SECTION 2 ENGINE

Group 1 Structure and Function ------------------------------------------------------------------------------------- 2-1

Group 2 Engine speed and Stall rpm ---------------------------------------------------------------------------- 2-12
Group 3 Fuel warmer system ----------------------------------------------------------------------------------------- 2-13
 SECTION 2 ENGINE
GROUP 1 STRUCTURE AND FUNCTION

1. STRUCTURE

Exhaust outlet connection

Crankcase breather

Lifting bracket

Flywheel housing Lubricating oil filter cooler

Lubricating oil filter

Starting motor Water inlet connection

Vibration damper

Oil pan

Air intake connection Turbocharger

Fan drive Lifting bracket

Fuel filter

ECM
(engine control module)

Oil fill arrangement

760F2EG05

 Direct 4-stroke, 6-cylinders, water-cooling and charge air cooled diesel engine in installed, cylinder
block and cylinder head are made of case iron and turbocharger is attached.

2-1
2. SYSTEM DIAGRAMS
The following drawings show the flow through the engine systems.

1) FUEL SYSTEM

760F2EG10

1 Fuel from supply tank 11 Fuel rail

2 Water/fuel separator filter 12 Fuel rail pressure relief valve
3 Priming pump 13 Common rail fuel return
4 Fuel supply to fuel gear pump 14 High-pressure fuel line to injector
5 Fuel gear pump 15 High-pressure connector
6 To pressure side fuel filter 16 Injector
7 Pressure side fuel filter 17 Fuel return from injectors
8 To high-pressure fuel pump 18 Combined fuel return
9 High-pressure fuel pump 19 Fuel return to fuel supply tank
10 To fuel rail

2-2
 2) LUBRICATING OIL SYSTEM

7609A2EG11

1 Lubricating oil pump 8 Filter bypass valve

2 Pressure regulating valve closed 9 Filter bypass valve closed
3 Pressure regulating valve open 10 Filter bypass valve open
4 From lubricating oil pump 11 To lubricating oil filter
5 To lubricating oil cooler 12 Full-flow lubricating oil filter
6 To lubricating oil pan 13 From lubricating oil filter
7 Lubricating oil cooler 14 To main lubricating oil rifle(s)

(1) Lubrication for the turbocharger

7609A2EG12

1 Turbocharger lubricating oil supply 2 Turbocharger lubricating oil drain

2-3
(2) Lubrication for the power components

7609A2EG13

1 From lubricating oil cooler 6 Oil supply to rod bearings

2 Main lubricating oil rifle 7 Crankshaft cross drilling from the main
3 To overhead components bearing journal
4 To upper main bearing 8 J-jet piston-cooling nozzle
5 To camshaft journal 9 To accessory drive oil feed

(3) Lubrication for the overhead components

7609A2EG14

1 Main lubricating oil rifle 4 Rocker lever shaft

2 Rocker lever support 5 Rocker lever bore
3 Transfer slot 6 Rocker lever

2-4
(4) Lubrication for the accessory drive

7609A2EG15

1 Oil supply to accessory drive 2 Oil feed from block

侍
Oil returns to pan through the gear housing.

2-5
 3) COOLING SYSTEM
1 Coolant inlet from radiator and aftertreatment diesel
exhaust fluid (DEF) dosing valve and DEF tank
2 Water pump lmpeller
3 Coolant flow past lubricating oil cooler
4 Coolant flow past cylinders
5 Coolant flow from cylinder block to cylinder head
6 Coolant flow between cylinders
1 Air compressor coolant supply line
2 Air compressor coolant return to coolant inlet connection
2-6
7609A2EG16
7 Coolant flow to thermostat housing
8 Thermostat open - bypass passage closed
9 Coolant flow back to radiator
10 Thermostat closed - bypass passage open
11 Coolant bypass passage in cylinder head
12 Coolant flow to water pump inlet
760F2EG17
COOLING SYSTEM

760F2EG18

1 Coolant supply to variable geometry turbocharger from the cylinder block

2 Variable geometry turbocharger coolant return to the EGR cooler outlet tube
3 Coolant supply to the EGR cooler from the rear of the cylinder block
4 EGR cooler coolant return to the coolant inlet connection
5 De-aeration port (to coolant top tank)

760F2EG19

1 Coolant supply to aftertreatment DEF dosing valve and DEF tank

2 Coolant supply to cab heater
3 De-aeration port (to coolant top tank)

2-7
4) AIR INTAKE SYSTEM

7609A2EG20

1 Air cleaner 9 Intake port

2 Turbocharger compressor inlet 10 Intake valves
3 Turbocharger compressor outlet 11 EGR connection tube
4 Charge air cooler inlet 12 EGR cooled exhaust gases
5 Charge air cooler outlet 13 Charge air cooled intake air
6 Air intake connection adapter 14 EGR valve
7 Air intake connection 15 Air mixture to combustion cylinder
8 Intake manifold

2-8
5) EXHAUST SYSTEM

7609A2EG21

1 Exhaust valves 6 Exhaust inlet to EGR cooler

2 Exhaust port 7 EGR cooler
3 Exhaust manifold 8 Cooled exhaust outlet to EGR valve
4 Turbocharger 9 EGR valve
5 Turbocharger exhaust outlet 10 EGR valve differential pressure sensor

2-9
 EXHAUST SYSTEM

760F2EG30

1 Exhaust from turbocharger

2 Aftertreatment diesel oxidation catalyst (DOC) intake temperature sensor probe
3 Aftertreatment DOC
4 Aftertreatment DOC outlet temperature sensor probe
5 Diesel exhaust fluid (DEF) supply to aftertreatment DEF dosing valve
6 Aftertreatment DEF dosing valve
7 Decomposion reactor
8 Exhaust DEF mixture
9 Aftertreatment selective catalyst reduction (SCR) intake temperature sensor probe
10 Aftertreatment SCR catalyst
11 Aftertreatment SCR outlet temperature sensor probe
12 Exhaust flow exiting aftertreatment system
13 Aftertreatment DEF dosing valve coolant fittings
14 Aftertreatment inlet mono-nitrogen oxides (NOx) sensor probe
15 Aftertreatment outlet NOx sensor probe

2-10
 EXHAUST SYSTEM

760F2EG31

1 Coolant flow from engine to aftertreatment DEF

2 Aftertreatment DEF tank coolant valve
3 Coolant flow to aftertreatment DEF tank
(only when aftertreatment DEF tank coolant valve is open)
4 Aftertreatment DEF tank
5 Coolant return to engine
6 Aftertreatment DEF supply from aftertreatment DEF tank
7 Aftertreatment DEF flow to aftertreatment DEF dosing unit
8 Aftertreatment DEF dosing unit
9 Aftertreatment DEF return to aftertreatment DEF tank
10 Aftertreatment DEF flow to aftertreatment DEF dosing valve

2-11
 GROUP 2 ENGINE SPEED & STALL RPM
1. TEST CONDITION
1) Normal temperature of the whole system
- Coolant : Approx 80˚C (176˚F)
- Hydraulic oil : 45 Ü 5˚C (113 Ü 10˚F)
- Transmission oil : 75 Ü 5˚C (167 Ü 10˚F)
2) Normal operating pressure : See page 6-60.
2. SPECIFICATION
Engine speed, rpm (P mode)
Fan motor Remark
Low idle High idle Pump stall Converter stall Full stall
800Ü25 2230Ü50 2220Ü70 1910Ü70 1880Ü100 950Ü50

3. ENGINE RPM CHECK

Remark : If the checked data is not normal, it indicates that the related system is not working properly.
Therefore, it is required to check the related system pressure : See page 6-60.
1) Pump stall rpm
- Start the engine and raise the bucket
approx 45 cm (1.5 ft) as the figure.
- Press the accelerator pedal fully and
45Cm

operate the bucket control lever to the

retract position fully.
- Check the engine rpm at the above
condition.
740F2EG01

2) Convertor stall rpm

- Start the engine and lower the bucket on
the ground as the figure.
- Set the clutch cut off mode at the OFF
Clutch cut off mode
position.
- Press the brake pedal and accelerator
pedal fully.
- Shift the transmission lever to the 4th
forward position.
- Check the engine rpm at the above 740F2EG02

condition.
3) Full stall rpm
- Start the engine and raise the bucket
approx 45 cm (1.5 ft) as the figure.
- Set the clutch cut off mode at the OFF
Clutch cut off mode
position.
- Press the brake pedal and accelerator
45Cm

pedal fully .
- Shift the transmission lever to the 4th
forward position and operate the bucket
lever to the retract position fully. 740F2EG03

- Check the engine rpm at the above

condition.
2-12
GROUP 3 FUEL
FUEL WARMER SYSTEM

1. SPECIFICATION
PECIFICATION
1) Operating voltage : 24Ü4V
2) Power : 350Ü50W
3) Current : 15A
Fuel warmer
2. OPERATION
PERATION
1) T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s
automatically controlled without thermostat
according to fuel temperature. Prefilter
2) At the first state, the 15A current flows to the fuel
warmer and engine may be started in 1~2
minutes.
3) If the fuel starts to flow, ceramic-disk in the fuel
warmer heater senses the fuel temperature to
reduce the current as low as 1.5A.
So, fuel is protected from overheating by this
7609AW2EG05
mechanism.

3. ELECTRIC
LECTRIC CIRCUIT
FUSE BOX
10A TURN LAMP
01
30A START KEY SW
02
10A RADIO B+
03
10A TCU 24V B+
04
20A AC/HEATER B+
05
10A CLUSTER 24V B+
06 PRE-HEATER
20A MCU B+
07 GLOW RELAY
20A RMCU B+
08
20A ECM POWER 11
09
20A ROOM LP 12 CN-80
10
CR-24
CN-36
24 5
30 6 FUEL HEATER
FUEL WARMER RELAY
25 2 B
86 30 87a
26 1 A
85
87 3
86 1 12
CN-196
85 87 87a
30 18 8
CR-46 7
CN-4
PRE-HEATER RELAY CN-13
86 30 87a
33
85
12
87
86 16
85 87 87a
30 17
CR-36 26

FUSE BOX 25 MASTER

10A BEACON
24 SWITCH CN-351
25 20A 23 2 40A
WORK LAMP_REAR
26 30A 22 1
AIR-CON/HEATER 1
27 20A 21 CS-74
ILL.LAMP
28 20A 80A
HEAD LAMP CN-01
29 10A CN-352
BACK BZ. STOP LAMP
30 20A HORN BATTERY
31 20A BATT RY
HEAT MIRROR
32 20A FUEL WARMER 1
33 30A 2
FUEL WARMER 2
34 30A 1
CIGARLIGHTER
35 20A 3 CR-01
COWL OPEN
36 4
CN-38 CS-75 TO STARTER

FUSE BOX
20A 12V CONVERTOR
37 20A
CN-58A

CN-58B

SEAT HEAT/AIR-RIDE
38
A20
B32
B11
B33
B14

20A WORK LAMP_FRONT

39
CS-02

20A WIPER
40
NEUTRAL SIGNAL(24V)
ANTI-RESTART RELAY

20A
CR-30

PARK, PILOT CUT

CR-35

5
4

2
6

1
3

41
87
87

30
85
30

86
85

86

87a
87a

10A AUTO GREASE

BATTERY RELAY

42
B

FUEL WARMER

10A AIR PRE-HEAT 0,I

1
87 87a
87 87a

43
ALT LEVEL

20A FAN REVERSE, ATT.

30
30

44 10A
85
85

86
86

H0 I
CN-39
4
3
2
6
5

C ACC BR H

EG ECM RY IGNITION RY START SWITCH MCU 740F2EG07

2-13