Technical Service Group, Customer Support Department

Kobelco Construction Machinery Co., Ltd.

Issue date : JULY 2006
Code No. : S6CSA0001ZE03
Measures to clean exhaust gas

PM, Smoke NOx

PM: Particulate Material
Nitric Oxide (NO, NO2)
Smoke: Soot and Ember

Influence to
Cause of diseases Damage ozone / Acid rain
environment

Complete Gradual combustion

Measures
combustion Trade-off
Trade-off at low temp.

High pressure Fuelling

(Common rail system)
High pressure Air-intake
Technology
(Water-cooled Turbocharger)
Inter cooler
Pre-inject & delay main injection
(Common rail system)
EGR (Exhaust gas re-circulation)
Inter cooler
HINO’s technology for Tier 3

COMBUSTION
COMBUSTION CHAMBER
CHAMBER ENGINE
ENGINE ADVANCED
ADVANCED CONTROL
CONTROL
Optimum
Optimum configuration
configuration
COMMON
COMMON RAIL
RAIL SYSTEM
SYSTEM
OHC
OHC 44 VALVE
VALVE
Ideal
Ideal shape
shape swirl
swirl port
port COOL
COOL EGR
EGR
For
For cleaning
cleaning gas
gas
PISTON
PISTON COOLING
COOLING
Oil
Oil jetting
jetting system
system

WATER-COOLED
WATER-COOLED TURBO
TURBO
and
and INTER
INTER COOLER
COOLER

OIL
OIL COOLER
COOLER
High
High performance
performance
J-series engine
J-series
J-seriesFAMILY
FAMILYENGINE
ENGINE for
for20-33t
20-33tclass
class
J05E
J05Eand
andJ08E
J08Eengines
engineshave
havesame
samebore
bore&&stroke
stroke
spec.
spec.

J05E-TA J08E-TM
4 cylinders (5.1L) 6 cylinders (7.7L)
Applicable to 20 & 25t Applicable to for 33t.

Common
Commonparts:
parts:Valve,
Valve,Liner,
Liner,Bearing,
Bearing,Piston,
Piston,Con-rod,
Con-rod,Oil
Oilseals
seals
and
andEGR
EGRvalves
valves
Comparison of old and new engine
New model New model
MACHINE MODEL SK200-6E SK200-8 SK330-6E SK330-8
ENGINE MODEL 6D34TL J05E-TA 6D16TL J08E-TM
Number of Cylinder 6 4 6 6
Bore x Stroke mm 104 x 115 112 x 130 118 x 115 112 x 130
Displacement L 5.861 5.123 7.545 7.684
Reted Output kW/rpm 110 / 2,000 114 / 2,000 184 / 2,200 197 / 2,100
Max. Torque Nm/rpm 578 / 1,500 572 / 1,600 833 / 2,000 996 / 1,600
Fuel Consumption g/kWh 220 217 232 225
Dry Weight kg 480 515 580 680
L 1,183 1,063 1,321 1,294
Dimension W mm 684 725 806 868
H 890 995 991 987
Cylinder Head OHV 2-Valve OHC 4-Valve OHV 2-Valve OHC 4-Valve
Fuel Injection Injection Pump Common Rail Injection pump Common Rail
EGR N/A Cooled EGR N/A Cooled EGR
Specification
Water-cooled, Water-cooled,
Turbocharger Oil-cooled Oil-cooled
with Wastegate with Wastgate
Cylinder Liner Dry (Press) Dry (Loose-fit) Dry (Press) Dry (Loose-fit)
* Data is NET value with fan. Dimension of J08E-TM is without fan.
J05E-TA externals chart (20ton)
Turbocharger EGR cooler A/C Compressor Oil level gauge Common rail
・ Water-cooled ･ Bracket Strengthen ･ Extension of
・ Waist gate type gauge length
Alternator
EGR pipe ・ 50A Supply pump
Oil-filler
・ Brush-less
･ Height UP

Large-size fan EGR valve

・ 650mm
Crank pulley Oil drain
Oil filter location ･ Pulley ratio ･ One-touch
･ Remote type oil filter (i=0.89) drain cock
Starter motor
Water pump Oil pan (for Kobelco) ･ Large (5kW)
Fly wheel housing
･ Flow quantity UP ･ Containing Volume UP
･ For pump mount Engine speed sensor
･ Bearing strengthening ･ 35-degree inclination
･ Cast iron strengthen (Kobelco system use)
(for large-scale fan) (Cast iron material)
J08E-TM externals chart (33ton)
Water pump Oil level gauge
Turbocharger A/C Compressor ･ Extension of
･ Water-cooled ・ Bracket strengthen ･ Flow quantity UP
･ Bearing strengthening gauge length
･ Waist gate type
(for large-scale fan)
EGR pipe Supply pump
EGR cooler Common rail

Alternator
･ 60A EGR valve
Oil filter location ･ Brush-less
･ Remote type oil filter Large-size fan
・ 850mm Starter motor
･ Large (5kW)
Oil pan (for Kobelco)
Fly wheel housing Crank pulley Oil drain
･ Containing Volume UP
･ For pump mounting ･ Pulley ratio ･ One-touch Engine speed sensor
･ 35-degree inclination
･ Cast iron strengthen (i=0.75) drain cock (Kobelco system use)
(Cast iron material)
ECU < Feature >

Use Flash ROM & EEPROM

ECU controller
Flash ROM Engine
(Rewritable) Engine Control
Control Program
Program data
data

INJECTION
INJECTION amount
amount calibration
calibration data
data
EEPROM
(Rewritable)
SUPPLY
SUPPLY PUMP
PUMP calibration
calibration data
data
ECU < Function >
【 COMMON RAIL 】 -- Fuel Injection amount controlled by Sensors;
1. Accelerator signal
2. Engine speed (Main&Secondary)
3. Water temp.
4. Atmospheric pressure
5. Common rail pressure
【 EGR 】
　 Controlling EGR amount by Sensor Signals (ditto)
【 SUPPLY PUMP - calibration - 】
　 Calibrating Supply Pump to maximizing engine performance
【 INJECTOR - calibration - 】
Calibrating Injectors to maximizing engine performance
【 FAILURE DIAGNOSIS FUNCTION 】
Self-diagnosis ： Displaying fail codes on Kobelco multi display
Fail-safe function ： 1. ECU back up control when system fail
2. Engine emergency accel is standard
Common-rail fuel injection system
Function 1. Maintain High Press FUEL at common rail (Up to150MPa)
Function 2. Injecting High Press FUEL to combustion chamber

(1)ECU controller

Combustion (4)Injector (3)Common rail (2)Supply pump

Camber Injecting fuel Distributing fuel Pressurizing fuel

(2)Supply pump
(3)Common rail

(1)ECU PCB (4)Injectors

Common rail system feature

High pressure injection

Fully
Fully Combustion
Combustion
HIGH
HIGH PRESSURE
PRESSURE fuelfuel injection
injection
mixing
mixing fuel
fuel with
with air
air efficiently
efficiently
Current High-press
PM
PM &
& Smoke
Smoke reduce
reduce 1.
1. Maximize
Maximize Engine
Engine torque
torque at
at
mid-low
mid-low range
range of
of engine
engine speed
speed
Pilot injection 2.
2. Low
Low fuel
fuel consumption
consumption

Lowering
Loweringcombustion
combustiontemperature
temperature
PILOT-INJECTION
PILOT-INJECTION preventing
preventingdelay
delay
Pilot

ignition
ignitionand
andgiving
givingmild
mildcombustion
combustion Main

NOx
NOx &
& Noise
Noise reduce
reduce
Common rail system
< system comparison with old model injection pump >

Mechanical Common rail

Common rail
(1) (2)
(4)
(4)
(1) (3) (2) (3)
Inj. pump

Differences
IN-LINE INJECTION PUMP COMMON RAIL
Volume Adjust inject (1)Pump (Governor) (1)Injector
Timing Adjust Inject (2)Pump (Timer) (2)Injector
Feeding Fuel (3)Pump (3)Supply Pump
Distribution Fuel (4)Pump (4)Common Rail
Press Adjust Inject by Engine rpm & Inject Vol. (3)Supply Pump (SCV)

Note: Common rail system always keep high pressure at common rail.
Common rail system
< Hino (made in DENSO) common rail specification history >
: Applicable to SK200-8 / SK330-8

1st Generation 2nd Generation 3rd Generation

Pressure 120MPa 145MPa * 180MPa
Main
Main
Pilot After
Injection Pre
Pilot Post
Frequency
< for Exhaust Treatment >

Series 2 Cylinder Type Rotary Type

（Small/Middle Size)

Supply
Pump
< for Save Weight,Cost,Noise >

Series 2 Cylinder Type

(Large Size)

Taper Seat Type Flat Seat Type Flat Seat Type

Injector (Improve Fuel Improve) （Improve Sol. Response）
Valve
(Valve Spec)
< for High Press. Inject > < for Multi-injection >

ECU 16bit CPU 32bit CPU

< Controllability Improve >

*Operating pressure is 150MPa or less

Common rail system
< Outline of system >
【【 Injecting
Injecting AMOUNT
AMOUNT 】】
Controlling
Controlling INJECTOR
INJECTOR (Solenoid)
(Solenoid) to
to adjust
adjust for
for ideal
ideal AMOUNT
AMOUNT
　　 that
that ECU
ECU calculated
calculated by
by sensing
sensing Engine
Engine speed,
speed, Accelerator.
Accelerator.
【【 Injecting
Injecting PRESSURE
PRESSURE 】】
Controlling
Controlling SCV
SCV (Suction
(Suction Control
Control Valve)
Valve) of
of SPPLY
SPPLY PUMP
PUMP toto
adjust
adjust discharging
discharging fuel
fuel amount
amount toto obtain
obtain ideal
ideal COMMON-RAIL-
COMMON-RAIL-
PRESSURE
PRESSURE (=injecting
(=injecting pressure)
pressure) that
that ECU
ECU calculated
calculated by
by sensing
sensing
Engine
Engine speed
speed and
and fuel
fuel Injecting
Injecting amount.
amount.
【【 Injecting
Injecting TIMING
TIMING 】】
Controlling
Controlling INJECTOR
INJECTOR (Solenoid)
(Solenoid) to
to adjust
adjust for
for ideal
ideal TIMING
TIMING
that
that ECU
ECU calculated
calculated by
by Engine
Engine speed,
speed, Injecting
Injecting amount
amount etc.
etc.
【【 Injecting
Injecting percentage
percentage (%)
(%) ratio
ratio of
of PILOT
PILOT and
and MAIN
MAIN 】】
Controlling
Controlling INJECTOR
INJECTOR (Solenoid)
(Solenoid) to
to adjust
adjust for
for ideal
ideal fuel
fuel amount
amount
of
of each
each %% RATIO
RATIO OFOF PILOT
PILOT && MAIN
MAIN that
that ECU
ECU calculated
calculated byby Engine
Engine
speed
speed and
and Injecting
Injecting amount.
amount.
Common rail system
< Composition >

Common rail
Pressure sensor
(4)Flow damper
Engine
Speed Common rail (5)Injector
sensor (6)Pressure
Cylinder limiter
Recognition (3)Plunger
sensor
(2)Suction
Control
valve
(1) Feed pump

Supply pump
Common rail system
< Supply pump >
Structure : Supply pump consists by following 3 parts;
(1) FEED PUMP : Charging fuel to SCV and PLUNGER

(2) SCV (Suction Control Valve): Regulating fuel amount to plunger

(3) PLUNGER : Sending high pressure fuel to common rail unit

SCV(Suction Control Valve)

SCV
SCV (Suction
(Suction Control
Control Valve)
Valve)

Feed Camshaft
Feed pump Camshaft
Pump
pump
【 J05E 】 【 J08E 】
Common rail system
< Supply pump (feed pump) >

Function: FEED PUMP : Trochoid type and built-in Supply pump

Note: This feed pump has regulator valve maintaining
discharging fuel amount.

Inlet port Outer rotor

Inner rotor
Outlet port
Drive shaft

From fuel filter To SCV

Regulator valve
Common rail system
< Supply pump (SCV = Suction Control Valve) >

SCV (Suction Control Valve) : Fuel metering solenoid valve

Function: Metering fuel amount to plunger by solenoid valve for

Adjust common rail pressure.

Return Cylinder SCV Current

Average current
Spring
【 Small 】
Flow
【 Large 】

Pump body
Current
【 Large 】
Flow Flowing amount
【 Small 】
Common rail system
< Supply pump (Plunger) >

Function: PLUNGER is driven by Engine rotation,

and Discharging High-pressure fuel to common rail

Exhalation valve

SCV
Inhalation valve Plunger

Suctioning Discharging Not discharging

(Increase pressure) (Decreasing pressure)

Suctioning Discharging

Plunger 【 Condition not discharging 】

SCV close port to cut fuel
to plunger to decrease pressure
Cam lift
Common rail system
< Supply pump (Calibration) >

In order to maximize Common rail performance, ECU needs

memorize character of SUPPLY PUMP performance curve
In order to match them with target curve.

When you need calibration ? ECU controller calibrates

･ Replacing SUPPLY PUMP individual character of SUPPLY
PUMP to match with Program.
･ Replacing or reset ECU

Common rail pressure

Caution: NO CALIBRATION will result
Pressure-Shortage, or
Over-shoot at common-rail.

Performance down and PM, Smoke and

NOx level become increased
Common rail system < Common rail >
Function: Common-rail accumulates High-pressurized-fuel
supplied from Supply pump, and distributes fuel
to Injector.
Structure: Common rail unit consists by 3 parts;
1. Fuel-pressure-sensor
2. Pressure-limiter
3. Flow dumper

Fuel pressure sensor

Pressure
Pressure limiter Limiter
Flow dumper
Flow dumper

Fuel pressure sensor

【 J05E 】 【 J08E 】
Common rail system
< Common rail (Fuel pressure sensor) >

Function: Fuel-pressure-sensor feeds back Common-

rail pressure to ECU.

ECU controller then metering SCV (Supply

pump) to adjust Ideal Common-rail pressure.

Output voltage(V)
4.2

1.0

Vc Vout GND
0 200
(+5V)
Fuel pressure (MPa)
Common rail system
< Common rail (Pressure limiter) >

Function: Releasing abnormal high pressure at Common rail.

Note: Cracking pressure is approx. 200 MPa and

closing at 50 MPa.

Valve opening

Valve close

50 200
Pressure at common rail (MPa)
Common rail system
< Common rail (Flow damper) >

Function 1. Stabilizing High-pressurized-fuel flowing to Injector.

Function 2. In case of Fuel leaking at Injector & injection pipes,

this damper Blocks port to Injectors.

Piston
Body
【 Normal 】 Stopper

Orifice
Seat

【 Stabilizing 】
Common rail To Injector

【 Blocking 】
Common rail
Common rail system
< Injector >
Elec. terminals
Structure 1. Solenoid valve (2 way valve), Solenoid valve

2. Piston Return port

3. Injecting nozzle
Inlet port
Note: Very fine fuel jet directly splayed
to combustion chamber
Piston
J05E J08E
Hole dia. (mm) 0.15 0.20
No. of holes 6

Features 1. Injector assy Cramp mounted

2. Use O-ring at injector mount to block

engine oil
3. Valve seat shaped FLAT and Ceramic
Nozzle
material for “Sealing” and “Durability”
improvement against high pressure.
Common rail system
< Injector (Operation) >
Function 1. FUEL AMOUNT per cycle
2. TIMING injection
3. Fuel amount RATIO of Pilot & Main injection
Operation : Solenoid valve shifts plunger position up to release pressure
at “Control room” , then Piston/Nozzle lifted to injection.

Solenoid
Valve seat Valve spring
To the fuel tank
From common rail
Orifice Return
Control room
Piston
Orifice Inlet

Nozzle

Nozzle needle

【 No Injection 】 【 Start injection 】【 Stop Injection 】

Common rail system
< Injector (Calibration Injectors) >

Function: Variance of Injectors affect performance down ECU.

ECU calibrates Character of all injectors to match
with Programmed range (1.5%), and maximizing
performance of engine & clean gas.
Fuel amount at rated output

±1.5%
±5%

1 2 3 4 5 6 1 2 3 4 5 6
Cylinder No Cylinder No
Common rail system
< Injector (Calibration of Injectors) >

Injector assembly shows Stamp (Injector data) and QR-code

(Injector data, Parts No., Mfg No., Engine model etc.) on the top of Injector.

Use Diag. eXplorer (PC) to memory data to ECU.

When you need calibration for Injector ?

- Replacing Injectors Injector data(30 digits)
- Replacing and reset ECU
QR code

Caution: NO CALIBRATION will result

uneven injection

Stamp
Performance down and PM, Smoke and VIEW FROM TOP
NOx level become increased
Common rail system
< Engine speed sensor (NE sensor) >

Function: Mounted at Fly wheel housing,

Detecting engine speed and crank angle (every 6 dif.),
and feed back to ECU.

112 pulses/720°
Common rail system
< Cylinder recognition sensor (G sensor) >

Function: Mounted at rear side of Cam-housing,

and identifying the Number of cylinder.
Note: In addition, this sensor function as Secondary
back-up Sensor when Main engine speed
sensor fail.

Note: This notch is for identifying cylinder No.

Vol.
GND
SIG

J08E:7 pulse/720°

Vol.
GND
SIG

J05E:5 pulse/720°
Cool EGR
Cool EGR: Exhaust Gas Recirculation cooled by coolant water.

Exhaust
Structure 1. EGR Cooler Turbocharger
side
Suction side
Structure 2. EGR Valve solenoid Inter cooler
control by ECU
(2) EGR
Valve (1)EGR Cooler
Function 1: COOL EGR re-circulates
part of exhaust gas back
into Air intake line to give Mild
combustion for controlling gas
temperature down, and effort
Reduce NOx amount.
Function 2: Cooling re-circulation gas to making
high density.
(600deg.C => 160deg.C at 2000RPM)
Cooled EGR
< EGR Cooler (Main body) >
Structure: Many numbers-bunched-tubes for gas-passage, and
Coolant Water circulates in Main core in order to
condensate re-circulated gas for High efficiency.
Feature 1. Sub-piping improves cooling efficiency, and air
breeding after change coolant.
Feature 2. Stainless steel material of EGR cooler body for high
durability against Heat-resistance and Corrosion.

Main piping
Sub Piping Gas outlet
A

A
Coolant outlet A-A section

Gas inlet Cooling water Inlet

Cooled EGR
< EGR Cooler (Gas passage) >

Structure: A Spiral-Shaped-Tubes provides Higher cooling

efficiency, Clean gas and Low fuel consumption.

Coolant outlet
Sub-Piping

Exhaust entrance Suction entrance

(high temperature) (low temperature)

Cooling water entrance

Spiral type
Cooled EGR
< EGR Valve >

Function: Solenoid valve with seat valve improves EGR

volume control, and Reducing PM and NOx amount .
Lift sensor feeding back opening position to ECU
for accurate control.
EGR valve
Lift sensor
Linear solenoid
Actuator

Double seat valve

Valve
Gas inlet

Gas outlet
Cooled EGR
< EGR Valve >
Function: In order to control EGR, ECU reads valve opening
position by feed back of valve lift sensor, and
Regulating total Oxygen amount depending on
engine condition.

Real solenoid (proportion valve) input ･ Engine speed

･ Accelerator
ECU ･ Air in-taking pressure
EGR valve lift sensor
output ･ Atmospheric pressure
Cooling water ･ Coolant Temperature
･ Air in-taking Temperature

EGR valve
EGR cooler

Exhaust
(turbocharger)
Air in-take
Engine
(From inter cooler )
Other Engine Feature

(1)
(1) Turbocharger
Turbocharger: :Water-cooled
Water-cooledtype
typefor
forhigh
highperformance
performance

(2) Exhaust port : Shaped for best swirl ratio for clean gas
(3) Combustion chamber : Shaped for maximize swirl energy
(4) OHC 4 valve cylinder head : Providing higher reliability
(5) Cylinder block & Loose fit liner ;
Block for high performance and less noise &
Liner with special coating for good fitting and easy maintenance

(6) Latest design Piston

High positioned top ring for high efficiency of combustion and less noise.

(7) PVD coated Piston ring

Low oil consumption/blow-by-gas Loose fit liner
Turbocharger
Model: <GT22(SK200-8) / GT32(SK330-8) >
Garetto-turbo made by HONEYWELL
Feature 1. Water-cooled-system (Engine oil lubrication)
for high Cooling capability to avoid burnt.
Feature 2. Large capacity & Improved efficiency for
Saving fuel at MID-HIGH engine speed range.
Note: Fuel consumption at LOW engine speed range
is improved by common-rail-system.
Blower housing Turbine housing
Back plate

Water passage

Brower impellor Turbine wheel

Central housing
Turbocharger
Model: <GT22(SK200-8) / GT32(SK330-8) >
Garetto-turbo made by HONEYWELL
Feature 3. Waist-gate prevents Over-boost by sensing
excessive Air-boost-pressure and opening valve
at Exhaust manifold to reduce boost pressure.
Inter Cooler

Waist Gate

Turbine Case

Exhaust Manifold
Blower
Housing

Turbine Wheel
Intake Blower Impellor
Manifold
Other Engine Feature

(1) Turbocharger : Water-cooled type for high performance

(2) Exhaust port : Shaped for best swirl ratio for clean gas
(3) Combustion chamber : Shaped for maximize swirl energy
(4) OHC 4 valve cylinder head : Providing higher reliability
(5) Cylinder block & Loose fit liner ;
Block for high performance and less noise &
Liner with special coating for good fitting and easy maintenance

(6) Latest design Piston

High positioned top ring for high efficiency of combustion and less noise.
(7) PVD coated Piston ring
Low oil consumption/blow-by-gas Loose fit liner
Intake & Exhaust Port

Feature: New shape of Intake-Port controls air flow for Ideal

Swirl-Ratio, and provides better Fuel-Consumption.

Suction flow quantity coefficient

Exhaust port

Swirl-Ratio

Intake port
(helical port)
Note : Ratio of swirl
Swirl-Speed against Engine speed Intake port
at combustion chamber (Directional port)
Other Engine Feature

(1) Turbocharger : Water-cooled type for high performance

(2) Exhaust port : Shaped for best swirl ratio for clean gas
(3) Combustion chamber : Shaped for maximize swirl energy
(4) OHC 4 valve cylinder head : Providing higher reliability
(5) Cylinder block & Loose fit liner ;
Block for high performance and less noise &
Liner with special coating for good fitting and easy maintenance

(6) Latest design Piston

High positioned top ring for high efficiency of combustion and less noise.
(7) PVD coated Piston ring
Low oil consumption/blow-by-gas Loose fit liner
Combustion Chamber

Feature: Ideal shape of combustion chamber

maximizing Swirl-speed while fuel-injecting
period, and provides better fuel-consumption.

Kobelco
Other Engine Feature

(1) Turbocharger : Water-cooled type for high performance

(2) Exhaust port : Shaped for best swirl ratio for clean gas
(3) Combustion chamber : Shaped for maximize swirl energy
(4) OHC 4 valve cylinder head : Providing higher reliability
(5) Cylinder block & Loose fit liner ;
Block for high performance and less noise &
Liner with special coating for good fitting and easy maintenance

(6) Latest design Piston

High positioned top ring for high efficiency of combustion and less noise.
(7) PVD coated Piston ring
Low oil consumption/blow-by-gas Loose fit liner
Cylinder Head

Feature 1. OHC 4 valve made by Cast steel alloyed material

provides Heat-resistance-ability in heavy equipment
use with higher speed & load.

Feature 2. Injection-nozzle located at

center to complete combus-
tion and reduce PM and
smoke.

Valve Grow plug

Combustion chamber Nozzle(injector)
Other Engine Feature

(1) Turbocharger : Water-cooled type for high performance

(2) Exhaust port : Shaped for best swirl ratio for clean gas
(3) Combustion chamber : Shaped for maximize swirl energy
(4) OHC 4 valve cylinder head : Providing higher reliability
(5) Cylinder block & Loose fit liner ;
Block for high performance and less noise &
Liner with special coating for good fitting and easy maintenance

(6) Latest design Piston

High positioned top ring for high efficiency of combustion and less noise.
(7) PVD coated Piston ring
Low oil consumption/blow-by-gas Loose fit liner
Cylinder Block & Liner

Feature 1. Enlarged Water-gallery improves for

higher cooling performance & sound reduction.

Feature 2. Cooling-jet-system splays

oil to piston for higher
cooling performance.

Feature 3. Loose-fit-liner for easier

maintenance and special
coating either inside and
outside of liner makes
better fitting.
Cooling jet
There are 3 kinds of liners (A / B / C),
and it is different in each cylinder.
Other Engine Feature

(1) Turbocharger : Water-cooled type for high performance

(2) Exhaust port : Shaped for best swirl ratio for clean gas
(3) Combustion chamber : Shaped for maximize swirl energy
(4) OHC 4 valve cylinder head : Providing higher reliability
(5) Cylinder block & Loose fit liner ;
Block for high performance and less noise &
Liner with special coating for good fitting and easy maintenance

(6) Latest design Piston

High positioned top ring for high efficiency of combustion and less noise.
(7) PVD coated Piston ring
Low oil consumption/blow-by-gas Loose fit liner
Piston

Feature 1. Latest design piston with Unti-heat aluminum-alloy

material and matching with swinging motion, and
applies skirt surface special coat for sound reduction.
Feature 2. High-top-ring piston provides improved combustion
efficiency.
Feature 3. To maximize Oil-jet-cooling efficiency, apply
Oil-jet-pass routing oil to top ring groove directly.
New piston
Old piston (High-top-ring)

Oil-jet passage rout

Other Engine Feature

(1) Turbocharger : Water-cooled type for high performance

(2) Exhaust port : Shaped for best swirl ratio for clean gas
(3) Combustion chamber : Shaped for maximize swirl energy
(4) OHC 4 valve cylinder head : Providing higher reliability
(5) Cylinder block & Loose fit liner ;
Block for high performance and less noise &
Liner with special coating for good fitting and easy maintenance

(6) Latest design Piston

High positioned top ring for high efficiency of combustion and less noise.

(7) PVD coated Piston ring

Low oil consumption/blow-by-gas Loose fit liner
Piston Ring

Feature 1. Special designed SHAPE of all 【 Top ring 】 PVD-coat

rings for stable Oil consumption
level, Less wearing losses, Less
Nitric-layer
Gas escaping and Unti-scuffing.

Feature 2. Special designed MATERIAL of 【 Second ring 】

rings of Nitric-processed-steel
made for unti-wearing, that Nitric-layer
minimizes Oil consumption
and Blow by gas amount.
【 Oil ring 】
Nitric-
Feature 3. PVD-coating (applies Top-ring only) layer

for High-seizure-protection from

dust per field monitoring results Nitric-
layer
in China.
Fuel

Common rail system is lubricated by high pressurized fuel ,

Therefore, fuel quality influences the system.
Bad fuel Influences
Fuel quality standard
【 Defective lubrication, Particles 】 【 Lubricity 】
Wearing and seizure of supply HFRR ≦ 460μm
pump & injector.
【 Moisture 】
【 Residual carbon 】 ≦ 500ppm
Creating Slag attack Injector.
【 Sulfur 】
【 Moisture 】 ≦ 2000ppm(tentative)
Rusting nozzle and stuck
【 Fuel filter Spec 】
【 Sulfur 】
5μm
Corrosion of EGR cooler, Piston
(For common rail use)
ring cylinder liner
Caution: Any engine failures suspected cause
by insufficient maintenance should be
strictly investigated.
Fuel Filter
Priming pump Air pulling out bolt

Filter especially for common rail

Fuel entrance
- Filtration performance: 5μm
Note: Previous model’s spec 9μm
Fuel exit
- Filtration area: 1.8 times
Filter element
Water separator built-in design

【 Southeast Asia & Chinese spec 】 Water cup

Additional large size water
separator built-in secondary fuel
filter with 10μm. Water pulling out drain plug
Water separator switch harness

Caution: Any engine failures suspected cause

by insufficient maintenance should be
strictly investigated.

Pre-filter
Engine Oil

Performance of oil filter would be important since importance

Of fuel consumption recently.
And EGR system needs special engine oil with higher
Performance for oxidation neutralizing.

Japanese: Starting parts set of “DH-1” grade of oil

Overseas: Recommend “CF-4” grade of oil
But shorter period of oil change interval
if fuel consists high SULFUR ppm,
expediting oil rusting.
Caution: Any engine failures suspected cause
by insufficient maintenance should be
strictly investigated.
Engine Oil (Spot Tester)

It is recommended to use Engine oil analysis device to analyze

Engine oil quality as well as figuring out the rest of life till
oil change.
The follow exampled one shows Spot tester quick checking.

New oil(10.5) Use oil(7.5) Use oil(5.0) Use oil(2.5) Use oil(1.5) Use oil(0.3)

Kobelco schedules prepare service tool kit

Oil Filter

Combination of Full-flow filter and By-pass filter into one

To maximize filtering performance.
This filter advantages to eliminating residual carbon that
expedite oil wearing.

Bypass filter

Full flow filter