SEBHA00001A 1 of 8

GENERAL DYNAMO TESTS FOR THE COMMON RAIL TYPE ENGINES

APPLICABLE ENGINES SA6D140E-3

SAA6D140E-3

SAA6D125E-3

CONTENTS 1. Necessary equipment and devices -------------------------------------------------------------------------------- 2 2. Wire harness connection method ----------------------------------------------------------------------------------4 3. Preparations before starting the test ---------------------------------------------------------------------------- 5 4. Running-in --------------------------------------------------------------------------------------------------------------- 5 4-1. Items to check before starting the engine---------------------------------------------------------------------5 4-2. Starting the engine --------------------------------------------------------------------------------------------------5 4-3. Item to check while conducting running-in of the engine ----------------------------------------------- 6 4-4. Running-in standards ---------------------------------------------------------------------------------------------- 6 5. Performance test--------------------------------------------------------------------------------------------------------- 6 6. Others----------------------------------------------------------------------------------------------------------------------- 7 6-1. Measures to take after finishing the test---------------------------------------------------------------------- 7 6-2. How to delete the error codes------------------------------------------------------------------------------------- 7 7. Engine performance test standard values----------------------------------------------------------------------- 8

Nov.2008

SEBHA000012 of 8GENERAL

THIS MANUAL DESCRIBES THE DYNAMO TESTING METHOD FOR THE COMMON RAIL TYPEENGINES.IN THE MEANTIME, SINCE THE METHODS TO SET THE ENGINE ONTO THE TEST BENCH,METHOD TO ARRANGE THE COOLING PIPE AND THE METHOD TO ARRANGE THE FUEL PIPESHALL NOT BE DESCRIBED HERE SINE THEY ARE THE SAME AS WITH OTHER ORDINARYENGINES.

1. NECESSARY EQUIPMENT AND DEVICES

1) Dynamo test kitPart number: 799-607-4001

No. Part No. Part name Q'ty Remarks

1 799-607-4010 Throttle box 1

2 799-607-4020 Connection wire harness (1) 1 For connection to the "A" type controller

3 799-607-4030 Power line harness 1

4 799-607-4050 Connection wire harness (2) 1 For connection to the "D" type controller

2) Engine controller"A" type and D-type are available as the engine controller.Select the "A" type or D-type engine controller depending on the machine models on which theengine is being installed.

Type Applicable machine models Part No. of the controller

A HD325-6 7872-10-2304

A WA500-3 7872-10-5205

A PC600-6/PC800-6 7872-10-4105

A D155AX-5 7872-10-3106

A HM400-1/HM350-1 7872-10-2103

D WA470-5 7872-20-5104

D WA480-5 7872-20-5104

D D275AX-5 7872-20-3201

D D65EX-12 7872-20-3301

D PC1800-6 7872-20-4202

"A" type controller "D" type controller

After this, the "D" type controller shall be employed more frequently.

SEBHA000013 of 8GENERAL

Explanatory drawing for harness connection (in case of using the "A" type controller)

Explanatory drawing for harness connection (in case of using the "D type controller)

SEBHA000014 of 8GENERAL

3) BatteryPrepare a fully charged battery set with a capacity sufficient to start the testing engine.

2. WIRE HARNESS CONNECTION METHOD

1) Connect the engine controller and the throttle box using the connection wire harness.2) Connect to the testing engine proper.3) Connect the throttle box and the battery using the battery connection wire harness.

Before connecting to the battery, check to confirm that the stating key switch of the throttle box isbeing turned off. When connecting to the battery, connect the red colored wire to the plus terminalof the battery and connect the black colored wire to the minus terminal of the battery.

4) Similar to the case of testing mechanical engines, connect the plus terminal of the battery and the"B" terminal of the starting motor and connect the minus terminal of the battery and the engineproper using thick wires.

SEBHA000015 of 8GENERAL

3. PREPARATIONS BEFORE STARTING THE TEST

Similar to the case of testing mechanical engines, set the engine onto the test bench and connect thecooling pipe, fuel pipe, exhaust pipe etc. In the meantime, in case of an engine equipped with the air-cooling after cooler, connect the after cooler before dipping the after cooler into the water tank.While conducting the test, adjust the water feeding rate to the water tank so that the intake air tempera-ture may come within the range of 50°C to 55°C.1) Air bleeding method from the fuel circuit

Refer to the Section "Air bleeding from fuel circuit" for the 140-3 Series engines in the "Shop Manualfor Engines"

2) Remaining pressure releasing method from the fuel circuitRefer to the Section "Release of remaining pressure from fuel circuit" for the 140-3 Series engines inthe "Shop Manual for Engines"

4. RUNNING-IN

4-1. Items to check before starting the engineRefer to the Section "Checks to make before starting the engine" (12-424) for the 12V140-Seriesengines in the "Shop Manual for Engines".

4-2. Starting the engine (Operation method of the throttle box)

GENERAL SEBHA00001A

6 of 81) Turn OFF the starting key switch.2) Set the throttle dial to the position of "MIN".3) Set the machine model selection switch to the position indicated below.

No. ModelController pats

number ontroller typSwitch １ Switch ２ Switch ３1 HM400-1 7872-10-2104 CRI-A ON OFF OFF2 HM350-1 OFF ON OFF3 HM300-1 7872-10-2203 CRI-A OFF OFF ON

4 HD325-6 7872-10-2300,-1,-2,-3,-4 CRI-A OFF OFF OFF

5 HD325-6 7872-10-2305 ON ON OFF6 HD255-5 7872-10-2402 CRI-A ON OFF OFF7 HD285TN-5B OFF ON OFF8 D155AX-5 7872-10-3107 CRI-A OFF OFF OFF9 D155AX-5(EU spec.) ON ON OFF

10 D155AX-5B 7872-20-3601 CRI-D ON OFF OFF11 D275AX-5 7872-20-3202 CRI-D OFF OFF OFF12 D65EX-12 7872-20-3301 CRI-D ON OFF OFF13 D65EX-15 7872-20-3500 CRI-D ON OFF OFF14 D85EX-15 7872-20-3401 CRI-D ON OFF OFF15 PC600-6 7872-10-4106 CRI-A ON OFF ON16 PC800-6 ON ON OFF17 PC1800-6(Front engine) 7872-20-4203 CRI-D ON OFF OFF18 PC1800-6(Rear engine) OFF ON OFF19 PC400,450-7 7872-20-4301 CRI-D ON OFF OFF20 PC600,650-7 7872-20-4403 CRI-D ON OFF OFF21 PC750,800-7 OFF ON OFF22 PC600,650-7(EU spec.) OFF OFF ON

23WA470-5

(Turbocharger P/N:6156-81-8110) 7872-20-5105 CRI-D ON OFF OFF

24WA480-5

(Turbocharger P/N:6156-81-8110) OFF ON OFF

25WA470-5

(Turbocharger P/N:6156-81-8150) OFF OFF ON

26WA480-5

(Turbocharger P/N:6156-81-8150) ON ON ON

27 WA500-3 7872-10-5207 CRI-A OFF OFF OFF28 GD755-3 7872-20-7500 CRI-D ON OFF OFF29 GH320-3 OFF ON OFF

4) Turn OFF the test mode switch5) Turn ON the starting key switch.6) Turn ON the test mode switch within 0.5 sec. to 3 sec. after turning on the starting key switch.7) Drive to starting motor by starter switch on the test bench. (Throttle box cannot drive to starting motor.) Turn 'START' key switch on the throttle box When starting motor is running. At that time, check and make sure that the RH side display of the controller indicates "d" showing that the system has gone into the test mode. In the meantime, the LH side display of the controller shall indicate "0" - "9" depending on the

GENERAL SEBHA00001A

7 of 8 machine model setting number.. Although there may be cases where the "E36" (pressure switch failure) error occurs, it will disappear within about 10 seconds after starting the engine, in case the switch is normal.. When the "E20" error occurs, check and make sure that the machine model selection switch setting is correct.. When the "E31" error occurs, since the system has not gone into the test mode, repeat the above procedure starting from Item 1) once again.8) Operate the throttle dial to control the revalidation of the engine.

4-3. Item to check while conducting running-in of the engine As for the items to check while conducting running-in of the engine, refer to the Section "Check items while conducting running-in of the engine" (12-425) for the 12V140-Series engines in the "Shop Manual for Engines".

4-4. Running-in standardsRefer to the "Performance test standard value sheet" for respective engines.

5. PERFORMANCE TEST (MEASUREMENT OF THE ENGINE OUTPUT)Measure the revolution rate under the Low-Idling speed, measure the revolution rate under the Hi-Idlingspeed, measure the rated output and measure the output at the maximum torque point to confirm thatthey are all within the standard values.If the output values at the rated output and at the maximum torque point are out of the standard values,change the "Q" adjustment value of the controller. As for the "Q" adjustment value changing method,refer to the Service News No. AT01076 (for overseas markets) or No. "ENG ZEN-M-01-03" (for domesticmarket). In the meantime, regarding the test conditions and the standard values, refer to the "Performancetest standard value sheet" for respective engines.

6. OTHERS

6-1. Measures to take after finishing the test

1) Operate the engine at the Lo-Idling speed for 5 minutes.

2) Turn OFF the starting key switch of the throttle box.

6-2. How to delete the error codes (Operation method of the memory clear switch)

It is necessary to delete the error codes which occurred while the dynamo test were conducted

after finishing the dynamo test. Delete the error codes as per the procedure described below.

1) When the dynamo test has been finished, stop the engine.

2) Turn OFF the test mode changeover switch.

3) Turn ON the starting key switch of the throttle box once again and turn ON the test mode

changeover switch also. (The reason why bringing the system under the test mode once again is

not to let useless errors occur.)

4) After 2 seconds have passed since turning ON the starting key switch, turn ON the memory clear

switch and hold it for 2 seconds or more and, after that, turn OFF the memory clear switch.

5) Turn OFF the starting key switch and confirm that the controller indications have turned off.

6) Disconnect the battery connection wire harness.

7) Disconnect the wire harnesses connecting to the engine controller and throttle box.

SEBHA000018 of 8GENERAL

7. ENGINE PERFORMANCE TEST STANDARD VALUESWA470-5Performance test standard values for the SAA6D125E-3 engines

1. Running-in standards

Revolution rate Dynamometer load Output Operation time(rpm) (Kg) (HP{PS}) (Min.)

Lo-Idling 0 0 21,000 28 28 {28.4} 81,200 69 82 {83.2} 21,500 110 163 {165.3} 32,000 138 272 {275.9} 5

2. Performance test standard values

2,000 134.5 − 142.8 265.3 − 281.6 0.41 − 0.51{269.1 − 285.6} {4.2 − 5.2}

1,400 175.7 − 186.6 242.6 − 257.6 0.32 − 0.42{246.0 − 261.3} {3.3 − 4.3}

2,090 − 2,190 21.5 − 22.3

750 − 800 0.17 {17}or more

1,700 170.3 − 180.0285.5 − 301.7

{289.6 − 306.0}

Testing conditions: · Cooling water temperature : 72 − 82°C · Lubricating oil temperature : 90 − 105°C (98 − 105°C only in case of Lo − Idling)

Lubricating oil pressure(MPa{Kg/cm2})

Revolution rate(rpm)

Dynamometerload(Kg)

Output(HP{PS})

Rated output point

Max. torque point

Hi-Idling point

Lo-Idling point

Intermediatetorque point