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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

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THIS MANUAL DESCRIBES THE DYNAMO TESTING METHOD FOR THE COMMON RAIL TYPE ENGINES. 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 PIPE SHALL NOT BE DESCRIBED HERE SINE THEY ARE THE SAME AS WITH OTHER ORDINARY ENGINES. 1. NECESSARY EQUIPMENT AND DEVICES
1) Dynamo test kit Part number: 799-607-4001
No. 1 2 3 4 Part No. 799-607-4010 799-607-4020 799-607-4030 799-607-4050 Part name Throttle box Connection wire harness (1) Power line harness Connection wire harness (2) Q'ty 1 1 1 1 For connection to the "D" type controller For connection to the "A" type controller Remarks

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 the engine is being installed.
Type A A A A A D D D D D Applicable machine models HD325-6 WA500-3 PC600-6/PC800-6 D155AX-5 HM400-1/HM350-1 WA470-5 WA480-5 D275AX-5 D65EX-12 PC1800-6 Part No. of the controller 7872-10-2304 7872-10-5205 7872-10-4105 7872-10-3106 7872-10-2103 7872-20-5104 7872-20-5104 7872-20-3201 7872-20-3301 7872-20-4202

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

"A" type controller

"D" type controller

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

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

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2. WIRE HARNESS CONNECTION METHOD

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

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 is being turned off. When connecting to the battery, connect the red colored wire to the plus terminal of 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 engine proper using thick wires.

GENERAL
3. PREPARATIONS BEFORE STARTING THE TEST

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Similar to the case of testing mechanical engines, set the engine onto the test bench and connect the cooling pipe, fuel pipe, exhaust pipe etc. In the meantime, in case of an engine equipped with the aircooling 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 temperature may come within the range of 50C to 55C. 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 Manual for Engines" 2) Remaining pressure releasing method from the fuel circuit Refer to the Section "Release of remaining pressure from fuel circuit" for the 140-3 Series engines in the "Shop Manual for Engines"

4. RUNNING-IN
4-1. Items to check before starting the engine Refer to the Section "Checks to make before starting the engine" (12-424) for the 12V140-Series engines in the "Shop Manual for Engines". 4-2. Starting the engine (Operation method of the throttle box)

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1) 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. Controller pats No. ontroller typSwitch Switch Switch Model number HM400-1 7872-10-2104 CRI-A ON OFF OFF 1 HM350-1 OFF ON OFF 2 HM300-1 7872-10-2203 CRI-A OFF OFF ON 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 HD325-6 HD325-6 HD255-5 HD285TN-5B D155AX-5 D155AX-5(EU spec.) D155AX-5B D275AX-5 D65EX-12 D65EX-15 D85EX-15 PC600-6 PC800-6 PC1800-6(Front engine) PC1800-6(Rear engine) PC400,450-7 PC600,650-7 PC750,800-7 PC600,650-7(EU spec.) WA470-5 (Turbocharger P/N:6156-81-8110) WA480-5 (Turbocharger P/N:6156-81-8110) WA470-5 (Turbocharger P/N:6156-81-8150) WA480-5 (Turbocharger P/N:6156-81-8150) WA500-3 GD755-3 GH320-3 7872-10-2300,-1,2,-3,-4 7872-10-2305 7872-10-2402 7872-10-3107 7872-20-3601 7872-20-3202 7872-20-3301 7872-20-3500 7872-20-3401 7872-10-4106 7872-20-4203 7872-20-4301 7872-20-4403 CRI-A CRI-A CRI-A CRI-D CRI-D CRI-D CRI-D CRI-D CRI-A CRI-D CRI-D CRI-D OFF ON ON OFF OFF ON ON OFF ON ON ON ON ON ON OFF ON ON OFF OFF ON OFF OFF ON 7872-10-5207 7872-20-7500 CRI-A CRI-D OFF ON OFF OFF ON OFF ON OFF ON OFF OFF OFF OFF OFF OFF ON OFF ON OFF OFF ON OFF OFF ON OFF ON OFF OFF ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF ON OFF OFF ON ON OFF OFF OFF

7872-20-5105

CRI-D

4) Turn OFF the test mode switch 5) 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

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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 standards Refer 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-Idling speed, measure the rated output and measure the output at the maximum torque point to confirm that they 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 domestic market). In the meantime, regarding the test conditions and the standard values, refer to the "Performance test 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.

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7. ENGINE PERFORMANCE TEST STANDARD VALUES WA470-5 Performance test standard values for the SAA6D125E-3 engines
1. Running-in standards Revolution rate (rpm) Lo-Idling 1,000 1,200 1,500 2,000 Dynamometer load (Kg) 0 28 69 110 138 Output (HP{PS}) 0 28 82 163 272 {28.4} {83.2} {165.3} {275.9} Operation time (Min.) 2 8 2 3 5

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2. Performance test standard values

Dynamometer load (Kg) 134.5 142.8 175.7 186.6 21.5 22.3 170.3 180.0

Revolution rate (rpm) Rated output point Max. torque point Hi-Idling point Lo-Idling point Intermediate torque point 2,000 1,400 2,090 2,190 750 800 1,700

Output (HP{PS}) 265.3 281.6 {269.1 285.6} 242.6 257.6 {246.0 261.3} 285.5 301.7 {289.6 306.0}

Lubricating oil pressure (MPa{Kg/cm2}) 0.41 0.51 {4.2 5.2} 0.32 0.42 {3.3 4.3} 0.17 {17}or more

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