500 rpm (50 Hz)
74.9 HP/l,800 rpm (60 Hz)
100
80
60
?i 60 Hz -*
E
'j 50
p.
2
40
220 z
:
30 210 p
200 -;
190 .s
'L
180 E
2
170 z
u
160 L?
1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
Engine speed (rpm)
F614601087
95 SERIES
o'-$53
S6D95L-1 (For PC1 50-3, PC1 5OLG3)

30
-c
20 ;
s
b
k
IO
200 2
s
190 '5
180 .:
'L
170 $
160 2
z
150 I=
0 1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine speed (rpm)

F614601052-1
Ol-$54 95 SERIES
S6D95L-1 (For PC1 50-5)

70
/
50
40
/
/
30 2
200 %
B
- 190 .p
20 z
180 :
.P
- z
-170 E
10
-- zi
160 6
0
-150 5
I=
O- I
600 800 1000 1200 1400 1600 1800 2000 2200 2400
Engine speed (rpm)
F614601088
95 SERIES Ol-g55
S6D95L-1 (For PC200-5, BR200-1)

z
z
80
S
0.
5
0
60
0 600 800 1000 1200 1400 1600 1800 2000 2200 2400
Engine speed Irpm)

6206F803A
O’-F 95 SERIES
S6D95L-1 (For PC200-6)

Maximum torque: 490 Nm (50 kgm)/1,600 rpm
30 z
2
140
5
P
20 z
E
E
5 80
p.
5
0
60
0 400 800 1200 1600 2000 2400
Engine speed (rpm)
6206FlOOl
95 SERIES
O’-v-’
S6D95L-1 (For PWI 00-3, Engine No. up to 36829)

Flywheel horsepower: 99 HP/l,900 rpm
3 I
3 / I
0
/
0 220
210 g
F
0 200 9
0
190 'E
6
0 180 'XT
r
170 fj
0 160 :
3
150 LL
_
”
600 800 1000 1200 1400 1600 1800 2000 2200 2400
Engine speed (rPm)
F614601089
95 SERIES
01-$57
S6D95L-1 (For PWI 00-3, Engine No. 36830 and up)

40
90
80
70 _
60
50
40
30
20
10
0
800 1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine speed (rpm)
F614601090
Ol-g58 95 SERIES
S6Dg5L-1 (For WA150-1, Engine No. up to 47624)

60
190 B
.P
180 E
:
170 ‘i
160 a
5
0
0 1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine speed (rpm)

F614601053
95 SERIES 01-$59
S6D95L-1 (For WA150-1, Engine No. 47625 and up)

Maximum torque: 392 Nm (40 kgm)/1,600 rpm
800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
Engine speed Wxn) 6206F968
O’-if0 95 SERIES
S6D95L-1 (For WA180-1)

Flywheel horsepower: 110 HP/2300 rpm
40
30
z
01
120
110
80
40
30 _ Z
180 %
9
20 -
.P
E
170 6
._
'L
E
10
2
160 6
0
z
I=
800 1000 1200 1400
Ob 1600 1800 2000 2200 2400 2600 2800
Engine speed (rpm)
F614601091
95 SERIES
O’-FO-’
S6D95L-1 (For WA180-3)

Flywheel horsepower: 82.0 kW (110 HP)/2,400 rPm
-40 400
.30 300 a,
3
CT
I L
20 200 :
IO 100
I
0 Lo
a 3
z Y
120-
80-
IOO- 100
80- 60- 80
60- 60
40-
40- 40
20-
20- 20
o- o- n
”
" 1000 1200 1400 1600 1600 2000 2200 2400 2600
Ens i ne speed (rpm) SDE00922
O’-%“-2
95 SERIES
1
S6D95L-1 (For WA250-31

E
9 E
50 -500
40 -400
IO 100
0 / 0
1200 1400 1600 1600 2000 2200 2400 2600
Ens i ne speed (r pm) SOE00923
95 SERIES
O’-o&o-3 1
S6D95L-1 (For GD461A-1)

40
30
-z
rsr
Y
120 \ .20 2
P
:
110 I 10
/
100 0
50
40 -
30 2
%
- 200 ??
.?
20 190 E
5
A' -180 'g
E
lo.-\ / 170 z
- Fuel consumption ratio 6
-160 "
%
0 IL
1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
Engine speed (rpm)
F614601092
95 SERIES
O’-hi?’
S6D95L-1 (For GD51 OR-l)

50
40
10
80
170 5
;
"
z
160 y'
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
Engine speed @pm)
F614601093
01-t&62 95 SERIES
S6D95L-1 (For GD51 IA, R-l, GD513A, R-l)

50
40
30 $
Y
2
20 ;
10
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200
Engine speed (rpm)
F614601094
95 SERIES 01g43
S6D95L-1 (For LW80-1)

Flywheel horsepower: 110 kW (148 HPV3,OOO rpm
160-7
140-
/ I
IZO-
.< I \
\
IOO-
\
40-
0
1000 is00 2000 2500 3000 3500
Engine speed @pm)
62OSF964
O’-if3-’ 95 SERIES
S6D95L-1 (For EG85B, BS-1, DCA85, QAS85)

Flywheel horsepower: 85.8 HP/l,500 rpm (50 Hz)
99.6 HP/l,800 rpm (60 Hz)
Minimum fuel consumption ratio: 165 g/HPh (at rated output)
90
80 -
I
70 ,
50Hz--c 60 Hz-m
60
50
40
30
20
10
0
1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
Engine speed (rPm)
F614601095
95 SERIES
O’-Oi3-*
SA6D95L-1 (For PC220-5, BR300-I)

Torque - 60
.
--
I
J
e
20 g
60
Engine speed (rpm)

6206F804A
O’-if4 95 SERIES
SA6D95L-1 (For PCZZO-6)

0 400 800 1200 1600 2000 2400
Engine speed (rPm)
6206F1002
95 SERIES
O’P
SAA6D95LE-1 [WING100 (LWIOO-1, LWIOOM-I)]

Flywheel horsepower: 118 kW {I58 HPY3,OOO rpm (Net)
Maximum torque: 457 Nm j46.6 kgmI/?,800 rpm (Net)
- - - - - E
s
I-2.
2
- - - - - -50 500
-
/ ‘u/e
- - \ t - .40 400
7 i a,
zl
- - - - - \-
.30 300 :
a
/ c
- - - - - .20 200
- - - - - - - - - -10 100
- - - - - ,O 0
3
_: :: /
150 - - - - -
I
-
7
IOC
/
100 - - - - -
.i
<
50
/
- - - -
I
50 -
0 0 it- - - - - - -
500 1.000 1.500 2~000 2.500 3.000
Ens i ne speed (r pm) SWE01174
O’-Oi5-’ 95 SERIES
GENERAL WEIGHT TABLE
WEIGHT TABLE
* There may be differences according to the machine model.
3D95 4D95
No Item Main item
s-w-1 s-w-1
1 Turbocharger -
Cylinder head, valve,

2 Cylinder head assembly 22 28
valve sorino
Cylinder block, main bearing
3 Cylinder block assembly 66 70
block, cylinder liner
4 Gear case (front cover) 3 3 3 3
--
5 Oil pan 1.6 2 2
13
f
I 22
6 Flywheel assembly Flywheel, ring gear 27 25 21
E -
c
-
I 40
11 11
5
7 Flywheel housing 11
Rear plate:
20 25.5
-
8 Crankshaft assembly Crankshaft, crankshaft gear 21 25 25 1 25
Camshaft, cam gear, thrust plate 3.2 5.5
+-I-+
9 Camshaft assembly
Piston, piston ring, piston pin,

10 Piston, connecting rod assembly 2 2
connecting rod
-
c
11 Oil pump 0.5 0.5 0.5 1 0.5
-
10
12 Fuel injection pump 4.2 9 9
12
13 Water pump 5.2 6 3.1 6
-74 Alternator These differ according to the machine model.

Ti
- Starting motor
(See STRUCTURE AND FUNCTION)
- - - -
-16 Air compressor
O’-F 95 SERIES
GENERAL WEIGHT TABLE
Unit: kg
4D95 S4D95 SA4D95 6D95 S6D95 SA6D95 Remarks
L-l L-l L-l L-l L-l L-l
- I 7 I 7 I - I 7T6 I ‘I” I LW80-1
28 I 28 I 28 I 41 I 41 I 41 I
70 70 70 105 105 105
- - - - PCIOO, 120, PC128UU
2.6 2.4 2.6 2.6 D31, PC150, WA150, GD355, EG60,

3 2.6 EG85, WAIOO, WA200, WRII
3 3 PWIOO, PWl50
2 6 6 6 WA70
2 16
- - 19 WA40
16
4.4 - - 9.1 9.1 PClOO, 120, PC128UU, PC200-6, PC220-6
22 I I - I - I - I PC60, PC75, PC80, PW60, WA70
25 - - 25 LW80- 1
I
- 27 - 27 27 1 F”;;Vl;J, PCl28Uy EGT EG85
25 D31 PC100 PC120 PC128UUbC150 iv'000
- - 30 30
- - 32 32 WAIOO, WA150, WRII, PC200-6, PC220-6
- - - - 1 WA40
PC60, PC75, PC80, PW60, PWIOO,

11 25 25 25 WA70, WA100,WA150,WR11, GD355,
EC50, EC75, EG33, EG40, EG60, EG85
- 25
11 - WA80- 1
28
25 28 - D20,D21,D31,PC100,PC120,PC128UU, PC150,
PW15O.WA40
25.2 - - - - PCIOO, 120, PC128UU
25 25 25 36.5 36.5 36.5
5.5 5.5 5.5 7.5 7.5 7.5
2 2 2 2 2 2
0.5 0.5 0.5 0.5 0.5 0.5
10.5 13.5 13.5 13 D31, PC60, PC80, PW60, WA70

IO 10
9 - 12 12 D31, PC60, PC80, PC200-6, PC220-6
6.5 6
6 6 6 6.5
7.1 7.1 LW80-1, PC220-6
- - - - 7.0 -
95 SERIES
O’F7
ENGINE
II STRUCTURE AND FUNCTION
GENERAL STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-001-1 COOLING SYSTEM

Cooling system chart .................................. II-089
INTAKE AND EXHAUST SYSTEM Water pump ................................................. II-092
Intake and exhaust system . . . . . . . . . . . . . . . . . . . . . . 1 I-009-2 Corrosion resistor ........................................ 1 I-093
FTG air cleaner . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 11-016-I Thermostat and fan drive ........................... 1 I-094
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-019
After-cooler . . . . . . . . . . . . . . . .._............................. 1 I-019-7 ELECTRICAL SYSTEM
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-096
ENGINE BODY Starting motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-097
Cylinder head .............................................. 1 I-020 Electrical intake air heater .. . . . .. .. . . .. . . . . .. . . . . 1 T-099
Valve system ............................................... 1 I-030
Cylinder block .............................................. 1 I-036 ACCESSORY
Cylinder liner ............................................... 1 I-040 Air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 l-101
Main circulation system .............................. 1 I-042
Timing gear ................................................. 1 I-054
Flywheel and flywheel housing .................. 1 I-058
LUBRICATION SYSTEM
Lubrication system chart . . . .. . . . . . .. . . .. . . . . .. . . . 1 I-059
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-063
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-063-I
Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-064
FUEL SYSTEM
Fuel system chart ........................................ 1 I-066
Fuel injection pump ................................ 11-067-I 1
Governor ...................................................... 1 I-080
Feed pump ................................................... 1 I-084
Fuel injection nozzle .................................... II-086
Fuel cut solenoid ...................................... 1 I-087-2
Engine stop motor .................................... 1 I-087-5
Fuel filter ................................................. 11-087-I 0
Water separator .......................................... II-088
95 SERIES
’‘iO’
STRUCTURE AND FUNCTION GENERAL STRUCTURE
GENERAL STRUCTURE
3D95S-W-1 * There may be differences according to the machine model.
19 20. 21 22 23 24
18
17
18
III ~28
15
14
6206F513A
1. Front seal 11. Oil ring 21. Valve spring

2. Crankshaft pulley 12. Second ring 22. Head cover
3. Crankshaft 13. Top ring 23. Rocker arm spring
4. Crankshaft gear 14. Piston 24. Rocker arm bracket
5. Connecting rod 15. Water pump 25. Cylinder head
6. Cam bushing 16. Intake valve 26. Cylinder block
7. Cam gear 17. Exhaust valve 27. Push rod
8. Front cover 18. Thermostat 28. Flywheel
9. Connecting rod bushing 19. Fan 29. Tappet
10. Piston pin 20. Valve guide 30. Main bearing
“%‘-’ 95 SERIES
GENERAL STRUCTURE
6206F514
41. Oil filler cap Engine

31. Rear seal
42. Rocker arm - Model: 3D95S-W-1
32. Ring gear
33. Rear plate 43. Fuel injection nozzle . Type: In-line, 3 cylinder, water cooled,
44. Fuel filter swirl type combustion chamber,
34. Thrust bearing
45. Fuel injection pump 4 cycle diesel engine
35. Camshaft
36. Connecting rod cap 46. Starting motor
37. Oil pan 47. Oil strainer
38. Oil filter
39. Oil level gauge
95 SERIES
’ 1-oP2
4D95L-1
20 21 22 23 24 25
13
12
11
10
9
8
7
6
5
4
3
2 BI I’ I
6204FlOl
1. Crankshaft pulley 11. Oil ring 21. Valve guide

2. Front oil seal 12. Second ring 22. Valve spring
3. Crankshaft 13. Top ring 23. Cylinder head cover
4. Crankshaft gear 14. Fan pulley 24. Rocker arm bracket
5. Connecting rod 15. Piston 25. Rocker arm spring
6. Camshaft bushing 16. Water pump 26. Cylinder head
7. Camshaft gear 17. Intake valve 27. Cylinder block
8. Front cover 18. Exhaust valve 28. Push rod
9. Connecting rod bushing 19. Thermostat 29. Flywheel housing
10. Piston pin 20. Fan 30. Flywheel
’ ’-go2 95 SERIES
6204F102A
31. Ring gear 41. Oil cooler Engine: 4D95L-1

32. Tappet 42. Exhaust manifold Type: In-line, 4cylinder,
33. Main bearing 43. Oil filler cap water-cooled, direct
34. Rear oil seal 44. Rocker arm fuel injection, 4-cycle
35. Thrust bearing 45. Fuel injection nozzle diesel engine.
36. Oil pan 46. Electrical intake air heater
37. Camshaft 47. Intake manifold
36. Connecting rod cap 48. Fuel injection pump
39. Oil filter 49. Starting motor
40. Dipstick 50. Oil strainer
95 SERIES
’ ’-go3
4D95L-W-1
4D95S-W-1
3‘8 i7 3’6 3’5 6204F103A
1. Crankshaft pulley 11. Oil ring 21. Valve guide

2. Front oil seal 12. Second ring 22. Valve spring
3. Crankshaft 13. Top ring 23. Cylinder head cover
4. Crankshaft gear 14. Water pump 24. Rocker arm bracket
5. Connecting rod 15. Piston 25. Rocker arm shaft
6. Camshaft bushing 16. Fan pulley 26. Cylinder head
7. Camshaft gear 17. Intake valve 27. Cylinder block
8. Front cover 18. Exhaust valve 28. Push rod
9. Connecting rod bushing 19. Thermostat 29, Flywheel housing
10. Piston pin 20. Fan 30. Flywheel
11 -go4 95 SERIES
6204F104A
31. Ring gear 41. Oil cooler Engine: 4D95L-W-1

32. Tappet 42. Exhaust manifold
4D95SW-1
33. Main bearing 43. Filler cap
Type: In-line, 4qlinders, water cooled, pre-
34. Rear oil seal 44. Rocker arm
combustion chamber (whirl chamber)
35. Turust bearing 45. Glow plug
36. Oil pan type, 4-cycle diesel engine
46. Fuel injection nozzle
37. Camshaft 47. Hot plug
38. Connecting rod cap 48. Intake manifold
39. Oil filter 49. Fuel injection pump
40. Dipstick 50. Starting motor
51. Oil strainer
95 SERIES l l -go5
6D95L-1
6206FlOl A
1. Fan 11. Piston 21. Cylinder block

2. Camshaft gear 12. Intake valve 22. Push rod
3. Front cover 13. Exhaust valve 23. Flywheel housing
4. Connecting rod bushing 14. Valve guide 24. Flywheel
5. Piston pin 15. Thermostat 25. Tappet
6. Oil ring 16. Valve spring 26. Camshaft bushing
7. Second ring 17. Cylinder head cover 27. Rear oil seal
8. Top ring 18. Rocker arm shaft 28. Main bearing
9. Water pump 19. Rocker arm bracket 29. Ring gear
10. Fan pulley 20. Cylinder head 30. Thrust bearing
‘-’-kios 95 SERIES
47
43 48
49
42
50
6206F IO2
31. Camshaft 41. Dipstick Engine: 6D95L-1

32. Oil pan 42. Oil cooler Type: In-line, 6qlinders, water-cooled, direct
33. Connecting rod 43. Exhaust manifold fuel injection, 4-cycle diesel engine.
34. Connecting rod cap 44. Filler cap
35. Crankshaft 45. Rocker arm
36. Crankshaft gear 46. Fuel injection nozzle
37. Front oil seal 47. Electrical intake air heater
38. Crankshaft pulley 48. intake manifold
39. Vibration damper 49. Fuel injection pump
40. Oil filter 50. Starting motor
51. Oil strainer
95 SERIES 11-go7
S6D95L-1
*.
_I
6207FlOlA
1. Thermostat 11. Cylinder head cover 21. Main bearing cap

2. Valve spring 12. Cylinder head 22. Main bearing cap bolt
3. Valve guide 13. Tappet 23. Crankshaft gear
4. Intake valve 14. Flywheel housing 24. Front oil seal
5. Piston 15. Ring gear 25. Crankshaft
6. Exhaust valve 16. Flywheel 26. Connecting rod cap
7. Valve seat insert 17. Camshaft 27. Connecting rod bearing
8. Top ring 18. Rear seal 28. Crankshaft pulley
9. Second ring 19. Main bearing 29. Vibration damper
IO. Oil ring 20. Thrust bearing 30. Camshaft gear
’’-go* 95 SERIES
42
6207 F102A
31. Connecting rod 41. Fuel injection nozzle Engine: S6D95L-1

32. Piston pin 42. Electrical intake air heater Type: In-line, 6cylinder,
33. Water pump 43. Intake manifold water-cooled, direct

34. Cylinder block 44. Fuel injection pump fuel injection, 4-cycle
35. Fan pulley 45. Starting motor diesel engine with
36. Fan 46. Oil strainer turbocharger.
37. Turbocharger 47. Oil filter

38. Oil filler cap 48. Dipstick
39. Rocker arm 49. Oil cooler
40. Intake connector pipe 50. Exhaust manifold
95 SERIES
’’-go9
STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM
INTAKE AND EXHAUST SYSTEM

3D95S-W-1 (EC352,ZS-2) * There may be differences according to the machine model.
INTAKE SYSTEM
:
1. Air cleaner
2. Hose
3. Intake manifold
A. Intake port
6206F515
EXHAUST SYSTEM
1. Exhaust manifold
2. Muffler
3. Pipe
B. Exhaust port
6206F516
95 SERIES
’ ’-OF2
4D95L-W- 1 (WA40-1)
rl
6204Flll
1. Intake manifold
2. Air cleaner cap
3. Air cleaner element
4. Air cleaner body
5. Air hose
6. Muffler
7. Exhaust pipe
8. Exhaust manifold
“iF” 95 SERIES
III
/---’
J
-T /6
6204F112
A. Air intake
B. Exhaust outlet
95 SERIES
’’%’’
Ir There may be differences according

4D95L-1 (PC60-3) to the machine model.
6204F107
1. Intake manifold
2. Air connector
4. Intake pipe
7. Muffler
8. Exhaust pipe
9. Exhaust manifold
‘Y2 95 SERIES
6204F108
A. Air intake
B. Exhaust outlet
95 SERIES
‘T3
4D95L-1 (PC1 00-6, PC120-6, PC128UU-1)

(Intake equipment)
d---t-!&#-+;
-ii----H--wi I j !
SME00223
1. Air connector A: Air supply inlet

3. Engine breather pipe
4. Intake manifold
“i’4 95 SERIES
S4D95L-1 (PCIOO-6, PC120-6, PC128UU-1)

(Exhaust equipment)
1. Muffler
SME00224
2. Exhaust pipe
3. Exhaust pipe (turbocharger - muffler)
4. Turbocharger
5. Exhaust manifold
95 SERIES
“-:‘5
6D95L-1 (PCIOO-3, PC120-3)
6206F103
1. Inner element 11. Connector pipe

2. Outer element 12. Exhaust manifold
3. Air cleaner body
4. Air hose
5. Connector
7. Intake manifold
8. Vacuator valve
9. Exhaust pipe
10. Muffler
95 SERIES
“%Y
6206F104
A. Air intake
B. Exhaust outlet
a. Dust indicator pickup port
95 SERIES
“-~5-2
S6D95L-1 (PC150-3)
1. Muffler
2. Intake manifold
4. Air cleaner body
5. Outer element
6. Inner element
7. Air cleaner cap
8. Turbocharger 6207F108
9. Exhaust pipe
’’‘k’5-3 95 SERIES
8
\
6207F109
A. Air intake
B. Exhaust outlet
95 SERIES
“-v4
S6D95L-1 (PC200-6)
(Intake equipment)
\ ,/
5
“A.,\ /
,’
/’
---__----
ME00225
1. Intake manifold A: Air supply inlet

3. Air connector
4. Engine breather (separately located breather)
’’-: 5-5 95 SERIES

SA6D95L-1 (PC220-6)
(Intake equipment)
’ A
B
ME00226
1. Engine breather (separately located breather) A. To aftercooler

2. Air connector B. To intake manifold
4. Intake manifold
95 SERIES
’’3 5-6
S6D95L-1 (PC200-6)
SA6D95L-1 (PC220-6)
(Exhaust equipment)
ME00227
1. Exhaust pipe
2. Muffler
3. Exhaust pipe (turbocharger - muffler)
4. Turbocharger
5. Exhaust manifold
’’-K’
5-7 95 SERIES
AIR CLEANER
1. Air cleaner body

2. Fin
3. Outer element
4. Inner element
5. Evacuator valve
6. Dust cap
A. To engine
F614601001
Structure and function EVACUATOR VALVE

. The air cleaner is a centrifugal type (with a built-in
cyclone tube) which also uses filter paper. The air
cleaner contains guide fins to whirl the intake air
and allow the separated coarse dust to accumulate
in the dust cap. The accumulated dust is drained out
of the air cleaner by means of a evacuator valve.
F614601002
Structure and function

. The evacuator valve is an automatic dust drain
rubber valve. The valve outlet port is kept closed
under negative pressure. When the engine stops, the
outlet port opens, discharging the dust.
11-p 95 SERIES
FTG AIR CLEANER
FHG type FTG type
Guide vane (sleeve)
6 5 4
6137FOO9-10
Features Structure
* The element has the same diameter but the outside * Air containing dust is sucked into the tangential
diameter of the body is smaller. through inlet (I), and the dust is separated out by the
[The inlet is in the direction of the connection, so a centrifugal separating effect of vane (3). With the
guide vane is not needed; ample centrifugal force addition of primary element (4), more than 99.9% of
can be obtained with a simple spiral guide vane.] the dust is removed, so the air is clean before it
* There is no dust pan or guide vane, so the structure passes through safety element (5) and outlet (2) and
is simpler. is sucked into the engine.
The dust and water separated out by vane (3) circu-
latesaround the inside wall of the body, and flies into
vacuator valve (6), from where it is automatically
discharged to the outside.
95 SERIES
’ ‘-P-l
DUST INDICATOR
F614601003
Structure and function Action required after the dust indicator actuates
The dust indicator is installed to the side of the air . When the dust indicator actuated (when the red
connector and connected of the air intake passage signal is indicated), clean or replace the air cleaner
between the air cleaner and the engine. It is elements and depress the top button to release the
actuated under the negative air intake pressure. notch and restore the indicator to its original
If the air cleaner is clogged with dust, the negative condition.
air pressure in the air intake passage will increase, * If the engine is operated again without cleaning or
compressing a spring in the dust indicator which replacing the elements, the dust indicator will
will, in turn, actuate the indicator. actuate again.
If the dust indicator is once actuated (indicating a
red signal), the notch will be applied, enabling us to
confirm the increased air intake resistance even
when the negative air pressure is eliminated (for
example, when the engine stops.)
Dust indicator actuating pressure:
635 mm Hz 0 or more
95 SERIES 1317
MUFFLER
A. From engine
F614601004

. The main purpose of this muffler is to muffler the
exhaust noise. The muffler also helps to lower the
exhaust temperature by expanding the exhaust air.
The heat and noise energy of the exhaust gases
which enter through the inlet port are reduced while
the gases pass through the large and small holes in
the muffler.
Many factors have been taken into consideration in
order to obtain a good match between the engine
and muffler performance, to ensure that the engine
performance is not adversely affected by the action
of the muffler and the exhaust resistance.
11-X$8 95 SERIES
TURBOCHARGER
T-31
10 11 12 i5
6207FllOA
1. Piston ring A. Ambient air inlet TURBOCHARGER

2. Back plate B. Compressed air outlet Type: GARRETT CO. T-31
3. Thrust bearing C. Exhaust gas inlet Overall length: 211 mm
4. Seal ring Overall width: 189 mm
D. Exhaust gas outlet
Overall height: 159 mm
5. Retainer E. Lubricating oil inlet
Weight: 7 k9
6. Center housing F. Lubricating oil outlet
Continuous rotating speed: 150,000 rpm
7. Journal bearing Max. air supply: 15.6 kg/min.
8. Piston ring Compression ratio: 2.8
9. Shroud Applicable exhaust temp.: Max. 700°C
10. Lock nut Direction of rotation: Clockwise
11. Blower impeller (see from blower side)
12. Blower housing
13. Turbine housing
14. Turbine impeller (Wheel shaft)
15. Thrust collar
95 SERIES
’l-F9
T31 (with waste gate) (LW80-1, LW80M-1)
1 2 3 4 56 7 8 9
6207FllOA-1
1. Piston ring A. Ambient air inlet TURBOCHARGER

2. Back plate B. Compressed air Type: GARRETT CO. T-31
3. Thrust bearing outlet Overall length: 220 mm
4. Seal ring C. Exhaust gas inlet Overall width: 200 mm
5. Retainer D. Exhaust gas outlet Overall height: 179 mm
6. Center housing E. Lubricating oil inlet Weight: 7.6 kg
7. Journal bearing F. Lubricating oil outlet Direction of rotation: Clockwise
8. Piston ring (see from blower side)
9. Shroud
IO. Lock nut
11. Blower impeller
12. Blower housing
13. Turbine housing
14. Turbine impeller
(Wheel shaft)
“-;9-’ 95 SERIES
Fl\ l-2
6
6206F965
15. Retaining ring Actuator set pressure

16. Elbow housing assembly 865 f 25 mmHg (at 0.38 mm lift)
17. Nut, rod end
18. Rod
19. Actuator assembly (swing valve controller)
20. Hose
21. Rod end
22. Arm and valve assembly
95 SERIES
’’-%i
9-21
Outline of waste gate valve

This restricts any unnecessary turbocharged From exhaust
pressure from the compressor and maintains a
arged
suitable turbocharged pressure (set turbocharged
pressure) in order to prevent any excessive load
on the engine.
To achieve this, waste gate valve (I) is installed
in the exhaust passage before the turbine. If
turbocharged pressure (A) near the compressor
output port becomes high and exceeds the set
pressure of the actuator (swing valve control)
(2), waste gate valve (swing valve) (I) opens.
The waste gate valve starts to open at point c
6206F966
where the lines from engine speed a and
turbocharged pressure b cross.
t I X:
Y:
Before actuator is actuated
Actuator actuated
Engine speed -
6206F967
. The pressure (A) near the outlet port of the com-

pressor passes through (B), and acts on actua- High turbocharged
tor (2). Waste gate valve (I) opens, and part of
the exhaust gas is bypassed and does not go
through the turbine, so the pressure in the tur-
bine drops and the set turbocharged pressure
is maintained.
6206F968
’’-!a’
9-3 95 SERIES
TURBOCHARGER SAFETY VALVE
Turbocharger safety valve

1 2
1 3
4
5
6206F970
6206F969
1. Cover Actuating pressure

2. Shaft 105 f 7 kPA (785 k 50 mmHg)
3. Guide bushing
4. Spring
5. Valve
6. Nut
7. Valve seat
8. Spring seat
9. Casing
10. Retainer
Outline
. In the same way as with the waste gate
valve, there is a safety valve installed in the
intake manifold system to release any ex-
cessive turbocharged pressure (excess boost
pressure) from the compressor.
95 SERIES
“-z9-4
T04B
14FO36
1. Locknut 12. Turbine housing TURBOCHARGER

2. Blower housing 13. Piston ring Type: GARRETT CO. T04B ’
3. Blower impeller 14. Turbine impeller Overall length: 225 mm
4. Thrust collar (Wheel shaft) Overall width: 210 mm
Overall height: 180 mm
5. Back plate A. Air inlet
Weight: 6.5 kg
6. Thrust bearing B. Air outlet Continuous rotating speed: 125,000 rpm
7. Seal ring C. Gas inlet Max. air supply: 22 kg/min.
8. Center housing D. Gas outlet Compression ratio: 3.0
9. Retaining ring E. Oil inlet Applicable exhaust temp.: Max. 675°C
10. Journal bearing F. Oil outlet Direction of rotation: Clockwise
11. Shroud (see from blower side)
’’-i’9-5
95 SERIES
SCHWITZER S2D
,lO
.ll
6206F953
1. O-ring 15. Thrust ring Turbocharger

2. O-ring 16. Blower housing Type: Schwitzer S2D
3. Snap ring 17. Locknut Overall length: 212 mm
4. Oil deflector 18. Blower impeller Overall width: 170 mm
5. Thrust bearing 19. Thrower sleeve Overall height: 168 mm
6. Thrust collar (spacer sleeve) 20. Piston ring Weight: 7 kg
7. Center housing 21. Insert Direction of rotation:
8. Shroud (back plate) 22. Snap ring Clockwise (as seen from blower)
9. Turbine housing
10. Piston ring A. Oil inlet port (from
11. Turbine impeller (wheel shaft) engine main gallery)
12. Clip B. Oil outlet port (to oil
13. Clamp pan)
14. Journal bearing C. Intake port
D. Air supply outlet port
E. Exhaust inlet port
F. Exhaust outlet port
95 SERIES
“-t9-6
AFTER-COOLER (Air-cooled type)

SA6D95L-1
-A
-B
Section X - X
6206F517-1
1. Tank A: From turbocharger

2. Side support B: To intake manifold
3. Tube
4. Fin
95 SERIES
’’-“A9-7
AFTER-COOLER (Water cooled type)

SA6D95L-1
6206F517
1. Cover A: From turbocharger

2. Case B: To intake manifold
3. After-cooler core
95 SERIES
’’-OA9-*
STRUCTURE AND FUNCTION ENGINE BODY
ENGINE BODY
CYLINDER HEAD * There may be differences according to the machine model.
3D95S-W-1
6206F5 18
1. Glow wire 7. Valve seat insert

2. Head bolt 8. Breather pipe
3. Cylinder head 9. Glow plug
4. Head cover 10. Nozzle holder
5. Oil filler cap 11. Nozzle
6. Valve guide 12. Plug
’ ’-ih20 95 SERIES
View Z
Section A-A 6206F519
Cylinder head Valve seat

* For swirl chamber type . Exhaust side: Seat insert press fitted
. Unitized structure
. 2 valves (1 cylinder) Head cover
. Injection nozzle: - Float mount type
Installed to outside of head cover
* Glow plug installed
95 SERIES
’ ’-oio-1
4D95S-1
6202FOO2
1. Cylinder head 8. Bracket

2. Head cover 9. Nozzle holder
3. Oil filler cap 10. Seat gasket
4. Valve guide 11. Glow plug
5. Head bolt (Tightening by plastic range
turning angle) a: Blow-by suction port (to intake)
6. Lead plate
7. Breather pipe
’ ’-“io-2
95 SERIES
a \-
View Z
Section B - B
Section A -A
6206F106
Cylinder head Head cover

- Direct fuel injection type - Float mount type
* Unitized type
- 2 valves (1 cylinder)
* Injection nozzle:
Assembled outside head cover
Mount: Dry type (without sleeve)
. Glow plug installed
95 SERIES
’ ’-“;o-3
4D95L-1
S4D95L-1 (Except PClOO-6, PC120-6, PC128UU-1)
I I t-l
1. Cylinder head 6. Valve seat insert

2. Cylinder head cover 7. Blow-by suction pipe (4D95L-1)
3. Oil filler cap 8. Nozzle holder mounting bracket
4. Valve guide 9. Nozzle holder
5. Cylinder head mounting bolt 10. Seat gasket
a. Air vent hole
’ ’-“zo-4 95 SERIES
Section A -A
6207F112

. For swirl chamber type . Exhaust side: Seat insert press fitted (S4D95L-1)
* Unitized structure . Intake side: Seat insert press fitted (S4D95L-I)
. 2 valves (1 cylinder)
- Injection nozzle: Head cover
Installed to outside of head cover . Float mount type
95 SERIES
’’-“iio-5
S4D95L-1 (For PCIOO-6, PCIZO-6, PC128UU-1)
AME

2. Cylinder head cover 7. Nozzle holder mounting bracket
3. Oil filler cap 8. Nozzle holder
4. Valve guide 9. Seat gasket
5. Cylinder head mounting bolt
a. Air vent hole
’’-k20-6 95 SERIES
A-A Y
SME00229

. For swirl chamber type . Exhaust side: Seat insert press fitted
- Unitized structure . Intake side: Seat insert press fitted
. Injection nozzle: Head cover
95 SERIES
’’-“;o-7
View 2
Section A - A
6204F114
CYLINDER HEAD VALVE SEAT INSERT

. Direct fuel injection type . Press-fitted insert for exhaust (4D95L-I)
. One-piece type
. Press-fitted insert for intake (S4D95L-1)
. 2-valve for one cylinder
. injection nozzle assembled in cylinder head CYLINDER HEAD COVER
. Floating type seal
95 SERIES
’ ‘S2’
4D95L-W-1
4D95SW-1
3
/
6
I
u
7

2. Cylinder head cover 8. Blow-by suction pipe
3. Cylinder head mounting bolt 9. Fuel injection nozzle
4. Filler cap IO. Glow plug
5. Valve guide 1 1. Nozzle holder
6. Glow plug lead 12. Hot plug
’ ’-:** 95 SERIES
STRUCTURE AND FUNCTION ,ENGINE BODY
View 2
Section A - A
6204F115

. Precombustion chamber (whirl chamber) type . Press-fitted insert for exhaust
. One-piece type
. 2-valve for one cylinder CYLINDER HEAD COVER
. Injection nozzle mounted .
on cylinder head Floating type seal
. With glow plug
95 SERIES l l -g23
6D95L-1
6206F991
1. Cylinder head 6. Cylinder head mounting bolt

2. Cylinder head cover 7. Bracket
3. Filler cap 8. Nozzle holder
9. Seat gasket
4. Valve guide
5. Valve seat insert
a. Blow-by suction pipe
“z24 95 SERIES
I
Section A-A
6206F IO5

. Direct fuel injection type . Press-fitted insert
. One-piece type for exhaust
. a-valve for one cylinder
. Injection nozzle assembled
in cylinder head CYLINDER HEAD COVER
. Floating type seal
95 SERIES 11-825
(Without glow plug)

S6D95L-1
SA6D95L-1
4 5 6

3. Oil filler cap 8. Nozzle holder
4. Valve guide 9. Seat gasket
5. Cylinder head mounting bolt
1’i26 95 SERIES
-8
Section A - A
6207F112

. Unitized structure
. 2 valves (1 cylinder) Head cover
. Injection nozzle: . Float mount type
Installed to outside of head cover
95 SERIES
’’-:27
S6D95L-1 (With glow plug)
6206F994
1. Cylinder head 7. Valve seat insert (Intake, exhaust)

3. Filler cap 9. Nozzle holder
4. Valve guide IO. Seat gasket
5. Cylinder head bolt 11. Glow plug
6. Lead plate
95 SERIES
’’-F7-’
View Z
6206F995
Section A-A Section B-B
6206F105

- Unitized structure
. Intake side: Seat insert press fitted
* Injection nozzle: Head cover
. Glow plug installed
95 SERIES
’’-“i7-2
COMBUSTION CHAMBER ON CYLINDER HEAD
PRECOMBUSTION (WHIRL) CHAMBER TYPE DIRECT FUEL tNJECTlON TYPE
3D95S-W-1 4D95L-1
4D95L-W-1 S4D95L-1
4D95S-W-1 6D95L-1
S6D95L-1
SA6D95L-1
F614601005
F614601048
Structure and function Structure and function

. Fuel injected into the precombustion chamber on . Fuel is directly injected into each cylinder through
the cylinder hea‘d to allow 20 to 30 percent of injection nozzle and burned inside the cylinder.
injected fuel to burn in the precombustion chamber.
The resulting combustion pressure contributes to Features
spurt of remaining fuel into cylinder. . Good fuel consumption ratio
. Excellent startability of the engine
Features . Simple structure
. No smoky exhaust is produced.
. Since no rise in fuel injection pressure is required,
piston top profile is made simple.
11 -t&28 95 SERIES
VALVE SYSTEM
3D95S-W-1
6206F527
1. Cam gear (No. of teeth: 48) 10. Valve cotter

2. Thrust plate 11. Valve seat
3. Camshaft 12. Rocker arm spring
4. Tappet 13. Rocker arm bracket
5. Push rod 14. Rocker arm shaft
6. Exhaust valve 15. Adjustment screw
7. Intake valve 16. Locknut
8. Valve spring 17. Rocker arm
9. Valve guide 18. Valve seal (intake side)
’ ’-g30 95 SERIES
VALVE TIMING
Top dead center
18
Bottom dead center
Intake valve cam Exhaust valve cam
6206F528A
. The valve timing is given by

indicating the time when the
intake and exhaust valves are
Valve lift opened and closed by the
- Intake valve: 10.6 mm
rotary motion of the camshaft
- Exhaust valve: 10.6 mm
in terms of the crankshaft
angle (piston.positi0r-r).
. In the 4-cycle valve timing, the
intake valve begins to open
near the end of the exhaust
stroke. At TDC (Top Ded
Center), where the arrow
marks of the intake and ex-
haust valves overlap each other,
both valves open. This is called
“valve overlap”.
95 SERIES 11-0~0-1
4D95S-1
4D95L-1
S4D95 L-l
4D95L-W-1
4D95SW-1
1. Valve cotter 10. Cam gear (No. of teeth: 48)

2. Valve seal (exhaust side) (No. of teeth: 52, 4D95S-1)
(intake side, without 11. Spring seat
turbocharger only) 12. Rocker arm spring
3. Valve spring 13. Rocker arm bracket
4. Intake valve 14. Rocker arm shaft
5. Exhaust valve 15. Adjustment screw
6. .Push rod 16. Locknut
7. Tappet 17. Rocker arm
8. Camshaft
9. Thrust plate
’’-k30-2 95 SERIES
STRUCTURE AND FUNCTION ENGlNE BODY
VALVE TIMING
4D95L-W-1,4D95S-W-1,4D95L-?
Top dead center
?i?
Exhaust close
Bottom dead center
6204F122
4D95S-1
S4D95L-1 Top dead center
-
: open
Bottom dead center 6206Fl14A
6204F I2 I
Valve lift
- Intake valve: 10.6 mm
9.6 mm (4D95S-1, S4D95L-1, SA4D95L-1)
- Exhaust valve: 10.6 mm
Camshaft
- Induction hardening for cam and journal portion.
95 SERIES
“it3’
6D95L-1, S6D95L-1, SA6D95L-1
6206F852
1. Spring seat 9. Cam gear (No. of teeth: 48) 15. Adjustment screw
2. Valve spring 10. Valve cotter 16. Locknut
3. Intake valve 11. Valve seal (exhaust side) 17. Rocker arm
4. Exhaust valve (intake side, without 18. Housing
5. Push rod turbocharger only) 19. Roller bearing
6. Tappet 12. Rocker arm spring 20. Key
7. Camshaft 13. Rocker arm bracket 21. Plate
8. Thrust plate 14. Rocker arm shaft 22. Bearing
“z3* 95 SERIES
VALVE TIMING
Top center
open 12’ close
lift
* Intake valve: 9.6 mm
* Exhaust valve: 10.6 mm
Camshaft
- hardening
6206Fl13A
cam journal
Cam gear bolt tightening type Cam gear shrink-fit and bolt tightening type
19
18
Detail
(D31A, PL, D37A,
22,
2b i
6206F898
Cross diagram
tip camshaft
SERIES
“-ii33
TAPPET AND PUSH ROD CAMSHAFT
F614601007
% 6
F614601006
1. Valve 4. Push rod 1. Camshaft gear a. Camshaft journal

2. Valve spring 5. Tappet 2. Camshaft b. Intake cam
3. Rocker arm 6. Camshaft c. Exhaust cam

. The camshaft has a camshaft gear to drive the . Tappets and push rods, together with the camshafts,
shaft, and camshaft bearing journals and cams to rocker arms, and valves, are component parts of the
open and close the intake and exhaust valves. valve system.
. The camshaft gear is forced onto the camshaft and . The tappet serves to c,onvert the rotary motion of
meshes with the crankshaft gear through the idler the camshaft into linear vertical motion.
gear. . The push rod transmits the liner vertical motion
. The camshaft serves to open and close the intake from the tappet to the rocker arm.
and exhaust valves at the optimum time throughout . The tappets and push rods are raised by cams and
the entire cycle of the intake-compression-combus- lowered by valve springs. These movements are
tion-and exhaust strokes. equivalent to the amounts of lift of the cam.
. The camshaft speed is set to l/2 of the crankshaft
speed by the gear tooth ratio (24/48). Consequently,
the intake and exhaust valves open and close once
for every two revolutions of the crankshaft.
1 l-$34 95 SERIES
VALVE GUIDE AND VALVE SEAT INSERT VALVE SPRING
F614601008 F614601009
1. Valve guide 1. Rocker arm 4. Valve

2. Valve 2. Spring seat 5. Valve guide
3. Valve seat insert 3. Valve spring

VALVE GUIDE . A valve spring serves to raise a valve to achieve snug
. A valve guide slides against the valve stem which contact between the valve seat face and the valve
moves up and down. For this reason, there must be when the valve is closed. In addition, the spring can
lubricity between the valve guide and stem, but at quickly return any rocker arms, push rods, and
the same time, there must be sufficient tightness tappets which are actuated by the camshaft to their
against the exhaust. Thus, the guide is machined original positions without separating them from
accurately with valves and is made of high wear- each other.
resistant material. . When they are actuated, push rods and tappets
. When the sliding surface of the valve guide has worn “jump” because of inertia. As the inertial force
out, only the valve guide need be replaced. There is gains speed, “jumping” increases, thereby increasing
no need to replace the cylinder head. the wear and pitting of the rods and tappets. The
valve spring serves to prevent such “jumping”.
VALVE SEAT INSERT The valve spring has a large working force and is
. This is a heat- and wear-resistant ring which is subjected to repeated loads. Accordingly, the
forced into the opening-closing port area of a valve spring must be made of material which is high in
on the exhaust side of a cylinder head. both yield point and fatigue.
. The valve opening-closing port area is subjected to
repeated shocks and exposed to high temperature
combustion gases. Therefore, high strength, wear-
and heat-resistant material is required for the valve
seat insert.
. When the valve opening-closing port area has worn
out, only the valve seat inset need be replaced (on
the exhaust valve only).
95 SERIES l l-$35
CYLINDER BLOCK
3D95SW-1 * There may be differences according to the machine model.
Section A-A
Section B-B
6206F521B
1. Main bearing cap 7. Bushing for oil pump drive shaft

2. Main bearing cap bolt 8. Oil pump drive shaft
3. Cylinder block
4. Cam bushing (Journal No. 1)
(Engine No. 13175 and up)
95 SERIES
Section D-D
t--A
Front
Section C-C
Rear
6206F522
Cylinder block
* Crankshaft: 4 bearings
. Camshaft: 3 bearings
Cylinder
* Linerless
. Inside surface finishing: Honing
95 SERIES l l -026-l
4D95L-1
4D95S-1
S4D95L-1
4D95L-W-1
4D95S-W-1
S4D95L-1
SA4D95L-1
Section A - A
Section B - B
6206F606A
1. Main bearing cap 6. Camshaft bushing (No. 3 journal)

2. Main bearing cap bolt (Engine No. 33691 and up)
3. Cylinder block . 7. Oil pump drive shaft bushing
4. Camshaft bushing (No. 1 journal) 8. Oil pump driven shaft
5. Camshaft bushing (No. 2 journal)
(Engine No. 33691 and up) a. Piston cooling oil jet (S4D95L-1)
(SA4D95L-1)
’ ’-“z6-2 95 SERIES
Section 13 - D
Front
Section C - C
6204FI 16
CYLINDER BLOCK
. Crankshaft: 5 bearings
CYLINDER
. Linerless
. Inside surface finishing: Honing
95 SERIES
’ ’-:37
ENGINE BODY
6D95L-1
S6D95L-1
SA6D95L-1
Section A -A
Section B-B
6206F106B
1. Cylinder block a. Piston cooling oil jet

2. Camshaft bushing (S6D95L-1, SA6D95L-I)
3. Main bearing cap bolt
4. Main bearing cap
5. Oil pump drive shaft bushing
6. Oil pump driven shaft
95 SERIES
’ ’-Li3*
Section D-D
Front
Section C-C
6206F107A
CYLINDER BLOCK
. Crankshaft: 7 bearings
FRONT SEAL
. Single lip with dust seal
CYLINDER
- Linerless
- Inside surface finishing: Honing
95 SERIES
’ ‘-39
CYLINDER LINER (FOR REPAIR ONLY)
80 mm
F614601010
CYLINDER LINER
* The 95 series engine uses linerless cylinders. When
boring cylinder to recondition them, use only the
specified replacement liners.
. Selection of liners
Two sizes (A and B) of replacement cylinder liners
are available.
Choose the size of liner to match the inside dia-
meter of the cylinders after machining.
* Outside diameter of cylinder liner
1 l-$40 95 SERIES
MAIN CIRCULATION SYSTEM

3D95SW-1
6206F523
1. Crankshaft 10. Top ring

2. Crankshaft gear (No. of teeth: 24) 11. Second ring
3. Main bearing 12. Oil ring
4. Connecting rod bearing 13. Thrust bearing
5. Connecting rod 14. Connecting rod cap bolt
6. Cylinder block 15. Main cap bolt
7. Piston 16. Main cap
8. Connecting rod bushing 17. Connecting rod cap
9. Piston pin 18. Cam bushing
’ ’-ii42 95 SERIES
ENGINE BODY
section A -A 6206F524
CRANKSHAFT
* Stamp forging
PISTON
. For precombustion (whirl) chamber type
* Auto-thermatic, offset
95 SERIES
’’-Oi2-’
4D95S-1
4D95L-1
S4D95L-1
SA4D95L-1
15 16 li
6206F525A

2. Crankshaft gear No. of teeth: 24 11. Second ring
No. of teeth: 26 12. Oil ring
(4D95S-1) 13. Connecting rod cap
3. Main bearing 14. Main bearing cap
4. Connecting rod bearing 15. Main bearing cap mounting bolt
5. Connecting rod 16. Connecting rod cap mounting bolt
6. Cylinder block 17. Thrust bearing
7. Piston 18. Camshaft bushing
8. Connecting rod bushing
9. Piston pin
1 l-022-2 95 SERIES
6206F524
Section A-A
Crankshaft
. Closed die forging
Piston
l Swirl chamber type
. Auto thermatic piston with steel strut
(Suppresses heat expansion and keeps clear-
ance from cylinder small)
l Center of piston hole offset 1.0 mm
(to reduce vibration)
. Selected mating
(When the piston is assembled at the manu-
facturing plant, an L or S size piston is se-
lected to match the inside diameter of the
cylinder, but parts supplied for piston re-
placement are all assembled with S size pis-
tons.)
95 SERIES
’’-:43
4D95L-W-1
4D95S-W-1
8 9 10 11 12
1. Crankshaft gear (No. of teeth: 24) IO. Top ring

2. Crankshaft 11. Second ring
3. Main bearing 12. Oil ring
4. Connecting rod bearing 13. Connecting rod cap
5. Connecting rod 14. Main bearing-cap
6. Cylinder block 15. Main bearing cap bolt
7. Piston 16. Connecting rod cap bolt
8. Connecting rod bushing 17. Thrust bearing
9. Piston pin 18. Camshaft bushing
’’-:44 95 SERIES
Section A - A
6204F119A
Crankshaft
l Closed die forging
Piston
l Swirl chamber type
. Auto thermatic piston with steel strut
. Center of piston hole offset 1.0 mm
l Selected mating
tons.)
95 SERIES
’’-:45
4D95S-1
4D95L-1
S4D95L-1
SA4D95L-1
15 16 17
6206F525A

2. Crankshaft gear No. of teeth: 24 11. Second ring
No. of teeth: 26 12. Oil ring
(4D95S-1) 13. Connecting rod cap
3. Main bearing 14. Main bearing cap
4. Connecting rod bearing 15. Main bearing cap mounting bolt
5. Connecting rod 16. Connecting rod cap mounting bolt
9. Piston pin a: Piston cooling oil jet
b: Lubrication hole (S4Dg5L-1, SA4D95L-1)
95 SERIES
“it46
18
\
Section A-A
6204F117A
Crankshaft
. Closed die forging
Piston
Direct fuel injection type re-entrant combus-
tion chamber (4D95S-1 only)
Direct fuel injection toroidal combustion
chamber (all models except 4D95S-1)
Auto thermatic piston with steel strut
Center of piston hole offset 1.0 mm
Selected mating
tons.)
95 SERIES
’’-k47
6D95L-1
S6D95L-1
SA6D95L-1
6 7 8 9 10 11 12 a
6206FllO-1
Crankshaft 12. Oil ring

2. gear (No. teeth: 24) 13. Connecting rod cap
Main bearing 14. Main bearing cap
Connecting rod bearing 15. Connecting rod cap bolt
5. Connecting rod 16. Main bearing cap bolt
9. Piston pin a. Piston cooling oil jet
10. Top ring b. Lubrication hole
11. Second ring
“i4* 95 SERIES
18
Section A-A
6206F108A
Crankshaft
l Closed die forging
. Journal portion fillet portion: Tufftride treat-
ment (S6D95L-1, SA6D95L-1)
Piston
Direct injection toroidal combustion cham-
ber
Elliptical taper profile thermal flow
Auto thermatic piston with steel strut
Center of piston hole offset 1.0 mm
Selected mating
tons.)
95 SERIES
’’-:49
ENGINE BODY
CRANKSHAFT
F614601011
1. Vibration damper Structure and function

2. Crankshaft pulley . The crankshaft converts the reciprocating motion
3. Crankshaft gear of a piston obtained under combustion pressure into
4. Crankshaft rotary motor, which is then taken off as engine
5. Flywheel power.
. The crankshaft has a very complicated shape
because it transmits all the engine output horse-
power while converting the reciprocating motion
into rotary motion.
Therefore, extreme care should be taken about the
shaft strength.
. As bearing journals, the crankshaft main journals
and crankpin journals connected by the connecting
rod are subjected to the largest load in the engine.
The load variations are also severe and their running
speeds are fast.
Thus, conterweights are specially designed and
manufactured as monoblock forgings.
“FO 95 SERIES
PISTON AND CONNECTING ROD
1. Piston
2. Top ring
3. Second ring
4. Oil ring
5. Piston pin
6. Snap ring
8. Connecting rod
9. Connecting rod bearing
10. Crankshaft
11. Connecting rod cap bolt
12. Connecting rod cap
F614601012

. Like crankshafts, thepistons and connecting rods are
the main moving parts of the engine. The energy of
fuel combustion is converted into reciprocating
motiron which is, in turn, converted into rotary
motion by the pistons and connecting rods. The
upper portion of the pistons form a combustion
chamber with the cylinder and cylinder head.
. The top end of the connecting rod is connected to
the piston with a piston pin and moves up and
down. The bottom end is connected to the crank-
shaft with the connecting rod cap and makes rotary
motion.
. The connection at each end of the connecting rod
forms a running area which is subjected to a very
large load. The upper end (small end) has a bushing
forced in place and the lower end (big end) has a
connecting rod bushing made of the same material
as the main bearing.
95 SERIES
V’
PISTON
4D95L-1 3D95S-W-1
S4D95L-1 4D95L-W-1
-Offset
Offset
,Trochoidal
6206FlO9
6204F I20

. Pistons are directly exposed to the combustion gases - Pistons of 3D95S-W-1, 4D95L-W-1 and 4D95S-W-1
and repeatedly move up and down under the severe engine have following features.
load of the combustion pressure. At the same time, . Elliptical taper profile
they are subjected to severe sliding motion while . Precombustion (whirl) chamber type
being kept airtight with the cylinder. . Offset (1.0 mm between pin hole center and
. Pistons of 6D95L-1 engine have following features. piston center)
. Elliptical taper profile . Auto-thermatic
. Trochoidal combustion chamber . Two sizes of pistons are available
. Offset (1.0 mm between pin hole center and
piston center)
Auto-thermatic
(Control thermal expantion by steel strut which
is build in piston to achieve a smaller clearance
between biston and cylinder)
. Two sizes of pistons (S-mark and L-mark) are
available.
(Depending on the dimensions of the piston
outside diameter.
For detail, see 14. MAINTENANCE STAND-
ARD.)
ll-0%1 95 SERIES
PISTON RING
Top ring
Secondring
Oil ring

. The piston rings used in 95 series engines are shown . The upper two of the three piston rings are called
below. the top ring and the second ring. They are mainly
used to keep the pistons tight against combustion
gases.
The bottom ring of the three rings is called the oil
ring which is used to hold the lubricating oil film.
*I: PCIOO, 120-5, PClOO, 120-6, PC128UU-1: Hard chrome

plating
‘2: PC200-5, PC220-5: Hard chrome plating
*3: PC200-6: Hard chrome plating
*4: PC220-6: Hard chrome plating
I lexoander
-4Dg5s_w_,
/ g$&= jggjj= Y&
I I
S6D95L-1 Both keystone ITapered face /M-shape steel rinq.

barrel face, inner cut, Hard chrome pIat
Hard chrome Parkerizing ing with coil
plating treatment expander
S6D95L-1
.._.
t-31 Keystone, Keystone, M-shape steel ring,
SP4fiDg5L-’ barrel face, inner cut, Hard chrome
Hard chrome Parkerizing, plating with coil
plating Tapered face expander
95 SERIES
’’-Oil
-2
PISTON PIN
F614601015
1. Piston 4. Connecting rod bushing

2. Piston pin 5. Connecting rod
3. Snap ring

. The piston pin serves to join a piston and connect-
ing rod together: For this reason, the piston pins
are always subjected to the combustion pressure and
severe repeated loads caused by the inertical force
of the pistons.
. The piston pins are made of low carbon special steel
with high bending strength and wear resistance. The
surface is subjected to hard facing.
STRUCTURE AND FUNCTION ENGlNE BODY
CONNECTING ROD MAIN BEARING AND CONNECTING

ROD BEARING
F614601016
F614601017
1. Connecting rod bushing 5. Connecting rod cap
2. Connecting rod 1. Crankshaft 4. Lining
3. Connecting rod cap A. Small end 2. Bearing (intermediate layer)
bolt B. Big end 3. Back bearing 5. Overlay
4. Connecting rod bearing (base metal) (surface layer)

. The connecting rods are subjected to the energy of Main and connecting rod bearings are set into the
the combustion pressure received by the piston main and crankpin jounals on the crankshaft.
. These bearings support the severest running portion
through the piston pin as reciprocating motion, and
transmits the reciprocating motion to the crankshaft of the crankshaft as the engine bearings and there-
as rotary motion. fore, they are subjected to heavy surface pressure
\/
. The connecting rod is subjected to severe com- and severe high speed running motion.
pressive and hackling loads because of the combus- Each bearing is made of a single material (as the
tion pressure, and to tensile load and bending load base metal) but also has a lining (intermediate layer)
because of the inertial force of the connecting rod and overlay (surface layer) on the base metal to
itself and the piston. Connecting rods are made of obtain the high strength and break-in properties
die-forged special high strength, high fatigue required for bearings shown above.
strength steel.
* The connecting rod is subjected to severe and
complicated alternating loads. Be carefull in marred
(particularly in the lateral direction) or scored, the
concentration of stress may break the rod, when
checking.
“:52 95 SERIES
STRUCTURE AND. FUNCTION ENGINE BODY
THRUST BEARING OIL SEAL OF CRANKSHAFT
F614601019
F614601018
1. Cylinder block 4. Main bearing
2. Flywheel housing 5. Crankshaft
3. Oil seal (Rear)

. The crankshaft delivers the engine power through . The crankshaft gains the driving force in the
the flywheel at the rear end, and the clutch is cylinder block and transmits it outside the cylinder
mounted to the flywheel. Therefore, the crank- block.
shaft is subjected to the thrust load as the clutch Then, the cylinder block is sealed inside and outside
is operated. with the front and rear seals provided on both ends
. For this reason, three thrust bearings are installed to of the crankshaft.
receive the thrust load on the flywheel side of the . These seals must be able to withstand severe, high-
crankshaft. speed running motion and at the same time form
. The load imposed on the thrust bearings is not as tight seals to prevent the oil from leaking out. For
large as that imposed on the main and connecting thss reason, the seal lips are made of rubber material
rod bearings. Therefore, thrust bearings are made of which is high in heat-, wear-, and oil=resistance as
ordinary bearing meterial. well as in tight packing force.
95 SERIES 11-$53
TIMING GEAR
WITHOUT FRONT PTO TYPE (HELICAL GEAR)
\
--+--I---
F
D
--I
t--
1. Oil pump drive gear (No. of teeth: 21) (*) 6. Thrust plate
2. Camshaft gear (No. of teeth: 48) 7. Idler gear shaft
3. Crankshaft gear (No. of teeth: 24) 8. Idler gear bushing
4. Idler gear (No. of teeth: 48) 9. Front seal
5. Injection pump drive gear (No. of teeth: 48) A, B, C: Match marks for timing gears
(“) PC200-6, PC220-6 (No. of teeth: 20)
’1-:54 95 SERIES
k 9I
I
SectionF-F
Section D - D
Front oil seal

* Single lip with dust seal
95 SERIES
’ ’-:55
WITH FRONT PTO TYPE (SPUR GEAR)

4D95S-1
4D90L-1 (WITH BOOSTER PUMP FOR BLADE ON PC60-6, PC60-7, PC70-7)
Section E-E
i i j i
1. PTO gear (No. of teeth: 26) 7. PTO drive shaft

2. Oil pump drive gear (No. of teeth: 22) 8. Thrust plate
3. Cam gear (No. of teeth: 52) 9. Idler shaft
4. Crankshaft gear (No. of teeth: 26) 10. Bushing
5. Idler gear (No. of teeth: 52) 11. Front seal
6. Injection pump drive gear A, B, C: Gear match marks
(No. of teeth: 52)
’ ’-OZ5-’ 95 SERIES
10
11
SectionF-F
Section D-D
6206F112 A
Front seal
* Single lip with dust seal
95 SERIES
’ ’-Oi5-*
ENGINE BODY
WITH FRONT PTO TYPE (HELICAL GEAR)

(Except 4D95S-1 and 4D95L-1, WITH BOOSTER PUMP FOR PC60-6 BLADE)
Cam-gear bolt tightening type
Cam-gear shrink fitting type
Section E-E
7 13589
11s56 95 SERIES
ENGINE BODY
Cam-gear shrink fitting type Cam-gear bolt tightening type
Section D-D Section F-F
6206F112B
Front oil seal

. Single lip with dust seal
1. PTO gear (No. of teeth: 24) 8. Roller bearing

2. Oil pump drive gear (No. of teeth: 21) 9. Idler gear shaft
3. Camshaft gear (No. of teeth: 48) 10. Front seal
4. Crankshaft gear (No. of teeth: 24) 11. Housing
5. Idler gear (No. of teeth: 48) 12. Roller bearing
6. Injection pump drive gear (No. of teeth: 48)
7. PTO gear shaft A, B, C: Match marks for timing gear
95 SERIES
’’-kz57
FLYWHEEL AND FLYWHEEL HOUSING

WITHOUT REAR PTO TYPE (For PCIOO-3, PC120-3)
1. Flywheel housing REAR OIL SEAL

2. Starting motor . Dry type: Single lip with dust seal
3. Crankshaft . Wet type: Double lip
4. Rear oil seal
5. Flywheel
6. Ring gear (No. of teeth: 119)
(No. of teeth for 4D95S-1: 110)
’ ’-P8 95 SERIES
n /
6206Fl 15
’’-Oi8-’
95 SERIES
WITHOUT REAR PTO TYPE

S4D95L-1 (For PCIOO-6, PC120-6, PC128UU-I)
I 2
SME00230
1. Starting motor
2. Flywheel housing
3. Rear oil seal (Double lip)
4. Flywheel
6. Crankshaft
7. Sensor
’’-:8-2 95 SERIES
WITHOUT REAR PTO TYPE

S6D95L-1 (For PC200-61
SA6D95L-1 (For PC220-6)
A-A
SME00231
1. Starting motor
2. Flywheel housing
3. Rear oil seal (Double lip)
4. Flywheel
6. Crankshaft
7. Sensor
95 SERIES
’’-028-3
LUBRICATION SYSTEM
LUBRICATION SYSTEM CHART
3D95S-W-1
6206F530
1. Oil strainer 7. Camshaft

2. Oil pump 8. Piston
3. Regulator valve 9. Intake, exhaust valve
4. Oil filter 10. Rocker arm
5. Safety valve 11. Timing gear
6. Crankshaft 12. Fuel injection pump
95 SERIES
’’-kF9
STRUCTURE AND FUNCTION LUBRICATION SYSTEM
LUBRICATION SYSTEM
LUBRICATION SYSTEM CHART
3D95S-W-1
10
/--i
s
I
9
7 f%
/
/
6206F530

3. Regulator valve 9. Intake, exhaust valve
4. Oil filter 10. Rocker arm
5. Safety valve 11. Timing gear
6. Crankshaft 12. Fuel injection pump
95 SERIES
’ ’-“i9-2
4D95S-1
4D95L-1
4D95L-W-1
4D95S-W-1
4D95L-W-1
4D95S-W-1
‘1
6204F131A

3. Oil cooler (option) 10. Intake and exhaust valve
4. Regulator valve 11. Rocker arm
5. Oil filter 12. Timing gear
6. Safety valve 13. Fuel injection pump
7. Crankshaft
W: Cooling water
’ ’-EO
95 SERIES
S4D95L-1
SA4D95L-1
6206F1003A
1. Oil strainer 11. Rocker arm 15A. Piston cooling

2. Oil pump 12. Timing gear (For PC1 00-6, PC1 20-6)
3. Oil cooler 13. Fuel injection pump 16. Low-pressure oil switch
4. Regulator valve 14. Turbocharger 17. High-pressure oil switch
5. Oil filter 15. Piston cooling (For PCIOO-6, PC120-6)
6. Safety valve 18. Bypass filter (opt)
7. Crankshaft (For PCIOO-6, PC120-6, PC128UU-1)
8. Camshaft
9. Piston W. Cooling water
IO. Intake and exhaust valve
95 SERIES
Y’
6D95L-1
S6D95L-1
SA6D95L-1
11 6206F1004
1. Oil strainer 8. Camshaft 15. Piston cooling (S6D95L-1, SA6D95L-1)

2. Oil pump 9. Piston 15A. Connecting rod small end greasing (piston
3. Oil cooler 10. Intake and exhaust valve cooling) (for PC200-6, PC220-6, LW80-1)
4. Regulator valve 11. Rocker arm 16. Low-pressure oil switch
5. Oil filter 12. Timing gear 17. High-pressure oil switch
For PC200-6, PC220-6)
6. Safety valve 13. Fuel injection pump
18. Bypass filter (opt) (For PC200-6, PC220-6)
7. Crankshaft 14. Turbocharger (S6D95L-1, SA6D95L-1)
W: Cooling water
“iF2 95 SERIES
OIL PUMP
i ? i”
Section A-A
Section B--B 6206F117
1. Bushing OIL PUMP

2. Drive gear (No. of teeth: 7) . Type: Gear type
3. Pump cover . Pump speed: Engine speed x 1.143
4. Oil pump drive gear (No. of teeth: 21)(*) Engine speed x 1.182 (4D95S-I)
(No. of teeth: 22 (4D95SI)) Engine speed x 1.20 (PCZOO, 220-6)
5. Drive shaft
6. Driven shaft REGULATOR VALVE
7. Driven gear (No. of teeth: 7) . Set pressure
8. Regulator valve 3D95SW-1, 4D95L-1, 4D95L-W-1, 4D95S-W-1:
9. Valve spring 490 2 49 kPa (5.0 f 0.5 kg/cm*)
(*) PCZOO-6, PCZZO-6 (No. of teeth: 20) S4D95L-1, 6D95L-1, S6D95L-1, SA6D95L-1:
588 f 49 kPa (6.0 -c 0.5 kg/cm2)
95 SERIES
’’-F3
OIL FILTER
D-
Section A-A
Section B-B
6206Fl IBA
1. Safety valve OIL FILTER

2. Cartridge . Filtration area: 0.20 m2
3. Bracket (Installed on some machines) 0.29 m2 (Large capacity)
4. Filter caution sensor (Installed on some machines)
C. Oil inlet SAFETY VALVE
D. Oil outlet
. Set pressure: 196_‘~& kPa (2.01;;: kg/cmz)
FILTER CAUTION SENSOR
. Operating pressure: 147’39, kPa ( 1.5’t4 kg/cm?)

(Difference pressure)
’’-E3-’ 95 SERIES
OIL FILTER MOUNT (For PCZOO, 220-5)
(Engine No. up to 833501 (Engine No. 83351 and up)
From oil filter
To oil filter
View A
View B
6206F876
1. Cartridge
2. Head
3. Oil cooler
4. Safety valve (cold spec.)
95 SERIES
’’-%3-2
OIL COOLER
4D95S-1 (OP)
4D95L-1 (OP)
S4D95L-1 (STD)
4D95L-W-1 (OP)
4D95S-W-1 (OP)
Section A - A Section
B - B
6204F 132
1. Cooler element OIL COOLER

2. Cooler cover . Stages of element: 3 stages
3. Water drain plug . Stages of element: 6 stages
(For PCIZO-6, PC128UU-I)
C. Oil inlet (From oil pump)
D. Oil inlet (To element)
E. Oil outlet (From element)
F. Oil outlet (To filter)
G. Oil outlet (From filter)
H. Cooling water inlet
I. Cooling water outlet
’’-iF4 95 SERIES
6D95L-1 (OP)
S6D95L-1 (STD)
SA6D95L-1 (STD)
Section B-B
Section A -A
6206F119B
1. Cooler element OIL COOLER

2. Cooler cover . Effective area: 0.273 mz
C. Oil inlet
D. Oil outlet (To oil filter)
E. From oil filter
F. To engine
G. Oil (inside cooler)
H. Cooling water inlet
.I. Cooling water outlet
a. Water drain plug
95 SERIES
’’-F5
STRUCTURE AND FUNCTION FUEL SYSTEM
FUEL SYSTEM
FUEL SYSTEM CHART
3D95S-W-1
6206F533
1. Fuel tank
2. Feed pumd
3. Fuel filter
’ ’-P 95 SERIES
3D95S-W-1 (With automatic air bleed mechanism)
6206F003A
1. Fuel tank
2. Feed pump
3. Fuel filter
4. Air bleed plug
5. Overflow valve
95 SERIES 11-t&67
4D95S-W-1, 4D95L-W-1, 4D95L-1, S4D95L-1 (*), SA4D95L-1

(With automatic air bleed mechanism)
6204F220A
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Overflow valve
(“) Except PC1 00-6, PC1 20-6
’’-Og7-’ 95 SERIES
4D95S-W-1,4D95S-1,4D95L-W-1,4D95L-l, S4D95L-1, SA4D95L-1
4D95.sw-1
4D95L-W-1
6204F1336
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Air bleed plug
95 SERIES
’’-“g7-2
4D95S-W-1 (With automatic air bleed mechanism)
6 - 4D95S-W-1
4D95L-W-1 9-s
6204F133-1
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Air bleed plug
9. Overflow valve
’ ’-“ii7-3 95 SERIES
4D95L-1 (With automatic air bleed mechanism) (For PC60-7, PC70-7)
6206F1020
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Overflow valve
95 SERIES
’’-“g7-4
S4D95L-1 (For PClOO-6, PC120-6, PC128UU-1)

I
i
6206F1005
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Air bleed plug
9. Overflow valve
95 SERIES
’’-k67-5
6D95L-1, S6D95L-1 (“l), SA6D95L-1 (*2)

6206Flzo-1
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Air bleed plug
9. Overflow valve
(*I) Except PC200-6
(“2) Except PC220-6
95 SERIES
’’-“ii7-6
6D95L-1 (With automatic air bleed mechanism)

(D37A-2, D37P-2A)
6206F631
.I. Fuel tank

2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Overflow valve
95 SERIES
’’-tf7-7
1
6D95L-1, S6D95L-1, SA6D95L-1
i’;
///
:..
i./:,
:.
:..::
:/:/:
////
iii
.::
.::.
. ....
j////
(i:i/
6206F12OC
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Air bleed plug
95 SERIES
’’-Ot7-*
6D95L-1 (For D31A, P, PL, S, Q-20, D37A, P-5)

6206F955
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Air bleed plug
95 SERIES
’’-:7-9
S6D95L-1 (For PC200-6)

SA6D95L-1 (For PC220-6)
6206F1006
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Air bleed plug
9. Overflow valve
95 SERIES
“-06i-‘o
FUEL INJECTION PUMP

3D95S-W-1
6206F534
1. Fuel injection nozzle 8. Feed pump

2. Spill tube 9. Oil tube
3. Fuel injection pipe (No. 1) IO. Drive shaft
4. Fuel injection pipe (No. 2) 11. Pump holder
5. Fuel injection pipe (No. 3) 12. Pump drive gear (No. of teeth: 48)
6. Fuel filter 13. Fuel injection pump (pump body)
7. Fuel injection pump (governor)
95 SERIES
“-“i!i7-”
6206F535
\ View2
A. Fuel inlet port Fuel injection pump

B. To fuel filter * Type: Yanmar Diesel in-line type YPES-3CL
C. From fuel filter . Lubrication method: Forced lubrication using
D. To fuel injection nozzle engine oil
E. To fuel tank Governor
F. From oil pump (oil) * Type: Yanmar Diesel centrifugal all-speed type
95 SERIES
“-06i-‘2
4D95L-1 (PC60-3)
1. Lubricating tube 8. Fuel filter

2. Drive shaft 9. Priming pump
3. Tachometer pick-up 10. Fuel injection pipe (No. 1)
4. Feed pump Il. Fuel injection pipe (No. 2)
5. Fuel injection pump drive gear 12. Fuel injection pipe (No. 3)
(No. of teeth: 48) 13. Fuel injection pipe [No. 4)
6. Pump holder 14. Governor
7. Fuel injection pump 15. Spill tube
95 SERIES
’ ’-E8
FUEL SYSTEM
Ij
J-
ViewZ 1
6204F141
A. Fuel inlet (From fuel tank) FUEL INJECTION PUMP

B. To fuel filter
. Maker: DIESEL KIKI
C. From fuel filter

. Type: Bosch type PES-A
D. To fuel injection nozzle
. Lubrication method: Forced lubrication with
E. To fuel tank engine oil.
F. From oil pump (oil)
GOVERNOR
. Type: Bosch RSV
Centrifugal, all-speed type
95 SERIES 11-869
4D95L-W-1 (For WA40-1)

4D95S-W-1 (For ECSOZ(S)-5)
1. Governor 8. Priming pump

2. Lubrication tube 9. Fuel filter
3. Fuel injection pump drive gear 10. Fuel injection pipe (No. 1)
(No. of teeth: 48) 11. Fuel injection pipe (No. 2)
4. Drive shaft 12. Fuel injection pipe (No. 3)
6. Feed pump 14. Fuel injection nozzle
View Z
6204F I 42
A. Fuel inlet FUEL INJECTION PUMP

B. To fuel filter . Maker: DIESEL KIKI
C. From fuel filter . Type: Bosch PES-A
D. To fuel injection nozzle . Lubrication method: Forced lubrication with engine oil
E. To fuel tank
F. From oil pump (oil) GOVERNOR
. Type: Bosch RSV Centrifugal, all-speed type
95 SERIES 1571
S4D95L-1 (For PCIOO-6, PC120-6, PC128UU-1)
SME00232
1. Lubrication tube 9. Fuel injection pipe (No. 1)

3. Feed pump 11. Fuel injection pipe (No. 3)
4. Injection pump drive gear (No. of teeth: 48) 12. Fuel injection pipe (No. 4)
5. Pump holder 13. Spill tube
6. Fuel injection pump 14. Overflow valve
7. Fuel filter 15. Governor
8. Priming pump
‘l-oi’-’ 95 SERIES
SME00233

B. To fuel filter . Maker: ZEXEL
C. From fuel filter l Type: Bosch PES-A
D. To fuel injection nozzle . Lubrication method: Forced lubrication with
E. To fuel tank engine oil
G. To fuel tank GOVERNOR
. Maker: ZEXEL
. Type: Bosch RSV Centrifugal,
all-speed type
95 SERIES
’’-Oil
-2
6D95L-1 (FLANGE TYPE) (FOR PCIOO-3, PC120-3)

S6D95L-1
6206F1007

2. Tachometer pick-up IO. Fuel injection pipe (No. 2)
6. Priming pump 14. Fuel injection pipe (No. 6)
7. Fuel injection pump 15. Governor
8. Fuel filter
95 SERIES
“g7*
View Z
6206F I2 I

C. From fuel filter . Type: Bosch PES-A type
D. To fuel injection nozzle . Lubrication method: Forced lubrication with engine oil.
E. To fuel tank
F. From oil pump (oil) GOVERNOR
. Type: Bosch RSV Centrifugal, all-speed type.
95 SERIES 1 l-g73
FLANGE TYPE
S6D95L-1 (For PC200-6)
SA6D95L-1 (For PC220-6)
14
-15
SME00234

5. Priming pump 13. Fuel injection pipe (No. 6)
6. Fuel injection pump 14. Overflow valve
7. Fuel filter 15. Governor
8. Fuel injection pipe (No. I)
95 SERIES
’’-Oi3-’1
SME00235

B. To fuel filter . Maker: ZEXEL
C. From fuel filter l Type: Bosch PES-A
D. To fuel injection nozzle . Lubrication method: Forced lubrication with
E. To fuel tank engine oil
G. To fuel tank GOVERNOR
. Maker: ZEXEL
. Type: Bosch RSV Centrifugal,
all-speed type
95 SERIES
’’-“i3-2
6D95L-1 COUPLING TYPE (For PW150-I)

S6D95L-1
lY
I--
\
19 18 17 lb 6206F1008

4. Injection pump drive gear (No. of teeth: 48) 14. Governor
5. Feed pump 15. Air compressor connector hose
6. Fuel injection pump 16. Priming pump
7. Fuel filter 17. Lubrication tube
8. Fuel injection pipe (No. 1) 18. Coupling
9. Fuel injection pipe (No. 2) 19. Air compressor
10. Fuel injection pipe (No. 3)
95 SERIES
’ ’-$74
I
View Z
View Y 6206F122A

C. From fuel filter . Type: Bosch PE-A type
D. To fuel injection nozzle . Lubrication method: Forced lubrication with engine oil.
E. To fuel tank
F. To fuel injection pump (oil)
G. To oil pan (oil) GOVERNOR
H. To air compressor (air) . Type: Bosch RSV Centrifugal, all-speed type
95 SERIES
’’-:75
DCA85SPK (With electronical governor)
7 SDE00165
1. Fuel injection pipe (No. 1 cylinder) FUEL INJECTION PUMP

2. Fuel injection pipe (No. 2 cylinder) . Maker: ZEXEL
3. Fuel injection pipe (No. 3 cylinder) . Type: Bosch PES-A
4. Fuel injection pipe (No. 4 cylinder) . Lubrication method: Forced lubrication with
5. Fuel injection pipe (No. 5 cylinder) engine oil
6. Fuel injection pipe (No. 6 cylinder)
7. Oil outlet pipe GOVERNOR
8. Fuel injection pump . Maker: ZEXEL
9. Oil inlet pipe . Type: Electronical governor
IO. Feed pump system
’’-OF’ 95 SERIES
OUTLINE OF ELECTRONIC GOVERNOR SYSTEM
The electronic governor system consists of the injection pump governor portion (actuator drive),
electronic governor controller, and switches, volumes, and sensors. The electronic governor controller
has a built-in microcomputers.
It operates the engine and drives the governor actuator according to the operating conditions specified
by the volumes, external switches, and nature of the controls set by the microcomputer.
The structure of the electronic governor system is as shown in the diagram below, and it has the
functions given in Table 1.
In addition, it is possible to install a load detector to this system as an option. This detects the change
in the alternator load current and allows the governor correspond to these changes. This reduces the
momentary changes in speed when there is a sudden change in the load.
Overall structure diagram
Electronic governor controller
SDEOOl67
95 SERIES
’’-Oi5-*
ELECTRONIC GOVERNOR SYSTEM CONTROL ITEMS (for alternator)

Model: Power source machine (S6D95LI
Table 1
NO./ Item
Keeps engine speed constant even when

1 lsochronous control
there is change in load (50 Hz and 60 Hz)
2 Low idling/rated operation This switches between low idling and
changeover rated speed
It is possible to adjust rated speed with
3 Rated speed adjustment
external volume
4 Frequency (50 Hz/60 Hz)
Switches rated speed 50 Hz/60 Hz
changeover
5 Low idling isochronous control Keeps low idling speed constant even
(constant low idling) when there is change in load at low idling
Sudden acceleration limit Restricts full rack position at sudden
6 function (soft boost acceleration to prevent emission of black
compensator) smoke
Possible to adjust low idling speed with
7 Low idling speed adjustment
external volume
Stops engine when there is drop in oil
8 Emergency stop function pressure, rise in water temperature, or
overrun
(Common functions for
electronic aovernor) I
This increases the starting fuel amount
Fuel adjustment function when when starting and increases the amount
1
starting of fuel when the water temperature is
low to improve the ease of starting
This moves rack before starting in low
2 Rack pre-actuation function
temoeratures to reduce slidina resistance
3 Overrun prevention function This cuts fuel when engine speed is
(hardware) above set value
This carries out specified action if any
4 Diagnosis function abnormality should occur in electronic
governor system
5 Memory clear function This clears trouble data from memory
6 External output of failure

disolav I
This improves response to changes in
7 Load detection function (option)
load by detecting load current
’’-i75-3 95 SERIES
CONTROLLER
SEE00127
1. Case Function
2. Connector l The controller produces signals for control-
3. Mounting bolt ling the fuel injection pump for the engine
with signals received from sensors and
switches which are installed on the panel
and externally located.
The controller possesses a self-diagnostic
function, and abnormalities are displayed on
the LED.
95 SERIES
’’-tF4
SYSTEM ELECTRICAL CIRCUIT DIAGRAM
DCA85SPK with electronic governor)
E Alternator
.% Dust indicator
762i56mmH10
% Water temperature
gauge switch
% Oil pressure switch

9+1 9. 6kPa
0. 5+0. 2ka/cm’)
Battery 12v 70AHX2 Battery switch
% Fuel injection pump
E Speed sensor 10
Controller
E : Parts installed to engine SDEOD168
’’-OF5 95 SERIES
Electronical governor main unit
1. Housing
2. Actuator
3. Control rod
4. Connector
5. Copper plate
6. Cover
7. Lubrication outlet eyebolt
615OFl76
. The electronical governor is roughly com- . The actual injection rate is controlled by
posed of housing, actuator and cover. these series of motions. That is, the injection
. The actuator is composed of linear DC mo- rate is controlled at the optimum level that
tor, link and control rod position sensor. It corresponds to the machine running condi-
operates in accordance with signals from the tions as a result of arithmetic processing
control unit. executed in the control unit.
. The linear DC motor causes the coil assem- . The linear DC motor is composed of magnet
bly to make up/down motions in accordance unit that supplies magnetic field, pole unit
with signals from the control unit and causes that leads the magnetic field and coil assem-
the coil assembly to become still so that the bly that makes up and down motions.
control rod reaches the target position. (It is . The operating principle of the DC motor is
because arithmetic processing is executed in based on Fleming’s left-hand rule, as it is
the control unit.) related to the force applied to current leads
. The motion of the linear DC motor is further in a magnetic field.
transmitted to the connector through the l When the current fed to the coil is of direc-
link, and the fuel injection rate is increased/ tion A, the magnetic force is applied in direc-
decreased when the control rod moves right- tion C. When the current fed to the coil is of
ward/leftward. direction B, the magnetic force is applied in
. That is, the injection rate increases when the direction D. When the direction and magni-
coil assembly moves upward, and the injec- tude of the current fed to the coil are control-
tion rate decreases when the coil assembly led, therefore, the coil assembly can be
moves downward. moved up/down, and it is possible to cause
. The copper plate at the connector end is the the control rod to be still at an arbitrary
control rod position sensor. It senses the position by the feedback from the position
control rod position and feeds it back to the sensor.
linear DC motor.
95 SERIES
’’-“i5-6
FUEL SYSTEM
1) Actuator
Control rod
Copper plate Copper plate
position sensor
Connector. j
Connect
\ Link
uinea r DC motor
615OFl78
615OFl77
2) Linear DC motor
’ Pole
615OF179
(Upper side sectional view)
95 SERIES
’’-OF7
Control rod position sensor
Structural view l Operation diagram
Inductance
615OFl62
6150F161
1. Copper plate (fixed)

2. Compensator coil
3. E-core
4. Copper plate (movable)
5. Sensing coil
6. Copper plate
This position sensor is located at the center That is, the counter electromotive force gen-
of the governor top for sensing if the control erated in the coil changes when the position
rod is actually located at the correct position of the copper plate changes.
with respect to the target position instructed Another coil and copper plate are provided
from the control unit. for compensation. They compensate for im-
This position sensor is composed of E-core pedance changes such as temperature
shown above and sensing coils and copper changes.
plates of two sets. . The sensing accuracy is increased by ab-
One of copper plates is installed to the end sorbing the abnormality caused by the influ-
of the control rod, and another copper plate ence of temperature, etc. through sensing of
is fixed to the E-core. the control rod position by the ratio (ratio of
This position sensor senses changes in the counter electromotive force) of impedances
coil inductance (may be considered as im- of two sensing coils.
pedance changes) as changes in the counter
electromotive force generated in the coil.
When a copper plate is placed in a position
to intersect the magnetic field generated by
the coil as shown above, the magnetic field
beyond the copper plate is canceled.
95 SERIES
’’-Oi5-*
LOAD DETECTION SYSTEM (OPTION)
Name plate
SDEOOl69
External wiring diagram
Electrical characteristics
(VI ,
_z 320. 05
2
161 s 2+0.05
I42 I&O. 05
I03 H&L
-6 0 6
LOAD IN
SDE00170
95 SERIES
’’-OF9
LOAD DETECTOR SYSTEM (OPTION)
r
r 1 Primary 2 Secondary
lrTfi Load detector device
Current transformaer
Generator Load
Current transformer
SDE00171
i L SDE00172
Fig. 1 System diagram for load detection Fig. 2 Current transformer

system
Purpose Operation
If the system only uses feedback of the speed At the primary side of the current transformer,
from the speed sensor, the control will be car- the load current is always flowing. If the load.
ried out only after the speed changes when there increases or decreases, the load current changes,
is a sudden change in the load. As a result, so an electric current is generated at the sec-
there will be an excessive delay in the response, ondary side of the current transformer.
and it will be difficult to keep the momentary This current is converted to a voltage by the
change ratio low. shunt resistance. The change in this voltage is
The load detection system detects the change in detected and is sent as the load feedback signal
load with an electric signal, and sends the sig- to the control unit.
nal to the control unit, so it is possible to con-
trol the injection pump instantaneously. There-
fore, it is possible to keep the momentary change
ratio to the minimum.
95 SERIES
“-“z--‘o
SYSTEM STRUCTURE DIAGRAM (3-PHASE CURRENT)
Shunt resistance
+5v
To control
Load detector SIG
VP’ unit
GND
Bus 1
Shunt resistance
Bus 2
Shunt resistance
I’
Bus 3
SDEOOl73
’’-“i?-’
’ 95 SERIES
FUEL INJECTION PUMP

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

Its pump housing, governor housing are forced
lubricated with the engine oil.
. The fuel injection pump is driven by the pump drive
gear in the timing gear cluster and the direc-
tion of its rotation is clockwise as viewed from the
driving (flywheel) side.
’ ’-:76 95 SERIES
1. Structure of injection pump 5. Plunger barrel

17\
The Bosch type fuel injection pump contains; 6. Plunger
plunger barrels (5), plunger (6). plunger springs 9. Control sleeve
(lo), tappets (II), and tappet rollers (18), each in 10. Plunger spring
the same quantity as the engine cylinders, and these Il. Tappet
serve, together with the camshaft (12), as the parts 12. Camshaft
giving rise to the fuel injection pressure. 17. Fuel outlet and inlet port
18. Tappet roller
2. Pumping action
1) Each plunger makes a vertical piston movement to
deliver feel under pressure by the combined action
of the cam on the camshaft and plunger spring.
F614601020
2) If the plunger (6) is lowered so that the inlet and Plunger

discharge ports (17) in the plunger barrel (5) are 17 barrel
opened by the tip of plunger, fuel will begine to 6. Plunger
flow into the barrel and stop flowing when the 17. Fuel outlet
plunger comes into its lowest position. and inlet
5 port (suc-
tion and
discharge
port)
t
F614601021
“it
3) Then, the plunger (6) will start to rise, and as soon
as the inlet and discharge ports (17) in the plunger
barrel (5) are closed, the fuel pressure in the barrel
will begin to rise.
4) If the plunger rises further so that a helical relief
(19) in the plunger comes in line with the inlet and t
discahrge ports, fuel will flow back to the inlet and !!I
discharge ports through the helix from the plunger Increaseof Under transfer Completion Withdrawal
center, causing the fuel pressure to drop rapidly. pressure of transfer (no oil transfer)
F614601022
5. Plunger barrel
6. Plunger
17. Suction and discharge ports
19. Helical relief (Helix)
95 SERIES
’’-z77
3. Effective stroke
. Distance from a position where the rising plunger
(6) closes the suction and discharge ports (17) in
the plunger barrel (5) with its tip from a point
where the helical relief (19) in the plunger comes in
line with the inlet and discharge ports is called the
efective stroke (20). Quantity of fuel to be injected
varies in proportion to this effective stroke. Effective stroke is short Effective stroke is long
. The helical relief in the plunger is cut diagonally F614601023
with reference to the upper surface. Rotating the
plunger causes the effective stroke or the quantity 5. Plunger barrel 19. Helical relief
of fuel to be injected to vary as desired. 6. Plunger 20. Effective stroke
17. Suction and discharge port
4. Adjustment mechanism for fuel injection capacity

. In the lower part of plunger (6) is provided a T-
chaped flange (21). when is fitted into the helix in
the control sleeve (9).
. In the control sleeve is mounted the control pinion
(22) which is meshed with the control rack (8).
. The control rack is connected to the governor and
fuel control lever. The movement of the control
rack rotates the plunger, thereby adjusting the
quantity of fuel to be injected.
F614601024
5. Plunger barrel 9. Control sleeve

6. Plunger 21. Plunger flange
8. Control rack 22. Control pinion
5. Switching of fuel injection
. On the top of plunger is installed the delivery valve
holder (1) in which the delivery valve (3) and spring
(2) are set. 1. Delivery valve holder
. Fuel highly pressurized by the plunger opens the 2. Delivery valve spring
delivery valve, overcoming the tension of the 3. Delivery valve
delivery valve spring, and is discharged into the
injection pipe.
F614601025
1 l-g78 95 SERIES
. The piston section (23) is provided at the lower end

I fthe fuel pressure drops after : : 0
of delivery valve (3).
: : : 0
2 :;
fuel discharge by the plunger is completed, the deli- :
0 :
0
very valve will be pushed down by the delivery valve
spring (2), causing the piston section in the valve to
close the fuel port at first, which will, in turn,
prevent the reverse flow of fuel.
6. Retraction work
. The delivery valve will be pushed down further, F614601026
causing fuel in the fuel injection pipe to flow back,
and the valve will be stopped at its tapered seat. 2. Delivery valve spring
. The above valve action is called the RETRACTION 3. Delivery valve
WORK of injection, and such a working stroke of 23. Piston
the valve is called the retraction stroke (24). 24. Retraction stroke
. The RETRACTION WORK, prevents dribbling or
assists in producing a satisfactory cut-off of fuel
injection through the nozzle.
95 SERIES 1 l-Z79
GOVERNOR
Tension lever
Start spring
3. Floating lever
4. Guide lever
5. Idling sub-spring
6. :Shifter
7. ISleeve
8. Adapter spring
9. Flyweight
10. Full-load stopper
11. Control rack
12. Swivel lever
13. Governor spring
14. Control lever
15. Camshaft
GOVERNOR
. Bosch RSV Centrifugal
all-speed type
11 F033A
GENERAL DESCRIPTION
1. Functions of governor
. The governor is a Bosch RSV mechanical all-speed In addition to the above, the angleich unit adjusting
type and serves to control the engine output power the maximin fuel inejction quantity at various
by changing the position of the control rack in the rotational speeds, the torque spring unit to obtain .
fuel injection pump (by adjusting the quantity of an injection quantity corresponging to a sharp
fuel injected). change in load during engine operation, an idling

. A flyweight actuated by the centrifugal force in the such-spring to maintain an idling speed,a start
governor serves to move the sleeve depending on spring to as the engine starting, etc. are installed
change in the rotational speed and adjust the move- in the governor.
ment of control rack through the guide lever.

On the other hand, the fuel control lever adjusts
the movement of the control rack through the
tension lever for the governor spring.
1 l-$80 95 SERIES
Function of the governor

1. Engine starting
. If the fuel control lever (14) is pushed to START
position, the governor spring (13) connected to the
swivel lever (12) integrated with the control lever
will be pushed until the tension lever (1) is brought
into contact with the full-load stopper (10) at the
lower end.
. Then, the sleeve (7) will be shifted to the left, and
the control rack (11) will be pulled by the start
spring (2) in the direction of increasing the fuel
quantity, making ease the engine starting.
i 1’0 I IF034
1. Tension lever 13. Governor spring

2. Start spring 14. Control lever
7. Sleeve A. Start position
10. Full-load stopper B. Full-load position
11. Control rack C. Idling position
12. Swivel lever D. Stopping position
2. Engine idling
. If the control lever (14) is moved back to IDLING
position after engine start, the governor spring (13)
will become weak in tension, causing the flyweight
to open outward at a low speed. Then, the sleeve (7)
will move to the right, pushing the tension lever (I)
to a point where the idling sub-spring (5) applies
tension. Consequently, the floating lever (3) will
move to the right with the lower end used as the
fulcrum, bringing the control rack (11) into the
idling position.
. When the revolution increases, the flyweight opens
and move-the tension lever to the right, then the
idling sub-spring operates to adjust the idling re-
volution. If the revolution decrease excessively, the
start spring (2) works to keep the idling revolution.
i I I F035
1. Tension lever 9. Flyweight

2. Start spring 11. Control rack
3. Floating lever 13. Governor spring
4. Guide lever 14. Control lever
5. Idling sub-spring C. Idling position
7. Sleeve
95 SERIES
“i?*’
3. Max. speed control

. If the control lever (14) is pushed into FULL-LOAD
position, the governor spring (13) will be extended
all the way, pulling the tension lever (1) unit the
lever comes into contact with the full-load stopper
(IO). The flyweight (9) will be closed and at the
same time, the control rack will be moved in the
direction of increasing the fuel quantity. Thereby,
the maximum speed will be obtained.
. If the engine revolutions exceeds the specified
range, the centrifugal force of the flyweight will be
larger than the governor spring tension, causing the
sleeve (7) to move to the right, which will, in turn,
move the control rack (11) in the direction of
decreasing the fuel quantity. Thereby, the excessive
increase in the revolutions will be prevented.
I I F036
Tension lever 11. Control rack

Sleeve 13. Governor spring
Flyweight 14. Control lever
Full-load stopper B. Full-load position
4. Angleich unit
. In the engine, if the revolution increases excessively,
the intake aire resistance will increase, deteriorating
the air suction efficiency. In the injection pump,
fuel is injected approximately in proportion to the
revolutions and therefore, the complete combustion
over the shole range of revolution will be difficult.
. The angleich unit serves to prevent the torque re-
duction due to the trend of LOCK IS FUEL at low
speed, while aiming at COMPLETE COMBUSTION
at high speeds, thereby improving the above un-
satisfactory conditions.
. Where the revolutions are low with the tension
lever (1) in contact with the full-load stopper (10)
and the centrifugal force of flyweight (9) is smaller
than the tension of the adapter spring (8), the
adapter spring will shift the sleeve (7) to the left, i 110
causing the control rack (11) to move in the direc-
I I F037
tion of increasing the fuel quantity. Thereby, the
torque at low speeds will be increased.
. As the engine speed increases, the centrifugal force 1. Tension lever 9. Flyweight
of the flyweight will push the adapter spring 7. Sleeve IO. Full-load stopper
through the sleeve. When the spring comes into 8. Adapter spring 11. Control rack
contact with the tension lever, the function of

increasing the fuel quantity will be terminated.
11 -g82 95 SERIES
5. Engine stop
. The swivel lever (12) has a protrusion. If the control
lever (14) is pushed into STOP position, the swivel
lever protrusion intergrated with the control lever
will come into contact with the guide lever (4).
Then, the lever will the control to
the position the floating
(3).
I I
1. Tension lever 11. rack
11283
FEED PUMP
3 4 5 1. Check valve (Suction)

2. Piston (Priming)
3. Priming pump
4. Tappet
5. Camshaft
2 B
6. Check valve (Discharge)
7. Piston
8. Oil seal
9. Piston (Feed)
1
10. Piston spring
11. Nut
‘6
A. Suction port
B. Discharge port
F614601027
. The fuel pump is driven by the cam on the fuel in-

jection pump camshaft and delivers fuel under pres-
sure of approx. 1.5 kg/cm2. When removing the air,
you can feed the fuel by pushing the priming pump
by hands.
Function
Preparation for fuel delivery
The piston (9) in the feed pump is pushed in by the
cam on the camshaft (5) causing the fuel in the lower
section below the piston to open the check valve (6)
on the discharge side and flow into the upper section
of the piston. 6
Atthis time, the checkvalve (1) on the suction side is
closed under the pressure of fuel pushed in by the
piston, thereby preventing the reverse flow of fuel.
Suction and discharge F614601028

If the camshaft (5) is rotated, bringing the cam out of
the piston, the piston (9) will be pushed upward by
the piston spring (IO). The resultant fuel pressure
will close the check valve (6) on the discharge side,
while fuel is delivered to the discharge port (B).
In the section below the piston will be generated the
negative pressure, causing the check valve (1) on
the suction side to open’s0 as to draw in fuel.
F614601029
3. Control fuel supply

* Fuel in the section above the piston is through di-
rectly to the passage on the discahrge side. If the
fuel pressure on the discharge side increases, itwill
become impossible to push the piston (9) upward by
the piston spring (10). Thus, the suction and dis-
charge of fuel will be stopped until the fuel pressure
on the discharge side drops by controlling the fuel
quantity to be delivered.
F614601030
4. Function of the priming pump
- The priming pump discharges fuel in the section
below the piston when the piston (2) is pushed in by
hand, and sucks in fuel when the piston is drawn up
by spring (10). B B
* The check valves on the suction and the discharge
sides (I) and (6) are used in common with those in
6 6
the feed pump body. When delivery fuel, the valves
on the suction side are closed and those on the dis-
charge side are opened. When sucking in fuel, the
valves on the suction sides are opened and those on
A
the discharge side are closed. Fuel discharge Fuel suction
F614601031
95 SERIES l l-;85
FUEL INJECTION NOZZLE

FOR DIRECT FUEL INJECTION TYPE
4D95S-1,4D95L-1, S4D95L-1, SA4D95L-1
6D95L-1. S6D95L-1, SA6D95L-1
%I
6206F124
6
%I : Shape of spring seat and needle valve
Tip is rounded Tip is flat
(Use 5 and 8 as a oair)

-----6
I
JJYY
Diesel Kiki Diesel Kiki
I I
- Nihon Denso
B .
6206F123
1. Connector Fuel iniection nozzle

. Type: Diesel Kiki multiple-hole cylindrical type
2. Nozzle holder
. Injection pressure (cracking pressure):
3. Adjustment shim
19.6 MPa (200 kg/cm*)
4. Nozzle spring PCIOO-5 (106984 and up)
1
5. Spring seat (there are two types) PCIOOL-5 (106984 and up)
6. Retaining cap PC120-5 (106984 and up) : 22.1 MPa (225 kg/cm?
.
7. Nozzle body PC200-5 (83373 and up)
8. Needle valve (there are two types) PC220-5 (86473 and up) I
Cracking pressure adjustment: shim adjustment

A. Ful inlet port (from injection pump)
B. Fuel spray (inside cylinder)
C. Fuel return port (to fuel tank)
“ii86 95 SERIES
FOR SWIRL CHAMBER TYPE

3D95S-W-1
6206F537A 6206F538
1. Nozzle holder body Fuel injection nozzle

2. Adjustment shim * Model: Yanmar Diesel YKCA-S
3. Nozzle spring . Nozzle type: YDN-0SD177
4. Spring seat . Injection pressure (cracking pressure): 120 kg/cm*
5. Nozzle valve * Cracking pressure adjustment: Shim adjustment
6. Nozzle body
A. Fuel inlet port (from injection pump)

B. Fuel spray (inside swirl chamber)
95 SERIES
’ ’-:87
For swirl chamber type

4D95S-W-1
4D95L-W-1
6204F144A
1. Nozzle holder Fuel injection nozzle

2. Adjustment shim * Type: Diesel Kiki throttle nozzle type
3. Nozzle spring . Injection pressure (cracking pressure): 120 kg/cm*
4. Spring seat * Cracking pressure adjustment: Shim adjustment
5. Retaining cap
6. Nozzle body
7. Needle valve
A. Fuel inlet port (from injection pump)

B. Fuel spray (inside swirl chamber)
’’-OZ7-’ 95 SERIES
FUEL CUT SOLENOID
SOLENOID
A contact (electricity flows when stopped) method
1 2 3 4 0 BR terminal (AV2LW)
6206F703
1. Plunger
2. Return spring
3. Coil
4. Timer
Starting switch SOLENOID

. Maker: NIKKO DENKI
. Type: Sealed
Inner wiring
. Rated voltage: D C24V
. Pull-in force: Min. 5.0 kg
. Holding force: Min. 15.0 kg
. Performance of timer:
FUNCTION Current flows for
* When stopping the engine, the solenoid is energized, 17 seconds after
the solenoid plunger is electrically attracted, and the BR terminal circuit is
stop lever of the injection pump is moved by a rod to opened (OFF)
the stop (non-injection) position. As a result, the fuel Stroke: 20 mm
is cut off and the engine is brought to a stop. Accord- Weight: 2.0 kg
ingly, this solenoid is used only when the engine is
being stopped; it is in free condition during ordinary
operations.
- When installing the solenoid,refer to TESTING AND
ADJUSTING.
95 SERIES
’ ’-Oz7-*
SOLENOID
B contact (electricity flows in ordinary operation) method
1. Plunger 6. Solenoid
Inner wiring
2. Coil 7. Fuel control lever 6206F607
3. Moving contactor Cl : Pull-in coil

4. Stop lever C2: Holding coil Solenoid
5. Return spring
. Maker: NIKKO DENKI
* Type: Sealed
. Rated voltage: DC1 2V DC24V
* Coil current
Maximum: Max. 55A Max. 40A
Continuity: Max. 4A Max. 2A
* Stroke: 20+5mm
FUNCTION - Weight: 3.3 kg
* Starting engine
When the starting key is turned on, the solenoid is

energized.
Solenoid shaft (6) is electrically attracted, pulling
injection pump stop lever (4) and fixing it in the
RUN position.
* Stopping engine
When the starting key is turned off, the solenoid is

de-energized.
Injection pump stop lever (4) is returned to STOP
position (ncn-injection position) by return spring (5).
- During operation, the amount of fuel injection is

controlled by fuel control lever (7).
- When installing the fuel solenoid, adjust clearance A

referring to TESTING AND ADJUSTING. 6162F151 A
’’-“:7-3 95 SERIES
B CONTACT SYSTEM (CONSTANT CURRENT) 4D95L-1 (PC60,70-7)

S4D95L-1 (PC128UU-1)
AUX
6206F972
1. Case Solenoid
2. Return spring Type: SYNCHROSTART drip-proof type
3. Stop lever Cl. Attraction coil Rated voltage: DC24V
4. Fuel control lever C2. Holding coil Actuating current:
5. Solenoid When starting to pull: Approx. 25A
When finishing pulling: 0.5A
l When the engine is started, electricity passes Stroke: 25.4 mm
through the solenoid and the solenoid Weight: 1 kg
plunger is actuated. This extends return
spring (2) (built into the solenoid) and pulls
4
it to the engine run position, and holds it in
position.
l When stopping the engine, the key is turned
to the STOP position and the flow of current
through the solenoid is stopped. The mag-
netic force of the solenoid disappears, so /3
the force of the return spring moves the in-
jection pump stop lever to the engine STOP
position (no injection). The solenoid plunger
is also pulled back at the same time, and the
engine stops.
. The fuel injection amount is controlled by
fuel control lever (4) when the engine is run-
ning.
. Adjust clearance A when installing the fuel
solenoid valve (see TESTING AND ADJUST-
6162F151 A
ING). ‘5
95 SERIES
’’-“:7-4
ENGINE STOP MOTOR
Shape of cable tip

- (threaded stopper type)- Section A-A
6 7
I +onoseal
/ Made by AMP Co., Stroke
cy8P male i,,4. 6 (AV 0.85LR,
2. Not used (filler plug added)
,3. P, (AV 0.85LY)

A (AV 0.85L)
/ \
6 9
1. Motor assembly ENGINE STOP MOTOR

2. Cover * Maker: Jidosha Denki Kogyo Co. Ltd
3. Cable assembly - Rated voltage: DC24V
4. Cable clamp - Operating force: Min. 147 N (15 kg)
5. Coil spring
- Stroke: 35:;:: mm
6. Cable
7. Screw * Weight: 1.2 kg
8. Breather
9. Bracket assembly
10. Cover assembly
’’-“:7-5 95 SERIES
STRUCTURAL DRAWING (1)
1. Gear cover assembly

2. Slider assembly
3. Armature shaft
4. Contactor assembly
5. Roller
6. Worm wheel asserribly
7. Motor assembly
8. Gear case assembly
95 SERIES
’’-F7-6
STRUCTURAL DRAWING (2)
1. Gear cover assembly

2. Motor assembly
3. Cable clamp
4. Cable assembly
5. Gear case assembly
95 SERIES
’’-07-7
DESCRIPTION
Contact plate P2_

on plus side 1 E,
I I I
Auto-stop position on P, side Auto-stop position on P2 side
The above drawing shows the stopped condition when a

closed circuit has been formed. The slider assembly is
stopped at the auto-stop position on the PI side.
2. When switch is turned (when starting the motor)
Battery
I P2_
E,
ln7 Al
When the switch is moved to the Pz side (starting switch starting the motor. The slider assembly starts to move in
ON), an electric current flows from the plus side the direction of the arrow at the same time as the roller
contact plate through the Pz auto-stop terminal and starts to move.
switch and into the armature shaft assembly, thereby
3. Turning Condition (90’ in the drawing)
attery
I-i
I7
Electric current continues to pass through the armature the rotation of the roller, the slider assembly also
assembly and the motor continues to turn. Because of continues to move in the direction of the arrow.
95 SERIES
’’-k87-8
4. When stopped (180°)
A closed circuit is formed when the P2 auto-stop motor comes to a sudden stop. The slider assembly also
terminal rides on the minus-side contactor plate, and the stops.
5. When switch is turned (when starting the motor)
When the switch is moved to the PI side (starting switch motor. The slider assembly starts to move in the direc-
OFF), an electric current flows from the plus contactor tion of the arrow at the same time as the roller starts to
plate through the PI auto-stop terminal and switch and move.
into the armature shaft assembly, thereby starting the
6. Turning condition (270° in the drawing)
Batterv
+--1
2
Electric current continues to pass through the armature of the arrow. Then the circuit returns to stop condition
shaft assembly and the motor continues to turn. The 1.
slider assembly also continues to move in the direction
’-07-9 95 SERIES
FUEL FILTER
6206F125 I 6202FOO7
Fuel filter Fuel filter

* Filter area: 0.093 m2
. Filter area: 0.15 m*
Filter area: 0.2 m2 Filter area: 0.18 m*
Filter area: 0.3 m* 1. Overflow valve

2. Filter bracket
1. Air bleed plug 3. Cartridge
2. Filter bracket 4. Water level sensor
3. Cartridge (installed according to models)
A. Fuel inlet port

B. Fuel outlet port
C. To fuel tank
95 SERIES
“-“:7-‘o
WATER SEPARATOR
TA
Section A-A
F614601032
1. Bracket WATER SEPARATOR

2. Ring nut . Separation performance: Min. 99% (at 0.7Qlmin.)
3. Baff leplate . Pressure loss: Max . 20 mmHg (at 0.7Q/min.)
4. Body
5. Float
6. Drain plug
A. Fuel inlet (from fuel tank)

B. Fuel outlet (to feed pump).
11 -k88 95 SERIES
COOLING SYSTEM
COOLING SYSTEM CHART
3D95S-W-1
‘8
6206F539
1. Radiator
2. Thermostat
3. Water temperature sensor
4. Water pump
5. Water manifold
6. Cylinder head
7. Piston
8. Cylinder block
95 SERIES
’’-$89
STRUCTURE AND FUNCTION COOLING
4D95S-1
4D95L-1
S4D95L-1
4D95L-W-1
4D95S-W-1
1 2 3 4 5 6
'8
6204F151A
1. Radiator A. From oil pump (oil)

2. Thermostat
3. Water temperature gauge
4. Water pump
5. Water manifold
6. Cylinder head
7. Piston
8. Cylinder block
9. Oil cooler (option)
’’-ii90 95 SERIES
STRUCTURE AND FUNCTION COOLING SYSTEM
6D95L-1
S6D95L-1
.8
F614601037
1. Radiator 7. Cylinder head

2. Thermostat 8. Piston
3. Water pump 9. Cylinder block
4. Water temperature gauge 10. Oil cooler
5. Water manifold
6. Corrosion resistor (Option) A. Lubrication oil
95 SERIES 1 l-$91
WATER PUMP
l WITH SEPARATE TYPE WATER SEAL, INTEGRATED BEARING, SHAFT
FOR CONSTRUCTION EQUIPMENT, GENERATORS
t The shape may differ according to the machine model.
Ring assembled to Seat assembled to
water pump bodv imoeller
c(\ Detail P \ \
6206F 127-l
Water pump
1. Pump cover
* Type: Centrifugal type (V-belt drive)
2. Impeller
3. Water seal
4. Pump body
5. Boss
6. Drive shaft
A. Water inlet port (from radiator)

B. Water inlet port (from thermostat)
C. Water outlet port (to engine)
D. Water outlet port (to radiator)
F614601033
. The water pump has a simple structure and uses a

highly reliable centrifugal-type vortex pump.
. Vortex-shaped guide vanes are attached to the
impeller. Based on the rotation of the impeller,
the centrifugal-type vortex pump uses the centri-
fugal force which works in the external direction
to send out the cooling water.
“if9* 95 SERIES
l UNITIZED SEAL WITH ONE PIECE WATER SEAL, INTEGRATED BEARING, SHAFT
* The shape may differ according to the machine model.
Ring
1
Seat
/, \
Portion where shG of /

impeller has been changed
6206F127-2
1. Pump cover Water pump

2. Impeller * Type: Centrifugal type (V-belt drive)
3. Water seal
4. Pump body
5. Boss
6. Drive shaft

95 SERIES
’’-Og2-’
(BEARING, SHAFT SEPARATED TYPE, UNITIZED SEAL

WITH INTEGRATED WATER SEAL)
t The shape may differ according to the machine model.
Ring
1
eat
\\\__\\__
-A
6206F877
1. Pump cover Water pump

. Type: Centrifugal type (V-belt drive)
2. Impeller
3. Water seal
4. Pump body
5. Boss
6. Drive shaft
7. Ball bearing
95 SERIES
’’-z2-2
CORROSION RESISTOR (OPTION)
Section B-B
Section A-A
F614601034
1. Bracket CORROSION RESISTOR

2. Body . Filtration area: 0.13 m2
3. Element (Paper)
4. Element (Chemicals)
5. Spring
6. Valve
A. Water inlet
EL Water outlet
95 SERIES 1793
THERMOSTAT AND FAN DRIVE

S4D95L-1 (For PClOO-6, PC120-6, PC128UU-I)
6D95L-1
+ The shape may differ according to the machine model.
S6D95L-1
SA6D95L-1
Wind 0
L /
View 2
6206F I28
1. Fan (PC120-6, PC128UU-1: 6. To radiator (cooling water)

Bent axis flow fan) C. From engine (cooling water)
2. Fan belt D. Direction of wind
3. Water pump a, b, c: Outside diameter of pulley
4. Fan spacer d. Heater pickup port
5. Fan pulley e. Therm0 sensor
6. Vibration damper (installed on some models)
(6-cylinder engine only) f. Water temperature gauge pickup port
8. Crankshaft
9. Thermostat case cover
10. Thermostat
(PC100,120-6, PC128UU-1:
with jiggle valve)
11. Thermostat case
12. Alternator
95 SERIES
11:94
PClOO, 120-6. PCl28UU-I
l ,
i i
6206F129.1
Outer diameter of pulley (mm)

Engine Applicable machine
a b C
3D95S-W-1 EC35Z, ZS-2 139 65 141.4
4D95S-1 WA50-1 150 74.2 150
4D95L-W-1 WA40-1, GU60-1 150 95 150
WA70-1 135 95 150
PC60-6 (102171 and up) 165 75 150
PC60-6 (Up to 102170) 165 95 150
4D95L-1 PC60-3, PC60-5, PW60-3 150 95 150
1 PC80-3 I 169 I 95 I 150
CD35-1 150 95 150
PC1 00, 120-5, PC1 00-6 150 95 150
S4D95L-1 PC1 20-6 150 95 169
PC128UU-1 189 95 150
95 SERIES
6206F129-1

a b C
TP95S-1 150 85 150
6D95L-1 PC1 00-3, PC1 20-3 185 95 150
PW150-1 202 95 150
PC200-5, BR200-1 165 95 150

S6D95L-1 I PWIOO-3, PC150-3 I 165 I 95 I 150
WA150-1, WT150-1 185 95 150
SA6D95L-1 PC220-5, BR300-1 165 95 150
’’-k95-1 95 SERIES
6206F899
Note: The diagram shows the D31-18, 20, and D37-2, 5.

(Fan 1 a (Alternator) b (Crankshaft) c
D20-6, D21-6 139 95 150

4D95S-1
D20-7, D21-7 165 95 150
D31-18 187 95 150
D31-20 202 95 150

6D95L-1
037-2 187 95 150
1 D37-5 I 187 I 95 I 150
95 SERIES
’ ’ -Or2
6206F1021
Note: The diagram shows the PC60, 70-7.

(Fzn) (Altekator) (Crankhaft)
4D95L-1 PC60, 70-7 152 77 150
PC60, 70-7 (Blade specification) 152 95 150
’’-OF3 95 SERIES
S6D95L-1 (For PC200-6)

SA6D95L-1 (For PC220-61
L-A SME00.236
'C
1. Alternator
2. Fan belt (poly V-belt)
3. Fan (bent axis flow fan)
4. Water pump
5. Crankshaft
7. Vibration damper
8. Fan pulley
9. Fan spacer
10. Thermostat (cracking temperature: 82°C)
/----5
11. Connector (water outlet port)
12. Thermostat case
A: To radiator
1-s 6: From radiator
C: Heater pickup port
A-A

Engine Applicable machine b d
(Fzn) (Tension) (Crankshaft) (Water pump)
S6D95L-1 PC200-6
185 95 148 115
SA6D95L-1 PC220-6
95 SERIES 11-095-4
0
THERMOSTAT (WITH JIGGLE VALVE)
7
8 9 10 11
6206F1009
1. Piston
2. Case %: The jiggle valve allows air to flow but stops
3. Pellet water from flowing. It allows the engine
4. Seat water temperature to rise in a short time.
5. Valve
6. Case
7. Spring
8. Bypass spring
9. Bypass valve
10. Bypass seat
11. E-ring
12. Jiggle valve
’’-OF 95 SERIES
STRUCTURE AND FUNCTION ACCESSORY
EXHAUST BRAKE
BUTTERFLY VALVE TYPE
From exhaust brake valve
11
12
6206F973
1. 8. Air
2. Bushing 9. Insulator
Spindle 10. Stopper (fully open position)
4. 11. Yoke
5. Valve 12. Lever
6. Spindle 13. Stopper (fully closed position)
Bushing
Outline
The exhaust is installed between the
and muffler. is actu-
by the pressure from the
valve, the passage from
to the to reduce
engine speed.
exhaust brake of valve
mechanism and the cylinder which oper-
the valve.
95 SERIES
’’-OF6
SOLENOID VALVE
6206F974
Connector A. From air tank

2. Case B. To exhaust brake
3. Core C. Exhaust outlet port
4. Coil assembly
5. Spring
6. Plunger
7. Spring
8. Valve
9. Rod
10. Body
95 SERIES
’’-OF7
Operation
1. Exhaust brake switch OFF
“OFF”
When the switch is at the OFF position, sole-
noid (I) of the exhaust brake valve is
deenergized.
In this condition, the passage between ports
A and B of the exhaust brake valve is closed,
and the passage between ports B and C is
open.
Therefore, the air entering cylinder (5) of the
butterfly valve returns from port B to port C
and is released to the atmosphere. The pas-
sage from the turbocharger to the muffler
through butterfly valve (7) is fully open.
2. Exhaust brake switch ON

To muffler From dry tank
When the switch is ON, solenoid (1) of the
22X F459
exhaust brake valve is excited, so plunger
(3) and valve (4) move up in the direction of
the arrow. This closes the passage between
ports B and C, and opens the passage be-
tween ports A and B.
The air from the dry tank enters port B and
flows to cylinder (5) of the butterfly valve.
When this happens, the cylinder extends and
lever (6) moves down in the direction of the
arrow. The passage from the turbocharger
?? ,4
to the muffler through butterfly valve (7) is
fully closed. -Exhaust
As a result, the engine speed drops and the

travel speed is restricted when the machine
is traveling downhill.
t
Even if the switch is at the ON position, if t
From dry tank
the accelerator pedal is depressed, the low To muffler
22XF460
idling detection limit switch is actuated and
prevents the engine brake from taking effect.
95 SERIES
’ -OF*
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
ALTERNATOR
3D95S-W-1
6206F543
1. Collar
2. Flywheel
3. Bolt
4. Plate
5. Stator
6. Plate washer
7. Spring washer 6206F855
8. Nut Alternator wiring diagram

9. Coupler
Pulley
Weight
Engine Machine model Type Specification . Outside
No. of (kg)
diameter
pulleys
(mm)
3D95S-W-1 EC35Z, ZS-2 Nikko Denki, open type 12 V, 14A 1 65 1.4
95 SERIES
BUILT-IN REGULATOR TYPE (35A) (PC40-5, PC40-6, PCSOUU-1)
1. Alternator pulley
2. Alternator
B, E, F, IG, L: Terminals
Internal wiring diagram 6206F606
Pulley
Weight
Engine Machine model Type Specification Outside
No. of (kg)
diameter
pulleys
(mm)
PC40-5, PC40-6 1 72 3.6
3D95S-W-1 Nihon Denso, open type 12 V, 35 A
PC5OUU-1
95 SERIES
BUILT-IN REGULATOR TYPE (25A) (PC60, 70-7 OP, PCIOO, 200-6, PC128UU-1, PC200, 220-5)
(BR200-1)
(304 (PC200-6, PC220-6)
6206F856
2. Alternator
Internal wiring diagram
6206F857
Machine model
95 SERIES
BUILT-IN REGULATOR TYPE (35 A)
6202FOO5
2. Alternator
6, IG, L, E: Terminals
6206F858
Pulley
Engine Weight
Machine model Type Specification Outside
No. of (kg)
diameter
pulleys
(mm)
4D95S-1 WA50-1 Nihon Denso, open type 12 V, 35 A 1 74.2 2.7

L I 1
I1 ,
95 SERIES 11-096-3
BUILT-IN REGULATOR TYPE (22A, 25A)
B.R
Single pulley type Double pulley WPe
I Alternator I
Regulator I
6206F131
Inner wiring
1. Regulator B, E, F, R: Terminals
2. Alternator
Pulley
Weight
Engine Machine model Type Specification _ Outside (kg)
of
pulleys
4D95L-W-1 WA40-1, WA70-1 Nikko Denki, type 24V, 1 95
4D95L-1 PC60-3 Nikko open type V, 25 1 95
S4D95L-1 PC1 00-5, 20-5 Nikko open type V, 25 1 95
PCIOO-3, PC120-3
WAIOO-1 Nikko open type V, 25 2 95
GD313A-1
S6D95L-1 00-3, PC1 Nikko Denki, open type 24 U, 25 A 2 95 7.3

WA150-1, GD461A-1
95 SERIES
’’-:96-4
BUILT-IN REGULATOR TYPE (15 A)
Regulator
1. Regulator
2. Alternator
ET1Alternator
6206F544
Pulley
Weight
Engine Machine model Type Specification Outside
No. of (kg)
diameter
pulleys
(mm)
D20-6, D21-6 95
4D95S-W-1 Nikko Denki, open type 24V,15A 1 4.0
ECSOZ, ZS-5 77
PC60-5, PC75UU-1 1 95 7.5

Nikko Denki, open type 24V, 15A
PC80-3, PC75UU-2
4D95L-1
EC75Z, ZS-3 Nikko Denki, open type 24V,15A 1 77 4.0
D31A, P, S-18, D31-20 77 4.0

6D95L-1 Nikko Denki, open type 24V,15A 1
D37-5, EGGOB, BS-1 I
S6D95L-1 EG85B, BS-1 Nikko Denki, open type 24V, 15A 1 77 4.0
95 SERIES
ALTERNATOR WITH REGULATOR AND VACUUM PUMP
6206F545
1. Vacuum pump B., E, R: Terminals

2. Regulator
3. Alternator
A. Air inlet
B. Air and oil outlet
C. Oil inlet
Pulley
Engine Machine model Specification Weight
Type Outside
No. of (kg)
diameter
pulleys
(mm)
4D95L-1 PW60-3 Nikko Denki, open type 24 V, 25 A 1 95 11

I I I I I I
’’-“J6-6 95 SERIES
BUILT-IN REGULATOR TYPE
Double pulley Single pulley

6206F976
1. Regulator
2. Alternator
Pulley
Engine Machine model Specification Outside Weight
Type No. of (kg)
pulleys
diK%er
Sawafuji Denki,
S6D95L LW80-1 24 U, 50 A 2 77 10
Open type
95 SERIES 11-096-7
BUILT-IN REGULATOR TYPE
SDE00174
1. Regulator
2. Alternator
3. Alternator pulley B, E, F, R: Terminals
Pulley
Engine Machine model Type Specification Weight
No. of Outside
(kg)
pulleys
diK%er
S4D95L-1 D21A-7T Nikko Denki
(Trimming) Drip-proof type (Sealed) 24 V, 13 A 1 95 7.6
’’-oP-8 95
STRUCTURE AND FUNCTION ELECTRICAL SYTEM
STARTING MOTOR
WITH SAFETY RELAY TYPE
10 9 8
Starting motor wiring diagram

1. Yoke
2. Armature Starting switch
3. Ball bearing c&z
,\ 50
4. Pinion
5. Pinion
6. Starting pinion
7. Shaft
8. Housing
9. Brush
10. Starting switch
07BFl93A
Engine Machine model Specification

I 1 pin%:1
PC40-5, PC40-6 Hitachi sealed type,

3D95S-W-1 12V,2 kW 9 5.4
PC5OUU-1, EC35Z, ZS-2 reduction type
95 SERIES
WITH SAFETY RELAY TYPE
6206F832
Safety relay Starting motor
:@q-J
Inner wiring
Pinion gear C, F, R: Terminals

Magnetic switch
3. motor
Machine model Type pinyot Pefeth wlt$ht
4D95S-W-1 D21-6, EC502, ZS-5 Nikko sealed type V, 2.8 9 7
WA50-1 Nikko sealed type V, 2.5 9 8.9

I
D20-7, D21-7 Nikko Denki, sealed type 24 V, 2.8 kW 9 7
4D95L-W-l WA40-1, WA70-1 Nikko Denki, sealed tvDe 24 V. 2.8 kW 9 7.5
PC60-3, PC60-5, PW60-3,

4D95L-1 PC80-3, PC75U U-l, -2 Nikko Denki, sealed type 24 V, 2.8 kW 9 7.5
EC75Z, ZS-3, D21A-7T Nikko Denki, sealed type 24 V, 2.8 kW 9 7
11$98 95 SERIES
Terminal R Termin
Drip-proof 2-pin connector

(X connector)
6206F959
;eaq
Wiring connection diagram
B, C. F, R, S: Terminals
1. Pinion gear
2. Magnetic switch
3. Starting motor (body)
V, 2.8 kW 9 7.3
95 SERIES
Terminal R Terminal S
2-pin connector (male)

(drip-proof X connector)
l&qq--.
L.
Internal wiring connection diagram
6206F977
1. Pinion gear
2. Magnetic switch
Weight
Engine Machine model Type Specification pinyo: Efeth
(kg)
PC1 00, 120-5,

S4D95L-1 PCIOO, 120-6 Nikko Denki 24 V, 5.5 kW 11 12
(water-proof, oil-proof type)
PC128UU-1
Nikko Denki
S6D95L-1 PC200-5, PC200-6, BR200-1 (water-proof, oil-proof type) 24 V, 5.5 kW 11 12
Nikko Denki 11 12
SA6D95L-I PC220-5, PC220-6, BR300-1 (water-proof, oil-proof type) 24 V, 5.5 kW
’’-“g8-2 95 SERIES
SEPARATELY LOCATED SAFETY RELAY TYPE
Internal wiring connection diagram
6206F976
1. Pinion gear
2. Magnetic switch
Engine Machine model No. of Weight

Type Specification
pinion teeth (kg)
S6D95L-1 LW80-1 INihon Denso, sealed type 1 24 V, 4.5 kW 1 11 1 8.5
95 SERIES
’ ’ -“g8-3
_-_-_
rI e-s
Drip-proof X connector type
1
Open type
Terminal
\ R
/
Terminal S
r 5 1
;@@q
Wiring connection diagram
6206~133
1. Pinion gear 4. Safety relay B, C, F, R, S: Terminals

2. Magnetic switch 5. Connector
No. of Weight
Engine Machine model
I Type Specification pinion teeth
(kg)
D31A, P, S-18, -20

PCIOO-3, PC120-3
PW150-1, WAIOO-1 Nikko Denki, sealed type 24 V, 5.5 kW 12 11
6D95L-1 D37-2,-5, GD313A-1
EGGOB-1
EGGOBS-1 Nikko Denki, sealed type 24 V, 2.8 kW 11 7
PC150-3,
WA150-1, PWIOO-3
GD416A-1 Nikko Denki, sealed type 24 V, 5.5 kW 12 11
S6D95L-1
EG85-1 11 7
Nikko Denki, sealed type 24 V, 2.8 kW
EG85BS-1 I
’’-“i8-4 95 SERIES
ELECTRICAL INTAKE AIR HEATER
ELECTRICAL HEATER (DIRECT FUEL INJECTION TYPE)
1. Heater coil
2. Housing
Specification
. Rated voltage: DC24V
. Rated current: 11 OA (when 22 V)
Wiring diagram
6136FO25
(BIMETAL TYPE GLOW PLUG)
1. Sheath (Fe-Cr)
2. Coil (Fe)
3. Insulator
I 12 V (Blue)
24 V (Red)
Quick type 1 Birnetai =I
F614601049
95 SERIES
“if99
CONTROLLER (QUICK GLOW SYSTEM)
1. Connector (round 8-pin), (Short 8-pin)

Round 8-pin 2. Lead wire
3. Case
4. Bracket
1 Pin No. 1 Color of lead wire 1
I ’ 1 Blind plug I
I 5 1 Red/yellow I
6204F200
WATER TEMPERATURE SENSOR (QUICK GLOW SYSTEM)
1 1. Water temperature sensor

2. Lead wire (blue/red)
I 3. Connector
Width
(round
across flats:
l-pin)
22 mm
6204F201 F614601098
GLOW RELAY (QUICK GLOW SYSTEM)
1. Glow relay
2. Lead wire
3. Connector (round 2-pin)
1. Controller (WR: white with red)
2. Ground (B: black)
6204F202
’’-Oi!i9-’ 95 SERIES
CONTROLLER
1. Connector (round &pin)

2. Lead wire
3. Case
4. Bracket
1 Pin No. ) Color of lead wire 1
6204F200
I 7 ( Blind plug
r 8 I White
WATER TEMPERATURE SENSOR

Connector type

2. Lead wire (blue/red)
3. Connector (round l-pin)
Width across fiats: 22 mm
6204F201
Terminal type

2. Terminal
Width across flats: 22 mm
\ M16xP1.5
F614601098
95 SERIES
’ ’-Oi9-*
GLOW RELAY
1. Glow relay
2. Lead wire
3. Connector (round 2-pin)
! 3
1. Controller (WR: white with red)
2. Ground (B: black)
6204F202
’ ’-“g9-3 95 SERIES
ACCESSORY
AIR COMPRESSOR
1. Oil seal 12. Cylinder head A. Air inlet

2. Crankshaft 13. Unloader valve spring B. Air outlet
3. Ball bearing 14. Unloader valve C. Unloader
4. Front cover 15. Unloader valve guide
5. Connecting rod 16. Inlet valve
6. Oil ring 17. Inlet valve spring
7. Piston pin 18. Spring seat
8. Piston 19. Outlet valve
9. Second ring 20. Outlet valve spring
IO. Top ring 21. Crankcase
11. Cylinder block 22. Rear cover
11200 95 SERIES
AIR COMPRESSOR
. Maker: DIESEL KIKI
. Type: Single cylinder, double acting
. Discharge volume: 150 cc/rev
- Air pressure 8.5 kg/cm*
. Rotating speed: Engine speed x 0.5
- Weight: 6.5 kg
95 SERIES 11201
Adjusting valve clearance .... .. . 12-002
Measuring exhaust gas color .. .... . 12-004
ENGINE BODY
Measuring compression pressure ...... 12-005
Measuring blow-by pressure ......... 12-006
Adjusting engine speed sensor ....... 12-007
FUEL SYSTEM
Checking and adjusting
fuel injection timing ... . . . . . 12-008
Adjusting governor ..... . . . . . 12-01 O-6
Testing and adjusting fuel cut solenoid 12-010-9
Procedure for adjusting
engine stop motor cable . . . . 12-010-l 1
Adjusting fuel injection pressure. . . 12-011
LUBRICATION SYSTEM
Measuring oil pressure .. . . . . . . 12-014
Measuring oil temperature . . . . . . . . 12-015
COOLING SYSTEM
Measuring water temperature ... .. 12-016
Testing and adjusting fan belt tension . . . 12-017
FUEL INJECTION PUMP

CALIBRATION DATA ... . . 12-018
PERFORMANCE TEST
Run-in standard ................. 12-023
Performance test criteria ........... 12-030
Testing and adjusting tool list ...... 12-030-21
Testing and adjusting data ........ 12-030-22
TROUBLESHOOTING
Method of using
troubleshooting table ...... . . . 12-032
Troubleshooting table .. . .. . . 12-037
95 SERIES
’*zol
TESTING AND ADJUSTING INTAKE AND EXHAUST SYSTEM

ADJUSTING VALVE CLEARANCE “~
1. Remove cylinder head cover
2. Rotate the crankshaft in the normal direction. While

watching the movement of the intake valve of No. 3
cylinder (3-cylinder engine), No. 4 cylinder (Ccylinder
engine) or No. 6 cylinder (g-cylinder engine), bring the
No. 1 cylinder into Compression Top Dead Center posi-
tion and align the TOP engraved mark on crankshaft
pulley (1) with pointer (2).
Sr TOP engraved mark to be aligned with pointer
4-cylinder engine: 1.4 TOP mark
6-cylinder engine: 1.6 TOP mark
* When the No. 1 cylinder comes near Compression
Top Dead Center position, the No. 3 intake valve
(3-cylinder engine), No. 4 intake valve (Ccylinder
engine) or No. 6 intake valve (6-cylinder engine)
will start to move (open).
3. Adjust the valve clearance for valves marked l in the * Valve arrangement chart
valve arrangement chart. 3-cylinder engine
Cylinder No. 1 2 3
4. Rotate the crankshaft in the normal direction by one
I I I I I I
revolution and adjust the valve clearance for the remain-
ing valves marked 0.
4cylinder engine
Valve clearance (Engine at hot or cold)
G-cylinder engine
8.
=
Cylinder No. 1 2 3 4 5 6
Intake valve l l 0 l 0 0
Exhaust valve l 0 l 0 l 0
95 SERIES
’*-kio2
* To adjust the valve clearance, loosen lock nut (3) on

adjustment screw (41, insert feeler gauge A correspon-
4 3 6 5
ding to the specified clearance between valve stem (5)
and rocker arm (6). and adjust the clearance with the
adjustment screw until the thickness gauge can slide
lightly.
6206F202
5. After the clearance is properly adjusted, tighten the lock

nut to secure the adjustment screw.
m Lock nut: 4.5 + 0.5 kgm
* Intake and exhaust valve clearances may be adjusted

for each cylinder in a firing order by rotating the crank-
shaft with following angle at a time in the normal
direction.
* Crankshaft rotating angle
3-cylinder engine: 240
4-cylinder engine: 180”
6-cylinder engine: 120
* Engine firing order
3-cylinder engine: 1 - 3 - 2
4-cylinder engine: 1- 2 - 4 - 3
6-cylinder engine: 1- 5 - 3 - 6 - 2 - 4
95 SERIES
’2-;03
MEASURING EXHAUST GAS COLOR
A When measuring
not to touch
the exhaust
the exhaust pipe.
gas color, be careful
* Measure the exhaust gas color while engine is warm.

(Oil temperature: 40 - 6O’C)
1. Insert probe A in outlet of exhaust pipe (1) and secure

to exhaust pipe with clip.
2. Connect probe hose and connector hose for accelerator

switch to smoke checker B.
* The pressure of air supply should be under
15 kg/cm2.
3. Connect power cable to AC1 OOV socket.

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

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

of unused filter papers (10 sheet or more) inside filter
paper holder, and read indicated value.
* For the reference value of the exhaust gas color,
see TESTING AND ADJUSTING DATA.
12-gO4 95 SERIES
TESTING AND ADJUSTING ENGINE BODY
ENGINE BODY
MEASURING COMPRESSION PRESSURE
MEASUREMENT PROCEDURE
While measuring the compression pressure, take care

L!l
not burn yourself on the exhaust manifold or
muffler, and be careful not to get caught in any
revolving part of the engine.
* Measure the compression pressure while the engine
is warm.
(Oil temperature: 40 - 6O’C)
1. Adjust the valve clearance properly. For details, see

ADJUSTING VALVE CLEARANCE.
2. Remove spill tube and disconnect fuel injection pipe.
3. For machines with a key stop system, remove the wir-

ing of the fuel cut solenoid.
(For machines with a stop motor installed, remove the
wiring of the connector.)
4. Remove nozzle holder assembly for each cylinder.

* Remove the nozzle holder assembly by prying it
with the spill tube mounting bolt.
* Take care not to let any dirt or foreign matter get
into the cylinder.
5. Install adapter to the nozzle holder mounting section

of the cylinder to be measured, and tighten the adapter
to the specified torque.
m Torque: 4.5 i- 0.5 kgm
6. Connect compression gauge A to the adapter.
7. Place the fuel control lever in NO INJECTION position,

crank the engine with the starting motor, and readthe
gauge when the pointer is stabilized.
If you do not put the fuel control lever in NO

A
INJECTION position, fuel will blow out.
* Most compression leakage can be prevented by
applying a small amount of oil to the mounting
section of the adapter.
* For the reference values of the compression pres-
sure, see TESTING AND ADJUSTING DATA.
95 SERIES
’2-iio5
MEASURING BLOW-BY PRESSURE
* Measure blow-by pressure while engine is warm.

(Oil temperature: Min. 85’C)
1. Remove head cover and install blind plug in blow-by

suction tube (1). then install head cover.
(For 4D95L-1, 4D95L-W-1, 4D95SW-1, 6D95L-1)
2. Install adapter to oil filler.
3. Connect adapter to pressure gauge A with tube.
4. Run the engine at high idling, and measure the blow-by

pressure.
* Blow-by pressure varies greatly according to the
condition of the engine.
Therefore, if the blow-by value is considered
abnormal, check for problem connected with
defective blow-by, such as excessive oil consump-
tion, defective exhaust gas color, and prematurely
dirty or deteriorated oil.
* For the reference value of the blow-by pressure,
see TESTING AND ADJUSTING DATA.
12-gO6 95 SERIES
ADJUSTING ENGINE SPEED SENSOR

PCIOO-6, PC120-6
PC200-6, PC220-6
1. install engine speed sensor (I) to flywheel hous-

ing (2), then screw in by hand until sensor (I)
contacts ring gear (3) lightly.
6 Thread of engine speed sensor:
Sealant (LG-6)
2. After sensor contacts ring gear (31, turn back l-

l/6 turns and secure in position with locknut (4).
+ When this is done, clearance a should be 1.5 V
TME00104
+. 0.25 mm.
w Locknut: 58.8 f 9.8 Nm (6 + 1 kgm)
Ir After adjusting, check that cranking can be
carried out smoothly.
DCA85
When the engine speed sensor has been re-
moved and is assembled again, do as follows.
Set the piston at top dead center and align the
pointer with the crankshaft pulley 1, 3, 4, top
line.
When this is done, pin (I) knocked into the fly-
wheel is immediately in front of the pickup
mounting hole.
In this position, tighten speed sensor (3) until it
contacts pin (I) in the flywheel, then loosen one
turn.
TOE00086
* Clearance a when this done: 1 f 0.2 mm
Tighten locknut (3).
w Locknut: 49.0 - 4.9 Nm (5 f 0.5 kgm)
* After adjusting, check that cranking can be
carried out smoothly.
95 SERIES
TESTING AND ADJUSTING FUEL SYSTEM
FUEL SYSTEM
CHECKING AND ADJUSTING FUEL
INJECTION TIMING
There are two methods for checking and adjusting the fuel
injection timing of an injection pump.
l The “MATCH MARK ALIGNMENT” method, which is
used when the injection pump is installed to the original mark C
engine and the pump is not being repaired.

l The “DELIVERY VALVE” method, which is used when
a repaired or replaced injection pump is installed to the
engine.
* Before inspecting and adjusting the fuel injection timing,
bring the No. 1 cylinder piston to the top dead center of
the compression stroke. For details, see 12 ADJUSTING
VALVE CLEARANCE. 614OF107
(View from flywheel side)
CHECKING AND ADJUSTING BY THE MATCH

MARK ALIGNMENT METHOD
1. Assemble pump holder and pump drive gear on injection
pump.
2. Set No. 1 cylinder at compression top dead center.

(See ADJUSTING VALVE CLEARANCE)
Align pointer with IT, 1.4T or 1.6T mark on crankshaft
pulley, then confirm that the mark ‘C’ on idler gear can
be seen.
If the mark ‘C’ can not be seen, rotate the crankshaft
one more turn.
3. Remove cover (1). 1’

4. Mount injection pump on engine, and insert pin (dia:
4 - 4.5 mm, length: 80 mm) in hole of drive gear a
through hole a. 614OFllO
Then confirm that mounting holes of pump holder and

front gear cover are aligned.
5. Tighten mounting bolts, confirm that lines on injection

pump, pump holder, and front plate are aligned.
6. If the position cannot be aligned, repeat Step 4.
7. After tightening all bolts, check that the lines on the in-
jection pump, injection pump holder, and front plate
are aligned.
’2-:08 95 SERIES
l With coupling type injection pump

1. Turn the crankshaft back 30 - 40” from the No. 1 cylin-
der TOP position.
2. Rotate slowly in the normal direction and align the in-

jection timing mark on the crankshaft damper with the
pointer.
3. Check that the line on the injection pump and the line
on the coupling are aligned.
* The injection timing differs according to the ma-
chine model, so refer to the values for testing, ad-
justing, and troubleshooting.
t If the lines are not aligned, loosen the nut in the
oblong hole, move the coupling to align the lines,
then tighten the nut again.
m Nut: 3.25 k 0.25 kgm
Coupling type
612FO82
95 SERIES
’2-o$8-1
CHECKING AND ADJUSTING BY THE

DELIVERY VALVE METHOD
1. Disconnect fuel injection tube (1) for the No. 1 cylinder.
Remove delivery valve holder (2).
Remove spring (3) and delivery valve (4) from the

delivery valve holder, and reassemble the delivery valve
holder.
Place the fuel control lever in FULL position, slowly

rotate the crankshaft in the normal direction while
operating the priming pump, and observe the position
when the fuel stops flowing out of the delivery valve
holder.
In the position where the outflow of fuel stops, check s 6150P210A

the injection timing stamp line on the crankshaft pulley
(5) to see if it is aligned with the pointer (6).
* If the injection timing stamp line passed through the
pointer: The injection timing is late.
* If the injection timing stamp line did not reach the
pointer: The injection timing is advanced.
* If the inspection shows that the injection timing is out

of adjustment, adjust the fuel injection timing in the
following manner.
* After the checking and adjusting, be sure to reassemble
the spring and the delivery valve.
1) Rotate the crankshaft 30’ to 40’ in the reverse

direction, starting from TOP position in No. 1
cylinder.
2) Align the injection timing stamp line on crankshaft
pulley (5) with pointer (6) by slowly rotating the
crankshaft in the normal direction.
95 SERIES 12-gO9
3) Loosen nut (7) on the injection pump mounting

flange slot, and rotate the flange on the pump side
little by little by operating the priming pump until
no fuel flows out of the delivery valve holder.
4) Tighten the nut on the injection pump mounting
flange slot.
* Recheck the injection timing to see if it is
properly adjusted.
5) Align match mark a with mark b and stamp the
marks.
After adjusting, be sure to assemble the spring and

delivery valve again.
* Always replace the copper gasket and O-ring on the
delivery valve with new parts.
TESTING AND ADJUSTING AN INJECTION

PUMP HAVING PLUNGERS WITH HELIX
* Injection pump (with plungers with helix)
This pump responds to an auto-timer to auto-
matically vary the injection timing depending on the
engine speed.
* An engine equipped with an injection pump having
plungers with helix is constructed to delay the
injection timing in a low speed range from the
activation of the start spring.
For this reason, it is difficult to obtain the normal
injection timing by making adjustment with the
conventional fuel delivery method.
Injection delays on pumps at engine rotation, 400
rpm, are as shown in the table on next page.
* The only difference in adjustment by the con-

ventional delivery method and the adjustment with
this injection pump is that in this injection pump a
rack cap pushes in the control rack by a given
dimension before adjustment in order to prevent the
adjustment of the injection timing from being
affected by the start spring.
Thus, an injection pump having plungers with helix
must have an adjustment rack cap. Injection timing adjustment rack cap
1. Replace the present rack cap in the injection pump

with an adjustment rack cap.
The subsequent adjustment steps are the same as the
standard adjustment procedure.
/
6204F202-3
Part No.: D K155404-6400
95 SERIES
‘2-Fo
TABLE OF INJECTION PUMPS USING PLUNGER WITH STEPPED LEAD
njectior Injection pump njectior Injection pump

Engine Machinemodel Engine Machinemodel
delay part No. delay part No.
D20,21A-6 6202-72-1210 PCIOO-3 6206-71-1210

4D95S-W-1 6D95L 4"36'
4"
D20,21E-6 6202-72-1230 PC120-3 6206-71-1220
4D95S-1 WA50-1 6202-73-1130 PWIOO-3 6207-71-1240
PC60-3 6204-71-1210 6207-71-1241
PC60-5 6204-71-1220 6207-71-1242
PC60-6 6204-73-1210 6207-71-1270
PW60-3 6204-71-1230 WA150-1 6207-71-1330
4D95L-1 PC80-3 6204-71-1240 6207-71-1331
PC75UU-1 6204-71-1280 6207-71-1332
PC90-1 6204-73-1220 S6D95L 4"36' 6207-71-1333
D20-6 6204-71-1260 6207-71-1334
6204-71-1270 PC200-5 6207-71-1260
PCIOO-5 6205-71-1230 6207-71-1261
6205-71-1231 6207-71-1262
6205-71-1232 6207-72-1260
S4D95L
PC120-5 6205-71-1240 6207-71-1230
6205-71-1241 6207-71-1251
6205-71-1242 PC150-3 6207-71-1320
PW150-1 6206-71-1240 PC150-5 6207-71-1220
r/VAlOO-1 6206-71-1330 S6D95L-1 PWIOO-3 4"36 6207-71-1240
6206-71-1331 v'lA150-1 6207-71-1332
6206-71-1332 6207-71-1333
6D95L 4"36' 6206-71-1333 X220-5 6209-71-1260
6206-71-1334 6209-71-1261
NA120 6206-71-1360 SA6D95L 4"36' 6209-71-1262
137A. P-2 6206-71-1370 6209-72-1260
131-18 6206-71-1250
95SERlES
’2-oio-1
ADJUSTMENT OF FUEL INJECTION AMOUNT

(3D95S-W-1)
Special tools
No. Part No. Part Name
Pump installation stand

YM 158090-51010
for Yanmar test stand
A Pump installation stand

YM 158090-51020 for Robert Bosch test
stand
078P241
B 1 YM 158090-51500 1 Rack indicator
Using pump installation stand A, set injection pump (1)

on the test stand.
Remove control rack blind plug (2), and install rack in-
dicator B.
Rack indicator
078F241
Rotate pinion (4) so that control rack (3) moves from a

the injection pump side face to the maximum position
at the drive side, then set the standard position (a) on
the scale of the rack indicator.
It Check that the control rack and indicator slide
smoothly.
Move the control lever to the maximum position in the

direction of operation and check that the position of
the rack is within the standard value.
Control rack stroke: 078F243
12 + 0.5 mm on the indicator scale

If the control rack stroke is not within the standard
value, replace the link connecting the ‘governor
lever and control rack.
The link is provided with marks every 1 mm.
’2-o&o-2 95 SERIES
TESTING FUNCTION OF PLUNGER (3D95S-W-1)
Special tools
No. 1 Part No. I Part Name
0 - 1000 kg/cm2 pressure

A YM 121820-92540 gauge
1. Install pressure gauge A to the delivery valve holder.

2. Drive the injection pump at approx. 200 rpm, move the
control pinion lightly from the side face of the pump in
078F247
the direction for increasing the amount of fuel, and
check that the pressure rises to above 500 kg/cm’.
* If the plunger pressure does not reach 500 kg/cm2,
replace the plunger.
* After the pressure rises, check that the pressure
does not suddenly drop and that there is no oil
leakage from any part.
* After the pressure rises, release the control pinion
immediately and set it to NO INJECTION.
078 P243
TESTING AIR-TIGHTNESS OF DELIVERY

VALVE
1. Follow the same procedure as when testing the

plunger function, and when the plunger pressure
reaches 120 kg/cm*, return it to NO INJECTION.
2. Measure the time taken for the pressure to change 100
+ 90 kg/cm*.
Ir If the time taken for the pressure to drop is less
than 5 seconds, wash the delivery valve and test
again.
If the drop in pressure is still too quick, replace the
plunger.
3. After adjusting, install the delivery valve holder.
w Delivery valve holder: 3.75 L- 0.25 kgm

4. Test the plungers of the other cylinders in the same
way.
95 SERIES
’2-oAo-4
MEASURING TOP CLEARANCE OF PLUNGER

(3D95S-W-1)
Special tools
No. Part No. Part Name
A YM 158090-51300 Top clear&ce gauge
1. Place top clearance gauge A on a flat surface and set

the zero point.
2. Remove the delivery valve holder, delivery valve, and
spring, then install the top clearance gauge.
3. Turn the pump camshaft, watch the movement of the
gauge indicator, and set the cam exactly to top dead
center.
4. in this condition, read the position of the dial gauge in-
dicator (top clearance between plunger (1) and a
plunger barrel (2): plunger top clearance “a”), and
check that it is within the standard value.
* Plunger top clearance: 0.5 + 0.05 mm
078F251
5. If the plunger top clearance is not within the standard

value, adjust the thickness of adjustment shim (5)
fitted between adjustment screw (4) of tappet (3) and
the roller guide.
* Plunger top clearance adjustment shim
Shim part No. Shim thickness (mm)
YM 129156-51750 1.45
YM 129156-51760 1.55
YM 129156-51770 1.65
YM 119865-51610 1.70
078F252
YM 119865-51670 1.75
YM 119865-51620 1.80
+ Standard shim thickness: 1.7 mm

* Prestroke: 2.0 mm
6. Assemble the delivery valve spring, valve, and holder
again.
m Delivery valve holder: 3.75 i 0.25 kgm
95 SERIES 12-O&O-5
J
FUEL SYSTEM
TESTING AND ADJUSTING
ADJUSTING GOVERNOR (3D95S-W-1)

1. Adjusting fuel limit bolt
(adjusting full load stopper) Full load position
1) Keep the pump speed at the rated speed N,, and move
the fuel control lever fully in the direction to increase
the amount of fuel.
2) In this condition, adjust the amount of tightening of the
fuel limit bolt so that the rack position is the standard
value (R,). N, % N, b
3) In this position, measure the amount of fuel injected, Pump speed (rpm)
078F253
and check that it is within the standard value.
4) Tighten the locknut of the fuel limit bolt.
2. Adjusting maximum idling speed
1) Keep the pump speed at the rated speed, and move

the governor control lever fully in the direction to in-
crease the amount of fuel.
2) Adjust the amount of tightening of maximum speed
adjustment bolt (1) at the point where the rack position
starts to move from R,.
3) Raise the speed, and check that the speed at rack posi-
tion R, corresponding to the maximum idling speed is
within the standard value.
078 F255
95 SERIES
’2-oho-6
3. Adjusting idling
1) Hold the pump speed at idling speed N,.
2) Move the governor control lever to the idling position
while measuring the injection amount. When the fuel
injection amount is the standard value, fix the position
of lever (1) with the idling adjustment bolt.
.
078F256
4. Checking injection amount when starting

1) From the idling speed gradually raise the speed and
check that the control rack moves smoothly.
2) Set the pump speed at the starting speed N,, and hold
the governor control lever at the full load position.
3) Check that the control rack position is at the maximum
rack position, then measure the fuel injection amount
to check that it is within the standard value.
95 SERIES
’2-oAo-7
5. Adjusting torque rise
* The injection pump includes an Angleich spring and

torque spring as the mechanism to increase the
amount of fuel. Adjust the torque rise to increase the
amount of fuel (increase the torque) as follows.
1. Adjusting Angleich
* Adjust the Angleich after adjustng the high idling
speed.
* Use the Angleich spring as part of the Angleich
assembly.
1) Place the governor control lever in the full load
position, and hold the pump speed at the
maximum torque speed (Ns).
2) Remove governor case cover (I), and screw
Angleich assembly (3) into the thread of ten-
sion lever (2).
3) Put the Angleich assembly in contact with the
governor lever (the position where the lever
begins to move), then screw it in further by
the specified angle (0”).
4) Check that the fuel injection amount is within
the specified value at maximum torque. 078 F257
5) Tighten the Angleich locknut.
* Do not let the Angleich turn together with
the nut when tightening.
w Angleich locknut: 2.75 + 0.25 kgm

6) Raise the injection pump to the rated speed
(N,), and check that the control rack moves the Torque rise stroke P
torque rise stroke (1) smoothly.
7) Check that rack position (R,) and the fuel injec-
tion amount are within the standard value at
rated speed (N,).
N, N, N,
Pump speed (rpm)
078F258
12-OAO-8 95 SERIES
TESTING AND ADJUSTING FUEL CUT

SOLENOID
3D95S-W-1
l With this type, electricity is passed to the solenoid for

17 seconds to actuate it when the engine is stopped
(no injection).
1. Push stop lever (1) of the injection pump fully in the

run position to extend the solenoid with a built-in re-
turn spring fully, then temporarily assemble rod (2).
* Do not tighten the rod locknut when doing this.
* Mark the thread of rod (2).
2. Turn the rod 0.5 turns in the direction for making it
shorter, then tighten the rod locknut.
* When the rod is turned 0.5 times, the rod becomes
approx. 1 mm shorter.
3. Pass electricity through the solenoid and check that
the engine stops correctly. Carry out this test three
times.
6206F548
95 SERIES 12-O&O-9
4D95L-W-1, 4D95L-1
6D95L-1, S6D95L-1
If the solenoid is not actuated smoothly, an exces-

sive current will flow and the solenoid coil will burn
out, or there will be a drop in output because of the
reduction in the injection amount. To avoid this,
check the clearance between the stopper and lever,
check the stroke of the solenoid, and adjust the
length of the rod as follows.
1. Pull the rod by hand towards the solenoid so

that the stop lever is actuated when the sole-
noid is actuated.
Adjust the length of the rod so that the clear- 2 3 4 5
ance between the stop lever and the stopper is 6204~203
0.3 - 0.5 mm. 1. Fuel injection pump

2. Pass electricity through the solenoid and check 2. Stopper
the solenoid stroke (12 mm) and the clearance 3. Stop lever
between the stop lever and stopper (0.3 - 0.5 4. Rod
mm), and make final adjustment. 5. Solenoid
3. Start and stop the engine 2 or 3 times and check
that the solenoid is actuated smoothly and that
the engine stops.
Note: The diagram above shows the system for

the WA70-1.
The mounting position of the fuel cut sole-
noid and the shape of the stop lever for the
WAIOO-1, WA150-1 are different from the
diagram above, but the method for testing
and adjusting is exactly the same.
The D21A-7T (trimming specification) has no
stop lever.
4D95S-W-1
1. Confirm that the stop lever of the fuel injection pump

is in the injection position (ordinary operation side).
2. Adjust the length of rod (1) so that the clearance bet-

ween the lever and stopper is less than 1 mm, then
tighten locknut (2).
3. Push the rod (stroke: 20 mm) towards the solenoid

and confirm that there is a clearance between the stop
lever and stopper.
4. Start the engine, actuate the solenoid, and confirm that

the engine comes to a complete stop. Repeat three
times.
5. This solenoid is a type in which an electric current

passes (for 17 set) when the engine is stopped.
12-OAO- 10 95 SERIES
4D95L-1 (PC60, 70-7)

S4D95L-1 (PC128UU-1)
Install ball joint (2) to solenoid (I) and tighten

locknut (3).
+ a: Approx. 1 mm (I thread)
Portion P 6206F1022
Assemble rod (4) and rod end (5) temporarily to

ball joint (2).
* Depth b for screwing rod into ball joint:
Approx. 12.5 mm
* Depth c for screwing rod end into rod:
Approx. 10.0 mm
6206F1023
3. Pass electricity through solenoid (1) to make it

attract.
* When doing this, if rod end (5) and stop
lever (6) of the injection pump are connected
before the solenoid is actuated, the solenoid
will not be pulled away (the actuating cur-
rent will continue to flow) when the sole-
noid is actuated, and the coil will burn out.
To prevent this, do not connect the rod end
and stop lever. Solenoid held I)
I 6206F1024
4. Check that solenoid (I) is attracted, then con-

nect rod end (5) to stop lever (61, and adjust the
length of rod (4) so that the stop lever contacts
the end of the lever at the constant end.
Solenoid held b
6206F1025
95 SERIES
’2-oiF’
’
Stop lever (6) contacts the end of the lever

at the constant end. (Contacts inside the in-
jection pump)
* Play: 0 mm
Constant RUH
;; stopper 6206F1026 1
Detail of stop lever angle 6206F1030
*
Do not pull beyond
stop lever end
When adjusting the length of rod (4), do not
apply any excessive force to pull stop lever
(6) beyond the lever end.
The method for adjusting the rod length is
* To make rod shorter
as shown in the diagram on the right.
* To make rod longer
6206F1027
5. Tighten nut (7) at the connection of stop lever

(6) and rod end (5), then install a split pin.
Ir Install the rod end so that greasing port (8)
is at the top.
& Rod end: Grease (G2-LI)
Solenoid held *
I 6206F1026
6. Make rod (4) longer to give play at the constant

end of the stop lever. Play from constant end
* Play d: 1.0 - 2.0 mm
(loosen the rod l/2 - 1 turn) Stop lever constant end
Solenoid held l
4
6206F1029
95 SERIES
’*-OAO-’
*
7. Tighten locknut (8).

Ir When doing this, be careful that rod (4) does
not turn together with locknut (9). Be careful
also not to twist stop lever (6) with exces-
sive force.
8. Stat-t and stop the engine 2 or 3 times and check

that solenoid (6) is actuated smoothly and that
the engine stops.
6206F1031
95 SERIES
’2-o’z-’
3
PROCEDURE FOR ADJUSTING

ENGINE STOP MOTOR CABLE
Engine stop motor
4D95S-1
6D95L-1 (D31-20, D37-5)
S6D95L-1
/b 6206F900
6206F1032
Temporarily install a ball joint to the cable of

the engine stop motor (screw in fully, then turn
back approx. l/2 turns). Install a ball joint to the
stop lever of the injection pump also.
Clearance between stopper and
STOP stopper 6206F901
Pull the injection pump stop lever by hand to

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

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

STOP stopper
6206F999
’2-oAo-’
4 95 SERIES
4. Tighten all nuts and bolts. * Problems caused by defective adjustment

of the engine stop motor cable
5. Turn the engine starting switch ON/OFF sev- -
eral times to check that the engine stop l Clearance between l Engine does not stop
motor and cable operate smoothly, then stop lever and STOP
check the following points again. stopper is too lame
1) Check visually that there is slack in the when engine stop
engine stop motor cable when the en- motor cable is
gine is running, and that the stop lever pulled.
of the fuel injection pump has returned l Clearance between l Engine output drops
fully to the RUN side. stop lever and RUN because of drop in
2) Check again that the clearance between stopper is too large amount of fuel in-
the stop lever and the STOP stopper is 1 when cable is free. jected
- 2 mm when the engine is stopped.
* Limit switches are built into the engine
stop motor at both ends of the cable
stroke.
* Stroke of engine stop motor: 35 mm
Stroke of fuel injection pump stop lever:
30 mm
* The action of the spring (this is usually
built into the fuel injection pump) en-
sures that there is slack in the engine
stop motor cable when the engine is run-
ning and that it is kept in the operating
position.
* There is a loose spring inside the engine
stop motor and when the engine is
stopped, this absorbs the tolerance of
the stop motor.
However, if this is absorbed by the loose
spring of the engine stop motor, force is
applied at the injection pump end, so
depending on the model, this is made
impossible.
With such models, if the clearance be-
tween the STOP stopper and the stop
lever is set at zero when the engine is
stopped, there is danger that problems
may arise with the injection pump.
95 SERIES
‘2-oF5 1
ADJUSTING FUEL INJECTION PRESSURE

(CRACKING PRESSURE)
1. Remove retaining cap (1). For swirl chamber type For swirl chamber type
3D95S-W-1 4D95S-W-1
2. Remove nozzle (2), spring seat (3), and nozzle spring 4D95L-W-1
(4).
3. Adjust thickness of shim (5) to adjust injection press-

ure (cracking pressure).
* Pressure adjustment for 0.1 mm of shim thickness Q
3D95S-W-1 : Approx. 10.6 kg/cm2
4D95S-W-1 : Approx. 9.5 kg/cm*
4D95L-W-1 : Approx. 9.5 kg/cm2
4D95S-1 : Approx. 15 kg/cm2
(S)(SA)4D95L-1 : Approx. 15 kg/cm*
(S)(SA)6D95L-I : Approx. 15 kg/cm2
m Retaining cap
3D95S-W-1 : 7.5 + 0.5 kgm
4D95S-W-1 : 7.5 f 0.5 kgm
4D95L-W-1 : 7.5 + 0.5 kgm
4D95S-1 : 4.5 f 0.5 kgm
(S)(SA)4D95L-1 : 4.5 + 0.5 kgm
(S)(SA)6D95L-1 : 4.5 + 0.5 kgm
6206F547 6204F202.1
For direct injection type

4D95S-1
(S)(SA)4D95L-1
(S)(SA)6D95L-1
6204F202
95 SERIES
‘*i?’
SHIM DATA FOR ADJUSTING INJECTION PRESSURE
* Always use sets of shims made by the same maker for

the injection nozzle and pressure adjustment shims.
Enaine I Shape Range of shim thickness
3D95S-W-1 a= 4.0 mm 0.8 - 1.2 mm

b=11.5 mm
Part No. Thickness (mm) Part No. Thickness (mm)
YMI 23325-53800 0.800
YMI 23325-53810 0.95
YMI 23325-53820 1 .oo
YMI 23325-53830 1.05
YMI 23325-53840 1.20
Engine Shape Range of shim thickness Range of shim clearance
4D95S-1 a
(S)(SA)4D95L-1 a=2.1 mm 0.1 - 0.58 mm 0.025 mm

(S)(SA)6D95L-1 b-7.2 mm
DKI 50534-3600 0.100 DKI 50534-4400 0.580
DKI 50534-3700 0.200
DKI 50534-3800 0.300
DK150534-3900 0.400
DKI 50534-4000 0.500
DKI 50534-4100 0.520
DKI 50534-4200 0.540
DKI 50534-4300 0.560
12%12 95 SERIES
Engine Shim thickness Shim thickness

Shim contour
model (Range) (Interval)
a
4D95L-W-1 a = 4.5 mm
4D95SW-1 0.50 - 1.54 mm 0.02 mm
b= 11.5mm
DK150523-5000 0.50 DK150523-7900 1.08
DK150523-5100 0.52 DKI 50523-8000 1.10
DK150523-5200 0.54 DK150523-8100 1.12
DK1505235300 0.56 DK150523-8200 1.14
DKI 50523-5400 0.58 DK150523-8300 1.16
DK150523-5500 0.60 DK150523-8400 1.18
DK150523-5600 0.62 DK 150523-8500 1.20
DK150523-5700 0.64 DK150523-8600 1.22
DK150523-5800 0.66 DK150523-8700 1.24
DKI 50523-5900 0.68 DKI 50523-8800 1.26
DK150523-6000 0.70 DK 150523-8900 1.28
DK150523-6100 0.72 DK 150523-9000 1.30
DK150523-6200 0.74 DK150523-9100 1.32
DK 150523-6300 0.76 DK150523-9200 1.34
DK150523-6400 0.78 DKI 50523-9300 1.36
DK150523-6500 0.80 DKI 50523-9400 1.38
DK150523-6600 0.82 DK150523-9500 1.40
DK150523-6700 0.84 DK150523-9600 1.42
DK150523-6800 0.86 DK150523-9700 1.44
D K150523-6900 0.88 DK 150523-9800 1.46
DK150523-7000 0.90 DK 150523-9900 1.48
DK150523-7100 0.92 DKI 50530-0000 1.50
DK150523-7200 0.94 DK150530-0100 1.52
DK1505237300 0.96 DK150530-0200 1.54
DK150523-7400 0.98
DK150523-7500 1 .oo
DK150523-7600 1.02
DK150523-7700 1.04
DKI 50523-7800 1.06
95 SERIES 12-gl3
TESTING AND ADJUSTING LUBRICATION SYSTEM
LUBRICATION SYSTEM
MEASURING OIL PRESSURE
A When measuring the oil pressure,
get caught in rotating parts.
be careful not to
A Always
with
remove or install plugs or oil pressure gauges
the engine stopped.
* Measure the oil pressure while engine is warm.

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

* For reference value of oil pressure, see TESTING
AND ADJUSTING DATA.
12;14 95 SERIES
TESTING AND ADJUSTING LUBRICATION SYSTEM
MEASURING OIL TEMPERATURE
1. Remove dipstick (1).
2. insert sensor of thermistor temperature gauge in dipstick

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

measure temperature of oil in oil pan.
* For reference value of oil temperature, see
TESTING AND ADJUSTING DATA.
95 SERIES 12-p
TESTING AND ADJUSTING COOLING SYSTEM
COOLING SYSTEM
MEASURING WATER TEMPERATURE
n When measuring
not to get the
the water
sensor
temperature,
cable or clothes
be careful
caught in
rotating part.
1. Disconnect wiring of water temperature gauge, then

remove sensor (1).
2. Install adapter and sensor of thermistor temperature

gauge in water temperature pick-up port.
3. Connect sensor cable to thermistor temperature gauge A,

and measure water temperature.
‘*-P 95 SERIES
TESTING AND ADJUSTING COOLING SYSTEM
TESTING AND ADJUSTING FAN BELT TENSION
TESTING FAN BELT TENSION

Approx. 6 kg
Check the amount the fan belt deflects when pushed with a
force of 6 kg at a point midway between the fan pulley and
the altqnator pulley.
Alternator pulley ( )
* For the reference values of the fan belt tension, see
TESTING AND ADJUSTING DATA.
21 KF102
ADJUSTING FAN BELT TENSION
1) Loosen mounting bolt of alternator pulley and belt

tension adjustment bolt (1).
2) Using a bar, raise alternator and adjust fan belt tension.
Tighten adjustment bolt (I), then tighten mounting
bolt.
95 SERIES 12X$7
TESTING AND ADJUSTING FUEL INJECTION PUMP CALIBRATION DATA
FUEL INJECTION PUMP CALIBRATION DATA
3D95S-W-1
4D95S-W-1
6202-73-I 160
6204-71-1560
4D95L-W-1
95 SERIES
TESTING AND ADJUSTlNG FUEL INJECTION PUMP CALIBRATION DATA
Engine model Pump assembly No. Engine serial No. Applicable machine Page
6205-71-1232~I~~~ I PCIOO-5 I 12-022-18
6205-71-1240 31713 and up PC120-5 12-022-19
6205-71-1241 48811 and up PC120-5 12-022-20
6205-71-1242 48811 and up PC120-5 12-022-21
6205-71-1243 PC120-5 12-022-22

S4D95L-1
1 6205-71-1271 ) PCIOO-5 I 12-022-23
6205-71-1510 PCIOO-6 12-022-80
6205-71-1520 PC120-6 12-022-81
1 6205-71-1320 1 PC128UU-1 I 12-022-81
I 6205-71-1290 1 JV70DW-1 I 12-022-107
1 6206-71-1310 1 WA120-1 I 12-022-24
6206-71-1320 10018 and up GD300-2 12-022-25
6206-71-1335 WAIOO-1, WRII-1 12-022-26
6206-71-1360 26324 and up WA120-1 12-022-27
I-6206-71-1361 I WA120-1 I 12-022-85
6206-71-1420 23424 and up EG60-1, EG65S 12-022-28
6D95L-1
6206-71-1251 D31E, P, S, Q-18 12-022-36
D31E, P, PL, PLL-20(A)

6206-71-1252 12-022-65
D31S,Q,AM,SM-20
6206-71-1331 WAlOO-1 12-022-37
6206-71-1333 22592 and up WAIOO-1 12-022-38
6206-71-1334 WAlOO-1 12-022-39
6206-71-1370 29245 and up D37E-2 12-022-40
6206-71-1371 D37E-2 12-022-86
95 SERIES
’2-oA8-’1
SL6D95L-1
6207-71-1242 PWIOO-3 12-022-90
6207-71-1243 PWIOO-3 12-022-91
6207-71-1250 PC200-5 12-022-92
6207-71-1251 PC200-5 12-022-93
6207-71-1252 PC200-5 12-022-93
6207-71-1262 PC200-5, BR200-1 12-022-47

I I
6207-71-1271 PWIOO-3 12-022-48
6207-71-1281 PC150-3c 12-022-94
6207-71-1320 10001 and up PC150, LC-3 12-022-49
6207-71-1320 32941 and up PC150-3 12-022-50
S6D95L-1 6207-71-1331 13460 and up WA150-1 12-022-51
1 6207-71-1332 1 23243and up 1 WA150-1 1~ ~~12-022-52
1 6207-71-1335 WA150-1 I
1
12-022-53
6207-71-1510 WA180-3 12-022-108
6207-71-1520 WA250-3 12-022-109
6207-71-1360 27750 and up PC150-3C,PC18OLC, LLC3 12-022-54
6207-71-1361 PC150-3, PC180-3 12-022-55
6207-71-1380 26330 and up WA180-1 12-022-56
6207-71-1381 WA180-1 12-022-95
6207-71-1390 PC18OLC, LLC-3 12-022-57
6207-71-1410 EG85-1 12-022-96
6207-71-1420 EG85-1 12-022-96
6207-71-1421 EG85-1 12-022-96
6207-71-1430 EG85-1 12-022-96
6207-71-1540 DCK85SPK 12-022-97
6207-71-1690 EG85-1 12-022-96
6207-71-1811 24866 and up GD461A-1 12-022-58
‘T 8-2 95 SERIES
Engine model Pump assembly No. Engine serial No. Applicable machine Page
6207-71-1910 26244 and up GD511,513A, R-l 12-022-59
6207-71-1930 GD510R-1 12-022-60
6207-71-1941 WA150-1 12-022-98
6207-71-1950 GD511A, R-l 12-022-99
S6D95L-1 6207-71-1951 GD511A, R-l 12-022-99
6207-71-1960 GDSIOR-1 12-022-61
6207-71-1961 GDSIOR-1 12-022-100
6207-72-1210 PC200-6 12-022-101
6207-72-1270 PWIOO-3 12-022-102
1 6207-71-1211 I 1 PC220-5 I 12-022-103
6209-71-1230 PC220-5 12-022-62
6209-71-1250 PC220-5 12-022-104
SA6D95L-1 6209-71-1251 PC220-5 12-022-105
6209-71-1252 PC220-5 12-022-105
6209-71-1262 PC22OLC-5, BR300-1 12-022-63
6209-71-1210 PC220-6 12-022-106
6209-71-1110 WING100 (LWIOO-I, LWIOOM-I) 12-022-110
I 1 I
SAA6D95LE-1
95 SERIES
’2-28-3
Pump Assembly Number Applicable Machine Applicable Engine
6201-72-I 110 (771353-51 iO0)
Model Serial No. Model Serial No.
( ) : Manufacturer’s part No.
EC35Z-2 3D95SW-1
EC35ZS-2
Injection Timing Engine specification

, 1
Rotating direction Clockwise view from drive end Rated horsepower HP/rpm 3512,650
injection order 1-2-3 Maximum torque kgm/rpm 13/l ,800
High idling rpm 2,750 to 2,850

Injection interval 120”+30’
Low idling rpm 650 to 750
Plunger pre-stroke mm 2.0 i 0.05

Delivery valve
retraction volume mm3/st 36 I Pump tester capacity
for Service standard I Motor 7.5 KW
I
Calibration Standard
Conditions Service standard Manufacturer standard

Service standard
Nozzle part no. (171353-53000)(YDN-0SD177)
indicates data
using calibration Nozzle holder part no. (771353-5305O)(YKCA-S)
test parts.
Injection ipe
Manufacture 6 x 2 x 450
(O/D x I/g x length) mm
standard is data
for factory test. Test oil ASTM D975 No. 2 diesel fuel or equivalent
Oil temperature OC 40 to 45
Nozzle opening pressure kg/cm’ 120
Transfer pump pressure kg/cm2 0.3
Injection volume Service standard (cc/lOOOst) Manufacturer standard (cc/ st

Rack Pump
Rack
position speed Maximum Maximum
point variance
(mm) (wm) Basis Allowance “b”df’$$ Basis Allowance between
cylinder cylinder
Rack positions - Each cyl. Each cyl.
B to E are the refer- Basic point [ 14.41 1,325 1451 *I .35
ence volume when [451
adjusting the injec- B *
L15.21 1,300 52.7 *51.65 to 53.75 ?I ,054
tion volume.
Marks l are aver- C L16.51 900 60.0 *57.60to62.40 +2.4 *
age volumes.
Approx. 350 15.0 *12.75to17.25 k2.25 *
D 17.8
E [19.01 200 80.0 *75.0 to85.0 *
sovernor performance ( 350 - 1,325rpm)
(16.5)
7 (15.2)
z (14.4)
.-
C
=12.8
z
a *Il.8
Y
8
u
I
0 200 350 900*50 1130 / \ \
1300+;0 1325 1400*25
Pump speed (rpm)

SEBH4525-01
95 SERIES
12219
6201-72-1120 (771353-51200)
( ): Manufacturer’s part No.
PC40-5 3D95S-W-1 10467 and up
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 38.4I2.600
Injection order Maximum torque kgm/rpm 12.5/1,800

1-2-3
High idling rpm 2,800 t0 2,900
Injection interval 120” ? 30’
Plunger pre-stroke mm 2.0 * 0.05
Pump tester capacity
Motor 7.5 KW
~t~~~~~~$$?ume mm3/st 36 for Service standard

- Service standard
Nozzle part no. (171353-53000)(YDN-0SD177)
indicates data
using calibration Nozzle holder part no. (771353-53050) (YKCA-S)
test parts.
Injection ipe
- Manufacture 6x2~450
(O/D x I/6 x length) mm
standard is data
Oil temperature “C 40 to 45
Nozzle opening pressure kg/cm2 120
Transfer pump pressure kg/cm* 0.3
I I
Injection volume
* Rack positions
B to E are the refer-
ence volume when
adjusting the injec-
tion volume.
* Marks * are aver-
age volumes.
Governor performance ( 450 - 1300 rpm)
Pump speed (rpm)

SEBH4524-1
’*-8*O 95 SERIES
6201-72-1121 (771353-51201)
PC40-6 10001 and up 3D95SW-1 10467andup
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 38.512.600
1
Injection order 1-2-3
Injection interval 1 2o” f 30’
Plunger pre-stroke mm 2.0 f 0.05

Delivery valve Motor 7.5 KW
36 for Service standard
retraction volume mm3/st

Service standard
Nozzle part no. (171353-5300)(YDN-OSD177)
indicates data
using calibration Nozzle holder part no. (771353-53050)(YKCA-S)
test parts.
Manufacture Injection ipe
(O/D x l/g x length) mm 6x2~450
standard is data
Injection volume Service standard kc/l 000 st) Manufacturer standard (ccl st
Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance TerE’,$, Basis Allowance between
cylinder cylinder
Rack positions 4. o Each cyl. Each cyl.
B to E are the refer- Basic point 14.0 1300 . 39.0 to 41 .o k1.0
ence volume when
adjusting the injec- B Approx. 8.9 * 7.4 to 10.4 t1.78 *
12.4 490
tion volume.
Marks * are aver- C L15.11 900 47.5 *46.0 to 49.0 k1.9 *
age volumes.
D L19.01 200 *75.0 to 85.0 *
E * *
Pump speed (rpm) SEBH470C
95 SERIES
’*-iii*’
6201-72-1210 (771353.51220)
( 1: Manufacturer’s part No.
PC5OUU-1 1001 andup 3D95SW-1 12209 and up
Rotating direction Clockwise view from drive end Rated horsepower HP/rpm 38.5/2,500
Maximum torque kgm/rpm 12.2/1,800

Injection order I 1-2-3 I
High idling rpm
Injection interval 120° 2 30’
Low idling rpm 950 to 1,000
J
Plunger pre-stroke mm 2.0 If 0.05 r I I

- Service standard
Nozzle part no. (171353-530OO)(YDN-0SD177)
indicates data
using calibration Nozzle holder part no. (771353-5305O)(YKCA=S)
test parts.
* Manufacture Injection ipe
(O/D x l/g x length) mm 6 x 2 x 450
standard is data

Transfer pump pressure kg/cm’ 0.3
Injection volume Service standard (cc/l 000 st) Manufacturer standard (cc/ stl
Rack Pump
Rack
point variance
(mm) b-n) Basis Allowance “b”,:$$ Basis Allowance
between
cylinder cylinder
Rack positions Each cyl. Each cyl.
B to E are the refer- Basic point 14.0 1,250 40.0 k1.0
ence volume when 39.0 to 41 .o
adjusting the injec- B 47.5 *45.6 to 49.4 k1.9 *
l15.11 900
tion volume.
Approx.
Marks * are aver- C 12.4 490 8.9 * 7.4 to 10.4 k1.78 *
age volumes.
D t19.01 200 80.0 *75.0 to 85.0 *
E 115.71 400 *Min. 44.0 *
Governor performance ( 450 - 1,300 rpm)
400 750+50 1250’;

Pump speed (rpm)
SEBH4807
95SERlES
’2-ih22
Injection Pump
Machine Model Engine Model
Pump Type Manufacturer I Pump Assembly Number
D20A,P,S-6 4D95S-W-1 PES-A DIESEL KIKI 6202-72-1210 (101452-3051). 1
D21 A,P,S-6 S/N 233 18 and up
Injection Timing
Unit Basis Allowance I
I Specification for engine with fan (reference only)
Rated horsepower: HP/rpm 39.5/2450

I
Plunger pre-stroke mm 1.5 1.45 to 1.55
I
Delivery valve
35
retraction volume mm3
Manufacturer standard Service standard
Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)
Nozzle part no. 6202-l 2-3130 (105000-1770) (105780-0000)
Nozzle holder part no. 6202-12-3110 (105071-1450) (105780-2080)

I’
mm 6x2~550 6x2~600
c”d%t%%?fenqthI
Test oil ASTM D975 No. 2 diesel fuel or equivalent
Oil temperature “C 40 to 45 40 to 45
Nozzle opening pressure kg/cm2 120 175
Transfer pump pressure kg/cm2 1.6 1.6
Specifications Injection volume (cc/l OOOst) Injection volume (cc/l OOOstJ

for manufacturer standard for service standard
l [ 1: Reference data
Maximum Maximum
Rack. . Pump
variance variance
osltlon ~g;? Basis Allowance Basis Allowance
between between
Pmm) cylinder cylinder
Calibration Each cyl. Each cyl.
basic point A 11.0 1225 35.4 32.4 31.4t033.4 kO.81
B approx.
l Rack positions 410 8.0 t l 8.0 * 7.0 to 9.0 z!I 1.2
8.4
ence volume when C * *
tion volume. D * *
l Marks * are aver-
age volumes. E * *
Marked *: Rack position approx. 9.3 mm

Governor performance (41 o - I 225 rpm)
ack cap: approx. 17.5 mm
Pump speed (rpm)

SEBH4526
Numbers in parentheses are pump manufacturer part numbers.
95 SERIES
’ 2-oz2-’
Machine Model Engine Model Injection Pump
Pump Type Manufacturer .Pump Assembly Number
D21 E-6 4D95S-W-1 PES-A DIESEL KIKI 6202-72-I 230 (101452-3070). 0
S/N 24252 and up
Injection Timing

Rotating direction Counterclockwise viewed
from drive end
Specification for engine with fan (reference only)
I Rated horsepower: HPlrpm 44.4/2450

1
Delivery valve
35
~auoraaon aranaara I I
Conditions Manufacturer standard Service standard

Unit
Nozzle part no. 6202-l 2-3130 (105000-I 770) (I 05780-0000)
Nozzle holder part no. 6202-12-3110 (105071-1450) (I 05780-2080)

In ectron rpe
mm 6x2~550 6x2~600
(d/D x l/$x lenqth)
Specifications Injection volume (cc/l OOOst) Injection volume (cc/l OOOst)

l [ 1 : Referencedata
Rack Maximum Maximum
Pump
osition speed Basis variance variance
Allowance Basis Allowance
Pmm) between between
(rpm)
cylinder cylinder
Calibration Each cyl. Eachc I.
basic point A E11.31 1225 38.0 37.0 to 39.0 20.95 l34.81 [33.& to L35.81 LkO.871
B approx.
l Rack positions
8.4
410 8.0 * 7.0 to 9.0 21.2 ‘[ 8.01 *[ 7.01 to 1 9.01 [*I.21
tion volume. D * *
l Marks * are aver-
age volumes. E * *
Governor performance (410 - 1225 rpm) Marked Rack
mm
410 670t20 -10
Pump speed
in parentheses are
95 SERIES
6202-72-1230 (101452-3071)
Model
I
Serial No.
I
Model 1
I
Serial No.
( ): Manufacturer’s part No. 1 4D95SW-1 (
I D21 E-6 I
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 44.412.450 I
Injection order 1-2-4-3

1 Maximum torque kgm/rpm 1
Injection interval 9o” f 30’
1 Low idling rpm I 800 to 850 I
Delivery valve
rptrartinn Vn~llmP mm3/st 35 IPump tester capacity
I

* Servicestandard
Nozzle part no. ( 105780-0000) 6202-l 2-3130 (105000-1770)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6202-12-3110 (105071-1450)
test parts.
* Manufacture Injection ipe 6x2~600 6x2~550
(D/D x l/g x length) mm
standard is data
Transfer pump pressure kg/cm’ 1.6 1.6
Injection volume Service standard (CC/I OOOst) Manufacturer standard (cc/lOOOs~

Rack Pump
Rack
position speed _ Maximum Maximun
point variance
(mm) (rpm) Basis Allowance $rgE”, Basis Allowance between
cylinder cylinder
t Rack positions Each cyl. Each cyl.
B to E are the refer- Basic point
ence volume when 11.3 1225 34.6 33.6 to 35.6 to.865 38.0
adjusting the injec- B Approx. 410 8.0 * 7.0 to 9.0 k1.2 8.0 t
tion volume. 84
sMarks * are aver- C * *
age volumes.
D * *
E * *

Rack cap: approx. 17.5 mm
t y!\ j.!lI
0 (590) 650(11801~40 ‘*go**5
400 410
1225:::
Pump speed (rpm)
SEBH460:
95 SERIES
’2-oi2-3
6202-72-1610 (101452-3020,3021,3022)
EC502 (S)-5 4D95S-W-1
Rotating direction Clockwise viewed from drive end
Injection order l-2-4-3

~1
I Pump tester capacit

for Service standar J I
Motor 7.5 KW
I
holder and injec-
Rack positions
B to E are the ref-
erence volume
when adjusting
the injection vol-
ume.
Marks * are aver-
Governor performance (400-1400 rpm)
ackcap:approx.17.5mm
1270+50/ 15400r1ess
1400*5
Pump speed(rpm)
SEBH4527-01
’2-022-4 95 SERIES
Pump Assembly Number Aoolicable Machine I Applicable Engine
6202-73-l 130 (101492-3700)
Model 1 Serial No. I_ Model Serial No.
WA50-1 10001 and up 4D95S-1 40337andup
WA55-1

r
1 Rotating direction Clockwise viewed from drive end I
1 Injection order I I-2-4-3 I
IInjection interval
Plunger pre-stroke mm
90” f 30’
3.6 * 0.05
l
I I Motor 7.5 KW
FZZY?Zkl(f Imp mm3/st 51 for Service standard

*Service standard
Nozzle part no. (105780-0000)
indicates data
using calibration Nozzle holder part no. (105780-2080)
test parts.
(O/D x l/g x length) mm 6 x 2 x 600
standard is data
Nozzle opening pressure kg/cm’ 175
Injection volume Service standard (cc/l 000 st) Manufacturer standard (cc/ st
Rack Pump
Rack
point variance
(mm) bm) Basis Allowance rer&2”, Basis Allowance between
cylinder cylinder
Rack positions
33.4 Each cyl. Each cyl.
B to E an? the refer- Basic point 9.0 1,250 kO.835
ence volume when 32.4 to 34.4
adjusting the injec- B Approx. *
tion volume.
400 10.5 * 9.5 to 11.5 k1.575
- Marks l are aver- C * *
age volumes.
D * *
E * *
Rack cap.: approx. 17.5 mm
L
I
0 350 \ 6Ti0 900*50 /I350125
400 I250$::
Pump speed irpm) SEBH4699
95 SERIES
’
6202-73-l 131 (01495-3160)
WA50-1 4D95S1
WA55-1

7
Rotating direction Clockwise view from drive end Rated horsepower HP/rpm 5512,500
Injection order l-2-4-3 Maximum torque kgm/rpm 16.6/1,600

Injection interval 90” * 30’

Del ivery valve Motor 7.5 KW

’ Service standard
Nozzle part no. (105780-0000) 6202-13-3530 (105017-0840)
indicates data
using calibration Nozzle holder part no. (105780-2080) (105048-3300)
test parts.
Injection ipe
5Manufacture (O/D x l/6 x length) mm 6 x 2 x 600 6x 1.6x600
standard is data
injection volume Service standard (cc/l OOOst) Manufacturer standard (cc/lOOOst

Rack Pump
Rack
position speed Maximum Maximur*
point variance
(mm) (rpm) Basis Allowance ~“,:‘~$ Basis Allowance between
cylinder cylinder
Rack positions 4. 8 Each cyl.
9.7 40,4 Each cyl.
B to E are the refer- Basic point 1,250 tl.O1 .
adjusting the injec- Approx.
B 8.1 400 8.0 * 7.0 to 9.0 t1.2 10.5 *
tion volume.
* Marks * are aver- C * *
age volumes.
D * *
E * *
18’:
ck limit : Approx. 13’E’mm
-C
E
10.5
S
E 9.7
B
6 7.5
B
5.8
Pump speed (rpm)

SEBH4808
95 SERIES
6204-71-1210 (101492-3411)
PC60-3 4D95L-1
PC6OL-3
1 PC6OU-3 1
injection Timing Engine specification

I
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 5912,400 I
Injection order l-2-4-3 1 Maximum torque kgm/rpm 1 20/I ,500 I
Injection interval
I High idling rpm I 2,590 to 2,690 I
Plunger pre-stroke mm 3.6 + 0.05
Delivery valve
retraction volume mm3/st 51 I I Motor 7.5 KW
I

8 Nozzle part no. (105780-0000) 6207-I I-31 30 (105017-0090)
data
using calibration Nozzle holder part no. (I 05780-2080) 6207-I l-3110 (105048-3060)
test parts.
- Manufacture Injection ipe
(O/D x I/g x length) mm 6 x 2 x 600 6x1.6x600
standard is data
Nozzle opening pressure kg/cm’ 175 200
Injection volume Service standard (cc/l OOOst) Manufacturer standard (cc/l OOOst
Rack Pump
Rack
point variance
(mm) (rPm) Basis Allowance ~er$$~ Basis Allowance
between
cylinder cylinder
6 to E are the refer- Basic point 10.3 1200 35.5 20.8875 38.0
adjusting the injec- A?EOs”.
B 400 10.5 * 9.5t011.5 fl.575 10.5 *
tion volume.
Marks * are aver- C * *
age volumes.
D * *
E * *

ack cap: 17.5mm
+30
‘2%20
Pump speed (rpm)
SEBH4685
95 SERIES
’2-o;2-7
Machine Model Injection Pump
Engine Model
Pump Type Manufacturer Pump Assembly Number
PC60-5 4D95L PE-S4A DIESEL KlKl 6204-71-l 220 (101492-3490). 0
54 HP S/N 16084 and up
( 1: Manufacturer’s par-t No.
Injection Timing
Unit Basis Allowance
Clockwise viewed
Rotating direction
from drive end
Injection order l-2-4-3 Specification for engine with fan (reference only)
Injection interval 90” 89”30’ to 90”30’ Rated horsepower: HPlrpm 5412 100
Plunger pre-stroke mm 3.6 3.55 to 3.65 Maximum torque: kgm/rpm 20.411500

Delivery valve
51 High idling: rpm 2250 to 2350
Low idling: rpm 850 to 900


Unit
Nozzle part no. 6207-l l-31 30 (105017-0090)
Nozzle holder part no. 6207-I l-31 10 (105048-3060)

Injection pipe
mm 6x1.6x600
(O/D x I/D x length)
jpecifications
Injection volume (cc/l OOOst) . Injection volumebY St)
m[ 1 : Reference data for manufacturer standard for service standard
Rack Pump Maximum Maximum

osition speed Basis variance variance
Allowance Basis Allowance
between between
Pmm) (rpm)
cylinder cylinder
basic point [I 0.91 1050 45 44 to46 k1.125
’ Rack positions B 8.4 400 10.5 * 9.5 to 11.5 a1.575 *

adjustingthe injec-
tion volume. D * *
’ Marks * are aver-
age volumes. E * *
Governor performance (425 - 1050 rpm)

Rack hm,ter set 17.5 mm
Pump speed (rpm) SEBH4517
95 SERIES
r
6204-71-1220 (101492-3491)
PC60-5 4D95L-1
/I
Rotating direction Clockwise view from drive end
Injection interval 9y f 30’

standard is data
for factory test.
Injection volume
- Rack positions
6 to E are the refer-
ence volume when
tion volume.
* Marks * are aver-
age volumes.
Governor performance ( 450 - 1050 wn)
ack cap: Approx. 17.5mm
0 450 750 1050/ 115oC25

1050:: (1120)
Pump speed (rpm) SEBH4517-01
95 SERIES 12-022-9
v
6204-71-1230 (101492-3510)
( ): Manufacturer’s part No. PW60-3 4D95L-1
Injection order l-2-4-3 ~1
Injection interval 90” f 30


*Service standard
Nozzle part no. (I 05780-0000) 6207-l l-3130 (105017-0090)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-I l-31 10 (I 05048-3060)
test parts.
Injection ipe
* Manufacture (O/D x l/g x length) mm
6 x 2 x 600 6x 1.6x600
standard is data
Injection volume
Rack Pump
Service standard (cc/lOOOst) _ Manufacturer standard (~~/10OOsl
Rack
position speed Maximum Maximun
point variance
(mm) (rpm) Basis Allowance yert$$E Basis Allowance between
cylinder cylinder
pRack positions Each cyl. Each cyl.
6 to E are the refer- Basic point
ence volume when 10.5 1250 37.5 36.5 to 38.5 kO.9375 40.0
adjusting the injec- B Approx. 10.5 * 9.5to 11.5 21.575 10.5 *
7 450
tion volume.
- Marks * are aver- C * *
age volumes.
D * *
E * *
Rack cap: arqxox. 17.5 mm
Pump speed (rpm)

SEBH461(
95 SERIES
’*-O;*-’
’
6204-71-1281 (101492-3971)
PC75UU-1 4D95L-1
Injection order l-2-4-3 ~1
Injection interval 90” f 30’
Plunger pre-stroke mm 3.6 +_0.05


I
~Service standard
indicates data Nozzle part no. (105780-0000) 6207-l I-3130 (105017-0090)
using calibration Nozzle holder part "0. (105780-2080) 6207-l I-3110 (105048-3060)
test parts
Injection ipe
(Nozzle, Nozzle 6 x 2 x 600 6; 1.6x600
(O/D x I/g x length) mm
holder and iniec-
Injection volume
when adjusting
the injection vol-
ume.
‘Marks Sr are aver- D * *
age volumes.
E 1 I* l
rat
h
LAY
Rack limit : 153.2 ,,,,,,
Pump speed (rpm)

SEBH4809-01
95 SERIES
’2-os?1
*
6204-71-1290
PC75UU-2 4D95L-1

1 Injection order 1-2-4-3 I
I Pump tester capacity

for Service standard Motor 7.5 kW
I

Service standard ~~~~~~ part “,,, (105780-0000) 6207-I I-3130 (105017-0090)
indicates data
using calibration Nozzle holder part no. (I 05780-2080) 6207-11-3110 (105048-3060)
test parts Injection
pipe
(Nozzle, Nozzle (O/D x IiD x length) mm 6 x 2 x 600 6x 1.6x600
holder and injec- Test oil
tion pipe) ASTM D975 No. 2 diesel fuel or equivalent
Manufacturer Oil temperature “C 43 - 47
standard is data
using factory test Nozzle opening pressure MPa(kg/cm2) 17.2 (175) 19.6 (200)
parts
(For reference) Transfer pump pressure MPa(kg/cm*) 0.16 (1.6) 0.16 (1.6)
njection volume Service standard (cc/lOOOst) Manufacturer standard (cc/1OOOsi

Rack Rack Pump
point position speed Maximum Maximum
(mm) (rpm) Basis Allowance “b”,$:ifi Basis Allowance “b”,ztE’,
cylinder cylinder
Each cyl. Each cyl.

Rack positions Basic point 10.6 950 49
B to E are the ref-
srence volume .
Nhen adjusting B 11.5 750 60.5
:he injection vol-
C 8.0 515 10.5
Jme.
blarks * are aver- D 15 100 80
3ge volumes.
E
(900) 950::;
Pump speed (rpm) 6206F960
95 SERIES
’ *-*%-’ 3
6204-72-1310 (101452-3000)
WA40-1 1001 and up 4D95L-W-1 10001 and up
Injection interval 90” 2 30’

Low idling rpm 800 - 850
1
Delivery valve
wtnrtinn v~III~~ mm3/st
4
35 I Pump tester capacity

for Service standard I
Motor 7.5 KW
I

) Service standard Nozzle Part no. (105780-0000) 6202-I 2-3130 (105000-I 770)
indicated data
test parts. Injection ipe
1 Manufacture (O/D x l/g x length) mm 6 x 2 x 600 6 x 2 x 457
standard is data
Oil temperature “C 43-47
Nozzle opening pressure Mpa(kg/cmz) 17.2 (175) 11.8 (120)
Transfer pump pressure Mpa(kg/cmz) 0.16 (1.6) 0.16 (1.6)
Injection volume Service standard (cc/l OOOSt) Manufacturer standard (cc/ 1 OOOst
Rack Pump
Rack
point variance
(mm) (rPm) Basis Allowance yertE”, Basis Allowance between
cylinder cylinder
1 Rack positions 33 8 Each cyl. Each cyl.
B to E are the ref- Basic Point 11.7 1100 . 32.8 - 34.8 kO.845 39.0
erence volume
when adjusting B AP,Porynx 11.0 * 10.0-12.0
400 *I .65 11.0 *
the injection
volume. C * *
1 Marks * are aver- *
age volumes. D *
E * *
3overnor performance (400 - 1100 rpm)
1100::8
Pump speed (rpm)

SEBH4566-01
95 SERIES
’ 2-o;2-’ 4
Pump Assembly Number I I
Applicable Machine Applicable Engine
6204-72-l 330 (101452-3010)
( ): Manufacturer’s part No. WA70- 1 10001 and up 4D95L-W-1 11437 and up
Injection Timing Engine Specification
Rotating direction Clockwise viewed from drive end Rated horsepower kW(HP)/rpm 41.2 (55.2)/2200
Injection order 1-2-4-3 Maximum torque Nm(kgm)/rpm 204(20.8)/l 500
lniection interval 900 + 30’ I I

1
High idling
1 Low idlinq
rpm
rpm I
2320 - 2420
800
--- - 8!irl
___
mm3/st 35 for Service standard
retraction volume
using calibration
test parts.
Manufacture
standard is data
for factory test.
1 Rack positions
6 to E are the ref-
erence volume
volume.
I Marks * are aver-
age volumes.

Rack limit 17 5 mm
(1165)
95 SERIES
Pump Assembly Number
6205-71-1230 (101492-3641)
I Applicable Machine I Applicable Engine I
I Model 1 Serial No. 1 Model 1 Serial No. 1
I Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 78.912100
Injection order l-2-4-3 Maximum torque kgm/rpm 30.5/1500
High idling rvm 2240 to 2360

I

1

Motor 7.5 KW
for Service standard

I
* Service standard
Nozzle part no. (105780-0000) 6206-l l-3130 (105017-0090)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-l l-31 10 (105048-3060)
test parts.
Injection ipe
- Manufacture (O/D x l/g x length) mm 6 x 2 x 600 6X 1.6x600
standard is data
Nozzle opening pressure kg/cm* 175 200
Transfer pump pressure kg/cm* 1.6 1.6
Injection volume Service standard h/l OOOst) Manufacturer standard (cc/lOOOst

Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance Tey$f”, Basis Allowance between
cylinder cylinder
B to E are the refer- Basic point 9.9 1050 69.5 68.5 to 70.5 fl.7375 66.0
ence volume when
adjusting the injec- B 10.7 750 70.6 * 68.6 to 72.6 - 76.2 *
tion volume.
* Marks l are aver- Apt.7~. 475
C 10.5 * 9.5 to 11.5 Al.575 10.5 *
age volumes.
D * *
E * *

Rack limit 17.5mm
1 I:
0 475 / 750 96C
600t50 105o::g
Pump speed (rpm)

SEBH4720
95 SERIES
’ 2-o$2-’ 6
6205-71-1231 (101492-3710)
(101492-3712) Model Serial No. Model Serial No.
PC1 00-5 28001 and up S4D95L-1 31710 and up
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 78.912100
Maximum torque kgm/rpm 30.5/1500

High idling rpm 2240 to 2360
Injection interval 90°a30’
Low idling 900 to 950
rpm
Plunger prestroke mm 3.2 f 0.05
retraction volume mm3/st 51 for Service standard

* Service standard
Nozzle part no. (105780-0000) 6206-I I-3130 (105017-00901
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-I I-3110 (105048-3060)
testparts.
(O/D x I/6x length) mm 6 x 2 x 600 6x 1.6x600
standard is data
Injection volume Service standard (cc/l OOOst) Manufacturer standard (cc/lOOOsl

Rack Pump
Rack
point variance
(mm) (w-n) Basis Allowance Fer$$e, Basis Allowance between
cylinder cylinder
- Rack positions Each cyl. Each cyl.
B to E are the refer- Basic point 9.5 1050 66.4 k1.66 63.2
adjusting the injec- 10.3 74.4 *
B 750 (66.4) * (64.4 to 68.4) -
tion volume.
- Marks * are aver- C AP~~x. 450 10.5 * 9.5to 11.5 ?I.575 10.5 *
age volumes.
D * *
E * *
18+;
Rack cap: 15.0 i 1 mm
970f50
Pump speed Irpm)

SEBH4721-01
’2-02-17
95 SERIES
6205-71-1232 (101492-3801)
PC1 00-5 28001 and up S4D95L-1

.
Injection order l-2-4-3 Maximum torque kgm/rpm 30.5/1500

Injection interval 90”+30’
Plunger pre-stroke mm 3.2kO.05


Nozzle part no. (105780-0000) 6206-l I-3130 (105017-0090)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-I l-3110 (105048-3060)
test parts.
Injection ipe
* Manufacture (O/D x l/g x length) mm 6x2~600 6x 1.6x600
standard is data
Injection volume Service standard (cc/l 0OOs.t) Manufacturer. standard (cc/l OOOst:
Rack Pump
Rack
point variance
(mm) (rPm) Basis Allowance r:gz”, Basis Allowance
between
cylinder cylinder
Rack positions
Basic point
67 4 Each cyl.
B to E are the refer- 9.7 1050 . 66.4 to 68.4
21.685 (66.6) Each “I’
ence volume when
B 10.0 750 (57.4) * (57.4) - (76.9) *
tion volume.
Marks l are aver- APT?.
C 450 10.5 * 9.5 to 11.5 ?I.575 (10.5) *
age volumes.
D * *
E * *
18+:
ackcap: 15flmm
Pump speed (rpm)

SEBH4786
’2-o&2-1
* 95 SERIES
6205-7 l-l 240 (101492-3651)
PC1 20-5 30001 and up S4D95L-1 31713 and up
Injection order Maximum torque kgm/rpm 30.5/1500

1-2-4-3
Injection interval 90°?30’


Service standard (105780-0000) 6206-I I-3130 (105017-0090)
Nozzle part no.
indicates data
usingcalibration Nozzle holder part no. (105780-2080) 6207-I I-3110 (105048-3060)
test parts.
Injection ipe
Manufacture 6 x 2 x 600 6x 1.6x600
(O/D x l/g x length) mm
standard is data
Injection volume Service standard (cc/l OOOst) Manufacturer standard (cc/lOOOst:

Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance Fe’$$‘, Basis Allowance between
cylinder cylinder
6 to E are the refer- Basic point 10.2 1100 75.4 *I.885 70
adjusting the injec- B 10.8 76.8 * 74.8 to 78.8 - - *
750
tion volume.
A
Marks * are aver- C p64r40x. 475 10.5 * 9.5 to 11.5 t1.575 10.5 *
age volumes.
D * *
E * *

Rack limit 17.5mm
11oo::g
95 SERIES
6205-71-1241 (101492-3720)
(101492-3722) Model Serial No. Model Serial No.
I PC1 20-5 30001 and up S4D95L-1 48811andup

I
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 83.812200 1
Injection order 1-2-4-3 Maximum torque kgm/rpm 30.5/1500

Injection interval 9o”*30n
1 Low idling rpm I 900 to 950 c
Del ivery valve 51 Motor 7.5 KW
retrsctinn I~-.II~~~ mm3/st for Service standard
I

* Service standard
Nozzle part no. (105780-0000) 6206- ‘1I-3 130 ( 105017-0090)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-l I-3110 (105048-3060)
test parts.
Injection ipe
* Manufacture 6 x 2 x 600 6x1.6x600
(O/D x l/E x length) mm
standard is data
Injection volume Service standard (cc/l OOOst) Manufacturer standard (cc/l 000~1
Rack Pump
Rack
point variance
hnm) (rpm) Basis Allowance Te!$$“, Basis Allowance
between
cylinder cylinder
* Rack positions Each cyl. Each cyl.
B to E are the refer- Basic point 9.8 1100 70.8 65.6
ence volume when 69.8 to 71.8 Y.77
adjusting the injec- B 75.4 *
10.4 750 (66.8) * (64.8 to 68.8) -
tion volume.
* Marks * are aver- C A~yy. 450 10.5 * 9.5to 11.5 k1.575 10.5 *
age volumes.
D * *
E * *
18+;
ckcap:15ilmm
-E
.E
c 9.8
.p 9.3
C
5
a.
:: 6.3
5.6
it
0
0
1Cmi5o ,l@g:z
Pump speed (rpm)
SEBH4723-01
’*-O;*-*O 95 SERIES
6205-71-1242 (101492-3811)
Model 1 Serial No. Model 1 Serial No.
h
Injection Pump
4 I PC1 20-5 1 30001 and up 1
I I
S4D95L-1 1 48811 and up
I
Pump Type Manufacturer
PES4A / DIESEL KIKI 1 I I I I
Clockwise viewed from drive end
Plunger prestroke mm 3.2 kO.05


- Service standard
Nozzle part no. (105780-0000) 6206-I I-3130 (105017-0090)
indicates data
using calibration Nozzle holder part no. (I 05780-2080) 6207-I I-31 IO (105048-3060)
test parts.
(O/D x l/g x length) mm 6 x 2 x 600 6x 1.6x600
standard is data
injection volume Service standard h/l OOOst) Manufacturer standard (cc/l 000~1
Rack Pump
Rack
point
(mm) (rpm) Basis Allowance rerg$, Basis Allowance variance
between
cylinder cylinder
- Rack positions
7l 8 Each cyl. Each cyl.
B to E are the refer- Basic point 9.9 1100 . 21.795 (67.8)
adjusting the injec- AP;,~. 450 10.5 * 9.5 to 11.5 21.575 10.5 *
B
tion volume.
- Marks l are aver- C * *
age volumes.
D * *
E * *
18+;
ackcap: 15f lmm
0 set pressure
-z
L
9.9
.-6 9.1
It:
::
0
:: 6.1
2 5.1
0
1100:::
Pump speed (rpm)
SEBH4787
95 SERIES
’ *-O$*-*’
6205-71-I 243 (101492-3880)
-1
Rotating direction Clockwise view from drive end Rated horsepower HP/rpm 83.812.200
Injection order 1-2-4-3 Maximum torque kgm/rpm 30.5/1,500

I I
Injection interval

retraction volume mm3/st 51 for Service standard I

* Service standard
Nozzle part no. (105780-0000) 6202-l 3-3330 (105017-0630)
indicates data
using calibration (105780-2080)
Nozzle holder part no. (105048-3300)
test parts.
Injection ipe
- Manufacture (O/D x l/g x length) mm 6 x 2 x 600 6x 1.6x600
standard is data
Injection volume
Rack Pump Service standard (cc/l 000 st) Manufacturer standard (cc/1OOOst
Rack
point variance
(mm) (rPm) Basis Allowance ~“,:‘$$. Basis Allowance between
cylinder cylinder
Rack positions
73,5 Each cyl. Each cyl.
B to E are the refer- Basic point 10.0 1,100
ence volume when 72.5 to 74.5 21.8375 65.2
adjusting the injec- B """qfs".
450 10.5 * 9.5 to 11.5 +I ,575 10.5 *
tion volume.
Marks l are aver- C 10.45 750 (63.2) f(61.2 to 65.2) - (77.5) *
age volumes.
D * *
E * *
cklimil:12.5’~’ mm
0 450 (580) 750 930+50 \ i2OOk30

1 100::;
Pump speed (rpm)
SEBH4810
95 SERIES
’2-o,2-22
6205-71-1271 (101492-3870)
PC1 00-5 S4D95L-1
1 Injection order 1-2-4-3 hi

I I
90” * 30’
rntrIPtir\n ,,n~,,mO mm3/st 51 for Service standard

- Service standard
Nozzle part no. (105780-0000) 6202-I 3-3330 (105017-0630)
indicates data
using calibration Nozzle holder part no. (105780-2080) (105048-3300)
test parts.
Injection ipe
* Manufacture (O/D x l/g x length) mm
6 x 2 x 600 6x1.6x600
standard is data
injection volume Service standard (cc/l 000 st) Manufacturer standard (cc/l 000 si
Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance $~~~~~ Basis Allowance between
cylinder cylinder
* Rack positions
6g g Each cyl. Each cyl.
B to E are the refer- Basic point 9.9 1,050 . +I .7475 63.6
B 10.35 750 (63.2) *(61.2 to 65.2) - (77.5) *
tion volume.
- Marks * are aver- Approx.
C 7.8 450 10.5 * 9.5to 11.5 ?I ,575 10.5 *
age volumes.
D * *
E * *
0
,
I ll.,L
450 (680)750 1 1050% ,,50*30
9OOk50
Pump speed (rpm)
SEBH4811
95 SERIES
’2-o2-23
I
6206-71-1310 (101692-3661)
Model Serial No. Model Serial No,
WA120-1 6D95 L-l
(For altitude spec.)
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 8512500
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 32.1/1600

Injection interval 60” + 30’
Plunger pre-stroke mm 3.6 & 0.05


* Service standard Nozzle Dart no (105780-0000) 6207-l I-3130 (105017-0090)
indicates data
test parts.
- Manufacture
Injection ipe
fO/Dx I/ E x lenathl mm 6 x 2 x 600 6x 1.6x600
standard is data
for factory test. 1Test oil ASTM D975 No. 2 diesel fuel or equivalent
injection volume Service standard (cc/l 000st) Manufacturer standard (cc/l 000s
* Rack positions
ence volume when
tion volume.
- Marks l are aver-
age volumes.
Governor performance 1 400 - 1250rpm)

Rack limit
0 400 62Oi20 1 w&o) T

850130 1:250
Pump speed (rpm)
SEBH473E
12-022-24 95 SERIES
6206-71-1320 (101692-3001)
10018andup
G D300A-2 6D95L-1
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 8412,550
Injection order 1-5-3-6-2-4 Maximum torque kgm/rpm 1 31/1.400

I
Injection interval 60/O f 30’

Delivery valve . Motor 7.5 KW

* Service standard
Nozzle part no. (105780-0000) 6207-I l-3130 (105017-0090)
indicates data
using calibration Nozzle holder part no. (I 05780-2080) 6207-I I-3110 (105048-3060)
test parts.
Injection ipe
- Manufacture
(O/D x l/g x length) mm 6x2~600 6x 1.6x600
standard is data
Injection volume Service standard (cc/lOOOst) Manufacturer standard (cc/lOOOst

Rack Pump
Rack
point
(mm) (wm) Basis Allowance Fe’$$E Basis Allowance
variance
between
cylinder cylinder
B to E are the refer- Basic point g8
ence volume when 1275 31.5 30.5 to 32.5 20.7875 34.3
adjusting the injec- A?$??. 400
B 10.5 *9.5to 11.5 *I .575 10.5 *
tion volume.
* Marks l are aver- C * *
age volumes.
D * *
E * *

Rack
capapprox.
17.5mm
0 400 700 1850) / 1375525

127538
Pump speed (rpm)

SEBH4598
95 SERIES 12-0%2-25
d
6206-71-1335 (101695-3340)
WAIOO-1 6D95L-1
WRII-1


8Service standard
Nozzle part no. (I 05780-0000) 6207-I I-3130 (105017-0090)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-I I-31 10 (105048-3060)
test parts.
(O/D x I& x length) mm 6 x 2 x 600 6x 1.6x600
standard is data
Injection volume Service standard (cc/lOOOst) Manufacturer standard (cc/lOOOst

Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance reysE”, Basis Allowance between
cylinder cylinder
Rack positions
3l .3 Each cyl. Each cyl.
B to E are the refer- Basic point 10.0 1,200 kO.7825 34.5
B 350 10.5 * 9.5to 11.5 11.575 10.5 *
tion volume. 107
Marks * are aver- C 11.1 800 36.3 * 34.3 to 38.3 - 48.3 *
age volumes.
D * *
E * *
ack limit: 13’:’ mm
g 12.2
E
6 10.0
:z
9.2
B
Y
s
a
6.0
0 350 850+30 / \ ‘1325i25

1150f50 1240::
Pump speed (rpm)
SEBH4813
95 SERIES
Engine Model
WA1 20-I 6D95L-1 PES-A DIESEL KIKI 6206-71-l 360 (I 01692-3450). . 0
S/N 26324 and up
Injection Timing
Clockwise viewed
Rotating direction
from drive end
Injection order 1-5-3-6-2-4 Specification for engine with fan (reference only)
Injection interval 60” 59”30’ to 60”30’ I Rated horsepower: HP/rpm 8512500 I

Delivery valve mm3 51 High idling: rpm 2700 to 2800

retraction volume
Low idling: rpm 800to 850


Unit
Nozzle part no. 6207-l l-31 30 (I 05017-0090) (105780-0000)
Nozzle holder part no. 6207-I I-31 10 (I 05048-3060) (105780-2080)

I.
mm 6x1.6x600 6x2~600
c”d%%C?!%ngth)
Specifications Injection volume (cc/l OOOst) Injection volume kc/l OOOst)

l [ 1 : Reference data
Maximum Maximum
Rack Pump
variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm)
cvlinder cvlinder
Calibration Each cyl Each cyl.
basic point A 10.7 1250 L41.51 36.7 35.7 to 37.7 co.91
l Rack positions
B a%p.?x~
400 110.51 * ‘10.5 * 9.5 to 1 1.5 k1.57
tion volume. D * *
l Marks * are aver-
age volumes. E * *
Marked l: Rack position approx. 10.5 mm

Rackcap: approx. 17.5 mm
Pump speed (rpmj SEBH4545

95 SERIES
’ 2-o&2-27
6206-71-1420 (101692-3161)
6206-71-1421 (101692-3800) Model Serial No. Model Serial No.
EG60-1 6D95L-1 23424 and up
EG65-S
Injection order l-5-3-6-2-4

1
* Service standard Nozzle part no. (105780-0000) 6207-I I-3130 (105017-0090)
indicates data
test parts.
* Manufacture Injection ipe 6 x 2 x 600
(O/D x I/g x lenath) mm 6 x 1.6 x 600
standard is data 4. 1

I I I I
Injection volume
Rack positions
6 to E are the refer-
ence volume when
tion volume.
Marks * are aver-
age volumes.

,Rxk limit
75&10 ;00+5
Pump speed (rpm)
SEBH4732-01
95 SERIES
’ 2-o&2-28
6206-71-1940(101692-3860) I I

Injection interval 60”*30’
r
Plunger prestroke mm 3.6kO.05
Delivery valve
Motor 7.5 KW
I

indicates data
Nozzle part no. (105780-0000) 6207-l I-3130 (105017-0090)
using calibration Nozzle holder part no. (105780-2080) 6207-I I-31 IO (105048-3060)
test parts.
) Manufacture Injection ipe
standard is data
Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance rergE”, Basis Allowance
between
cylinder cylinder
Rack positions
31 ,7 Each cyl. Each cyl.
B to E are the refer- Basic point 10.0 1250 kO.7925 35.8
adjusting the injec- AWF. 4clo 21.575 10.5 *
B 10.5 * 9.5 to 11.5
tion volume.
age volumes.
D * *
E * *
Sovernor performance ( 400 - 1250 rpm)
Rack limit 17.5 mm
L I I, I ,/,I
0 400 560+30 8OOf30 / / -i&-
11 OOf50 17.50::;
Pump speed (rpm)
SEBH4793
95 SERIES
’2-062-29
Injection Pump
PC1 00-3 6D95L PES-A DIESEL KlKl 6206-71-1210 (101692-3020). 1
PC1 OOL-3
Injection Timing
Clockwise viewed
Rotating direction
from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
Injection interval 60” 59”30’ to 60”30’ Rated horsepower: HP/rpm 7912100
Plunger pre-stroke mm 3.6 3.55 to 3.65 Maximum torque: kgm/rpm 30.5/l 400
Delivery valve


Unit
Nozzle part no. 6207-I l-31 30(105017-0090) ( 1

Nozzle holder part no. 6207-I I-31 10(105048-3060) ( 1
In ectron pope
mm 6x1.6x600
(d/D x I/D x length)
ipecifications
Injection volume (cc/l OOOst) Injection volume(cc/ St)
Maximum Maximum
Rack Pump
variance variance
position speed Basis Allowance Basis Allowance
between between
(mm) kpm) cylinder cylinder
basic point 10.5 1050 40.5 39.5 to 41.5 k1.01
Rack positions B 8.4 400 10.5 * 9.5 to 11.5 k1.57 *

tion volume. D * *
Marks * are aver-
age volumes. E * *
iovernor performance
0
5 g :gz;
_.- r
Pump speed (rpm)

95 SERIES
’ 2-o;2-30
6206-71-1210 (101692-3022)
PC 1003 18001 and UD 6D95L-1 10001 and up
PC1 OOL-3 18001 and up
~~


Service standard
indicates data
test parts.
Injection ipe
Manufacture 6 x 2 x 600
standard is data
for factory test. Test oil ASTM 0975 No. 2 diesel fuel or equivalent
Injection volume Service standard (cc/l OOOst) Manufacturer standard (cc/ si

Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance $gE!, Basis Allowance
between
cylinder cylinder
Rack positions 3. 4 Each cyl. Each cyl.
B to E are the refer- Basic point 9.8 1050 . 29.4 to 31.4
+0.76
ence volume when
adjusting the injec- *
B APBF 400 10.5 *9.5to11.5 fl.57
tion volume.
age volumes.
D * *
E * *
11.4
9.6
z
.z
6.4
E
._ 6.4
C
2
0
Y
P
LT
Pump speed (rpm)

SEBH4557
95 SERIES
’2-oi2-3
’
Injection Pump
PC1 20-3 6D95L PES-A DIESEL KIKI 6206-71-I 220 (101692-3030). . 1
Injection Timing
Clockwise viewed
Rotating direction
from drive end
Injection interval 60” 59”30’ to 60”30’ Rated horsepower: HP/rpm 82 /2200
Plunger pre-stroke mm 3.6 3.55 to 3.65 Maximum torque: kgm/rpm 31.5/1400

Delivery valve


Unit
Nozzle part no. 6207-I l-31 30(105017-0090) ( 1

Nozzle holder part no. 6207-I I-31 1 0(105048-3060) ( 1
In ectron pope
mm 6x1.6x600
Npecifications
Injection volume (cc/l OOOst) Injection volume&/ St)
Maximum Maximum
Rack Pump
variance variance
between between
(mm) (rpm) cylinder cylinder
basic point 10.4 1100 40.5 39.5 to41.5 21.01
Rack positions B 8.4 400 10.5 * 9.5 to 11.5 * 1.57 *

adjustingthe injec-
tion volume. D * *
Marks * are aver-
age volumes. E * *
iovernor performance
Pump speed (rpm)

.
Numbers In parentheses are pump manufacturer part numbers.
95 SERIES
’ 2-o;2-32
6206-7 l-l 220 (101692-3032)
PC1 20-3 18001 and up 6D95L-1 10001 and up
Rotating direction Clockwise Rated horsepower HP/rpm 8512200

viewed from drive end

Injection interval 605 + 30’
Plunger pre-stroke mm 3.6 2 0.05

Delivery valve
retmrtinn V~II~.O mm3/st 51 IPump tester capacity
Motor 7.5 KW

* Service standard
indicates data
usingcalibration Nozzle holder part no. (105780-2080)
test parts.
Injection ipe
* Manufacture (O/D x l/g x length) mm 6 x 2 x 600
standard is data
Nozzle opening pressure kg/cm* 175

Injection volume Service standard (cc/l OOOst) Manufacturer standard (cc/ st

Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance reTGEE Basis Allowance between
cylinder cylinder
* Rack positions 3, 8 Each cyl. Each cyl.
6 to E are the refer- Basic point 9.9 1100 . kO.795
adjusting the injec- B Appjox *
400 10.5 * 9.5to 11.5 +I .575
tion volume.
age volumes.
D * *
E * *
11.4
9.9
7
2 8.4
6
._ 6.4
c
x
Q
Y
P
u
95 SERIES
’2-oi2-33
Injection Pump
IPWl50-1 6D95L PE-A DIESEL KIKI I 6206-71-I 240 (101692-3010). 1
Injection Timing
Clockwise viewed
Rotating direction
from drive end
1Injection order l-5-3-6-2-4 I Specification for engine with fan (reference only)
I 1 1 ,
1Injection interval 60” 59’3O’to 60”30’ 1 ) Rated horsepower: HP/rpm 87 /2400 I

I I I I
1Plunger pre-stroke
I
mm 3.6 3.55 to 3.65 I
I
I Maximum torque:
I
kgm/rpm 32 /1600 II
Delivery valve

Calibration Standard I

Conditions Unit
Nozzle part no. 6207-l l-31 30(105017-0090) ( 1

Nozzle holder part no. 6207-I I-31 1 0(105048-3060) ( )
In ectron pope mm 6x1.6x600
ipecifications
Injection volume (cc/l OOOst) Injection volume&/ St)
Maximum Maximum
Rack Pump variance
variance
between between
(mm) (rpm) cylinder cylinder
basic point 10.3 1200 38.5 37.5 to 39.5 kO.96
’ Rack positions B 8.4 400 10.5 * 9.5 to 11.5 * 1.58 *

adjustingthe injec-
tion volume. D * *
’ Marks +r are aver-
age volumes. E * *
jovernor performance
Pump speed (rpm)

95 SERIES
’ 2-o&2-34
6206-71-1250 (101692-3532)
D31 E, P-18 40001 and up 6D95L-1 29222 and up
/I D31S. Q-18 40001 and up 6D95L-1 29222 and up

Injection interval 60’ + 30’


Service standard
Nozzle part no. (105780-0000) 6207-11-3130 (105017-0090)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-I 1-31 IO (105048-3060)
test parts.
Injection ipe 6x1.6x600
Manufacture
(O/D x l/g x length) 6 x 2 x 600
mm
standard is data

Injection volume Service standard (cc/l OOOst) Manufacturer standard (cc/lOOOst)

Rack Pump
Rack
point variance
(mm) (wm) Basis Allowance rert$$“, Basis Allowance between
cylinder cylinder
Rack positions 34 6 Each cyl. 36.0 Each cyl.
kO.865
ence volume when
adjusting the injec- B 11.1 650 (36.4) *(34.4 to 38.6) - (45.2) *
tion volume.
sMarks * are aver- C APP~:;. 350 10.5 * 9.5 to 11.5 51.575 (10.5) *
age volumes.
D * *
E * *
Governor performance ( 350 - II75 rPm)
/Racklimit
/ 1300+;0
180)
95 SERIES
’ 2-o;2-35
Pump Assembly
6206-71-1251
Number
(101695-3260)
I Applicable Machine Aoolicable Engine
Rotating direction, Clockwise view from drive end
Injection order 1-5-3-6-2-4 ~~
Plunger pre-stroke mm 3.6 f 0.05 I I

Delivery valve
retraction volume mm3h 51 I Pump tester capacity
Motor 7.5 KW
I

* Service standard
Nozzle part no.
indicates data (105780-0000) 6207-I l-3130 (105017-0090)
using calibration Nozzle holder part no. (105780-2080) 6207- 1 l-31 10 (105048-3060)
test parts.
standard is data
for factory test, Test oil ASTM D975 NO. 2 diesel fuel or equivalent
injection volume Service standard (cc/lOOOst) Manufacturer standard (cc/lOOOst

Rack Pump
Rack
point
(mm) (rpm) Basis Allowance “d’,:ggR Basis Allowance variance
between
cylinder cylinder
* Rack positions
Each cyl.
B to E are the refer- Basic point 88 Each cyl.
1,175 28.8 +0.72 28.7
adjusting the injec- B Approx.
tion volume. 9.3 350 8.0 * 7.0 to 9.0 21.2 10.5 *
- Marks * are aver- C * *
age volumes.
D * *
E * *
ck limit: 13’1’ mm
Pump speed (rpm)

SEBH4812
’2-062-36 95 SERIES
I Machine Model Engine Model
Injection
Pump Type
Pump
Manufacturer Pump Assembly Number
WA1 00-l 6D95L-1 PE-S6A DIESEL KIKI 6206-71-1331 (101692-3191)....2
Injection Timing

I
I Rotating direction
Counterclockwise viewed
from drive end I
Injection interval 60” 59”30’ to 60”30’ Rated horsepower: HP/rpm 7312400
Plunger pre-stroke mm 3.6 3.55 to 3.65 Maximum torque: kgm/rpm 29/l 600
Delivery valve High idling: 2600 to 2700

51 rpm


Conditions Unit
Nozzle part no. (I 05017-0090~ (I 05780-0000)

-
Nozzle holder part no. (105048-3060) (I 05780-2080)
I t mm 6x1.6x600 6x2~600
8% ?l%%ngth)
specifications
Injection volume (cc/l 000s.t) Injection volume(cc/l OOOst)
Maximum Maximum
Rack Pump variance variance
between between
Pmm) (rpm) cylinder cylinder

basic point 9.3 1200 28.6 27.6 to 29.6 a0.72 27.4 26.4 to 28.4 kO.69
) Rack positions B 10.5 400 10.5 * 9.5 to 1 1.5 &I.58 10.5 * 9.5 to 11.5 * 1.58
adjustingthe injec-
tion volume. D * *
1 Marks * are aver-
age volumes. E * *
jovernor performance
95 SERIES
’2-o?-37
Injection Pump
Machine Model Engine Model Pump Assembly Number
Pump Type Manufacturer I
WA1 00-l 6D95L-1 PES-A DIESEL KIKI 6206-71-I 333 (I 01692-3480). 0
S/N 22592 and up
Injection Timing
Clockwise viewed
Rotating direction
from drive end
Injection order 1-5-3-6-2-4 Specification for engine with fan (reference only)
Injection interval 60’ 59”30’ to 60”30’
Plunger pre-stroke mm 3.6 3.55 to 3.65
Delivery valve 51

Conditions Unit (with nearly the same actual machine parts) (with calibration test parts)
Nozzle part no. 6207-ll-3130(105017-0090) (I 05780-0000)
Nozzle holder part no. 6207-I l-31 10 (I 05048-3060) (I 05780-2080)

I’ . mm 6x1.6x600 6x2~600
(nd%t%%?!ngth)
jpecifications Injection volume (cc/l OOOstj Injection volume (cc/l OOOst)

B[ 1 : Reference data
Maximum Maximum
Rack Pump
variance variance
between between
basic point A 9.3 1200 f28.61 27.4 26.4 to 28.4 kO.68
Rack positions 350 [IO.51 * ‘10.5 * 9.5 to 11.5 a1.57

B %Yox.
adjustingthe injec-
tion volume. D * *
Marks * are aver-
age volumes. E * *

sovernor performance (400 - 1200 rpm)
Rackcap: a~r~~17.5 mm
6.0
o--- 350 800 105OSC )l 315*25

+
12(IOt40
t30
Pump speed (mm) SEBH4544

12-022-38 95 SERIES
Pump Assembly Number Applicable Machine
I Applicable Engine
6206-71-1334 (101692-3780)

, retraction volume mm3ht

* Service standard
Nozzle part no. (105780-0000) 6207-l I-3130 (I 05017-0090)
indicates data
using calibration Nozzle holder part no. (I 05780-2080) 6207-l l-31 10 (I 05048-3060)
test parts.
injection ipe
* Manufacture (O/D x l/6 x length) mm 6 x 2 x 600 6x1.6x600
standard is data
for factory test. Tat oil ASTM D975 No. 2 diesel fuel or equivalent
injection volume Service standard (cc/l 000 St) Manufacturer standard (cc/l OOOst
Rack Pump
Rack
point variance
(mm) (rPm) Basis Allowance TerE$ Basis Allowance between
cylinder cylinder
t Rack positions 2g 6 Each cyl. 31 o Each cyl.
B to E are the refer- Basic point (9.5) 1200 .
ence volume when 28.6 to 30.6 ‘o.74 ’
adjusting the injec- A~$yx. 10.5 *
B 350 10.5 * 9.5to 11.5 kl.575
tion volume.
bMarks * are aver- C * *
age volumes.
D * *
E * *

Rackcap: a~~rox. 17.5mm
0 / 800 1200_$o\ 1325t25

(330)350 1200~;
Pump speed (rpm)

SEBH 4708
95 SERIES
’2-oi2-39
<
6206-71-1370 (101692-3541)
D37 E-2 6D95L-1 29245 and up
Injection order 1-5-3-6-2-4
Plunger pre-stroke mm 3.6kO.05

Delivery valve 51 Motor 7.5 KW
retraction volume mm3/st for Service standard

’ Servicestandard
Nozzle part no.
indicates data (105780-0000) 6207-11-3130 (105017-0090)
using calibration Nozzle holder part no. (105780-2080) 6207-I 1-31 IO (105048-3060)
test parts.
(O/D x l/g x length) mm 6 x 2 x 600 6 x 1.6 x 600
standard is data
Injection volume Service standard (cc/l 000 St) Manufacturer standard (cc/l 000~1
Rack Pump
Rack
point
(mm) (vm) Basis Allowance ce’$$‘, Basis Allowance
variance
between
cylinder cylinder
Rack positions 35.6 Each cyl.
B to E are the refer- Basic point 10.0 1175 20.89 37.6 Each cy’.
34.6 to 36.6
ence volume when
adjusting the injec- (33.6) k31.6 to 35.6 -
B 10.9 650 (43.7) *
tion volume.
Marks * are aver- “““go. 350 10.5 * 9.5 to 11.5 ?I ,575 10.5 *
C
age volumes.
D * *
E * *

Rack limit
Pump speed (rpm)

SEBH4597-01
’2-oi2-4o 95 SERIES
‘6206-71-1550 (101692-3670)
D31 E, P-18 SL6D95L-1
Rotating direction 1 Clockwise viewed from drive end 1 Rated horsepower HP/rpm 7012350
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 26.611400
1 High idling rpm I 2600 to 2700

Injection interval 60; f 30’
I
retrartinn vnlllmo mm3/st

- Service standard
Nozzle part no. (I 05780-0000) 6207-11-3130 (105017-0090)
indicates data
test parts.
Injection ipe
- Manufacture (O/D x I/g x length) mm
6 x 2 x 600 6x1.6x600
standard is data
Injection volume Service standard (cc/lOOOstj Manufacturer standard (cc/lOOOst

Rack Pump
Rack
point variance
(mm) (rPm) Basis Allowance ~e~~~“, Basis Allowance between
cylinder cylinder
- Rack positions
34 , Each cyl. Each cyl.
kO.8525 36.1
ence volume when
adjusting the injec- 10.6 650 32.5 t 30.5 to 34.5 - 44.8 *
B
tion volume.
- Marks are aver-
l
C
Apprgq$ 350 10.5 * 9.5 to 11.5 f1.575 10.5 *
age volumes.
D * *
E * *

Rack limit
Pump speed (rpmj

SEBH4737
95 SERIES
’ 2-062-41
6206-71-l 570 (101692-3680)
Model / Serial No. Model 1 Serial No.
D37 E-2 SL6D95L-I
I
I Injection
Pump Type
Pump
Manufacturer I (For altitude spec.)
PES-GA DIESEL KlKl

I
51 for Service standard I I

Service standard (105780-0000) 6207-I I-3130 (105017-0090)
Nozzle part no.
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-l I-31 10 (105048-3060)
test parts.
standard is data

Injection volume Service standard (CC/I OOOst) Manufacturer standard (cc/lOOOst

Rack Pump
Rack
point variance
(mm) b-pm) Basis Allowance ye’tEE”, Basis Allowance between
cylinder cylinder
Rack positions
point 38 6 Each cyl. 42.4 Each cyl.
B to E are the refer- Basic 10.4 1175 . 37.6 to 39.6 +-‘.‘EJ~
ence volume when
adjusting the injec- 11.1 650 35.4 * 33.4 to 37.4 -
B 47.1 *
tion volume.
Marks l are aver- A
C ““3
350 10.5 * 9.5 to 11.5 k1.575 10.5 *
age volumes.
D * *
E * *
3overnor performance ( 350 - 1175 rpm)

Rack limit
Pump speed (rpmj

SEBH4736
’2-o62-42 95 SERIES
6207-71-I 210 (101692-3890) Applicable Machine Applicable Engine

(CUSTOM)
BR200_,
Injection order l-5-3-6-2-4 Maximum torque Nm(kgm)/rpm 475 (48.5)/1560
High idling rpm 2205 - 2325

Injection interval 60° + 30’
Plunger pre-stroke mm 3.6 -t 0.05
Delivery valve mms/st 51 Motor 7.5 KW
retraction volume for Service standard
Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
for factory test.
Rack positions
ence volume when
tion volume.
Marks * are aver-
age volumes.
ck limit159’mm
930 * 50 , 025z$
Pump speed (rpm)

SEBH 4775
95 SERIES
’ 2-o2-43
6207-71-1211 (101695-3050)
PC200-5 S6D95L-1
I Injection
Pump Type
Pump
Manufacturer I CUSTOM
PES-GA DIESEL KlKl BR200-1


* Servicestandard
Nozzle part no. (105780-0000) 6202-I 3-3330 (105017-0630)
indicates data
usingcalibration Nozzle holder part no. (105780-2080) 6202-I 3-3110 (105048-3300)
test parts.
Injection ipe
- Manufacture (O/D x l/g x length) mm 6 x 2 x 600 6 x 2 x 600
standard is data
Oil temperature OC 43 - 47
Nozzleopening pressure Mpa(kg/cmz) 17.2 (175) 22.1 (225)
Injection volume Service standard (CC/I OOOst) Manufacturer standard (cc/l OOOst
Rack Pump
Rack
position speed Maximum Maximurr
point variance
(mm) (rpm) Basis Allowance Fey::“, Basis Allowance between
cylinder cylinder
ence volume when 10.1 1,025 69.7 68.7 - 70.7 fl.7425 65.1
adjusting the injec- 8 68.2 *66.2-70.2 -
10.7 750 76.1 *
tion volume.
* Marks * are aver- Approx.
C 8.0 475 12.5 *11.5- 13.5 21.875 12.5 *
age volumes.
D * *
E * *
960 +50
12-022-44 95 SERIES
6207-7 l-l 230 (101692-3820)
PC200-5 45001 and up S6D95L-1 48356 and up
I Injection
Pump Type
Pump
Manufacturer I BR200-1
PES-GA DIESEL KlKl
Injection interval
I
60’+30’
I I Low
- idling rpm 875 - 925

retractinn ~nhrme mm3/st

*Service standard
Nozzle part no. (105780-0000) 6206-11-3130 (105017-0140)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-I I-3110 (I 05048-3060)
test parts.
Injection ipe
pManufacture (O/D x I/g x length) mm 6 x 2 x 600 6x 1.6x600
standard is data
Oil temperature OC 73.0 - 75.0
Nozzle opening pressure Mpalkgicmz) 17.2 (175) 22.1 (225)
Transfer pump pressure Mpa(kg/cm*) 0.16 (1.6) 0.16 (1.6)
Rack Pump
Rack
point variance
(mm) b-pm) Basis Allowance ybaer$re!$ Basis Allowance between
cylinder cylinder
B to E are the refer- Basic point 10.5 1025 74.0 fl.85 73.6
ence volume when 73.0 - 75.0
adjusting the injec- B 750 (74.0) (* 72.0 - 76.0) -
11.2 (81.4) *
tion volume.
Marks l are aver- C *yyx. 450 12.5 t 11.5-13.5 +I.875 12.5 t
age volumes.
D * *
E * *
Governor performance ( 450 - 10% rpm)

18’3
-G
2 10.5
9.7
.-6
C
g
a
Y 6.7
z
[r 5.7
1 II-
0 450 750 950*50 1135?30
(670) 1025:::
95 SERIES
’ 2-02-45
Injection Pump
PWl OO-3 S6D95L-1 PE-A DIESEL KIKI 6207-71-1240 (101692-3221). 1
S/N 15060 and up
Injection Timing
Unit Basis Allowance -1

Clockwise viewed
Rotating direction
from drive end
Delivery valve 51 High idling: rpm 2050 to 2150


Conditions Unit
Nozzle part no. 6207-I l-31 30 (105017-0090) (105780-0000)
Nozzle holder part no. 6207-I l-31 10 (105048-3060) (I 05780-2080)

I’
mm 6x1.6x600 6x1.6x600
;d%t?l%%anqth)
Specifications Injection volume kc/l OOOstI Injection volume (cc/l OOOstI

Maximum Maximum
Rack Pump
variance variance
between between
basic point A 11.2 950 55.0 44.5 43.5 to 45.5 21.11
l Rack positions B atyp 425 12.5 t ll 2.5 * 11.5 to 13.5 k1.87

adjustingthe injec-
tion volume. D * *
l Marks * are aver-
age volumes. E * *

Pump speed (rpm ) SEBH4528

95 SERIES
’ 2-o&2-46
6207-71-1262 (101692-3880)
PC2005 S6D95L-1
BR200-1
Injection order 1-5-3-6-2-l ~1

_ retraction volume mm3/st
conditions Service standard Manufacturer standard

Service standard Nozzle part no
indicates . data . (I 05780-0000) 6206-11-3130 (105017-0140)
uarn9 cafrbratron Nozzle holder part no. (105780-2080) 6207-l 1-31 IO (105048-3060)
test parts
Injection ipe
(Nozzle, Nozzle (O/Ox l/g x length) mm 6 x 2 x 600 6x 1.6x600
holder and injec- .
tion pipe) Test oil ASTM D975 No. 2 diesel fuel or equivalent
Manufacture
siandard is data Oil temperature OC 43-47
using facton/ teat NO~ZI~ openingPressureMpa(kg/cmz) 17.2 (175) 19.6 (200)
parts
(For reference) Transfer pump pressureMpa(kg/cmz) 0.16 (1.6) 0.16 (1.6)
njection volume
Rack Pump Service standard (d1000st) Manufacturer standard (cc/t OOOst
Rack
point variance
(mm) (rPm ) Basis Allowance yert$!$“, Basis Allowance between
cylinder cylinder
Rack positions 6g o Each cyl. 68 2 Each cyl.
Basic point 9.9 1025 . +I.725 .
B to E are the ref- 68.0 - 70.0
erence volume 750 - * - - - *
B 10.2
when adjusting
the injection vol- A
C ““692. 450 12.5 *11.5- 13.5 fl.875 12.5 +
ume.
Marks * are aver- D * *
age volumes. *
E *
Zovernor performance ( 450 - 1025 rpm)
Pump speed (rpmj

SEBH4733-01
95 SERIES
’2-oE-47
6207-71-1271 (101695-3020)
Service standard Manufacturer standard

* Service standard Nozzle part no. (105780-0000) 6207-11-3130 (105017-0090)
indicates data
test parts.
Injection ipe
standard is data
Injection volume Service standard (cc/lOOOst) Manufacturer standard (cc/lot)~)st

Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance ~e~~~‘, Basis Allowance
between
cylinder cylinder
6 to E are the refer- Basic point
11.3 1,050 49.9 48.9 to 50.9 +I .2475 55.4
ence volume when
8 10.4 425 12.5 t 11.5 to 13.5 21.875 12.5 *
tion volume.
age volumes.
D * *
E * *
Rack limit: Approx. 15’:’ mm
Damper spring set

7.510.1 mm
Pump speed (rpm)

SEBH4815
’2-o$2-48 95 SERIES
Injection Pump
Machine Model Engine Model Pump Assembly Number
Pump Type Manufacturer I
PC1 5O(LC)-3 S6D95L-1 PE-S6A DIESEL KIKI 6207-71-1320 (101692-311 I). 3
Injection Timing
Clockwise viewed
Rotating direction
from drive end
Injection interval 60” ,59”30’ to 60”30 Rated horsepower: HP/rpm 9912200
Plunger pre-stroke mm 3.6 3.55 to 3.65 Maximum torque: kgm/rpm 38/I 400
Delivery valve High idling: 2350 to 2450

51 rpm


Conditions Unit (with calibration test parts)
(with nearly the same actual machine parts)
Nozzle part no. (I 05017-0090) (I 05780-0000)
Nozzle holder part no. (I 05048-3060) (I 05780-2080)

I t mm 6x 1.6x600 6x1.6x600
8% ?l%?%ngth)
specifications
Injection volume kc/l OOOst) Injection volumekcll OOOst)
Maximum Maximum
Rack Pump variance
variance Allowance
osition ye$d Basis Allowance Basis
between between
Pmm) r
cylinder cylinder
basic point 10.7 1100 49.5 48.5 to 50.5 k1.24 41 40 to42 f 1.03
l Rack positions B 10.4 425 12.5 * 11.5 to 13.5 * 1.88 12.5 * 1 1.5 to 13.5 * 1.88
tion volume. D * *
l Marks * are aver-
age volumes. E * *
sovernor performance
18+B
95 SERIES
’2-oi2-49

( I: Manufacturer’s part No.
PC1 50-3 S6D95L-1 32941andup

Motor 7.5 KW
F%ZXr;v,,V~~~ ,mp mm3/st 51 for Service standard

Service standard 6207-I l-3130 (105017-0090)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-I 13110 (105048-3060)
test parts.
Injection ipe
Manufacture 6 x 2.0 x 600 6x 1.6x600
standard is data
Injection volume Service standard (cc/l 000 st) Manufacturer standard (cc/lOOOsl
Rack Pump
Rack
point variance
(mm) (rPm) Basis Allowance T$!$i”, Basis Allowance between
cylinder cylinder
6 to E are the refer- Basic point 10.8 1100 42.5 41.5 to 43.5 +I .0625 51.3
ence volume when
B A??? 425 12.5 * 11.5t013.5 k1.875 12.5 *
tion volume.
age volumes.
D * *
E * *
Governor performance ( 425 _ 1100 rpm)
1gc3
0
-C 11.5
L 10.8
:
Z
.- 8.5
0”
a
Y
z 6
cc
Pump speed Irpm) SEBH4579-’
12-0$2-50 95 SERIES
Injection Pump
WA1 50-I S6D95L-1 PE-S6A DIESEL KIKI 6207-71-1331 (101692-3201). __1
Injection Timing

I
Clockwise viewed
Rotating direction
from drive end
Delivery valve High idling:

mm3 51 rpm 2600 to 2700
retraction volume

Conditions Unit
Nozzle part no. (105017-0090) (105780-0000)
Nozzle holder part no. (105048-3060) (105780-2080)
6x1.6x600 6x1.6x600
Specifications
Injection volume (cc/l OOOst) Injection volume(cc/l OOOst)
Maximum Maximum
Rack Pump
variance variance
between between

basic point 9.6 1200 32.5 31.5 to 33.5 CO.81 32.5 3 1.5 to 33.5 a0.81
l Rack positions B 10.5 400 12.5 * 1 1.5 to 13.5 * 1.88 12.5 * 1 1.5 to 13.5 f 1.88
adjustingthe injec-
tion volume. D * *
l Marks * are aver-
age volumes. E * *
Governor performance
SEBH4507
95 SERIES
’ 2-o;2-51
6207-71-1332 (101692-3330)
( 1: Manufacturer’s part No. 23243 and up
WA150-1 S6D95L-1
-1
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 9412,400
I
Injection order Maximum torque kgm/rpm 36/l ,600
l-5-3-6-2-4
Plunger prestroke mm 3.6 2 0.05

Delivery valve
retractinn vnlllme mm3/st 51 I Pump tester capacity
Motor 7.5 KW

* Servicestandard
Nozzle part no. (105780-0000) 6207-11-3130 (105017-4090)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-l l-3110 (105048-3060)
test parts.
(O/D x l/g x length) mm 6 x 2.0 x 600 6x 1.6x600
standard is data
Injection volume Service standard (cdl 000st) Manufacturer standard (cc/l OOOst
Rack Pump
Rack
point variance
(mm) (rPm) Basis Allowance rer$$“, Basis Allowance between
cylinder cylinder
ence volume when 10.1 1,200 36.6 35.6 to 37.6 kO.915 42.6
B 8.6 400 12.5 * 11.5 to 13.5 21.875 12.5 *
tion volume.
age volumes.
D * *
E * *

ck limit 17.5 mm
18+:
z
11.6
z.
5 10.1
.-
.%
x 8.6
Y
m”
oz
5.6
0 400 620+20 850 1000 + \1325125

1170+30 1200%
Pump speed (rpm)
SEBH4799
’2-062-52 95 SERIES
6207-71-1335 (101695-3070)
WA1 50-l S6D95L-1
Rotating direction. Clockwise view from drive end Rated horsepower HP/rpm 9412.400
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 36/l ,600


Motor 7.5 KW
~&~~~~$$me mm3/st 51 for Service standard

- Service standard
Nozzle part no. (105780-0000) 6207-11-3130 (105017-0090)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-l ‘l-3110 (105048-3060)
test parts.
Injection ipe
standard is data
Injection volume Service standard (cc/l 000 st) Manufacturer standard (cc/lOOOsi
Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance rerts’$, Basis Allowance between
cylinder cylinder
8 to E are the refer- B&c point 10.9 +1 .I325 53.4
ence volume when
1,200 45.3 44.3 to 46.3
adjusting the injec- -
B 11.5 800 46.2 *44.2 to 48.2 60.2 *
tion volume.
- Marks * are aver- C APW;.
350 12.5 *I 1.5 to 13.5 +I.875 12.5 *
age volumes.
D * *
E * *
ack limit: 1s:’ mm
z-
E 11.7
; 10.9
.o
s
g 0.7
5
d 6.8
1200-L 1200:9
Pump speed (rpm)
SEBH481E
95 SERIES 12-022-53
6207-71-1360 (101692-3430)
( 1: Manufacturer’s part No. PC150-3c S6D95L-1 27750 and up
PC180(L)LC-3
Injection order 1-5-3-6-2-4

I
51 for Service standard I I

) Service standard Nozzle part no. (I 05780-0000) 6207-11-3130 (105017-0090)
indicated data
calibration part no. (I 05780-2080) 13110 (105048-3060)
test parts.
Injection ipe
Manufacture (O/D x l&x length) mm 6 x 2 x 600 6x 1.6x600
standard is data
for factory test. Test oil ASTM 0975 No. 2 diesel fuel or equivalent
Oil temperature “C 43 - 47
Nozzleopening pressure Mpa(kg/cmz) 17.2 (175) 19.6 (200)
Injection volume Service standard (cc/l 000 st) Manufacturer standard (cc/l 000 si
Rack Pump
Rack
point variance
(mm) (rPm) Basis Allowance rerzE”, Basis Allowance between
cylinder cylinder
sovernor peIfOrmanCe ( 425 - 1100 rpm)

Rack limit apprcx 17.5 mm
18+3
0
L/
0’ I’
425 700 (990)?50 \
+20 12OOi25
“00,lO
Pump speed (rpm)
SEBH4580-01
’2-oi2-54 95 SERIES
6207-71-1361 (101692-3990)

injection Pump
Pump Tvpe Manufacturer
ZEXEL
PES-GA (DIESEL KIKI)
Rotating direction Clockwise view from drive end Rated horsepower kW(HP)/rpm 78.3 (105)/2,200
Injection order 1-5-3-6-2-4 1 Maximum torque Nm(kgm)/rpml 389(39.7)/l ,490 1

High idling rpm 2,350 - 2,450

I
l ~d’.$e.$ay$rd Nozzle part no. (105780-0000) 6207-11-3130 (105017-0090)
test parts.
Injection ipe
l Manufacture (O/D x I& x length) mm 6 x 2 x 600 6x 1.6x600
standard is data .
Oil temperature “C 43 - 47
Injection volume Service standard (cc/l OOOstj Manufacturer standard (cc/lOOOst

Rack Pump
Rack
point variance
(mm) (rPm) Basis Allowance perE$, Basis Allowance
between
cylinder cylinder
l Rack positions Each cyl. Each cyl.
B to E are the ref- Basic point 11.1 1,100 45.1 44.1 - 46.1 +I.1275 54.4
erence volume
when adjusting Approx.
B 10.4 425 12.5 t 11.5- 13.5 t1.875 12.5 *
the injection
volume. C * *
l Marks * are aver-
age volumes. D * *
E * *
Governor performance ( 400 - 1,100 rpmj
ck limit: Approx. 1st’ mm
Pump speed (rpm)

SEBH4817-01
95 SERIES
’ 2-ozz-55
Engine Model
WA1 80-I S6D95L-1 PES-A DIESEL KIKI 6207-71-I 380 (101692-3460). 0
S/N 26330 and up
Injection Timing
Clockwise viewed
Rotating direction
from drive end
Injection interval 60” 59’30’ to 60”30’ Rated horsepower: HP/rpm 11 O/2500

I
Plunger pre-stroke mm 3.6 3.55t03.65 1 1 Maximum torque: kgm/rpm 40.5/l 600 I

Delivery valve
I


Unit
Nozzle part no. 6207-I I-3130 (105017-0090) (I 05780-0000)
Nozzle holder part no. 6207-I I-31 IO (I 05048-3060) (I 05780-2080)

In ectron rpe
mm 6x1.6x600 6x2~600
(d/D xl/$x length)
Oil temperature OC 40 to 45 40 to 45

[ 1 : Reference data
Rack Maximum Maximum
Pump
variance variance
between between
Pmm) (mm) cylinder cylinder
basic point A 11.0 1250 L54.01 45.7 44.7 to 46.7 f1.14
Rack positions 400 112.51 * ‘12.5 * 11.5 to 13.5 k1.87

8 to E are the refer- 8 aYq;iox.
adjustingthe injec-
tion volume. D * *
Marks * are aver-
age volumes. E * *

1a+; Rack cap: approx. 17.5 m,,,

/ ,I//,
17.5’
62OQO 1200+50 1250:;0,

95 SERIES
6207-71-I 390 (101692-3550)
( ): Manufacturer’s part No. PC1 80LC-3 S6D95L-1
PC180LLC-3
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 1 105/2,200 1
Maximum torque kgm/rpm I 39.7/1,500 I
High idling rpm I 2,350 to 2,450 1
I

for Service standard I I

- Service standard
Nozzle part no. (105780-0000) 6207-I l-31 30 ( 105017-0090)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-I I-3110 ( 105048-3060)
test parts.
Injection ipe
- Manufacture (O/D x l/g x length) mm
6x 1.6x600 6x 1.6x600
standard is data
for factorv test. Test oil ASTM D975 No. 2 diesel fuel or equivalent
Injection volume Service standard (cc/l 000st) Manufacturer standard (cc/ 1 OOCkt
Rack Pump
Rack
point variance
(mm) (w-4 Basis Allowance rergzF Basis Allowance between
cylinder cylinder
pRack positions Each cyl. Each cyl.
6 to E are the refer- Basic point 1100 45.1 44.1 to 46.1 kl .I275 54.4
ence volume when 11.1
B 12.3 700 * - 174.21 t
tion volume.
- Marks * are aver- Approx.
C 8.5 425 12.5 * 11.5 to 13.5 21.875 12.5 *
age volumes.
D * *
E * *

1100::;
95 SERIES
’2-o;2-57
Injection Pump
GD461A-1 S6D95L-1 PES-A DIESEL KlKl 6207-71-1811 (101692-3351)....1
S/N 24866 and up
Injection Timing
Clockwise viewed
Rotating direction
from drive end
Injection interval 60” 59”30’ to 60”30’ Rated horsepower: HP/rpm 113/2500
Delivery valve 51 2700 to 2800

High idling: rpm

Conditions Unit
Nozzle part no. 6207-I l-31 30 (I 05017-0090) (I 05780-0000)
Nozzle holder part no. 6207-I l-31 IO (105048-3060) (105780-20801

In ectron rpe 6x1.6x600 6x2~600
mm
(d/D xl/$x lenqth)
Specifications Injection volume (cc/l OOOst1 Injection volume h/l OOOst)

l [ I : Reference data
Maximum Maximum
Rack Pump
variance variance
between between
basic point A 10.7 1250 51.5 43.0 42.0 to 44.0 f 1.07
B approx. k-1.87
l Rack positions 400 12.5 * ‘12.5 * 1 1.5 to 13.5
8.6
tion volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance (400- 1250 rpm)
Rack cap: approx.17.5 mm
/L
0 400 590*20800*30 1170*50\ 1375?35

1250::;

95 SERIES
’ 2-o$2-58
Machine Model Engine Model Injection Pump
GD51 lA,R-1 S6D95L-1 PES-A DIESEL KIKI 6207-71-l 910 (101692-3390). . 0
GD513A,R-1 S/N 26224 and up
Injection Timing

Clockwise viewed
Rotating direction
from drive end
Injection interval 60” 59”30’ to 60”30’ Rated horsepower: HP/rpm 135/2900

1
Plunger pre-stroke mm 3.6 3.55 to 3.65 Maximum torque: kgm/rpm 44/l 600
Delivery valve
51 1 High idling: rpm 3050 to 3 150 I
I Low idling: rpm 850to 950 I
Unit
Nozzle part no. 6207-l l-3 130 (I 05017-0090) (105780-0000)
Nozzle holder part no. 6207-l I-31 10 (105048-3060) (105780-2080)

I.
mm 6x1.6x600 6x2~600
c”d%t%%?%nqth~

Maximum Maximum
Rack Pump
variance variance
between between
Pmm) (rpm)
cylinder cylinder
Calibration Each cyl. Each c I.
basic point A 11.2 1450 56.8 55.8 to 57.8 f 1.42 156.81 [55.& to 157.81 [+ 1.421
l Rack positions 12.5 * 1 to 13.5 f 1.87

a%?F
E are refer-
l: Rack
Rack cap: apjxox. 17.5 mm
1450+20

95 SERIES
’ 2-022-59
6207-71-1930 (101695-3120)
GDSIOR-1 S6D95L-1
Rotating direction Clockwise viewed from drive end Rated horsepower kW(HP)/rpm 93.3 (125)/2,500
I
Maximum torque Nm(kgm)/rpm 431(44)/l ,600
Injection order I l-5-3-6-2-4 I
High idling rpm I 2,700 - 2,800
Injection interval 60’ ? 30’
I
’ fn~~c~t~~~a~~~d Nozzle part no. (105780-0000) 6207-I I-3130 (105017-0090)

using calibration Nozzle holder part no. (I 05780-2080) 6207-I I-3110 (105048-3060)
1 Manufacture (O/D x l/g x length) mm 6 x 2 x 600 6x 1.6x600
standard is data
Injection volume Service standard (cc/lOOOstj Manufacturer standard (cc/l OOOst

Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance ~er~~~ Basis Allowance between
cylinder cylinder
1 Rack positions
,“,oE,“:~;h;,ref- Basic Point [11.31 1250 [56.3] fEa5c5?3cfj7.31 [+I .4071 59.7 Each cyl*
when adjusting B [ 8.41 450 L12.51 [* 11.5- 13.5 I Lk1.8751 12.5 *

the injection
volume. C * *
1 Marks * are aver- *
age volumes. D *
E * *
jovernor performance ( 450 - 1250 rpm)
cklimlt 15~8’mm
,Lj
1250:::
Pump speed (rpm)
SEBH4642-01
12-022-60 95 SERIES
GD510R-1 S6D95L-1


1 Service standard Nozzle part no. ( 105780-0000) 6207-11-3130 (105017-0090)
indicated data
using calibration Nozzle holder part no. (105780-2080) 6207-I I-31 10 (105048-3060)
test parts. injection ipe
’ Manufacture (O/D x l/g x length) mm 6 x 2 x 600 6x 1.6x600
standard is data
Injection volume Service standard (cc/l 000 st) Manufacturer standard (cc/lOOOst
Rack Pump
Rack
point variance
(mm) (rpm ) Basis Allowance ~e~~~“, Basis Allowance between
cylinder cylinder
Rack positions 54 7 Each cyl.
B to E are the ref- Basic point 11.4 1250 . fl.3675 59.7 Each “1.
53.7 - 55.7
erence volume
when adjusting B 12.0 800 52.4 * 50.4- 54.4 - 69.2 *
the injection A
volume. C pK50
450 12.5 * 11.5 - 13.5 + 1.875 12.5 *
Marks t are aver- _
age volumes. D * *
E * *
ck limit 15’g2mm
-j
:::
95 SERIES
’ 2-oF’
6209-7 l-l 230 (101692-3830)
I Applicable Machine Aoolicable Enaine 1

PC220-5 35001 and up SA6D95L-1
Injection Pump
I I I
PES-GA 1 DIESEL KIKI I
I I I I 1 I I I
I Rotating direction Clockwise viewed from drive end I

I
IPump tester capacity

Motor 7.5 KW
1

Service standard
Nozzle part no. (105780-0000) 6207-11-3130 (105017-0090)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207- II-311 0 ( 105048-3060)
test parts.
standard is data
for factory test. Test oil ASTM D975 NO. 2 diesel fuel or equivalent
Injection volume Service standard (CC/j 00G.t) Manufacturer standard (cc/l OOOst
Rack Pump
Rack
point
(mm) b-pm) Basis Allowance yerrtz’, Basis Allowance variance
between
cylinder cylinder
Rack positions
Each cyl. Each cyl.
B to E are the refer- Basic point 10.9 1100 78.2 k1.955 81.6
adjusting the injec- 11.2 750
B 78.6 * 76.6 to 80.6 - 85.0 t
tion volume.
Marks * are aver- Approx. 450
C 6.7 12.5 * 11.5t013.5 k1.875 12.5 t
age volumes.
D * *
E * *
Zovernor performance ( 450 - 1100 rpm)
Rack limit 1~+8.~
Lf I I
0 450 (590) / 870*50 \
750 11oo::g 12ooxio
Pump speed (rpm)
SEBH4712
12-022-62 95 SERIES
9
6209-71-1’262 (101692-3910)
PC22O(LC)-5 SA6D95L-1
-1 BR300-1
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 53.711500

Injection interval 60”+30
Plunger pre-stroke mm 3.620.05

Motor 7.5 KW
~~$$$$J$ume mm3/st 51 for Service standard

r
Nozzle part no. (105780-0000) 6207-l I-3130 (105017-0090)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-l l-3110 (1050483060)
test parts.
Injection ipe
* Manufacture (O/D x i/g x length) mm 6 x 2 x 600 6x 1.6x600
standard is data

Injection volume Service standard (cc/l OOOst) Manufacturer‘standard (cc/l OOOst

Rack Pump
Rack
point variance
(mm) bm) Basis Allowance ~e~~~~ Basis Allowance
between
cylinder cylinder
- Rack positions 74 6 Each cyl. Each cyi.
B to E are the refer- Basic point 10.6 1100 . *I .865 79.4
adjusting the injec- 89.8 t
B 11.05 750 74.9 *72.9 to 76.9 -
tion volume.
bMarks * are aver- c Ap84’20x~ 450 12.5 * 11.5to 13.5 k1.875 12.5 *
age volumes.
D * *
E * *
Rack cap: approx. 15 +:‘mm
F 10.6
E 9.6
C
.P
C
H 66
“u 6.2
a
450(560) 750’930i50\1200~30
11CO::;
Pump speed @pm)

SEBH4788
95 SERIES
’ 2-o;2-63
Applicable Machine I Applicable Ennine
6202-73-I 160 (101495-3262)
DZOAG, P, PG-7(A) 4D95S-1
Injection Pump
Pump Tvpe Manufacturer D20PL, PLL-7
PES-A ZEXEL D21A, AG, PG-7(A)

I
D21S, QG-7
Maximum torque kgm/rpm 15.5/l 300

Delivery valve Motor 7.5 kW
retractinn V~IIITI.+mm3/st I for Service standard I
. Service standard
indicates data
using calibration
test parts.
. Manufacturer
standard is data
for factory test.
. Rack positions
ence volume when
tion volume.
. Marks * are aver-
age volumes.
Zovernor performance Marked %: Rack position approx: 9.2 mm
Rack cap: approx. 15 +i’ mm

18 ‘0”
15.0
P 11.8
E
: 9.9
.-
.z
i 8.8
0
oz 7.6
1290 * 25
Pump speed (rpm)
95 SERIES
6206-71-I 252 (10695-3622)
D31 E, P-20(A) 6D95L-1
D31 PL, PLL, S-20
D310, AM, SM-20

Injection interval 60” k 30’

Motor 7.5 kW
Delivery valve for Service standard
retraction volume mm3/st 51
. Service standard Nozzle part no. (105780-0000) 6206-I I-3130 (105017-0140)

indicates data
test parts. Injection pipe
. Manufacturer in/n x I/n Y Innnthl mm 6 x 2 x 600 6x1.6x600
standard is data
I I I I I
Injection volume Service standard (cc/l OOOst) Manufacturer standard (cc/l OOOst)
Rack Pump
Rack
position speed Maximum Maximur
point variance
(mm) (rPm) Basis Allowance ~~$$~ Basis Allowance
cylinder :;KY::
. Rack positions
B to E are the refer- 30,6 Each cyl.
Basic point 9.0 1175 29.6 Ey8h6cT;.30,6 i2.5
ence volume when
tion volume. B 10.3 700 (32) * (30 to 34) (43.4) *
. Marks * are aver- C A~g,y. 350 * 215 10.5 *
age volumes.
D Ap&ox. 500 8 *7to9 ?I5 *
E * *
,B+;h RFkcap: approx.15C~2mm
15.0 1”““’
Pump speed (rpm)
95 SERIES 1 Z-UZZ-63
0
6206-71-I 480 (101692-3933)
D37E, P-5(A) 6D95L-1

Injection interval 60” k 30’
Plunger pre-stroke mm 3.6 k 0.05
Delivery valve
rn+r.,,.+;fin l,~lll_d mm3/st 51 IPump tester capacity
Motor 7.5 kW
I
. Service standard
indicates data
using calibration
test parts.
. Manufacturer
standard is data
for factory test.
Injection volume
Rack positions
ence volume when
tion volume.
. Marks * are aver-
age volumes.
k cap: approx. 17.5 mm
1250 _&
Pump speed (rpm)
12-022-66 95 SERIES
0
Applicable Machine I Applicable Engine
6202-72-1211 (101452-3131)
Model 1 Serial No. 1 Model 1 Serial No.
( ): Manufacturer’s part No. D20, 21-6 4D95.SW-1
Injection Pump
Pumo Tvoe Manufacturer I I I
ZEXEL
PES-4A (DIESEL KIKI)
injection Timing Engine Specification
Injection order l-2-4-3 Maximum torque Nm(kgm)/rPm/ 152(15.5)/1300

I
Injection interval 9o” * 30’
1 Low idling rpm 800 - 850
Plung& pre-stroke mm 1.5 f 0.05
Deliveryvalve Motor 7.5 KW
wtractinn vnl~~mP mm3/st 35 for Service standard I
1Service standard
indicates data
using calibration
test parts.
1Manufacture
standard is data
for factory test.
1 Rack positions
B to E are the ref-
erence volume
when adjusting
volume.
1 Marks * are aver-
cklimit 15’8’mm
J->5
+:8
Pump speed (rpm) SEBH482i
95 SERIES
’2-o%-67
6202-72-1231 (101452-3140) I Applicable Machine I Applicable Engine I
~1
Delivery valve
retraction vnlllme mm3/st IPump tester capacity
Motor 7.5 KW
I
Manufacture
standard is data
for factory test.
Rack positions
B to E are the ref-
erence volume
when adjusting
volume.
1 Marks tare aver-
age volumes.
jjz5
1225 ;::
6204-72-l 331 (101452-3082)
( ): Manufacturer’s part No. WA70- 1 12001 and up 4D95L-W-1 36216 and up
Clockwise viewed from drive end Rated horsepower kW(HP)/rpm 41.2 (55.2)/2200
Maximum torque NmCkgmVrpm 204(20.8)/l 500
Low idlina tom

I~
8nO - 850
--_
mm3/st for Service standard
retraction volume
ervice standard
indicates data
using calibration
test parts.
Manufacture
standard is data
for factory test.
Rack positions
B to E are the ref-
erence volume
when adjusting
volume.
Marks * are aver-
Rack limit 15 -8’ mm
Pump speed (rpm)

SEBH4618-01
95 SERIES
’2-o%-69
Pump Assembly Number .
6204-71-l 211 (101492-3940)
PC60-3 4D95L-1
Rotating direction Clockwise viewed from drive end Rated horsepower kW(HP)/rpm 44 (59)/2400
Injection order l-2-4-3 Maximum torque Nm(kgm)/rpm 196(20)/1500

Injection interval 9oV30*1
I Low idling rpm 850 - 900
~,“,!.$+~~,Va!~ra,mO mm3/st 51 IPump tester capacity

Motor 7.5 KW
1 Service standard
indicates data
using calibration
test parts.
1Manufacture
standard is data
for factory test.
I Rack positions
B to E are the ref-
erence volume
volume.
Marks * are aver-
age volumes.
18+;
Rack limit 15 *8’ mm
/, , , , , , , , , , ,, , ,
-z
z
s
._
C
H
5
2
1200 :::
Pump speed @pm)
SEBH4830
12-022-70 95 SERIES
Pump Assembly Number r I
6204-71-1221 (101492-3950)
( ): Manufacturer’s part No. PC60-5 4D95L-1
I Rotating direction Clockwise viewed from drive end 1 Rated horsepower kW(HP)/rpm 40.3 (54)/2100
Maximum torque Nm(kgm)/rPm 200(20.4)/l 500
I
I

m+rar+;,Tn*r*l,,mn m ms/st 51 for Service standard I
Service standard
indicates data
using calibration
test pans.
Manufacture
standard is data
for factory test.
B to E are the ref-

erence volume
volume.
Marks * are aver-
age volumes.
ck limit 15 ‘8’mm
Pump speed @pm)

SEBH4831
95 SERIES
’2-o%-7’
Pump Assembly Number I
6204-71-l 231 (101492-3960)
PW60-3 4D95L-1

al
Plunger pre-stroke mm 3.6 ?c 0.05

Delivery valve
retraction volume mm3/st 51
u Service standard
indicates data
using calibration
test parts.
) Manufacture
standard is data
for factory test.
) Rack positions
B to E are the ref-
erence volume
volume.
’ Marks t are aver-
age volumes.
18’8 Rack limit 15 ‘8’ mm
-z 11.7
L
10.5
.-6
.Z
:: 6.7
a
%
a”
5.7
j /L
0 450 (620) 800 1130f50\1325125

1256 ‘::
Pump speed (rpm)

SEBH4832
’2-o;2-72 95 SERIES
6204-71-1241 (1014923980) Applicable Machine Applicable Engine

PC80-3 4D95L-1

Rotating direction Clockwise viewed from drive end Rated horseoower HP/mm 6412400
Delivery valve
retraction volume mmz/st
1

Motor 7.5 KW
I
‘Service standard
indicates data
using calibration
(Nozzle, Nozzle
holder and injec-
Manufacture
standard is data
Rack positions
8 to E are the ref-
erence volume
when adjusting
the injection vol-
ume.
+x)
Pump speed (rpm)
SEBH4883
95 SERIES
’2-o%f-73
6204-71-1550
6204-71-1560 Model Serial No. Model Serial No.
D21A-7T 4D95L-1
Trimming spec.)
Injection interval 90” t 30’

Delivery valve Pump tester capacity
51 for Service standard Motor 7.5 kW
retraction volume mmVst
Service standard
indicates data
using calibration
(Nozzle, Nozzle
holder and injec-
Rack positions
B to E are the ref-
erence volume
when adjusting
the injection vol-
ume.
Marks t are aver-
Governor performance (100 - 1225 rpm1
IS’: Racklimit : 15. O+t’mm
4 L
0 / l&70)\ (I OSOl/\\
400 410 650 (124011270 1310
Pump speed (rpm)
TDE00091
’2-o:2-74 95 SERIES
6204-73-1210 (101492-3730)
PC60-6 4D95L-1
Clockwise viewed from drive end Rated horsepower HP/rpm
Plunger prestroke mm 3.6 + 0.05

1 Low idling rpm 950 to 1000
I
Delivery valve
Motor 7.5 KW
I

- Service standard
Nozzle part no. (105780-0000) 6207-I I-3130 (105017-0090)
indicates data
test parts.
(O/D x l/g x lenath) mm 6 x 2 x 600 6x 1.6x600
standard is data
for factory test. Test oil ASTM D975 No. 2 diesel fuel or eauivalent
Oil temperature
Injection volume Service standard Manufacturer standard (cc/l
* Rack positions
ence volume when
tion volume.
- Marks * are aver-
age volumes.
E * *
Rack cap approx. 17.5 mm
18+$U~,,,,,
\
I
8.0 C
6.4
95 SERIES
’ 2-o%-75
6204-73-I 211 (101492-3732)
( ): Manufacturer’s part No. PC60-6 4D95L-1
Rotating direction Clockwise viewed from drive end Rated horseoower HP/ram 1 54.2/2100 I
Injection order 1-2-4-3~’ 1 Maximum torque kgm/rpml 23/l 500 I

I
Injection interval 9o” f 30’
I I Low idling rpm 950 to 1000

Delivery valve
retraction volume
mm3/st 51 I Pump tester capacity
Motor 7.5 KW
I
indicates data
using calibration
test parts.
Manufacture
standard is data
for factory test.
Rack positions
B to E are the ref-
erence volume
volume.
Marks tare aver-
age volumes.
ck limir 15 -8’ mm
Pump speed (rpm)

SEBH4834
95 SERIES
’ 2-o;2-76
6204-73-1220 (101492-3742)
PC90-1 4D95L-1
Rotating direction Clockwise view from drive end Rated horsepower HP/rpm 64.1/2,300

/I
IInjection interval
r I
Plunger pre-stroke mm 3.6 t 0.05

Service standard Nozzle part no. (105780-0000) 6207-I I-3130 (105107-0090)
indicates data
test parts.
(O/D x 1/g x length) mm 6 x 2 x 600 6x 1.6x600
standard is data
Injection volume Service standard (oC/1OOOSt) Manufacturer standard (cc/lOOOstj

Rack Pump
Rack
point variance
(mm) (rPm) Basis Allowance ~“,:‘~~~ Basis Allowance between
cylinder cylinder
Rack positions Each cyl.
B to E are the refer- Basic point 10.8 1,150 140.21 ~~“.~~k 41.21
ence volume when *I ,005 47.0
adjusting the injec- B AP;‘~x.
tion volume.
475 10.5 * 9.5 to 11.5 k1.575 10.5 *
Marks l are aver- C * *
age volumes.
D * *
E * *
Governor performance ( 475 - I ,150 rpm)
Rack limit: 17.5 mm
Damper spring set

7.3kO.l mm
0 475 750 (1000) 1 ‘124Ok25

1 150%
95 SERIES
’2-o%-77
6204-73-I 221 (101492-3990) Applicable Machine Applicable Engine
PC90- 1 4D95L-1
Injection order 1-2-4-3 ~1
Injection interval 9o” + 30’
Plunger pre-stroke mm 3.6 i 0.05

_ retraction volume
1 Service standard
indicates data
using calibration
test parts.
1Manufacture
standard is data
for factory test.
1 Rack positions
B to E are the ref-
erence volume
when adjusting
volume.
1 Marks It are aver-
age volumes.
cklimit 15 8’mm
Damper spring set

7.3kO.l mm
Pump speed (rpm)

SEBH4835
95 SERIES
’ 2-o:2-78
6204-73-1240
PC60-7 4D95L-1
PC70-7

Rotating direction Clockwise viewed from drive end Rated horsepower kW(HP)/rpm 41(54)/1900
Injection order 1-2-4-3 Maximum torque Nm(kgm)/rpm 225(23)/1500
High idling rpm 2050-2150

retraction volume mm%
Calibration

Service standard ~~~~~~ pae no. (105780-0000) 6207-11-3130 (105017-0090)
indicates data
test parts Injection pipe
(Nozzle, Nozzle (O/D x l/D x length) mm 6 x 2 x 600 6x 1.6x600
standard is data
using factory test Nozzle opening pressure MPa(kg/cm*) 17.2 (175) 19.6 (200)
parts
(For reference) Transfer pump pressure MPa(kg/cm2) 0.16 (1.6) 0.16 (1.6)
njection volume Service standard (cc/lOOOst) Manufacturer standard (cc/1OOOsl

Rack Rack Pump
(mm) (t-pm) Basis Allowance ‘1”,$::: Basis Allowance $$?:Ei
cylinder cylinder
Each cyl. Each cyl.

Rack positions Basic point 11.3 950 41 51.5
B to E are the ref-
erence volume
when adjusting B 12.1 750 44.5 * 62.5 *
the injection vol-
C 8.2 495 10.5 Ir *
ume.
Marks t are aver- D Ir *
age volumes.
E * *
95 SERIES
’ 2-o%-79
6205-71-1510

Injection Pump
\ Pumo TvDe
I I.
Manufacturer
I I I
ZEXEL
PES-4A
(DIESEL KIKI)
Rotating direction Clockwise viewed from drive end Rated horsepower kW(HP)/rpm 58.9(78.9)/2100
Injection order 1-2-4-3 Maximum torque Nm(kgm)/rpm 299(30.5)/1500

Servicestandard ~~~~~~part no, (105780-0000) 6206-11-3130 (105017-0140)
indicates data
test parts Injectionpipe
(Nozzle, Nozzle (O/Dx I/D x length1 mm 6 x 2 x 600 6x1.6x600
~~~~~,“e;” injec- Test oil ASTM D975 No. 2 diesel fuel or equivalent
Manufacturer Oil temperature “C 43-47
standard is data
using factory test Nozzle opening pressure MPa(kg/cm*j 17.2 (175) 19.6 (200)
parts
(For reference) Transfer pump pressure MPa(kg/cmz) 0.16 (1.6) 0.16 (1.6)
njection volume Service standard (cc/lOOOst) Manufacturer standard (cc/IOOOS~

Rack Rack Pump
(mm) (rpm) Basis Allowance ~“,~~~~ Basis Allowance “b”$%,
cylinder cylinder
Each cyl. Each cyl.
Rack positions Basic point 9.9 1050 69.9 63.6
B to E are the ref-
erence volume
when adjusting B 10.35 750 63.2 * 77.5 *
the injection vol-
C 6.4 450 10.5 * 10.5 *
ume.
age volumes.
E * Ir
L&J&&
I090
Pump speed (rpm) 6206FlOll
6205-71-152O(PC120-6) Applicable Machine Applicable Engine
6205-71-132O(PC128UU-I)
PC1 20-6 S4D95L-1
PC128UU-1
Rotating direction Clockwise viewed from drive end Rated horsepowerkW(HP)rpm 62.5(83.8)/2200
Injection order 1-2-4-3 Maximum torque Nm(kgm)/rpm 299(30.5)/1500
Service standard
indicates data
using calibration
(Nozzle, Nozzle
holder and injec-
Manufacturer
standard is data
Rack positions
B to E are the ref-
erence volume
when adjusting
the injection vol-
ume.
Marks * are aver-
18’;
95 SERIES
’ 2-o%*’
,
6206-71-1211 (101695-3290)
PC 100-3 6D95L-1
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 79/2100

Motor 7.5 KW
Conditions Service standard . Manufacturer standard

l Service standard Nozzle part no. (105780-0000) 6207-I I-3130 (105017-0090)
indicated data
test parts.
Injection ipe
l Manufacture (O/D x l/g x length) mm 6 x 2 x 600 6x 1.6x600
standard is data
for factory test, Test oil ASTM D975 No. 2 diesel fuel or equivalent
Injection volume Service standard (cc/l OOOst) Manufacturer standard (cc/ st

Rack Pump
Rack
point
(mm) (vm) Basis Allowance rertz?, Basis Allowance variance
between
cylinder cylinder
l Rack positions
5 t0 E are the ref- Basic point 9.8 3. 4 Each cyl. Each cyl.
1050 . kO.76
erence volume 29.4 to 3 1.4
when adjusting
B “Pg.;“” 400 10.5 * 9.5 to 11.5 k1.57 *
the injection
volume. C * *
l Marks * are aver-
age volumes. D * *
E * *
Pump speed (rpm)

SEBH4837
95 SERIES
6206-71-l 221 (101695-3300)
( ): Manufacturer’s part No. PC1 20-3 6D95L-1
yzJ-z%J I I I
Injection order l-5-3-6-2-4 ~1
injection interval 60° f 30’

mm”/st 51 for Service standard
retraction volume
Cal’ibration Standard
Conditions I Service standard I Manufacturer standard

1Service standard
indicates data
test parts.
Manufacture Injection pipe
(O/D X I/D X length) 6X2X600
standard is data - mm
I
for factory test.
Test oil ASTM D975 No.2 diesel fuel or equivalent
Nozzle opening pressure kg/cm* 175
njection volume
Rack positions
B to E are the ref-
erence volume
when adjusting the
injection volume.
Marks + are aver-
age volumes.

is%-
Rack limit : lS,O” mm
0 425 700 1080~\ 1200f25

1 loo:5
Pump speed (rpm)

SEBH486t
95 SERIES
’ 2-oz83
6206-71-l 241 (101695-3320) Applicable Machine ADDlicable Enaine I
( ): Manufacturer’s Dart No.
PW150-1 6D95L-1
I lniection I PUrnD I
I I I
Injection order l-5-3-6-2-4 -~I
Injection interval 60° f 30’

mService standard
indicates data
using calibration
test parts.
) Manufacture
standard is data
for factory test.
1 Rack positions
B to E are the ref-
erence volume
volume.
1 Marks * are aver-
age volumes.
18+;
Rack limit 15 -8’ mm
12.0
z
10.9
E
.-6
C 9.0
::
P
7.4
t:
z
L I-
O 425 (720) &o/ \ 1325125

1020150 12OO:g
Pumpspeed (rpm)
SEBH483E
Pump
6206-71-1361 (101695-3351)
( ): Manufacturer’s part No. WA1 20-I 6D95L-1
Rotating direction Clockwise viewed from drive end Rated horsepower HP/mm 1 85/2500 I
I
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm) 32.1 /1600

mmz/st 51 for Service standard
retraction volume
) Service standard
indicates data
using calibration
test parts.
’ Manufacture
standard is data
for factory test.
B to E are the ref-

erence volume
volume.
Marks t are aver-
age volumes.
j L/
0 400 570+20 880+30 ,,+ 340)‘, 375+25

1250:::
--- -_
95 SERIES
6206-71-1371 (1016953240)
6D95L-1

Delivery valve 51 Motor 7.5 KW
retraction volume mm3/st for Service standard

) Service standard Nozzle part “o_
indicated data ( 105780-0000) 6207-l I-3130 (105017-0090)
using calibration Nozzle holder part no. (105780-2080) 6207-l I-31 10 (105048-3060)
) Manufacture (O/D x l/g x length) mm 6 x 2 x 600 6 x. 1.6 x 600
standard is data
Nozzle opening pressure kg/cm2 I75 200
Injection volume Service standard (cc/l 000 st) Manufacturer standard (cc/l OOOst
Rack Pump
Rack
point
(mm) (rpm ) Basis Allowance Fer$$!, Basis Allowance
variance
between
cylinder cylinder
) Rack positions 35.6 Each cyl.
6 to E are the ref- Basic point 10.0 1175 kO.89 37.6 Each ‘y’.
34.6 to 36.6
erence volume
when adjusting B 10.9 650 [33.6] +[31.6 to 35.61 - 143.71 *
the injection
volume. C A?!$?. 350 10.5 * 9.5to 11.5 +I .575 10.5 *
1 Marks * are aver-
age volumes. D * *
E * *
Governor performance ( 350 - I I75 rpm)
ck limit 15 ‘8’ mm
0 / / \
3504k (550) 6.;650*20 1175 ::: (1350) 22
(1300)
6206-71-l 422 (101695-3451)
EG65-S 6D95L-1
njection Timing Engine specification

65.111500 (50 Hz)
Rotating direction Clockwise viewed from drive end Rated horsepower HP/r-pm 74.911800 (60 Hzl
Injection order l-5-3-6-2-4 I Maximum torque kgm/rpm II - I

Max. 1575 (50 Hz)
High idling rpm Max. 1890 (60 Hz)
Injection interval 60’ * 30’
I I
Plunger pre-stroke mm 3.6 + 0.05 I I I
“..&_^^*:^-
DeliverY Y!!!f.__ mm%t 51 I Pump tester capacity
Motor 7.5 KW
I

~Service standard
Nozzle part no. (105780-0000) 6207-I l-3130 (105017-0090)
indicates data
using calibration nozzle holder part no. (105780-2080) 6207-l I-3110 (105048-30601
test parts
Injection ipe 6 x 2 x 600 6x1.6x600
(Nozzle, Nozzle (O/D x l/g x length) mm
holder and injec- Test oi,
~Manufacture 43 to 47
Oil temperature “C
standard is data
using fectorV teat Nozzle opening pressure kg/cm’ I75 200
parts
(For reference) Transfer pump pressure kg/cm* 1.6 1.6
Injection volume Pump

Service standard h/l 000st) Manufacturer standard (cc/l 000~
Rack
Rack
point variance
(mm) (w-n) Basis Allowance ~e~~~“, Basis Allowance between
cylinder cylinder
wrack positions 52.0 Each cyl. 58 o Each cyl.
Basic point 10.3 900 21.3
B to E are the ref- 51 .o to 53.0
erence volume APP~;. 400 10.5 * 9.5 to 11.5 k1.575 10.5 *
B
when adjusting
the injection vol- C * *
ume.
1Marks * are aver- D * *
age volumes. ‘*
E *
ack limit approx. 17.5 mm
1. k1.k'.
0 / 550 \ 9oois
400 750flO
95 SERIES
’2-oz-87
6206-71-1940 (101695-3420)
GD313A-1 6D95L-1
Plunger pre-stroke mm r
3.6 + 0.05
1 Service standard Nozzle part no. (105780-0000) 6207-I I-3130 (105017-0090)

indicated data
1 Manufacture (O/D x l/g x length) mm 6x2~600 6x 1.6x600
standard is data .
Injection volume Service standard (cc/l OOOSt) Manufacturer standard (cc/lOOOsl

Rack Pump
Rack
point variance
(mm) (Vm) Basis Allowance Ter&2E Basis Allowance
between
cylinder cylinder
) Rack positions 3l 7 Each cyl. Each cyl.
B to E are the ref- Basic point 10.0 1250 . 30.7 to 32.7
20.7925 35.8
erence volume
when adjusting B AYF$?. 400 10.5 * 9.5to 11.5 fl.575 10.5 *
the injection
volume. C * *
) Marks * are aver-
age volumes. D * *
E * *
18’:
cklimit 15’8’mm
F
E 11.4
._s 10.0
f
x 8.4
a
a”
6.0
0 400 56M30 \ 1100+50\ 1375f25

800f30
1250 ::8
6207-71-I 221 (101695-3030)
( ): Manufacturer’s part No. PC1 50-5 S6D95L- I
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 98.6/2000
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 40/ 1400

Injection interval 60° * 30’
Plunger pre-stroke mm 3.2 & 0.05
retraction volume

Service standard Nozzle part no,
(105780-0000) 6206-I l-3130 (105017-0140)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6207-I l-31 10 (105048-3060)
test parts.
Injection pipe
Manufacture 6 X 2 X 600 6X1.6X600
(O/D X I/D X length) mm
standard is data
for factory test. Test oil ASTM D975 No.2 diesel fuel or equivalent
Oil temperature DC 43 to 47
njection volume
Service standard (cc/l OOOst) Manufacturer standard (cc/lOOOst
Rack Pump
Rack
position speed Marimum Maximum
point vanance
(mm) (rpm) Basis Allowance gz;;nE; Basis Allowance
Rack positions cylm 3 er !$x &ee,”
B to E are the ref-
55,1 Each cyl. fl.3775 58.4 Each ‘yf.
erence volume Basic point 9.1 1000
when adjusting 54.1 to 56.1
the injection 6 9.7 700 [50.0] * [48.0 to 52.01 - [67.8] +
volume.
Marks k are aver- C *%?Y 450 12.5 + 11.5t013.5 +I.875 12.5 Ir
age volumes.
D * *
E * *
ck limit 15’E2 mm
s30*50 ,m ::g
Pump speed (rpm)

SEBH4847
95 SERIES
’2-o%f-89
Pump Assembly Number I 4
6207-71-I 241 (101692-3222)
6207-71-I 242 (101692-3690)

Injection Pump
PumD. TvDe.. , Manufacturer
ZEXEL
PE-GA
(DIESEL KIKI)
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 99/l 900
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 42,’ 1400
Ilniection interval I 60° + 30’ I I

High idling
Low idling
rpm
rpm
2135 to 2235
850 to 900
I

mms/st 51 for Service standard
retraction volume
standard is data
for factory test.
1 Rack positions
B to E are the ref-
erence volume
when adjusting
volume.
Marks t are aver-

Rack limit 17.51bO.2 mm
\ (050125
950 3
_- --- --
’z-“i2-90 95 SERIES
6207-71-l 243 (101695-3010)
PWl OO-3 S6D95L-1
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 99/I 900
Injection order l-5-3-6-2-4 Maximum torque kgm/rpml 42/ 1400 I

I I Low idling rpm 850 to 900
mm3/st 51 for Service standard I I
retraction volume
) Service standard
indicates data
using calibration
test parts.
1Manufacture
standard is data
for factory test.
Rack positions
B to E are the ref-
erence volume
when adjusting
volume.
Marks + are aver-
age volumes.
mperspring set.
7.7ztO.l mm
425 470140 / \ 105oi25

91oi30 950::;
Pump speed (rpm)

SEBH4850
95 SERIES
’ *-O%F9’
6207-71-1250
PC200-5 S6D95L-1
Injection Pump
ZEXEL
PES-4A
(DIESEL KIKI)
lniection Timing Engine specification
Rotating direction Clockwise viewed from drive end Rated horsepowerkW(HP)rpm 94.5( 126.7)/2050
Injection order l-5-3-6-2-4 I Maximum torque Nm(kgm)/rpm ( 475(48.5)/1500 1
IInjection
Plunger
interval
pre-stroke mm
60” f 30’
3.2 2 0.05
1 High idling
1 Low idling
rpm
rpm I
2200 - 2310
875 - 925
I
I

retraction volume mmVst
alibration Standard
Service standard ~~~~~~ pae no, (105780-0000) 6206-11-3130 (105017-0140)

indicates data
using calibration Nozzle holder part no. - (105780-2080) 6207-11-3110 (105048-3060)
(Nozzle, Nozzle (O/D x I/D x length) mm 6 x 2 x 600 6x1.6x600
aX%pzd injec- Test oil ASTM D975 No. 2 diesel fuel or equivalent
Manufacturer Oil temperature .“C 43 - 47
standard is data -
parts
(For reference) Transfer pump pressure MPa(kg/cm? 0.16 (1.6) 0.16 (1.6)
njection volume Service standard (cc/lOOOst) Manufacturer standard (cc/lOOOsl

Rack Pump
Rack
position speed Maximum Ma~llllUm
point
(mm) (rpm) Basis Allowance “b”$tzi Basis Allowance “b”$g,““,
cylinder cylinder
10.1 Each cyl. Each cyl.

Rack positions Basic point 1025 68.2 65.8
B to E are the ref- <I .99>
erence volume -
when adjusting B 7.3<2.5> 375 12.5 - 12.5
the injection vol- r
U
ume.
Marks t are aver- D
age volumes.
E
Note: Inside of < > represents the rack sensor output (V) at the time when the control unit is connected.
Rack sensor gradient adjust standard
R2=1 lltlmm
\ R2-R1=61tO. 05mm
Ri (approx. 5) R2 (approx. 11)
Rack position (mm)

TAE00061
’2-oi2-92
95 SERIES
6207-71-1251
6207-71-1252 Model Serial No. Model Serial No.
PC200-5 S6D95L-1

retraction volume mm%t
alibration Standard
~d~c~ia”t”,~t~$~rd
Nozzlepart no. (105780-0000) 6206-11-3130 (105017-0140)
Jsing calibration Nozzle holder part no. (I05780-2080) 6207-11-31 IO (105048-3060)

:est parts Injectionpipe
‘Nozzle, Nozzle (O/D x I/D x length) mm 6x2~600 6 x 1.6 x 600
iolder and injec- Test oi,
:ion pipe) ASTM D975 No. 2 diesel fuel or equivalent
Vlanufacturer Oil temperature “C 43 - 47
standard is data
Jsing factory test Nozzle opening pressure MPa(kg/cm*) 17.2 (175) 19.6 (200)
Iarts
For reference) Transfer pump pressure MPa(kg/cm2) 0.16 (1.6) 0.16 (1.6)
I I
B to E are the ref-

erence volume
when adjusting
the injection vol-
ume.
Marks * are aver-
R2=1 lltl mm
\ R2-R1=6fO. 05mm
RI (approx. 5) Rz (approx. 11)
Rack position (mm)

TAE00061
95 SERIES
’ 2-o:-93
6207-71-1281 (101692-3980)
S6D95L-1
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 100/2200
Injection order 1-5-3-6-2-4 Maximum torque kgmjrpm 38/l 400
1 High idling 2350 to 2450
I I
rpm
Injection interval
Delivery valve
Motor 7.5 KW

l Service standard bottle part no. (105780-0000) 6207-11-3130 (105017-0090)
indicated data
using calibration Nozzle holder part no. (I 05780-2080) 6207-I l-31 10 (105048-3060)
test parts.
injection ipe
l Manufacture (O/D x l/g x length) mm 6 x 2 x 600 6x‘1.6x600
standard is data
Injection volume Service standard (cc/l OOOst) Manufacturer standard (cc/l 000s
Rack Pump
Rack
point
(mm) (rpm ) Basis Allowance yer$$‘, Basis Allowance variance
between
cylinder cylinder
1 Rack positions Each cyl. Each cyl .
B to E are the ref- Basic point 10.8 1100 42.5 k1.0625 51.3
41.5 to 43.5
erence volume
A
when adjusting B 425 12.5 * 11.5to 13.5 k1.875 12.5 *
K
the injection
volume. C * *
1 Marks * are aver-
age volumes. D * *
E * *
ck limit 15 ‘8’ mm
1100:::
Pump speed (rpm)
SEBH4851
Pump Assembly Number I 1
6207-71-1381 (101695-3091)
( ): Manufacturer’s part No. WA1 80-I S6D95L-1
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm ) II O/2500
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm( 40.5/l 600

I
Injection interval 60° f 30’
Plunger pre-stroke mm 3.6 +_ 0.05
mms/st 51 for Service standard
retractinn vnlllme I
Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
for factory test.
Rack positions
6 to E are the ref-
erence volume
when adjusting the
injection volume.
Marks t are aver-
age volumes.
j!
1200f50 1375525
Pump speed (rpm)

SEBH486E
95 SERIES
’ 2-o%95
Pump Assembl Number
6207-71-1410
6207-71-1420
6207-71-1421
1016953150)
r 101692-3150)
101692-3900, 101695-3160
1
I Applicable
Model
Machine Applicable Engine
I
6207-71-1430 I 101692-3260.101695-3170 Serial No. Model Serial No.
6207-71-1690 (101695-3190)
( 1: Manufacturer’s part No. EG85-1 S6D95L-1
I I , \ I
-1 1 EG85B-IL I(For ALGERIA) 1 I I
1 GENERATOR 1 I I I

85.8/1500 (50 Hz)
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm
99.6/1800 (60 Hz)
-
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm
Max 1560 (50 Hz)
High idling rpm Max 1877 (60 Hz)
Low idling rpm 800
Plunger prestroke mm 3.6 + 0.05

bl I Motor 7.5 KW
re~r%rtX%r me mm%t 51 for Service standard
,

4ervice standard Nozz,epart no. ( 105780-0000) 6207-I I-3130 (105017-0090)
indicates data
uain9 calibration NO& holder part "0. (I 05780-2080) 6207-I I-31 10 (105048-3060)
test parts
Injection ipe
(Nozzle, Nozzle (O/D x l/g x length) mm
6 x 2 x 600 6x1.6x600
holder and injec- .
~Manufacture
standard is data _Oil temperature OC 43 to 47
uain9 factory teat Nozzle opening pressure kg/cm’ 175 200
YZ%eference) Transfer pump pressure kg/cm* 1.6 1.6
Injection volume Service standard (cc/lOOOst) Manufacturer standard (cc/l 000 st

Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance Fert$ Basis Allowance
between
cylinder cylinder
) Rack positions Each cyl. 76 o Each cyl.
Basic point 11.7 750 56.0 55.0 to 57.0 21.4
B to E are the ref-
erence volume B Apry. 400 12.5 * 11.5 to 13.5 *I.875 12.5 *
when adjusting
ume.
age volumes. *
E *

Rack cap a~!xox. 17.5 mm
450 75ot5
Pump speed (rpm)

SEBH4761-03
95 SERIES
’ 2-oZ2-96
3
6207-71-1540
DCA85SPK S6D95L-1
Injection Pump
ZEXEL
PES-GA
(DIESEL KIKI)
1 Injection order l-5-3-6-2-4 I ~1


Service standard ~~~~~~part no. (105780-0000) 6206-11-3130 (105017-0090)
indicates data
using calibration Nozzle holder part no. (I 05780-2080) 6207-I I-31 10 (I 05048-3060)
(Nozzle, Nozzle (O/Dx I/D x length) mm 8 x 3 x 600 6x1.6x600
holder and injec- Test oi,
ASTM D975 No. 2 diesel fuel or equivalent
tion pipe)
standard is data
parts
(For reference) Transfer pump pressure MPa(kg/cm2) 0.16 (1.6) 0.16 (1.6)
Injection volume Service standard (cc/l OOOst) Manufacturer standard (cc/1OOOs

Rack Rack Pump
(mm) (rpm) Basis Allowance z%% Basis Allowance “b”,E%
cylinder cylinder
10.8 62.7 Each cyl. Each cyl.
Rack positions Basic point 750 83.4
B to E are the ref- <I .84>
erence volume - -
when adjusting B 7.1<2.6> 400 -
the injection vol- 12.5
C 8.6<2.3> 400 12.5
ume.
Marks + are aver- D
age volumes.
E
Note: Inside of < > represents the rack sensor output W at the time when the control unit is connected.
R2=1 IzLlmm
R2-R14fO. 05mm
>
0 Ri (approx. 5) R2 (approx. 1 I)
Rack position (mm)

TAE00061
95 SERIES
’2-oE-97
6207-71-1941 (101695-3080)
WA1 50-l S6D95L-1
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 108.5/2,400
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 40/l ,600

I I
Injection interval 60” f 30
I Low idling rpm 675 to 725

1 Service standard Nozzle part no. ( 105780-0000) 6207-l I-3130 (105017-0090)

indicated data
I Manufacture (O/D x l/6x length) mm 6 x 2 x 600 6i 1.6x600
standard is data
Transfei pump pressure kg/cm’ 1.6 1.6
Rack Pump
Rack
point
(mm) (rpm) Basis Allowance rerEsE Basis Allowance variance
between
cylinder cylinder
1 Rack positions Each cyl. Each cyl.
B to E are the ref- Basic point 10.0 1200 35.4 34.4 to 36.4 kO.885 41.2
erence volume
when adjusting B [IO.91 800 38.2 * 36.2 to 40.2 - 52.2 t
the injection
volume. C A7gy. 350 12.5 * 11.5 to 13.5 +I.875 12.5 +
1 Marks *are aver-
age volumes. D * *
E * *
Governor performance ( 350 -1200 rpm)
Rack limit 15 ‘8’ mm
Pump speed (rpm)

SEBH4853
95 SERIES
’ 2-o%?98
I Applicable Machine Applicable Engine I
6207-71-1950 (101695-3130) I

GD51lA(R)-1 S6D95L-1
I lniection I Pumo I
Clockwise view from drive end

Motor 7.5 KW
,“,F~~t%,vd~Furne mm3/st 51 for Service standard

~Service standard 6207-I I-3130 (105017-0090)
indicates data
using calibration Nc221e holder part no. (105780-2080) 6207-I l-31 10 (105048-3060)
test parts
(Nozzle, Nozzle Injection ipe 6x 1.6x600
(O/D x l/g x length) mm 6x2~600
holder and injec-
~Manufacture
standard is data Oil temperature Oc ’ 43 to 47
using facton/ teat N ozzle opening pressure kg/cm* 175 200
?to?referenceI Transfer pump pressure kg/cm* 1.6 1.6
Injection volume Service standard (cc/lOOOst) Manufacturer standard (cc/1OOOsl

Rack Pump
Rack
point variance
(mm) (W’n) Basis Allowance ‘gg:i Basis Allowance between
cylinder cylinder
67 3 Each c I. Each cyl.
1Rack positions Basic point 11.7 1450 . f&$ to 68.3 *I .6825 62.4
B to E are the ref-
erence volume Approx.
B 9.5 450 12.5 * 11.5to 13.5 +I.875 12.5 *
when adjusting
ume.
‘Marks j, are aver- D * *
age volumes. *
E *
0 450 ‘450::8:550*25
800 800*50

~- --- --
95 SERIES
’2-o%99
I I
6207-71-1961 (101692-3710) Model 1 Serial No. ) Model ) Serial No. I
GDSlOR-1 S6D95L-1
I I , I
Rotating direction Clockwise view from drive end 1 Rated horsepower HP/rpm 1 12512500 I
Injection order I l-5-3-6-2-4 I Maximum torque kgm/rpm I -44/1600 1
Injection interval 60’430’

I High idling rpm I 2700 to 2800 I
I Low idling rpm 850 to 950
I I
Motor 7.5 KW
~~~~riy,~$~ume mm’/st 51 for Service standard
L

*Service standard
Nozzle part no. (105780-0000) 6207-l l-3130 (105017-0090)
indicates data
usin9 calibration Nozzle holder part no. (105780-2080) 6207- 11-3 110 ( 105048-3060)
test parts
(Nozzle, Nozzle Injection ipe
holder and injec-
aManufacture
standard is data Dir temperature OC 43 to 47
using factory test Nozzle opening pressure kg/cm2 175 200
parts
(For reference) Transfer pump pressure kg/cm2 1.6 1.6
Injection volume Service standard (cc/l 000 st) Manufacturer standard(cc/lOOO St

Rack Pump
Rack
point variance
(mm) hm) Basis Allowance yergs’, Basis Allowance
between
cylinder cylinder
‘Rack positions 54.7 Each cyl. Each cyl.
Basic point 11.4 1250 +I.3675 59.7
B to E are the ref- 53.7 to 55.7
erence volume
B 12.0 800 52.4 * 50.4 to 54.4 - 69.2 *
when adjusting
the injection vol- Approx.
C 9.5
450 12.5 *11.5to 13.5 f1.875 12.5 *
ume.
age volumes. *
E *
Rack cap: 15+$'*mm
95 SERIES
6207-72-1210
PC200-6 S6D95L-1
Injection Pump
ZEXEL
PES-GA
(DIESEL KIKI)
Injection order 1-5-3-6-2-4 ~1
Injection interval 60” 2 30’

retraction volume mm%
alibration Standard
Service standard ~~~~~~ pae no. (105780-0000) 6206-11-3130 (105017-0140)

indicates data
(Nozzle, Nozzle (O/D x I/D x length1 mm 6x2~600 6 x 1.6 x 600
~c$e[paeld injec- Test oil ASTM D975 No. 2 diesel fuel or equivalent
standard is data
using factory test Nozzle opening pressure MPa(kg/cm? 17.2 (175) 19.6 (200)
parts
I I
v”‘ume!
ii%
njection Service standard (cc/lOOOst) Manufacturer standard WlOOOfi
Al,owance Allowance
B to E are the ref-

erence volume
Rack limit: 12.5+$2mm

/
(I 14/d
Pump speed (mm) 6206F1013
95 SERIES
6207-72-l 270 (101692-3641)
PWl OO-3 S6D95L-1
Injection interval 60° f 30

retraction volume
indicates data
using calibration
test parts.
1Manufacture
standard is data
for factory test.
1Rack positions
B to E are the
ence volume when

tion volume.
1Marks t are aver-
age volumes.
Damper springset 7.7
425 470f40
1050::
Pump speed (rpm)
SEBH482’
’2-oz-’
O2 95 SERIES
Pump Assembly Number I
6209-71-l 211 (101695-3520)
( ): Manufacturer’s part No. PC220-5 SA6D95L-1
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 53.7/l 500

retraction volume
) Service standard
indicates data
using calibration
test parts.
1Manufacture
standard is data
for factory test.
) Rack positions
B to E are the ref-
erence volume
when adjusting
volume.
) Marks * are aver-
ck limit 12.5’E2 mm
0
550130 1100:::
95 SERIES
O3
’2-02z-’
6209-72-I 250
I Model ( Serial No. ( Model ( Serial No.
PC220-5 SA6D95L-1
Injection Pump
ZEXEL
PES-GA
(DIESEL KIKI)
Rotating direction Clockwise viewed from drive end Rated horsepower kW(HP)rpm 117(157.2)/2200
Injection order 1-5-3-6-2-4 Maximum torque Nm(kgmVrpm 526(53.7)/1500
holder and injec-
Manufacturer
standard is data
using factory test
Rack positions
B to E are the ref-
erence volume
when adjusting B 7.3<2.5> 375 12.5 12.5
the injection vol-
C
ume.
Marks Ir are aver- D
age volumes.
E
Note: Inside of < > represents the rack sensor output W) at the time when the control unit is connected.
R2=1 lflmm
> R2-Rl=6fO. 05mm
3
5
P
s
0
b
?
z 1.8
%
2
0 RI (approx. 5) Rz (approx. 11)
Rack position (mm)

TAE00061
95 SERIES
’ 2-o%-’ O4
6209-71-1251
6209-7 l-l 252 Model Serial No. Model Serial No.
( 1:Manufacturer’s part No.
PC220-5 SA6D95L-1

1 Injection order ~


Service standard Nozzle part no. (105780-0000) 6209-11-3130 (105017-0880)
indicates data
(Nozzle, Nozzle (O/Dx I/D x length) mm 6x2~600 6x2~600
standard is data
using factory test Nozzle opening pressure MPa(kg/cmz) 17.2 (175) 22.1 (225)
parts
[For reference) Transfer pump pressure MPa(kg/cmz) 0.16 (1.6) 0.16 (1.6)
njection volume Service standard (cc/lOOOst) Manufacturer standard (cc/lOOOst

Rack Rack Pump
(mm) (t-pm) Basis Allowance vba,;:,“‘, Basis Allowance vb%$~
cylinder cylinder
Each cyl. Each cyl.

3ack positions Basic point 1025 65.8
3 to E are the ref-
srence volume
,vhen adjusting B 375 * - 12.5
:he injection vol-
Jme.
C Ir *
age volumes.
E * *
RZ=l If1 mm
R2-Rl=6fO. 05mm
>
3
S
a
%
:
:
z 1.8
Y
B
(r
0 RI (approx. 5) R2 (approx. 11)
Rack position (mm)

TAE00061
95 SERIES
’ 2-o%-’ O5
6209-72-1210
PC220-6 SA6D95L-1
ql
Clockwise viewed from drive end 1 Rated horsepower kW(HP)/rpm 1 118(157.7)/2300
Maximum torque Nm(kgm)/rpm 554(56.5)/l 600
I Low idlina rDm I 975 - 1025

Delivery valve
retraction volume mmY.st
ialibration Standard

Service standard Nozzle pan no, (I05780-0000) 6209-I I-3130 (105017-0880)
indicates data
(Nozzle, Nozzle IO/D x I/D x length) mm 6x2~600 6x2~600
ASTM D975 No. 2 diesel fuel or equivalent
tion pipe)
Manufacturer Oil temperature “C 43 to 47
standard is data
using factory test Nozzle opening pressure MPa(kg/cm2) 17.2 (175) 22.1 (225)
parts
Rack positions
6 to E are the ref-
erence volume
Governor performance (450 - 1100 rpml
(I 165)
95 SERIES
injection Pump Assembly Number
6205-71-1290
1: injection pump manufacturer’s part No.
Injection Pump Specification Engine Specification

Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) 55.2 I73.91/2,000 (Net)
Injection order l-3-4-2 Maximum torque (Nm {kgm}/ rpm) 299 {30.5)/1,500 (Net)
Injection interval 89’30’ - 90”30’ High idling speed (rpm) 2,200 - 2,280
Plunger pre-stroke (mm) 3.15 - 3.25 Low idling speed (rpm) 900 - 950
Delivery valve (mm3/st) Pump tester capacity

retraction volume 51 Motor 7.5 kW
for service standard
CiPlibration Standard 1: lniection DumD manufacturer’s Dart number
C onditions
. Service standard
indicates data
using calibration
Manufacturer
standard is data
$3ction volume
B to E are the
reference volume
when adjusting
Marks * are
average volumes.
Governor Performance Curve
Rack I imi t : 12. 5’8’ (mm)
-z
IO. 5
E 10.0
9. 4
.-z
.-
z
oi
*: 6.4
nf
5. 4
950+40 I 100+25
Pump speed (rpm) TDE00570
’2-o%f-’
O7 I
Injection Pump Assembly Number
6207-71-1510
1: Injection pump manufacturer’s part No. WA1 80-3 S6D95L-1
Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) 82.0 {I lOY2,400 (Net;
Injection order l-3-4-2 Maximum torque (Nm IkgmI/ rpm) 417 {42.51/1,500 (Net1 I
Injection interval 89”30’ - 90”30’ High idling speed (rpm) I 2,600 - 2,700
I
Delivery valve (mm3/st)
51 Pump tester capacity
retraction volume Motor 7.5 kW
alibration Standard ( 1: Injection pump manufacturer’s part number

Service standard Manufacturer’s standard
Conditions Nozzle & nozzle holder part No.
Nozzle part No. (105780-2080) 6207-l I-31 10
) Service standard
indicates data Nozzle holder part No. (105780-0000) 6207-l l-3130
using calibration Injection pipe (mm) 6 x 2 x 600 6x 1.6x600
test parts. (Outside dia. x inside dia. x length)
I Manufacturer Test oil ASTM D975 No. 2 diesel fuel or eauivalent
standard is data
Oil temperature 1°C) 40 - 50
for factory test.
Nozzle opening pressure (MPa{kg/cm2}) 17.2 {175} 19.6 I2001
Transfer pump pressure (kPa(kg/cm2H 157 (I.601 157 Il.601
/ Service standard (cc/1000 St.1 / Manufacturer standard icc/lOOO st.)

njection volume
Rack positions
B to E are the
reference volume A
when adjusting (Basic point) 10.8 1,200 *43.5 - 45.5 2.2 *52.5
the injection
B 11.3 750 *43.0 - 47.0 t59.0
volume.
Marks * are C 8.4 385 *11.5 - 13.5 3.8 fi12.5
average volumes. D
E I I I I I I
Governor Performance Curve
Rack I imi t : 15. 0’:’ (mm)
4’60 /li70\
1230 1325
Pump speed (rpm) TDE00571
’*-Oi2-’
O8 95 SERIES
Applicab!e Machine Applicable Engine
6207-71-1520
): Injection pump manufacturer’s part No. WA250-3 S6D95L-1

Rotating direction Clockwise
injection order 1-3-4-2
Injection interval 89”30’ - 90”30’
Plunger pre-stroke (mm) 3.15 - 3.25
Delivery valve (mm3/st)

retraction volume 51 Motor 7.5 kW
I lniartinn
Service standard
indicates data
I Manufacturer
standard is data
ijection volume
B to E are the
reference volume
Marks t are
average volumes.
Governor Performance Curve Boost Compensator Performance Curve
Rack limit :15. 0':' (mm)
oost compensator strake:l. 2+0. 1 (mm)
E 12.3
c
”
._
UT
: il. 1
z
--r
0 6 7i2. 7 22. 7+6. 7
(50F201 ~17Oi501
Boost pressure (kPa(mmHsl)

0 385 \ 1100 \
400 1300 TDE00573
/\
1235 1330
Pump speed (rprn) TOE00572
95 SERIES
’ 2-oz-’ 1 O9
6209-71-1110 (101691-3041)
Model 1 Serial No. Model / Serial No.
): injection pump manufacturer’s part No. WING100 SAA6D95LE-1
(LWIOO-1,
LWIOOM-1)
PES-A ZEXEL
Injection Pump Specification Enaine Snecification

Rotating direction Clockwise 1 Flywheel horsepower (kW {HP}) / rpm) 1 118 {1581/3,000 (Net11
Injection order 1 l-5-3-6-2-4 Maximum torque (Nm IkgmY rpm) 457 {46.6}/1,800 (Net)
Injection interval 59”30’ - 60”30’ High idling speed (rpm) 3,400 - 3,500
Delivery valve (mm3/st) Pump tester capacity

51 Motor 7.5 kW
retraction volume
Conditions
I Service standard
indicates data
I Manufacturer
standard is data
njection volume
I Rackpositions
B to E are the
reference volume
when adjusting
volume.
Governor Performance Curve # Adjusting the injection pump at 375 (rpm) is as follows: adjust injection
volume and variance of injection pump without governor to adapt to the
values in the chart above at the rack position on 10.0 (mm), and after
coupling with the governor, check if the rack position is 9.0 (mm), checking
of injection volume or variance at rack position 9.0 (mm) is not necessary.
B.ldle lever set point

Boost comvensator J:Lever limit set Point
for increasing injection
E :0.45-O. 65 (mm) oiume at engine stariina
E
I I. 4
Il.25 E
.-z Il. I
.v, 10. 23-10. 5
: 6. 66-10. 2
330 400
Pump speed (rpm) Boost Pressure (kPa(mmHa))
Pump speed (rpm)
lWE00725
‘2-o~2-“o 95 SERIES
TESTING AND ADJUSTING PERFORMANCE TEST
PERFORMANCE TEST
RUN-IN STANDARD * Load are given for the case of the dynamometer arm lensth is 716 mm.
This list shows the standard on condition that the fan isremoved.
Engine 1 T Order
model Item
1 2 3 4 5 6
Running time 3 IO 3 10
Engine speed 950 1,000 1,600 2,600

PC40-5
147 147
PC40-6 Load 0
(“53 (15) (15)
output 0 3.7 17.7 28.7
(4.9) (23.7) (38.5)
Running time 3 10 2 3 10
Engine speed 950 1,000 1,200 1,600 2,500

3D95S-W-1 PC5OUU-1 Load 0 147 147
:; (Fz, (15) (15)
output 0 3.7 8.8 17.7 27.6
(4.9) (I 1.8) (23.7) (37)
Engine speed 700 1,000 1,200 1,600 2,650

EC35Z-2
EC35ZS2 118 147 147
EC35ZSB-2
Load 0
(E, (12) (15) (15)
10.6 17.7 29.4
output 0
(E, (14.2) (23.7) (39.4)
D20A, P,S, Engine speed 825 1,000 1,600 2,450

Cl, PL, PLL-6
147 166
D21A, P, S,
Q, PL-6
Load 0
(“53 (15) (17)
output 0 3.7 17.7 30.9

(4.9) (23.7) (41.4)
4D95S-W-1
Running time min. 2 10 3 IO
EC50Z-5 Engine speed rpm 700 1,400 2,000 2,300 2,800

EC50ZS-5 Load 0 118 137 162
EC50ZSB-5 & (“9”, (12) (14) (16.5)
output 0 17.7
CK &, (23.7) :% $6:
Running time min. 2 10 2 3 Min. 10
DZOAG, P, PG Engine speed 800 - 850 1,000 1,200 1,600 2,450
rpm
PL, PLL-7(A)
D21A. AG, PG Load 0 216 226 161
S, QG-7(A) & $, (22) (23) (16.4)
output 0 19.1 27.2 29.5

(k!, t;:;, (25.6) (36.5) (39.6)
Running time min. 2 IO 2 3 10
Engine speed rpm 800 - 850 1,000 1,200 1,600 2,500

4D95S-1 WA50-1 216 220
Load
$I,
0
5, (22) :% (22.4)
output 0 7.3 19.1 27.2 41.2

& (9.8) (25.6) (36.5) (55.2)
Running time
Engine speed
Load
output
95 SERIES
’2-:23
* Load are given for the case of the dynamometer arm length is 716 mm.
This list shows the standard on condition that the fan is removed.
T
Order
Engine
model
1 3 4 5 6
-
min. 2 10 2 3 10
rpm 800 - 850 1,000 1,600 2,200
0 196 196 275

6% (20) (20) (28)
0 17.7 29.4 33.1

(K, (23.7) (39.4) (44.4)
min. 2 2 3 10
rpm 800 - 850 1,000 1,200 1,600 2,200

4D95L-W-1 WA70-1 196 294 196
Load 0
(kNg, z, (20) (30) (20)
7.3 17.7 35.3 32.4
&F, 0 (9.8) (23.7) (47.3) (43.4)
2 2 3 IO
800 - 850 1,200 1,600 1,800

EG33B, BS-1 Load 0 147 196 245
(15) (20) (25)
13.2 23.5 33.1
output 0 (17.7) (31.5) (44.4)
-
Running time min. 2 10 2 3 10
PC60-3 Engine speed rpm 800 - 850 1,000 1,200 1,600 2,400
PC6OL-3 196 275 255
PC6OU-3 Load 0
& % (20) (28) (26)
7.3 17.7 33.1 45.6
output CkY, 0 (9.8) (23.7) (44.4) (61.1)
Running time min. 2 2 3 10
?C60-5 Engine speed rpm 900 - 950 1,200 1,400 2,100

‘C6OL-5 196 294 265
Load 0
?C6OU-5 (kNg) (20) (30) (27)
output 0 17.7 26.5 41.7

(K, (23.7) (35.5) (55.9)
-
Engine speed rpm 350 - 1,000 1,000 1,200 1,400 2,100

PC60-6
4D95L-1 196 294 265
PC70-6 Load
&
0
5, (20) (30) (27)
output 0 7.3 17.7 30.9 41.7

(%, (9.8) (23.7) (41.4) (55.9)
Running time min. 2 10 2 3 Max. 10
Engine speed rpm 1,000- 1,05( 1,000 1,200 1,500 1,900

PC60-7
PC70-7 Load 0 196 294 284
& (Z, (20) (30) (29)
output 0 7.3 17.7 33.1 40.4

(“& (9.8) (23.7) (44.4) (54.2)
Running time min. 2 10
Engine speed rpm 950 - 1,000
0
(kNg)
0
&Y,
’2z24 95 SERIES
Order
Engine Applicable
Item
model machine
2 4 5 6
Iqunning time 2 10 2 3 10
IEngine speed ,000 - 1,051 1,100 1,200 1,600 1,900
‘C75UU-2 0 196 294 275

I_oad
% (20) (30) (28)
8.1 17.7 35.3 39.2
(3utpLlt 0
(23.7) (47.3) (52.5)
(10.8)
Iqunning time 2 10 2 3 10
I%gine speed 900 - 950 1,000 1,200 1,600 2,400
‘C80-3 0 196 294 275

I_oad
$, (20) (30) (28)
7.3 17.7 36.1 49.7
(3lJtput 0
(23.7) (48.3) (66.6)
(9.8)
Ikrnning time 2 10 2 3 10
Iingine speed 50 - l,OO( 1,000 1,200 1,600 2,300

x90-1 196 343 287
I_oad 0
(E, (20) (35) (29.3)
(zwtput 0 7.3 17.7 41.2 49.5

(9.8) (23.7) (55.2) (66.3)
IQnning time 2 10 2 3 10
IIngine speed 900 1,000 1,200 1,600 2,500

4D95L-1 ‘W60-3 196 278
I_oad 0
% (20) :3904 (28.4)
7.3 17.7 35.3 52.2

(3utput 0
(23.7) (47.3)
(9.81 (70)
Iknning time 2 10 2 3 10
I%gine speed 825 1,000 1,200 1,600 2,450

121A-7T
147 206
‘Trimming) I_oad 0
f53 (Y!, (15) (21)
3.7 17.9 38.4
(3utput 0
(51.5)
(5) (:2, (24)
I3unning time 2 10 2 3 10
Ikgine speed BOO - 850 1,500 2,100 2,400 3,000

x75z. zs-3 118 167 204 235
I_oad 0
(12) (17) (20.8) (24)
(3utput 0 13.2 26.5 36.8

(17.7) (35.5) (49.3) (Y,
IQrnning time 2 IO 2 3 10
IEngine speed BOO - 850 1,000 1,200 1,600 1,800
196 245 294

EG40B. BS-1 Load 0
(E, (20) (25) (30)
17.7 29.4 39.7
output 0
(E, (23.7) (39.4) (53.2)
95 SERIES
’2-:25
Order
Engine Applicable
item
model machine
1 2 3 4 5 6
-
Running time nin. 10 2 3 10
Engine speed rpm 1,000 1,200 1,600 2,100

‘ClOO-5
Load 200 290 360
‘CIOO-6
6% % (20) (30) (37)
output 7.3 17.7 35.3 57.1

:% (9.8) (23.7) (47.3) (76.6)
Running time nin. 10 2 3 10
Engine speed rpm 1,000 1,200 1,600 2,200

PC120-5
PC1 20-6 Load 200 290 370
PC128UU-1 (kNg, $, (20) (30) (38)
output 7.3 17.7 35.3 61.8

K (9.8) (23.7) (47.3) (82.8)
Running time nin. 10 2 3 Min. 10
Engine speed rpm 1,000 1,200 1,600 2,000

JV7ODW-1 Load 196 390 390
& % (20) (40) (40)
output 7.46 17.9 47.7 59.7

6% (10.0) (24.0) (64.0) (80.0)
Running time nin.
Engine speed ‘pm
Load
&
output
&I$
Running time
Engine speed
Load
output
Running time
Engine speed
Load
output
Running time
Engine speed
Load
output
Running time
Engine speed
Load
output
1 Z-026 95 SERIES
Ir Load are given for the case of the dynamometer arm length is 716 mm.
Order
Engine
model
-
1 2 3 4
I 5 6
min 2 IO 2 3 10
Engine speec 700 - 75c 1,000 1,200 1,600 2,350
D31A, P, S,
196 343 294
Q-18 Load 0
(f, (20) (35) (30)
output 0 7.3 17.7 41.2 51.8
-I-
(9.8) (23.7) (55.2) (69.5)
Engine speec 700 - 75c 1,000 1,200 1,600 2,350
D31E, P, PL,
PLL, S, 0, Ab Load 0 196 343 294
SM-LO(A) z, (20) (35) (30)
output 0 7.3 17.7 41.2 51.8
(9.8) (23.7) (55.2) (69.5)
Running time 2 2 3 IO
Engine speed 700 - 750 1,200 1,600 2,500
D37A-2 +
D37P-2A Load 0 196 343 323
(20) (35) (33)
output 17.7
(23.7)
Running time 2
Engine speed rpm 1,200

137E, P-5(A) Load 196
w$ (20)
output 0 17.7
r”& (23.7)
6D95L-1
Running time nin. 2 IO 2
PC100-3 Engine speed rpm 850 - 900 1,000 1,200

PClOOL-3 Load 0 196 392 392
PClOOU-3 & z, (20) (40) (40)
output 0 7.3 17.7 47.1 61.8
F,
,.:o.
(9.8) (23.7) (63.1) (82.8)
-
Running time nin. 2 10 2
Engine speed ‘pm 800 - 850 1,000 1,200

X120-3 Load 0 196 392 392
0% $, (20) (40) (40)
output kW 0 17.7 47.1 64.7
HP) G, (23.7) (63.1) (86.7)
Running time nit-b 2 10 2
Engine speed ‘pm 850 - 900 1,000 1,200

‘W150-1 196
Load
:kNg,
0
3, (20)
output kW 0 7.3 17.7

HP) (9.8) (23.7)
-
Running time nin. 2 10 2
Engine speed ‘pm 575 - 725 1,000 1,200

‘VAIOO-1
196 314
YRII-1 Load
kNg)
0
(Z, (20)
392
(40) (32)
output kW 0 7.3 17.7
HP) (9.8) (23.7)
-
95 SERIES
’2-:27
Sr Load are given for the case of the dynamometer arm length is 716 mm.
Engine
Item
T Order
model
1 2 3 4 5 6
Running time 2 IO 2 3 10
WAIOO-1 Engine speed 675 - 725 1,000 1,200 1,600 2,400

WRII-1
Load 0 196 392 363
(Engine No. $, (20) (40) (37)
46799 and u,
output 0 7.3 17.7 47.1 65.3
(9.8) (23.7) (63.1) (87.5)
Running time 2 IO 2 3 10
Engine speed 750 - 850 1,000 1,200 1,600 2,500

6D95L-1 GD313A-1 196 392 353
Load 0
(% (20) (40) (36)
output 0 7.3 17.7 47.1 66.2

(9.8) (23.7) (63.1) (88.7)
Engine speed 800 - 850 1,000 1,200 1,600 1,800

EGGOB, BS-1 196 294 392
Load 0
(?I, (20) (30) (40)
output 0 7.3 17.7 35.3

(9.8) (23.7) (47.3) $,
Engine speed 800 - 850 1,000 1,200 1,600 2,200

PC150-3
PC15OLC3 Load 0 245 490 466
% (25) (50) (47.5)
output 0 7.3 22.1 58.9 76.8

(9.8) (29.6) (78.9) (103)
Engine speed rpm 900 1,000 1,200 1,600 2,000

PC150-5 196 490 519
Load 0
6% z, (20) (50) (53)
output 0 7.3 17.7 58.9

(F, (9.8) (23.7) (78.9) (10748.5,
Engine speed rpm 950 1,000 1,200 1,600 2,050

6D95L-1 PCZOO-5
BRZOO-1 Load . 0 196 490 598
& % (20) (50) (61)
output 0 7.3 17.7 58.9 82.6

(“Y, (9.8) (23.7) (78.9) (110.7)
Running time min. 2 10 2 3 Min. 10
Engine speed rpm 1,000 1,200 1,400 1,600 2,200

PCZOO-6 Load 0 147 294 588 637
& (15) (30) (60) (65)
output 0 13.2 30.9 70.6 105.2

IF, (17.7) (41.4) (94.7) (141)
Running time min. 2 10 2 3 IO
Engine speed rpm 850 - 900 1,000 1,200 1,600 1,900

PWI 00-3
(Engine No. Load 0 196 392 529
up to 36829) (I% c% (20) (40) (54)
Output 0 7.3 17.7 47.1 75.7

I% (9.8) (23.7) (63.1) (101.5)
’2z28 95 SERIES
Load for case of arm is 716

This list the standard condition that fan is removed.
Engine
model
Item
r Order
1 3 4 5 6
bnning time min. 2 10 2 3 10
Engine speed rpm 850 - 900 1,000 1,200 1,600 2,100

‘Wl OO-3
Engine No. _oad 200 390 537
16830 and up & (:, % (20) (40) (54.8)
7.3 17.7 47.1 84.6
3tltput
CK? & (9.8) (23.7) (63.1) (113)
3unning time 2 10 2 3 10
Engine speed JJ5 1,000 1,200 1,600 2,400

NA180-3 0 250 490 470
Load
!O) E, (25) (50) (48)
Qutput 7.5 85.8

!& (IO) (%, & (115)
sunning time 10 2 3 10
Engine speed 1,000 1,200 1,600 2,400

NA250-3 250 440 490
Load
1% (25) (45) (50)
Qutput 7.5
(10) (%, (?I$ $FO,
Engine speed 750 - 850 1,000 1,200 1,600 2,500

S6D95L-1 ;D461A-1 250 540 470
Load
Ii, (% (25) (55) (48)
output 7.5 22.1 64.8

i: (9.8) (29.6) (86.8) H8188s,
Running time 2 10 2 3 Min. 10
Engine speed 750 - 850 1,000 1,200 1,800 3,000

_W80-1 200 390 490
Load
A (% (20) (40) (50)
7.5 17.6 110
output (J?O,
i, (9.8) (23.7) (148)
Running time IO 2 3 10
Engine speed 1,000 1,200 1,600 1,800

:G85B, BS-1 200 390 670
Load
% (20) (40) (68)
7.5 17.6 47.1 90.3
output
(9.8) (23.7) (63.1) (121)
Running time 10 2 3 10
Engine speed 1,000 1,200 1,600 1,800

DCA85
200 390 590
QAS85 Load
% (20) (40) (60)
7.5 17.6 47.1 79.8

output
(9.8) (23.7) (63.1) (107)
Running time 10 2 3 10
Engine speed 1,000 1,200 1,600 2,200

PC220-5 590 710
SA6D95L-1 200
BR300-1 Load
I%, (20) (60) (72)
7.5 17.6 JO.6 116

output (23.7) (94.6) (156)
(9.8)
95 SERIES
’*-Oi*-’
1
l-
Engine Applicable
Item
l- Order
model machine
1 2 3 4 5 6
-
Flunning time nin. 2 10 2 3 10
Eingine speed rpm 1,000 1,200 1,400 1,600 2,300

SA6D95L-1 PC220-6 294 764 686
1.oad 0
$1 (% (30) (78) (70)
(kItput 0 7.3 30.9 91.8 117.7

rk!, (9.8) (41.4) (123) (157.8)
Fsunning time nin. 10 2 3
E.ngine speed rpm 1,000 1,200 1,600

WING100
250 440
LWIOO-1
1 LWIOOM-1 1
1.oad
& (E, (25) (45)
(Iutput 7.5
K, (10) &
FIunning time nin.
Eingine speed rpm
1.oad
&
(Iutput
IK,
FIunning time nin.
Eingine speed rpm
1.oad
&
(XJtput
rk!,
SAA6D95LE-’ I -
FIunning time nin.
Eingine speed rpm
1.oad
&
tIutput
$,
FIunning time min.
E!ngine speed rpm
Load
&
output
(!zJ
Running time min.
Engine speed rpm
Load
&
output
K,
-
95 SERIES
’2-z8-2
PERFORMANCE TEST CRITERIA
Engine Applicable Specified value Engine speed Dynamometer

Test item
model machine (fully equipped) (rpm) (kg)
Flywheel horsepower 38.5 HP/2,600 rpm 2,595 - 2,605 14.2 - 15.4
Maximum torque 12.5 kgm/1,800 rpm 1,700 - 1,900 Min. 17.1

PC40-5
PC40-6
High idling speed 2,800 rpm 2,750 - 2,850 0
Low idling speed 950 rpm 950 - 1,000 0
Maximum torque 12.2 kgm/l,800 rpm 1,700 - 1,900 Min. 17.1

PC5OUU-1
Low idling speed 950 rpm 950 - 1,000 0

3D95SW-1
Flywheel horsepower 35 HP/2,650 rpm 2,645 - 2,655 14.8 - 16.2
EC35Z-2 Maximum torque 13 kgm/l,800 rpm 1,700 - 1,900 18.7 -

EC35ZS2
EC35ZSB-2 High idling speed 2,800 rpm 2,700 - 2,900 0
Low idling speed 700 rpm 650 - 750 0
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed

D20A. P, S, Q,
Maximum torque 15.5 kgm/l,300 rpm 1,200 - 1,450 21.3 - 22.6
PL, PLL-6
D21A, P, S, Q,
PL-6
EC50Z-5 Maximum torque 15 kgm/2,000 rpm 1,900 - 2,100 21 - 22.5

4D95SW-1 EC50Z.55
EC50ZSB-5 High idling speed - - 0
Low idling speed 1,500 rpm 1,450 - 1,550 0
’*-g30 95 SERIES
The values given for the output and torque are with the fan removed, so they differ from those of the specification.
Values are standardized under the following conditions: Air cleaner installed; alternator idling; and air compressor
(if installed) open.
Dynamometers are given for the case of the arm length is 716 mm.
Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
Lubrication oil used: CLASS-CD SAEBO.
Coolant Lubrication oil Lubrication oil Exhaust

output Torque Fuel consumption
temperature temperature pressure temperature (“C)
0-W t&m) (sec./l 00 cc)
(“C) (“C) (kg/cm? (t=lntake temp. - 20°C)
35.5 - 39.2 - Min. 19.4 70 - 90 go- 120 3.0 - 6.0 Max. 650 + 3t
- Min. 12.2 70 - 90 90 - 120 - Max. 650 + 3t
0 0 _ 70 - 90 90 - 120 _ -
0 0 - 70 - 90 Min. 90 Min. 1 .O _
36.5 - 39.4 _ 19.4 - 20.9 70 - 90 90 - 120 3.0 - 6.0 Max. 700 + 3t
Min. 12.2 _ 70 - 90 90 - 120 _ Max. 650 + 3t
0 0 - 70 - 90 90 - 120 - _
0 0 - 70 - 90 Min. 80 Min. 1 .O -
36.4 - 42.4 - Min. 36.4 70 - 90 90 - 120 3.0 - 6.0 Max. 700 + 3t
- 13.4 70 - 90 90 - 120 _ Max. 700 + 3t
0 _ - 90 - 120 - _
0 0 - Min. 80 Min. 1.0 -
40.6 - 43
0
,,,I,,, 0 -
70 - 90
70 - 90
70 - 90
90 - 120
90 - 120
90 - 120
3.5 - 6.0
-
Max. 700 + 3t
Max. 700 + 3t
0 0 - 70 - 90 Min. 80 Min. 1 .O _
48.3 - 50.8 - 29.7 - 33.3 3.0 - 6.0 Max. 700 + 3t
_ 15.0 :‘i’ 1 37.9 T.6 _ Max. 700 + 3t
0 _ _
0 Min. 1.5 _
95 SERIES
’2-020-1
Engine Applicable Specified value speed Dynamometer

Test item
model machine (fully equipped) (rpm) (kg)
Flywheel horsepower 39.5 HP/2,450 rpm 2,445 - 2,455 15.9- 16.9

D20AG, P, PG.
Maximum torque 15.5 kgm/1,300 rpm 1,200 - 1,450 21.2 - 22.6
PL, PLL-7(A)
D21A, AG, PG. _
High idling speed 2,530 - 2,630 rpm 2,530 - 2,630
S, QG-7(A)
Low idling speed 800 - 850 rpm 800 - 850 -
4D95S1

WA50-I
Flywheel horsepower 41 HP/2,200 rpm 1 2.195-22205

I
Maximum torque 19 kgm/l,400 rpm 1,300 - 1,500 27.0 - 28.3
WA40-1

WA70-I
Low idling speed 800 rpm I 800 - 850 I 0

Flywheel horsepower (50 Hz) 34.5 HP/l,500 rpm 1,495 - 1,505 22.9 - 24.3
(60 Hz) 41.4 HP/l ,800 rpm 1,795 - 1,805 23.2 - 24.6
EG33B, BS-1
4D95L-W-I (50 Hz) Max. 1,560 rpm Max. 1,560 0
Prime High idling speed
(60 Hz) Max. 1,872 rpm Max. I,872 0
1 Low idling speed I 800 rpm I 800 -850 1 0
Flywheel horsepower (50 Hz) 38.5 HP/l,600 rpm 1,495 - 1,505

(60 Hz) 45.4 HP/I ,800 rpm 1,795 - 1,805 25.4 - 26.8
EG33B, BS-I
High idling speed (50 Hz) Max. 1,575 rpm Max. 1,575
Stand-by
(60 Hz) Max. 1,890 rpm Max. 1,890
Low idling speed 800 rpm
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
’*-O2O-* 95 SERIES
* The values given for the output and torque are with the fan removed, so they differ from those of the specification.
t Values are standardized under the following conditions: Air cleaner installed; alternator idling; and air compressor
* Dynamometers are given for the case of the arm length is 716 mm.
t Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
* Lubrication oil used: CLASS-CD SAEBO.
Coolant 1 Lubrication
oil 1 Lubrication
oil 1 Exhaust
Torque Fuelconsumption
temperature temperature pressure temperature (C)
(H+) (k9m) (sec./100cc)
('C) ('C) (ko/cm2) It-lntaketemo.- 2o'CI
38.5- 40.8 _ Min.40.5 70-90 80-110 3.5- 6.0 Max600+3t
15.2- 16.2 - 70-90 80-110 -
_ - 70-90 80- 110 -
- 70-90 Min.80 Min. 1.0
52.6- 58 70-90 80-120 3.5- 6.0 Max.600 + 3t
_ 70-90 80-120 _ Max.650 + 3t
0 70-90 80- 120 - -
0 70-90 Min.80 Min. 1.0
42.1 - 44.7 70-80 80-110 3.0- 6.0 Max.600 + 3t
- 70-80 80-110 - Max.650 + 3t
0 - 70-80 80 -110 - -
0 0 - 70-80 Min.80 Min.l.O
42.1 - 58.6 - Min. 25.8 70-80 90-120 3.0- 6.0 Max.650+ 3t
- 20.2- 21.8 _ 70-80 90-120 - Max.650+ 3t
0 0 - 70-80 90 -120 - -
0 0 _ 70-80 Min.80 Min. 1.0
33.8 - 35.9 - Min. 46.9 70-85 80-115 2.5- 5.0 Max.700 + 3t

41.1 - 43.6 - Min. 39.1 70-85 80- 115 3.0- 5.5 Max.700 + 3t
0 0 - 70-85 80-115 - _
0 0 - 70-85 80-115 _ -
0 0 - 70-885 Min.80 Min.l.5 -
37.7 - 39.3 - Min. 42.1 70-85 80-115 2.5 - 5.0 Max.700+3t

45.1 - 47.5 _ Min. 35.7 70-885 80-115 3.0- 5.5 Max.700+3t
0 0 - 70-85 80-115 _ _
0 0 _ 70-85 80-115 _ -
0 0 - 70-85 Min.80 Min. 1.5 -
95 SERIES 12-O$O-3
I
Engine Specified value Engine speed Dynamometer

Test item
model (fully equipped) (rpm) N (kg)
Flywheel horsepower 44 kW (59 HP)/2,400 rpm 243 - 277.7

2,395 - 2,405
(24.8 - 26.3)
PC60-3 Maximum torque 196 Nm (20 kgm)/1,500 rpn 267.5 - 293
1,400 - 1,600
PC6OL-3 (27.3 - 29.9)
PC6OU-3 High idling speed 2,640 rpm 2,590 - 2,690
Low idling speed 850 rpm 850 - 900
Flywheel horsepower 40.3 kW (54 HP)/2,100 rpm 257.7 - 271.4

2,095 - 2,105
(26.3 - 27.7)
PC60-5 Maximum torque 200 Nm (20.4 kgm)/1,500 rpm Min. 284.2
1,400 - 1,600
PC6OL-5 (29.0)
PC6OU-5 High idling speed 2,300 rpm 2,250 - 2,350
Flywheel horsepower 40.3 kW (54 HPV2,lOO rpm 256.8 - 272.4

2,095 - 2,105
(26.2 - 27.8)
Maximum torque 225.4 Nm (23 kgm)/1,500 rpm Min. 319.5

PC60-6 1,400 - 1,600
(32.6)
PC70-6
High idling speed 2,300 rpm 2,250 - 2,350
Low idling speed 950 rpm 950 - 1,000
Flywheel horsepower 40.4 kW (54.2 HP)/1,900 rpm 284.2 - 300.9

1,895 - 1,905
(29.0 - 30.7)

PC60-7 1,400 - 1,600
(32.7)
PC70-7
Low idling speed 950 - 1,000 rpm 950 - 1,000

4D95L-1
Flywheel horsepower 40.3 kW (54 HP)/1,900 rpm 264.6 - 290.1
1,895 - 1,905
(27.0 - 29.6)
Maximum torque 200 Nm (20.4 kgm)/1,500 rpm Min. 261.7

1,400 - 1,600
PC75UU-1 (26.7)
Flywheel horsepower 40.5 kW (54.2 HP)/1,900 rpm 264.6 - 290

1,895 - 1,905
(27.0 - 29.6)
Maximum torque Min. 319.5

PC75UU-2 225.4 Nm (23 kgm)/1,500 rpm 1,400 - 1,600
(32.6)
Low idling speed 1,000 - 1,050 rpm 1,000 - 1,050
Flywheel horsepower 47.8 kW (64.1 HP)/2,400 rpm 268.5 - 284.2

2,395 - 2,405
(27.4 - 29)
Min. 298
Maximum torque 210 Nm (21.4 kgm)/1,600 rpm 1,500 - 1,700
PC80-3 (30.4)
High idling speed 2,550 rpm 2,500 - 2,600 _
Flywheel horsepower 47.8 kW (64.1 HP)/2,300 rpm 278.3 - 295

2,295 - 2,305
(28.4 - 30.1)

1,400 - 1,600
PC90-1 (32.6)
High idling speed 2,475 rpm 2,425 - 2525
’2-020-4 95 SERIES
t The values given for the output and torque are with the fan removed, so they differ from those of the specification.
t Values are standardized under the foilowina conditions: Air cleaner installed: alternator idling; and air compressor
+ Dynamometers are given for the case of the arm length is 16 mm.
Sr Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel. -
* Lubrication oil used: CLASS-CD SAESO.

Outupt Torque Gel consumptior
temperature temperature pressure temperature (“C)
kW (HP) Nm (kgm) (sec./100 cc)
(“0 (“C) MPa (kg/cm*) [t=lntake temp. -20°C)
43.9 - 46.5 0.3 - 0.6
27.5 - 29.1 70 - 80 80 - 110 Max. 650 + 3t
(58.8 - 62.3) (3.0 - 6.0)
192 - 210
39.2 - 45.5 70 - 80 80 - 110 Max. 650 + 3t
(19.6 - 21.4)
70 - 80 80 - 110
Min. 0.1
70 - 80 Min. 80
(1.0)
0.3 - 0.6
30.1 - 33.9 70 - 80 80-110 Max. 650 + 3t
(3.0 - 6.0)
Min. 202.9
70 - 80 80 - 110 Max. 650 + 3t
(20.7)
70 - 80 80 - 110
Min. 0.1
70 - 80 Min. 80
(1.0)
40.4 - 43 0.35 - 0.6
Min. 31.4 70 - 90 90 - 120 Max. 700 + 3t
(54.2 - 57.6) (3.5 - 6.0)
Min. 228.3
70 - 90 90 - 120 Max. 700 + 3t
(23.3)
70 - 90 90 - 120
Min. 0.1
70 - 90 Min. 80
(1.0)
41 - 43.6 0.35 - 0.6
Min. 31.0 70 - 90 90 - 120 Max. 600 + 3t
(55.0 - 58.4) (3.5 - 6.0)
Min. 229.3
70 - 90 90 - 120 Max. 650 + 3t
(23.4)
70 - 90 90 - 120
Min. 0.1
70 - 90 Min. 80
(I.01
37.7 - 41.3 0.3 - 0.7
Min. 32.3 70 - 80 80 - 110 Max. 650 + 3t
(50.6 - 55.4) (3.0 - 7.0)
Min. 187.2
70 - 80 80 - 110 Max. 650 + 3t
(19.1)
0.3 - 0.7
70 - 80 80 - 110
‘3&- ;.y
70 - 80 Min. 80
c1:o;
38.3 - 41.9 0.35 - 0.7
Min. 32.3 70 - 80 90 - 120 Max. 650 + 3t
(51.3 - 56.2) (3.5 - 7.0)
Min. 228.3
70 - 80 90 - 120 Max. 650 + 3t
(23.3)
0.35 - 0.7
70 - 80 90 - 120
(3.5 - 7.0)
Min. 0.1
70 - 80 Min. 80
(1.0)
48.3 - 51.1 0.3 - 0.6
25.3 - 28.4 70 - 80 80 - 110 Max. 650 + 3t
(64.8 - 68.5) (3.0 - 6.0)
Min. 213.6
70 - 80 80 - 110 Max. 650 + 3t
(21.8)
70 - 80 80 - 110
Min. 0.1
70 - 80 Min. 80
(I.01
48.0 - 51 0.35 - 0.6
Min. 26.4 70 - 90 90 - 120 Max. 600 + 3t
(64.4 - 68.3) (3.5 - 6.0)
Min. 228.3
70 - 90 90 - 120 Max. 600 + 3t
(23.3)
70 - 90 90 - 120
Min. 0.1
70 - 90 Min. 80
II .O)
95 SERIES
’ 2-o:o-5

Test item
model machine (fully equipped) (rpm) N (kg)
-
270.5 - 286.2
Flywheel horsepower 419.2 kW (66 HP)/2,500 rpm 2,495 - 2,505
(27.6 - 29.2)
300
Maximum torque 2‘15.6 Nm (22 kgm)/1,600 rprr 1,500 - 1,700
PW60-3 Min. (30.6)
thigh idling speed 2,650 rpm 2,600 - 2,700

-
228.3 - 235.2
clywheel horsepower 417.7 kW (64 HP)/3,000 rpm 2,995 - 3,005
(23.3 - 24)
275.4
Vlaximum torque 2 01.9 Nm (20.1 kgm)/Z,OOOrpm 1,900 - 2,100
EC75Z. ZS-3 Min. (28.1)
iigh idling speed
_ow idling speed

-
206.8 - 217.6
-lywheel horsepower 3 6.8 kW (49.3 HP)/2,450 rpm 2,445 - 2,455
(21.1 - 22.2)
237.2 - 249
D21A-7T Maximum torque 171.5 Nm (17.5 kgm)/1,300 rpm 1,200 - 1,400
4D95L-1 (24.2 - 25.4)
[Trimming)
iigh idling speed 2,530 - 2,630 2,530 - 2,630
_ow idling speed 800 - 850 800 - 850

-
31.6 (42.4 HP)/1,500 rpm 1,495 - 1,505 r5.4- 292(28.1- 29.8)
-lywheel horsepower 1:: !zi
37.5 (50.3 HP)/l,SOO rpm 1,795 - 1,805 ‘5.4- 291.1128.1
- 29.7)
EG40B, BS-1
Max. 1,560 rpm Max. 1,560
‘rime iigh idling speed
Max. 1,872 rpm Max. 1,872
LOW idling speed 800 rpm 800 - 850
35.3 (47.3 HPY1.500 rpm 1,495 - 1,505 07.7- 325.4131.4- 33.2)

Flywheel horsepower I$ $i
41.2 (55.2 HPY1.800 rpm 1,795 - 1,805 01.8- 319.5(30.8- 32.6)
EG40B, BS-1 (50 Hz) Max. 1,575 rpm Max. 1,575

High idling speed
Stand-by (60 Hz) Max. 1,890 rpm Max. 1,890
372.4 - 395
Flywheel horsepower is.9 kW (78.9 HPY2.100 rpn 2,095 - 2,105
(38.0 - 40.3)
Min. 424.3
PCIOO-5 Maximum torque 198.5 (30.5 kgm)/1,500 rpn 1,400 - 1,600
(43.3)
PClOO-6
378.3 - 400.8
Flywheel horsepower i2.5 kW (83.8 HP)/2,200 rpn 2,195 - 2,205
(38.6 - 40.9)
PC120-5 Min. 424.3
Maximum torque 198.5 (30.5 kgm)/1,500 rpn 1,400 - 1,600
S4D95L-1 PC120-6 (43.3)
PC128UU-1 High idling speed. 2,400 rpm 2,340 - 2,460
385 - 409
Flywheel horsepower 55 kW (74 HP)/2,000 rpm 1,995 - 2,005
(39.3 - 41.7)
Min. 425
Maximum torque 199 Nm (30.5 kgm)/1,500 rprr 1,400 - 1,600
JV7ODW-1 (Min. 43.3)
High idling speed Max. 2,200 rpm Max. 2,200
Low idling speed 900 - 950 rpm 900 - 950
’2-oio-6 95 SERIES
t Values are standardized under the following conditions: Air cleaner installed; alternator idling; and air compressor
* Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
t Lubrication oil used: CLASS-CD SAE30.

Outupt Torque :uelconsumption
temperature temperature pressure temperature ("C)
kW (HP) Nm (kgm) (sec./100cc)
("C) ("0 MPa (kg/cm*) :=lntake
temp. -20°C)
50.7 - 53.7 0.3 - 0.6
23.4 - 26.2 70 - 80 80-110 Max.650
(68 - 72) (3.0- 6.0)
Min. 316.5
Min. 37.4 70 - 80 80- 110 Max.650
(Min. 32.2)
70-80 80- 110
Min. 0.1
70-80 Min. 80
(Min. 1.0)
51.4 - 53 0.3 - 0.6
23-28 70-80 80- 110 Max.650
(68.9 - 71) (3.0- 6.0)
Min. 197
38 - 43 70-80 80 - 110 Max.650
(Min. 20.1)
70-80 80-110
Min. 0.1
70-80 Min. 80
(Min. 1.0)
37.8 - 40.1 0.3 - 0.6
Min. 33.3 70-90 90 - 120 Max.650
(50.7- 53.7) (3.0- 6.0)
169.5 - 178.4
70-90 90 - 120 Max.650
(17.3- 18.2)
70-90 90 - 120
Min. 0.1
70-90 Min. 80
(Min. 1.0)
31- 32.9(41.5
- 44.11 - Min. 42.1 70-85 80- 115 1.25
- 0.5(2.5- 5.0 Max.700
37.2- 39.2(49.8
- 52.6) - Min. 36.5 70-85 80- 115 1.3
- 0.55(3.0- 5.5 Max.700
70-85 80- 115

70-85 80- 115
Min. 0.15
70-80 Min. 80
(Min. 1.5)
34.6- 36.6(46.4
- 49.11 - Min. 37.7 70-85 80-115 1.25
- 0.5(2.5- 5.0 Max.700
37 - 43.1(49.6
- 57.8) - Min. 32.3 70-85 80-115 I.3
- 0.55(3.0- 5.5 Max.700
70-85 80-115
70-85 80-115
_ Min. 0.15
70-80 Min. 80
(Min. 1.5)
58.7 - 62.2 0.35 - 0.4

Min. 22.9 70- 80 80-110 Max. 650
(78.7- 83.4) (3.5- 6.0)
Min. 303.6
70- 80 80-110 Max.650
(Min. 31.0)
70- 80 80-110
Min. 0.1
70- 80 Min. 80
(Min. 1.0)
62.4 - 66.2 0.35 - 0.6
Min. 21.1 70- 80 80- 110 Max. 650
(83.7 - 88.7) (3.0- 6.0)
Min. 303.6
70 - 80 80- 110 Max.650
(Min. 31.0)
70-80 80- 110
Min. 0.1 _
70-80 Min. 80
(Min. 1.0)
57.7 - 61.4 0.34 - 0.69
Min. 22.1 70-90 80- 120 Max.650
(77.4- 82.3) (3.5- 7.0)
Min. 306 _
70-90 80 - 120
(Min. 31.2)
70-90 80 - 120
Min. 0.1 -
70-90 Min. 80
(Min. 1.0)
95 SERIES
1
’ 2-oio-7

Test item
model machine I (fully equipped) @pm) (kg)
Flywheel horsepower 70 HP/Z,350 rpm 2,345 - 2,355 29.6 - 31.3

D31A, P, S, Q-18
Flywheel horsepower 70 HP/Z,350 rpm 2,345 - 2,355 29.6 - 31.2
D31 E, P, PL, Maximum torque 27.0 kgm/l,400 rpm 1,300 - 1,500 38.0 - 39.9
PLL, S, Q, AM,
SM-20(A) High idling speed 2,535 - 2,635 rpm 2,535 - 2,635 _
Low idling speed 700 - 750 rpm 700 - 750 -

D37A-2
D37P-2A

6D95L-1 D37E, P-5(A)
Flywheel horsepower 79 HP/2,100 rpm 2,095 - 2,105 38.9 - 41 .I
PC1 00-3 Maximum torque 30.5 kgm/1,400 rpm 1,300 - 1,500 Min. 43.4
PC1 OOL-3
Pc1oou-3 High idling speed 2,300 rpm 2,250 - 2,350 0
Maximum torque 31.5 kgm/1,400 rpm 1,300 - 1,500 Min. 43.4

PC1 20-3
Maximum torque 32 kgm/l,600 rpm 1,500 - 1,700 Min. 43.3

PWI 50-I
’2-20-8 95 SERIES
* Values are standardized under the following conditions: Air cleaner installed; alternator idling; and air compressor
(ifinstalled)open.
* Lubrication oil used: CLASS-CD SAE30.
Coolant Lubrication
oil Lubrication
oil Exhaust
output Torque Fuel consumption
temperature temperature pressure temperature ("C)
(HP) (kgm) (sec./100cc)
("C) ('C) (kg/cm?) (t=lntaketemp.- 20°C)
68.5 - 72.5 - Min.24.3 70- 80 90 -110 3.5 - 7.0 Max.650 + 3t
- 27.2- 28.6 - 70- 80 90 -110 _ Max.650 + 3t
0 0 _ 70-80 90-110 - -
0 0 - 70-80 Min. 80 Min. 1.0
68.5 - 72.5 - Min. 23.8 70- 90 90-110 3.5- 6.0 Max.650 + 3t
_ 27.2- 28.6 _ 70- 90 90-110 - _
0 0 - 70- 90 90-110 _ -
0 0 _ 70-90 Min. 90 Min.l.O _
78.1 - 82.8 - Min. 21.2 70-80 80-110 3.5- 7.0 Max.650 + 3t
_ 26.9- 28.5 _ 70-80 80 -110 - Max.650+ 3t
0 0 - 70- 80 80-110 _ _
0 0 _ 70- 80 Min.80 Min.l.5
78.1 - 82.8 _ Min. 20.7 80- 95 80-110 3.5 - 6.0 Max.600 + 3t
- 26.9 - 28.5 - 80- 95 80- 110 _ -
0 0 - 80- 95 80-110 _ _
0 0 - 80- 95 Min.80 Min. 1.0
80.5- 85.2 _ 19.8- 23.6 70- 80 80-110 3.5- 6.0 Max.650 + 3t
- Min. 31.1 28.9- 32.8 70- 80 80-110 - Max.650+ 3t
0 0 _ 70- 80 80-110 _ _
0 0 - 70- 80 Min. 80 Min.l.5 -
85.2 - 90.3 _ 18.6- 22.3 70- 80 80-110 3.5- 6.0 Max.650 + 3t
- Min. 31.1 28.9 - 32.8 70-80 80-110 _ Max.650 + 3t
0 0 _ 70-80 80-110 - -
0 0 _ 70-80 Min. 80 Min 1.5
84.2- 89.3 _ 17.3- 20.5 70-80 80-110 3.5 - 7.0 Max.650 + 3t
- 31.0 - 33.0 25.4- 28.8 70- 80 80-110 _ Max.650 + 3t
0 0 - 70-80 80-110 _ _
0 0 _ 70-80 Min.80 Min 1.5
95 SERIES
’2-020-9

Test item
model machine (fully equipped) frpm) (kg)
WAIOO-1 Maximum torque 29 kgm0.600 rpm 1,500 - 1,700 39.8 - 44.0

WRll-1
High idling speed 2,650 rpm
800 rpm (EngineNo. upto 25582)
Low idling speed 700 rpm (EngineNO. 25583 and up)
WAIOO-1 Maximum torque 32 kgm/l,600 rpm 1,500 - 1,700 44.0 - 48.1

(Engine No.
46799 and up) High idling speed 2,650 rpm 2,600 - 2,700 0
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower 85 HPI2.500 rpm 2,495 - 2,505 35.5 - 37.5

6D95L-1 GD313A-1
I I I I
Flywheel horsepower (50 Hz) 65.1 HP/l,500 rpm 1,495 - 1,505 44.0 - 46.6
(60 Hz) 74.9 HP/l ,800 rpm 1,795 - 1,805 42.6 - 45.2
EGGOB, BS-1
High idling speed (50 Hz) Max. 1,560 rpm Max. 1,560 0
Prime
(60 Hz) Max. 1,872 rpm Max. 1,872 0
Flywheel horsepower (50 Hz) 72 HP/l,500 rpm 1,495 - 1,505 48.6 - 51.4
(60 Hz) 82.8 HP/l ,800 rpm 1,795 - 1,805 46.9 - 49.7
EGGOB, BS-1
High idling speed (50 Hz) Max. 1,575 rpm Max. 1,575 0
Stand-by
(60 Hz) Max. 1,890 rpm Max. 1,890 0
12-0~0-10 95 SERIES
i
* Lubrication oil used: CLASS-CD SAE30.
Coolant Lubrication
oil Lubricarion
oil 1 Exhaust
Output Torque Fuel consumption
temperature temperature
U-W ikim) (sec.000 cc)
("C) ("C~
74.2 - 78.8 - Min. 22.8 70- 80 80-110
- 28.5- 31.5 - 70- 80 80-110
0 0 - 70- 80 80-110
0 0 _ 70-80 Min. 80
84.8 - 89.9 - Min. 19.2 70- 80 80-115
- 31.5 - 34.5 _ 70-80 80-115
0 0 - 70-80 80-115 - _
0 0 _ 70 - 80 Min.80
I
87.6 - 92.5 - Min. 19.5 70- 80 80-115
- -
0
31.2- 33.2
0 _
70-80
70- 80
80-115
80-115 -
I -
0 0 - 70- 80 Min. 80 Min. 1.5 _
65.1 - 68.9 Min. 27.4 70- 85 80-115

75.5 - 80.2 Min. 23.8 70- 80 80-115
0 - 70-885 80-115 - -
0 _ 70-85 80.- 115 - _
0 - 70-85 Min. 80
71.9- 76.0 Min. 24.8 70-85 80-115

84.4 - 88.4 Min. 21.6 70-85 80-115
0 _ 70- 85 80-115
0 - 70- 85 80-115 _ -
0 - 70- 85 Min. 80 Min.1.5 _
95 SERIES 12-0~0-11
./
Engine Specified value Engine speed Dynamometer

model (fully equipped) (rpm) N (kg)
451.8 - 479.2
(46.1 - 48.9)
Min. 551.7
Maximum torque 372.4 Nm (38 kgm)/1,400 rpm 1,300 - 1,500
PC150-3 (56.3)
I 1Low idling speed I 850 rpm 1 850 -900 1 -

504.7 - 534.1
(51.5 - 54.5)
Min. 262.5
Maximum torque 392 Nm (40 kgm)/1,400 rpm 1,300 - 1,500
PC1 50-5 (57.4)
I 1Low idling speed I 900 rpm I 900 - 950 I -
Flywheel horsepower 91.8 kW (123 HP)/2,050 rpm 1 2,045 - 2,055 17;;:; I ;;f;F
657.6 - 697.8
PC200-5 Maximum torque 475.3 Nm (48.5 kgmV1.500 1,400 - 1,600
(67.1 - 71.2)
BR200-1
Flywheel horsepower 99.3 kW (133.1 HP)/2,200 rpm 2,195 - 2,205 617.4 - 651.7
(63.0 - 66.5)
682 - 722.3
Maximum torque 490 Nm (50 kgmV1.600 rpm 1,500 - 1,800
PC200-6 (69.6 - 73.7)
975 - 1,025 rpm 975 - 1,025
)
S6D95L-1
73.9 kW (99 HP)/1,900 1,895 - 1,905 515.5 - 546.8
rpm
(52.6 - 55.8)
Min. 583.1
411.6 Nm (42 kgm)/1,400 rpm 1,300 - 1,500
(59.5)
2,100 rpm 2,050 - 2,150
1Low idling speed I 850 rpm 850 - 900 I -

529.2 - 559.6
Flywheel horsepower 80.9 kW (108.5 HP)/2,100 rpn 2,095 - 2,105
(54.0 - 57.1)
PWIOO-3 Min. 589
Maximum torque 411.6 Nm (42 kgm)/1,400 rpm 1,300 - 1,500
(Engine No. (60.1)
36830 and up) High idling speed 2,400 rpm 2,350 - 2,450
Flywheel horsepower 110.4 kW (148 HP)/3,000 rpm 2,995 - 3,005 474.3 - 502.7
(48.4 - 51.3)
594.9 - 629.2
-
LW80-1 Maximum torque 435 Nm (44.4 kgm)/1,800 rpm 1,700 1,900 (60.7 - 64.2)
’*-OiO-’
* 95 SERIES
+ The values given for the output and torque are with the fan removed, so they differ from those of the specification.
Ir Dynamometers are given for the case of the arm length is 716 mm.
Ir Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.

Outupt Torque :uelconsumption
temperature temperature pressure temperature ("0
kW (HP) Nm (kgm) (sec./100cc)
("C1 ("C) MPa (kg/cm21 (t=lntaketemp.-20T)
74.6 - 79.1 0.3 - 0.7
Min. 17.0 70-80 80-110 Max.650 + 3t
(100-106) (3.0- 7.0)
394.9
70-80 80-110 Max.650 + 3t
(40.3)
70-80 80-110
Min. 0.15
70-80 Min. 80
(1.5)
75.8 - 80.2 0.35 - 0.7
Min. 17.2 70 -80 80-110 (3.5- 7.0) Max. 650 + 3t
(101.6 - 107.5)
402.8
70-80 80-110 Max. 650 + 3t
(41.1)
70-80 80-110
70-80 Min.80
89.4 - 94.5
Min. 14.7 70-80 80-110
(119.9 - 126.7)
470 - 499.6
70-80 80-110 1 Max.650 + 3t
(48.0- 51.0)
70-80 80-110
70-80 Min. 80
101.9 - 107.7
Min. 12.5 70-80 go- 110
(136.6 - 144.4)
488 -517.4
70-80 go- 110
(49.8- 52.8)
70-80 90-110
Min. 0.1
70-80 Min. 80
(I.01
73.6 - 78 0.35 - 0.7
17.2 - 18.3 70-80 80- 110 Max.650 + 3t
(98.6- 104.5) (3.5- 7.0)
417.5
21.4 - 22.7 70-80 80- 110 Max.650 + 3t
(42.6)
70-80 80- 110
83.4 - 88.3
(111.8- 118.3)
Min. 15.5
70-80
70-80
Min. 80
80 - 110
-i&j-+
Min. 421.4
70-80 80-110 Max. 650 + 3t
(43.0)
70-80 80-110
70-80 Min. 80
106.7- 113.2
Min. 10.2 70-90 go- 110
(143- 151.8)
425-450.8 0.35 - 0.7
(43.4 - 46.0) 70-90 90 - 110 Max. 650 + 3t
(3.5- 7.0)
70-85 90 - 110
Min. 0.1
70-85 Min. 80
(1.0)
95 SERIES
’2-o%-’
3

Test item
model machine (fully equipped) hx-n) N (kg)
(485.1 514.5)
WA150-1 - 485.1 - 514.5
Maximum torque 352.8 (36 kgm)/1,600 rpm 1,500 1,700
(Engine No. (49.5 - 52.5)
up to 47624) High idling speed 2,650 rpm 2,600 - 2,700
Low idling speed 800 rpm (Engine No. up to 23242) 800 - 850
700 rpm (EngineNo. 23243and up) 675 - 725
Flywheel horsepower 80.9 kW (108.5 HP)/2400 rpm 2,395 - 2,405 456.7 - 482.2
(46.6 49.2)
I I
WAl50-1 Maximum torque
392 (40 kgm)/1,600 rpm I 1,500 - 1,700 I- 538 - 570.4
(54.9 - 58.2)
(Engine No.
47625 and up) High idling speed 2600 - 2700 rpm 2,600 - 2,700

(46.6 49.4)
Ffywheef horsepower (50 Hz) 64 kW (85.8 HP)/1,500 rpm 1,495 - 1,505 556- 589(56.7
- 60.1)
(60 Hz) 74 kW (99.6 HP)/1,800 rpm 1,795 1,805 541 574(55.2 58.61
EG856, BS-1 (50 Hz) Max. 1,560 rpm Max. 1,560

S6D95L-1 High idling speed
Prime (60 Hz) Max. 1,872 rpm Max. 1,872
1 Low idling speed I 800 rpm 1 800 - 850 1 -

Ffywhee’ horsepower (50 Hz) 71.4 kW (95.7 HP)/1,500 rpm 1,495 - 1,505 621.3
-- 658.6
(63.4
-- 67.21
(60 Hz) 83.1 kW (111.4 HP)/1,800 rpm 1,795 1,805 604.7641(61.7 65.4)
EG85B, BS-1 (50 Hz) Max. 1,575 rpm Max. 1,575

Stand-by High idling speed (60 Hz) Max. 1,890 rpm Max. 1,890
Low idling speed I 800 rpm 800 - 850 I -

Fh’whee’ horsepower (50 Hz) 64 kW (85.8 HP)/1,500 rpm 1,495 - 1,505 555.7
- - 589156.7
- 60.1)
(60 Hz) 74.3 kW (99.6 HP)/1,800 rpm 1,795 1,805 541 574.3(55.2 58.61
(50 Hz) Max. 1,560 rpm Max. 1,560

(At rated output) High idling speed (60 Hz) Max. 1,872 rpm Max. 1,872
F’ywhee’ horsepower (50 Hz) 71.3 kW (95.6 HP)/1,500 rpm 1,495 - 1,505 621-
- 659(63.4- 67.2)
(60 Hz) 83.1 kW (111 HP)/1,800 rpm 1,795 1,805 605 641(61.7 65.4)
DCA85
QAS85 (50 Hz) Max. 1,575 rpm Max. 1,575
High idling speed Max. 1,890
(At rated outupt) (60 Hz) Max. 1,890 rpm
’2-020-’
4 95 SERIES
t Values are standardized under the following conditions: Air cleaner installed: alternator idling; and air compressor
t Dynamometers are given for the case of the arm length is 716 mm.
Outupt Coolant Lubrication oil Lubrication oil Exhaust

Torque :uel consumption
kW (HP) temperature temperature pressure temperature (“0
Nm (kgm) (sec./l00 cc)
(“C) 1°C) MPa (kg/cm*) t=lntaketemp. -20°C)
71.4 - 75.7 0.35 IO.7
17.4 - 18.6 70 - 80 80 - 110 Max. 650 + 3t
(95.7 - 101.5) (3.5 - 7.0)
347 - 368.5
21.5 - 22.9 70 - 80 80 - 110 Max. 650 + 3t
(35.4 - 37.6)
70 - 80 80 - 110
Min. 0.1
70 - 80 Min. 80
(1.0)
82.1 - 87.0 0.35 - 0.7
Min. 15.3 70-80 90 - 110 Max. 650 + 3t
(110.1 - 116.6) (3.5- 7.0)
385.1 - 408.7
70-80 90 - 110
(39.3 - 41.7)
70-80 90 - 110
70-80
Min. 0.1
Min. 80
(1.0)
85.7 - 90.9 0.35 - 0.7
11.2 - 14.0 70-80 80 - 110 Max. 650 + 3t
(114.9 - 121.8) (3.5 - 7.0)
407.7 - 434.1
16.7 - 21.0 70-80 80- 110 Max. 650 + 3t
(41.6- 44.3)
Min. 0.1
Min. 80
(1.0)
62.5
- 66.2(83.8
- 88.8 Min. 20.8 70-85 80 - 115 I.3
- 0.55(3.0- 5.5 Max. 700 + 3t
73.0
- 77.5
(97.9
- 103.9 Min. 17.9 70-85 80 - 115 I.3
- 0.55(3.0- 5.5 Max. 700 + 3t
70-85 80 - 115
70-85 80 - 115 _
Min. 0.15
70-85 Min. 80
(1.5)
70.0- 74.2(93.8
- 99.4 Min. 18.7 70-85 80 - 115 I.3 - 0.55 (3.0 - 5.5 Max. 700 + 3t
81.6
- 86.5(109.4- llf Min. 16.0 70-85 80 - 115 I.3 - 0.55 (3.0 - 5.5 Max. 700 + 3t
70-85 80 - 115
70-85 80 - 115
70-85 Min. 80
62.5
- 66.2(83.8
- 88.8 Min. 20.8 70-85 80-115 1.3
- 0.55(3.0- 5.5 Max. 700 + 3t
73.1
- 77.5
(97.9
- 103.9 Min. 17.9 70-85 80- 115 I.3
- 0.55(3.0- 5.5 Max. 700 + 3t
70-85 80 - 115
70-85 80-115
Min. 0.15
70-85 Min. 80
(1.5)
70.0- 74.2(93.8
- 33.4 Min. 18.7 70-85 80-115 1.3
- 0.55(3.0- 5.5 Max. 700 + 3t
61.6
- 86.61109.4
- 116.1 Min. 16.0 70-85 80-115 1.3
- 0.55(3.0- 5.5 Max. 700 + 3t
70-85 80-115
70-85 80 - 115
70-85 Min. 80
95 SERIES 12-030-15
Applicable Specified value Engine speed lynamometer

Test item
machine (fully equipped) (rpm) N (kg)
32.0 kW (110 HP)/2,400 rpr 456 - 484

Flywheel horsepower 2,395 - 2,405
(Net) (46.5 - 49.4)
417 Nm (42.5 kgm)/1,600 rpn 595 - 672
Maximum torque 1,500 - 1,700
(Net) (60.7 - 68.5)
VA1 80-3
37.0 kW (130 HP)/2,400 rpr 521 - 548

(Net) (53.1 - 55.9)
Maximum torque
441 Nm (45.0 kgm)/1,600 wn 1,500 - 1,700
610 - 644
S6D95L-1 VA250-3 (Net) (62.2 - 65.7)
High idling speed 2550 - 2,650 rpm 2,550 - 2,650
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
114 kW (153 HP)/2,200 rpn 648 - 670

‘C220-5 (Net) (66.1 - 70.4)
With air to air 713 - 757
527 Nm (53.7 kgmU1.500 rprr
aftercooler) Maximum torque 1,400 - 1,600
(Net) 172.7 - 77.2)
!R300-1
High idling speed 2,355 - 2,475 rpm
With air to air
aftercooler)
Low idling speed 925 - 975 rpm
118 kW (158 HPV2.300 rpn 661 - 703

(Net) (67.4 - 71.7)
‘C220-6 554 Nm (56.5 kgm)/1,600 rpn 750 - 797

Maximum torque 1,500 - 1,700
With air to air (Net) (76.5 - 81.3)
aftercooler) High idling speed 2,470 - 2,590 rpm 2,470 - 2,590
Low idling speed 975 - 1,025 rpm 975 - 1,025

SA6D95L-1
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Note: The SA6D95L engine for the PC220-5 and PC220-6 are equipped with an air-cooled aftercooler,
which is installed at the front of the radiator. When carrying out an outupt performance test on
the engine as an individual part, install the radiator and air-cooled aftercooler to a stand in the
same way as when carrying out a test with the engine installed on the machine, and run with
the fan equipped.
12-030- 16 95 SERIES
Sr The values given for the output and torque are with the fan removed, so they differ from those of the specification.
Ir Dynamometers are given for the case of the arm length is 716 mm.
li Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
* Lubrication oil used: CLASS-CD SAESO.
Flywheel Coolant Lubrication oil Lubrication oil Exhaust

Torque :uel consumption
horsepower temperature temperature pressure temp(er$ure)
Nm (kgm) (sec./100 cc) 0
kW (HP) (“C) (“C) kPa (kg/cm?
82.0 - 87.1 0.35 - 0.71
Min. 14.2 70 - 80 90 - 110 Max. 650
(110 - 117) (3.5 - 7.0)
411 - 436 0.35 - 0.71
70 - 80 90 - 110
(41.9 - 44.5) (3.5 - 7.0)
70 - 80 90 - 110
Min. 0.1
70 - 80 Min. 80
(Min. 1.0)
93.6 - 98.8 0.35 - 0.71
Min. 12.8 82 - 95 90 - 120 Max. 650
(125 - 132) (3.5 - 7.0)
373 - 392
82 - 95 90 - 120 Max. 650
(38.0 - 40.0)
82 - 95 90 - 120
Min. 0.1
82 - 95 90 - 120
(Min. 1.0)
107 - 114 0.35 - 0.60

Min. 11.6 70 - 80 80- 110 Max. 650
(144 - 153) (3.5 - 6.0)
511 - 542
107 - 114 70 - 80 80- 110 Max. 650
(52.1 - 55.3)
70 - 80 80 - 110
Min. 0.1
70 - 80 Min. 80
(Min. 1.0)
114 - 121 0.35 - 0.70
Min. 11.0 70 - 80 90 - 110 Max. 650
(153 - 163) (3.5 - 7.0)
537 - 570
70 - 80 90 - 110 Max. 650
(54.8 - 58.2)
70 - 80 90 - 110
Min. 80
70 - 80 90 - 110
95 SERIES
’*-OF’
7 1
Engine speed Dynamomete

Test item Specified value
(rpm) (N {kg})
Flywheel horsepower . 118 kW {I58 HPY3.000 rpm 2,995 - 3,005 487 - 520 149.7 - 53.0) (Gross)
(Net) 447 - 507 148.3 - 51.71 (Net)
WING100 Maximum torque 57 Nm i46.6 kgm}/1,800 rpm 1,700 - 1,900 624 - 672 (63.6 - 68.5) (Gross)
(LWIOO-1, (Net) 619 - 668 (63.1 - 68.1) (Net)
LWlOOM-I)
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower
Maximum toraue
SAA6D95LE-1
High idling speed
Low idling speed I I I

Long time
flywheel horsepower
Normal
flywheel horsepower
High idling speed
Low idling speed
Rated
flywheel horsepower
Maximum
flywheel horsepower
High idling speed

I
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idlina speed
’2-oio-’
* 95 SERIES
Sr Values are standardized under the following conditions: Air cleaner installed; alternator idling; and air comoressor
It Dynamometers are given for the case of the arm length is 716 mm.
t Lubrication oil used: CLASS-CD SAE30.
Coolant Lubrication oil

Flywheel horsepower Torque :uel consumption Lubrication oil Exhaust
temperature pressure
(kW {HP}) (Nm Ikgm}) (sec./lOOcc) (“C) tmperature (“C) (kPa {kg/cm% emperature (“0
110 - 117 1147- 157) (Gross) - Min. 10.5 82 - 95 90 - 120 340 - 590 Max. 700
107 - 114 1143 - 153) (Net) 13.5 - 6.0)
446- 481145.5
- 43.11
IGros 82 - 95 90 - 120 Max. 650
443-47914% WlNel
a2 - 95 340 - 590
90 - 120
{3.5 - 6.0)
82 - 95 90 - 120
95 SERIES 12-030-19
@
TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST
TESTING AND ADJUSTING TOOL LIST
Part No. Remarks
Digital reading: L: 60 - 2,000 rpm

799-203-8001
H: 60 - 19,999 rpm
799-203-8000
6210-81-4111
1.100 - 1.300
Battery coolant tester 795-500-1001
-5 - -50°C
799-101-1500 -99.9 - 1,299”C
0 - 2 MPa (0 - 20 kg/cm?
0 - 4.9 MPa (0 - 50 kg/cm?
Engine pressure
799-203-2000 0 - 1,000 mmHg
0 - 500 mmH,O
-100 - 0 mmH,O
795-502-1205
- 795-502-1380
Compression gauge kii
(Direct injection 1 0 - 6.9 MPa (0 - 70 kg/cm?
l 795-502-1370
(Swirl chamber)
799-201-1504 0 - 500 mmH,O
795-114-1370 0.35, 0.50 mm
Dirtiness 0 - 70% with standard color

799-201-9000
(Dirtiness % x l/IO = Bosch scale)
Provided with 0.1 and 0.2 water

799-201-6000
content standard sample
Commercially
Nozzle holder 0 - 29.4 MPa (0 - 300 kg/cm?
available
,7 Fuel injection nozzle spray
condition
18 Coolant quality Water quality tester 799-202-7001 PH, nitrite ion concentration
19 Pressure valve function

Radiator cap tester 799-202-9001 0 - 0.2 MPa (0 - 2 kg/cm*)
20 Leakage in cooling system
21 Radiator blockage Anemometer 799-202-2001 1 - 40 m/s
22 Engine cranking Cranking kit 795-61 O-l000 Engine with DC 24 V starting motor
95 SERIES
’2-oio-21
TESTING AND ADJUSTING TESTING AND ADJUSTING DATA
TESTING AND ADJUSTING DATA
Engine model 3D95SW-1
PC40-5
Applicable machine model PC5OUU-1
PC40-6
T
Standard Permissible Standard Permissible
Item Condition, etc. Unit
value value value value
High idling speed rpm !,750 - 2,850 ,750 - 2,850 !,650 - 2,750 1,650 - 2,750
Engine speed
Low idling speed rpm 950 - 1,000 950 - 1,000 950 - 1,000 950 - 1,000
0°C (without starting aid) rpm Min. 150 Min. 150

Necessary
starting speed
-20°C (with starting aid) rpm Min. 100 Min. 100
Intake resistance All speed mmH,C Max. 300 762 Max. 300 762
intake pressure At rated output mmHg
Exhaust pressure
At rated output mmHg
(Turbine inlet pres.)
Exhaust temperature All speed

“C Max. 650 700 Max. 650 700
(Turbine inlet temp.) (Intake air temp.: 20°C)
Quick acceleration
Max. 4.0 6.0 Max. 4.0 6.0
(Low idling + High idling)
Bosch
Exhaust gas color At rated output Max. 1.5 2.5 Max. 1.5 2.5
scale
At high idling
Intake valve mm 0.35

Valve clearance
(When engine is hot
or cold)
Exhaust valve mm
Compression pressure Oil temperature: 40 - 60°C MPa Min. 2.9 2.1 Min. 2.9
(SAE30) (Engine speed: 320 - 360 rpm (kg/cm’ (Min. 30) (21) (Min. 30)
Blow-by pressure At rated output

mmH,C Max. 100 200 Max. 100
(SAE30) Water temperature: Min. 70°C
MPa 0.3 - 0.6 0.3 - 0.6

At rated output (SAE 30)
(kg/cm’ (3.0 - 6.0) (3.0 - 6.0)
MPa 0.3 - 0.55 0.3 - 0.55
Oil pressure At rated output (SAE IOW)
(kg/cm’ (3.0 - 5.5) (3.0 - 5.5)
(Oil temperature:
MPa Min. 0.1 0.07 Min. 0.1
Min. 80°C) At low idling (SAE 30)
(kg/cm’ (Min. 1.0) (0.7) (Min. 1.0)
MPa Min. 0.08 Min. 0.08
At low idling (SAE 1OW)
(kg/cm’ (Min. 0.8) (Min. 0.8)
Oil temperature All speed (oil in oil pan) “C 80 - 110 80 - 110
At continuous rated output

Oil consumption ratic % Max. 0.5 1.0 Max. 0.5
(Ratio to fuel consumption)
MPa
Fuel injection pressun Nozzle tester 11.8+‘.3(120”3
+0.5 5 10.1 (103) 11.8+'~3(120+'3
+0.5 5
10.1 (103)
(kg/cm; l I
Fuel injection timing B.T.D.C. degree 18* 1 18 + 1 18 + 1 18 + 1
Opening pressure kPa 88.3 ? 14.7 88.3 + 14.7 88.3 + 14.7 88.3 + 14.7
Radiator pressure valve
(Differential pressure) (kg/cm’ (0.9 f 0.15) (0.9 + 0.15) (0.9 + 0.15) (0.9 + 0.15)
Fan speed At rated engine speed rpm 2,390 - 2,53t !,390 - 2,53( 2,083 - 2,21’ 2,083 - 2,211
Fan belt tension Deflects when pushed with

mm 8 6- 10 8 6- 10
(Alternator to fan pulley a force of 6 kg
Ir 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.
12-030-22 95 SERIES
@
3D95S-W-1 4D95S-W-1
EC35Z. ZS-2, D20A. P, Q, PL, PLL-6 EC50Z, ZS-5,

EC35ZSB-2 D21A, P, 0, PL-6 EC50ZSB-5
I
Standard Permissible Standard Permissible Standard Permissible Standard Permissible
I
value value value value value value value value
2,700 - 2,900 2,700 - 2,900 2,530 - 2,630 2,530 - 2,630
650 - 750 650 - 750 800 - 850 800 - 850 1,450 - 1,550 1,450 - 1,550
Min. 150 Min. 150 Min. 150
Min.
Max.
100
300 762
Min.
Max.
100
300 762
Min.
Max.
100
300 -e-j--
_
Max. 650 700 Max. 700 750 Max. 700 750
Max. 6 8 Max. 3.5 5.5 Max. 3.5 5.5
Max. 2.5 3.5 Max. 3.0 4.0 Max. 3.0 4.0
1.0 2.0 Max. 3.0
0.35 0.35 0.35 -+--+-
0.50 0.50 0.50

Min.
(Min.
2.9
30)
2.1
(21)
Min.
(Min.
2.9
30)
2.1
(21)
Min.
(Min.
2.9
30) -iid---
Max. 100 200 Max. 50 100 Max. 50
0.3 - 0.6 0.25 0.35 - 0.6 0.25 0.35 - 0.55

(3.0 - 6.0) (2.5) (3.5 - 6.0) (2.5) (3.5 - 5.5)
0.3 - 0.55 0.2 0.35 - 0.55 0.25 0.25 - 0.5
(3.0 - 5.5) (2.1) (3.5 - 5.5) (2.5) (2.5 - 5.0)
Min. 0.1 0.07 Min 0.1 0.07 Min. 0.15
(Min. 1.0) (0.7) (Min. 1.0) (0.7) (Min. 1.5)
Min 0.08 0.07 Min. 0.08 0.07 Min 0.12
(Min. 0.8) (0.7) (Min. 0.8) (0.7) (Min. 1.2)
=I=
80 - 110 120 SO- 110 120 SO- 110 120
Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0
11.8:;::(120:‘:) 10.1 (103) 11.8:;:;(120:';) 10.1 (103) 10.1 (103)
18 * 1 18 2 1 16 + 1 16* 1 162 1 16+ 1
49 2 9.8 49 t 9.8 88.3 k 14.7 88.3 k 14.7 88.3 k 14.7

(0.5 * 0.1) (0.5 +. 0.1) (0.9 t 0.15) (0.9 t 0.15) (0.9 + 0.15)
3,080 (502)
2,750 2,750 2,620 - 2,750 2,620 - 2,750
2.370 (5OZS)
8 6- 10 8 6- 10 8 6- 10
95 SERIES 12-030-23
@
Engine model
r 4D95S-1
Classifi.
Item
Condition, etc. Unit

120AG, P, PG, PL, PLL-7(A)
121A. AG, PG. S, QG-7(A)
Standard I‘ermissible
r Standard
WA50-1
Permissible
cation value value value value
High idling speed wm !,530 - 2,63C 12 ,530 - 2,630 !,650 - 2,75( ‘,650 - 2,750
8 Engine speed
: Low idling speed rpm 800 - 850 800 - 850 800 - 850 800 - 850
E
b
‘t 0°C (without starting aid) rpm Min. 150 Min. 150
Necessary
a”
starting speed
-20°C (with starting aid) vm Min. 100 Min. 100
Intake resistance All speed mmH,O Max. 380 762 Max. 380 762
Intake pressure At rated output mmHg
Exhaust pressure

“C Max. 650 700 Max. 650 700
Quick acceleration
Max. 4.0 6.0 Max. 4.0 6.0
Bosch
scale
At high idling Max. 1.5 2.5 Max. 1.5 2.5
Intake valve mm 0.35 0.35

Valve clearance
(When engine is hot
or cold)
Exhaust valve mm 0.50 0.50
F;A;prrion pressure Oil temperature: 40 - 60°C MPa Min. 3.1 2.2 Min. 3.1
(Engine speed: 320 - 360 rpm) Ikg/cm2: (Min. 32) (22) (Min. 32)

nmH,C Max. 50 Max. 50
fSAE30) Water temoerature: Min. 70°C
MPa 0.35 - 0.6 0.25 0.35 - 0.6 0.25

kg/cm* (3.5 - 6.0) (2.5) (3.5 - 6.0) (2.5)
MPa 0.3 - 0.6 0.21 0.3 - 0.6 0.21
kg/cm2 (3.0 - 6.0) (2.1) (3.0 - 6.0) (2.1)
(Oil temperature:
MPa Min. 0.1 0.07 Min. 0.1 0.07
.kg/cm2 (Min. 1.0) (0.7) (Min. 1.0) (0.7)
MPa Min. 0.08 0.07 Min. 0.08 0.07
At low idling (SAE 1OW)
:kg/cm* (Min. 0.8) (0.7) (Min. 0.8) (0.7)
Oil temperature All speed (oil in oil pan) “C 80- 110 120 80 - 100 120

Oil consumption ratio % Max. 0.5 1.0 Max. 0.5 1.0
MPa
Fuel injection pressure Nozzle tester !2.1:::(225:‘; 2.1+‘.5(225+‘5
r0.5 +5 18.4 (188)
:kg/cm2
Fuel injection timing B.T.D.C. degree 14* 1 14* 1 14% 1 14* 1
Opening pressure kPa 88.3 * 9.8 88.3 + 9.8 88.3 + 9.8 88.3 + 9.8
Radiator pressure valve (0.9 * 0.1)
(Differential pressure) [kg/cm2 (0.9 * 0.1) (0.9 * 0.1) (0.9 * 0.1)
Fan speed At rated engine speed rpm 2,140 - 2,27( 1,140 - 2,27C 2,425 - 2,57! !,425 - 2,575

mm 8 6- 10 7-8 7-8
(Alternator to fan pulley a force of 6 ka
* The values given in the Testing and Adjusting Data are NOT for adjustment of the output.
12-030-24 95 SERIES
@
4D95L-W-1 4D95L-1
Standard
WA40-1
Permissible Standard
WA70-1
Permissible
EG336, BS-1
Standard Permissible
T Standard
PC60, 6OL-3
PC6OU-3
Permissible
lax.l,560(50Hz
2,350 - 2,450 2,350 - 2,450 2,320 - 2,420 2,320 - 2,420 2,590 - 2,690 2,590 - 2,690 2,590 - 2,690
lax.l,872(60Hz
800 - 850 800- 850 800 - 850 800 - 850 800- 850 850- 900 850 -900 850-900
Min. 150 Min. 150 Min. 150 Min. 150
Min. 100 Min. 100 Min. 100 Min. 100
Max.380 762 Max.300 762 Max.300 762 Max.380 762
Max.650 700 Max. 650 700 Max.650 700 Max. 650 700
Max. 4.5 6.5 Max. 4.0 6.0 Max. 4.5 6.5
Max. 3.0 4.0 Max. 3.0 4.0 Max. 2.0 3.0 Max. 3.0 4.0
Max. 2.5 3.5 Max. 2.5 3.5 Max. 1.0 2.0
0.35 0.35 0.35
0.50 0.50 0.50
Min. 2.9 Min. 2.9 2.1 Min. 2.9 2.1 Min. 2.9 2.1
(Min. 30) (Min. 30) (21) (Min. 30) (21) (Min. 30) (21)
Max.50 Max. 50 100 Max.50 100 Max. 50 100
0.35 - 0.6 0.25 0.3 - 0.6 0.21 0.3 - 0.55 0.21 0.35 - 0.6 0.25
(3.5- 6.0) (2.5) (3.0- 6.0) (2.1) (3.0- 5.5) (2.1) (3.5- 6.0) (2.5)
0.3 - 0.55 0.21 0.3 - 0.55 0.21 0.25 - 0.5 0.18 0.3 - 0.55 0.21
(3.0- 5.5) (2.1) (3.0- 5.5) (2.1) (2.5- 5.0) (1.8) (3.0- 5.5) (2.1)
Min. 0.1 0.07 Min. 0.1 0.07 Min. 0.15 0.07 Min. 0.1 0.07
(Min. 1.0) (0.7) (Min. 1.0) (0.7) (Min. 1.5) (0.7) (Min. 1.0) (0.7)
Min. 0.08 0.07 Min. 0.08 0.07 Min. 0.12 0.07 Min. 0.08 0.07
(Min. 0.8) (0.7) (Min. 0.8) (0.7) (Min. 1.2) (0.7) (Min. 0.8) (0.7)
80- 110 120 80- 110 80- 110 80- 110
Max. 0.5 Max. 0.5 Max. 0.5 Max. 0.5
11.8+'.3
(120+'3)
+0.5 +5 11.8+=
+05 (120+'?
+5 1.8+= (120:';)
+0.5 19.6+'.5
(200"'
r0.5 +5 16.7 (170)
14tl 1421 16 + 1 1621
88.3 + 9.8 88.3 + 9.8 88.3 -c9.8 88.3 k 9.8 88.3 k 14.7 88.3 -c 14.7 88.3 2 9.8 88.3 2 9.8
(0.9 * 0.1) (0.9 f 0.1) (0.9 * 0.1) (0.9 * 0.1) (0.9 + 0.15) (0.9 * 0.15) (0.9 -c0.1) (0.9 * 0.1)
,610-1,690(50Hi1,610-1,690(50H.
2,150 - 2,250 2,150 - 2,250 2,360 - 2,480 2,360 - 2.48C 2,350 - 2,450 2,350 - 2,450
,930-2,030(60Hi1,930-2,030(60H
8 6-10 12.5 8-12 8 6-10
95 SERIES 12-030-25
@
I

PC60, 6OL-5
PC6OU5 T PC60-6
PC70-6
Permissible
Classifi Standard Permissible Standard
High idling speed rpm 1,250 - 2,35( ,250 - 2,351 ,250 - 2,35C !,250 - 2,350
Engine speed
Low idling speed rpm 900 - 950 900 - 950 950 - 1.000 950 - 1,000

Necessary
starting speed
Intake pressure At rated output mmHg _
Exhaust pressure

“C Max. 650 700 Max. 650 700
(Turbine inlet temp.) (Intake air temo.: 20°C)
Quick acceleration
Max. 4.5 6.5 Max. 4.0 6.0
Bosch
scale

Valve clearance
LWzz;engine is hot
CoA;proyion pressure Oil temperature: 40 - 60°C MPa Min. 2.9 2.1 Min. 2.9 2.1
(Engine speed: 320 - 360 rpm: (kg/cm2 1 (Min. 30) (21) (Min. 30) (21)

mmH,C 1 Max. 50 100 Max. 50
(SAE30) Water temoerature: Min. 70°C
MPa 0.3 - 0.6 0.21 0.35 - 0.6 0.25

(kg/cm2 1 (3.0 - 6.0) (2.1) (3.5 - 6.0) (2.5)
MPa 0.3 - 0.55 0.21 0.3 - 0.6 0.21
[kg/cm* ) (3.0 - 5.5) (2.1) (3.0 - 6.0) (2.1)
(Oil temperature:
MPa Min. 0.1 0.07 Min. 0.1 0.07
lkglcmz ) (Min. 1.0) (0.7) (Min. 1.0) (0.7)
MPa Min. 0.08 0.07 Min. 0.08 0.07
At low idling (SAE IOW)
lkglcm’ ) (Min. 0.8) (0.7) (Min. 0.8) (0.7)
Oil temperature All speed (oil in oil pan) “C 80- 110 120 80- 110 120
At continuous rated output 1.0

Oil consumption ratio % Max. 0.5 1.0 Max. 0.5
MPa
Fuel injection pressure Nozzle tester 19.6+'.5(200+" 16.7 (170) 9.6+'?200+'5
+0.5 + 5
16.7 (170)
(kg/cm’ ‘) , +0.5 +
Fuel injection timing B.T.D.C. degree 16? 1 16 + 1 16? 1 16= 1
Opening pressure kPa 68.6 + 9.8 68.6 ? 9.8 88.3 ? 9.8 88.3 =’ 9.8
(Differential pressure) (kg/cm’ ‘) (0.7 * 0.1) (0.7 f 0.1) (0.9 -c 0.1) (0.9 + 0.1)
Fan speed At rated engine speed rpm 1,843 - 1,93 1,843 - I,93 1,840 - 1,94( 1,840 - 1,940
Fan belt tension Deflects when pushed with 7 - 10

mm 8 6- 10 8
(Alternator to fan oullev a force of 6 ka
Ir The values given in the Testing and Adjusting Data are NOT for adjustment of the output.
12-030-26 95 SERIES
a4
4D95L-1
Standard
PC60-7
PC70-7
Permissible
r PC75UU-1
PC75UU-2
Permissible
r
Standard
PCSO-3
Permissible
value value st~~lduaerd value value value value value
2,050 - 2,150 2,050 - 2,150 2,050 - 2,150 2,050 - 2,150 ?,050 - 2,150 2,050 - 2,150 E.500 - 2,600 2,500 - 2,600
950- 1,000 950- 1.000 950 - 1,000 950 - 1,000 1,000 - 1,050 1,000 - 1,050 850- 900 850 - 900
Min. 150 Min. 150 Min. 150 Min. 150
Min. 100 Min. 100 Min. 100 Min. 100
Max.300 762 Max. 300 762 Max.300 762 Max. 300 762
Max.650 700 Max.650 700 Max.650 700 Max.650 700
Max. 4.0 6.0 Max. 5.0 Max. 5.0 7.0 Max. 5.0 7.0
Max. 2.0 3.0 Max. 2.5 Max. 2.5 3.5 Max. 2.5 3.5
Max. 1.0 2.0 Max. 2.0 Max. 2.0 3.0 Max. 5.5 6.5
0.35 0.35 0.35 0.35
0.50 0.50 0.50 0.50 _

Min. 2.9 2.1 Min. 2.9 2.1 Min. 2.9 2.1 Min. 2.9 2.1
(Min. 30) (21) (Min. 30) (21) (Min. 30) (21) (Min. 30) (21)
Max. 50 Max. 50 Max.50 100 Max. 50 100
0.35 - 0.6 0.25 0.3 - 0.7 0.21 0.3 - 0.7 0.21 0.3 - 0.6 0.21
(3.5- 6.0) (2.5) (3.0- 7.0) (2.1) (3.0- 7.0) (2.1) (3.0- 6.0) (2.1)
0.3 - 0.6 0.21 0.3 - 0.65 0.21 0.25 - 0.65 0.18 0.3 - 0.55 0.21
(3.0- 6.0) (2.1) (3.0- 6.5) (2.1) (2.5- 6.5) (1.8) (3.0- 5.5) (2.1)
Min. 0.1 0.07 Min. 0.1 0.07 Min. 0.1 0.07 Min. 0.1 0.07
(Min. 1.0) (0.7) (Min. 1.0) (0.7) (Min. 1.0) (0.7) (Min. 1.0) (0.7)
Min. 0.08 0.07 Min. 0.08 0.07 Min. 0.08 0.07 Min. 0.08 0.07
(Min. 0.8) (0.7) (Min. 0.8) (0.7) (Min. 0.8) (0.7) (Min. 0.8) (0.7)
SO- 110 120 80 - 110 120 80 - 120 120 SO- 110 120
Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.o
19.6+'.5(200+'5)
*cl.5 f 5 16.7 (170) 19.6:;:;(200:':) 16.7 (170) 19.6+'-5(200"5)
r0.5 + 5 16.7 (170) 19.6:;::(200:':) 16.7 (170)
16kl 1621 1651 16 + 1 14*1 14 + 1 16kl 16 + 1
88.3 k 9.8 88.3 k 9.8 68.6 f 9.8 68.6 + 9.8 68.6 + 9.8 68.6 k 9.8 68.6 k 9.8 68.6 + 9.8
(0.9 + 0.1) (0.9+ 0.1) (0.7 t 0.1) (0.7 * 0.1) (0.7 * 0.1) (0.7 t 0.1) (0.7 + 0.1) (0.7 + 0.1)
1,840 - 1,960 1,840 - 1,960 1,660 - 1,760 1,660 - 1,76( 1,660 - 1,760 1,660 - 1,760 2,110 - 2,210 2,110 - 2,210
8 7 - 10 8 6-10 8 6-10 8
1 6-10
95 SERIES
’2-oio-27
Applicable machine model PC90-1 PW60-3

f
Classifi Standard Permissible Standard Permissible
High idling speed rpm !,425 - 2,525 ,425 - 2,525 $600 - 2,700 I i !,600 - 2,700
Engine speed
Low idling speed rpm 950 - 1,000 900 - 950 900 - 950

Necessary
starting speed
Intake pressure At rated output mmHg
Exhaust pressure

“C Max. 650 700 Max. 650 700
Quick acceleration
Max. 4.0 6.0 Max. 5.0 7.0
(Low idling --f High idling)
Bosch
Exhaust gas color At rated output Max. 2.5 Max. 2.5 3.5
scale
At hiah idlina Max. 1.0

Valve clearance
(When engine is hot
or cold)
Exhaust valve mm 0.50
F:s”A”E”36”,ssion
pressure Oil temperature: 40 - 60°C MPa Min. 2.9 Min. 2.9 2.1
(Engine speed: 320 - 360 rpmj (kg/cm’ (Min. 30) (Min. 30) (21)

mmH,C Max. 50 Max. 50
MPa 0.35 - 0.6 0.25 0.35 - 0.6 0.25

:kg/cm* (3.5 - 6.0) (2.5) (3.5 - 6.0) (2.5)
MPa 0.3 - 0.6 0.21 0.3 - 0.5 0.21
Ikg/cmz (3.0 - 6.0) (2.1) (3.0 - 5.0) (2.1)
(Oil temperature:
MPa Min. 0.1 Min. 0.1 0.07
Ikg/cm2 (Min. 1.0) (Min. 1.0) (0.7)
MPa Min. 0.08 Min. 0.08
[kg/cm’ (Min. 0.8) (Min. 0.8)
Oil temperature 411speed (oil in oil pan) “C 80- 110 80 - 110

Oil consumption ratio % Max. 0.5 1.0 Max. 0.5
Ratio to fuel consumption)
MPa
Fuel injection pressure Vozzle tester 9.6+'.5(200+'5)
+0.5 + 5
16.7 (170) 9.6+‘~5(200+‘51
+0.5 15 16.7 (170)
kg/cm?
Fuel injection timing 3.T.D.C. degree 16e 1 16? 1 16? 1 16 f 1
Dpening pressure kPa 88.3 ? 9.8 88.3 t 9.8 49 t 9.8 49 + 9.8

:Differential pressure) kg/cm2: (0.9 * 0.1) (0.9 f 0.1) (0.5 f 0.1) (0.5 + 0.1)
Fan speed At rated engine speed rpm 1.020 - 2,120 ,020 - 2,120 !,350 - 2,450 1,350 - 2,450
Fan belt tension 3eflects when pushed with

mm 8 7 - 10 8 6- 10
(Alternator to fan pulley) 3 force of 6 kg
’2-oo-28 95 SERIES
4D95L-1
Standard
D21A-7T
(Trimming)
Permissible
r Standard
EC75Z,ZS-3
EG40B, BS-1
Permissible Standard Permissible

lLlax.l,560(50H Aax.l,560(50Hz
2,530 - 2,630 2,530 - 2,630 3,250 - 3,350 3,250 - 3,35C
’ hlax.l,872(60H Aax.l,872(60Hz
800- 850 800 - 850 750 - 850 750- 850 800 - 850 800- 850
Min. 150 Min. 150 Min. 150
Min. 100 Min. 100 Min. 100
Max.380 762 Max.380 762 Max. 400 762
Max. 650 700 Max.650 700 Max. 650 700
4.0 6.0 Max. 5.0 7.0
3.0 4.0 Max. 2.5 3.5 Max. 3.5 4.5
1.5 2.5
0.35 0.35 0.35
0.50 0.50 0.50

Min. 2.9 2.1 Min. 2.9 2.1 Min. 2.9 2.1
(Min. 30) (21) (Min. 30) (21) (Min. 30) (21)
Max. 50 Max. 50 100 Max. 50 100
0.3 - 0.6 0.21 0.3 - 0.55 0.21 0.3 - 0.55 0.21

(3.0- 6.0) (2.1) (3.5- 5.5) (2.1) (3.0- 5.5) (2.1)
0.3 - 0.55 0.21 0.25 - 0.5 0.18 0.25 - 0.5 0.21
(3.0- 5.5) (2.1) (2.5- 5.0) (1.8) (2.5- 5.0) (2.1)
Min. 0.1 0.07 Min. 0.15 0.07 Min. 0.15 0.07
(Min. 1.0) (0.7) (Min. 1.5) (0.7) (Min. 1.5) (0.7)
Min. 0.08 0.07 Min. 0.12 0.07 Min. 0.12 0.07
(Min. 0.8) (0.7) (Min. 1.2) (0.7) (Min. 1.2) (0.7)
80- 110 80 - 110 120 80- 110 120
Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0
19.6".5(200+'5)
+0.5 + 5 16.7 (170) 19.6+'.5(200+'5)
+0.5 + 5 16.7 (170) l9.6:;:;(200:': 17.6 (180)
16kl 16~1 20 k 1 20 + 1 1621 16 t 1
88.3 2 9.8 88.3 k 9.8 88.3 t 14.7 88.3 k 14.7

(0.9t 0.1) (0.9+ 0.1) (0.9-c0.15) (0.9-c0.15)
,610-1,690(50Hi,610-1,690(50Hz)
2,810 - 2,990 !,810 - 2,990 1,420 - 3,600 8,420- 3,600
.930-2.030160H;.930-2.030(60Hz)
8 6-10 8 6-10 10 8 - 12
95 SERIES 12-030-29
@
I
Engine model S4D95L-I
Applicable machine model PCIOO-5 PCIOO-6

High idling speed vm !,240 - 2,360 ,240 - 2,360 X,240 - 2,360 1,240 - 2,360
Engine speed
Low idling speed rpm 900 - 950 900 - 950 900 - 950 900 - 950
0°C (without starting aid) vm Min. 150 Min. 150

Necessary
starting speed
-20°C (with starting aid) vm Min. 100 Min. 100
Intake pressure At rated output mmHg Min. 500 450 Min. 500 450
Exhaust pressure
At rated output mmHg Min. 350 300 Min. 350 300

“C Max. 650 700 Max. 650
Quick acceleration
Max. 6.0 7.5 Max. 6.0
Bosch
Exhaust gas color At rated output Max. 3.0 4.0 Max. 3.0
scale
At high idling Max. 1.0 2.0 Max. 1.0

Valve clearance
(When engine is hot
or cold) _
Compression pressun Oil temperature: 40 - 60°C MPa Min. 2.9 2.1 Min. 2.9 2.1
(SAEBO) (Engine speed: 320 - 360 rpm: (kg/cm2 ) (Min. 30) (211 (Min. 30) (211

mmH,C 1 Max. 50 100 Max. 50 100
(SAE30) Water temoerature: Min. 70°C
MPa 0.35 - 0.7 0.25 0.35 - 0.7 0.25

[kg/cm2 1 (3.5 - 7.0) (2.5) (3.5 - 7.0) (2.5)
MPa 0.3 - 0.7 0.21 0.3 - 0.7 0.21
(kg/cm2 ) (3.0 - 7.0) (2.1) (3.0 - 7.0) (2.1)
(Oil temperature:
MPa Min. 0.1 0.07 Min. 0.1 0.07
[kg/cm’ 1 (Min. 1.0) (0.7) (Min. 1.0) (0.7)
MPa Min. 0.08 0.07 Min. 0.08 0.07
(kg/cm2 ) (Min. 0.81 (0.7) (Min. 0.8) (0.7)
Oil temperature All speed (oil in oil pan) “C 80- 110 120 80- 110 120

Oil consumption ratic % Max. 0.5 1.o Max. 0.5 1 .o
MPa /kl)
Fuel injection pressur Nozzle tester 19.6+‘.5(200+‘5 16.7 (170) !2.1:;:;(225:‘: 18.4 (188)
(kg/cm’ ‘1 ’
+o.s +5
Fuel injection timing B.T.D.C. degree 18 + 1 18 * 1 18 2 1 18 + 1
Opening pressure kPa 49 + 9.8 49 -c 9.8 49 -c 9.8 49 e 9.8

(Differential pressure) (kg/cm’ ‘) (0.5 + 0.1) (0.5 * 0.1) 10.5 -c 0.1) (0.5 z? 0.1)
Fan speed At rated engine speed rpm 2,040 - 2,16C !,040 - 2,16( 2,100 + 60 2,100 + 60

mm 8 6- 10 8 6- 10
(Alternator to fan pullej a force of 6 kg
j, The values given in the Testing and Adjusting Data are NOT for adjustment of the output.
* (%I) PCIOO-5 (106894 and up): 22.1:::: MPa (225:‘: kg/cm’)
12-030-30 95 SERIES
a4
S4D95L-1
PC120-5 PC120-6, PC128UU-1 JV70DW-1

2,340 - 2,460 2,340 - 2,460 2,340 - 2,460 2,340 - 2,460 2,200 - 2,280 2,200 - 2,280
900 - 950 900 - 950 900 - 950 900 - 950 900 - 950 900 - 950
Min. 150 Min. 150 Min. 150
Min. 100 Min. 100 Min. 100
T
Max. 300 762 Max. 300 762 Max. 300 762
Min. 550 500 Min. 550 500 Min. 450 400
Min. 400 350 Min. 400 350 Max. 350 315
Max. 650 700 Max. 650 700 Max. 650 700
Max. 6.0 7.5 Max. 6.0 7.5
Max. 3.0 4.0 Max. 3.0 4.0 2.0
Max. 1.0 2.0 Max. 1.0 1.0
0.35
0.50
Min. 2.9 2.2 Min. 2.9 2.2 Min. 3.0 2.1
(Min. 30) (22) (Min. 30) (22) (Min. 30) (21)
Max. 50 Max. 50 100 Max. 50 100
0.35 - 0.70 0.25 0.35 - 0.70 0.25 0.35 - 0.70 0.25

(3.5 - 7.0) (2.5) (3.5 - 7.0) (2.5) (3.5 - 7.0) (2.5)
0.30 - 0.70 0.21 0.30 - 0.70 0.21 0.30 - 0.70 0.21
(3.0 - 7.0) (2.1) (3.0 - 7.0) (2.1) (3.0 - 7.0) (2.1)
Min. 0.10 0.070 Min. 0.1 0.070 Min. 0.10 0.070
(Min. 1.0) (0.70) (Min. 1.0) (0.70) (Min. 1.0) (0.70)
Min. 0.080 0.070 Min. 0.080 0.070 Min. 0.080 0.070
(Min. 0.80) (0.70) (Min. 0.80) (0.70) (Min. 0.80) (0.70)
80- 110 120 80 - 110 120 80 - 120 120
Max. 0.5 Max. 0.5
22.6 - 23.6 22.6 - 23.6

16.7 (170) 18.4 (188) 18.4 (188)
(230 - 240) (230 - 240)
17 - 19 17 - 19 17 - 19 17 - 19
39 - 59 39 - 59 39 - 59 39 - 59
(0.40 - 0.60) (0.40 - 0.60) (0.40 - 0.60) (0.40 - 0.60)
F12~61 1,910
- 2,031
3 if'ClZo-6)
1,910
- 2,031
2,135 - 2,265 2,135 - 2,265 1,940 - 2.06C 1,940 - 2,060
C128UU-111,696
- 1.71
16(PClZWU-111.696
- 1.7s
8 6- 10 8 6- 10
95 SERIES
’2-oio-3’
D3lE. P, PL, PLL, S, Q,

Applicable machine model D31A, P, S-18
AM, SM-20(A)
Classifi Standard Permissible Standard Permissible

High idling speed rpm ,600 - 2,700 2,600 - 2,7OC 1,535 - 2,635 $535 - 2,635
Engine speed

Necessary
starting speed i
Intake resistance All speed nmH,O Max. 300 762 Max. 300 762
Intake pressure At rated output nmHg
Exhaust pressure
At rated output nmHg _

“C Max. 650 700 Max. 650 700
Quick acceleration
Max. 4.0 6.0 Max. 4.0 6.0
Bosch
Exhaust gas color At rated output
scale
Max. 3.0 1 4.0 Max. 3.0 4.0
At high idling Max. 2.0 1 3.0 Max. 2.0 3.0

Valve clearance
I”t,e;ldengine is hot
Compression pressure Oil temperature: 40 - 60°C MPa Min. 2.9 2.1

(SAE30) (Engine speed: 320 - 360 mm) kg/cm21 (Min. 30) (21)
At rated output
nmH,C Max. 50 100 Max. 50
Water temperature: Min. 70°C
MPa 0.35 - 0.7 0.25 0.35 - 0.7 0.25

(g/cm2 (3.5 - 7.0) (2.5) (3.5 - 7.0) (2.5)
MPa 0.3 - 0.7 0.21 0.3 - 0.65 0.21
<g/cm2 (3.0 - 7.0) (2.1) (3.0 - 6.5) (2.1)
(Oil temperature:
MPa Min. 0.1 0.07 Min. 0.1 0.07
<g/cm2 (Min. 1.0) (0.7) (Min. 1.0) (0.7)
MPa Min. 0.08 0.07 Min. 0.08 0.07
<g/cm2 (Min. 0.8) (0.7) (Min. 0.8) (0.7)
Oil temperature All speed (oil in oil pan) “C 80 - 110 120

Oil consumption ratic % Max. 0.5 1.0
MPa
Fuel injection pressurl Nozzle tester 9.6:;,:(200+‘5)
+5 16.7 (170) 9.6+=(200
r0.5 +5
+” 16.7 (170)
kg/cm2
Fuel injection timing B.T.D.C. degree 162 1 16 + 1 16* 1 16+ 1
Opening pressure kPa 68.6 & 9.8 68.6 + 9.8

(Differential pressure) kg/cm* (0.7 * 0.1) (0.7 c 0.1)
Fan speed At rated engine speed rpm 1,687 - 1,79’ 1,687 - 1,791

mm 10 8- 12
(Alternator to fan pulle) a force of 6 kg
6D95L-1
D37A-2. D37P-2A
T D37E, P-5(A)
Standard
PClOO, IOOL-3
Permissible
r Standard
PC120-3
Permissible
value value value value value value
2,650 - 2,750 2,650 - 2,750 2,300 - 2,400 2,300 - 2,400 2,350 - 2,450 2,350 - 2,450
700-750 700-750 850- 900 850- 900 850 - 900 850-900
Min. 150 Min. 150 Min. 150
Min. 100 Min. 100 Min. 100
Max.300 762 Max.300 762 Max.380 762 Max.380 762
Max.650 Max.600 700 Max. 650 700 Max.650 700
Max. 5.0 Max. 5.0 7.0 Max. 5.0 7.0 Max. 5.0 7.0
Max. 3.5 Max. 3.5 4.5 Max. 3.5 4.5 Max. 3.5 4.5
Max. 2.5 Max. 1.0 2.0 Max. 1.0 2.0
0.35 0.35 0.35
0.50 0.50 0.50 _
Min. 2.9 2.1 Min. 2.9 2.1 Min. 2.9 2.1 Min. 2.9 2.1
(Min. 30) (21) (Min. 30) (21) (Min. 30) (21) (Min. 30) (21)
Max. 50 100 Max.50 100 Max. 50 100 Max. 50 100
0.35 - 0.7 0.25 0.35 - 0.7 0.25 0.35 - 0.7 0.25 0.35 - 0.7 0.25
(3.5- 7.0) (2.5) (3.5- 7.0) (2.5) (3.5- 7.0) (2.5) (3.5- 7.0) (2.5)
0.3 - 0.65 0.21 0.3 - 0.65 0.21 0.3 - 0.7 0.21 0.3 - 0.7 0.21
(3.0- 6.5) (2.1) (3.0- 6.5) (2.1) (3.0- 7.0) (2.1) (3.0- 7.0) (2.1)
Min. 0.1 0.07 Min. 0.1 0.07 Min. 0.1 0.07 Min. 0.1 0.07
(Min. 1.0) (0.7) (Min. 1.0) (0.7) (Min. 1.0) (0.7) (Min. 1.0) (0.7)
Min. 0.08 0.06 Min. 0.08 0.07 Min. 0.08 0.07 Min. 0.08 0.07
(Min. 0.8) (0.6) (Min. 0.8) (0.7) (Min. 0.8) (0.7) (Min. 0.8) (0.7)
80-110 120 80- 110 120 80 - 110 120 80- 110 120
Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0
19.6+'.5(200+'5)
r0.5 * 5 16.7 (170) 19.6:;::(200:'; 17.6 (180) 19.6+=
r0.5 (200+
+I”
5’
16.7 (170)
16kl 16 + 1 16 + 1 16kl 1621 16 + 1
68.6 k 9.8 68.6 f 9.8 49 f 9.8 49 k 9.8 49 2 9.8 49 f 9.8

(0.7t 0.1) (0.7 2 0.1) (0.5 2 0.1) (0.5f 0.1) (0.5 + 0.1) (0.5 + 0.1)
1,940 - 2,060 1,940 - 2,060 1,640 - 1,72C 1,640 - 1,720 1,720 - 1,800 1,720 - 1,800
10 8-12 8 6-10 8 6-10
95 SERIES
’2-oio-33
WAIOO-1
Applicable machine model PW150-1
WRl l-l
Classif Standard Permissible Standard Permissible

cation I value value value value
rpm !,600 - 2,700 ,600 - 2,700 1,600 - 2,700 !,600 - 2,700
100-&350(-25582 00-850(-25582)
vm 800 - 850 800 - 850
i75-725(25583- 75-725(25583-j
rpm Min. 150 Min. 150
starting speed
Intake pressure At rated output mmHg _
Exhaust pressure
“C Max. 650 Max. 650

Max. 5.0 Max. 4.5 6.5
Bosch
Max. 3.5 Max. 3.0
scale
Max. 1.0 Max. 2.0
mm 0.35
mm 0.50 0.50
Compression pressure Oil temperature: 40 - 60°C MPa Min. 2.9 Min. 2.9
(SAE30) (Engine speed: 320 - 360 rpml (kg/cm2 (Min. 30) (Min. 30)

mmH,C Max. 50 Max. 50
MPa 0.35 - 0.7 0.25 0.35 - 0.7 0.25

kg/cm2 (3.5 - 7.0) (2.5) (3.5 - 7.0) (2.5)
MPa 0.3 - 0.7 0.21 0.3 - 0.7 0.21
:kg/cm2 (3.0 - 7.0) (2.1) (3.0 - 7.0) (2.1)
(Oil temperature:
MPa Min. 0.1 0.07 Min. 0.1 0.07
Min. 80°C) At low idling (SAE 30) (Min. 1.0)
:kg/cm2 (Min. 1.0) (0.7) (0.7)
MPa Min. 0.08 Min. 0.08
At low idling (SAE 1OW) (Min. 0.8)
:kg/cm2 (Min. 0.8)
Oil temperature All speed (oil in oil pan) “C 80- 110 80- 110
At continuous rated output Max. 0.5

Oil consumption ratio % Max. 0.5
MPa
Fuel injection pressure Nozzle tester 19.6+‘.5(200+‘5
+0.5 +5 16.7 (170) 19.6+'.5(200
r0.5 +”
+ 5
16.7 (170)
Ikg/cm2
Fuel injection timing B.T.D.C. degree 16* 1 16 + 1 16? 1 16 + 1
Opening pressure kPa 49 -c 9.8 49 + 9.8 49 2 9.8 49 k 9.8

Radiator pressure valve (0.5 * 0.1)
(Differential pressure) Ikg/cm2 (0.5 t 0.1) (0.5 * 0.1) (0.5 * 0.1)
I
Fan speed At rated engine speed rpm 1,850 - 1,95C ‘,850 - 1,95( 1,736 - 1,81f 1,736 - 1,816
Fan belt tension Deflects when pushed with 8 6- 10

mm 8 6- 10
(Alternator to fan pulley) a force of 6 kg
6D95L-1
WAlOO-1
GD313A-1 EGGOB, BS-1
Standard 'ermissible Standard Permissible Standard Permissible Standard Permissible

_
~ax.l,560(50Hzllax.l,560(50Hz
2,600 - 2,700 2 ,600 - 2,700 2,700 - 2,800 2,700 - 2,800
~ax.l,872(60Hzllax.l,872(60Hz
675-725 675-725 800 - 850 800- 850 800 - 850 800- 850
-
Min. 150 Min. 100 Min. 150
Min. 100 Min. 80 Min. 100
Max.300 762 Max.300 762 Max. 400 762
Max.650 700 Max.650 700 Max. 650 700

_
Max. 4.5 6.5 Max. 5.0 7.0
Max. 3.0 4.0 Max. 2.5 3.5 Max. 3.5 4.5
Max. 2.0 3.0 Max. 2.5 3.5

_
0.35 0.35 0.35
0.50 0.50 0.50

Min. 2.9 2.1 Min. 2.9 2.1 Min. 2.9 2.1
(Min. 30) (21) (Min. 30) (21) (Min. 30) (21)
-
Max.50 Max.50 100 Max. 50 100
-
0.35 - 0.7 0.25 0.35 - 0.7 0.25 0.3 - 0.6 0.21
(3.5- 7.0) (2.5) (3.5- 7.0) (2.5) (3.0- 6.0) (2.1)
0.3 - 0.7 0.21 0.3 - 0.7 0.21
(3.0- 7.0) (2.1) (3.0- 7.0) (2.1)
Min. 0.1 0.07 Min. 0.1 0.07 Min. 0.15 0.07
(Min. 1.0) (0.7) (Min. 1.0) (0.7) (Min. 1.5) (0.7)
Min. 0.08 0.07 Min. 0.08 0.07 Min. 0.12 0.07
(Min. 0.8) (0.7) (Min. 0.8) (0.7) (Min. 1.2) (0.7)
80- 110 80 - 110 120 80-110 180
Max. 0.5 Max. 0.5 Max. 0.5
19.6:;:;(200
:‘:I 16.7 (170) 19.6+'.5(200+'5)
+0.5 + 5
16.7 (170) 19.6+'-5(200
4.5 +“)
+ 5
16.7 (170)
16 k 1 16kl 16 k 1 16&l 16kl 16 + 1
68.6 k 9.8 68.6 c 9.8 68.6 2 9.8 68.6 2 9.8 49 +. 9.8 49 + 9.8
(0.72 0.1) (0.7 2 0.1) (0.7* 0.1) (0.7 + 0.1) (0.5 + 0.1) (0.5 -c0.1)
1,462-1,538(50Hz
1,462-1,538(50Hz
1,736 - 1,816 1,736- 1,816 1,950 - 2,050 1,950 - 2,050
1,755-1,845(60Hz
1,755-1,845(60Hz
8 6-10 10 8 - 12
95 SERIES 12-030-35
@
Applicable machine model PC150-3 PC1 50-5

f
Classifi Standard ‘ermissible Standard Permissible
High idling speed rpm !,350 - 2,45t ,350 - 2,450 !,I 40 - 2,26( 12 !,I 40 - 2,260
Engine speed

Necessary
starting speed
Intake pressure At rated output mmHg Min. 280 250
Exhaust pressure Min. 380 335

Exhaust temperature All speed Max. 650

“C Max. 650 700 700
Quick acceleration
Max. 6.0 8.0 Max. 6.0 8.0
Bosch
scale

Valve clearance
$J;~;engrne is hot
Compression pressure Oil temperature: 40 - 60°C MPa Min. 2.7 2.0 Min. 2.7 2.0
(SAE30) (Engine speed: 320 - 360 rpm) [kg/cm2. (Min. 28) (20) (Min. 28) (20)

mmH,C Max. 50 100 Max. 75 150
MPa 0.35 - 0.7 0.25 0.35 - 0.7 0.25

At rated output (SAE 30) (3.5 - 7.0)
kg/cm2 (3.5 - 7.0) (2.5) (2.5)
MPa 0.3 - 0.7 0.21 0.3 - 0.7 0.21
Oil pressure At rated output (SAE 1OW)
kg/cm2 (3.0 - 7.0) (2.1) (3.0 - 7.0) (2.1)
(Oil temperature:
MPa Min. 0.1 0.07 Min. 0.1 0.07
Min. 80°C) At low idling (SAE 30) (Min. 1.0)
:kg/cmz (Min. 1.0) (0.7) (0.7)
MPa Min. 0.08 0.07 Min. 0.08 0.07
At low idling (SAE IOW) (Min. 0.8)
:kglcm2 (Min. 0.8) (0.7) (0.7)
Oil temperature All speed (oil in oil pan) “C 80 - 110 120 80- 110 120
At continuous rated output 1.0 Max. 0.5 1.0

Oil consumption ratic % Max. 0.5
MPa 16.7 (170)
Fuel injection pressurl Nozzle tester 19.6+‘.5(200
r0.5 +‘!!
+ 16.7 (170) 19.6:;::(200:‘;
[kg/cm2
Fuel injection timing B.T.D.C. degree 22 f 1 22 * 1 18 -c 1 18 -c 1
Opening pressure kPa 49 + 9.8 49 f 9.8 34.3 5 14.7

Radiator pressure valve (0.35 2 0.15)
(Differential pressure) [kg/cm2 (0.5 * 0.1) (0.5 +. 0.1)
Fan speed At rated engine speed wm 1,930 - 2,031 1,930 - 2,03( 1,940 - 2,06 1,940 - 2,060
Fan belt tension Deflects when pushed with 6- 10

mm 8 6- 10 8
(Alternator to fan pulleb a force of 6 kg
12-030-36 95 SERIES
a9
S6D95L-1
PC200-5 PWl OO-3 PWI 00-3

PC200-6
BR200-1 (Engine No. up to 36829) (Engine No. 36830 and up)

2,200 - 2,320 2,200 - 2,320 2,360 - 2,480 2,360 - 2,480 2,050 - 2,150 2,050 - 2,150 2,350 - 2,450 2,350 - 2,450
925 - 975 925 - 975 975 - 1,025 975 - 1,025 850 - 900 850 - 900 850 - 900 850 - 900
Min. 150 Min. 150 Min. 150 Min. 150
Min. 100 Min. 100 Min. 100 Min. 100
Max. 300 762 Max. 300 762 Max. 300 762 Max. 300 762
Min. 900 800 Min. 380
Min. 1000 900
Max. 650 700 Max. 650 700 1 Max. 650 1 700 Max. 650 700
Max. 5.5 7.5 Max. 7.5 8.5 Max. 6.0 7.0 Max. 6.0 8.0
Max. 3.7 4.7 Max. 2.0 3.0 Max. 3.5 4.5 Max. 1.5 2.5
Max. 1.0 2.0 Max. 1.0 2.0 Max. 3.5 4.5 Max. 1.0 2.0
0.35 0.35
0.50 0.50
Min. 2.7 Min. 2.7 2.0
(Min. 28) (Min. 28) (20)
Max. 75 Max. 50 100 Max. 75 150
0.35 - 0.7 0.24 0.35 - 0.7 0.25 0.35 - 0.7 0.25

(3.5 - 7.0) (2.4) (3.5 - 7.0) (2.5) (3.5 - 7.0) (2.5)
0.35 - 0.7 0.21 0.3 - 0.7 0.21 0.3 - 0.7 0.21
(3.5 - 7.0) (2.1) (3.0 - 7.0) (2.1) (3.0 - 7.0) (2.1)
Min. 0.1 0.07 Min. 0.1 0.07 Min. 0.1 0.07
(Min. 1.0) (0.7) (Min. 1.0) (0.7) (Min. 1.0) (0.7)
Min. 0.08 0.07 Min. 0.08 0.07 Min. 0.08 0.07
(Min. 0.8) (0.7) (Min. 0.8) (0.7) (Min. 0.8) (0.7)
!
I I I I
80- 110 120 80 - 110 120 80- 110 120 80- 110 120
Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0
&I) a
19 .6+=(200 +‘? 16.7 (170) 22.1 +‘.5(225+‘5)
+,,5 +5 17.6 (180) 19.6:;::(200:‘:) 16.7 (170) 19.6+'.5(200+'5) 16.7 (170)
+a5 +5 +a5 + 5
20 20 18 + 1 18 f 1 16 + 1 16k 1 16k 1 16k 1
49 2 9.8 49 -c 9.8 49 * 9.8 49 -c 9.8 38.2 k 9.8 38.2 t 9.8 49 k 9.8 49 k 9.8
(0.5 k 0.1) (0.5 -c 0.1) (0.5 + 0.1) (0.5 2 0.1) (0.39 -c 0.1) (0.39 + 0.1) (0.5 k 0.1) (0.5 t 0.1)
2,000 - 2,100 2,000 - 2,100 1,710 - 1,810 1,710 - 1,810 1,390 - 1,460 1,390 - 1,460 1,640 - 1,720 1,640 - 1,720
8 6-10 4 3-4 8 6- 10 8 6- 10
(~1) pC200-5 (83373 and up), BR200-1: 22.1 ::::MPa (225:‘: Wcm2)
(g2) pc200-5 (83373 and up), BR200-1: 17.6 MPa (170 kg/cm’ )
95 SERIES 12-030-37
@
S6D95L-1
DCA85
GD461A-1 LW80-1 EG85B. BS-1
QAS85

flax.l,560(50Hzlax.l,560(50Hi Aax.l,560(50Hz)Max.l,560(50Hz)
2,700 - 2,800 2,700 - 2,800 3,400 - 3,500 3,400 - 3,500
Jax.l,872(60Hz lax.l,872(60Hi ~ax.l,872(60Hz)Max.l,872(60Hz)
800- 850 800-850 750- 800 750 -800 800 - 850 800-850
Min. 150 Min. 150 Min. 150 ,.,
Min. 100 Min. 100 Min. 100
Max.300 762 Max.300 762 Max. 400 762 Max.500 762
Min. 500 400 Min. 600 550
Min. 550 450 Min. 550 850
Max.650 700 Max.650 700 Max.700 700
Max. 7.0 6.0 Max. 6.0 7.0 _
Max. 2.0 3.0 Max. 2.5 3.5 Max. 4.5 5.5 Max. 4.5
Max. 1.0 2.0 Max. 1.0 2.0
0.35 0.35 0.35
0.50 0.50 0.50

Min. 2.7 2.0 Min. 2.7 2.0 Min. 2.7 2.0
(Min. 28) (20) (Min. 28) (20) (Min. 28) (20)
Max.75 150 Max.85 150 Max.100 200 200
0.35 - 0.7 0.25 0.35 - 0.7 0.25 0.3 - 0.7 0.25

(3.5- 7.0) (2.5) (3.5- 7.0) (2.5) (3.0- 7.0) (2.5)
0.3 - 0.7 0.21 0.3 - 0.7 0.21 0.25 - 0.7 0.18
(3.0- 7.0) (2.1) (3.0- 7.0) (2.1) (2.5- 7.0) (1.8)
Min. 0.1 0.07 Min. 0.1 0.07 Min. 0.15 0.07
(Min. 1.0) (0.7) (Min. 1.0) (0.7) (Min. 1.5) (0.7)
Min. 0.08 0.07 Min. 0.08 0.07 Min. 0.12 0.07
(Min. 0.8) (0.7) (Min. 0.8) (0.7) (Min. 1.2) (0.7)
80- 110 120 go- 110 120 80- 110 120 80 - 110 120
Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0
19.6:;::(200:':) 16.7 (170) 19.6+'5(200"5)

*0.5 5 l
16.7 (170) 19.6".5(200+'5)
+0.5 I 5 16.7 (170)
22 + 1 22 * 1 16 + 1 1621 1421 1421
49 f 9.8 49 k 9.8 68.6 k 9.8 68.6 f 9.8 49 + 9.8 49 t 9.8

(0.5 + 0.1) (0.5 + 0.1) (0.7f 0.1) (0.7* 0.1) (0.5k 0.1) (0.5 + 0.1)
1,462-1,538(50Hz,462-1,538(50Hz
1,950 - 2,050 1,950 - 2,050 2,153 - 2,287 2,153 - 2,287
1,755-1,845(60Hz,755_1,845(60Hz
9 6-10 10 8-12
95 SERIES 12-030-39
@
Cate-
Item
Applicable machine
Measurement
model
conditions Unit
I
Standard
WA1 80-3
IPermissible
r Standard
WA250-3
IPermissible
gory value value value value
High idling speed 12 ,600 - 2,700 $600 - 2,70( 12 ‘,600 - 2,700

x Engine speed
5 Low idling speed 750 - 800 750 - 800 750 - 800
E
b 0°C (Without starting aid) Min. 150
‘t
Necessary
h starting speed
-20°C (With starting aid) Min. 100
Min. 2.94 7.47

Intake resistance At all speed
(Min. 300) 1762)
Min. 5.88 4.95
Boost pressure At rated flywheel horsepower
(Min. 600) (500)
Exhaust pressure Min. 6.86 5.88
At rated flywheel horsepower
(Turbine inlet press.) (Min. 700) (600)
700 Max. 650 700
Quick acceleration
7.5 Max. 5.5
Bosch
Exhaust gas color At rated flywheel horsepower Max. 3.0 5.0 Max. 3.0
index
Hiah idlina soeed Max. 1.0 2.0 Max. 1.0

Valve clearance
($:;2lengme is hot
Exhaust valve i mm 0.50 0.50
Compression pressure Oil temperature: 40 - 60°C MPa 1 Min. 2.7 2.0 Min. 2.7 2.0
(SAE30 or SAE15W-40) (Engine speed: 320 - 360 rpml kg/cm? ( (Min. 28) (20) (Min. 28) (20)
Blow-by pressure At rated flywheel horsepower kPa Max. 0.49 0.98 Max. 0.49 0.98
(SAE30 or SAE15W-40) (Water temperature: Min. 70°C) nmHzOl (Max. 50) (100) (Max. 50) (100)
At rated flywheel horsepoer MPa 0.35 - 0.70 0.25 0.35 - 0.70 0.25
SAE30 or SAE15W-40 oil kg/cm? (3.5 - 7.0) (2.5) (3.5 - 7.0) (2.5)
0.21 0.30 - 0.70 0.21
Oil pressure SAE 1OW oil
(2.1) (3.0 - 7.0) (2.1)
(Oil temperature:
At low idling 0.070 Min. 0.1 0.070
Min. 80°C) (0.70) (Min. 1.0) (0.70)
SAEBO or SAE15W-40 o il
0.070 Min. 0.080 0.070
SAE IOW oil
(0.70) (Min. 0.80) (0.70)
Oil temperature All speed (Oil in oil pan) 120 go- 110 120
At continuous rated horsepower

Oil consumption ratio % Max. 0.5 1.0 Max. 0.5 1.0
16.7 20.1 - 21.1 16.7
Fuel injection pressure Nozzle tester
(170) (205 - 215) (1701
Fuel injection timing B.T.D.C. 21 -23 19 - 21 19 - 21
s
x
Opening
(Differential
pressure
pressure)
59 - 7.8
(0.6 - 0.8)
t
Fan speed At rated engine speed 3 1,730 - 1,83C 1,870 - 1,9713 11,730 - 1,830
.-P
% Fan belt tension
Deflects when pushed with
6- 10 8 6- 10
6 a force of 60 N 16 kg>
12-030-40 95 SERIES
@
SA6D95L-1
Standard
PC220-5
BR300-1
Permissible
PC220-6
r
_
value value value value value value
2,300 - 2,475 2,355 - 2,475
925 - 975 925 - 975
Min. 150
Min. 100
Min. .94 7.47 Min. 2.94 7.47

(Min. 300) (762) (Min. 300) (762)
Min. 5.88 5.88
(Min. 600) (600)
Min. 6.88 5.88
(Min. 700) (600)
Max. 650 700 Max. 650 700
Max. 5.5 7.5 Max. 8.0 9.0
Max. 4.0 5.0 Max. 2.0 3.0
Max. 1.0 2.0 Max. 1.0 2.0
0.35
0.50 I
Min. 2.7 2.0
(Min. 28) (20)
0.74 1.47 0.48 0.98

(Max. 75) (150) (Max. 50) (100)
0.35 - 0.70 0.25 0.35 - 0.7 0.25

(3.5 - 7.0) (2.5) (3.5 - 7.0) (2.5)
I
0.30 - 0.70 0.21 0.30 - 0.70 0.21
(3.0 - 7.0) (2.1) (3.0 - 7.0) (2.1)
Min. 0.1 0.070 Min. 0.1 0.070
(Min. 1.0) (0.70) (Min. 1.0) (0.70)
Min. 0.080 0.070 Min. 0.080 0.070
(Min. 0.80) (0.70) (Min. 0.80) (0.70)
80- 110 120 80- 110 120
Max. 0.5 1.0 Max. 0.5 1.0
Jp to364721
16.7(170)
6473and up)17.6
1160
20 20
5.9 - 7.8
(0.6 - 0.8)
2,330 - 2,470 2,330 - 2,470
8 6- 10 8 6- 10
95 SERIES
’2-oio-4’
I
Engine model SAA6D95LE-1
WING100
(LWIOO-1, LWIOOM-1)
Cate- Standard Permissible Standard Permissible
!
Item Measurement conditions Unit
gory value value value value
High idling speed rpm $400 - 3,500 :,400 - 3,500

Engine speed
Low idling speed rpm 750 - 800 750 - 800
0°C (Without starting aid) rpm Min. 150

Necessary
starting speed
-20°C (With starting aid) rpm Min. 100
kPa Min. 2.94

Intake resistance At all speed
ImmHzO {Min. 300)
Min. 66.7
Boost pressure At rated flywheel horsepower imkiig
{Min. 500)
Exhaust pressure Min. 126 107
At rated flywheel horsepower ImkJja,g
(Turbine inlet press.) {Min. 900) 18001
“C Max. 700 700
I
Quick acceleration
Max. 5.5 6.5
Bosch
Exhaust gas color At rated flywheel horsepower index Max. 2.5 3.5
High idling speed Max. 2.0 3.0

I
Valve clearance
f”E,e;dengine is hot
Compression pressurt Oil temperature: 40 - 60°C MPa Min. 2.7 2.0

(SAE30 or SAE15W-40 (Engine speed: 320 - 360 rpm) (kg/cm2 {Min. 281 I201 I
Blow-by pressure At rated flywheel horsepower kPa Max. 0.98 2.0 I
(SAE30 or SAE15W-40 (Water temperature: Min. 70°C) {mmHzO {Max. 100) QOO} 1
At rated flywheel horsepoer MPa 0.34 - 0.59 0.25
SAE30 or SAE15W-40 oil (kg/cm2 (3.5 - 6.01 l2.51
MPa 0.29 - 0.54 0.21
Oil pressure SAE 1OW oil
{kg/cm2 (3.0 - 5.5) 12.1)
(Oil temperature:
At low idling MPa Min. 0.098 0.07
Min. 80°C) IO.701
SAE30 or SAE15W-40 o il {kg/cm’ {Min. 1.0)
MPa Min. 0.069
SAE 1OW oil
{kg/cm2 {Min. 0.70)
Oil temperature All speed (Oil in oil pan) “C 90 - 120
At continuous rated horsepower

Oil consumption ratic % Max. 0.3
MPa 20.1 - 21.1
Fuel injection pressurl Nozzle tester
{kg/cm2 (205 - 2151
Fuel injection timing B.T.D.C. degree II- 13
Opening pressure MPa

(Differential pressure) {kg/cm2
Fan speed At rated engine speed rpm !,150 - 2.29c 1,150 - 2,290
Deflects when pushed with mm

Fan belt tension 8 6- 10
a force of 60 N (6 kg}
SAA6D95LE-1

95 SERIES
’2-oio-43
TROUBLESHOOTING
Method of using troubleshooting chart ...................................................................................................... 12-032
Points to remember when troubleshooting ................................................................................................ 12-036
S-l Starting performance is poor (Starting always takes time) .............................................................. 12-037
s-2 Engine does not start

@ Engine does not turn .............................................................................................................. 12-038
0 Engine turns but no exhaust gas comes out (Fuel is not being injected) ..................................... 12-039
0 Exhaust gas comes out but engine does not start (Fuel is being injected) ................................... 12-040
s-3 Engine does not pick up smoothly (Follow-up is poor) .................................................................... 12-041
s-4 Engine stops during operations ..................................................................................................... 12-042
s-5 Engine does not rotate smoothly ................................................................................................... 12-043
S-6 Engine lacks output (no power) ..................................................................................................... 12-044
s-7 Exhaust gas is black (incomplete combustion) ................................................................................ 12-045
S-8 Oil consumption is excessive (or exhaust gas is blue) ... . ................................................................. 12-046
s-9 Oil becomes contaminated quickly ................................................................................................ 12-047
s-1 0 Fuel consumption is excessive ...................................................................................................... 12-048
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 12-049
S-l 2 Oil pressure lamp lights up (drop in oil pressure) ........................................................................... 12-050
S-l 3 Oil level rises ............................................................................................................................... 12-051
s-14 Water temperature becomes too high (overheating) ....................................................................... 12-052
S-l 5 Abnormal noise is made ............................................................................................................... 12-053
S-l 6 Vibration is excessive ................................................................................................................... 12-054
s-17 Diagnosis of electronical governor by diagnosis display

(electronical governor made by ZEXEL) ................................................................................................... 12-055
95 SERIES
’2-:31
TESTING AND ADJUSTING TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHART
This troubleshooting chart is divided into three

sections: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure 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 @ -I- @ in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in @I are
items that can be obtained from the user,
depending on the user’s level.
[Check items]
The serviceman carries 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 from
information @ that he has obtained from the
user and the results of 0 that he has obtained
from 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] and
[Check items].
’2-:32 95 SERIES
The basic method of using the troubleshooting chart is as fol-

lows.
items listed for [Questions] and [Check items] that have a rela-
tionship with the Cause items are marked with 0, and of these,
causes that have a high probability are marked with 0.
Check each of the [Questions] and [Check items] in turn, and
marked the 0 or 0 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, so starttroublesh-
ooting for that item to make final confirmation of the cause.
For (Confirm recent repair history) in the [Ques-

tions] Section, ask the user, and mark the Cause
column with A to use as reference for locating
the cause of the failure. However, do not use this
when making calculations to narrow down the
causes.
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.
%l Confirm recent repair history

L
%2 Degree of use Operated for long period A A A
Precautions when carrying out troubleshooting
A 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.
A When
thorized
carrying
person
out operations
near the machine.
with two or more workers, always use signals, and do not allow any unau-
A When checking the water level, if the radiator cap is removed when the engne is hot, boiling water will
spurt out and may cause burns, so always wait for the engine to cool down before checking the water
level.
A Be extremely careful not to touch any hot parts.
A Be extremely careful not to get caught in the fan or any other rotating parts.
Y Y
a+ When removing the plugs or caps from places under hydraulic pressure, water pressure, or air pressure,
release the internal pressure first. Fit the measuring tools securely before carrying out any testing, adjusting,
or troubleshooting.
Method of using testing, adjusting, and troubleshooting values table

l When using the standard values table for judgment in testing, adjusting, or tourbleshooting, 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 the new machine and machine shipped from the factory. They should be used as values
for estimating wear during operation or as target values when carrying out repairs.
2. The failure judgment 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 toghther with the repair and operation history of the machine when judging failures.
3. Doo not use this standard values able as a standard for judging claims.
95 SERIES
’2-;33
- 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-
er], and [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.
I I I
III I
12-034
17
95 SERIES
\/7
v ‘I
Five causes
Step 1
Clarify the relationship between the three symptoms

in the [Questions] and [Check items] section and
the five Cause items in the vertical column.
rThree symptoms
L Step 2
Add up the total of 0 and 0 marks where the hori-

zontal lines for the three symptoms and the vertical
columns for the causes intersect.
(I) Clogged air cleaner element: 000
(2) Air leakage between turbocharger and
head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0
Step 3
V
The calculations in Step 2 show that the deepest
relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting
area and carry out the troubleshooting item marked
0. The Remedy is given as [Clean], so carry out
cleaning, and the exhaust gas color should return
to normal.
95 SERIES
’2-:35
POINTS TO REMEMBER WHEN TROUBLESHOOTING
Troubleshooting means locating the basic cause of the failure, and carrying out swift repairs to ensure that the
failure does not occur again.
When carrying out troubleshooting, it is of course important to understand the structure and function, but to
carry 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 4. Confirming failure

because there is a failure * Check the degree of the problem to judge for
. If the machine is disassembled immediately yourself if it is really a failure, or if there is
just because there is a fuilure: some problem in the handling or operation of
- Unrelated or unnecessary places are also the machine.
disassembled * When driving the machine and re-enacting
- It becomes difficult to locate the cause of the failure, be sure that the investigation or
the failure measurement does not make the failure
This means that there is not only a waste of worse.
time and money on replacement parts, oil, and
grease, but this action will also lose the confid- 5. Troubleshooting
ence of the user and operator. * Narrow down the causes of the failure from
For this reason also, it is important to carry out the results of the inspection and check in
troubleshooting based on full investigation before Items 2 - 4, then follow the troubleshooting
starting and troubleshooting following the correct flow chart to locate the failure.
order. * Basic procedure for troubleshooting
1) Start from the simple places.
2. Questions to ask the user and operator 2) Start from the most probable places.
1) Are there any problems other than those 3) Investigate related parts also.
already reported?
2) Did anything unusual happen before the failure 6. Basic action to remedy cause of failure ’
occurred? . Even if the failure is repaired, if the root
3) Did the failure occur suddenly, or had the cause of the failure is not repaired, the same
condition of the machine been poor before the failure will occur again.
failure occurred? To prevent this, it is necessary to investigate
4) What were the conditions when the failure why the failure occurred, and to remove the
occurred? root cause of the failure.
5) Had any repairs been carried ot before the fai-
lure occurred?
6) Had any similar failure occurred before?
3. Checks before troubleshooting

1) Check the oil level.
2) Check for any external leakage of oil from the
piping and hydraulic equipment.
3) Check the travel of the control levers.
4) Check the spool stroke of the control valve.
5) Other maintenance items can also be carried
out visually, so carry out any check that is
considered necessary.
12-036 95 SERIES
a
S-l Starting performance is poor (Starting always takes time)

General causes why starting performance is poor
Defective electrical system
insufficient supply of fuel
Insufficient intake of air
Improper selection of fuel
(At ambient temperature of -10°C or below, use
ASTM D975 No. 1, and -10°C or above, use ASTM
D975 No. 2 diesel fuel.) I causes I
l Charging rate of batterv. /lil/L Starting
aid lllllll
90% 80% 75% 70%
2o’c 1.28 1.26 1.24 1.23 1.22
O’C 1.29 1.27 1.25 1.24 1.23
-10°C 1.30 1.28 1.26 1.25 1.24
The specific gravity should be for the charging rate of 70% or more in
the above table.
Incold weather the specific gravity must be for the charging rate of at
lea?.t 75% in the above table.
recent repair
hktory
I
Confirm
I ODerated far lono aeriad
lDQ*e”K
III I II I III III III
Leakaae from fuel him I lol I
There is hunting
from engine (rotamn is irregular) I I I lolol I I I I I I I I I lo1
95 SERIES
S-2 Engine does not start

0 Engine does not turn
General causes why engine does not turn

. Internal parts of engine seized
* If internal parts of the engine are seized, carry
out troubleshooting for “Engine stops during I 1
operations”.
. Failure in power train
. Defective electrical system
When starting switch is
turned to START, pinion
moves out, but
1) When terminal B and terminal C of starting switch are connected,
95 SERIES
0 Engine turns but no exhaust gas comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust gas

comes out
* Supply of fuel impossible
. Supply of fuel is extremely small
- Improper selection of fuel (particularly in
winter)
Standards for use of fuel
95 SERIES 12-039
0
0 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 electri-
cal system
* Insufficient supply of fuel
- Insufficient intake of air
. Improper selection of fuel
loosened
temperature of some cylinder is low
When fuel filter is drained, no fuel comes out
12-040 95 SERIES
0
S-3 Engine does not pick up smoothly (Follow-up is poor)

General causes why engine does not pick up
smoothly
- Insufficient intake of air
. Improper condition of fuel injection
. Use of improper fuel
1 Non-specified fuel has been used I lolalol-~~

Engine oil must be added more frequently 0
Rust and water are found when fuel is drained I lolol I I I I I I I

Dust indicator is red
Noise of interference is heard from around turbocharaer
.= when load is applied

z There is hunting from engine (rotation is irregular) 000 0
_I?
” When exhaust manifold is touched immediately after starting engine,
0 0
temperature of some cylinders is low
I Blow-by gas is excessive 8

I
95 SERIES 12-041
0
S-4 Engine stops during operations

General causes why engine stops during
operations
* Seized parts inside engine
* Overheating
+ If there is overheating and insufficient
output, carry out troubleshooting for over-
heating.
* Failure in power train
* If the engine stops because of a failure in
the power train, carry out troubleshooting
for the chassis.
Condition when engine
o urn by hand using bar
ring tool
When fuel filter, strainer are inspected directly, they are found I I I I I I I 1-l
w
I I I I IZ
I
1
5,n
4
to
I When
be clogged
feed pump strainer is inspected directly, it is found I I I I I I I I l-1 I I I

d
2
I?
Check feed pump directly
When control rack is pushed, it is found to be heavy or
does not return
’*-hi4* 95 SERIES
S-5 Engine does not rotate smoothly

General causes why engine does not rotate
smoothly (hunting)
. Air in fuel system
. Defective governor mechanism
. Defective electrically controlled throttle
mechanism
(electrically controlled throttle type)
* If there is no hunting when the electrically
controlled throttle rod is disconnected, carry
out troubleshooting for the electrical sys-
tem.
Condition of hunting
95 SERIES
S-6 Engine lacks output (no power)

General causes why engine lacks output
* Insufficient intake of air I Ci%W?S I
. Insufficient supply of fuel //1111111/11/
- Improper condition of fuel injection
. Use of improper fuel
(if non-specified fuel is used, output drops)
* Lack of output due to overheating
l If there is overheating and insufficient
output, carry out troubleshooting for over-
heating.
Degree of use
Power was lost

Suddenly
II IIQI I II II II II II II II II II
Gradually 0 0 0 0 0 0
II
b Engine oil must be added more frequently 0
‘=
I Replacement of filters has not been carried out according to operation
S 0 0 8
manual
Color of exhaust gas
95 SERIES
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
. Insufficient intake of air
* Improper condition of fuel injection
* Excessive injection of fuel I /
Color of exhaust gas
When turbocharger is rotated by hand, it is found to be heavy l

When air cleaner is inspected directly, it is found to be clogged 0
When compression pressure is measured, it is found to be low 0 l

Speed of some cylinders does not change when operating on reduced
l
95 SERIES 12-045
0
S-8 Oil consumption is excessive (or exhaust gas is blue)

* Do not run the engine at idling for more than
20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is excessive
. Abnormal combustion of oil
. External leakage of oil
. Wear of lubrication system
When intake manifold is removed, dust is found inside l

When intake manifold is removed, inside is found to be dirty with oil 0
$ g .h .L .= .= ?j 8 B .= .= .L
Remedy { $ uSBgggmssggg
~ o
oagggmw,m
$$o=eaec,,EtTE
’2-:46 95 SERIES
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
- Intake of exhaust gas due to internal wear
* Clogging of lubrication passage
* Improper combustion
f Use of improper oil
. Operation under excessive load
Colorof exhaust
gas
95 SERIES 12-047
0
S-l 0 Fuel consumption is excessive

General causes why fuel ‘consumption is exces-
sive
* Leakage of fuel
* Improper condition of fuel injection
. Excessive injection of fuel
I I
Condition of fuel consumption
When check is made using delivery method, injection timing is found
95 SERIES
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down
Generl causes why oil is in cooling water
* Internal leakage in lubrication system
. Internal leakage in cooling system
95 SERIES 12-049
0
S-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 oil pressure control
* Use of improper oil (improper viscosity)
. Deterioration of oil due to overheating
* Standards for engine oil selection
operation manual
3 Caution lamp lights up 8 0
2
Non-specified fuel has been used 0 0
Lights up at low idling 0 0
Condition when oil pressure Lights up at low, high idli “g 000QOOO

lamp lights up Lights up on sl OK3 0
Sometimes ligt Its up 0 0 0 0
1 There is clogging, leakage from hvdraulic ,.“+.,m.l\
1 Oil level sensor lame liohts UD
I Metal oarticles are stuck to oil filter E
When oil filter is inspected directly, it is found to be clogged 0 l F

‘Z
Remove oil pa” and check directly l l a x
P
gzi
.Z Oil pump rotation is heavy, there is play l
8 ? .t
There is catching of relief valve, regulator valve, spring, g-$
f 11
1 % 1 valve guide is broken
I 1 When oil pressure is measured, it is found to be within sti
12p 95 SERIES
S-13 Oil level rises

* If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
. Water in oil (cloudy white)
. Fuel in oil (diluted, and smells of diesel fuel)
. Entry of oil from other component
ewe radiator cap open. When engine is run at idling. an abnormal
umber of bubbles appear, or water spurts back
95 SERIES
S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes
too high
. Lack of cooling water (deformation, damage of
fan)
* Drop in heat dissipation efficiency
* Defective in cooling circulation system
. Rise in oil temperature of power train
* Carry out troubleshooting for chassis.
Condition of overheatin
3 Water temperature gauge Does not go down from

2
red ranae I I I I I I I I I I ’
Radiator water level sensor lights up Q
Fan belt whines under sudden load I I I I I I 101 I I I I

1 I r-~-l
/I
Cloudy white oil is floating on cooling water Q
Coolina water flows out from overflow hose I I I I I I I I lo1

Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
There is play when fan pulley is rotated
Temperature difference between top and bottom radiator tanks is

l
excessive
Temperature difference between top and bottom radiator tanks
I I.1 I I I I I I I I I<
When water filler port is inspected, the core is found to be clogged a $
P
‘Z z
When a function test is carried out on the thermostat, it does not open ‘G
8 0
8
even at the cracking temperature
5
When water temperature is measured, it is found to be normal a
f
‘: P
F When oil cooler is inspected directly, it is found to be clogged 0 a
b
When measurement is made with radiator cap tester, set pressure is
0 2
found to be low ?
When compression pressure is measured, it is found to be low
) Remove oil pan and check directly
’*-SF* 95 SERIES
S-l 5 Abnormal noise is made

* Judge if the noise is an internal noise or an
external noise.
General causes why abnormal noise is made
. Abnormality due to defective parts
* Abnormal combustion noise
. Air sucked in from intake system
Condition of abnormal noise
Metal particles are found in oil filter y c
Blow-bv oas is excessive 0)
Noise of interference is heard from around turbocharger
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after starting engine,
/ temoerature of some cvlinders is low I I I IY’l”l I I I I I I I
reduced cylinders
95 SERIES 12-053
S-l 6 Vibration is excessive

* If there is abnormal noise together with the
vibration, carry out troubleshooting for “Abnor-
mal noise is made”.
General causes why vibration is excessive
- Defective parts (abnormal wear, breakage)
- improper alignment
. Abnormal combustion
Remove oil pan and check directly 1.1 11 11 11 /

Remove
side cover and check directly I I.1 I I I I I I
Remove head cover and check directly 0

Injection pump test shows that injection amount is incorrect 0
E : 0” 8 g .& .5 B 6
Remedy $ $ $ $ 2 0 g $ 5
k$e”$$CcK L? -z
12-054 95 SERIES
S-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.
Sr 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 diagnosis
1. Abnormalities in controller system
2. Abnormalities in governor servo system
3. Abnormalities in rack sensor system
4. Overrun abnormality
5. 1st speed sensor abnormality
6. 2nd speed sensor abnormality
7. Low idling speed control dial abnormality
8. Droop changeover dial abnormality
9. Abnormality in load current signal (when equipped with feed forward controller)
10. Failure in lighting of diagnosis lamp
11. Normal indication
a. Failure in changeover between low idling speed and rated speed
b. Failure in changeover between 50Hz and 60Hz
c. 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.)
e. The engine stalls during running.
12. Memory clear cannot be achieved by pressing the memory clear switch (when failure indication is made
by diagnosis lamp).
95 SERIES
’2-:55
SYSTEM RELATED ELECTRIC CIRCUIT DIAGRAM
50/60 Hz changeover
Low idling/rated speed
changeover
Table of terminals and signals
N fl .Name of signal N fl *Name of signal N n .Name of signal
ller ground terminal

(Tightened together with
controller bolt)
Table of wirino harness connectors and eauioment
1Awicable
wire Size 1 Type
I IIIL I II I
__________________________- _____ + ---- -I__ ------------------ _I
I I
+ 2 4 v Oil pressure
detection ON/OFF
Engine Chassis wiriing harness
, Lamp RL.UP8-87-R -
0 LED-R. R:3KQlW
lzumi Denki
J Lamp GL. UP8-87-G - lzumi Denki

17 LED-G. R:ZKQlW
PB.SB-221 N/O _ Nihon
IP. ACl25V3A
kaiheiki
Switch
TDE00094
95 SERIES
’2-:58
Diagnosis lamp indication
l Lit @ @ Simultaneous flashing

0 out @ 6%)Alternate flashing
@ Quick flashing (0.25 second) @ @ Alternate quick flashing
@ Slow flashing (2 seconds)
Diagnosis lamp indication

Indication type &es”Red
I 0 0
Controller system
Governor servo system I Q (>
Rack sensor system CD 0

I
Overrun
1st speed sensor (engine)
2nd speed sensor (Fuel injection pump)
Low idling speed control dial 0 @
Droop changeover dial
Load current signal 0 8

_ I
No indication 0 0
Normal indication l 0
TROUBLESHOOTING DIAGNOSIS OF ELECTRONICAL GOVERNOR
1. Abnormality in controller
Green Red
5YES
rES Is there catching

2. Abnormality in governor servo system Is resistance between
inside injection -
pump?
q (female) 8 (0)
YES and qfemalel @
and between q - * Remove rack cap No
- (@I),,.
3 (female) @ @I and to check.
Is resistancebetween W (female) 8 60)
0 (female) 6 and a normal?
ySS (female)0 @ (female)
*Resistancebetween0 N 0
- (0). and between 0 - (female)QI (@I and q(femalei@ @I: 30.5-33.5 R
(female) @and 0 -Resistance between Ej (female)@@I and @ (female)
(female10 &Z (female)
2 @@,,: 0.75-z?Q
(0) normal?
. Turn powersource OFF.
Is resistance - Resistancebetween D *Disconnect0. (Connectqand qI.)
YES between q (female) _ (female) 0 and 0 NO
L
r 0 (8) and @(@I (female)0 @Iffemale)
norrnal? (a,,: 30.5 - 38.5 n
1
-Resistance between q (female) @and 0
Is resistance between * Resistance: (female) 0 l@female) IQ : 0.75- 22 R
9-10.5Q -Turnpower source OFF.
(female) t@j and 0
- Turn power *Disconnect 0 and q.
source OFF. NO
* Disconnect a.
* Resistance:
(Connect q and q.)
9-10.5R
* Turn power I
1 Green Red source OFF. NO
* Disconnect q
and q.
3. Abnormz ity in rack sensor system
TDE00095
95 SERIES
Cause Remedy
-L ibnormality in controller Replace
-c Iefective injection pump Replace
-C )efective controller Replace
IIjefective wiring harness Replace (repair

(Ibetween q and q,@I wiring harness)
-C jefective injection pump
jefective wiring harness Repair wiring

aetween q and 0) harness
clefective injection pump, Replace (repair

d efective wiring harness wiring harness)
95 SERIES
’2-F
4. Overrun abnormality
1 YES Cause is probably outside

Replace
Is resiStance electronic governor system
OFF ON
between 0 (female)
8 and 0 (female) @I
*z
Green infinity? Defective injection pump, Replace, repair
defective wiring harness wiring harness
(Overrun) . Turn power NO
source OFF.
l Disconnect q.
TDE00095
’*2* 95 SERIES
5. Abnormality in No. 1 speed sensor Cause Remedy
2 YES
I I Iefective controller 3eplace
Is resistance
YES between q
1 (female) @ and @I
1 2.1 - 2.5 kQ? defective wiring harness 3epair or
Isresistance I
between q (male) _ NO between q and q) .eplace
*Turn power
@and q (male) @ source OFF.
2.1 - 2.5 kR? , * Disconnect q.
* Turn power (Connect HI.) Iefective engine
c
source OFF. NO nstallation, speed sensor
* Disconnect q.
6. Abnormality in No. 2 speed sensor
2 YES
jefective controller
Is resistance defective wiring harness 3epair or

Slow alternateflashing
between q (female) between q and q) ,eplace
@ @- @Iand q (female) s
Green Red 1 I~.l-2.5M?
pump) * Turn power

(Euikintoinjection Iefective speed sensor
qeplace
source OFF. NO nside injection pump
* Disconnect q.
I@ ::“[Jg --------------I /
TDE000915
95 SERIES
’*-iF3
7. Abnormality in low idling speed adjustment volume
Cause I Remedy
2 YES
Abnormality in controller Replace
resistance
rl
Is
YES between q (female)
1 Q and q (female) @ H Defective wiring harness
- normal? (between H @ and low Repair wiring
; :Ec _zzz$~Yrl&l_ ’* Resistance idling speed adjustment harness
changes: Approx. 0.5 - 10.5 kR volume)
Green normal? *Turn power source OFF.
- * Disconnect q. Defective low idling speed
* Resistance *Turnlow idling speed adjustment volume. adjustment volume or
Replace or
;hytt;;prox. NO defective wiring harness
repair wiring
(between L%@ and low
*Turnpower source harness
idling speed adjustment
OFF. volume)
. Disconnect q.
*Turn low idling I
speed adjustment
volume.
cl
Cl----
TDE00097
’2P4 95 SERIES
8. Abnormality in droop adjustment volume
2 YES
- Abnormality in controller Replace
Is resistance
YES_ between q (female) _
@and q (female) @
1 Defective wiring harness
- normal? Repair wiring
ON Quick flashing Is resistance - (between q @and droop
l (# _ between q (female) _
* Resistance NO
changes: Approx. 0.5 - 10.5 kD
adjustment volume)
harness
@and q (female) @I
Green Red normal? *Turn power source OFF.
Defective droop
* Disconnect k3.
* Resistance adjustment volume or Replace or
*Turn droop adjustment volume.
) defective wiring harness repair wiring
(between q @ and droop harness
*Turn power adjustment volume)
source OFF.
* Disconnect 0.
*Turn droop
adjustment
TDE00097
95 SERIES
’*-F5
9. Abnormality in load current signal

(when equipped with feed forward controller)
Cause Remedy
2 YES
,bnormality in controller eplace
,bnormality in load eplace

OFF Slow flashing Is wiring harness
NO etector
* Start engine.
0 @ -betweenBandH -
* Connect T-adapter to 0.
normal?
Green Red * Voltage between q 0 - @ (@I: 5V
(if it is not 5 + 0.25 V, controller is
*Disconnect
abnormal.)
conneztofsOand0
- No continuity *Voltage between q (4) !@0)- 0 t@): l -3V
between any of Load detector output adjustment value
q (female) @, @, Generator load: 0% - 3V
8 and chassis [ Generator load: 100% -) IV Defective wiring harness lepair wiring
ground.
I\IO (between q and q) larness
l Connect each of
q (female) @I,@, (@), @I, (8) to chassis ground.
* Continuity between each of q (female) @, @, @ and
chassis ground.
95 SERIES
’*P
lO.Diagnosis lamp gives no display
1 YES
Abnormality in controller
Is voltage between q
OFF OFF
(checkterminal) @
- and generator body, - Defective wiring harness
and between @and
(between q @ t@) and
generator normal?
r- ACC terminal, or between
* 0 voltage: NO q @ (I@ @)) and battery
+20 - +3ov ground)
* 0 voltage: 0 - +2V
*Turn power source ON.
TDE00099
95 SERIES
’2-:67
11. Normal display
a. Low idling/rated does not switch

Cause Remedy
1 YES
-Abnormality in controller Replace
Is voltage
; “6;- between q @ -
Green Red and q @ normal? Defective wiring harness
(between low idling/rated Repair wiring
* Turn power NO changeover switch and harness
source ON. controller)
. At low idling:
20 - 3ov
* At rated: 0 - 2V
I I
TDEOOlOO
b. 50/60 Hz does not switch Cause Remedy
1 YES
L Abnormality in controller Replace
Is continuity
between q (female) _
@and q (female) d Defective wiring harness
Green Red normal?
III (between 50/60 Hz Repair wiring
I
* Disconnect q. NO changeover switch and harness

* 50 Hz selected: Continuity controller)
. 60 Hz selected: No continuity
50/60 Hz changeover
gl &
=
0
&
F
s
TDEOOIOI
’*2* 95 SERIES
c. Defective starting
(engine is cranked but no exhaust smoke comes out)
Check first for any cause outside the electronic
governor system (abnormality in fuel system, etc.)
Cause Remedy
ON OFF Is there short

1
YES
I
. Defective injection pump
(defective wiring harness) I
Fleplace or
r’epair
circuit between q
0 0 (female) 8 and q 2 YES Defective wiring harness lepair or
Green Red (female) @I?
Is there short circuit (between 0 and q ) eplace
-Turn power between q (female)
source OFF. NO @ (6% and q
- Disconnect 0. (female) @ @?
Defective controller leplace
- Turn power NO
source OFF.
- Disconnect a.
L..
TDE00095
95 SERIES
’*-Lf9
d. Exhaust smoke comes out, but engine does not start
Cause Remedy
YES Defective injection pump leplace or

(defective wiring harness) epair
ON OFF 1 Ilsthereshort ‘1 :
Short circuit in rack
YES lepair or
sensor wiring harness
eplace
between 0 and q
IS mere snort (
* Turn power
source OFF. Cause is probably outside
* Disconnect 0. electronic governor
system
___.__ _. F.
Defective wiring harness
* Disconnect a. lepair or
[between starting switch
eplace
*20-3ov NO terminal q and q)
(battery voltage)
* Disconnect @I.
* Turn power
source ON.
* Start engine.
-2
51
r- 40
L- 52
•1C
I I
TDE00095
Starting switch
C terminal
-
TDE00102
’2i?70 95 SERIES
e. Engine stops during operation

This electronic governor system is designed to stop the engine in the
following cases.
1. When the emergency stop switch is being pressed
2. When the engine water temperature is abnormal
3. When the engine oil pressure is abnormal
95 SERIES
’*-ii7’
12. Memory is not cleared when memory clear switch is pressed

(when diagnosis lamp displays failure)
To clear the memory, keep the memory clear switch pressed for at least 5 seconds. The
memory is not cleared if the switch is pressed only momentarily.
If the memory is not cleared when memory clear switch is pressed for more than 5 seconds,
carry out the troubleshooting below.
Cause Remedy
1 YES
Replace
= _ Defective controller
Is continuity
between q
Defective memory clear
(female) @ and @J
switch or defective wiring Replace switch
normal?
) harness (between memory or repair wiring
- Turn power NO clear switch and harness
source OFF. controller)
* Disconnect a.
* Memory clear switch ON: Continuity
* Memory clear switch OFF: No continuity
Memory clear switch
TDE00103
‘2i72 95 SERIES
ENGINE
13 DISASSEMBLY AND ASSEMBLY
3D95S-W-1
General disassembly . . . . . . . . . 13-001-I
General assembly . . . . . . . . . . . . 13-001-9
4D95S-1
General disassembly . . . . . . . . . . . . 13-001-22
General assembly .. ... . . . . . 13-001-33
4D95L SERIES
General disassembly . ..... . . . . . 13-002
General assembly ..... . . . . . . . . . . 13-016
6D95L SERIES
General disassembly . . . . . . . . . . . . 13-036
General assembly .... . ..... . . . . 13-050
Disassembly and assembly of

air compressor . . .. ..... ..... 13-070
* The work procedure may differ slightly from that given here depending upon the ma-
chine in which the engine is mounted and also the particular stand used, however it is
fundamentally the same.
* Use the correct service tools when performing disassembly and assembly.
95 SERIES
’3-:01
GENERAL DISASSEMBLY AND ASSEMBLY (3D95S-W-l)
GENERAL DISASSEMBLY GENERALASSEMBLY

1. Fan, fan pulley ................. ....... 13-001-2 1. Tappet ............................. . 13-OOI- 9
2. Alternator ..................... ....... 13-001-2 2. Camshaft assembly ................. . 13-OOI- 9
3. Starting motor ................. ....... 13-001-3 3. Crankshaft .......................... . 13-OOI- 9
4. Water pump ................... ....... 13-001-3 4. Main cap ........................... . 13-001-10
5. Filter, level gauge .............. ....... 13-001-3 5. Piston, connecting rod assembly .... . 13-001-11
6. Fuel filter, injection tube ........ ....... 13-001-3 6. Oil pump ........................... . 13-001-13
7. Nozzle holder .................. ....... 13-001-3 7. Idler gear ........................... . 13-001-13
8. Glow plug ..................... ....... 13-001-3 8. Gear cover ......................... 13-001-14
9. Fuel injection pump............ ....... 13-001-3 9. Oil suction pipe ..................... . 13-001-14
10. Cylinder head cover ............ ....... 13-001-4 10. Oil pan ............................. 13-001-14
11. Rocker arm .................... ....... 13-001-4 11. Crankshaft pulley ................... . 13-001-14
12. Push rods ..................... ....... 13-001-4 12. Housing ............................ . 13-001-15
13. Cylinder head assembly ........ ....... 13-001-4 13. Flywheel ............................ . 13-001-15
14. Flywheel ....................... ....... 13-001-5 14. Cylinder head ....................... . 13-001-15
15. Housing ....................... ....... 13-001-5 15. Push rods .......................... 13-001-17
16. Crankshaft pulley .............. ....... 13-001-5 16. Rocker arm ......................... 13-001-17
17. Oil pan ........................ ....... 13-001-5 17. Adjusting valve clearance ........... . 13-001-18
18. Oil suction ................
pipe ....... 13-001-5 18. Cylinder head cover ................. . 13-001-18
19. Gear cover .................... ....... 13-001-6 19. Fuel injection pump ................. . 13-001-18
20. Idler gear ...................... ....... 13-001-6 20. Glow plug .......................... . 13-001-18
21. Oil pump ...................... ....... 13-001-6 21. Nozzle holder ....................... . 13-001-19
22. Camshaft assembly ............ ....... 13-001-6 22. Fuel filter, injection tube ............. . 13-001-19
23. Piston, connecting rod assembly ....... 13-001-6 23. Oil filter, level gauge ................ . 13-001-19
24. Main cap ...................... ....... 13-001-8 24. Water pump ........................ . 13-001-19
25. Crankshaft ..................... ....... 13-001-8 25. Starting motor ...................... . 13-001-19
26. Tappet ........................ ....... 13-001-8 26. Alternator .......................... . 13-001-20
27. Fan, fan pulley ...................... 13-001-20
95SERlES
‘3-08’-’
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY (3D95S-W-1)
GENERAL DISASSEMBLY (3D95S-W-1)
Special tools
No. 1 Part No. Part Name Q’ty
A 1 795-102-2102 1 Spring pusher I 1

B I 795-100-4710 I Valve guide remover I 1
C I 795-100-2800 I Piston ring tool I 1
l Preparatory work
l Remove all dirt and mud from around the engine.

l Remove the drain plug and drain the oil from the
engine.
:
I Engine oil: Approx. 5.0 I!
l Prepare a stable engine stand @ which will pre-

vent the engine from falling over, then put the en-
gine securely on the stand.
1. Fan, fan pulley

Remove fan.
Loosen mounting bolts of adjustment plate (I),
then loosen mount bolt, and remove belt.
A Be careful not to catch

age the alternator when
your
moving
fingers or dam-
the alterna-
tor towards the cylinder block.
Remove fan puley (2).
2. Alternator
Remove adjustment plate and mount bolt, then
remove alternator (3).
95 SERIES
’3-oz’
-*
3. Starting motor
Remove starting motor (4).
4. Water pump
Pull out pilot portion, then remove water pump (5).
5. Filter, level gauge

1) Remove filter (6).
2) Remove level gauge (7).
3) Remove hose (8).
6. Fuel filter, injection tube

1) Disconnect hose (9) and remove fuel filter (IO)
2) Remove fuel injection tube (11).
7. Nozzle holder
Disconnect spill tube, and remove nozzle holder (12).
* Be careful not to damage the tip of the nozzle
holder when removing.
* Mark the nozzle holders with tags showing the PO-
sition of installation. If there is no abnormality in
the nozzle holder, install it in the same position
when assembling.
8. Glow plug
Remove glow wire (13), then remove glow plug (14).

Disconnect lubrication tube, then remove fuel injection
pump (15).
13-tP3 95 SERIES
10. Cylinder head cover

Remove cylinder head cover.
11. Rocker arm

Remove rocker arm (16).
* When removing the rocker arm, loosen the locknut
and turn the adjustment screw back 2 - 3 turns.
12. Push rods

Remove push rods (17).
* Mark the push rods with tags to show the position
of installation. If there is no abnormality in the
push rod, install it in the same position when
assembling.
13. Cylinder head assembly

Remove cylinder head mounting bolts.
Remove cylinder head assembly (18).
* Lay cardboard on the floor to protect the bot-
tom face of the cylinder head from damage.
When disassembling the cylinder head assembly,
do as follows.
1) Using tool A, compress valve spring, then
remove valve cotter (19).
ii) Release pressure on spring, and remove
spring seat (20) and valve spring (21).
iii) Remove valve (22).
P614701Of5
iv) Using tool B, remove valve guide (23).
95 SERIES 13-og l-4

14. Flywheel
Remove flywheel (24).
a If the flywheel comes out from pilot, the fly-

wheel may drop suddenly, so handle carefully.
15. Housing
1) Remove housing (25).
2) Remove rear seal (26).

1) Remove plate (27).
2) Remove crankshaft pulley (28).
17. Oil pan

* Turn the engine over and set the oil pan at the top,
then remove the engine oil pan.
18. Oil suction pipe

Remove oil suction pipe (29).
13-O$l-5 95 SERIES
19. Gear cover

1) Remove gear cover (30).
2) Remove front seal (31).
20. Idler gear

2) Remove idler gear (33).
21. Oil pump

1) Remove oil pump (34).
2) Remove driven gear (35).
22. Camshaft assembly

1) Remove mounting bolts (36) through casting hole
in gear.
2) Remove camshaft assembly (37).
* When removing, rotate the camshaft lightly
and be careful not to damage the bushing.
23. Piston, connecting rod assembly

* Check that the number stamped on the connecting
rod cap matches the cylinder number.
Sr Taking care not to damage the inside of the cylin-
der, use fine sandpaper to remove the carbon on
the top wall of the cylinder.
* Measure the side clearance of the connecting rod
with dial gauge 0.
95 SERIES
Rotate the crankshaft to set the piston to be

removed at bottom dead center.
Remove mounting bolts of connecting rod cap
(38), then remove connecting rod cap together
with bearing.
Push piston and connecting rod assembly with a
wooden bar or hammer handle from oil pan side.
Support piston at cylinder head end, then push bar
in further from oil pan side and remove piston and
connecting rod assembly (39).
Disassemble piston and connecting rod assembly

as follows.
Using snap ring pliers, remove snap ring (40).
Remove piston pin (41), and separate connect-
ing rod (42) and piston (43).
* If the pin does not come out, soak in hot
water.
Remove snap ring on other side in the same
way.
P6 I 470 IO28
4) Using tool C, remove piston ring (44).
5) When replacing bushing (45), use push tool @

(outside diameter: 32 mm) to remove bushing.
* Keep the pistons, connecting rods, bear-

ings, piston rings, and piston pins in sets
for each cylinder number.
P61470t031
d2 P634708032
95 SERIES
13-iP7
24. Main cap

* Measure end play of crankshaft using dial gauge
0.
* The end play measurement is necessary for
judging wear of the thrust bearing and abnor-
mal wear of the crankshaft, so measure before
removing the crankshaft.
1) Remove mounting bolts of main cap, then remove

main cap (46) together with lower bearing.
* Rubber seal (47) is assembled to No. 4 main
cap.
25. Crankshaft
1) Remove crankshaft (48).
* Be careful not to hit the crankshaft against the
cylinder block and damage the sliding surface.
2) Remove upper main bearing (49), and thrust bear-
ing (50).
* Mark the main bearing and thrust bearing with
tags or a felt pen to show the position of in-
stallation, and keep in sets for each cap
number.
26. Tappet
Remove tappet (51).
95 SERIES
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY (3D95SW-1)
GENERAL ASSEMBLY
Special tools
No. Part No. Part Name O’ty
A 795-l 02-2102 Spring pusher 1
C 795-l 00-2800 Piston ring tool 1
D 795-l 00-4720 Push tool 1
F ) 795-213-1800 ) Piston holder I 1

G 1 795-100-4700 1 Push tool I 1
H 795-l 25-l 370 Feeler gauge 1
* Coat the sliding surfaces of all parts with engine oil

(EOBO-CD) before installing.
1. Tappet
Assemble tappet (51).
1) Insert camshaft assembly (37) into cylinder block.
* Rotate the camshaft lightly when inserting to
avoid damaging the bushing.
2) Tighten mounting bolts (36) of thrust plate through
casting hole of gear.
m Mounting bolt: 1.4 k 0.5 kgm
3. Crankshaft
1) Align protrusion of upper main bearing (49) with
notch in cylinder block, then assemble to cylinder
block.
* Check that there is no dirt or dust stuck to the
rear face of the bearing.
2) Assemble thrust bearing (50).
3) Assemble crankshaft (48) to mounting position.

t Be careful not to hit the crankshaft against the
cylinder block.
t When the crankshaft gear has been replaced,
heat the crankshaft gear in an electric furnace
to 230 - 250°C for approx. 30 minutes, then
shrink fit the gear.
’3-oz’-9 95 SERIES
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY (3D95S-W-1)
4. Main cap
1) Align protrusion in lower main bearing with notch
in cap (46), then install main bearing cap.
* Assemble rubber seal (47) and the thrust bear-
ing to No. 4 main cap.
Rubber seal
IT
P
I
L
L 6206F554
& Rubber seal groove: Gasket sealant
2) Check that number stamped on main cap is the

same as number on cylinder block, then assemble
main cap and tighten mounting bolts.
t Assemble the main cap with the casting part
number facing the front.
3) Tighten mounting bolts of main cap with a torque
wrench as follows.
* When tightening the mounting bolts of the
main cap, start in the middle and work to the
outside symmetrically to the left and right.
Tighten in steps to the following torque.
& Bolt thread, seat face: Engine oil
B Mounting bolt of main cap

kgm
Order Target Range
1 st step 11.5 11 - 12
2nd step I 0 I Loosen completely

3rd step 13.5 13 - 14
* After tightening the main cap mounting bolts,

check that the crankshfat rotates smoothly.
95 SERIES
‘3-oP’o
4) Measure end play of crankshaft. (See DIS-

ASSEMBLY for details)
+ Permissible range of end play: 0.13 - 0.35 mm

* If the piston and connecting rod were disassem-
bled, assemble the piston and connecting rod as-
sembly first as follows.
1) Using push tool @ (outside diameter: 32 mm),
press fit connecting rod bushing (45).
P614701032 P614705031
2) Using tool C, install piston ring (44).

* Set the compression ring with the
stamped mark at the end gap facing up.
* When fitting the oil ring, assemble the ex-
pander to the piston first, and fit securely
into the groove on the inside diameter of
the oil ring.
* The end gap of the ring should be at 180
to the join of the coil in the expander.
3) Assemble snap ring on one side in snap ring
groove of piston.
_ PSf4708030
4) Set F mark on piston boss surface facing in

same direction as casting number on connect-
ing rod. Insert piston pin (41), and assemble
connecting rod (42) and piston (43).
5) Assemble snap ring (40) and secure with pis-
ton pin.
* Assemble the snap ring securely in the
ring groove.
* After assembling the snap rings, check
that the connecting rod moves smoothly
forward and backward.
P614701028
13-oP1
’ 95 SERIES
Position of oil ring end gap

Assemble the piston and connecting rod in the
cylinder block as follows.
Set end gaps of piston rings as shown in diagram.
Set crankshaft pin of piston and connecting rod to
be installed at bottom dead center. Position of top ring
end gap
Align protrusion in upper bearing of connecting
rod with notch in connecting rod, then install
Position of
bearing. undersize line
* Coat the inside face of the cylinder, the piston
rings and the surface of the connecting rod
bearing with engine oil.
Position ofcsecond ring end gap
4) Align direction of F mark on piston boss surface to

face front of engine. Using tool F, insert piston and
connecting rod (39) from cylinder head gnd.
5) When piston rings are inserted inside cylinder
liner, push in head of piston. In addition, pull big
end of connecting rod and fit to crankshaft pin.
6) Align protrusion of lower bearing of connecting
rod with notch in connecting rod cap, then as-
semble bearing.
f Check that there is no dirt or dust stuck to the
7) Set with stamped mark at camshaft end, then in-

stall connecting rod cap (38).
t Check that the stamped number on the con-
necting rod cap is the same as the number of
the cylinder.
9) Tighten mounting bolts of connecting rod cap as
follows.
a Bolt thread, seat face: Engine oil
m Mounting bolt of connecting rod

1 st stap Tighten in turn to 4+t2 kgm
2nd step Mark bolt head and cap seat with a felt
pen, then turn bolt 90+s0’to tighten.
* After tightening, make a punch mark on the
bolt head to indicate the number of times the Put a mark on the bolt cap
bolt has been tightened.
The bolt can be used a maximum of five
times. Always replace any bolt that already
has five punch marks.
t After assembling the connecting rods, check
that the crankshaft rotates smoothly. After tightening, stamp
mark the tightening time
on bolt head by punch
6206F303
95 SERIES 13-og-12
9) Measure side clearance of connecting rod cap.

(See DISASSEMBLY for details.)
* Permissible range of side clearance: 0.20 -
0.40 mm
6. Oil pump
1) Install driven gear (35) of oil pump.
2) lnstal oil pump (34).
7. Idler gear
Align match marks of gear, and install idler gear
(33).
* Match marks
Crankshaft gear and idler gear: “A”
Cam gear and idler gear: “B”
Install plate (32), then tighten mounting bolts.
m Mounting bolt: 110.2 + 12.3 Nm

(11.25 + 1.25 kgm)
Measuring backlash of gears
Align match mark “C” of fuel injection pump (15),
install temporarily, then measure backlash of each P6t4701022
gear.
* When measuring the backlash of each gear,
hold one gear in position securely, and move
the other gear to measure.
P614701041
j, Gear backlash (helical gear) t Gear backlash (helical gear)

(Serial No.: 106425 and below) Unit: mm (Serial No.: 106426 and up) Unit: mm
Match Match
Position of measurement Range Position of measurement Range
mark mark
I I
A - A Crankshfat gear and idler gear 0.14 - 0.28 A - A 1Crankshaft crear and idler aear 1 0.08 - 0.19
B - B 1 Cam gear and idler gear / 0.15 - 0.30
C- C ) Injection pump gear and idler gear / 0.13 - 0.34

- Cam gear and oil pump gear 0.13 - 0.35
- 1Cam gear and PTO gear (With PTO) 1 0.15 - 0.30
13-oP’3 95 SERIES
8. Gear cover
1) Using push tool, install front seal (31).
* Fill 40 - 60% of space at seal lip with grease.
& Front seal: Grease (G2-LI)
2) Coat mounting surface on cylinder block side with

gasket sealant.
a Gear cover mounting surface:

Gasket sealent (LG-7)
* Coat the gasket sealant in a line with a width

of approximately $1 mm.
P6l4701021
3) Install gear cover (30).

4) Measure difference in height of surface for mount-
ing oil pan on cylinder block and gear cover.
+ Permissible difference in height of oil pan
mounting surface: Max. 0.15 mm
p6:4701020
9. Oil suction pipe

Fit O-ring and install oil suction pipe (29).
10. Oil pan

Coat mounting face with gasket sealant, then install
engine oil pan.
t Coat the gasket sealant in a line with a width of
approximately $1 mm.
a Oil pan mounting face:

Gasket sealant (LG-7)
m Mounting bolt: 1.9 + 0.5 kgm

614701019

1) Align with crankshaft key, then install crankshaft
pulley (28).
2) Fit plate (27), then tighten mounting bolts.
w Mounting bolt: 9.5 + 0.5 kgm
95 SERIES
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY (3D95SW-1)
12. Housing
1) Install rear seal (26).
* Fill 40 - 60% of space at seal lip with grease.
& Rear seal: Grease (G2-LI)
2) Coat mounting surface with gasket sealant, and in-

stall housing (25).
& Housing mounting surface:

* When fitting the seal lip to the outside
diameter of the crankshaft flange, be careful
not to apply force to the seal lip surface.
13. Flywheel
Install flywheel (24).
& Bolt thread: Engine oil
m Mounting bolt:
Unit: kgm
Order Target I Range
1st step 11.0 IO- 12
2nd step 19.5 19-20
14. Cylinder head

* If the cylinder head assembly has been disassem-
bled, assemble as follows.
i) Using push tool G, install valve guide (23).
ii) Coat valve stems with engine oil, and as-
semble valve (22).
iii) Assemble valve spring (21) and spring seat 22 ’
(20), then using tool A, compress valve spring,
and fit valve cotter (19) in valve stem groove.
* Tap the top of the valve stem with a plas-
tic hammer to check that the valve cotter
is completely fitted.
‘3-oF 95 SERIES
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY (3D9BS-W-1)
3) Tighten mounting bolts of cylinder head in the Exhaust side

order shown in the diagram.
Ml
Intake side 6206F555
* There are two methods of tightening the head

bolts: the tightening torque method which
controls the tightening force, and the plastic
turning angle method. (See the figure on the
28
right.)
120
m Cylinder head mounting bolt m
1st step: 68.6 - 88.2 Nm (7 - 9 kgm) Tightening by plastic turning angle Tightening by torque
2nd step: 107.8 - 127.4 Nm
(II-13kgm) 6206F872
3rd step: 142.1 - 151.9 Nm
(14.5 - 15.5 kgm)
& Bolt thread: Anti-friction compound (LM-P)
m Cylinder head mounting bolt

Make mark with punch
1st step: 68.6 + 9.8 Nm (7 * 1 kgm) \
2nd step: 107.8 f 4.9 Nm (11 + 0.5 kgm)
3rd step: Mark bolt head and cylinder head Make mark on cylinder
with a felt pen, then turn bolt 90+i”
to tighten.

bolt head to indicate the number of times the
bolt has been tightened.
The bolt can be used a maximum of five
times. Always replace any bolt that already F621201067A F621201061
95 SERIES
13-oP6
16. Rocker arm
13-oP17 95 SERIES
17. Adjusting valve clearance

* Adjust the clearance between the valve and rocker
lever.
* Standard value for valve clearance
Intake valve: 0.35 mm, Exhaust valve: 0.5 mm
1) Rotate the crankshaft in the normal direction to

align the pointer on the gear cover with the 1 TOP
mark on the crankshaft pulley. When rotating,
check the movement of the intake valve of No. 1
cylinder.
2) Insert feeler gauge H between rocker lever and

valve stem and turn adjustment screw until clear-
ance is a sliding fit. Then tighten locknut to hold
adjustment screw in position.
w Locknut: 4.5 + 0.5 kgm
3) When No. 1 cylinder is at top dead center, adjust

the valves of No. 1 cylinder. Then rotate the crank-
shaft in the normal direction, and adjust the valves
of each cylinder in the firing order.
* Firing order: 1 - 3 - 2

Fit O-ring and install cylinder head cover.

Tighten mounting bolts of fuel injection pump (15)
fully, then fit gasket and install lubrication tube.
20. Glow plug
1) Install glow plug (14).
m Glow plug: 1.25 + 0.25 kgm
2) Install glow wire (13).
95 SERIES
13-OiP8
13-o:1-‘9 95 SERIES
26. Alternator
Install alternator (3), then temporarily tighten adjust-
ment plate (1).
27. Fan, fan pulley

1) Tighten fan pulley (2) together with fan. Fan pulley
2) Fit belt in pulley groove, then insert a bar or pipe Alternator pulley
between alternator and cylinder block, and raise

alternator to outside to adjust fan belt tension.
‘\
* Adjust so that the belt deflects the amount ‘\
\\
given below when pushed with a finger press-
‘v
ure of 6 kg at a point midway between the al- 14- 17 mm ‘\
‘\
ternator pulley and the crankshaft pulley. ‘\
* Deflection of belt: 14 - 17 mm
3) After adjusting the belt tension, tighten the bolts Q
Crankshaft pulley
fully.
614OF301
95 SERIES
’3-o&’
-20
GENERAL DISASSEMBLY AND ASSEMBLY (4D95S-1)
GENERAL DISASSEMBLY GENERAL ASSEMBLY

1. Unit repair stand ............... 13-001-23 1. Unit repair stand ...................... 13-001-33
2. Fan.. .......................... . . . 13-001-23 2. Tappet ............................... 13-001-33
3. Alternator ..................... . . . 13-001-23 3. Crankshaft ............................ 13-001-33
4. Fan pulley ..................... . . . 13-001-23 4. Main cap ............................. 13-001-34
5. Starting motor ................. . . . . 13-001-24 5. Piston, connecting rod assembly ...... 13-001-34
6. Fuel injecttion pipe ............. . . 13-001-24 6. Flywheel housing ..................... 13-001-38
7. Fuel injection pump ............ . . . . 13-001-24 7. Flywheel .............................. 13-001-39
8. Intake manifold ................ . . . 13-001-24 8. Camshaft assembly ................... 13-001-39
9. Water pump ................... ... 13-001-25 9. Idler gear ............................. 13-001-39
10. Glow wire, glow plug .......... . 13-001-25 10. Oil pump ............................. 13-001-40
11. Nozzle holder .................. . . . 13-001-25 11. Gear case cover ...................... 13-001-41
12. Cylinder head cover ............ ... 13-001-25 12. Crankshaft pulley ..................... 13-001-41
13. Rocker arm assembly .......... .. 13-001-25 13. Oil suction pipe ....................... 13-001-41
14. Push rods ..................... .. 13-001-26 14. Oil pan ............................... 13-001-42
15. Cylinder head assembly ........ . 13-001-26 15. PTO shaft ............................. 13-001-42
16. PTO shaft ...................... ... 13-001-27 16. Cylinder head assembly ............... 13-001-42
17. Oil pan ........................ 13-001-27 17. Push rods ............................ 13-001-43
18. Oil suction ................
pipe . . . . 13-001-27 18. Rocker arm assembly ................. 13-001-44
19. Crankshaft pulley .............. 13-001-27 19. Adjusting valve clearance ............. 13-001-44
20. Gear case cover ............... . . . 13-001-28 20. Cylinder head cover ................... 13-001-45
21. Oil pump ...................... . . . . 13-001-28 21. Nozzle holder ......................... 13-001-45
22. Idler gear ...................... . . 13-001-28 22. Glow wire, glow plug ................. 13-001-45
23. Camshaft assembly ............ . . 13-001-28 23. Water pump .......................... 13-001-45
24. Flywheel ....................... . . 13-001-29 24. Intake manifold ....................... 13-001-45
25. Flywheel housing .............. . . . . 13-001-29 25. Fuel injection pump ................... 13-001-46
26. Piston, connecting rod assembly . . 13-001-29 26. Fuel injection pipe .................... 13-001-46
27. Main cap ...................... . . . . 13-001-30 27. Starting motor ........................ 13-001-46
28. Crankshaft ..................... .. 13-001-30 28. Fan pulley ............................ 13-001-47
29. Tappet ........................ . . . . 13-001-30 29. Alternator ............................ 13-001-47
30. Fan.. ................................. 13-001-47
31. Lowering engine ...................... 13-001-47
95 SERIES
’3-o$’
-22
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY (4D95S-1)
GENERAL DISASSEMBLY (4D95S-1)
Special tools
No. Part No. Part Name Q’ty
790-501-5000 Unit repair stand

or or 1
A 790-501-2000 Engine repair stand
. Preparatory work
. Remove all dirt and mud from around the engine.
. Remove the drain plug and drain the oil from the
engine.
4
.(. Engine oil: Approx. 6 P
. Prepare a stable engine stand which will prevent

the engine from falling over, then put the engine
assembly securely on the stand.
r?zlkg Engine assembly: Approx. 255 kg

(The weight differs according to the ma-
chine model.)
1. Setting in unit repair stand

1) Remove oil filter.
2) Install engine assembly on unit repair stand A.
2. Fan
Remove fan (1).
3. Alternator
1) Loosen mounting bolts of adjustment plate (I),
and mounting bolt and nut of alternator.
6202P500
2) Move alternator towards cylinder block, and
remove belt (2).
A Becareful not to catch your fingers or dam-

age the alternator when moving the alter-
nator towards the cylinder block.
3) Remove alternator (3).
4. Fan pulley
Remove fan pulley (4).
13-0(&l-23 95 SERIES
5. Starting motor
_.-. ;” ,,;
6202P504
6. Fuel injection pipe

1) Remove clamp (1).
2) Remove sleeve nut, then remove fuel injection
pipe (2).

1) Remove oil supply tube (1).
4 Remove bracket (2).
3) Remove cover (3), then remove fuel injection
pump (4).
* Remove mounting bolts (5) from the fuel injec-
tion pump side.
* To prevent dirt or dust from entering, fit caps
or use tape to cover the oil and fuel inlet and
outlet ports.
8. Intake manifold
Remove intake manifold (1).
1
202P509
95 SERIES
’ 3-oih’ -24
9. Water pump
Remove water pump (1).
10. Glow wire, glow plug

Remove glow wire (I), then remove glow plug (2).
11. Nozzle holder

Disconnect spill hose (3), and remove nozzle holder (4).
* Mark the nozzle holders with tags showing the po-
sition of installation. If there is no abnormality in
the nozzle holder, install it in the same position
when assembling.

Remove cylinder head cover (5).
13. Rocker arm assembly

1) Remove rocker arm assembly (1).
t When removing the rocker arm, loosen the
locknut and turn the adjustment screw back
2 - 3 turns.
2) Remove stem cap (1).
’3-o:’
-25 95 SERIES
14. Push rods

Remove push rods (1).
* Mark the push rods with tags to show the position
of installation. If there is no abnormality in the
push rod, install it in the same position when
assembling.

1) Remove cylinder head mounting bolts.
2) Fit lifting tool to mount on cylinder head, then lift
off cylinder head assembly (1) with crane.
* Lay cardboard on the floor to protect the bot-
tom face of the cylinder head from damage.
el kg Cylinder head: 30 kg
l When disassembling the cylinder head assembly,

do as follows.
i) Using spring pusher B, compress valve spring,
then remove valve cotter (2).
ii) Release pressure on spring, and remove
spring seat (3) and valve spring’(4).
iii) Remove valve (5).
6206F30i
iv) Using valve guide remover C, remove valve

guide (6).
95 SERIES
16. PTO shaft

1) Remove flange (1).
2) Remove PTO shaft (2).
17. Oil pan

Remove oil pan (1).
* If the oil pan is stuck and cannot be removed, in-
sert a wedge at the boss on the oil pan mounting
surface and remove.
6202P519

Remove oil suction pipe (I)

2) Remove crankshaft pulley (2).
’3-o2
-27 95 SERIES
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY (4095S-1)
20. Gear case cover

1) Remove gear case cover (1).
2) Remove front seal (1).
6206P406
21. Oil pump

Remove oil pump (1).
22. Idler gear

2) Remove idler gear (3).
* For machines with PTO, a bearing is used for the
idler gear bushing.

1) Turn over cylinder block so that cylinder head
mounting face is facing down.
2) Remove mounting bolts (1) through casting hole in
gear.
3) Remove camshaft assembly (3) together with
thrust plate (2).
* When removing, rotate the camshaft lightly and be
careful not to damage the bushing.
95 SERIES
’3-oii1
-28
24. Flywheel
1) Remove flywheel (1).
A The pilot is short,

suddenly,
and the flywheel
so be careful not to get your
may come off
fingers
caught.
25. Flywheel housing

1) Remove flywheel housing (1).
2) Remove rear seal (1).

1) Checking connecting rod cap number.
i) Turn over cylinder block, and set so that cylin-
ders are horizontal.
* Turn over carefully and make sure that the
tappets do not fall out.
ii) Check that the number stamped on connecting
rod cap matches cylinder number.
* If there is no number stamped on the connect-
ing rod cap, stamp a number at the camshaft
end.
-29
’3-oki1 95 SERIES
2) Removing carbon
Using fine sandpaper, remove carbon at top of cy-
linder wall.
t Be careful not to damage the inside of the cy-
linder.
t Measure the end play of the connecting rod with
dial gauge @ before removing the piston and con-
necting rod assembly.
3) Connecting rod cap

i) Rotate the crankshaft to set the piston to be
removed at bottom dead center.
ii) Remove mounting bolts of connecting rod cap
(I).
iii) Tap cap with plastic hammer and remove con-
necting rod cap together with bearing.
4) Piston, connecting rod assembly

Push piston and connectng rod assembly with a
wooden bar or hammer handle from oil pan side.
Support piston at cylinder head end, then push bar
in further from oil pan side to remove piston and
connecting rod assembly (2).
6206P332
5) Disassembly of piston and connecting rod assembly

i) Using pliers 0, remove snap ring (3) on one
side.
ii) Remove piston pin (4), and separate connect-
water.
iii) Remove snap ring on other side in the same

way.
95 SERIES
’3-oE
-30
iv) Using piston ring tool D, remove piston ring

(7), oil ring (9), and expander (IO) from piston.
6202P524
v) If bushing (8) is worn, use push tool @ (out-

side diameter: 32 mm) to remove bushing.
* Keep the pistons, connecting rods, bear-
ings, piston rings, piston pins, and bush-
ings in sets for each cylinder number.
6206P336
27. Main cap

1) Measuring end play
i) Turn over cylinder block so that oil pan is fac-
ing up.
ii) Measure end play of crankshaft using dial
gauge 0.
* The end play measurement is necessary
for judging wear of the thrust bearing and
abnormal wear of the crankshaft, so
measure before removing the crankshaft.
2) Main cap
i) Remove mounting bolts (1) of main cap.
ii) Insert mounting bolt in bolt hole in cap, then
lever cap, or tap with plastic hammer on left
and right, and remove main cap (3) together
with lower main bearing (2).
13-oz’-3’ 95 SERIES
* Thrust bearings (4) are assembled on both sides of

cap (3) at the flywheel end, so after removing,
mark them to show the position of installation.
28. Crankshaft
1) Crankshaft
Remove crankshaft (1).
PI kg Crankshaft: 25 kg
2) Upper main bearing

Remove upper main bearing (2).
tags to show the position of installation, and
keep in a safe place in sets for each cap
number.
29. Tappet
Remove tappet (1).
95 SERIES
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY (4D95S-1)
GENERAL ASSEMBLY (4D95S-1)
Special tools
No. Part No. Part Name O’ty
790-501-5000 Unit repair stand

or or 1
A 790-501-2000 Engine repair stand
790-901-I 250 Bracket 1
B 795-l 02-2102 Spring pusher (KIT) 1
D 795-l 00-2800 Piston ring tool 1
E 795-213-l 800 Piston holder 1
F 795-l 00-4700 Push tool 1
G 795-l 25-l 370 Feeler gauge 1

Set cylinder block on unit repair stand A.
2. Tappet
1) Turn over cylinder block so that cylinder head side
is facing down.
2) Coat with engine oil and assemble tappet (1).
3. Crankshaft
1) Upper main bearing
i) Align protrusion of upper main bearing (2)
with notch in cylinder block, then assemble to
cylinder block.
* Check that there is no dirt or dust stuck to
the rear face of the bearing. Coat the in-
side face of the bearing with engine oil
(SAE30) before assembling.
’3-o:’
-33 95 SERIES
ii) Raise crankshaft (I), and assemble to mount-

ing position.
* Be careful not to hit the crankshaft against
the cylinder block.
4. Main cap
1) Lower main bearing
i) Align protrusion in lower main bearing (2) with
notch in cap, then install main cap (3).
the rear face of the bearing.
2) Main cap
i) Check that number stamped on main bearing
cap is the same as number on cylinder block.
ii) Set casting number of main cap facing front,
and assemble mounting bolts (1).
iii) Align thrust bearing (4) with dowel pin, then
install in main cap (3).
* Assemble two thrust bearings at the top
and bottom at the flywheel end and one at
the opposite end.
Note: Depending on the machine model,
there may be only one thrust bear-
ing at the bottom at the flywheel
end.
* Install each thrust bearing with the oil
groove on the outside.
iv) Set casting number facing front, and install

main bearing cap (3).
* Be careful not to let the thrust bearings
slip out of place.
v) Tighten cap bolts with torque wrench as
follows.
* Coat the bolt thread and seat face with en-
gine oil (SAE30).
95 SERIES
’3-o&A’
-34

main bearing cap, start in the middle and
w Mounting bolt of main cap
work to the outside symmetrically to the
Unit: kgm
left and right. Tighten in steps to the fol-
lowing torque. Order Target I Range
* After tightening the main cap mounting
1 st step 11.5 I II-12
bolts, check that the crankshaft rotates
smoothly. 2nd step I cl I Loosen completely
I
3rd step 13.5 13 - 14
vi) Measuring end play of crankshaft

Put probe of dial gauge @ in contact with end
face of crankshaft. Read movement of gauge
when crankshaft is moved forward and back-
ward.
* Permissible range of end play: 0.13 - 0.35 mm

1) Assembly of piston and connecting rod assembly.
* If the piston and connecting rod were disas-
sembled, assemble the piston and connecting
rod assembly first as follows.
i) Using push tool @ (outside diameter: 32 mm),
press fit bushing (8) to connecting rod.
6206P336
ii) Set with stamped mark at end gap facing up

(compression ring only), then use piston ring
tool D to assemble piston ring (7), oil ring (9),
and expander (IO) on piston (6).
* Be careful not to damage the piston or
break the rings.
* Fit expander (10) in the groove on the in-
side diameter of oil ring (9) before install-
ing. Check that the expander is completely
fitted into the ring groove.
* The end gap of the ring should be at 180”
6202P524
13-og-35 95 SERIES
iii) Using pliers 0, assemble snap ring on one

side only in snap ring groove of piston.
iv) Set F mark on piston boss facing in same di-

rection as casting number on connecting rod.
6206P421
Insert piston pin (4), and assemble connecting
rod (5) and piston (6).
* If it is difficult to insert the piston pin, put
the piston in hot water to expand the
diameter of the pin hole, then insert the
pin.
v) Assemble other snap ring on other side of
piston.
vi) Align protrusion in upper bearing of connect-
ing rod with notch in connecting rod, then in-
stall.
6206P433
2) Assemble piston and connecting rod assembly in

cylinder block as follows. Oil ring Size mark IS or L)
1) Turn over cylinder block so that crankshaft is
vertical.
ii) Set end gaps of piston rings as shown in
diagram.
iii) Set crankshaft at bottom dead center in cylin- mark
der where piston and connecting rod assem-

bly are to be assembled.
* Coat the inside face of the cylinder, the
piston rings and the surface of the con-
necting rod bearing with engine oil. 6206F302
iv) Align direction of F on side face of piston to

face front of engine. Using piston holder E, in-
sert piston and connecting rod assembly (2)
from cylinder head end.
v) When piston rings are inserted inside cylinder,
push in head of piston with palm of hand or
wooden bar. In addition, pull big end of con-
necting rod to align with crankshaft pin.
95 SERIES 13-0(&l-36
vi) Align protrusion of lower bearing with notch in

cap, then assemble to connecting rod cap.
the rear face of the bearing.
vii) Set with stamped mark at camshaft end, then
install connecting rod cap (1).
Coat the connecting rod bearing with en-
gine oil.
Check that the stamped number on the
connecting rod cap is the same as the
number of the cylinder.
Tighten the connecting rod cap as follows.
Coat the connecting rod bolt thread and
seat face with engine oil.
6J3 Connecting rod cap bolt

1st step Tighten in turn to 4+:.* kgm
2nd step Mark bolt head and cap seat 4 ‘i.’ kgm
with a felt pen, then turn bolt
Put a mark on
90fi0’ to tighten. the bolt cap
After tightening, make a punch mark on
the bolt head to indicate the number of
times the bolt has been tightened. The
bolt can be used a maximum of five times.
After tightening, stamp
Always replace any bolt that already has mark the tightening time
five punch marks. on bolt head by punch
After assembling the connecting rods,
check that the crankshaft rotates
smoothly.
6206F303
’3-og’
-37 95 SERIES
6. Fhwheel housing
1) Using push tool @ (outside diameter: 120 mm), in-
stall rear seal (2) on flywheel housing (1).
4 After press fitting rear seal, fill 40 - 60% of space
at seal lip with grease.
3) Align with dowel pin, and install flywheel housing

(1).
a Mounting surface of flywheel housing:

* When fitting the seal lip to the outside
diameter of the crankshaft flange, be careful
not to apply force to the seal lip surface.
m Mounting bolt: 7 f 0.5 kgm
4) Measuring difference in height of mounting surface

Measure distance in height between surface for
mounting oil pan on cylinder block and flywheel
housing.
* Permissible difference in height of oil pan
5) Measure radial and face runout of flywheel hous-

ing with dial gauge 0.
* Radial runout: Max. 0.30 mm
* Face runout: Max. 0.35 mm
95 SERIES 13-O;l-38
7. Flywheel
1) Install flywheel housing (1).
w Mounting bolt:
Unit: kgm
2) Measure radial and face runout of flywheel.

Radial runout: Max. 0.15 mm
Face runout: Max. 0.20 mm
2) Tighten mounting bolts (1) of thrust plate (2)
through casting hole of gear to secure camshaft
assembly.
w Thrust plate mounting bolt: 1.9 * 0.5 kgm
3) Put dial gauge @ in contact with end face of cam-

shaft, move camshaft backward and forward, and
read movement of gauge.
* Camshaft end play: 0.15 - 0.35 mm
9. Idler gear
Align match marks of gear, and install idler gear
(3).
* Match marks
Crankshaft gear (5) and idler gear: “A”
Idler gear and cam gear (4): “B”
Install plate (2).
Tighten mounting bolt (1) of idler gear.
w Idler gear mounting bolt: 11.25 & 1.25 kgm
put dial gauge in contact with end face of idler

gear, move idler gear backward and forward, and
measure end play of idler gear.
* End play of idler gear: 0.03 - 0.09 mm
’3-o&Y
-39 95 SERIES
10. Oil pump

2) Install cover (2) and drive gear (3) of oil pump.
3) Mesuring end play
Measure end play of oil pump gear in same way
as measuring end play of camshaft.
* Permissible range of end play: 0.02 - 0.07
mm
* Measuring backlash of gears

Install fuel injection pump (1) temporarily, then
use dial gauge @ to measure backlash of each
gear.
* When measuring the backlash of each gear,
hold one gear in position securely, and move
the other gear to measure.
6206F411A
* Backlash of gears
Unit: mm
Match
Position of measurement Range
mark
A - A 1 Crankshfat gear and idler gear IO.08 - 0.31
B - B 1 Cam gear and idler gear IO.09 - 0.34
C - C I Injection pump gear and idler gear 10.08 - 0.31
a I Cam gear and oil pump gear 10.08 - 0.31

Cam gear and PTO gear
b 0.08 - 0.31
(machines with PTO)
95 SERIES
’3-oF&1
-40
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY (4D95S-II
11. Gear case cover

Using push tool (outside diameter: 72 mm), install
front seal (1).
After press fitting front seal, fill 40 - 60% of space
&!?I+ Front seal: Grease (G2-LI) ,
Coat mounting surface on cylinder block side with

gasket sealant (LG-7).
& Cylinder block: LG-7
6206P424
4) install gear case cover assembly (1).

mounting oil pan on cylinder block and gear case
cover.

1) Align with key of crankshaft, then install crankshaft
pulley (2).
2) Fit plate (I), then tighten mounting bolts.

’3-o&
-41 95 SERIES
14. Oil pan

1j Fit gasket and install under-plate.
2) Fit gasket and install oil pan (1).

m Drain plug: 6.0 f 1.0 kgm
6202P51 I9
15. PTO shaft

1) Align gear of PTO shaft (2) with tooth surface of
camshaft gear, and install.
2) Fit O-ring and install flange (1).

1) Assembly of cylinder head
i) Using push tool F, install valve guide (6) in cy-
linder head.
ii) Coat stems of intake and exhaust valves and
inside face of valve guide with engine oil.
iii) Install valve (5).
iv) Assemble valve spring (4) and spring seat (3).
v) Using spring pusher B, compress valve spring,
and fit valve cotter (2).
L..,
-6
6206F301
95 SERIES
2) Installation of cylinder head

* Remove all carbon and dirt from the contact
surfaces of the cylinder block and cylinder
head. Remove all burrs and damage, and
clean out all dirt form inside the cylinder block.
i) Install cylinder head gasket.
* Fit the gasket with the TOP mark facing
up.
ii) Raise cylinder head (1) then using 4 head bolts
as guide, install cylinder head to cylinder
block.
2P516
3) Tightening mounting bolts of cylinder head Order for tightening head bolts
Coat thread of cylinder head mounting bolts with
antifriction compound (LM-P), then tighten mount- Exhaust side
ing bolts of cylinder head in the order shown in
the diagram.
1st step: 68.6 - 88.2 Nm (7 - 9 kgm)
2nd step: 107.8 - 127.4 Nm
(11 - 13 kgm)
3rd step: 142.1 - 151.9 Nm Intake side
(14.5 - 15.5 kgm)

bolts: the tightening torque method which
Tightening by plastic Tightening by torque
right.) turning angle 6206F672
w Cylinder head mounting bolt Make mar< with punch
1st step: 68.6 2 9.8 Nm (7 + 1 kgm)

2nd step: 107.8 c 4.9 Nm (11 + 0.5 kgm)
Mark bolt head and cylinder head with Make mark on cylinder
3rd Step
head and bolt
a felt pen, then turn bolt 90+zV to
-6@
tighten. 90
bolt head to indicate the number of times the 3 .
bolt has been tightened. The bolt can be used
a maximum of five times. Always replace any
bolt that already has five punch marks. F621201067A F621201061
17. Push rods

Insert push rods (1) in tappet guides.
* The same part is used for the intake and exhaust
push rods.
* If there is no abnormality in the push rod, install in
the same position as before disassembly.
’3-okL1
-43 95 SERIES

1) Install stem cap (1).
2) Install rocker arm assembly (1).

f Check that the ball of the adjustment screw is
fitted properly into the socket of the push rod,
then tighten the nuts and bolts uniformly.
m Mounting bolt of rocker arm bracket:

2.5 * 0.5 kgm
* If the valve spring tension pushes against the
rocker arm, loosen the locknut and turn the
adjustment screw back 2 to 3 turns to prevent
strain on the push rod.

Adjust clearance between valve and rocker arm as
follows.
Standard value for valve clearance (both warm
and cold)
Intake valve: 0.35 mm Exhaust valve: 0.5 mm
Rotate the crankshaft in the normal direction to
align pointer (b) on the gear case cover with the
1.4 TOP mark (a) on crankshaft pulley (1). When
rotating, check the movement of the valves of No.
4 cylinder.
When No. 1 cylinder is at compression top dead
center, adjust the valves marked 0. Then rotate
the crankshaft 360” in the normal direction, and ad-
just the vales marked 0.
* Valve arrangement
Cylinder No. 1 2 3 4
k- Exhaust valve 0 l 0 0
Intake valve 0 0 0 0
95 SERIES 13-og -44

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY 14D95S-1)
3) To adjust, insert feeler gauge G between rocker

arm and valve stem and turn adjustment screw
until clearance is a sliding fit. Then tighten locknut
to hold adjustment screw in position.
m Locknut: 4.5 f 0.5 kgm
4) After adjusting valves of No. 1 cylinder at top dead

center, it is also possible to turn the crankshaft
180” each time and adjust the valve clearance of
each cylinder according to the firing order.
* Firing order: 1 - 2 - 4 - 3

Fit packing and install cylinder head cover (5).
21. Nozzle holder

1) Fit gasket and install nozzle holder (4).
2) Connect spill hose (3).
22. Glow wire, glow plug

Install glow plug (2), then install glow wire (1).
m Glow plug: 1.25 + 0.25 kgm

Glow wire mounting nut: 0.125 f 0.025 kgm
23. Water pump

Fit gasket and install water pump (1).
24. Intake manifold

Install intake manifold (1).
& Mounting surface: Gasket sealant (LG-7)

m Mounting bolt: 4.1 f 0.6 kgm
* Coat the gasket sealant in a line with a width of

approximately 41 mm.
202P509
13-og-45 95 SERIES

1) Fit O-ring, align match marks with idler gear, and
install fuel injection pump (4).
* Check that the match marks are aligned, then
fit an O-ring and install cover (3).
* Tighten mounting bolts (5) at the fuel injection
pump end.
2) Install bracket (2).
3) Install oil supply tube (1).

Before installing the fuel injection pipe, blow com-
pressed air through it to clean it.
Install fuel injection pipes (2), then temporarily
tighten sleeve nuts at both ends.
Align clearance between fuel injection pipes, then
tighten clamp (1).
Fully tighten sleeve nuts of injection pipes.
w Sleeve nut: 2.3 + 0.2 kgm
Pi89
27. Starting motor

Fit O-ring and install starting motor (1).
,-._
6202P504
.” ; ,:
95 SERIES
-46
’3-o:1
28. Fan pulley

Install fan pulley (4).
29. Alternator
1) Install alternator (3).
2) Fit belt (2) in pulley groove, then temporarily
tighten adjustment plate (1).
3) Insert a bar or pipe between alternator and cylin-
der block, and raise alternator to outside to adjust
fan belt tension.
a Be careful not to get your fingers caught.
* Adjust so that the belt deflects the amount

given below when pushed with a finger press-
ure of 6 kg at a point midway betwen the al-
ternator pulley and the crankshaft pulley.
* Deflection of fan belt: 7 - 10 mm
4) After adjusting belt tension, tighten bolts fully.
30. Fan
install fan (1).
31. Lowering engine

1) Remove unit repair stand A from engine assembly.
6202P500
2) Install oil filter.
* Clean the filter holder, then coat the cartridge seal
surface with engine oil or grease (G2-LI).
* Tighten by hand approx. 2/3 turns after the pack-
ing surface contacts the seal surface of the filter
holder.
13-og-47 95 SERIES
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY (4D95LSERIES)
GENERAL DISASSEMBLY (4D95L SERIES)
I I
I
(4D95L-W-1 only)
4D95L
SERIES
Engine
14 15 16
’3-:02 95 SERIES
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY (4D95L SERIES)
95 SERIES
Special tools
AI 1 790-901-1250 1 Bracket
B 1 795-102-2102 1 Spring pusher I 1
l Preparatory work
1) Remove all dirt and mud from around the engine.
2) Remove the drain plug and drain the oil from the
engine.
- : Engine oil: Approx. 9.5 R

3) Prepare a stable stand which will prevent the engine
from falling over, then put the engine securely in
the stand.
Engine assembly: Approx. 300 kg

(The weight of the engine differs according
to the model of machine on which it is
mounted.)

I.) Remove starting motor (1).
2) Install bracket A1 to engine.
3) Install engine assembly (2) in repair stand A.
’3-:04 95 SERIES
2. Muffler
Remove muffler (1) together with bracket.
3. Fan
Remove fan (1).
4. Fan pulley
1) Loosen mounting bolt of adjustment plate (I), and
mounting bolt and nut of alternator.
2) Move alternator towards cylinder block, and remove
belt (2).
Be careful not to catch your fingers or

A
damage the alternator when moving the
alternator towards the cylinder block.
3) Remove fan pulley (3).
5. Alternator
Remove adjustment plate, then remove alternator (1).
6. Oil filter, dipstick guide

1) Remove oil filter (2).
2) Remove dipstick guide (3).
95 SERIES
7. Water pump
8. Exhaust manifold
Remove exhaust manifold (I 1.

2) Remove sleeve nut, then remove fuel injection pipe
(2).
10. Intake manifold

Remove intake manifold (I 1.
’3-:06 95 SERIES
11. Glow wire, glow plug (4D95L-W-1 only)

1) Remove glow wire (1).
2) Remove glow plug (2).
12. Spill tube

Remove spill tube (1).
13. Nozzle holder

Remove nozzle holder (2).
* When removing the nozzle holder, clean around the
nozzle holder and fit a blind plug to prevent dust or
dirt from entering.
* Be careful not to damage the tip of the nozzle holder
when removing.
* Mark the nozzle holders with tags showing the
cylinder No. and keep in a safe place. If there is no
abnormality in the nozzle holder, install in the
same position when assembling.


Remove rocker arm assembly (1).
and turn the adjustment screw back 2 - 3 turns.
16. Push rods

Remove push rods (1) from cylinder head.
f Mark the push rods with tags to show the places of
installation and keep in a safe place. If there is no
abnormality in the push rod, install in the same
position when assembling.
95 SERIES
’3-:07
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY (4D9!5L SERIES)

1) Remove mounting bolts of cylinder head assembly.
2) Fit lifting tool to hanger of cylinder head, then lift
* Lay cardboard on the floor to protect the
bottom face of the cylinder head from damage.
* When disassembling the cylinder head assembly, do

as follows.
ii) Loosen spring, and remove spring seat (3) and
valve spring (4).
iii) Raise cylinder head and remove valve (5).
* Mark the valves with tags to show the
place of installation and keep in a safe place.
For 4D95L-1
\.$-A
6206F301
iv) Using remover C, remove valve guide (6)
13-$08 95 SERIES

1) Remove lubrication tube (1).
2) Remove bracket (2).
3) Remove mounting bolts (3) of fuel injection pump,
then remove fuel injection pump (4).
* There is one bolt installed from the fuel injec-
tion pump side, so do not forget to remove it.
* To prevent dirt or dust from entering, fit caps or
use tape to cover the oil and fuel inlet and outlet
ports.
* Remove cover (5) so that the match marks can
be aligned when the fuel injection pump is
installed.
19. PTO shaft

1) Remove flange (I ).
2) Remove PTO shaft (2).
20. Oil pan

Remove oil pan (1).
95 SERIES


1) Remove plate (I).
2) Set flange puller D in position, then pull out crank-
shaft pulley (2).
62OW322
23. Gear case cover

1) Remove gear case cover (I).
2) Remove front oil seal (I).
13-go 95 SERIES
24. Oil pump

25. Idler gear

2) Remove idler (3).
* If a PTO is installed, the idler gear bushing uses a
bearing.

1) Turn over cylinder block, so that cylinder head
2) Remove mounting bolts (1) through casting hole in
gear.
3) Remove camshaft assembly (3) together with thrust
plate (2).
* When removing, rotate the camshaft lightly and
be carefuel not to damage the bushing.
27. Flywheel
1) Remove coupling (1).
2) Remove flywheel (2).
The pilot is short, so the flywheel may

A
come off suddenly.

95 SERIES
2) Remove rear oil seal (I).

i) Turn over cylinder block, and set with cylinders
horizontal.
* Turn the cylinder block over carefully to
prevent the tappets from coming out of
position.
ii) Check that number stamped on connecting rod
cap matches cylinder number.
* If there is no number stamped on the
connecting rod cap, stamp a number at the
camshaft end.
2) Removing carbon
Using fine sandpaper, remove carbon at top of
cylinder.
* Be careful not to damage the inside of the
cylinder.
* Measure the end play of the connecting rod with a
dial gauge before removing the piston and connecting
rod assembly.

i) Rotate crankshaft to set piston at bottom dead
center.
ii) Remove mounting bolts of connecting rod cap
(I).
iii) Tap cap with plastic hammer and remove con-
13-$12 95 SERIES

Push a wooden bar or hammer handle through from
oil pan side. Support piston at cylinder head end,
then push bar in further from oil pan side to remove
piston and connecting rod assembly (2).
5) Disassembly of piston and connecting rod assembly

i) Using pliers 0, remove snap ring (3) on oneside.
ii) Remove piston pin (4), and separate connect-
* If the pin does not come out, leave in hot
water, then try again.
iii) Remove snap ring on other side in the same way.
iv) Using piston ring tool E, remove piston ring (7)

from piston.
v) If bushing (8) is worn, remove using push tool

@ (outside diameter: 32 mm).
* Keep the pistons, connecting rods, bearings,
piston rings, piston pins, and bushings in
sets for each cylinder number.
95 SERIES
30. Main bearing cap

i) Turn over cylinder block, so that oil pan is
facing up.
ii) Measure end play of crankshaft using dial gauge
0.
judging wear of the thrust bearing and
abnormal wear of the crankshaft, so measure
before removing the crankshaft.
2) Main bearing cap

i) Remove mounting bolts (1) of main bearing cap.
ii) Insert mounting bolt in bolt hole in cap, then
lever cap, or tap with plastic hammer on left
and right sides, and remove main bearing cap (3)
together with lower bearing (2).
* Thrust bearings (4) are assembled on both sides

of cap (3) at the flywheel end, so after removing,
mark to show the place of installation.
31. Crankshaft
13-:14 95 SERIES
2) Rel move upper main bearing (2).

tags to show the place of installation, and keep in
a safe place in sets for each cap number.
32. Tappet
Remove tappet (1).
95 SERIES 13-g15
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY (4D95L SERIES)
GENERAL ASSEMBLY (4D95L SERIES)

a
13-p 95 SERIES
i-i
H
18 19 20 21
H H
Adjusting
Fuel injec-
16
<
Push rods
Rocker
arm ass’y
valve
clearance
Cylinder
head cover
1
tion pump / \
Alternator
I
33
Muffler
95 SERIES 13-g 7
Special tools
>
AI 1 790-901-1250 1 Bracket I 1
B 795-102-2102 Spring pusher (KIT) 1
E 795-100-2800 Piston ring tool 1
F 1 795-213-1800 1 Piston holder ~ r
G ) 795-100-4720 ) Push tool I 1

Ii 1 795-125-1370 ( Feeler gauge I 1

1) Install bracket AI to cylinder block.
2) Set cylinder block in unit repair stand A.
2. Tappet
1) Turn over cylinder block so that cylinder head side
is at bottom.
2) Coat with engine oil and assemble tappet (1).
3. Crankshaft
1) Align protrusion of upper main bearing (2) with
notch in cylinder block, then assemble to cylinder
block.
rear face of the bearing. Coat the inside face of
the bearing with engine oil (SAE30) before
assembling.
13-$18 95 SERIES
2) Taking care not to hit crankshaft (1) against cylinder

block, set crankshaft in mounting position.
* If the crankshaft gear has been replaced, insert
the crankshaft gear in an electric furnace and
heat at 230 - 25O’C for about 30 minutes,
then shrink fit the gear.
4. Ma lin bearing cap

1) Align protrusion in lower main bearing (2) with notch
in cap, then install main bearing cap (3).
rear face of the bearing. Coat the inside face of
the bearing with engine oil (SAE30) before
assembling.
2) Check that number stamped on main bearing cap is
the same as number on cylinder block.
3) Set casting number of main bearing cap facing front,
and assemble with mounting bolt (1).
4) Align lower thrust bearing (4) with dowel pin, then
install in main bearing cap (3).
* Assemble two pieces at the top and bottom at
the flywheel end, and one piece at the opposite
end.
* Install each thrust bearing with the oil groove on
the outside.
5) Set casting number facing front, and install main

bearing cap (3).
* Be careful not to let the thrust bearings slip out
of place.
95 SERIES 13-g19
6) Tighten mounting bolts of main bearing cap with a

torque wrench as follows.
* Coat the bolt thread and seat face with engineoil.
* When tightening the mounting bolts of the main
bearing cap, start in the middle and work to the
outside. Tighten to the following torque.
w Mounting bolt of main bearing cap
Unit: kg
Order Target Range
1 st step 11.5 II-12
2nd step 0 Loosen completely
3rd step 13.5 I 13 - 14
* After tightening the mounting bolts, check that

the crankshaft rotates smoothly.
7) Measuring end play of crankshaft

Put probe of dial gauge @ in contact with end face
of crankshaft. Read movement of gauge when crank-
shaft is moved forward and backward.

1) Assembly of piston and connecting rod assembly.
* If the piston and connecting rod assembly has
been disassembled, assemble the piston and
connecting rod assembly first as follows.
i) Using push tool @ (outside diameter: 32 mm),
press fit bushing (8) on connecting rod.
6206P336
13-020 95 SERIES
ii) Set rings with stamped mark at end gap facing up

(compression ring only), then use piston ring tool
E to assemble piston ring (7) on piston (6).
Be careful not to damage the piston or break the

piston rings.
Fit expander (IO) in the groove on theinsidediameter
of oil ring (9) before installing. Check that the
expander is completely fitted into the ring groove.
The end gap of the ring should be at 180’ to the join
of the coil in the expander.
iii) Using pliers 0, assemble snap ring on one side in

snap ring groove of piston.
iv) Set F mark on piston pin boss facing in same direction

as casting number on connecting rod. Insert piston
pin (4), and assemble connecting rod (5) and piston
(6).
* If it is difficult to insert the piston pin, put
the piston in hot water to expand the diameter
of the pin hole, then insert the pin.
VI Assemble other snap ring on other side of piston,
* After assembling the snap rings, check that the
connecting rod moves smoothly forward and
backward.
vi) Align protrusion in upper bearing of connecting rod
with notch in connecting rod, then install.
95 SERIES
’3-:21
2) Turn over cylinder block so that crankshaft isvertical.
3) Set end gaps of piston rings as shown in diagram. Oil ring Size mark (.Sor L)
4) Set crankshaft pin at bottom dead center.

Over size mark
bearing with engine oil.
5) Align direction of F mark on side face of piston to

Size mark (S or L)
face front of engine. Using piston holder F, insert
piston and connecting rod assembly (2) from cylinder
head end. 6206F302
5) When piston rings are inserted inside cylinder, push in

head of piston with hand or wooden bar. In addition,
pull big end of connecting rod to align with crankshaft
pin.
7) Align protrusion of lower bearing with notch in cap,

then assemble to bearing cap.
8) Set with stamped mark at camshaft end, then install

connecting rod cap (1).
* Check the connecting rod bearing with engine
oil.
* Check that the stamped number on the connect-
ing cap is the same as the number of the cylinder.
13-$22 95 SERIES
* Tighten the connecting rod cap as follows.

Ir Coat the connecting rod bolt thread and seat Put a mark on the bolt cap
face with engine oil.
go0 +30°
m Mounting bolt of connecting rod
0
Unit: kgm
Order Target Range

After tightening, stamp
1 st step 4.0 4.0 - 4.2 on bolt head by punch
Mark bolt head and cap seat with felt

pen, then tighten to following angle.
2nd step
6206F303
9o” 9o” - 120°
* The connecting rod bolts may be reused five

times. Make a punch mark on the bolt head
each time the bolts are used. If there are already
five marks on the bolt head, replace with new
bolts.
* After assembling the connecting rods, check
that the crankshaft rotates smoothly.
9) Measuring side clearance of connecting rod cap.

i) Turn over cylinder block so that oil pan faces up.
ii) Using dial gauge 0, measure side clearance of
connecting rod cap.
* Permissible range of side clearance:
0.20 - 0.40 mm
6. Flywheel housing
1) Using push tool @ (outside diameter: 120 mm),
install rear oil seal (2) on flywheel housing (1). 0
2) After press fitting rear oil seal, fill 40 - 60% of space - r
95 SERIES 13-$23
3) Align with dowel pin (3). and install flywheel housing

(1).
a,, Mounting surface of flywheel housing:
* When fitting the seal lip to the outside diameter
of the crankshaft flange, be careful not to
apply excessive force to the seal lip surface.

Measure distance in height betweensurfacefor mount-
ing oil pan on cylinder block and flywheel housing.
* Permissible difference in height of flywheel
housing mounting surface: Max. 0.15 mm
5) Measure radial and face runout of flywheel housing

with dial gauge 0.
614OF286
7. Flywheel
1) Install flywheel (2).
w Mounting bolt: 12.0 f 0.5 kgm

Unit: kgm
2) Install coupling (1).

3) Measure radial and face runout of flywheel.
’3-:24 95 SERIES
2) Tighten mounting bolts (1) of thrust plate (2) through

casting hole of gear to secure camshaft assembly.
m Mounting bolt of thrust Plate:

1.9 f 0.5 kgm
3) Put dial gauge 0 in contact with end face of cam-
shaft. Read movement of gauge when camshaft is
moved backward and forward.
* End play of camshaft: 0.15 - 0.35 mm
9. Idler gear
II Align match marks of gear, and install idler gear
(3).
* Match marks
Idler gear and cam gear (4): “9”
2) Install plate (2).
3) Tighten mounting bolt (1) of idler gear shaft.

4) Put dial gauge @ in contact with end face of idler
gear. Read movement of gauge when idler gear is
moved backward and forward.
* End play of idler gear: 0.03-0.09 mm
95 SERIES
’3-ii25
10. Oil pump

Measure end play of oil pump gear in same way as
measuring end play of camshaft.
* Measuring backlash of gears
Temporarily fit fuel injection pump assembly
(I), and measure backlash of gears with dial
gauge 0.
* When measuring the backlash of the gears, hold
one gear securely, then move the other gear and
measure the backlash.
Ir Backlash of gears (helical gear)

(Serial No.: 106425 and below) Unit: mm
D_ C ,lnjection pump gear and

0.13 - 0.34
Idler gear
- Camshaft gear and oil

0.13 - 0.35
oumo clear
- ;;;;;fb”,i;;r and PTo gear 0.15 - 0.30
13-ii26 95 SERIES
* Backlash of gears (helical gear)

(Serial No.: 106426 and up)
Unit: mm
Match
mark
1
Camshaft gear and oil pump o.07 _ o.2g
t Backlash of gears (spur gear) for PC60-6

(with blade)
Unit: mm
-measurement 1 Range
A _ ,,+ Crankshaft gear and idler 0.08 - 0.31

gear
B - B Camshaft gear and idler gear 0.09 - 0.34

6206F411A
q;tionFp gear and idler 1o.08 _ o.3,
_ i;;shaft gear and oil pump o,08 _ o,3,
- Camshaft gear and PTO gear

0.08 - 0.31
(with PTO)
95 SERIES
’3-F-’
11. Gear case cover

1) Using push tool (outside diameter: 72 mm), install
front oil seal (1).
2) After press fitting front oil seal, fill 40 - 60% of
space at seal lip with grease.
a Front oil seal: Grease (G2-LI)

gasket sealant.
a Mounting surface: Gasket sealant (LG-7)
4) Install gear case cover assembly (1).

cover.
* Permissible difference in height of oil pan mount-
ing surface: Max. 0.15 mm

1) Align with crankshaft key, then install crankshaft
pulley (2).
2) Fit plate (l), then tighten mounting bolts.
m Mounting bolt: 9.5 * 0.5 kgm

95 SERIES 1%_027
14. Oil pan

Coat mounting face with gasket sealant, then install oil
pan (1).
m Drain plug: 6.0 + 1 .O kgm
& Mounting face: Gasket sealant (LG-7)

* Coat the gasket sealant in a 1 mm wide film.
15. PTO shaft

1) Align gear of PTO shaft (2) with surface of teeth of
camshaft gear.
2) Fit O-ring and install flange (1).

1) Turn over cylinder block so that cylinder head is
at top.
install fuel injection pump (4) together with fuel
injection pump.
3) Tighten mounting bolts (3).
4) Install bracket (2).
5) Install lubrication tube (1).
+ Check that the match marks are aligned, then
fit O-ring and install cover (5).
’3-:28 95 SERIES

13 Assemble cylinder head assembly as follows.
i) Using push tool G, install valve guide (6) in cylin-
der head (1).

6206F301
For 4D95L-1
VI Using spring pusher B, compress valve spring,
* After releasing the valve spring, tap the top
of the valve stem with a plastic hammer to
check that the cotter is completely fitted.
For 4D95L-W-1
6206P396
95 SERIES 13-829
2) Install cylinder head assembly.

Remove all carbon and dirt from the contact
surfaces of the cylinder block and cylinder
head. Remove all burrs and damage, and
clean out all dirt from inside the cylinder block.
Install cylinder head gasket.
t Fit the gasket with the TOP mark facing
up.
Raise cylinder head (1) then using 4 head bolts
block.
3) Tighten mounting bolts
Coat thread of the mounting bolts with antifriction
compound, then tighten mounting bolts as shown in Tightening order of cylinder head mounting bolt
diagram.
1st step: 68.6 - 88.2 Nm (7 - 9 kgm)
2nd step: 107.8 - 127.4 Nm Front 11 Rear
(11 - 13 kgm)
3rd step: 142.1 - 151.9 Nm
(14.5 - 15.5 kgm)
Intake side

bolts: the tightening torque method which controls
the tightening force, and the plastic turning angle
method. (See the figure on the right.)

1st step: 68.6 -c 9.8 Nm (7 +_ 1 kgm)
turning angle
2nd step: 107.8 f 4.9 Nm 6206F872
(11 + 0.5 kgm)
3rd step: Mark bolt head and cylinder
head with a felt pen, then
turn bolt 90’“8’ to tighten.
* After tightening, make a punch mark on the bolt Make mark on cylinder head
head to indicate the number of times the bolt has and bolt
been tightened. The bolt can be used a maximum
of five times. Always replace any bolt that already
F621201067A F621201061
18. Push rods

Insert push rods (1’) in tappet guides.
push rods.
* If there is no abnormality in the push rod, install
in the same position as before disassembly.

’3-:30
95 SERIES
2) Check that ball of adjustment screw is fitted properly

into socket of push rod, then tighten the nuts and
bolts uniformly.
m Mounting bolt of rocker arm bracket:

2.5 f 0.5 kgm
adjustment screw back to prevent strain on the
push rod.

Adjust clearance between valve and rocker arm as follows.
* Valve clearance (hot or cold)
Unit: mm
Intake ~~
valve 7 Exhaust
~ valve
0.35 I 0.5

align pointer (b) on the gear case cover with the 1.4
TOP mark (a) on crankshaft pulley (1). When rotating,
check the movement of the intake valves of No. 4
cylinder.
2) When No. 1 cylinder is at compression top dead
center, adjust the valves marked 0. Then rotate the
crankshaft 360’ in the normal direction, and adjust
the valves marked 0.
* Valve arrangement chart
, 1
I Cylinder No. I11213141
3) To adjust, insert tool H between rocker lever and

valve stem and turn adjustment screw until clearance
is a sliding fit. Then tighten locknut to hold adjust-
ment screw in position.
w Locknut: 4.5 + 0.5 kgm

4) After adjusting No. 1 cylinder at compression top
dead center, it is also possible to turn the crankshaft
180” each time and adjust the valve clearance of
* Firing order: 1- 2 - 4 - 3
* After tightening the locknut, check the clearance
again.
95 SERIES 13-031
0
(For precombustion chamber type (4D95L-W-1))

1) Fit O-ring to cylinder head cover.
2) Install cylinder head cover (3).
22. Nozzle holder

For 4D95L-1
i) Install gasket (5).
ii) Install nozzle holder (2).
For 4D95L-W-1
i) Install gasket (4).
* Install the gasket with the blue mark facing
up.
ii) Install nozzle holder (2).
B Nozzle holder: 7 k 1.0 kgm
23. Spill tube

Install spill tube (1).
w Mounting bolt: 4.5 f 0.5 kgm (4D95L-W-1
24. Glow plug, glow lead (4D95L-W-1 only)

1) Install glow plug (2).
w Glow plug: 1.75 + 0.25 kgm

2) Install glow lead (1).
25. Intake manifold

Install intake manifold (1).
a Mounting surface: Gasket sealant (LG-7 ‘1
* Coat the gasket sealant in a 1 mm wide film.
w Mounting bolt: 4.1 * 0.6 kgm
’3-;32 95 SERIES

* Before installing the fuel injection pipe, blow com-
pressed air through to clean it.
1) Install fuel injection pipe (21, then temporarily
2) Align fuel injection pipes, then tighten clamps (1).
3) Fully tighten sleeve nuts of injection pipes.
w Sleeve nut: 2.3 f 0.2 kgm

.Fit gasket and install exhaust manifold (I)
w Mounting bolt: 4.5 f 1 .O kgm
28. Water pump

Assemble O-ring on pilot, then fit gasket and install
water pump (1).
29. Oil filter, gauge guide

1) Install gauge guide (21, then secure with clamp.
2) Install oil filter (1).
95 SERIES
30. Alternator
install alternator (1 j.
31. Fan pulley

1) Install fan pulley (3).
2) Fit belt (2) in pulley groove, then temperarily tighten

adjustment plate (1).
3) Insert a bar or pipe between alternator and cylinder
block, and raise alternator to outside to adjust fan
belt tension.
A Be careful not to get your fingers caught.

* The belt should deflect 14 - 17 mm when pushed
with a finger pressure of 6 kg at a point midway
between the alternator pulley and the crankshaft
pulley.
* After adjusting the belt tension, tighten the bolts
fully.
Crankshaft pulley
614OF301
32. Fan
Install fan (1).
13-$34 95 SERIES
33. Muffler
Install muffler (I 1.
34. Lowering engine

1) Sling engine assembly (2). disconnect engine from
unit repair stand A, then lower engine on to a stable
stand.
2) Remove bracket AI from engine.
3) Fit O-ring and install starting motor (I).
95 SERIES
GENERAL DISASSEMBLY (6D95L SERIES)

3
Oil cooler
13 14 15
13236 95 SERIES
95 SERIES
Special tool
Part No. Part name Q’ty
A 790-501-5000 Engine repair stand 1
Al 790-901-l 250 Bracket 1
B 795-102-2102 Spring pusher 1
C 795-100-4710 Valve guide remover 1
D 795-240-2801 Flange puller 1
E 795-l 00-2800 Piston ring tool 1
a Prepartory work
1) Remove all dirt and mud from around the engine.
2) Remove drain plug and drain oil from engine.
_ : Engine oil: Approx. 10.5 II
3) Prepare a stable stand which will prevent the engine

from falling over, then put the engine securely in
the stand.
Engine assembly: Approx. 410 kg.

(The weight of the engine differs according
to the model of machine on which it is
mounted.)
1. Starting motor
2. Setting engine onto repair stand

I) Install bracket Al to engine assembly (I),
2) Install engine assembly (1) onto engine repair
stand A using bracket Al.
. For the engine, install Al to the engine first.

. For the transmission, install Al to the stand first.
’3-838 95 SERIES
3. Alternator
1) Loosen mounting bolts of adjustment plate (I), and
mounting bolt and nut of alternator.
2) Move alternator towards cylinder block, and remove
belt (2).
t Be careful not to catch your fingers or

Q
damage the alternator when moving the
alternator towards the cylinder block.
3) Remove alternator (3).
4. Oil cooler
_Remove oil cooler (1).
5. Exhaust manifold
Remove exhaust manifold (1).
6. Water pump
95 SERIES
7. Fuel filter
1) Disconnect hose (1) between pump and filter at
pump end.
2) Disconnect hose (2) between pump and filter at
pump end.
3) Remove fuel filter (3).

2) Remove sleeve nut, then remove fuel injection
pipe (2).
9. Spill tube
Remove spill tube (1).
* When removing the nozzle holder, the inserted part
is easier to pull out if the spill tube is removed after
the nozzle holder is removed.
IO. Fuel injection pump

1) Remove oil supply tube (1).
2) Remove fuel injection pump holder bolt (2).
3) Remove gear and nut (3), then remove fuel injection
pump (41.
* There is one bolt installed from the fuel injec-
tion pump side, so do not forget to remove it.
* To prevent dirt or dust from entering, fit caps
or use tape to cover the oil and fuel inlet and
outlet ports.
13-$40 95 SERIES
11. Intake manifold

Remove intake manifold (1).
12. Nozzle holder

-1) Remove nozzle holder (I).
* When removing the nozzle holder, clean around
the nozzle holder and fit a blind plug to prevent
dust or dirt from entering.
* Mark the nozzle holders with tags showing the
cylinder No. and keep in a safe place. If there
is no abnormality in the nozzle holder, install
in the same position when assembling.

14. Rocker arm assembly *,~.“< ,, ‘,,,\,:\

__
Remove rocker arm assembly (1).
and turn the adjustment screw back 2 to 3 turns.
95 SERIES
15. Push rods

Remove push rods (1) from cylinder head.
* Mark the push rods with tags to show the places of
installation and keep in‘a safe place. If there is no
abnormality in the push rod, install in the same
position when assembling.

1) Remove mounting bolts of cylinder head assembly.
2) Fit lifiting tool in mount on cylinder head, then lift
* Lay cardboard on the floor to protect the
bottom face of the cylinder head from damage.
,,
l Disassemble the cylinder head assembly as follows.

ii) loosen spring, and remove spring seat (3) and

valve spring (4).
iii) Raise cylinder head.and remove valve (5).
* Mark the valves with tags to show the place
of installation and keep in a safe place.
iv) Using remover C, remove valve guide (6).
6206F301
13$42 95 SERIES
17. Flywheel
Remove mounting bolts, then remove flywheel (1).
* The pilot is short, so the flywheel may come off
suddenly.

2) Remove rear oil seal (2).
19. Vibration damper

Remove vibration damper (1).

2) Set flange puller D in position, then pull out crank-
shaft pulley (2).
* The tapered collar is press fitted, so hit the bolt
portion of the flange puller with a hammer to
remove it.
6206P322
95 SERIES 13-$43
21. Gear case cover

1) Remove gear case cover (1).
2) Remove front oil seal (2).
22. Oil pan

Remove oil pan (1).
23. Oil pump

13344 95 SERIES
24. Idler gear

1) Remove bolts (1), then remove plate (2).
2) Remove gear (3).

I) Turn over cylinder block, so that cylinder head
2) Engine No. 10001 - 10036
. Remove mounting bolts (I) through casting
hole in gear, then remove thrust plate (2).
Engine No. 10037 and up
. Remove mounting bolts (1) through casting
hole in gear.
3) Engine No. 10001 - 10036
. Remove camshaft assembly (3).
Engine No. 10037 and up
. Remove camshaft assembly (3) together with
thrust plate (2).
* When removing, rotate the camshaft lightly
and be careful not to damage the bushing.

95 SERIES
27. Piston, connecting rod assembly.

i) Turn over cylinder block, and set with cylinders
horizontal.
ii) Check that the number stamped on connecting
rod cap matches cylinder number.
* If there is no number stamped on the
connecting rod cap, stamp a number at the
camshaft end.
2) Removing carbon
Using fine sandpaper, remove carbon at top of
cylinder.
* Be careful not to damage the inside of the
cylinder.
* If necessary, measure the end play of the
connecting rod with a dial gauge before remov-
ing the piston and connecting rod assembly.
i) Rotate the crankshaft to set the piston at
bottom dead center.
ii) Remove mounting bolts of connecting rod
cap (I).
iii) Tap cap with plastic hammer and remove
connecting rod cap together with bearing.
* Be careful not to damage the thread of
the mounting bolts.

Push a wooden bar or hammer handle through from
oil pan side. Support piston at cylinder head end,
then push bar in further from oil pan side to remove
piston and connecting rod assembly (2).
6206P332
l Disassemble piston and connecting rod assembly

as follows.
i) Using pliers 0, remove snap ring (3) on one
side.
ii) Remove piston pin (4), and separate connecting
water.
iii) Remove snap ring on other side in the same
way.
13-$46 96 SERIES
iv) Using piston ring tool E, remove piston ring (7)

from piston.
v) Using push tool @_I, remove bushing (8) of

connecting rod.
* Keep the pistons, connecting rods, bearings,
piston rings, piston pins, and bushings in
sets for each cylinder number.
28. Main bearing cap

i) Turn over cylinder block, so that oil pan is
facing up.
ii) Measure end play of crankshaft using dial
gauge 0.
judging wear of the thrust bearing and
abnormal wear of the crankshaft, so
measure before removing the crankshaft.
2) Remove mounting bolts (1) of main bearing cap.

3) Insert mounting bolt in bolt hole in cap, then
lever cap, or tap with plastic hammer on left and
right and remove main bearing cap (3) together
with lower main bearing (2).
95 SERIES
0
* Thrust bearings (4) are assembled on both

sides of cap (3) at the flywheel end, so
after removing, mark to show the place
of installation.
29. Crankshaft
* Be careful not to hit the crankshaft against
the cylinder block and damage the sliding
surface.
2) Remove upper main bearing (2).

tags to show the place of installation, and
keep in a safe place in sets for each cap number.
30. Tappet
Remove tappet (1)
13$48 95 SERIES
GENERAL ASSEMBLY (6D95L SERIES)

2 6
15
I
9
Cylinder
block
13-$50 95 SERIES
16
Vibration
damper
31 32
--
Fuel filter
21
Exhaust
manifold
95 SERIES
13F
Special tool
Part No. Part name Q’W

A ) 790-501-5000 ) Engine repair stand / 1
A1 1 790-901-1250 1 Bracket I ’
1. Setting in engine repair stand

1) Install bracket AI to engine repair stand A.
2) Set cylinder block in engine repair stand A.
96 SERIES
2) Raise crankshaft (l), and assemble to mounting

position.
cylinder block.
4. Main bearing cap

1) Lower main bearing
i) Align protrusion in lower bearing (2) with
notch in cap, then install main bearing cap.
the rear face of the bearing. Coat the in-
side face of the bearing with engine oil
(SAEBO) before assembling.
2) Main cap
1) Check that number stamped on main bearing
cap is the same as number on cylinder block.
ii) Set casting number of main cap facing front,
and install with mounting bolt (1).
iii) Align lower thrust bearing (4) with dowel pin,
then install in main bearing cap (3).
* There is one upper thrust bearing but two
lower thrust bearings. Be careful not to
mistake these bearings.
* Install each thrust bearing with the oil
groove (portion “a”) on the outside.
iv) Set casting number facing front, and install

main bearing cap (3).
t Be careful not to let the thrust bearings
slip out of place.
95 SERIES
5) Tighten mounting bolts of main bearing cap as

follows.
* Coat the bolt thread and seat face with engine
oil.
main bearing cap, start in the middle and work
to the outside. Tighten to the following torque.
w Mounting bolt of main bearing cap
Unit: kgm
Order Target I Range
1st step 11.5 I 11-12
2nd step 0 Loosen completely
3rd step 13.5 13- 14
* After tightening the mounting bolts, check

that the crankshaft rotates smoothly.
6) Measuring end play of crankshaft

Put probe of dial gauge @ in contact with end face
of crankshaft. Read movement of gauge when
crankshaft is moved forward and backward.

1) Assemble piston and connecting rod assembly as
follows.
i) Set piston ring with stamped mark at end gap
facing up, then use piston ring tool E to assem-
ble piston rings (7) on piston (6).
* Be careful not to damage the piston or
break the piston rings.
* Fit expander (10) in the groove on the
inside diameter of oil ring (9) before
installing. Check that the expander is
completely fitted into the ring groove.
* The end gap of the ring should be at 180’
13-854 95 SERIES
ii) Using pliers (1), assemble snap’ring on one side

in snap ring groove of piston.
iii) Using push tool 0, press fit bushing (8)

on connecting rod.
iv) Set arrow on head of piston facing in same

direction as casting number on connecting rod.
Insert piston pin (4), and assemble connecting
* If it is difficult to insert the piston pin,
put the piston in hot water to expand the
diameter of the pin hole, then insert
the pin.
v) Assemble other snap ring on other side of
piston.
vi) Align the protrusion in the upper bearing of
the connecting rod with the notch in the
connecting rod, then install.
95 SERIES 13255
2) Turn over cylinder block so that crankshaft is

vertical.
Oil ring Size mark (S or L)
3) Set end gaps of piston rings as shown in diagram.
4) Set crankshaft-pin at bottom dead center.
bearing with engine oil. Over size mark
Size mark (S or L)
6206F302
5) Align direction of F (Front) mark on side face of

piston to face front of engine. Using piston holder
F, insert piston and connecting rod assembly (2)
from cylinder head end.
6) When piston rings are inserted inside cylinder, push
in head of piston with hand or wooden bar. In
addition, pull big end of connecting rod to align
with crankshaft pin.
7) Align protrusion of lower bearing with notch in
cap, then assemble to bearing cap.
81 Set with stamped mark at camshaft end, then install

connecting rod cap (1).
* Coat the connecting rod bearing with engine
oil.
* Check that the stamped number on the connect-
ing rod cap is the same as the number of the
cylinder.
13356 95 SERIES
9) Tighten mounting bolts of connecting rod cap as

Put a mark on the bolt cap
follows.
* Coat the connecting rod bolt thread and seat
face with engine oil.
w Mounting bolt of connecting rod
Unit: kgm After tightening, stamp

on bolt head by punch
Order Target Range
1st step 4.0 4.0 - 4.2
Mark bolt head and cap seat with felt 6206F303

pen, then tighten to following angle.
2nd step
1 9o"-120°
* The connecting rod bolts may be reused five

times. Make a punch mark on the bolt head
each time the bolts are used. if there are already
five marks on the bolt head, replace with new
bolts.
* After assembling the connecting rods, check
that crankshaft rotates smoothly.
10) Measuring side clearance of connecting rod cap.

i) Turn over cylinder block so that oil pan faces
up.
ii) Using dial gauge 0, measure side clearance of
connecting rod cap.
* Permissible range of side clearance:
0.20 - 0.40 mm
* When inserting the camshaft assembly, insert
thrust plate (2) from the side to install.
2) Tighten mounting bolts (1) of thrust plate through

casting hole of gear to secure camshaft assembly.
m Mounting bolt of thrust plate:

1.9 + 0.5 kgm
95 SERIES
’3-:57
(When tightening cam gear bolts)

insert camshaft assembly into cylinder block.
Use sleeve inserted into block as a pilot, and in-
stall housing.
press fit gear finally so that all shoulders of
sleeve, bearing, and gear are in contact.
Tighten housing to block assembly with mounting
bolts through casting hole of gear to secure
assembly.
w Mounting bolt: 1.9 k 0.5 kgm

Mesh cam gear with PTO gear and idler gear,
then tighten mounting bolts of cam gear fully.
m Mounting bolt: ‘18 - 20 kgm
(When shrink fitting cam gear and tightening)

Insert camshaft assembly into cylinder block.
Use sleeve inserted into block as a pilot, and in-
stall housing.
Press fit gear finally so that all shoulders of
sleeve, bearing, and gear are in contact.
Tighten housing to block assembly with mounting
bolts through casting hole of gear to secure cam-
shaft assembly.
m Mounting bolt: 1.9 k 0.5 kgm
’3-t?7-1 95 SERIES
3) Measuring end play of camshaft

Put probe of dial gauge @ incontact with end face
of camshaft. Read movement of gauge when cam-
shaft is moved.
7. Idler gear
1) Align match marks of gear, and install idler gear (3).
* March marks
Idler gear and cam gear (5): “B”
2) Install plate (2).

3) Tighten lock bolt (1) of idler gear shaft.
m Lock bolt: 11.25 f 1.25 kgm
13-058 95 SERIES
8. Oil pump
3) Measuring backlash
Measure backlash of oil pump gear in same way as
measuring backlash of idler gear.
* Standard backlash:
Cam gear and oil pump gear:
0.13 - 0.35 mm

Measure end play of oil pump gear in same way as
measuring end play of camshaft.

. Fuel injection pump
1) Turn over cylinder block so that cylinder head is
at top.
install fuel injection pump (1).
3) Fit gasket and install oil supply tube.
. Measuring gear backlash

Measure the backlash of each gear with a dial gauge.
(Serial No.: 106425 and below)
Unit: mm
Match
mark
A - A Crankshaft gear and idler gear 0.14 - 0.28
B - B Cam gear and idler gear 0.15 - 0.30
C - C 1Injection pump gear and idler gear 0.13 - 0.34
- Cam gear and oil pump gear I 0.13 - 0.35

- 1Cam gear and PTO gear (With PTO) 1 0.15 - 0.30

(Serial No.: 106426 and up)
/.. --I 6206F41 I
Unit: mm
Match
mark
A - A Crankshaft gear and idler gear 0.08 - 0.19
B - B /Cam gear and idler gear 1 0.08 - 0.19

C - C 1Injection pump gear and idler gear 1 0.07 - 0.29
- ICam gear and oil pump gear I 0.07 - 0.29

- Cam gear and PTO gear (With PTO) 0.15 - 0.30
95 SERIES
’3ii59
10. Gear case cover

1) Using push tool H, install front oil seal (1).
2) After press fitting front seal, fill 40 - 60% of space

a Front seal: Lithium grease

gasket sealant.
6 Mounting surface: Gasket sealant (LG-7)
4) Install gear case cover assembly (2).

cover.
10A. Gear case cover (front cover)

. For camshaft with bearing support at both ends
(D31-20, D37-5)
1) Using push tool H, install front seal (1).
2) After press fitting front seal (I), fill 40 - 60% of
space at seal lip with grease.
& Front seal: Lithium grease
3) Coat mounting surface at cylinder block end with
gasket sealant.
6 Cylinder block: LG-7
4) Install gear case cover (front cover) assembly (3).
5) Measure stepped difference at mounting surface.
Measure stepped difference at oil pan mounting
6206F950
surface of gear case cover and cylinder block.
* Repair limit for stepped difference at oil pan
mounting surface: 0.15 mm
6) Assemble outer race (6) of bearing (5) to bearing
case (4), then coat bearing case mounting sur-
face of front cover (3) with gasket sealant, and
install bearing case to front cover.
* Insert outer race (6) until it contacts the bot-
tom surface of the bearing case pilot.
6206F951
’3iYo 95 SERIES
Ir Center the inner race at the tip of the cam-

shaft, then secure the bearing case to the
front cover.
& Bearing case mounting surface of front
cover: Gasket sealant (LG-7)
m Bearing case mounting bolt:
18.6 + 4.9 Nm (1.9 f 0.5 kgm)
t If the bearing case is installed to the front
cover and then installed to the engine, it will
not be centered with the shaft and there will
be excessive force brought to bear on the
cam bushing. This may cause seizure of the
bushing. To make it possible to center the
bearing and camshaft when assembling the
bearing case, always install the bearing case
after installing the front cover.
7) Install sound-suppressing cover (8) to front cover
(3).
Ir This sound-suppressing cover does not re-
quire the use of any grommet as a blind
plug.
m Sound-suppressing cover mounting bolt:
7.8 + 2 Nm (0.8 i: 0.2 kgm)
6206F952

Using push tool J (outside diameter: 120 mm),
install rear oil seal (2) on flywheel housing (1).
& Outside circumference of rear seal:

After press fitting rear seal, fill 40 - 60% of space at

seal lip with grease.
Coat mounting surface of flywheel housing with

gasket sealant.
a Mounting surface: Gasket sealant (LG-7)
Align with dowel pin (3), and install flywheel

housing (1).
* When fitting the seal lip to the outside diameter
of the crankshaft flange, be careful not to
apply force to the seal lip surface.
w Mounting bolt:
66.2 + 7.4 Nm (6.75 + 0.75 kgm)
95 SERIES
’ 3-i!to-’

mounting oil pan on cylinder block and flywheel
housing.
* Permissible difference in height of flywheel
housing mounting surface: Max. 0.15 mm
6) Measure radial and face runout of flywheel housing

with dial gauge 0.
Face runout: Max. 0.35 mm
614OF286
12. Flywheel
1) Install flywheel (1).
m Mounting bolt:
Unit: kgm
2) Measure radial and face runout of flywheel with

dial gauge.

Fit O-ring and install oil suction pipe (l), then secure
with bracket. ~
95 SERIES 13-06 1
a
14. Oil pan

1) Install under plate with gasket.
2) Install oil pan (1) with gasket.
Q~z Mounting bolt: 3.25 + 0.25 kgm
m Drain plug: 6.0 f 1.0 kgm

1) Insert tapered collar, then install crankshaft pulley
(2).
2) Fit plate (I), then tighten mounting bolts.
w Mounting bolt: 38.0 -+ 3.0 kgm
16. Vibration damper

Install vibration damper (1).
m Mounting bolt: 3.1 t 1.1 kgm

1) Assemble cylinder head assembly as follows.
i) Using push tool G, install valve guide (6) in
cylinder head (1).
’3-kL62 95 SERIES

6206F301
v) Using spring pusher B, compress valve spring,

* After releasing the valve spring, tap the top
of the valve stem with a plastic hammer
to check that the cotter is completely
fitted.
2) Install cylinder head assembly.

* Remove all carbon and dirt from the contact
surface of the cylinder block and cylinder head.
Remove all burrs and damage, and clean out all
dirt from inside the cylinder block.
i) Install cylinder head gasket.

* Fit the gasket with the TOP mark facing
up.
ii) Raise cylinder head (1) then using 4 head bolts
block.
Tightening order of cylinder head mounting bolt

3) Tighten mounting bolts.
t Coat the thread of the mounting bolts with
antifriction compound (LM-P). Front mi Rear

bolts: the tightening torque method which Intake side 6206F40 I
right.)

turning angle
6206F872
95 SERIES 13-063
@
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY (6D95L-1)
w Cylinder head mounting bolt

Unit: kgm \
Order Target Range Make mar.k on cylinder head

and bolt
1st step 7 6-8
2nd step 11 10.5-11.5
3rd step 90” 9o”-120°

I
* After tightening, make a punch mark on the bolt F621201067A F621201061
head to indicate the number of times the bolt has

been tightened. The bolt can be used a maximum
of five times. Always replace any bolt that already
18. Push rods

Insert push rods (1) in tappet guides.
push rods.
* If there is no abnormality in the push rod, install
in the same position as before disassembly.

2) Check that ball of adjustment screw is fitted properly
into socket of push rod, then tighten the nuts and
bolts uniformly.

adjustment screw back 2 to 3 turns to prevent
strain on the push rod.

a Adjust clearance between valve and rocker arm as
follows.
* Valve clearance (hot or cold)
Unit: mm

align pointer (b) on the gear case cover with the 1.6
TOP mark (a) on crankshaft pulley (1). When
rotating, check the movement of the valves of No. 6
cylinder.
95 SERIES
’3-E4
2) When No. 1 cylinder is at compression top dead

center, adjust the valves marked 0. Then rotate
the crankshaft in the normal direction, and when
No. 6 cylinder is at compression top dead center,
adjust the valves marked0.
* Valve arrangement chart
8=
Cylinder No. 1 2 3 4 5 6
Intake valve l l 0 l 0 0
Exhaust valve 0 0 0 0 0 0
* To adjust, insert feeler gauge H between rocker

arm and valve stem and turn adjustment screw
until clearance is a sliding fit. Then tighten
locknut to hold adjustment screw in position.
m Locknut: 4.5 f 0.5 kgm
* After adjusting No. 1 cylinder at compression top

dead center, it is also possible to turn the crankshaft
120’ each time and adjust the valve clearance of
* Firing order: 1 - 5 - 3 - 6 - 2 - 4

Fit O-ring and install cylinder head cover (I).
22. Nozzle holder

Fit gasket and install nozzle holder (1).
w Mounting bolt: 4.5 * 0.5 kgm
* When remove the nozzle holder, replace the seat

gasket with new one.
* Insert the spill tube before installing the nozzle
holder.
95 SERIES
23. Spill tube

Install spill tube (1).

* Before installing the fuel injection pipe, blow
compressed air through it.
1) Install fuel injection pipe (2), then temporarily
2) Align fuel injection pipes, then tighten clamps (1).
3) Fully tighten sleeve nuts of injection pipes.
w Sleeve nut: 2.3 f 0.2 kgm
25. Intake manifold

Coat mounting surface with gasket sealant, then install
intake manifold (1).
&,s Mounting surface: Gasket sealant (LG-7)
m Mounting bolt: 3.0 f 1 .O kgm
26. Fuel filter

1) Install fuel filter (3) to bracket.
2) Fit gaskets to both faces of joints of fuel hoses
(2) and (I), then connect with joint bolts.
w Joint bolt: 2.3 f 0.2 kgm
13-p 95 SERIES
27. Water pump

Fit gasket and install water pump (1).
&I& Both faces of gasket: Gasket sealant (LG-1 )

Fit gasket and install exhaust manifold (1).
m Mounting bolt: 4.5 * 1.5 kgm
29. Oil cooler, oil filter

1) Install oil cooler (1).
* Be careful not to get gasket sealant on the mount-
ing surface of the filter.
2) Oil filter (for PC200, 220-5)

Fit O-ring to mounting surface of oil filter bracket,
then install bracket. If there is no oil groove, coat
with gasket sealant (LG-7) and install bracket.
30. Alternator
1) Install alternator (3).
2) Fit belt (2), then temporarily tighten adjustment
plate (1).
95 SERIES
3) Insert a bar or pipe between

block,
belt tension.
and raise alternator
alternator
to outside
and cylinder
to adjust fan Alternator Pullev
\\ Fan pulley
w
A Be careful not to get your fingers caught.
*
‘\J
The belt should deflect 14 - 17 mm when 14-17mm ‘\
\\
pushed with a finger pressure of 6 kg at a point ‘,
_
midway between the alternator pulley and
the crankshaft pulley. After adjusting the
belt tension, tighten the bolt fully.
Crankshaft pulley
614OF301
31. Lowering engine

Sling engine assembly (11, disconnect engine from
bracket AI and engine repair stand A, then lower engine
on to a stable stand.
32. Starting motor

Install. starting motor (1).
0 Refilling with oil

1) Tighten drain plug.
2) Add engine oil through oil filler to the specified
level.
Q Engine oil: Approx. 10.5 II
13868 95 SERIES
DISASSEMBLY AND ASSEMBLY AIR COMPRESSOR
DISASSEMBLY AND ASSEMBLY OF AIR COMPRESSOR
Specifications
The air compressor is used as a source of supply of
compressed air to the air brakes, etc.
Komatsu Part No. 6206-91-I 100
Maker Part No. DK408717-0300
Applicable Engine Model (S)6D95L-1
Air-cooled, single cylinder,

Tvw double acting type
Cylinder diameter x stroke 70 x 40

Operation of unloader valve
Usual max. pressure 8.5
Usual max. speed 1,450
The stroke volume at each speed is as shown in the

table below.
Speed (rpm) 250 500 1,000 1,500

Air intake
Discharge amount (Illmin) 38.5 77 154 231 port *
Actuation
This equipment is generally installed between the en-
gine timing gear and the fuel injection pump, and is
driven by the timing gear. It is connected directly to
the engine, so the air compressor is always rotating
when the engine is running.
The intake valve and delivery valve open and close 6206F910
automatically according to the pressure inside the
cylinder. On the up-stroke of the piston, the air in-
side the cylinder is compressed, the intake valve
closes and the delivery valve opens to discharge
Air pressure from air
the compressed air. On the down-stroke, the de- governor
livery valve closes and intake valve opens to draw
in more air from the air cleaner.
An air governor is provided to control the amount
of air inside the air tank. When the air pressure in-
side the air tank reaches the specified pressure,
the compressed air inside the tank passes through
the air governor and pushes the rod of the un-
loader valve down to open the intake valve. For
this reason, while the unloader valve is being actu- Air intake
ated, the air sucked in is not compressed. port e
if the air pressure inside the air tank goes below

the specified pressure of the air governor, the rod
of the unloader valve returns to its original posi-
tion, the intake valve returns to the normal opera-
ting condition, and air is force fed again.
6206F911
13g70 95 SERIES
3. Structure of parts Lubrication

1) Cylinder Engine oil is used as the lubricant. The oil force
The cylinder is made of cast iron; the bottom fed from the engine to the oil supply joint in the
is jointed to the crankcase and it is installed side face of the crankcase is splashed up by the
with four bolts. crankshaft balance weight and the big end of the
2) Cylinder head connecting rod, and flows out through the over-
The cylinder head is an aluminium casting, flow holes provided at the engine end.
and has cooling fins. Both intake and delivery
vales are installed in the head, and the un- Disassembly
loader valve is installed on top of the intake The air compressor consists of three main com-
valve. The delivery valve and unloader valve ponents: cylinder head, cylinder, and crankcase.
can be installed and removed with the head The cylinder head, connecting rod, and piston
still installed to the body. cannot be disassembled unless the compressor is
The cylinder head is installed with four bolts; removed from the engine. The compressor is
when tightening the bolts, tighten uniformly in overhauled as follows.
turn to avoid tightening too much on one
side. Partial disassembly of compressor
3) Crankcase For details of the part numbers of the cylinder head
The crankcase is an aluminium casting, and portion, see the cylinder head cross-sectional
four holes are provided on the side face to in- drawing.
stall the compressor. There are also mounting 1) Cylinder head
holes for the oil supply joint. Furthermore, i) Remove 4 bolts tightening cylinder head.
there is an overflow installed for the excess ii) Tap cylinder head from bottom with a
oil that flows in the engine crankcase. The wooden hammer to remove.
face with holes is put in contact with the ap- iii) Remove gasket inserted between cylinder
propriate face of the timing gear case when and cylinder head.
installing the compressor. 2) Cylinder, connecting rod, piston
4) Crankshaft i) Remove 4 bolts tightening cylinder, then
The crankshaft is a forging that forms one remove cylinder from crankcase.
part with the balance weight. It is supported ii) Remove 2 bolts tightening big end of con-
by two ball bearings: one end is connected by necting rod.
a taper shaft to the timing gear, and the other iii) Remove piston and connecting rod from
end is connected to the fuel injection pump. crankcase.
5) Piston iv) Using a tool, remove 2 piston rings and 1
The pistons are made of aluminium alloy. oil ring from piston.
Two piston rings are installed at the top, and
one oil ring is installed at the bottom. Because
of the heat expansion when the piston is
moving, the outside diameter at the top is
smaller than the outside diameter at the
bottom.
6) Connecting rod
The big end of the connecting rod uses a
steel back split bearing. As it is impossible to
adjust the tightening by using shims, the
bearing must be replaced if it becomes worn.
The match mark used when assembling is
made on the side face.
95 SERIES
’3-:71
v) Remove 2 snap rings from piston pin hole,

then remove pistn pin and disconnect pis-
ton from connecting rod.
Unload
Air intake Dart
6206F912
1. Intake valve guide 9. Rod

2. intake valve spring IO. Unloader valve body
3. Plate valve 11. Delivery valve body
4. Intake valve seat 12. Spring guide
5. Snap ring 13. Delivery valve spring
6. Washer 14. Plate valve
7. Unloader valve spring 15. Delivery valve seat
8. O-ring 16. Gasket
’3-ii72 95 SERIES
3) Bearing cover ii) Measure the clearance between the ring

i) Remove 4 bolts tightening bearing cover and ring groove, and if it exceeds the re-
installed to crankcase, then remove from pair limit (Table 2), replace the piston or
crankcase together with oil seal. ring.
ii) Remove oil seal from bearing cover. Unit: mm
4) Crankshaft Nominal Standard
Repair limit
dimension clearance
i) Remove crankshaft in direction of bearing
cover with 2 ball bearings still installed.
ii) Remove ball bearings from crankshaft
with a hand press.
5) Unloader valve assembly
&Y$G, 1 4 / 0JyG5 I 0.20
i) Remove unloader valve body (10) in-
stalled to top of cylinder head.
ii) Remove snap ring (5) in middle of un- Table 2
loader valve body (IO), then remove

washer (6), spring (7), and rod (9). iii) If the clearance at the ring end gap ex-
6) Delivery valve assembly ceeds the repair limit (Table 3), replace.
i) Remove delivery valve body (11) installed
Unit: mm
to top of cylinder head.
Standard
ii) Lever seat (15) to remove, then remove Repair limit
clearance
spring (13) and valve (14) from inside. 0.10 -
Clearance at piston ring end gap 2.0
7) Intake valve assembly 0.25
0.10 -
i) Guide (1) is screwed into bottom of cylin- Clearance at oil ring end gap
0.50
1.5
der head and thread is caulked, so
remove caulking before removing guide. Table 3
ii) Remove guide (I), then remove spring
3) Wear of piston pin and piston pin hole
(2), valve (3), and seat (4) at the same
If the fitting between the piston pin and piston
time.
pin hole is loose, and exceeds the repair limit
(Table 4), replace the piston or piston pin.
6. Inspection and maintenance
Wash all the disassembled parts in flushing oil, Unit: mm
then lay them out in the order of disassembly to Nominal Standard
Repair limit
make assembly easy. Carry out inspection and dimension clearance
measurement, and use the maintenance stan-
dards to determine if parts can be used again or if
they must be replaced.
1) Cylinder Table 4
Check for any wear of the cylinder, or dam- 4) Wear of piston pin and connecting rod
age to the inside wall. If any damage is found, Measure the outside diameter of the piston
or if there is eccentric wear of more than 0.1 pin and the inside diameter of the connecting
mm, replace cylinder. rod small end, and if the clearance exceeds
2) Piston and piston rings the standard (Table 5), replace with the con-
i) Measure the outside diameter of piston, necting rod.
and if the clearance from the inside Unit: mm
diameter of the cylinder exceeds the re- Nominal Standard
pair limit (Table I), replace with a new dimension clearance Repair limit
part. b Clearance between

piston pin and 0.006 -
Unit: mm 16 0.1
inside diameter of 0.022
small end
Nominal Standard
Repair limit
dimension clearance
Table 5
% Measure the outside diameter of the piston at

the skirt.
Table 1
95 SERIES
’3-$73
5) Wear of connecting rod and crank pin ii) Delivery valve

Measure the inside diameter of the crank pin Press fit spring guide (12) in body (11).
bearing at the connecting rod small end and Then put spring (13) and plate valve (14)
the outside diameter of the crank pin, and if on top in turn, and press fit seat (15).
the clearance exceeds the standard (Table 6), When doing this, check that valve (14)
replace the connecting rod. and spring (13) move smoothly. Caulk
Unit: mm seat (15) at three places with a punch.
Nominal Standard Next, insert gasket (16) in head, coat
Repair limit
dimension clearance thread of delivery valve with Three Bond
Clearance be- 1360 adhesive, and tighten to specified
tween crank pin 0.020 -
30 0.15 torque.
bearing and 0.060
crank pin Unloader valve
iii)
Assemble O-ring (8) to rod (9), coat sur-
Table 6
rounding area with molybdenum disul-
6) Crankshaft phide grease (LM-G), and assemble in
If rotating portion is damaged, replace. body (10). Next, insert spring (7) and
7) Bearing cover and oil seal washer (6), and secure with snap ring (5).
Check surface of oil seal for scratches and Tighten unloader valve to head with spe-
roughness, and replace if necessary. cified torque. Push rod (9) with a bar, and
8) Intake valve and delivery valve check that valve (3) moves.
Check the valve and valve seat for damage iv) Piston and connecting rod
and wear. Check the valve spring also, and re- Align the piston pin hole and the hole in
place any defective part. the small end of the connecting rod, in-
9) Unloader valve sert the piston pin, then secure at both
Check for any damage to the O-ring. Then as- ends with snap rings.
semble to cylinder head and check operation. v) Piston rings and oil ring
If operation is poor, replace. Install the top and second rings with the
stamped face of the ring facing up. As-
7. Assembly semble so that the end gaps of the rings
1) Tightening torques are not at the same place. If the rings are
i) Cylinder head bolt: 300 kgcm assembled upside down, oil will leak up,
ii) Cylinder tightening bolt: 300 kgcm so be extremely careful to assemble cor-
iii) Bearing cover tightening bolt: 60 kgcm rectly. There is no difference between the
iv) Connecting rod tightening bolt: 250 kgcm top and bottom of the oil ring.
v) Guide intake valve: 1200 kgcm vi) Oil seal and bearing
vi) Delivery valve body: 1500 kgcm When press fitting the oil seal to the bear-
vii) Unloader valve: 500 kgcm ing cover, coat the outside diameter of
2) Assembly the oil seal with Three Bond 1360 ad-
For details of the part numbers, see the cylin- hesive. Press fit both ball bearings to the
der head cross-sectional drawing. crankshaft with a press.
i) Intake valve 3) Overall assembly
Insert seat (4) in head, then put valve (3) Insert the crankshaft from the bearing
and spring (2) on top in turn, and tighten cover end of the crankcase, then install
guide (1) temporarily. When doing this, the cover. Coat the area between the
check that valve (3) and spring (2) move cover and case with Three Bond 1104
smoothly. After doing this, tighten guide packing agent, then tighten to the speci-
(1) to the specified torque. If guide (1) fied torque.
protrudes from the bottom face of the Insert the connecting rod from the top of
head, there is danger that it may contact the crankcase (cylinder end), then tighten
the top face of the piston, so be ex- the cap to the specified torque. Check
tremely careful when tightening. Finally, that the connecting rod match marks are
caulk at three places with a punch. aligned.
13-l&74 95 SERIES
iii) When assembling the cylinder, first coat

the crankcase adhesive surface with
, Outside of oioe
Three Bond 1104 packing agent, keep the
piston ring compressed, mate the cylinder
correctly, then tighten to the specified
torque.
iv) Lay the gasket on the top surface of the If X+X exceeds 1.5 mm, the
pipe must be cleaned or
cylinder, then put the cylinder head as-
sembly on top of the gasket and tighten
the 4 mounting bolts gradually and uni- 6206F913
formly to the specified torque.
8. Performance test after assembly (2) If carbon is stuck to connecting joints, remove
After carrying out disassembly, inspection, and the carbon with a screwdriver and blow with
assembly, carry out the air-tightness test and per- compressed air to clean.
formance test as follows. (3) If there is carbon stuck inside the check valve
Air-tightness test installed between the air compressor and wet
Apply air pressure at 7 kg/cm2 to the delivery tank, remove the carbon with a screwdriver
port and unloader valve at the same time, and and blow with compressed air to clean. (If the
measure the amount of leakage from the in- rubber valve seat is broken, replace the
take port. valve.)
Standard for leakage: Max. 450 cc/min 9.2 Air compressor
Charging performance Remove the head and carry out the following
The amount of time taken to charge the tank maintenance.
capacity of 35 liter between a tank pressure of (1) If there are no deep vertical scratches in the
0 and 7 kg/cm2 shall be as shown below. cylinder and there is carbon stuck to the top
surface of the piston, remove the carbon from
Speed (rpm) Charging time (set) the top surface of the piston with a sharp tool.
1,100 Max. 158 When doing this, be careful not to let the car-
bon fall through the gap between the piston
Oil leaking up and cylinder.
Remove the pipe at the delivery port of the * If there are vertical scratches in the cylin-
cylinder head, run the engine and check the der deep enough to catch your finger-
condition. Check that there is no abnormal nails, replace the cylinder, piston, and pis-
spray of oil from the delivery port. ton ring kit.
(2) If there is carbon stuck to the bottom surface
9. Periodic inspection of the head or the air intake and delivery
Carry out the following maintenance every 4000 holes, remove the carbon with a screwdriver
hours. and blow with compressed air to clean.
9.1 Delivery air pipe (between air compressor and (3) If there is carbon stuck to the delivery valve,
wet tank) intake valve, seat, guide, or spring, remove
Remove the delivery air pipe and do as follows. the carbon with a screwdriver and blow with
(1) If there is more than 1.5 mm of carbon accu- compressed air to clean.
mulated on the inside surface (see diagram (4) If there is carbon stuck to the unloader valve
below), blow compressed air through the pipe and spring, remove the carbon with a screw-
to clean it. If the carbon cannot be removed, driver and blow with compressed air to clean.
replace the piping. If washing agent KO: Part (If the O-ring is worn, replace the unloader
No. 600-311-3310 (for circuit at oil cooler ele- valve assembly.)
ment oil end) is available, it is possible to * When removing the carbon with a screw-
clean out the carbon with this. (See the en- driver, be careful not to scratch the sur-
closed explanations for the method of use.) face.
It is easy for carbon to stick at joints, check
valves, and other points where the flow is re-
stricted, so check these places carefully.
95 SERIES 13g75
9.3 Tightening torques when piping to air compressor

and air compressor has been disassembled.
95 SERIES
’3-:76
ENGINE
14 MAINTENANCE STANDARD
Turbocharger ............................................ 14-002

Cylinder head ........................................ 14-003-2
Valve and valve guide ............................. 14-008
Rocker arm shaft,
push rod and tappet.. ........................ 14-009
Cylinder block.. ......................................... 14-010
Crankshaft ................................................. 14-012
Camshaft ................................................... 14-014
Timing gear .............................................. 14-018
Flywheel and Flywheel housing ............. 14-019
Piston, piston ring and piston pin.. ........ 14-020
Connecting rod ......................................... 14-027
Oil pump ................................................... 14-028
Regulator valve ........................................ 14-030
Water pump and thermostat .................. 14-031
Fuel system ............................................... 14-034
95 SERIES 14-001
0
MAINTENANCE STANDARD TURBOCHARGER
TU RBOCHARGER (S4D95L-1, SA4D95L-1, S6D95L-1, SA6D95L. ml)

T-31
I--
6207F402
1
3 5 4 6207F401 A
- Unit: mm
No Remedy
-
Radial play of rotor
Repair or
Retighten
Thickness of thrust bearing
Outside diameter of
wheel shaft
6
Bend of wheel sha qeplace
Inside diameter of
back plate
C 15.80 15.81
inside diameter of
8
center housing
D 18.03 18.08
14202 95 SERIES
T04B
I \
5 4
I4F036A I4FO36- I I4FO36-2
I’\. - Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
1 Radial play of rotor

0.075 - 0.150 0.18
Replace
2 End play of rotor 0.025 - 0.075 0.10
Target Nm (kgm) Range Nm (kgm)

Tightening torque of blower
3 16.4 - 18.6
housing mounting bolt 17 (1.3)
(1.15 - 1.5)
Tightening torque of turbine 17.6 - 21.6

4
housing mounting bolt I (1.8 - 2.2)
- Tightening torque of back 8.4 - 10.2

9.3 (0.95)
plate mounting bolt (0.86 - 1.04)
L 5 Thickness of thrust bearing

4.36 4.35
Measuring point Standard size Repair limit
A 17.34 17.25
Outside diameter of
wheel shaft
6
B 10.16 10.15
Bend of wheel shaft Repair limit: 0.010 (Total indicated runout) Replace

Inside diameter of
7
back plate 12.70 12.73
Measuring point Standard size Repair limit
C 15.80 15.81
Inside diameter of
8
center housing
D 18.03 18.08
95 SERIES 14-003
0
S2D (SCHWITZER)
6206F954
Unit: mm
1 Play of rotor in radial

direction
-
Play of rotor in axial
2
direction

Tightening torque of turbine Tighten
3
housing VEE clamp 6.9 (0.7) 6.9 (0.7)
4 Thickness of thrust bearing

4.35 4.30
l Outside diameter
Measuring point 1 Standard size Repair limit
I I
10.152 10.130
I I
-1
Outside diameter, curvature
5
of wheel shaft B 17.32 17.25
- Curvature
Repair limit: 0.0076 (Total indicator runout)

- Replace
6 Inside diameter of insert

12.71 12.71
-
Measuring point 1 Standard size 1 Repair limit
7
Inside diameter
housing
of center
C
I 15.80
I
15.82
I
D 18.06 18.06
14-003-l 95 SERIES
0
MAINTENANCE STANDARD CYLINDER HEAD
CYLINDER HEAD
3D95S-W-1
i 6206F558
Exhaust side
6206F557
Intake side
Unit: mm
No. Check item Criteria Remedy
Tolerance Repair limit

Distortion of cylinder head mounting Grind to correct,
surface or replace
0 - 0.05 0.30
Protrusion of swirl chamber insert Standard: 0 - 0.08 Replace insert
Sequence Target Nm (kgm) Range Nm (kgm)
Tightening torque of cylinder head 1st Step 58.8 - 78.4 (6 - 8)

68.6 (7)
mounting bolt
[Coat bolt seat surface and thread
. Tighten
102.9 - 112.7
with molybdenum disulphide (LM-P)] 2nd Step 107.8 (11)
(IO.5 - 11.5)
3rd Step 90 go’- 120
4 Tightening torque of nozzle holder 100 + 2.5 Nm (10.25 + 0.25 kgm)
5 Tightening torque of glow plug 12 t 2.5 Nm (1.25 * 0.25 kgm)

- Tighten
6 Tightening torque of terminal nut 1.5 + 0.49 Nm (0.15 * 0.05 kgm)
Tightening torque of head cover

7 8.8 f I Nm (0.9 + 0.1 kgm)
mounting bolt I
-
95 SERIES
’ 4-oii3-2
4D95S-1
4D95L-1 (For PC60-6, PC60,70-7, PC90-I)
6202FOO26
i 6202F002A
Tightening order of cylinder heat mounting bolt
Front r Rear
Intake side
6204F403
6206F401 A
Unit: mm
No
Distortion of cylinder head

1
mounting surface
2 Protrusion of hot
Tightening torque of cylinder head

mounting bolt
3
(Coat bolt threads and washers
with molybdenum disulphide)
tening torque of nozzle

4
-
5
-
6 Tightening torque of terminal nut 1.2 + 0.2 Nm (0.125 + 0.025 kgm)
Tightening torque of head

7 8.8 L 1 Nm (0.9 + 0.1 kgm)
cover mounting bolt
95 SERIES
4D95L-1
S4D95L-1
1 6204F401
Tightening order of cylinder heat mounting bolt

Ir I
Intake side
6206 F401 A
Unit: mm

Reljair by
Distortion of cylinder head grinding or
1
mounting surface
0 - 0.05 0.30 replace
2 Protrusion of nozzles 3.12 + 0.28 2.7 - 3.5

I Replace nozzle
gasket
Tightening torque of cylinder head 1st step

mounting bolt (Coat bolt threads 68.6 (7) 58.8 - 78.4 (6 - 8)
3
and washers with molybdenum
disulphide) 2nd step 107.8 (11) 102.9 - 112.7
(10.5 - 11.5)
I 3rd step I 90” I 90” - 120” 1 Retighten
Tightening torque of nozzle

4 44.1 + 4.9 Nm 14.5 + 0.5 kgm)
holder mounting bolt
I
-
Tightening torque of
5 8.8 f 1 Nm (0.9 + 0.1 kgm)
head cover mounting bolt I
95 SERIES
4D95L-W-1
4D959-W-1
i 6204F404
I/ .
Rear
Intake side
6204F405 6204F403
Unit: mm
Standard Repair limit

Distortion of cylinder head Repair by
1 grinding
mounting surface
o-0.05 0.30 or replace
-
2 Protrusion of hot plug Standard: 0 - 0.08 Replace

hot plug
Order Target Nm (kgm) Range Nm (kgm)
Tightening torque of cylinder head 1st step 68.6 (7) 58.8 - 78.4 (6 - 8)
3 mounting bolt
(Coat bolt threads and washers 102.9 - 112.7
with molybdenum disulphide) 2nd step 107.8 (II)
(10.5 - 11.5)
3rd step 90” 90” - 120”

4 88.2 + 9.8 Nm (9 t 1 kgmj
holder I Retighten
-
Tightening torque of injection

5 44.1 k 4.9 Nm (4.5 + 0.5 kgm)
pipe nut I
6 Tightening torque of glow Plug 17.2 k 2.5 Nm (1.75 + 0.25 kgm)

I I
7 Tightening torque of terminal nut 1.2 f 0.2 Nm (0.125 + 0.025 kgm)

8 8.8 + 1 Nm (0.9 t 0.1 kgm)
cover mounting bolt
14-006 95 SERIES
0
6D95L-1
S6D95L-1
SA6D95L-
Intake side
I +--2 6206F401A
Unit: mm
NC Check item Criteria Remedy

-
Distortion of cylinder head
1 Repair by
mounting surface grinding or
0 - 0.05 0.30 replace
2 Protrusions of nozzles 3.12 f 0.28 2.7 - 3.5 Replace

I I nozzle gasket
-
Order Target (kgm) Range (kgm)

Tightening torque of cylinder head
mounting bolts 1st step 7 6-8
3
(Coat bolt threads and washers 11 10.5-11.5
2nd step
with molybdenum disulphide)
Retighten
3rd step 9o” 9o” - 120”
-

4 4.5 + 0.5 kgm
holder mounting bolt

5 0.9 t 0.1 kgm
cover mounting bolt
95 SERIES 14-007
0
Applicable engine Tolerance Repair limit
3D95S-W-1
Sinking of valve 4D95S-W-1 0.8 + 0.18 1.80 Replace valve or
1
4D95L-W-1 valve seat
4D95S-1
(SA)4D95L-1 0 f 0.18 1 .oo
3D95S-W-1
4D95S-W-1
2 Thickness of valve head 4D95S-1 1.40 - 1.60 1 .oo Replace
4D95L-W-1
(SA14D95L-1
Standard Tolerance Repair limit

Correct valve or
3 Valve seat angle Judge contact surface valve seat, or
45 f 15 condition with vacuum replace
Clearance between valve guide and

4
valve stem
/ Exhaust 18 / ~~:‘~~ 1 +i’015 1 ““~~& 1 0.20 1
Part No.
(distinguishing feature)
I I
Free length of valve spring
I 6204414410
(Peach color)
I
49.2
I
48.5
I
I 6204-41-4431
(Red)
Part No.
I
Installed
56.0
Standard load
55.0
5 Load limit (kg) Replace

(distinguishing feature) length (kg)
6204-41-4410
40.5 18.5 f 0.9 16.5
Installed load of valve spring (Peach color)
6204-41-4431
(Red) 40.5 15.6 * 1.5 13.0
Out-of-square of valve spring Repair limit: 1.85
Standard size Tolerance
6 Driving-in height of valve guide Correct

14.5 * 0.2
* 4D95S1 engine: no valve seat insert (EX)

* 4D95L-1 engine for PC60-6, PC90-1: No valve seat insert (EX, IN)
’4-:08 95 SERIES
MAINTENANCE STANDARD VALVE, VALVE GUIDE
6D95L-1,
6206F403
2
I IN Unit: mm
-
Sinking of valve Replace valve or

6D95L-1
valve seat
S6D95L-1 0 f 0.18 1 .oo
SA6D95L-1
6D95L-1
2 Thickness of valve head S6D95L-1 1.40 - 1.60 1.oo Replace
SA6D95L-1
Standard Tolerance Repair limit

Correct valve or
3 Valve seat angle Judge contact surface valve seat, or
45 f 15 condition with vacuum replace
test
Tolerance
Standard size Standard Clearance
Shaft Hole clearance limit
Clearance between valve guide and Replace either

4 Intake 8 -0.035 +0.015 0.035 - valve or valve
valve stem -0.050 0 0.065 0.20 guide or both
-
-0.065 0 0.080 0.20
Exhaust I 8 1 -0.050 f0.015 0.050 I
Part No.
(distinguishing feature)
I I
6204-41-4410
49.2 48.5
Free length of valve spring (Peach color)
I I !
6204-41-4431
56.0 55.0
(Red) I
I I
Part No. Installed Standard load

5 Load limit (kg) Replace
(distinguishing feature) length (kg)
6204-41-4410
40.5 18.5 * 0.9 16.5
Installed load of valve spring (Peach color)
6204-41-4431
40.5 15.6 + 1.5 13.0
(Red) I I
I I

14.6 * 0.2
95 SERIES
’4-oz8-1
MAINTENANCE STANDARD VALVE, VALVE GUIDE
S4D95L (PCIOO-5, P&20-5, PCIOO-6, PC120-6, PC128UU-I)

S6D95L (PC200-5, PC200-6, BR200-1)
SA6D95L (PC220-5, PC220-6, BR300-1)
6206F403
IN
I
I Unit: mm
-
-
S4D95L 0 f 0.18 1.00

Replace valve or
1 Sinking of valve
S6D95L valve seat
SA6D95L 0 f 0.18 1 .oo
S4D95L
2 Thickness of valve head S6D95L 1.40 - 1.60 (Exhaust) 1.OO (Exhaust)
1.90 - 2.10 (Intake) 1.50 (Intake) Replace
SA6D95L
3 i/alve seat angle

Standard Tolerance
I Correct valve or
“CD,cxrKiusq
43
,T__L_.__~L 1Judae contac valve seat, or
I * 15 condition with vacuum replace
7r-P,ln+~tn\
“” ,..“..,.W,
I
Replace either
Clearance between valve guide and
4 valve stem -0.035 +0.015 0.035 - valve or valve
Intake 8 0.20
-0.050 0 0.065 guide or both
Exhaust 8 -0.050 +0.015 0.050 -

-0.065 0 0.080 0.20
-
Free length of valve spring

5 31 Replace

14.5 f 0.2
’4-ooo8-2 95 SERIES
MAINTENANCE STANDARD ROCKER ARM SHAFT, PUSH ROD AND TAPPET
ROCKER
6206F405
Unit: mm
Standard Tolerance
Outside diameter of rocker arm _ Replace rocker
shaft arm shaft
19
-:.020
Inside diameter of rocker arm +0.030 Replace

19
shaft hole +0.010 rocker arm
1
Standard clearance Clearance limit

Clearance between rocker arm Replace rocker
arm or rocker
and rocker arm shaft
0.010 - 0.050 0.12 arm shaft
Bend of rocker arm shaft

I
Repair limit: 0.20 (Total indicated runout)
I Replace rocker
arm shaft
Replace
2 Bend of push rod Repair limit: 0.30 (Total indicated runout)
push rod
Valve Standard Tolerance
3 Valve clearance (at cold)

I Intake 0.35
I * 0.02
1
Adjust
Exhaust 0.50 * 0.02

-
Standard Tolerance
Replace
Outside diameter of tappet
-0.015 tappet
16
-0.030
+0.018 Replace
Inside diameter of tappet hole 16
I 0 cylinder block
I I
4
Replace tappet
Clearance between tappet and
or cylinder
tappet hole
0.015 - 0.090 0.12 block
Tightening torque of adjustment

4.5 + 0.5 kgm Retighten
nut of rocker arm
95 SERIES
’ 4-:09
MAINTENANCE STANDARD CYLINDER BLOCK
CYLINDER BLOCK
6206F407
6206F406
Unit: mm
No. Check Criteria Remedy
size Standard Tolerance Repair Repair by

I I I using over
Inside diameter of cylinder
Roundness of cylinder Repair limit: 0.02
Repair limit: 0.02
14-010 95 SERIES
a
MAINTENANCE STANDARD CYLINDER BLOCK
Unit: mm
No Check
l When using the Standard (STD) piston,

use the size of pistons indicated by the stamped mark (S or L)
on the top surface of the cylinder block.
l When using the Over Size (0.S.) piston,
measure inside diameter of cylinder at points 40 mm, 100 mm
and 160 mm from the cylinder block top face.
Then select S-size or L-size piston according to the smallest
of the three inside diameters.
When changing
the piston size,
Piston size / Standard size ;“‘inder~~~~~e~iameter 1 ~~~~t~~~ correct the
1 Selection of pistons stamped mark
I
L (95.250
O
95.25+0.011
- 95.261)
S-size piston
(S or L) on the
cylinder block
top face
0.25 O.S. 95.25
95.25 +O.O’ ’
+0.022 L-size piston
(95.261 - 95.272)
95.50 O
+0.011 S-size piston
(95.500 - 95.511)
0.50 0,s. 95.50
95.50 +O.O’ ’
+0.022 L-size piston
(95.511 - 95.522)

Distortion of cylinder head Repair by
2
mounting surface graiding
Inside diameter of main bearing

lole
Repair or
3 replace
Roundness of main bearing hole Repair limit: 0.005 cylinder block
Fitraighteness of main
Jearing holes Repair limit: 0.010
-
Standard size Tolerance Repair limit
STD 70.00 70.20
0.25 U.S. 69.75 69.95

Replace
4 Inside diameter of main bearing
main bearing
0.50 U.S. 69.50 +0.103 69.70
+0.058
0.75 U.S. 69.25 69.45
1 .oo U.S. 69.00 69.20

-
Standard Tolerance Rapair or
5 nside diameter of cam bushing
replace
lole 53.5 +0.030 cylinder block
n
ournal I Standard I Tolerance / Repair limit
nside diameter of cam + 0.030
No. 1 50.5 50.60 Replace
lushing
6 I -0.040
No. 2 -0.031
Inside diameter of cylinder block No. 3 50.5 -0.050 50.60 Press fit bushing
-
Order I Target (kgrn) Range ikgm)
rightening torque of main bearing
:ap mounting bolts 1st step 11.5 11-12
I I
7 Fietighten
Coat bolt threads and washers 2nd step 0 Loosen completely
with engine oil)
3rd step 13.5 13 - 14
95 SERIES 14-p
MAINTENANCE STANDARD CRANKSHAFT
CRANKSHAFT
3D95S-W-1
6206F558
Unit: mm
NC Check Item Criteria
1 End play
Outside diameter of main journal
Repair limit: 0.020
_ Replace main
Clearance of main journal
bearing
0.043 - 0.103 0.25
I I I
0.50 U.S. 56.50 +0.015 Repair by

56.41
Outside diameter of crankpin 0 using under
journal size bearing
0.75 U.S. 56.25 56.16 or replace
3
1 .oo U.S. 56.00 55.9 1
Roundness of crankpin journal Repair limit: 0.020

Replace
Clearance of crankpin journal connecting
0.029 - 0.089 0.22 rod bearing
-
Repair by
using under
4 Bend of crankshaft Repair limit: 0.09 (Total indicated runout) size bearing
14-iik’2 95 SERIES
4D95L-1
S4D95L-1
4D95L-W-1
4D95SW-1
6204F405
Unit: mm
/ -
No Check Item Criteria Remedy
Standard Repair limit Repair by

using over
1 - olav
End
-7-, I size thrust
I
I
0.131 - 0.351
II
0.40
I
bearing
or replace
STD 70.00
0.25 U.S. 69.75 Repair by

using under
Outside diameter of main journal
size bearing
0.50 U.S. 69.50 or replace
0.75 U.S. 69.25

2
1.00 U.S. 69.00
Roundness of main journal Repair limit: 0.020

Replace main
bearing
0.043 - 0.103 0.25
STD 57.00 56.91
0.25 U.S. 56.75 56.66
Repair by
Outside diameter of crankpin using under
iournal size bearing
or replace
3
1 .oo U.S. 56.00
I
1
qoundness of crankpin journal Repair limit: 0.020
I I
Replace
Clearance of crankpin journal connecting
0.029 - 0.089 0.22 rod bearing
I I
Repair by
using under
4 send of crankshaft Repair limit: 0.09 (Total indicated runout) size bearing
95 SERIES
S4D95L-1
SA4D95L-1
6204F405
Unit: mm
Repair by using over

Standard Repair limit size thrust bearing
or replace.
End play
Note: The tufttride
0.131 - 0.351 0.40 crankshaft cannot
be corrected.

I I
STD 70.00 69.86
Repair by using
Dutside diameter of main journal under size bearing
0.25 U.S. 69.75 +0.015 69.61 or replace.
0
Note: The tufttride
0.50 U.S. 69.50 69.36 crankshaft cannot
be corrected.
2
qoundness of main journal Repair limit: 0.020

I I

Replace main
bearing
0.043 - 0.103 0.25
-
I Standard size tolerance Repair limit
STD 57.00 56.91

Repair by using
Outside diameter of crankpin journal under size bearing
0.25 U.S. 56.75 +0.015
0 56.66 or replace.
Note: The tufttride
0.50 U.S. 56.50 56.41 crankshaft cannot
be corrected.
3

Replace connecting
Clearance of crankpin journal
rod bearing.
0.029 - 0.089 0.22
I
Repair by using
under size bearing
or replace.
4 Bend of crankshaft Repair limit: 0.09 (Total indicated runout)
Note: The tufttride
crankshaft cannot
be corrected.
-
95 SERIES
6D95L-1
SA6D95L-1
6206F408
* Marked % are applied only for 6D95L-1 Unit: mm
Check item Criteria Remedy
Reoair by using over size

Standard Repair limit thrust bearing or replace.
Repair by using over size
Engine thrust bearing or replace.
0.130 - 0.350 0.40 Note: The tuftbide crank-
shaft cannot be corrected.
I I
STD 70.00 69.86
0.25 U.S. 69.75 69.61 Repair by using under size

Outside diameter of main
bearing or replace.
journal
0.50 U.S. 69.50 +0.015 69.36 Repair by using under size
0 bearing or replace.
Note: The tufttride crank-
0.75 VS.” 69.25 69.11 shaft cannot be corrected.
1 .oo U.S.” 69.00 68.86
Roundness of main journal Repair limit: 0.020
Clearance of main journal Replace main bearing.

0.043 - 0.103 0.25
-
‘,.
STD 57.00 56.91

Outside diameter of crankpin
bearing or replace.
journal +0.015
0 bearing ore replace.
0.75 U.S? 56.25 56.16 shaft cannot be c,orrected.
3 1 .oo U.S.% 56.00 55.91

Replace connecting rod
Clearance of crankpin journal bearing.
0.029 - 0.089 0.22
- I
Repair by using under size
bearing or replace.
Repair by using under size
4 Bend of crankshaft Repair limit: 0.09 (Total indicated runoutj
bearing or replace.
95 SERIES 14-O 13-2

MAINTENANCE STANDARD CAMSHAFT
CAMSHAFT
3D95S-W-1
(without bushing for No. 2 and No. 3 journals)
6206F559
Unit: mm
T
No. Check item Criteria

Replace
1 End play thrust
0.150 - 0.350 0.50 plate
I
-
Tolerance
Standard Standard Clearance
Journal
size clearance timit
Shaft Hole Replace
bushing
Clearance between camshaft
2 and bushing No. 1 50.5 -0.080 +0.030 0.040 -
-0.110 -0.040 0.140 0.25
Press-fitt
No. 2 -0.080 -0.031 0.030 -
No. 3 50.5 -0.110 -0.050 0.079 0.25 insert
bushing
3 Bend of camshaft Repair limit: 0.03 (Total indicated runout)

-
Cam Standard size Tolerance Repair limit Replace

1 camshaft
4 Cam height 42.7
Intake 43.24
to.10
Exhaust 43.44 42.9
95 SERIES
3D95S-W-1
(with bushing for No. 1, No. 2 and No. 3 journals)
SectionA-A
6206F559
Unit: mm
I I
-
Replace
1 End play thrust
I 0.150 - 0.350
I 0.50 plate
Tolerance
Journal
size clearance limit
Clearance between camshaft Shaft Hole Replace
2 bushing
and bushing No. 1
-
No. 2 50.5 -0.080 +0.030 0.040 0.25
No. 3 -0.110 -0.040 0.140
-

camshaft
4 Cam height intake 43.24 42.7
20.10
Exhaust 43.44 42.9
95 SERIES
4D95S-1
4D95L-1 (without for PC60-6 and PC90-1)
S4D95L-1
SA4D95L-1
4D95L-W-1
4D95S-W-1 (without bushing for No. 2 and NO. 3 journals)
6204 F406
Unit: mm

Replace
1 End play thrust
0.150 - 0.350 0.50 plate
Journal
/ .Stasn;:rd / ,hal’“a,nceHo,e 1 .Sta;;;; / Cl;E;ce
Replace
I I I I I
bushing
2
and bushing No. 1 50.5 -0.080 II -0.040
+0’030 1o.~& 1 0.25
-0.110
Press-fitt
insert
bushing

-
Cam Standard site Tolerance Repair limit Replace
43.24 42.7
camshaft
4 Cam height Intake 14D95S-1 4D95S-1
S(A)4D95L: 42.69 ( S(Aj4D95L: 42.2 )
43.44 *0.10 42.9
4D95S1 4D95S-1
Exhaust
( S(A)4D95L: 43.04 1 C S(A)4D95L: 42.5 1
14-g 6 95 SERIES
4D95L-1 (for PC60-6 and PC90-1)

(without busing for No. 2 and No. 3 journals)
-fzzz3-
6204F406
Unit: mm
/ Standard Repair limit

Replace
1 End play thrust
0.150 - 0.350 0.50 plate
I
Replace
bushing
2
and bushing
No. 2 -0.080 Press-fitt

-0.03 1 0.030 -
No. 3 50.5 -0.110 -0.050 0.079 0.25 insert
bushing
3 Bend of camshaft Repair limit: 0.03 (Total indicator reading)

camshaft
4 Cam height
,’ 95 SERIES
’4-?A
&’
4D95S-1
4D95L-1
S4D95L-1
SA4D95L-1
4D95L-W-1
4D95SW-1
(with bushing for No. 1, No. 2 and No. 3 journals)
6204F406
‘Init: mm

-
I Replace
1 End play thrust
plate
Clearance between camshaft Replace

2 and bushing bushing

-
camshaft
42.7
4 Cam height 4D95S-1
t S(A14D95L.1: 42.2 1
42.9
4D95S-1
( S(A)4D95L-1: 42.5 1
’4-%
6-2 95 SERIES
6D95L-1
S6D95L-1
SA6D95L-1
6206F409
Unit: mm
1~
-

I Replace
1 End play thrust
bearing
Clearance between camshaft Replace

2
and bushing bushing
-
50.5 -0.080 +0.020 0.030 0.25
-0.110 -0.050 0.130
3 Bend of camshaft Reapir limit: 0.03 (Total indicated runout)

camshaft
4 Cam height Intake 42.7 42.2
to.10
Exhaust 43.4 42.9
95 SERIES
MAINTENANCE STANDARD TIMING GEAR
TIMING GEAR (HELICAL GEAR)

Serial No. 106425 and below
(Except for 4D95S-1)
6206F412A
6206F4llA
Unit: mm
Measuring Repair limit

Gears Standard
point
A Crankshaft gear and idler gear 0.14 - 0.28
B Idler gear and camshaft gear 0.15 - 0.30
Replace bushing
1 sacklash of each gear or gear
Idler gear and fuel injection
C 0.13 - 0.34 0.4
pump gear
Camshaft gear and oil pump

a 0.13 - 0.35
gear
Camshaft gear and PTO gear

b 0.15 - 0.30
(with PTO)
Tolerance
Standard Clearance
Standard size limit Replace bush-
clearance
Iearance between idler gear bushing Shaft Hole ing (Supplies
2 are semi-fabri-
snd shaft
cated) or gear
0 +0.035 0.015 -
45 0.10
-0.015 +0.015 0.050

Replace idler
3 ind play of idler gear shaft, thrust
0.03 - 0.09 0.20 plate or gear
14-:18 95 SERIES
Serial No. 106426 and up
6206F412A
6206F411A
Unit: mm
Measuring Repair limit

Gears Standard
point
I A
I
Crankshaft gear and idler gear 0.08 - 0.19
Replace bushing
1 Backlash of each gear or gear

b 0.15 - 0.30
(with PTO)
Tolerance
Standard Clearance
Standard size
clearance limit
Clearance between idler gear bushing Shaft Hole Replace bush-
2 ing or gear
and shaft
+0.035 0.015 -
45 0.10
-:.015 +0.015 0.050
-
Replace idler
3 End play of idler gear shaft, thrust
0.03 - 0.09 0.20 plate or gear
95 SERIES
14-Z8-’
WI ‘HOUT FRONT PTO TYPE

s41 195L-1 (For PClOO, 120-6, PC128UU-I)
S6l 195L-1 (For LW80-I)
2 3
\ \ ,:p======
mm
Repair limit
Replace bushing
1 Backlash of each gear or gear
Idler gear and fuel injection
C 0.07 - 0.29 0.4
pump gear

a 0.07 - 0.29
gear
Clearance between idler gear bushing Replace bush-

2 ing or gear
and shaft

Replace idler
plate or gear
95 SERIES
’4-%
*-*
WITH FRONT PTO (SPUR GEAR)

4D95S-1 (For PC60-6 BLADE SPEC.1
4D95L-1
6206F411A 6206F412A
Unit: mm
Standard ! Repair limit
0.14 - 0.28 1
0.15 - 0.30
Replace bushing
1 3acklash of each gear or gear
0.13 - 0.34 0.4
a
Camshaft gear.and oil pump
gear

1
0.13 - 0.35
b 0.15 - 0.30
(with PTO)
-
Standard Clearance
clearance limit
;;daFhnc; between idler gear bushing Replace bush-
2 ing or gear
““b’,;,/
-
Replace idler
1
0.03 - 0.09 0.20 plate or gear
I
-
95 SERIES
“-od8-3
FLYWHEEL AND FLYWHEEL HOUSING
6206F4 I5
6206F4 I6
Unit: mm

-
Face runout of flywheel
1 housing
Repair limit: 0.30
‘. -
Radial runout of flywheel

2 Repair limit: 0.35
housing
Repair by
reassembling
3 Face runout of flywheel Repair limit: 0.15
4 Radial runout of flywheel Repair limit: 0.20

-
Target Range
Order
Nm (kgm) Nm (kgm)
Tightening torque of 1st step 107.8 98 - 117.6
flywheel mounting bolts (IO - 12)
5 (11)
(Coat bolt threads and
washers with engine oil)
2nd step 191.1 186.2 - 196
(19.5) (19 - 20) Retighten
3D95S-W-1 Repair limit: 53.9 2 19.6 Nm (5.5 + 2.0 kgm) (IO mm)
24.5 2 9.8 Nm (2.5 2 1.0 kgm) (8 mm)
Tightening torque of flywheel
6
housing mounting bolts
Except
3D95S-W-1 Repair limit: 68.6 2 4.9 Nm (7 * 0.5 kgm)
95 SERIES 14-019
0
MAINTENANCE STANDARD PISTON, PISTON RING AND PISTQN PIN
PISTON, PISTON RING AND PISTON PIN

3D95S-W-1
4D95S-W-1
.-
6206F708 6706F413-1 ‘_
Unit: mm
-
Standard
Piston size Size mark Tolerance Repair limit
size
STD 95.00 L -0.130 94.76

1 Xrtside diameter of piston -0.145 Replace piston
0.25 O.S. 95.25 ~ 95.01
-0.145
0.50 O.S. 95.50 S -0.t60 95.26
,o, Measuring
point
2 Top ring 0.30 - 0.45 2.0
IReplace piston
‘iston ring gap
Iping
Second
3 0.30 - 0.45 2.0
ring
I I
4 0.25 - 0.45 1.5
Tolerance
uo, Measuring Standard Standard Clearance
point size clearance limit
Ring Piston
I
5 /Top ring 1 2.2 1 1::‘; 1 Judge using wear gauge
Clearance between piston ring Replace piston
groove and piston ring or piston ring
-
7 Oil ring 4 -0.01 +0.04 0.03 0.15
-0.03 +0.02 0.07
Tolerance
Clearance between piston Shaft Hole Replace piston
8 and piston pin I I I
or piston pin
I I
30 0 i6.012 0.004 - 0.05

-0.006 iC.004 0.018
-L
’4-Fk20 95 SERIES
MAINTENANCE STANDARD PISTON, PISTON RING AND PISTON PIN
4D95S-W-1 (D20,21-6)
7
f 28mm
6206F708
6206F413.1
Unit: mm
T
Check item Criteria
Piston size 1 Sta$:rd 1 Size mark 1 Tolerance 1 Repair limi
STD 95.00
L
1 I;:cm; 1 94.76
1 Outside diameter of piston Replace piston
0.25 O.S. 95.25 - ~ 95.01
-0.145
0.50 0,s. 95.50 s -0.160 95.26
rJo. Measuring
point
2 Top ring 0.30 - 0.45 2.0
Piston ring gap Replace piston

Second ring
3 0.30 - 0.45 2.0
ring
I I I
4 Oil ring 0.25 - 0.45 1.5

I I
Tolerance
Jo, Measuring Standard Standard Clearance
5 I\
Ring Piston
5 Top ring 2.2 -0.01

Judge using wear gauge
Clearance between piston ring -0.03 Replace piston
6
6 Second 2 -0.01
ring -0.03
7
7 Oil ring 4 -0.01 +0.04 0.03 - ‘o., 5
-0.03 +0.02 0.07
Clearance between piston

8
and piston pin
95 SERIES
4D95L-W-1
4D95S-W-1
I
25
6202FOO6
6206F413- 1
Unit: mm
-
Standard
size
1 Outside diameter of piston
No, Measuring
point I
2 Top ring 0.30 - 0.45 2.0

3 Second 0.30 - 0.45 2.0 ring
ring
4 Oil ring 0.25 - 0.45 1.5
I I
I I I I 1
5 I Top ring 1 2.2 1 1::‘: 1 Judge using wear gauge
Clearance between piston ring I Replace piston
groove and piston ring I I I I
I I I I I
or piston ring
7 1 Oil ring I 4 I 1:::; I 2::; 1 “‘““,,, / 0.15 1

8 md piston pin
95 SERIES
MAiNTENANCE STANDARD PISTON, PISTON RING AND PISTON PIN
4D95S-1
4D95L-1
6D95L-1 1
\
8
5mm7
8
,‘^
I
6206F4 I3
Unit: mm
Standard
Size mark Tolerance Repair limit
size
Replace piston
STD 95.00 L -0.045 94.85 (only S size
Outside diameter of piston
1 -0.060 supplied as
(at right angle to boss)
0.25 O.S. 95.25 - ~ 95.10 replacement
part)
-0.050
0.50 O.S. 95.50 S -0.075 95.35
,o. Measuring
point
2 Top ring 0.30 - 0.45 2.0

Second ring or liner
3 0.30 - 0.45 2.0
ting
I I I
t 0.25 - 0.45 1.5

I
Tolerance
Jo. Measuring Standard Standard Clearance
Ring Piston
-
Clearance between piston ring 5 Top ring 2 -0.01 +0.07 0.05 0.15
-0.03 +0.05 0.10
groove and piston ring
Replace
-
6 Second 2 -0.01 +0.04 0.03 0.20 piston ring
ring -0.03 +0.02 0.07
or piston
-
7 Oil ring 4 -0.01 +0.04 0.03 0.15
-0.03 +0.02 0.07
I I 1
Replace
8 and piston pin
piston or
piston pin
+0.012 0.004 -
30 0.05
-00.006 +0.004 0.018
95 SERIES
‘,4-:23
S4D95L-1
S6D95L-1 (PC200-5, PC200-6, BR200-1) 4
1
\
8
3.6mm 7
6207F413 6206F413
Unit: mm
NC Check item Criteria Remedv
Standard
size
I I I I
Replace piston
STD 95.00 I -0.045 94.85 (onlv S size
Outside diameter of piston L
replacement
-
No. Measuring
2 point
2 Top ring 0.28 - 0.38 2.0
3 Piston ring gap Replace oiston

3 0.40 - 0.50 2.0
ring
I I
4
4 0.25 - 0.50 1.5
I
-0.06
5 Top ring 2.5 Judge using wear gauge
Clearance between piston ring -0.08 Replace piston
6 1 ‘,;;’ ) 2.2 ( 1;:;; ( Judge using wear gauge

I
Tolerance
8
end piston pin or piston pin
I
30 0 +0.012 0.004 -
-0.006 +0.004 0.018 0.05
L
’4-ii24 95 SERIES
MAINTENANCE STANDARD PISTON. PISTON RING AND PISTON PIN
SA4D95L-1
6
‘mm ii
8
6207F413 6206F413
Unit: mm
No. Check item
Piston size 1 Staitfrd 1 Size mark ) Tolerance ) Repair limit

1 Replace piston
,o Measuring
2
. ooint
Replace piston
3 Piston ring gap
ring or liner
\.
4

6
7
7 1 Oil ring 1 4 / ~~:~~ 1 2::: / o.“~,~7 1 0.15
Sta;;zrd 1 ShafTo’er,ce Hole 1 z;$;‘pe / Ck?arma;ce
Clearance between piston Replace piston

8 I I I I
and piston pin or piston pin
-
30 0 +0.012 0.004 0.05
-0.006 +0.004 0.018
95 SERIES
’4-i25
MAINTENANCE STANDARD PISTON, PISTON RING AND PlSTCjN PIN
S6D95L-1
6
5mm 7
6207F413
Unit: mm
Standard
size
Replace piston
STD 95.00 -0.045 94.85 (only S size
Outside diameter of piston L
(at right angle to boss) replacement
0.25 OS. 95.25 ~ 95.10
part)
S -0.060 .
0.50 OS. 95.50 -0.075 95.35
-
,o, Measuring
point
2
Replace piston
3 Piston ring gap ring or liner
Second
3 0.30 - 0.45 2.0
ring
I I I
4
4 Oil ring 0.25 - 0.45 1.5
I I 1
5 (Top ring ( 2.5 ( Ii::: 1 Judge using wear gauge

Replace piston
Clearance between piston ring
-
6 Second 2 -0.01 +0.05 0.04 0.20
ring -0.03 +0.03 0.08
7 1 Oil ring 1 4 ) _~:~~ 1 $:zi 1 “.““,,, ) 0.15

I I I I I I
I I
Tolerance
8 and piston pin or piston pin
I
-
30 0 +0.012 0.004 0.05
-0.006 +o.oO4 0.018
’4-$26 95 SERIES
SA6D95L-1
6206F709 6207F413
Unit: mm
Replace piston
(only S size
1 supplied as
replacement
part)
,o, Measuring
point
2
2 Top ring 0.28 - 0.38 2.0
Replace piston
3 Piston ring gap ring or liner
3 0.30 - 0.45 2.0
I
4
4 Oil ring 0.25 - 0.50 1.5
-
I I I

6
6 Second 2.2 -0.01
ring -0.03
7
-
7 Oil ring 4 -0.01 +0.04 0.03 0.15
-0.03 +0.02 0.07
-
Tolerance
8
I
-
30 0 +0.012 0.004 0.05
-0.006 +0.004 0.018
-
95 SERIES
’4-%6-1
SA6D95L-1 (For PC220-5, PC220-6, BR300-1)
6206F709 6207F413
Unit: mm
No Check item Criteria

-
Piston size 1 Stai$rd 1 Size mark 1 Tolerance 1 Repair limit
Replace piston
(only S size
1 Outside diameter of piston
supplied as
replacement
part)
2 Top ring 0.28 - 0.38 2.0

I I
Replace piston
Piston ring gap
3 0.40 - 0.50 2.0
ring
4 1 Oil ring 1 0.25 - 0.50 1.5

I I
Tolerance
do. Measuring Standard Standard Clearance
Ring Piston
Clearance between piston ring

groove and piston ring
-
7 Oil ring 4 -0.01 +0.04 0.03 0.15
-0.03 +0.02 0.07
Clearance between piston Replace piston

8
30 -0.006
0 +0.004
+0.012 0.018
0.004 - 0.05 I
’4-if6-2 95 SERIES
MAINTENANCE STANDARD CONNECTING ROD
CONNECTING ROD
1 2 7 5 3 4 6
6206F414A
Unit: mm
NO Check item Criteria Remedy

I
Clearance between connecting rod

bushing and piston pin
(carry out reaming after press
fitting)
Standard Tolerance
Inside diameter of connecting Replace
2
rod bushing hole
I
+0.025 connecting rod
33
0
-
STD 57.00 57.20
0.25 U.S. 56.75 56.95 Replace

Inside diameter of connecting +0.095
3 connecting
rod bearing +0.045
0.50 U.S. 56.50 56.70 rod bearing
0.75 U.S. 56.25 56.45
1.00 U.S. 56.00 56.20
Standard Tolerance
4 Inside diameter of connecting
rod bearing hole +0.025
61
0
-
Bend Replace
Connecting rod
-wist
Bend and twist of connecting
5
rod
Order Target Nm (kgm) Range Nm (kgm)

Tightening torque of connecting
rod cap mounting bolts
6 1st step 39.2 (4) 37.2 - 41.2 (3.8 - 4.2)
(Coat bolt threads and washers
with engine oil)
2nd step Retighten with 90” 90” - 120”
95SERIES
’4-:27
MAINTENANCE STANDARD 01 L PUMP
OIL PUMP
3D95S-W-1
4D95L-1, S4D95L-1
4D95L-W-1, 4D95S-W-1
6D95L-1, S6D95L-1
6206F4 17 Unit: mm
I
NO. Check item Criteria Remedy
Tolerance Standard Clearance

Standard
Engine clearance limit
size
Gear width Body depth (End play) fEnd play)
1 Axial clearance of pump gear
Replace
gear
2 Radial clearance of pump gear
+0.115 +0.245 0.045 -

38 0.13
+0.065 +0.205 0.090 I
Interference between pump drive

3
gear and drive shaft
Clearance between drive 13 -0.024 +0.018 0.024 - Replace

4
shaft and cover -0.042 0 0.060 bushing
Interference between pump -

5 13 -0.024 -0.065 0.025 - Replace
gear and drive shaft -0.042 -0.086 0.061
-
Clearance between drive shaft -0.024 +0.048 0.028 - Replace
6 13
and bushing -0.042 +0.004 0.09 I bushing
-
Clearance between driven 16 +0.064 M.018 0.028 - - Replace
7
shaft and cylinder block +0.046 0 0.064 cylinder block
Clearance between driven 13 -0.110 -0.065 0.024 - Replace

8 shaft and gear -0.125 -0.086 0.060 shafr or gear
-
Interference between drive shaft +0.087 +0.018 0.042 - - Replace
9 16
bushing hole and cylinder block +0.060 0 0.087 cylinder block
’4-$28 95 SERIES
MAINTENANCE STANDARD 01 L PUMP
S4D95L-1 (For PCIOO, 120-5, PCIOO, 120-6)

S6D95L-1 (For PC200-5, PC200-6, BR200-1)
SA6D95L-1 (For PC220-5, PC220-6, BR300-1)
v’ J
6206F4 I7
Unit: mm
-
NO Check item
1 Axial clearance of pump gear
S6D95L-1
SA6D95L-l 1 32 1 _:.0,5 1 _‘:::;; 1 “‘“$&j 1 O.‘O 1:::‘aCe
-
2 Radial clearance of pump gear
nterference between pump drive

3
ear and drive shaft
Xearance between drive

4
;haft and cover
nterference between pump

5
ear and drive shaft
Clearance between drive shaft

6
nd bushing
-
Clearance between driven
7
haft and cylinder block cylinder block
Clearance between driven 13 -0.110 -0.065 0.024 - Replace

8
haft and gear -0.125 -0.086 0.060 shaft or gear
-
nterference between drive shaft +0.087 +0.018 0.042 - Replace
9 16
bushinghole and cylinder block a.060 0 0.087 cylinder block
95 SERIES
’4-229
MAINTENANCE STANDARD REGULATOR VALVE
REGULATOR VALVE
6206F4 I8
Unit: mm
-
NO. Check item Criteria Remedy
I olerance
Standard Clearance
clearance limit
_.._.. Hole
Clearance between valve and body
I 11
I
-0.077
-0.050
I
-0.020
+0.020 0.030 0.097
-

Replace
Installed Installed Installed
Free length Free length
length load load
3D95S-W-1
2 Regulator valve spring ~~~~~:~_, 33.1 27.8 2.44 kg - 2.3 kg
4D95S-W-1
Except above
models 30.1 27.8 2.02 kg 1.92 kg
Standard: 5.0 * 0.5 kg/cm* (3D95S-W-1,4D95L-1,4D95L-W-l, 4D95S-W-1) Repair or

3 Regulator valve set pressure replace spring
6.0 f 0.5 kg/cm2 (except above models)
14-030 95 SERIES
8
MAINTENANCE STANDARD WATER PUMP, THERMOSTAT
WATER PUMP, THERMOSTAT

(WITH SEPARATE TYPE WATER SEAL, INTEGRATED BEARING, SHAFT)
6206F419
Unit: mm
Clearance of impeller body Standard clearance: 0.30 - 1.00
Standard Tolerance Standard

size Shaft Hole interference
Interference between shaft
and fan pulley boss

3
and body
Interference between shaft 4.013 I -0.043 0.030 - 0.070

4 12
and impeller -0.070
5 Curvature of shaft Repair limit: Runout at face A: 0.1
qeplace
Wear of seal of Repair limit: Dimension A: 0
6
water seal ring
l Cracking temperature: 76 + 1.5”C (Fully open: Shall open fully when

immersed in hot water bath at
temperature between 95°C and
Thermostat (For WA50, 71°C for 4 - 5 minutes)
WA55, and generators)
l Fully open temperature: 90°C
- Fully open lift: Min. 8 (when immersed in hot water bath
at 90°C for 4 - 5 minutes)
7
l Cracking temperature: 82 + 2°C (Fully open: Shall open fully when
Thermostat 77°C for 4 - 5 minutes)
l Fully open lift Min. 8 (when immersed in hot water bath
-
95 SERIES 14-031
0
(BEARING, SHAFT SEPARATED STRENGTHENED TYPE, UNITIZED SEAL

WITH INTEGRATED WATER SEAL)
6206F877 -1
Unit: mm

-
1 Clearance of impeller body Standard clearance: 0.77 - 1.92
Standard Tolerance Standard

size Shaft Hole interference
2
and fan pulley boss +0.015 -0.027
20 0.029 - 0.063
+0.002 -0.049

3
and impeller
12 I 4.013 1 -0.070
-0.043 0.030 - 0.070
Wear of seal of
5 Repair limit: Dimension A: 0
water seal ring
-
l Cracking temperature: 76 2 1.5”C (Fully open: Shall open fully when
Thermostat (For WA50,
71°C for 4 - 5 minutes)
* Fully open temperature: 90°C
l Fully open lift: Min. 8 (when immersed in hot water bath
6
l Cracking temperature: 82 + 2°C (Fully open: Shall open fully when
* Fully open temperature: 95°C
* Fully open lift: Min. 8 (when immersed in hot water bath
14-032 95 SERIES
0
(BEARING, SHAFT INTEGRATED TYPE, UNITIZED SEAL WITH

INTEGRATED WATER SEAL)
6206F419
Unit: mm
-
1 Clearance of impeller body Standard clearance: 0.40 - 1.30
Standard
size Hole
interference between shaft
2
-
and fan pulley boss
I
I
I -0.066
-0.082
0.053

3 I I -0.022 - 0.043
and body

4 12 I 4.013 I -0.043 0.030 - 0.070
and impeller -0.070

-
Replace
Wear of seal of
6 0
water seal ring
k 15°C
Thermostat (For WA50,

4 5 minutes)
Fully temperature: 90°C
7
. Cracking temperature: 82 k 2°C (Fully open: Shall open fully when
95 SERIES 14-833
MAINTENANCE STANDARD FUEL SYSTEM
FUEL SYSTEM
INJECTION PUMP
3D95S-W-1
078~420
Unit: mm
-

Replace plunger
1 Outside diameter of plunger ass’y
- -
7.5
I I I I
Replace plunger
2 Function of plunger Standard generated pressure: Min. 49 MPa (500 kg/cm’) (at 200 rpm) ass’y
-
Correct or
3 Function of delivery valve Standard time for drop in pressure: 9.8 MPa (100 kg/cm’) --t Min. 5 sec. replace
-
Replace plunger
4 Clearance at top of plunger guide
- Cam lift
0.45 - 0.55 7mm
I I I
Sliding resistance of control rack Repair limit: 60 g Correct

I
I Standard size I Repair limit I

Free length of plunger spring I I I
35.5 -
5 I I
Installed length Standard load Load limit
Installed load of plunger spring

11.59 kg -
29.5
Replace
Free length of delivery valve spring

19.5 -
6
Installed load of delivery valve spring

2.34 kg -
16.3
Tightening torque of delivery valve 36.8 -c 2.5 Nm (3.75 2 0.25 kgm)

7
holder
Tighten
Tightening torque of injection pump 63.7 + 4.9 Nm (6.5 + 0.5 kgm)
mounting bolt
95 SERIES
’4-:34
MAINTENANCE STANDARD FUEL SYSTEM
FUEL INJECTION NOZZLE

3D95S-W-1
6206F560
Unit: mm

I I I
I I I
Spray angle Standard size: 15 Replace nozzle
l -- -,,.s(,20,
Standard MPa (kg/cm? Repair limit
+ 0.5 (5)
MPa (kg/cm?
Adjust or
replace
Free length of nozzle spring

22.0 -
2 Replace
Installed load of nozzle spring

21.06 28.04 kg -
95 SERIES
’4-835
ENGINE
15 REPAIR AND REPLACEMENT
CYLINDER HEAD SECTION

Grinding cylinder head
mounting surface . . . . . . .. . . . . . . .. .. . . .. . . .. . . . .. . . 15-003
Replacing valve seat insert . .. . . . .. . . .. .. .. .. . .. . . 15-003
Replacing valve guide . .. . .. . . . . . .. . . . . . .. . . . . .. . . . . . 15-008
Grinding valve . . .. .. . .. . . . .. . . . .. . . . .. . .. . . . . .. . . .. .._.... 15-009
CYLINDER BLOCK SECTION

Replacing camshaft bushing . . .. . .. . . . . .. . . . . . . .. 15-010
Replacing gears . . . . . .. .. . . . .. . . . . . . .. .. . . . . . .. . . . . .. . . . . . 15-012
Procedure for pressure test . .. . . . . .. . .. . . . .. . . . .. 15-014
Cylinder liner (special restoration part) .. 15-015
Machining drawing
for cylinder block bore . . . . .. . . . . . . .. . . . . . .. . . . 15-016
Additional machining of cam journal . . . . . . 15-017
Grinding crankshaft . . . . . . .. .. . .. . . . . . . .. . . . . . .. . .. . . . . . 15-018
95 SERIES 15-00 1
0
REPAIR AND REPLACEMENT OF PARTS TABLE OF SPECIAL TOOLS
TABLE OF SPECIAL TOOLS

Operation iymbol Part No. Part Name Q’ty Remarks
Replacing valve seat
Replacing valve guide
Grinding valve
Replacing cam bushing H l 795-215-1120 l Push tool 1
l 795-215-l 140 l Collar 1
l 795-215-1150 l Guide 1
Pressure test
1 I 790-513-4200 Coolant tester kit I 1 I
J 79A-471-1050 Pump ass’y 1
’%02 95 SERIES
REPAIR AND REPLACEMENT OF PARTS GRINDING CYLINDER HEAD MOUNTING SURFACF
GRINDING CYLINDER HEAD

MOUNTING SURFACE
1. Grinding
Grind the bottom surface of the cylinder head with
a surface grinding machine to remove deforma-
tion or corrosion. Do not exceed the repair limit of
cylinder head height H. After grinding, make an R
mark at the rear on the left side (intake side) of the
cylinder head.
+ Standard dimension of cylinder head height H:
90 - 0.: mm
Repair limit: 89.5 mm
* Amount to remove per grinding:
0.10 - 0.15 mm
* Surface roughness of grinding surface:
6202FOlOA
Within 6s
* Flatness (deformation): Within 0.05 mm
* Grinding limit: 0.3 mm
+ Difference in head height per unit:
Within 0.15 mm
* For details of the surface grinding machine,
see the operation manual.
Ir For engines with a swirl chamber, leave the
swirl chamber insert (port plug) in position
when grinding.
2. Checking after grinding

l Check that the insertion depth of the valve is within
the standard value.
Insertion depth of valve (mm)
I I
3D*4D95S-W-1
0.8 + 0.18
4D95L-W-1
4D95S-1
0 2 0.18 (SKSA) 4D95L-1
(S)(SA) 6D95L-1
Check the protrusion of the swirl chamber in-

sert (port plug) from the bottom of the cylinder
head and check that it is within the standard
value.
Rrotrusion : 0 - 0.08 mm
t
6204F405A Protrusion
95 SERIES 15203
REPAIR AND REPLACEMENT OF PARTS GRINDING CYLINDER HEAD MOUNTING SURFACE
REPLACING VALVE SEAT INSERT

Ir When correcting the valve seat insert and not re-
placing it, use tool A and finish at a range within
0.5 mm of the insert seat face.
* Insertion depth after machining:
Insertion depth of valve

Seat Standard Repair
Correction limit: 0 - 0.5 mm Applicable engine
angle size limit
Insertion depth of valve I 3D95S-W-1 45”
Seat (Swirl chamber
1.80
P
angle
4D95S-W-1 Both intake 0.8 + 0.18
4D95L-W-1 type) Ind exhaust)
_-
__- 4D95S-1
S4D95L-1 45”
(Direct injection
SA4D95L-1 Both intake 0 + 0.18 1.00
S6D95L-1 type) Ind exhaust)
SA6D95L-1
__
S4D95L-1
45”
(PCIOO, 120-A, PCIOO-6,
Exhaust
PC120-6, PC128UU-1)
fl
S6D95L-1 0 k 0.18 1.00
(PCZOO-A,WA1 50-3, 60’
:- Intake
I I WA200-3)
SA6D95L-1 (PC220-A)
6202FOll
15to4 95 SERIES
REPAIR AND REPLACEMENT OF PARTS REPLACING VALVE SEAT INSERT
1. Removal of valve seat
a When using a grinder to carry out this work,

carry out a test run for one minute before start-
ing the operation to check that there is no ab-
normality.
. If the grindstone has been replaced, carry
out the test run for 3 minutes.
A Check that there is no damage to the grind-

stone, fit it to the grinder spindle so that there is
play, and wear safety glasses when using the
grinder.
. When removing with a valve seat puller

1) Install grindstone @ to grinder 0.
2) Align the groove of sleeve @ with holder 0,
and insert.
* Adjust the position of the grinder with
set screw 0.
6162F504
3) Adjust the position of the grinder so that the

center of grindstone @ is at the center of
valve seat (I), then tighten the set screw to
fix the grinder in place.
4) Rotate the grindstone and move it slowly
until it contacts valve seat (I).
5) Press the grindstone lightly against the in-
side face of the valve seat and make a groove
around the whole circumference of the in-
side face of the valve seat.
* Depth of groove: Approx. 1 mm
I 6162F505
6) Push three claws @ of puller head @ of tool

B inwards by hand, and fit into valve seat
(I).
7) Tighten screw @ to push the three claws
into the groove on the inside face of the
valve seat.
* When the claws are completely in con-
tact with the groove, stop tightening.
8) Insert bridge @ on the outside of the puller
head, set plates @ and 0 on top of the
bridge, and tighten nut @ to pull out the
valve seat. 6162F506
95 SERIES 15005
0
. When welding a bar to the valve seat to

remove
1) Weld bar (2) (length: 0.1 - 0.5 mm shorter
than inside diameter of valve seat, diameter:
approx. 10 mm) to inside of valve seat (1).
* Be careful not to deposit any of the weld-
ing metal on the head itself.
2) When the temperature of the weld has
dropped to around room temperature, in-
sert a used valve (3) in the opposite direc-
tion, and hit the face of the valve with a
small hammer to remove the valve seat. I 6127F205
* Be careful not to hit too hard, as any
excessive shock may cause the weld to
break off.
!n_take.,valve
2. Machining mounting hole for valve seat
insert
+ When no valve seat insert is used, and
the seat face is damaged or worn, fol-
low the same procedure and use tool A
to grind, then press fit the insert.
1) Using tool A, grind the hole to a one- 0.50 0.S 045.50 ;;:;;; 8.62 _o”,, 045.50 +;020 11.62 too’2 3.0 _i,2 2.0 i.2
level larger oversize.
* Machine within an oversize range of (Direct injection) Unit : mm
Insert Insert mounting hole
0.5 mm. If it is more than 0.5 mm, Insert
Dia(n&;ter H&hg)ht Diameter Height Chamfer Chamfer
replace the cylinder head. seal 1
1 (dz) thzl (Cl) (CA
S.T.D. 045.00 :I;;; 8.50 _o”,, 045.00 tgoo20 ,o,70 $2 2.2 :,2 2.0 -“.2
0.25 0.S 045.25 :;:;;; 8.50 _o”,, 045.25 +;02’ l

10.70 ;’ 2.2 _;,2 2.0 -00.2
.
10.82 l
Method of machining insert and mount- 2.2 _;,2 2.0 _“o.,
0.50 0.S 045.50 ;;:A;; 8.62 _;,, 045.50 +;020 y
ing hole
Exhaust valve
(Swirl chamber) Unit : mm
h Insert
Diameter Diameter Chamfer
seal
Insert (d,) H:e:tI (dz) 2
H&Ag:’ (Cl)
S.T.D. 039.00 :t;;; 6.50 -o”., 039.00 to.020 9.50 *o.2 3.0 0
o 0 -0.2
m[‘h
Intake valve
0.25 0.S 039.25 ;t;;; 6.50_;,, 039.25 +;020 9.50 +i.2 3.0 4.2
LAL_l 0.50 OS 039.50 $1;;; 6.62-i,, 039.50 +;o25 9.62 +;‘2 3.0 j.2
(Direct iniection) Unit : mm

Insert
Height Chamfer
seal
1
DiaI?Yer 1
H?hg; 2
DiafZ?er hz) (Cl)
Exhaust valve
6202FO12 S.T.D. 039.00 +o,070
to.080 6.50 ;,, 039.00 +ZO2O 8.70 +I2 3.0 _:.2
* Roughness of inside surface: +o,070 6.50 ;,, 039.25 +ZO2O 8.70 +i2 3.0 j.2
0.25 0.S 039.25 to.080
Within 6.3s
0.50 0,s 039.50 $f;; 6.62 _;,, 039.50 +zo2’ 8.82 +i2 3.0 j.2
* Roughness at bottom of mounting hole:
Within 12.5s
* Concentricity with inside surface of valve
guide: Within 0.05 mm (TIR)
15-006 95 SERIES
0
3. Press fitting valve seat insert

1) Using tool C or tool D, press fit insert (2) of a
size that matches the oversize of the mounting
hole.
* Use the inside diameter of valve guide (4) as a
guide, and press fit, taking care that the insert
is not fitted at an angle.
* To check that insert bottom face (C) is com-
pletely sealed, tap with a hammer and listen to
the change in sound, or judge from the spring-
ing back of the push tool.
2) Check the insertion depth of the insert from
615FOO4
the mounting surface of the cylinder head.
+ Insertion depth of insert
Standard h3: 3.0 + t” mm (Swirl) t

1 h3
2.2 + t” mm (Direct injection)
1
4. Finishing insert seat surface

1) Using tool A, finish the surface of the insert
seat to the dimension shown in the diagram
below.
Sr When selecting a pilot to insert into the valve
guide, choose one that leaves no clearance
6206F1017
when it is inserted.
Intake valve
6202FO14
Swirl Direct injection Direct injection, intake only seat angle 60” + O”15 %
a 3.8 + 0.1 3.0 + 0.1 2.835 + 0.1
1 b 1 3.8 + 0.1 1 3.0 + 0.1 1 3.0 + 0.1 I

% Applicable machines for seat angle 60” + O”15
PC100,120-A, PC100,120-6, PC128UU-1
PC200, 220-A
WA1 50, 200-3
95 SERIES 15007
0
REPAIR AND REPLACEMENT OF PARTS REPLACING VALVE GUIDE
REPLACING VALVE GUIDE
1. Removing valve guide

Insert tool E from the top surface of the cylinder
head, put it in contact with the valve guide, then
hit with a hammer to remove the valve guide.
2. Press fitting valve guide

I) Press fit the valve guide until the tip of tool
F contacts the cylinder head.
* After press fitting, insert the valve, and if
the valve does not enter smoothly, machine
the hole with a reamer (0 8 + $015).
2) Measure the protrusion of the valve guide

and check that it is within the standard range.
* Valve guide protrusion
Tolerance: 14.5 + 0.2 mm
15008 95 SERIES
0
REPAIR AND REPLACEMENT OF PARTS REPLACING VALVE GUIDE
GRINDING VALVE
Grinding seat face

After using tool G to adjust the valve seat angle,
grind the seat face.
Ir For details of the angle of the valve seat, see
the Maintenance Standard Table.
Checking after grinding

Measure the thickness of valve head, insertion
depth of the valve and the contact of the valve
seat face to check that they are within the stand-
ard range.
* Thickness of valve head:
1.40 - 1.60 mm
1.90 - 2.10 mm (PCIOO-5, PC120-5,
PC200-5, PC220-5 intake only)
* Insertion depth of valve
Unit: mm
r
3D*4D95S-W-1
4D95L-W-1
* Contact width of valve

Standard
Intake valve: 2.0 mm
2.2 mm (PCIOO-5, PCl20-5,
PC200-5, PC220-5
(seat angle 29”45’ - 30”15’)
Exhaust valve: 2.0 mm
* For details of handling the valve refacer, see
the operation manual.
95 SERIES 1709
1
REPAIR AND REPLACEMENT OF PARTS REPLACING CAM BUSHING
REPLACING CAM BUSHING
1. Removing front and rear bushings

As shown in the diagram, assemble push tool
(2), collar (31, and push bar (I) of push tool H,
then hit the push bar to knock bushing (6) out
from cylinder block (5).
6202FO15
2. Removing center bushing

Assemble push bar (I), push tool (21, collar (31,
3 2 4 1
and guide (4) of push tool H, then hit the push
bar to knock bushing (6) out from cylinder block
(5). c
6202F016
* Cam bushing assembly drawing

After removing the bushing, remove any burrs
or dirt from the mounting hole of the bushing. Oil hole
Bushing
6 I27F242
3. Press fitting center bushing

Assemble bushing (6) to tool H, and press fit the
bushing until the oil hole in cylinder block (5) is 36 2 1 4
aligned with the oil hole in the bushing.
6202FO17
‘%‘O 95 SERIES
REPAIR AND REPLACEMENT OF PARTS REPLACING CAM BUSHING
4. Press fitting front and rear bushings

Assemble bushing (6) to tool H, and press fit the 36 2 1
bushing until the oil hole in cylinder block (5) is
aligned with the oil hole in the bushing.
6202FO18
5. After press fitting bushing

. Using inside gauge 0, measure the inside
diameter of the bushing.
l Check the clearance between the bushing
and shaft, and if the clearance is not within
the specified range, or the shaft does not
pass through smoothly, correct the inside
diameter of the bushing with a reamer.
. When correcting the inside diameter of
the bushing with a reamer, clean all chips
6202FO19
from the oil hole and oil groove.
* Inside diameter of cam bushing:

050.5 +Jiii mm
* Clearance of camshaft journal:

0.030 - 0.130 mm
95 SERIES 15211
REPAIR AND REPLACEMENT OF PARTS . REPLACING CRANKSHAFT GEAR, CAM GEAR
REPLACING CRANKSHAFT REPLACING CAM GEAR

GEAR
1. Removal of gear 1. When using only shrink fitting
Remove the gear with a gear puller. 1) Check the gear mounting surface, key
groove, and flange surface, and if there
2. Press fitting gear are any scratches, correct them with an
1) Check the gear mounting surface, key oilstone.
groove, and flange surface, and if there 2) Knock the key into the key groove of the
are any scratches, correct them with an shaft.
oilstone. 3) Heat the gear for the specified time at
2) Knock the key into the key groove of the the specified shrink-fitting temperature.
shaft. Sr Cam gear shrink-fitting temperature:
3) Heat the gear for the specified time at 250 - 270°C
the specified shrink-fitting temperature. Heating time: 30 minutes
* Crankshaft gear shrink-fitting tempera-
ture: 2. When combining shrink fitting and tight-
230 - 250°C ening with bolt
Heating time: 30 minutes 1) Press fit with the bearing installed to the
4) Put the timing mark on the outside, then camshaft. Leave no
use a hitting tool to press fit until the Put the inner race of
J/-Z-Y
side face of the gear is in tight contact the bearing in contact
with the shaft flange. with the shoulder of
* Knock in quickly before the gear be- the No. 1 journal. -
comes cool. 2) Knock the key (6206-
41-1380) into the cam- a
Camshaft
shaft.
When doing this, check that the key is
below the surface of the tip of the cam-
shaft. (See diagram on right)
3) Heat the cam gear in a furnace at 220°C
- 240°C for approx. 35 minutes.
4) When press fitting the cam gear to the
camshaft, use a press to apply a force of
approx. 2 tons to the outer shoulder of
the gear so that the bearing inner race is
pressed against Position for oushing
with press
the end of the
inside of the I---I
cam gear. When
the cam gear
has cooled to
room tempera- \!
ture, push with a
press to press fit Cam.shaft’support
* po~lon
it fully.
5) Insert the bolts in the plates and coat
the thread with LT-2, then tighten to the
camshaft.
sr After tightening to the specified torque,
loosen the bolts, then tighten again to
the specified torque.
* Tightening torque of bolt:
98 - 122.5 Nm (IO - 12.5 kgm)
After press fitting, tighten the bolts fully
within 2 minutes, and be sure that the
cam gear temperature has not gone
down.
15i12 95 SERIES
REPAIR AND REPLACEMENT OF PARTS REPLACING FLYWHEEL RING GEAR
REPLACING FLYWHEEL RING

GEAR
a Be careful not to let the flywheel fall and injure
you.
1. Removal of ring gear

1) Prepare a support for the flywheel, and set
on the support with the ring gear surface
facing down.
2) Heat the area around the ring gear with a
torch lamp, then hit it with a hammer to
remove it.
2. Press fitting ring gear

1) Check the ring gear mounting surface, and if
there are any scratches, correct them with
an oilstone.
2) Heat the ring gear for the specified time at
the specified shrink-fitting temperature.
* Ring gear shrink-fitting temperature:
Max. 200°C
Heating time: 45 minutes
3) Set the chamfered face of the ring gear fac-

ing the flywheel, and press fit until the side
face of the gear is in tight contact with the
flywheel.
95 SERIES 15-013
0
REPAIR AND REPLACEMENT OF PARTS PRESSURE TEST
PRESSURE TEST
. When corrections have been made around the

head, test the pressure as follows.
1. Water pressure test

I) Tighten the nozzle holder assembly to the
specified torque.
2) Assemble tool I and tool J, and connect the
hose to flange (1).
3) Apply water pressure 0.25 - 0.6 MPa (2.5 -
6.0 kg/cm*) for approx. 10 minutes, and check
that there is no leakage from around the
head.
* When carrying out this test, heat the whole
cylinder head and carry out the test with hot
water (82 - 93°C).
2. Air pressure test

1) Tighten the nozzle holder assembly to the
specified torque.
2) Connect the compressor hose to flange (I). 6202FO20
3) Put the head in the container of water, apply
air pressure 0.2 MPa (2.0 kg/cm? for approx.
30 seconds, and check that there is no leak-
age in the water.
* If the above test shows any cracks in the nozzle

holder or around the plate plugs, replace the
cylinder head.
* If cracks are found in any other places, weld to
repair.
15-t14 95 SERIES
REPAIR AND REPLACEMENT OF PARTS CYLINDER LINER
CYLINDER LINER
(SPECIAL RESTORATION PART)
:::,_
30mm ;
0 I
40mm :
F614601010
Cylinder liner
. The 95 Series engine has a liner-less cylinder,
so if the cylinder bore exceeds 95.40 mm be-
cause of wear, the cylinder is bored, and this
cylinder liner is used to restore the cylinder.
Selection of liner
There are two sizes of cylinder liner: A and B.
After machining the cylinder bore, select the size
of liner to match the bore.
l Outside diameter of cylinder liner Unit: mm
Category mark Measurement location [Remark]

Part No. Machined dimen-
Letter Line 0 @ 0 sion of cylinder
6207-21-2110 +0.020 g8 +0.025 g8 +0.025 gB +0.0125

I g8 +0.005 -0.010 -0.020 0
% 6354-21-2210 A
6207-21-2120 +0.035 g8 +0.040 g8 +0.040 +0.0250
II g8 +0.020 +0.005 -0.005 ‘* +0.0125
% 6354-21-2220 B
I I I I I I I
%: For alcohol engine
95 SERIES
REPAIR AND REPLACEMENT OF PARTS MACHINING DRAWING FOR CYLINDER BLOCK BORE
MACHINING DRAWING FOR

CYLINDER BLOCK BORE
. Honing
At this position, measure the diameter into two directions as
shown in the diagram below, and stamp at the position in Fig. 2
according to the average diameter.
I
r face
Too surface of cylinder block ’
Note, bench mark C is the center of the

crankshaft
A honing droop is permissible if it is within

,0.005mm at the diameter between 20 mm
from the bottom end and 15 mm from the
top face.
.-
‘Aj d 98 +0.0125
o
B d 9B +0.025
c-2 to.0125
Right side face
’ c_ 499io.04
There must be no burrs or
flashes at these corners
Stamp A or B (6 places) Erase stamp mark S or L
Detail of portion R Fig. 2
6206F904 6206F904-1
15-g 6 95 SERIES
REPAIR AND REPLACEMENT OF PARTS ADDITIONAL MACHINING OF CAM JOURANL
ADDITIONAL MACHINING OF
CAM JOURNAL
Carry out additional machining of the cam journal,
and install a cam bushing (Part No.: 6206-21-1420)
to correct the damage.
1. To carry out the additional machining, disas-
semble to make the cylinder block into an indi-
vidual part.
* To clean out the metal particles after ma-
chining, remove the taper plug from the oil
hole, the p-plug, and the oil pressure cau-
tion switch. Remove parts a - e in the dia-
gram.
6206F874
2. Center with an undamaged cam journal and

carry out additional machining. (Cross-sectional
diagram No. I)
Inside diameter 0 after machining: 53.5 +‘.‘i mm
(Surface roughness: Max. 12.5 S)
3. Align the oil hole in the cam bushing with the

oil hole in the cylinder block, and press fit.
After press fitting, insert a 0 3.5 check bar
through the oil hole in the main journal and
check that it passes through the oil hole.
(Diameter of bushing oil hole: 0 4)
4. After press fitting, check the inside diameter of

the bushing. (Cross-sectional diagram No. 2)
Inside diameter of bushing: 0 50.5 $,“,’ mm
5. Clean thoroughly and check that there are no

metal particles remaining in the oil hole.
6. To check the alignment of the journal at three

places, insert the cam shaft and check that it
rotates smoothly by hand.
7. Remove the cam shaft, then install the taper

plug for the oil hole, the p-plug (replace with a
new part), and the oil pressure caution switch to
the cylinder block.
15217
REPAIR AND REPLACEMENT OF PARTS GRINING CRANKSHAFT
GRINDING CRANKSHAFT
Applicable crankshaft
. It is possible to correct by grinding and rebuild
so that undersize bearings can be used only
with crankshafts which have received induction
hardening.
This method of repair may not be used for crank-
shafts that have received tufftride treatment. (*I)
. It is possible to distinguish these two types of
crankshaft from the engine serial number(*2),
but check the crankshaft as follows to ensure
that there is no mistake.
(New) crankshaft given induction hardening (Old) crankshaft given tufftride treatment
(possible to correct by grinding) (not permitted to correct by grinding)
Temper color caused by

No temper color can be
harge symbol (PI) on
art No. 6207-31-3310 t No. 6204-31-3410

tamped on rear face) mped on rear face)
The counterweight and arm The counterweight and arm are

have the black skin from forging a grey color from the tufftride treatment
6206F890 6206F891
(*I): With tufftride treatment, the hardened layer

is thin, so if additional grinding is carried out,
the hardened layer will be removed and it
will be impossible to ensure the strength and
wear resistance.
(“2): The part number does not change when there
is change in the surface treatment of the crank-
shaft, but as shown above, the crankshaft pin
bearing is changed at the same time.
15t18 95 SERIES
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

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

CORRECTIVE ACTION:
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SEBE61460114

January 1998 Copyright 1998 Komatsu America International Company OO@-1

01 GENERAL . . . . ..‘...............................,..........‘..,..................... 01-001

11 STRUCTURE AND FUNCTION . . . . . ..n................................ 11-001

12 TESTING AND ADJUSTING ,....,.,.,....................m..,.......... 12-001

13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 13-001

14 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-001

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