SOP IM TAN INO ILs KOMATSU 108 series DIESEL ENGINE 00-101 1 12 13 14 15 00-2 ® CONTENTS No. of page GENERAL STRUCTURE AND FUNCTION.........:sssssssssresssssessseessess TESTING AND ADJUSTING........:ccsssscsesssssesseesseseresnees DISASSEMBLY AND ASSEMBLY ..............1ssessssssesssees MAINTENANCE STANDARD..............sscesseeseeesteseseeeeaeen REPAIR AND REPLACEMENT OF PARTS.............--:+000+ 124 134 141 15-1 622101622101 LIST OF REVISED PAGES UST 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 tothe table below. © | Page to te newly added Add © | Pogo to be replaced Replace ( } | Peveto be deleted Discard Pages having no marks are those previously revised or made additions. LIST OF REVISED PAGE Mark Page Maik Page TSO mark Page TSN Merk Peco Tinet 2 01 @ 107 ® no © no% @ 2.08 @ a2 @ 01-008 @ 191 @ no @ 200 © © 021 @ 01009 @ n0n2 @ 110% © non @ © 0.22 @ ooo noe O noe @ wow @ © cs oon nos © 040 @ nowy @ oe we oor ® now @ no @ |e 20104 @ © 05 010121 @ non @ 1982 @ nou @ © 00.6 o022 @ now © 108 @ 208 @ © 00.7 oro @ no © 084 @ |e 12051 @ © 08 101% @ no @ 01 @ | @ 2052 © © 00-9 10192 @ 1105 @ |e noe © = © 0010 11001 @ 100 © 1.0854 @ 120161 @ © 00.11 v002 @ non @ 11068 @ 120162 @ © 00-12 11003 @ 102 @ 087 @ 12063 @ © 0073 11008 @ 11.023 @ 08 @ 20164 @ © 00-14 11.005 @ 114028 @ 1108 @ 120165 @ © 0045 11.008 @ 11.02% @ v050 @ 12.0166 @ © 06 11.007 @ 11027 @ 11051 ® 120167 @ © 00.17 11.0071 @ 08 @ 1082 @ 12068 @ © 18 11-0072 @ 11023 ® 11053 @ 120168 @ © 0019 110073 ® 11.0281 @ 12.016-10@ 11.007-4 @ 110232 @ 1201 @ | Oo 120161 @ 01-001 @ 11-0075 @ 110293 @ 120022 @ 2017 @ 01002 @ 11.008 @ 11.030 @ 12003 @ 12018 @ 01-003 @ 11003 © 11.031 @ 12008 @ 201 @ © 108 @ now @ n032 @ 12008 @ 12020 @ ~ © 01005 @ no ® 11.038 @ 12008 @ 120201 @ 01-008 @ n02 @ 11.035 ® 12007 @ | 0 12002 @ 00-2-1 @LUST OF REVISED PAGES LIST OF REVISED PAGES Mark Page TIME Of Mack Peae TIS OM mark Pace 12021 © 3015 @ 019 @ 12022 @ 13016 @© 14020 @ 203 Bor @ 14021 @ 102 @ B08 @ wor © 1202 «=D 12019 @ 12023 @ 13020 © 15.001 @ 12027 O 13021 @ 15-002 @ 2028 O 130211 @ 1$:003 @ 12028 OD 130212 @ 15008 @ 12030 © 13022 ® 15.005 @ 12031 @ 13023 @ 15.006 @ 12022 02% @ 16.007 @ 12033 @ 13025 © 15.008 @ 12038 © 1302 @ 15009 @ 1205 «D 027 15010 @ 120% 13022 @ sor @ 12.037 © 130781 @ 1012 @ 1038 13.0202 @ 1013 @ 12039 © 13020 ® wou @ 1200 @ 13039 @ 15015 @ 200 @ 303 ® 101 @ 1208 © 13032 @ i017 @ 12089 wore @ 108 14.001 @ 5019 @ 12085 @ 14-002 15020 @ 14003 @ 15.021 @ 13001 O 14008 @ 15022 @ 13.002 © 14008 @ 13003 O 14007 @ 13.008 © 14.008 @ 13.005 © 14.003 @ 13.006 © 4010 ® 13007 © won ® 13.008 © wor © 13.009 © 14013 @ 00 woe @ won D 14015 @ 3012 OD 14018 ® 3013 O wor @ B01 D wow ® 00-2-2 @ 622101SAFETY SAFETY SAFETY NOTICE ‘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 @& is used to merk 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 Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1, Before carrying out any greasing or repairs, ‘ead all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. + Always wear safety glasses when hitting Parts with a hammer. + Always wear safety glasses when grind- ing parts with a grinder, ete. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work, When carrying out welding work, al- ways wear welding gloves, apron, hand shield, cap and other clothes suited for weld- ing work. 4. When carrying out any operation with two or more workers, always agree on the oper- ating procedure before starting. Always in- form your fellow workers before starting any step of the operation, Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keop the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. ‘Smoke only in the areas provided for smok- 19. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 2 Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to pravent the work equipment from falling. In addition, be sure to lock all the control levers and hang warn- ing signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or ‘other places used to get on and off the ma- chine. Always use the handrails, ladders or steps when getting on or off the machine, Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3SAFETY PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the clreuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 19. Before starting work, ramove the leads from the battery. Always remove the lead from the negative (+) terminal first. 14, When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use @ hoist or crane and operate slowly to prevent the component from hit ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- 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 oF 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 19. 21. 22, 23. 24. SAFETY NOTICE Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. « When installing hoses and wires, be sure that they will not be damaged by contact with other parts whan the machine is be- ing operated. When installing high pressure hoses, make suro that they are not twisted. Damaged tubes aro dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check thet connecting parts are correctly installed. When assembling or installing parts, always use the specified tightaning torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track.FOREWORD GENERAL 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 tepairs 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 aro 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.FOREWORD HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as 2 guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical valine Each issued as one ‘Attachments volume; | volume to cover all models These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is neces sary that chassis, engine, electrical and attach ment volumes be available, DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you stert any work. FILING METHOD 1, See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10-3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 2-5 | unit number (1. Engine) tem number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indi- cated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 12-203 10-41 12-203-1 10-421 Added pages —l12-203-2 108 12-204 00-6 HOW TO READ THE SHOP MANUAL REVISED EDITION MARK When a manual is revised, an edition mark (D@W....) is recorded on the bottom of the Pages. REVISIONS Revised pages are shown in the LIST OF RE- VISED PAGES noxt to the CONTENTS page. SYMBOLS So that the shop manual can be of ample prac- tical use, important safety and quality portions are marked with the following symbols. symbol | item Remarks Special safety prec Recessary when performing the work ‘Spacial tachnical precautions or other precautions for pre: serving standards are neces: sary when performing the work Satety Caution Weight of parts of systems. Caution necessary when so: Weight | lecting hoisting wire, or when | working posture is important, ete. kg — ee Places that require special at- tention for the tightening torque during assembly. iTightening torque Places to bo coated with ad- Coat | hesives and lubricants, etc. Places where ol, water 0 fuel must be added, ond the co | pacity. Oil, water| Places where oil or water must be drained, and quan- tity to be drained, E-\e|>| 3 | Be DrainFOREWORD HOISTING INSTRUCTIONS HOISTING Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISAS- SEMBLY AND ASSEMBLY section, every part weighing 25 kg or more,is indicated clearly with the symbol a) «If a part cannot be smoothly removed from the machine by hoisting, the following checks should be mad 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part caus- ing interference with the part to be re- moved. WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to table belo Wire ropes (Standard "Z* or "S* twist ropes without galvanizing) Rope diameter Allowabie load _ mm KN. tons. 10 98 10 n2 137 14 125 187 16 14 216 22 16 278 28 8 35.3 36 20 43.1 44 22.4 54.9 56 30 98.1 10.0 40 1765 18.0 50 2748 28.0 60 392.2 40.9 % The allowable load value is estimated to be one-sixth or one-seventh of the break- ing strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. HOISTING INSTRUCTIONS Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and 2 serious accident can re- sult. Hooks have maximum strength at the middle po: O 100% 88% = 79% = 71% = 1%. sapere 3) Do not sling @ heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. B Siinging with one rope may cause turing of the load during hoisting, untwisting of the rope, or si of the rope from its original winding position on the load, which can ro- sult in a dangerous accident. 4) Do not sling a heavy load with ropes form- ing a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allow- able load KN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 KN (1000 kg} vertically, at various hanging angles. ‘When two ropes sling a load vertically, up to 19.6 KN (2000 kg) of total weight can be ‘suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN (4000 kg) if they sling 2.19.6 kN {2000 kg} load at a lifting angle . oe 2 ist ee a ie @ tm ss nao0) ie 0 120180 Lattiae antic aattee skooeaee 00-7FOREWORD COATING MATERIALS 4 The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. 4 For coating materials not listed below, use the equivalent of products shown in this list. COATING MATERIALS Caegory [Koma seco] Penne. [Gy | onnnes | __ tan apes fates ~ Used to prevent rubber gasate rubber L144 |790-129-9030} 150g | Tube | cushions, and cock plug from coming out, : places requiring an immecany trong adhesive. Used for aaa Lr-18 |r9e-ras-enso| 29 [Poyetvene| See escopt polytnvena,polyprorhylens saa Lad tetrafluoroethlene and vinyl chloride), rub- ter maal and nonmetal + Features: Resistance heat and che Polyethylene) cals —— 09840-00030 | 50.9 container |+ Used for anti-loosening and sealant pur- poco for bolts and pugs 700-129-9080 [Aas * Used as adhesive or eal for metal, las (Set of adhe-| 1 kg and plastic. urs | Sveand [Harsoring) con rBrdoning | agent gent) | 8008 Ahesv ur |r90-128-9040] 250g [Polvethvene|- Used as sealant for machined holes. woke Used a3 hest-essting seslant for repair ict Trao-r26-0120| 759 | tube |° Voed a he * Quick hardening type adhesive ‘Three bond | Potvtnylne|” Cura ime: within 8200 to 3 min 1736 |790-128-8140/ $0.9 + Used mainly for adhesion of metals, rub- bors plastics ond wood > Ouiexnarsening type acherve Aconstoho |raq 430-0130) ag [Pevtvlene|” Oulekeure type imax. strength after 30 min- 201 9 container “ + Used rainy for adhesion of ubbers,plas- | joe and metal. * Features: Resistance o how, chemicals 9act2asi10) 50 ce. |Potetvene|” Used at jin ore subject to high tem | peratures. + |; Used as adhesive or sealant for gaskets co Too-1ze20N0) | 200.9. Tube and packing of power train case, etc. Features: Resistance to heat Used ae sealant Yor ange surfoee and Gosket bolts at high emperator locations, used eso wes |ro0-r20-g070] 149 | can | to prevent aoaure Used as sealant for heat resistance gasket for high temperature locstions such as en: gine pracombustion chamber, exhaust pipe, etc.FOREWORD COATING MATERIALS sa Category [Komatsu code] Par No. | ary | Container Main applications, features + Features: Resistance to water, oll + Used as seelant for flange surface, thread. 185) Tue |* Also possible to use as sealant for flanges pastzs.n020) 2opio; | My with large clearance + Used ae sealant for mating surfaces of fi nal drive case, transmission case Used as sealant for various threads, pipe Polyethylone| joints, flanges. LG-5 [790-129-8000] ko |" container |* Used a8 sealant for tapered plugs, elbows, nipples of hydraulic piping, “Features: Silicon based, resistence to heat, Gasket cold sealant tc | ovgao-00011] 250 | Tube |+ Used as seolant for lange surface, tread Used as sealant for ol pan, final drive co ate. + Footures: Silicon based, quick hardening type ts7 | 3820-00150 | 1509 | Tube. Used as sealant for flywheel housing. in- take manifold, ol an, thermostat housing, ate. ree bon: + Used as heat-resisting sealant fr repaiin [wes bard coz0.con] soon | Tune _* Lf as hatenng set for ropetng + Used as lubricant for sliding portion (to pre- Molybde- | LMG | oss4o-coost | 909 | Can |” vert rom squeaking! num disulchide + Used to prevent seizure or scuffing of the lubricant ump | 09940-00040] 200g | Tube | thread when press fitting of shrink fiting. + Used as lubricant for linkage, bearings, ote. [sve2-4o0u * General purpoee type [sve a50u | e2u — [sve2ao0c.a | various | Various Isv@2 160! IsvGa-160CM1 + Used for normal temperature, light 1oad Sites srezsenca 19 at places in contact with water or G2ca |SyG24000A.A| Various | Various | S¥G2.160C4 |SYGA160CNCA Melybdenum 4009 + Used for places with heavy load disulphide | SYG2-400M | (10 per [Belows type " m lubricant caso!FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) + In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diemeter Width @ ey) es) of bolt across flats mm mm Nm kam 6 10 132114 13510.15 8 3 3123 3203 10 v 6527 67407 2 19 313210 wet 4 2 aT 19 iat? 76 24 279230 28513 8 n ans 39 ata 20 30 549459, 5046 FH 32 745483 76485 2 36 9274103 9452105 ar a 73202 140 138415 30 46 17202 190 175420 33 50 22101 240 725125 36 55 2750: 200 20+ 30 39 60 32001 340 306435 Thread diameter Width of bolt across flats heey mm mm Nm kam 6 10 7.852 1.95 oBt02 8 9 186149 19405 10 “4 40.2459 47406 2 z 82354 7.85, Baton ‘TABLE OF TIGHTENING TORQUES FOR FLARED NUTS In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter | Width across flat Tightening torque mm mm. Nm kgm ™ 19 245249 25205 8 2 494196 5x2 2 7 7854196 B22 24 2 137.34 28.4 1423 30 36 178,6423.4 18:3 33 4 195.1449 2025 36 46 245.24 49 2525 2 55 294,249 30=6FOREWORD STANDARD TIGHTENING TORQUE TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS %* In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below. “Thveed diameter | Wiath across fat] Tightening forave a a Nm vam 0 7s wersn e707 2 ° nage wget % Z 28229 mes3 ‘TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS * Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Nominal No. |_Thfead diameter h across flat Tightening torque mm mm Nm kam o2 4 33149 |B 05 03, 04 20 Varies depending on| 93198 =| 61 05, 06 24 type of connecter. 142.12 196 14522 10, 12 33 | 421.42 68.8 436 14 2 877.14 1323 89.52 13.5 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS % Unless there are special instructions, tighten the O-ring boss plugs to the torque below. Nominal No, |Thread diameter | Width across flat | __—_—Tightening torque I mm mm | Nm kgm 8 ] 2 1% 738+ 147 O7520.18 10 10 7 3232147 1.1540.15 2B rH 19 84 196 yas02 4 4 2 22.56 196 2320.2 16 16 rr 20.4249 3205 8 8 27 392243 4205, 20 20 30 49149 5205 2 er 32 68.5298 1 30 30 32 107.8147 na15 B | 33 = 127.42 19.6 1342 36 36 36 15192245 155425 42 2 = 21072 29.4 2523 52 52 — 323.42 44.1 9344.5 00-11FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS) Use these torques for bolts and nuts (unit: mm) of Cummins Engine. ___ Thread diameter _ Tightening torque mm Nm kgm 6 +2 3.02 + 0.20 8 2rd 2.45 + 0.47 10 4326 438 +061 12 Ts 76 + 1.22 TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS) Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter Tightening torque mm | Nm kgm 6 B42 081 £0.20 8 142 102 +020 10 1242 1.22 £0.20 2 284 245 £0.41 u 36 +5 367 £051 TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS) Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter ~___ Tightening torque inch Nm kgm V6 Bat O31 +0.10 178 Ba2 081 £0.20 14 1242 41.22 40.20 3/8 1642 153 +041 1/2 244 245 £0.81 3/4 36 +5 367 £051 4 60 +9 612 £0.92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: SWB indicates a cable having a nominal number 5 and white coating with black stripe CLASSIFICATION BY THICKNESS Nominal | copper wie x} Cable 0.0. fourent rating) papi number | Number of ia of arardeirexs sexton) nm) way plicable circuit 0.85 " 0.32 0.88 24 [__12 _| Staring ughtng, signal ot. 2 28 0.2 209 34 20 ighting, signal ete 5 5 032 523 48 37 | Charging and signal 6 045, 1336 70 59 | starting (Glew plug) 0 35 0.80 42:73 14 135 | Starting 60 127 0.80 eaee 136 ve | starting 109 207 0.80 109.1 76 230 | starting CLASSIFICATION BY COLOR AND CODE Creu] Por bigest | Charging | Ground | Staring | Lighting | Instrument | signal | Other ation + fw [ease] w 8 8 R Y ¢ L ™|Color| White | Block Black Red Yellow Green Blue code] WA = aw AW va ow ww ; [Color[ White & Rea] — [Black & White] Rea & wnito Yotow & Red{ireen & White|Biue & White code] wa = By RB Ye GR ur 7 Color|White & Black] — [Bleck & Yellon| Red & Black |Velow & Bick|Green & Red] Blue & Rod Code] WL = BR RY Ye oy Wy “|! [cotor[white & Bue] _— [lack & Red fed & Velon\ Voto & Geen & Yionfon& Yetow [cove] We = = RG YL ca is . Color|whis & Green] — —___ [fed & Green fetiow & BluefGreen & Black/Blue & Black code] — = = AL yw Gt = i color] — = —_ [Fed stus fotowa write|sreon & atuel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. (1) 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 ©. This point © gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) 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 multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. ® Millimoters to inches 1 mm = 0.03937 in ° 1 2 3) 4 5 6 7 8 8 0 0.039 | 0.079 | 0.118 | 0.187 | 0.1973] 0.236 | 0.276) 0.315 | 0.354 0.394 | 0.433 | 0.472 | 0.612 | 0.551 | 0.991 0.787 | 0.827 | 0.866 | 0.906 | 0.945 | 0.984 1.181 | 1.220] 1.260 | 1.299 | 1.339] 1378) 1.575 | 1.614| 1.654 | 1.693 | 1.732 | 1.772! © 0.630 | 0.669 | 0.709 | 0.748 1.024 | 1.063 | 1.102 | 1.142 1.417 | 1.457 | 1.496 | 1.536 1.811 | 1.850 | 1.890 | 1.929 B88s° 2.205 | 2,244| 2.283 | 2.923 2.598 | 2.638 | 2.677 | 2.717 2.756 | 2.795| 2835 | 2874 | 2913 | 2.953 | 2.992 | 3.032| 3.071] 3.110 3.150 | 3.189| 3.228 | 3268 | 3.307 | 3.346 | 3386 | 3.425 | 3.465) 3504 3.543 | 3.583| 3.622 | 3.661 | 3.701 | 3.740| 3.780 | 3.819] 3.858] 3.896 60 70 80 90 00-14FOREWORD CONVERSION TABLE Millimeters to Inches 1.mm = 0.03937 in 0 1 2 3 4 5 6 7 8 8 0 0 0.039 | 0.079 | 0.118 | 0.157 | 0.197 | 0.236 | 0.276 | 0.315 | 0.964 10 0.394 | 0.433 | 0.472 | 0512 | 0.551 | 0.591 | 0.630 | o.669 | 0.709 | 0.748 20 0.787 | 0.827 | 0.866 | 0.906 | 0.945 | o.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 1.675 | 1.614 | 1.654 | 1.693 | 1.792 | 1.772 | 1.811 | 1.850 | 1.890 | 1.929 50 1.963 | 2008 | 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 | 2.620 | 2.569 | 2508 | 2.638 | 2677 | 2.717 70 2.756 | 2.795 | 2.835 | 2.874 | 2.913 | 2.963 | 2.992 | 3.032 | 3.071 | 3.110 80 3.160 | 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.e5e | 3.98 Kilogram to Pound kg = 2.2046 Ib ° 1 2 3 4 5 6 7 8 9 0 0 220} 441| 661] ge2] 11.02 1323| 1543] 17.64| 19.84 0 22.05 | 24.25| 26.46] 28.66| 30.86] 3307| 36.27| a748| 3968| 41.29 20 44.09 46.30] 48.50] 50.71| 51.91) 95.12| 67.32] 5953/ 61.73| 63.93 30 66.14) 68.34) 70.55} 72.75| 74.96] 77.16| 79.37| 8157) 93.78| 95.98 40 98.18 | 90.99| 9259] 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 | 126.66 | 127.87 | 130.07 60 132.28 | 134.48 | 136.69 | 138.89 | 141.10 | 143.30 | 145.81 | 147.71 | 149.91 | 152.12 70 184.32 | 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 | 213.88 | 216.05 | 218.26 00-15FOREWORD CONVERSION TABLE Liter to U.S. Gallon 12642 US. Gal 0 1 a 3 4 5 6 7 8 9 0 o 0.264] 0,528 | 0.793 | 1.057 | 1.321] 1585 | 1.849 | 2.113 | 2.978 10 2642 | 2.906 | 3.170 | 3.434 | 3698 | 3.963 | 4.227 | 4.491 | 4.755 | 5.019 20 5.263 | 5.548 | 5.812 | 6.076 | 6340 | 6.604 | 6269 | 7.133 | 7.397 | 7.661 30 7.925 | 8.189 | 8.454 8.718 | 8982 | 9.245 | 9510 | 9.774 | 10.039 | 10.303 40 | 10.667 | 10.891 | 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 | 14.266 | 14.629 | 14.796 | 15.058 | 15.222 | 15.586 60 15.880 | 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 | 19.548 | 19.813 | 20.077 | 20.341 | 20.605 | 20.870 go — | 21.184 | 21.308 | 21.662 | 21.926 | 22.190 | 22.485 | 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.€89 | 26.153 Liter to U.K. Gallon 1 = 0.21997 U.K. Gal 0 1 2 a 4 5 6 7 8 9 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] 2.960] 3.080| 3300] 3520) 3740) 3.950 | 4.179 20 4399] 4619 | 4.839 | 5.059 | 5.279| 5.499] 5.719/ 5.939 6.159 | 6379 30 6599 | 6819 | 7.039] 7.259) 7.479| 7.969] 7.919) 8.199 | 8.359 | 8579 40 2.799 | 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 | 18.27 | 18.477 | 18.697 | 18.917 | 19.137 | 19.357 | 19.577 90 19.797 | 20.017 | 20.237 | 20.487 | 20.677 | 20.897 | 21.117 | 21.337 | 21.557 | 21.777 00-16FOREWORD CONVERSION TABLE kgm to ft. Ib 1 kgm = 7.239 ft Ib 0 1 2 3 4 5 6 7 8 9 0 0 72) 45| 217| 289] 362] 434] 506] 579| 65.1 10 723| 796| 868] seo] t013| 1085] 1157 | 1230] 1302| 137.4 20 1447 | 1519 | 159.1 | 166.4 | 1736} 1808 | 188.1 | 1953 | 2025 | 2098 30 217.0 | 2242 | 2318 | 238.7 | 2459 | 2532 | 2604 | 267.6 | 2749 | 202.1 40 289.3 | 2966 | 3038 | 317.0] 3183 | 3255 | 332.7 | 340.0 | 3672 | 364.4 ~ 50 3617 | 3689 | 376.1 | 3634 | 3906 | 3978 | 4051 | 4123] a195 | 4268 60 4340 | 4412] 4485 | 4557 | 4629 | 4702 | 4774 | 4946 | 491.8 | 499.1 70 5063 | 5135 | 5208 | 528.0 | 535.2 | 5425 549.7 | 5569 | 564.2 | 571.4 80 578.6 | 685.9 | 693.1 | 600.3 | 607.6 | 6148 | 622.0 | 629.3 | 6365 | 643.7 90 851.0 | 658.2 | 685.4 | 6727 | 6799 | 687.1 | 694.4 | 701.6 | 7088 | 716.1 100 | 7233) 7305 | 737.8 | 7450 | 7522 | 7598 | 766.7 | 7739 | 7812 | 788.4 110 | 7986 | 8029 | 810.1 | 8173 | 8246 | 8318 | 839.0 | 8463 | 9535 | 8607 120 | 968.0) 9752 | 882.4 | 999.7 | 9969 | 904.1) 911.4 9186 | 9258 | 939.1 130 | 9403 9475 | 9548 | 962.0 | 969.2 | 9765 | 9837 | 9909 | 9982 | 1005.4 140 | 1012.6 | 1019.9 | 1027.1 | 1034.3 | 1041.5 | 1048.8 | 1056.0 | 1063.2 | 10705 | 1077.7 150 | 1084.9 | 1092.2 | 1098.4 | 1106.6 | 1113.9 | 1121.1 | 1128.2 | 1135.6 | 1142.8 | 1150.0 ee qeo | 1187.3 | 1964.5 | 1177.7 | 1179.0 | 1186.2 | 1193.4 | 1200.7 | 1207.9 | 1215.1 | 1222.4 To | 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 | 1923.6 | 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FOREWORD CONVERSION TABLE kg/em? to tb/in? tiger? = 14.2233 Ibfin? 0 1 2 3 4 5 6 7 8 9 ° o | 142] 264] 427] 569] 71.1] 853] 996] 1138 | 128.0 10 1422 | 1565} 1707 | 1849] 1991 | 2134 | 2276 | 2418} 2560 | 270.2 20 284.5 | 298.7 | 3129 | 327.1 | 3414] 3856 | 3698 | 3e40| 3083 | 4125 30 426.7 | 440.9 | 455.1 | 469.4| 4836 | 497.8 | 5120] 5263 | 5405 | 564.7 40 563.9 | 583.2 | 597.4] 611.6 | 6258 | 640.1 | 6543 | 6685 | 6827 | 6969 50 711.2 | 725.4 | 7396 | 7538 | 7681 | 7823 7965 | 6107] 625.0 | 839.2 60 253.4 | 867.6 | 881.8 | 896.1 | 9103 | 9245 | 9387 | 9530 | 9672] 981.4 70 995.6 [1010 | 1024 | 1038 | 1053 | 1067 | 1081 | 1095 | 1109 | 1124 go | 13a }1152 | 66 [1181 | 1195 | 1209 | 1223. | 1287 | 1252 | 1266 go | 1280 | 1298 |1309 | 1923 | 1937 | 1351 | 1365 | 1380 | 1304 | 1408 woo | 1422 | 1437 | 1461 | 1465 [1479 | 1493 | 1608 | 1522 | 1536 | 1560 ro | 1665 }1579 | 1593 | 1607 | 1621 | 1636 | 1650 | 1664 | 1678 | 1693 120 |1707 J1721 | 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 160 [2134 |2148 [2162 | 2176 | 2190 | 2205 | 2219 | 2233 | 2247 | 2262 160 | 2276 | 2290 |2308 | 2318 | 2393 | 2347 | 2061 | 2375 | 2389 | 2408 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 | 2630 200 2845 2859 | 2873 | 2887 | 2901 | 2916 | 2030 | 2944 | 2058 | 2973 210 =| 2987 3001 | 3015 |3030 | 3044 [2058 | 3072 | 3085 [3101 | 3115 220 «3129/3143 | 3158 |3172 | 3186 |az00 |a214 | 3229 | azaa | 3257 230 |3271 3286 | 3300 |a314 | 3328 [3343 | 3357 | 3371 | 3385 | 3399 240 |3414 3428 | 3442 | 3456 | 3470 | 3485 | 3499 | 3513 | 3527 | 3542FOREWORD CONVERSION TABLE Temperatu Fahrennett-Centigrade Conversion : 8 simple way to convert a Fahrenheit temperatura reading into # Centigrade tempera ture reading or vice versa Is to enter the accompanying table In the center or boldface column ot figures. ‘These figures refer to the temperature in either Fahrenheit or Centigrade degrees IH it ie dosirad to convert from Fahrenheit to Centigrade degrees, consider the center column os a table of Fabenheit ‘temperatures and read the corresponding Centigrade temperatura in the column at the left. itis desired to convert trom Centigrade to Fahrenheit degrees, consider the center column a8 a table of Certigre and read the corresponding Fahrenheit temperatura on the righ. ve = 338 of ] | vc - c Es 404 | 40 | -4o0 | 7] 19 | 519 | 78) 48 | ta | 272] m | ive -a72 | a5 | ao | 11] 2 | sas] a3) 47 | 1166] 278 | o | 196 wat | a0 | 220 | -106 | 13 | 554] 89 | 48 | 1194 | 283 | 89 | 1014 -317 | 25 | -130 | -100 | 8 | 572] 94 | «9 | 1202 | 289 | o | 1232 -ve9 | 20 | -40 | -s4| 15 | 530 | 100) so | 1220 | 294 | a5 | 1850 -283 | 19 | 22 16 | sos | we] s1 | 1238 | 300 | a6 | 1068 -2718 | 18 | -04 w | ozs | a1 | sz | 1256 | 206 | 97 | 106 2712 | -7 14 w | sae | a7 | 53 | wre | sia | oa | 1904 -267 | ~16 32 19 | 662 | 122 | se | 1292 | 317] 9 | 1922 -261 | 45 50 zo | 030 | 18 | 55 | 1310 | 322] 90 | 1940 256 | 68 2 | saa | 133 | se | raze | 228] 9 | 1958 28.0 | 86 z | ne | is] s7 | 1306 | 333 | 92 | rr 244 | 104 zz | 734] ua] sa | 1364] a39 | 93 | 1994 -239 122 zm | 752] 180 | 59 | 1982 | 944 | 94 | 202 133 40 2 | 70 | 156] 6 | 1400 | 350 | 95 | 2030 -2e | 9 | 18 | -33| 26 | 738 | 161 | 6 | wis | 3558 | 96 | 2008 -222| @ | 6 | -28| 27 | soe | 167 | o2 | 436 | 361 | 97 | 2086 17 | 7 | 194 2 | gs | 172 | 63 | 454 | 367 | 98 | 2084 a1} 6 | 22 2 | 2] ie] ce 72 | 372 | 99 | 2102 -06 | 5 | 230 30 | 830 | 183 | 05 | v0 | 378 | 100 | 2120 -200 | +4 | ze | -o6 | a1 | ozs | 129 | 66 | 1508 | 405 | 105 | 2210 -94 | 3 | 26] 0 | 32 | 996 | 194 |) 67 | 1526] 433 | 110 | 2300 9 | 2 | 24] o6 | 33 | o14 | 200 68 | r844 | 461 | 115 | 2300 -103 | «+ | 32] 11 | 34 | 932 | 206 69 | 1562 | 489 | 120 | 2450 -78| 0 | 320] 17) 35 | 950 | 211 70 | 80 | 517 | 125 | 2570 -v2| 1 | x8 | 22/| 36 | 968 | 21.7 7m | 198 | see | 190 | 2500 -7 | 2 | 356] 28 | 37 | 936 | 222 7 | wre | 572 | 195 | 2750 ser] a | ara | 33 | a8 soos | 228 7a | 634 | 600 | 140 | 2000 -156 | 4 | 302] 39 39 | 1022 | 239 74 | 1652 | 627 | 45 | 2930 60] 5 | 40] 44 | 4 1040 | 239 75 | 1670 | 56 | 150 | 3020 -44a| 6 | as] so 4 se | 24 76 | 688 | 583 | 165 | 3110 39 | 7 | a6] 56 | 42 1076 | 250 77 | v6 | 711 | 10 | 3200 93] 8 | aes] 61 | 43 | 1094 | 256 78 | 1724 | 739 | 165 | 3290 -28 | 9 | 432 | 67 | a6 | 12] 261 79 | 1742 | 767 | 170 | 3380 -122| w | soo | 72| 4 | 130 | 267 go | 60 | 798 175 | 397.0622101 ENGINE OI GENERAL Specifications Engine performance curve. Woight t2b16 srancnnnne 01-002 seneenee 01-008 wnue 01-014 01-001 ®SPECIFICATIONS 622101 Engine model S60108-1 - 7 $ see Applicable machine 0578-1 waszos =| waga03 Number of eylindor - Bore x Stroke | mm 6-108 x 130 Total piston displacement eto) 7.18 (7,160) ing order - 1-5-3-6-2-4 Overall tength mm vara 332 vat | overau wiath mm |700 jexcluding fan) 48 824 = | Overall height mm | 1,483 (excluding fan} 1.420 1.420 3 | (excluding exnaust pipe) Overall height mm - - = Gincluging exhaust pipe) Flywhee! horsepower kwipm | $9:3/100 121/230 140/2,200 caPiepm) | (133/800) 1163/2;380) (187/2'200) iNew ‘Neti (Net) : | E | Maximum torque Nem/rom_ 618/1.400 647/1,600 804/1,500 2 tkgmirpm}| —(63.0/1,400) (66.0/1,600) (82.0/1,500) é Neo inet) wot) High idling speed rom | 2050-2150 | 2,560-2,610 | 2,450 - 2,550 Low idling speed rom | 800 ~ 850, 780 - 830 00 - 850 inimum fuel consumption ratio] kW:h 218 212 212 1 M ei pe . {giHPeh) (163) (158) 4158) Dry weight «9 820 730 730 Fuel Injection pump - BOSCH PES-AD type Governor BOSCH ASV centrifugal, all speed type Lubricating oil amount ll 26 31 31 (refill cepacity) 22) (28) (28) Goci 59 2 53 2 el (engine only: 13) | (engine only: 13) | (engine only: 13) DAV TEA ‘Alternator | eee 24V, 50 A 24, SOA Starting motor | 2s V, 7.5 KW 24 .V, 7.5 KW 24V, 7.5 KW av 150. x2 Batery SBN BANE | 2v wo ana | 12 180 an x2 Turbocharger GARRET TO4E type/SCHWITZER S28 type| SCHWITZER $28 type Air compressor - - - others | = = = "7: cold terrain sper 01-002 ®622101 $60108-1 Ganerotor ES15085 6 Generator for OFM 6-108 - 130 7.45 (7,150) 1-5-3-6-2-6 1407 800 vier ated yw! hersopower 193 (1519/1,500 (50 He) 134 (180)/1,800 (60 Hr) acinar fynhoa horsepower 128 (1719/1,500 (50 He) 12 (2043/1/800 (60 H2) (Net) max. 1,575 (50 Hz) max. 1/890 (60 H2) 700 ~ 800 2 (159) 790 BOSCH BOSCH PES-AD type RSV centrifugal, all speed type 25 (23.5) 58. (engine only: 13) 28,25 24V, 7.5 KW 12 120 Anx 2 GARRET TO4E type 01-003 @Engine model SA6D108-1 aE Saar aaa Applieable machine psoas Wasz0-3_|AUSTOFT in AUSTRAUA Number of cylinder ~ Bore x Stroke | mm 6-108 x 130 ‘Total piston displacement ta 7.45 (7,150) Firing order - 1-8-3-6-2-4 ‘Overall length mm 1523 1,348 1216 2 | Overall wieth mm 21 838 788 2 | Overall height mm 427 4423 19070 B | texcluding exhaust pipe) 6 Overall height mm - - - {inehiding exhaust pipe) Flywheel horsepower ewiepm 754/1,950 162/220 17972,400 (HPicpm) | (207/2,980) 4217/2,200) (24072,400) (Net (New) (Gross) g © | Maximum torque Nevrpm | 814/1,500 847/1.500 785/1,500 5 tkgmirpm)) —183.0/1,600) (86.4/1,500 (60.0/1,600) : iNet) net) (Gross) High idling speed rom 2115-2236 | 2,426-2,56 | 2,560 - 2,640 Low idling speed tem 700 ~ 750 700 - 750 350 ~ 1.050 i sh 197 204 206 Minimum tual consumption ratio | mipery | an ath a, Dry woight ko | 700 790 610 Fuel injection pump DENSO NB (EP-9) typ Governor DENSO RSV centrifugal, all speed typ2 Lubricating oil amount i 28 31 28 (refill capacity) (25) (2) (25) octane amount ‘ 7 [engine ony: 14) | (engine ony: 13 Alternator 24,25 24, 25A 24 V, 508 Starting motor 24V, 7.5 KW 24 V, 75 kW 24V, 75 KW Battery 12V 180 Anx2 | 12V 150Ahx2 | 12V 120Ahx2 Turbocharger GARRET TO4E type] GARRET TOME Ps, IGARRET TOME typo Air compressor Others Aftercooler (with west goto valved Aftercooler Aftercooler 01-004 622101622101 SA6D108-1 gar cava harvester Generator Generator iEepine No sz?aeduol |e ALGERIA DENYO DCA199 | SABDIOE-M-1 6-108 130 7.15 (7,150) 5-3-6-2-4 1216 1507 71507 11738 788 828 a27 640 1.070 1267 1210 944.6 180/2,500 Long time rated | Rated flywhee! | Maximum flywheet (24172,500) | flywheel horsepower | __ horsepower horsopower Gross) 30/1,500 (136 (te2¥/1.500 (0 Has] 308/2,700, (182/1;500) | 162 (217V71,800 (60 Ha}—_—(42072.700) (Net) (Net! (Gross) Normal flywhest | Maximum flywheel horsepower horsepower 824/1,600 450/1,500 {150 (2010/1500 (50 Ha) - (84.0/1,500 (20v1;500) | 178 (23997200 (60 Ha) (Gross) (Net) (Net) [rac 1280 (ates, 50 ea 2,100 = 2,750 max 1575 [tar peso med 507] 2-970 3.020 950 - 1,080 700 - 800 750 700 - 750 206 215 210 (155) (50 He) : (151) 4160) 212 (158) (60 Hz)__| (Supplied by A..E.) 610 835 836 7 DENSO NB (EP-3) type DENSO ASY centrifugal, all speed type 2 25 28 2 (25) 23) (22) 78 59 (ongine only: 13) | (engine ony: 13) | (engine only: 14) 7 24 V, 504 2V, BA 2AV, 139A 24.7.5 kW 24.7.5 kW 24V, 7.5 KW Supplied by A.0.E.. wv ioAnx2 | 12v10Anx2 | 12V 120Ahx2 GARRET TO4E type GARRET TOSE type GARRET TOSE type Attercooler Aftercooler Aftercooler Aftercooler 01-005 aENGINE PERFORMANCE CURVE ‘$6D108-1 (0578-18) Flywheel horsepower : 99 KW (133 HPY/1,900 rpm Moe torQu 618 Nm (63 1gm/.400 rpm 0 [re [tonsa | so bee so 500 S t rar - o be wl | so soo] 7 = wt | uo | w v0 |_| 2 604 807 40. + 6 60 40: \ « re 0 O88 a8 He Ta TREE Tao Tae Tas Fase Fea cn thn. saaeayant reso 01-006 _ 22101‘$6D108-1 (WA320-3) Flywheel horsepower : 122 kW (163 HPY/2,380 rpm Max. torque. 647 Nm (68 kgm)/1,600 rpm a fi Toraue 79 7 800 1 — so fo so bow o ‘ woe 40 \ 30 F300 8 5 7 = 3 | ——+ 7 i350 150: ote 7 { £1004 754 100 4 | lds | = 50 \ vt | aot | ‘ | fot Sieh 01-007 @‘$6D108-1 (WA380-3) Flywheel horsepower 140 KW (187 HPY/2,200 rom Max. torque +: 840 Nm (82 kgm)/1,500 rpm fous 5 2 ra } ae 700 MTT | 30 F300 ia te | \ 5 + 190} 75 ovteut 1s 0 mi CH 0 0 «0 Bog acd F000 1260 1400 F600 Taco f00D 2200 2400 2600 25 os xy rq 87 | \ 0 o 150° 150 ad | 128; 125° Engine soned (ron) oe00138 01-008 ® 622101622101 ‘s6D108. outeut Flywheel horsepower : 162 KW (204 HP)/1,800 rpm (60 He} 128 KW (171 HPY/1,500 rpm (60 H2) He 250 200. 150. 100: 50: 150. 100 50 {EG150BS-5) Emergency Normal 134 KW (180 HP)/1,800 rpm (60 Hz) 193 KW (151 HP)/1,500 rpm (50 He) ken 80 ; \ \ 7 \ \ \ 7 \ LE \\ se \\ [I \ « \ il \ \ 0 1400 1800 iT 1700 1600 We Engine soeed (ram 0 0 50 1900 900 800 100 Torave 500 500 oE00107, 01-009 @‘SA6D108-1 (PC300-5) Flywheel horsepower Max. torque outout 1-010 ® ae 200: 180: 160. 140. 120; 100: 80 60 40 Fa sew 160 140 120) 100 20) * © ao Ps 220 200. 180) 1164 KW (207 HPI/1,950 rpm £814 Nm (83 kgm)/1.500 rom 150: 140. 120, \ Ti 100: 20. 50, 40 20 600 300 To0d 1200 1490 1800 Engine seed (ron) tect 7000 ®200 80 10 50 50 Ne 700 600 Terave 500 ToE00108 622101‘SA6D108-1 (WA420-3) Flywheel horsepower : 162 KW (217 HPY/2,200 «pm Max. torque 1 847 Nm (86.4 kgm)/1,500 rpm |__ a fe00 | | so feo co ooo so fe00 = | ao 400 =,i,2 30 300 vs 5 205 20 F200 2007 1501 p99 4 to fi09 5 175- 5 vos 78 o be 180 160 3 00+ = 125- 125) + v0] 754100 | 15: 16- a - so. 50 50 25 | 2s 5 y9) -0—$00 Gee ToGe 1200 1400 Ta60Ta0d 7900 F200 480 THO Enoing sroed (ron) weeoice 01-011 @SA6D108-1 (For Egypt EIM: Power unit) Flywheel horsepower : 119 KW (160 HP)/1,500 rpm Max. torque 706 Nm (72 kgini/,200 rpm 860 500 200 200 1604 120 140 ° ~ 00 S 0 80 100 07 00 eo “0 “o 20 “| rn) 00 1000) 1200 1400 1600 Enoine speed (rom) soeopiee 01-012 @ Toraue 22101622101 SA6D108-1 [Sugar cane harvester AUSTOFT in AUSTRALIA (Engine No. 10001 ~ 10296)] Flywheel horsepower : 179 KW (240 HP1/2,400 rpm Maximum, torque: 785 Nm (80.0 kgm}/1,600 cpm | fe Poraue so FO? | >t i ta fre Ly fe ale “ 200, ae 250 200] 1504 sop 2 | S50 ine | Z _| = fw & 100 100, % oy oo a TT Envine speed (ron! asi 01-012-1 @®SA6D108-1 [Sugar cane harvester AUSTOFT in AUSTRALIA (Engi Flywheel horsepower : 180 kW {241 HPY/2,400 rpm Maximum. torque horeeeower Flywheel 01-012-2 ® HP 260 200 160 00 80 kw 200 se oo 5 Ps £824 Nm (84,0 kgm}/1,600 rpm 20 200 150 too 60 1200 14090 W60C 1.800 2000 2.260 2400 2600 2809 Engine seeed (ren) No, 10297 and up)] fen 90 ao 70 80 50 40 00 800 700 500 Toraue 500 400 eveei086 622101WEIGHT TABLE A. This woight table is a guide for use when transporting or handling components No. tem ‘Components 6D108-1 GARRET TOAE typo 99 1 | Turbocharger SCHWITZER S28 type 10 Aftercooler assembly - 2 - Intako manifold 142 3 | cytinder head assembly | Cylinder head, valve, rocker arm 3.0 4| Cylinder block assembly | Cviinder block, bearing cap, 187 valve spring 5 | Crankshaft assembly Crankshat, crankshaft gear 783 queer Camshaft, camshait gear, 6 | Comshaft assembly fear 80 7 7 | Timing gear case assembly 195 8 | of pan no 9 | Piston and connecting rod _| Piston, piston ring, piston win, 210 assembly connecting rod i 5751 625 10| Flywheel assembly Wa3z0-3, was80-3 323 EG1508S-5 1130 0878.1 59.5 11| Ftywneet housing was203, wasa0-3 3a EG1S0BS-5 465, 0575-1, EGIS0BS5 160 12| Fuel injection pump 180 10.8 13] Water pump was20:3, WASBO:3 24.0 24V,13.A 85 18) Alternator 24V, 25 8s 24V, 50 100 15] Starting motor 145 01-014 @® 622101Unit: kg $A80108-1 238 63.0 187 753 - 80 135 110 20 = Pc300-5 313 S x waaz0-3 298 Sugar cane harvester AUSTOFT in AUSTRALIA 270 Pc300-5 468 Watz0-3 595 ‘Sugar cane harvester AUSTOFT in AUSTRALIA 295 Pc300-5 160 Waz0-3 165 Pc300:5 10.4 Wasz0-3 165 28V, 13 a5 24,258 35 jt 24, 50. 10.0 145 01-015 @ €ENGINE Il STRUCTURE AND FUNCTION 22101 GENERAL STRUCTURE 1. 11-002 INTAKE AND EXHAUST SYSTEM After-cooler. 11-004 Air cleaner 11-005 Electronic dust indicator .. 11-008 ‘Turbocharger 11-007 ENGINE BODY Cylinder head .. See oOR Cylinder biock 11.010 Main revolving system... sovee WOIZ Timing gear 014 Valve system mou nes TONG Flywheal end flywheel housina.. 11-018 LUBRICATION SYSTEM Lubrication system chart 11-020 Oi! pump. - 14-021 Oil filter (buittin safety valve) « 11-022 Oil cooler 11-023 FUEL SYSTEM Fuel system chart 11-024 Fuel injection pump 11-026 Fuol injoction nozzle ~ 11-030 Fuel filter. o se 11-031 Fuel injection pump drive case. 11-032 Engine stop motor. - von 11-034 Fuol cut solenoid 11-038, COOLING SYSTEM Cooling system chart 11-040 Thermostat. 1-083 Woter pumB ncn . 211-044 ELECTRICAL SYSTEM Wiring diagram 11-085 AMOIMAIOF se nonnnrn senses O86 Starting motor. 11-050 Oil pressure switch.. 11-052 Rolay switch ses 19-082 Glow plug, - 11-083 11-901 2GENERAL STRUCTURE Note : This figure is of SA6D108—1 1 2 3456789 10 35: i 12 g O 33 1 j 16 - Ha 32 TC RA [ }—17 > Lu i : a9 te LI LI | 4 |-1s 31 80 28 29 27 26 25 24 23 22 21 20 19 ez2r01080 1. Fan 11. Cylinder head 21. Thrust bearing 2. Water pump 12, Cylinder block 22. Main bearing cap 38. Cylinder liner 13. Flywheel housing 23, Main bearing 4, Valve seat insort 14. Ring gear 24. Oil pan 5. Valve guide 15. Flywheo! 25. Connecting rod cap 6. Valve (exhaust) 16. Teppet 28. Connecting rod bearing 7. Rocker arm shaft 17, Cam bushing 27. Front plate 8. Valve Cintake) 18. Camshaft 28. Crankshaft gear 9. Cylinder head cover 19, Rear seal 29. Oil pump drive gear 10. Breather 20. Crankshaft 30, Front soal 11-002 ® 622101622101 32. 33. 34. 36. 36, 37. 38. 39. 40, 65 — 54 - 83 AN (© o) Br ; i t S r %, 50 ‘ = # ie 49 pte i 52 AS 438 ‘2 aT 31. Crankshaft pulley 41, Exhaust menifold 51 Front cover 42. Top ring 62. Cam gear 43. Second ring 53. Connecting rod 44, Oil ring 54, Piston pin 45. Oil level gauge 55. Nozzle holder 46. Starting motor Oil filler 47. Oil strainer Rocker arm 48, Oil pump Turbocharger 49. Feed pump Piston 50. Fuel injection pump 36 37 38 39 40 41 42 43 45 46 exro1002 Intake manifold Oil filter Fuel filter Fuel injection pipe After -cooler 11-003 ®INTAKE AND EXHAUST SYSTEM AFTER-COOLER (SA6D108-1) e22ror003 1. After -cooler covar 2. After -cooler core 3. Intake manifold 11-004 ® 62101622101 AIR CLEANER Current type (FHG) FTG type ‘6:97F009.10 1. Inlet 4. Primary element 7. Dust pan 2. Outlet 5. Safety element 8. Diffusion vane (sleeve) 3. Guide vane 6. Vacuator 9. Body ADVANTAGES STRUCTURE The diameter of the element is the same but the outside diameter of the body is smaller. The inlet is placed in the direction of con: nection, so ample centrifugal force can be obtained from a simple spiral guide vane, without using a diffusion vane. + There is no dust pan of diffusion vane, so the structure is simple, Air containing dust is sucked in from inlet (1) at a tangent, and the dust is separated by the centrifugal force of guide vane (3) More than 89.9% of the remaining dust is removed by primary element (4), and the cleaned air then passes through safety olo- ment (5) and outlet (2), and is sucked into the engine. The dust and moisture that is separated by the guide vane (3) rotates around the inside wall of body (9), and goes inside vacuator (6), where is discharged automatically to the outside, 11-005ELECTRONIC DUST INDICATOR Core Gail y Permanent magnet sanr01113 exon + Ifaircleaner (1) becomes clogged, the nega- Actuation pressure: 762158mm H:O0 tive pressure inside the intake passage (in- Power source voltage: DC24 '° (V) take pipe) increases, pushes the spring in side dust indicator sensor (2), and actuates the shaft. + This is changed into an electromagnetic in- duction current, which lights up the moni tor lamp, 11-006 622101622101 TURBOCHARGER (For D57S-1B, EG150BS-5, PC300-5, DCA180) 25 eaxomeepe Turbine impeller Piston ring Turbine housing Shroud Journal bearing Retaining ring Center housing Seal ring Thrust bearing Back plate Spring 12. Thrust collar FOSSA, Specifications of turbocharger 13, Blower impeller Type: GARRET CO. TOAE 14, Blower housing Overall! length: 225mm 15. Lock nut Overall width 210mm Overall height : 180mm A. Intake Weight = 6.5 kg B. Air supply Continuous speed : 125,000 rpm (max.) C. Exhaust(inlet port) Max. air supply: 22ka/min D. Exhaust (outlet port) Compression ratio: 3 (max.) E, Oil (inlet port) F. Oil (outlet port) Applicable exhaust temp. : Max.675%0(at inlet) Direction of rotation: Clockwise (es seen from blower side) 11-007 aTO4E (WITH WESTGATE 1, Blower impeller 2. Blower housing 3. Back plate 4. Center housing 5. Heat shroud 8 Turbine housing 7. Seal ring 8. Thrust bearing 9. Snap ring 10. Journal bearing 11. Seal ring 12. Shaft & turbine impettor A. Air inlet port B. Air outlet port C. Exhaust inlet port D. Exhaust outlet port E. Oil inlet port F. Ol outlat port 11-007-1 bi VALVE) (WA420-3) 7 a a 10 i he 6160" 10¢=1 ‘Turbocharger specifications Type: GARRETT TOME Overall length: 223 mm Overall width: 222 mm Overall height: 185 mm Weight: TOsB: 7 kg TOME: 10 kg Max, speed: 120,000 rpm Applicable exhaust temperature: Max. 700°C Direction of rotation: Clockwise (as seen from blower} 622101622101 earovi14 1, Retaining ring Set pressure of actuator 14, Nut, rod end 3035 2 25 mmHg (at 0.38 mm lift) 18, Rod 16. Actuator assembly (swing valve controller| 17. Hose 18 Rod end 11-007-2 3)Outline of Westgate valve + This valve acts to suppress any unnecessary charged air pressure in order to ensure a suitable charged air pressure (set charged air pressure) and thereby pre vent overload on tho engin + In order to do this, Westgate valve (1) Is installed in the exhaust passage before the turbine. When charged alr pressure (A) near the outlet port of the compres- sor rises and exceeds the set pressure of actuator (swing valve control] (2), Westgate valve (swing valve) (1) opens. + Point © where engine speed a and chargad air pres: sure b intersect, is the point where the Westgate valve starts t0 open. Charged air pressure (A) near the outlet port of the compressor passes through (B! and actuates actuator (2), Westgate valve (1) opens and part of the exhaust {gas bypasses the turbine, so the output of the turbine ‘drops and the set charged air pressura is maintainod. 11-007-3 From exhaust manifold 9 Shaw shrged To intoke varitold From ait leaner & Compr e2ocroce X: Before actuator ie operated ¥: Actuator operated CCherged air prossura = Engine speed ——= 2007907 High charged it pressure tot = To muffler 2208F968 622101622101 TURBOCHARGER SAFETY VALVE WaA4z20-3 f Mafiler Air cleaner \ ‘Attercooler exons Guide bushing Spring Valve Nut Valve seat Spring seat Casing Retainer Turbocharger safety vaive (with Westgate valve! Outline + In the sama way as with the Westgate valvo, safety valve (11) is Installed to the intake manifold to re- lease any excess charged air pressure \excess boost pressure) coming from the compressor. Cover ‘Actuating pressur Shaft 147 = 11 kPa (1100 » 80 mmHg) 6206970 11-007-4$2B (SCHWITZER) (For WA320, 380-3) 20 1 O-ring - O-ring Oil deflector . Thrust bearing . Thrust collar (spacer sleeve) Center housing Shroud (back plate) . Turbine housing Piston ring 10.Turbine impeller (whee! shaft) 11.Clip 12.Journal bearing 13.Thrust ring SE4oraens 11-007-5 “ay 14.Blower housing 1.Locknut 16.Biower impeller 17.Siinger sleeve 18.Piston ring 19.Insert, 20.Snap ring 4. cin enn) man anlen) &. Oi out Tova pat C, Intake inlet D. Intake outlet E. Exhaust inlet F. Exhaust outlet ‘Turbocharger ‘Type: Schwitzer $28 Overall length: 212 mm Overall width: 170 mm Overall height: 168 mm Weight: 7 kg Direction of rotation: Clockwise (as seen from blower end) 622101ENGINE BODY CYLINDER HEAD 11-008 SePngogaene Cylinder head mounting bolt Nozzle holder Rocker arm assembly Cylinder head Cylinder head gasket Head cover Valve guide Exhaust valve Valve seat insert Nozzle holder packing 12 13, 14, 18. 16. 17. 18, e22F01008 Fuel injection nozzle Oil filler cap Valve cotter Valve spring Valve spring seat Intake valve Push rod 622101622101 Cross section of exhaust valve (No. 1 cylinder) 14 16 18 Cross section of intake valve (No. 1 cylinder) Cylinder head Direct injection type, 2 valva, injection nozzle assembled, integrated type Valve seat Valve seat insert press fitted for both intake and ‘exhaust valves Fuel injection nozzle Type : Diesel Kiki, Multiple hole nozzle : Nippon Denso, Multiple hole nozzle Injection prossure (Cracking pressure} Ditfers according to machine mode! ‘See values in STANDARD VALUE TABLE. Pressure adjustment: Shim adjustment type ks1ec008 Ksro000sCYLINDER BLOCK SdL oo 82201061 Cylinder block Cylinder liner Main bearing cap bolt Main bearing cap Cam bushing 11-010 622101622101 exzro1082 11-011MAIN REVOLVING SYSTEM TOROIDAL COMBUSTION CHAMBER a22F01063 Piston 11. Crankshaft Top ring 12, Main bearing (upper) ‘Second ring 13, Main bearing (lower) Oil ring 14, Thrust bearing Snap ring Piston pin Connecting rod Oil pump drive gear (68 testh) Crankshaft gear (34 teeth) Conneecting rod bearing SeRNoMAwN= 11-012 622101622101 Piston + Aluminum alloy + Elliptical tapor profile, thermal flow type + Toroidal combustion chamber Front seal + Single lip with dust seal Rear seal + Double lip (PC300-5) (D57S-1B) (WA320, 380-3) (WA420-3) + Single lip type + Lay-down lip type Connection rod bolt + Screw-in type Piston cooling: Yes Crankshaft + Stamp forging + Induction hardening on journal portion and filet portion, sziFo1064 Piston ring Topring | Second ring | Oil ring Both faces: | Both faces: | With coil Keystone Keystone expander barrel face | tepar face Hard chrome | Hard chrome plating plating Single lip zr ‘SLEoCORO ‘SLeDoDa(RE-ENTRANT COMBUSTION CHAMBER) 1. Piston 2. Top ring 3, Second ring 4. Oil ring 5. Snap ring 6. Piston pin 7. Connecting rod 11-013-1 Tee ey Ae Hf LL | —— JT n 12 13 14 8. Oil pump drive gear (No. of teeth: 58) 9. Crankshaft gear (No. of teeth: 34) 10, Connecting rod bearing 11. Crankshaft 12, Main bearing (upper) 13. Main bearing (lower) 14, Thrust bearing 622101622101 CASE PISTON + Aluminium alloy (shaker cooling galley) + Conical taper profile, thermal flow type + Re-entrant combustion chamber + Pin offset (1.1 mm) Front seal + Single lip type with dust seal Rear seal + Single lip type + Lay-down seal lip type Connecting rod bolt + Sorew-in type Piston cooling: Provided ankshaft Closed die forging + High induction hardening of journal and fil let Piston ring Topring | Secondring | Oilring Keystone Keystone | With coil barrel face for |taper face for | expander both faces, hard chroma plating | both facos, hard chrome plating, inner cut Seals Single Coca | 2 11-013-2@ TIMING GEAR 11-01422101 A\B.C: Match marks for timing gears TIALVALVE SYSTEM 22101 sya wt 10. Thrust plate IOWA1oizza 11.017FLYWHEEL AND FLYWHEEL HOUSING $6D108-1 (For D57S-1B, WA320, 380-3) SA6D108-1 (WA420-3) Note: This figure is for S6D108-1. e22ror08s 1. Flywheel housing 2. Flywheel mounting bolt 3. Ring gear (134 teeth: For D57S-1B, WA420-3), (122 teeth: For WA320, 380-3) 4. Flywhoot 5. Crankshaft rear seat 6. Ball bearing |For D57S-18) 11-01822101 622F01070 11.010SAGD108-1 (For PC300-5) exon |. Flywheel housing Flywheel mounting bolt Ring gear (148 teeth) Rear seal Flywhool 17-019-1LUBRICATION SYSTEM LUBRICATION SYSTEM CHART ew! 16 5 W LUBRICATION SYSTEM. 1, Structure of Lubricating system + The lubricating system consists mainly of the oll strainer, ol! pump, oll pump regu- lator, oi! cooler oil filter and safety valve to lubricate various engine parts. 2, Circulation of lubricating oi! + The lube oil flows from the ail pan to the oil pump through the oil strainer where relatively large particles of dust, dirt, or, foreign matter is removed from the oil. The oil pump is driven by the gear in the crankshaft cluster to suck in and charge out the oil under pressure. sa aan Oil strainer Oil pump Oil cooler Oil filter Regulator valve Safety vaive Oil cooler safety valve Crankshaft Camshatt Piston Piston cooling nozzle Rocker arm Intake/exhaust valve Turbocharger Fuel injection pump Timing gear Cooling water 622101 + The oil discharged from the pump is cleaned fully through the oi! Iter (full-flow type). Thus, the oil is distributed to various lubri- cation points in the engine, + The oil is cooled, through heat exchanger with the engine cooling water at pices in tho oil bracket or in tho oil cooler._— 622101 OIL PUMP Regulator valve sxzroi014 Oil pump body Oil pump Drive gear (Steeth) Type: Pump cover Speed Pump drive gear (41 teeth) Drive shaft Driven gear (Stesth) Driven shaft Regulator valve Valve spring Valve retainer Gear pump Engine speed 1.415 Regulator valve * Cracking pressure : 8.5:0.5ka/cn* ©CPANMaRron= 3 From oil strainer From oil pump To engine To oi! pan pe 9OIL FILTER (Built-in safety valve) Handstand type s2aror018 Suspended type sizeFor7 i ee 1. Filter bracket 2 Cartridge 3. Safety valve A. From oil pump B. To engine Oil pressure tap Safety valve Actuating pressure : 0.2 = 0.02 mPa { 0.2 kg/om’) Oil filter 1. Filter bracket 2. Cartridge 3. Safety valve From oil pump To engine > Oil pressure pickup port Oil pressure switch device Safety valve ‘Actuation pressure: 0.2 = 0.02 MPa (2 = 0.2 kglem’) Oil filter Filtering area: 0.63 m? 622101622101 Dp OIL COOLER cw B © B 6 ra { : t a ®&O ei + 20\\9 a oO lo | “e t cH eB D a 1 2 3 4 5 Section A-A Setlen BB: Section C—C srrroror6 1, Valve case Oil cooler by-pass valve 2. valve spring 3. By-pass valve Actuating pressur: 42£0.2k9/ cnt 4, Cooler cover 5. Cooler element s From oil pump. Water drain port Structure and function + The oi! cooler consists of element ard cover. The oil flowing through the cooler element with the cooling fin is cooled properly by the engine cooling water flowing outside the element.FUEL SYSTEM FUEL SYSTEM CHART 1. Fuel tank 2. Feed pump 3. Fuel filter 4. Fuel injection pump 5. Fuel injection nozzle 4 6. Over-flow valve ks100027 GENERAL DESCRIPTION 1, Structure of fuel system + The fuel system consists mainly of the fuel tank, feed pump, fuel filter. fuel 2) Fuel entering the i Pressurized by the pump plunger to that required for injection and injected into Injection pump, fuel injection nozzles each cylinder through the injection nozzle and governor (built as. one unit with the in the quantity required, meeting the fusl injection pump). injection timing for the cylinder. 2, Circulation of fuel 1) Fuel is delivered from the fuel tank to the injection pump through the fuel filter by the feed pump driven by the fuel injection pump cam, During the course from the tank to the injection pump, the fuel is cleaned of rough dirt through the gauge filter at the inlet to the feed pump. Then, complete dust removal and water separation from the oi! are accomplished through the filter, wae 622101esFUEL INJECTION PUMP (WITH MECHANICAL GOVERNOR) ‘S6D108-1 (For D57S-1B, WA320, 380-3) 9. Fuel injection pipe (No. 6) Fuel injection pipe (No. 5) Fuel injection pipe (No. 4) Fuel injection pipe (No. 3) Fuol injection pipe (No. 2) Fuol injection pipe (No. 1) Fuel hose Injection pump gear Ball bearing 10. n 7201074 Drive shaft Fue! injection pump Fuel filter From fuel tank To fuel fiter To fuel injection pump To injection nozzle 622101— SPEED CONTROL LEVER ANGLE ating Full epood 622101 saaranii7 ezaro01s Fuel injection pump Type: Bosch PES-AD Lubrication method: Forced lubrication using engine oil Governor Type: Bosch RSV centrifugal type All-speed governor Fuol injection timing: Ditters according to machine modal Soe values in STANDARD VALUE TABLE.SA6D108-1 (For PC300-5, WA420-3) PPANATason> Fuel injection pipe(No.6) Fusl injection pipe(No.5) Fuel injection pipe (No.4) Fuel injection pipe(No.3) Fuel injection pipe (No.2) Fuel injection pipe(No.1) Fuel hose Injection pump gear Ball bearing 10, . Drive shaft 12, 13. Rotetion pick-up shaft Fuel injection pump Fuel filter ange s22ro1076 : From fuel tank (fuel) : To fuel filter (fuel) 2 To fuel injection pump fuel) 1 To injection nozzle (fuel) : From cylinder block (oil) 622101Tso @ , \ SS Na \6 e22r01or7 22101 INJECTION PUMP GOVERNOR LEVER ANGLE s22roi078 Fuel injection pump Type: Nippon Denso NB (EP-9) Lubrication method: Forced lubrication using engine oil Governor Type: Bosch RSV centrifugal type All-spead governor Fuel injection timing: Differs according to machine mode! ‘See values in STANDARD VALUE TABLE.FUEL INJECTION PUMP (WITH MECHANICAL GOVERNOR) (WITH BOOST COMPENSATOR DEVICE) Fuel injection pipe (No. 6) fuel eon abs Ne: 5 Ful inction pipe (Ne. 3) Fuel hose Fuel injection pipe (No. 2) Fuel injection pipe (No. 1) 10. Nn. 2. 13. 14, . Injection pump gear Ball bearing Speed pickup shaft Drive shaft Fuel injection pump. Air pipe Fuel filter ereage susonoes From fuel tank To fuel filter To fuel injection pump To injection nozzle From oylinder block To fuel injection pump (boost pressure) 1-029 ® 62210111-029-1 ® — SPEEDCONTROL LEVER ANGLE 2 ol 2 i Ro) \ a ~*~ \e fannie Fuel injection pump Governor Type: Bosch RSV centrifugal type All-speed governor Fuel injection timing: Differs according to machine model See values in STANDARD VALUE TABLE.11-029-2 @ BOOST COMPENSATOR DEVICE P@rnowaena Governor spring Floating lever Guide lever Tension lever Push rod Boost compensator spring Adjustment screw Diaphragm Boost compensator lever 10. " 12. 4 15, ouFi0@ Idling sub spring A. Air supply pressure (boost pressure) Angleich spring _B, Fuel increase direction Full load stopper Camshaft Flyweight Swivel lever Control rack . Start spring 622101Tt-O27-3 @FUEL INJECTION NOZZLE 1 2 PBrPaarye Nozzle spring Nozzle holder Push rod Retaining cap Nozzle body Nozzle From fuel injection pump To cylinder Cinjection) To fuel tank FUEL INJECTION NOZZLE «Maker : DIESEL KIKI (S6D108—1) : NIPPON DENSO (SA6D108—1) Type: Mult:hole type + Injection pressure : 235kg/cn? (S6D1 08-1) 2 265kq/ont (SABD108—1) %& Adjustment of injection pressure: by shim 2210111-030 ® 622101 FUEL FILTER 1 A» | is =e t nd NI 2 Vi i cD 1. Bracket FUEL FILTER 2. Cartridge + Filtration area : 0.5nr A. From food pump B. To injection pumpFUEL INJECTION PUMP DRIVE CASE gaep ZC ~\ 622101 ksccos2 ‘Snap ring Ball bearing Drive shaft Ball bearing Case11-032 ®ENGINE STOP MOTOR Shape of cable tip —(non-threaded stopper type), Shape of cable tip Stroke 4 *— (threaded stopper typey——~_ SectionA—A Made by AMP Co, Econoseal connector, 8Pmale | Strok 2. Not used (filler plug added) 1, Not used (filler plug added) 4B (AV 0.85LR) 3. Pr (AV O.85LY) 5, Not used (filer plug added) 7. A (AV 0.851) ©. Pr (AV 0.85LW) 8. E (AV 0.853) s210F 24 1. Motor assembly ENGINE STOP MOTOR 2. Cover + Maker: Jidosha Denki Kogyo Co. 3, Cable assembly Ltd 4. Cable clamp + Rated voltage De2av 5. Coil spring * Operating force: 15kg min. 6. Cable + Stroke: 36+ 1.0mm 7. Serew 7 8. Breather + Weight: 1.2kg 9, Bracket assembly 10. Cover assembly 6221011 1-934 622101 STRUCTURAL DRAWING (1) PNOMPeN> 522F01081 Gear cover assembly Slider assembly Armature shaft Contactor assembly Roller Worm wheel assembly Motor assembly Gear case assombly1 1.935 STRUCTURAL DRAWING (2) 622101 e2oror0e2 Gear cover assembly Motor assembly Cable clamp Cable assembly Gear case assembly gRON=11-036 o DESCRIPTION OF OPERATION AND CIRCUITS 1, Stop Condi 0" or 360° ) on Ibe ide ‘Auto-stop Position on Py side“ SESH auto-ston position on Ps sida 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 P) sida. ~ 2. When switch is turned (when starting the motor) When the switch is moved to the Pz side (starting The slider assembly starts to move in the switch ON), an electric current flows from the direction of the arrow at the same plus side contact plate through the P2 auto-stop as the roller starts to move, torminal and ewitch and into the armature shaft ascembly, thereby starting the motor. 3. Turning Condition (90° in the drawing) Electric current continues to pass through the slider assembly also continues to move armature assembly and the motor continues to in the direction of the arrow. turn, Because of the rotation of the roller, the11-037 4. When stopped (180° ) A closed circuit is formed when the P; a sudden stop. The slider assembly also stops. auto-stop terminal rides on the minus-side contactor plate, and the motor comes to 5. When switch is turned (when starting the motor) 22101 When the switch is moved to the P; side (starting The slider assembly sterts to move in the switch OFF), an electric current flows from the direction of the arrow at the same time plus contector plate through the P; auto-stop as the roller starts to move, terminal and switch and into the armature shaft assembly, theraby starting the motor. 6. Turning condition (270° in the drawing) Electric current continues to pass through the Then the circuit returns to stop condition 1. armature shaft essembly and the motor continues to turn. The slider assembly also continues to move in the direction of the arrow,11-038 © 622101 FUEL CUT SOLENOID A. Contact method (continuous when stopped) When tha engine is stopped, electricity passes through the solenoid and the solenoid plunger is pulled electrically. This moves @ rod, which moves the injection pump stop lever to the STOP position and cuts tha fuel to stop the en- gine. Therefore, this solenoid is only used when stop- ping the engine; during normal operations, it is inthe free position. When running the engine, no electricity passes through the solenoid. Tne solenoid has no magnetic force, so the solencid shaft is pulled back by the return spring. 1 2 e22F01080 Return spring Plunger1 1-939 COOLING SYSTEM COOLING SYSTEM CHART ‘$6D108-1 (D57S-1) + Inlet contro! thermostat L_—6 Radiator Thermostat Water pump Water temperature gauge Corrosion resistor Cylinder head Cylinder tiner Piston Cylinder block Oil cooler A. From oil pump (oil) 822101 s22Fot08s622101 ‘$6D108-1 (WA3Z0, 380-3, EG150BS-5) ‘SA6D108-1 (WA420-3) Outlet control thermostat 2 3 4 ia) a 10 Radiator A. From oil pump (oil) Thermostat Water pump Water temperature gauge Corrosion resistor Cylinder head Cylinder liner Piston Cylinder block Oi! cooler e22F01062SA6D108-1 (PC300-5) (AUSTOFT) + Inlet control thermostat 11 1 2 3 5 = 6 |—-7 8 a ho & = Le | 10 i A W Radiator 11. Oil coolar A. From oil pump (oil) . Thermostat Water pump Beenaason= Water temperature gauge After-cooler Corrosion resistor Cylinder head Cylinder liner Piston Cylinder block 041 @ 62210111-042 @ 622101 THERMOSTAT INLET CONTROL THERMOSTAT 1. Thermostat 2, Thermostat housing 1 a! Radiator _ b: Bypass (from cylinder head) a Water pump 2 Thermostet Cracking temperature: 71 + 2°C Full opan temperature: 85°C Fully open lift: 10 nm sxenono2 Outlet control thermostat (WA320, 380-3, WA420-3), (EG150BS-5) 1. Connector 2. Thermostat 3. Gasket 4. Thermostat housing To radiator To water pump From radiator app ‘Thermostat Cracking temperature: 76.5 = 2°C Full open temperature: 90°C Full open lift: 10 mm ererea-2a11-043 @ WATER PUMP Fan pulley Pump shaft Bearing Water seal Pump body Impeller Pump cover Engine Machine model Outside diameter of pulley (mm) exaro1t19 ez2Fo1120 S60108-1 Ds7S-18 '5A60108-7 Poa008 18 Engine Lock nut Pump shaft Oil seal . Ball bearing Fan pulley Pump body |. Water seal Impeller 1. Snap ring . Pump cover To en 22101 ———————— Machine model ‘Ouieiso diameter (xm) $60108-1 WAS203 Waa0.3 238 22611-044 ® > Sex epeene 2 2 sete | EG150855 195) 196F021-1 62210111-044-1 2ELECTRICAL SYSTEM WIRING DIAGRAM Relay switch Glow plug Starting 4 lswitch Tih Battery relay| relay Starting switch 2101 key pos Starting switch connections PREHEAT, OFF ON [Posi BBR Ri] Ra C START o PREHEAT, N. _ =< Automatic “automatic return e22F010951 1.045 EG 1608S-5 ge, AH os 01 pressure drop warning sich 3 | cio sa we 4 L RiNCF Yap wees] SON” a Si iA me 622101 Starting switch connostion chart Bontey 12V 1200%2 eatery switch = eee s22rori2sALTERI INATOR Sealed type Internal wiring disarm 8188F1928 1. Reguistor 2 Alternator 3. Alternator pulley Engine Machine Type Specifications Weight Pulley 0.0. $60108-1 D75S-1__|_ Nikko Denki, sealed ype | 28¥, 719A | 85kg 35 mm saspi08-1 | BaYpLETD | Nikko Denti, sealed ype | 24V,79A | 88kg 95 mm 62210111-046 @ (Regulator) ru Internal wiring diagram With built-in regulator (open type) e 7 1. Alternator 2. Alternator pulley 8, E, R: Terminals Engine Machine | Type Specifications | Weight Pulley 0.0. 36010841 | 0576-1 10P) | Nikko Denk Open bee | _24¥,25A | a5ta | 85mm SA6DI08-1 | _PCS00-5 | Nikko Denki, Open tye | 24, 25. 85 ko 88. mm11-047 2 With built-in regulator (open type) 1. Alternator 2. Alternator pulley ‘r06r66 622101 000 Internal wiring diagram s206Fes7 Engine Machine Type Specifications | Weight | Pulley OD. sepios-1 | eG1s0Bs-5 | Nikko Denki, Opontype | 24 V, 256A 65 kg 95 mm11-048 @ With built-in regutator (open type) t f / ‘cor teat 1. Alternator pulley 8, R, N, &: Terminals, 2, Alternator Engine Machine Type ‘Specifications | Weight | Pulley 0.D. WAS203 880108-1 wae DAV, 50A 10 kg 95 mm ‘SAGD108.1 | waar0-s | Sawafuji Denki, open type | 24 V, 50 A 10 ko 95 mm11-049 ® STARTING MOTOR Alternator R terminal -R, s Key switch “7 Iternal wiring diagram 622101 motor motor pinion B, R, S : Terminals Engine | Machine mode Type Specifications | Weight No. of pinion teeth Ds7SB : wa3203 | Fujisawa Denki, sealed tyne : ae ‘wWa3a0-3 (waterproot, oiiproof) | 24 75W | 14.5 kg a EG 1508-5 7 PC300-5 | Fujisawa Denki, sealed type SasD108-1 | was20-3 (waterproof, oilproof) | 24. 7-SW | 145 kg 211-050 > (AUSTOFT) 2 = 1 Alternator f i R terminal “<3 [] vs . Key ewiteh 8 Internal wiring diagram 1, Starting motor 2, Starting motor pinion as BRS: Terminals No. of Specifications | Weight | pinion teeth SAGD108—1 14.5ka 12 Sawafuji Denki, sealed type 24V, 7.5kW11-051 @ OIL PRESSURE SWITCH 1. Nipple 2. Switch 7 3. Connector OIL PRESSURE SWITCH + Operating point ON :0.15 *8-83 MPa (1.5 +293 kgiem’) (es +003 40.03 OFF :0.1 * 9:65 MPa (1.0 *3-03 kgiem’) on OFF Rew Aevon geri RELAY SWITCH RELAY SWITCH + Rated voltage : DC 24 V 22101 e22F0103011-052 @ — GLOW PLUG (METAL 2-WIRE TYPE GLOW PLUG) ‘ a ‘ (color marking! Rated voltage Toe 1. Heat generation coil (Fe-Crl 2. Control coil (Fe) 3. Body 4, Rated voltage color marking Name Standard type Self-control type ceramic glow plug - 2aV (Reo) | 2av rea) Quick glow type Metal 2-wire type glow plug11-053 @ENGINE 12 TESTING AND ADJUSTING INTAKE AND EXHAUST SYSTEM Adjusting vaive clearance 12-008 a ENGINE BODY Measuring compression pressure ui. 12-008 FUEL SYSTEM Testing and adjusting fuel injection timing wnmene 12005 Adjusting fuel cut solenoid link 12-008 Procedure for adjusting angine stop motor cable .. i 12.010 Adjusting engine speed sensor .. 12.012, 622101 PERFORMANCE TEST Run-in standard Performance test criteria TESTING AND ADJUSTING DATA Fue! injection purnp calibration data. Testing and adjusting tool ls Standard valve table ‘TROUBLESHOOTING ... 12.02112-001 > 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. When cartying out operations with two or more workers, always use signals, and do not allow any unauthorized person near the machine. A. When checking the water level, if the radiator cap is removed when the engine 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. 80 oxtromoly carctul not to get caught in the fan or any other rotating parts 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 * ‘When using the standard values table for judgament in testing , or troubleshooting, it is neces- sary 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 new machones and machines 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 judgement 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 together with the repair and operation history of the machine when judging failures. Do not use this standard values table as a standard for judging claims. 62210112.002 ® 62210) INTAKE AND EXHAUST SYSTEM ADJUSTING VALVE CLEARANCE Method of adjusting valve clearance 1. Remove cylinder head cover (1) 2. Rotate the crankshaft in normal direction to align pointer (4) with the 1-6 TOP mark on crankshaft pulley (3} When rotating, chack the movement of the Intake valve of No. 6 cylinder. 3. Adjust the clearance of the valves marked © in the valve arrangement table below. * Vaive arrangement table Cylinder No.| 1 | 2 | intake valve | |e) [el elo [Exhaust valvel oS 4, Next, rotate the crankshaft one turn in the normal direction and adjust the valve clear- ance of the remaining valves marked ‘%* To adjust the vaive clearance, loosen locknut (8) of adjustment screw (7), then insert feeler gauge 7 of the specified thickness between valve stem (6) and rocker arm (5), and adjust with the ad- justment screw to a tight fit. 5, Tighten the locknut to keep the adjustment screw in position. eeoorie Locknut : 44.1 + 4.9Nm (45 40.5 kgm) Firing order : 1-5-3-6-2-4 It is also possible to turn the crankshaft 120° each time and adjust the intake and exhaust valve clearance of each cylinder according to the firing order. * For details of the vaive clearance, see TEST. ING AND ADJUSTING, Standard Value Table. +12-003 ENGINE BODY MEASURING COMPRESSION PRESSURE Method of measuring compression pressure Aivinen measuring the compression pressure, be careful not to touch the exhauet mani fold or muffler, or to get caught In rotating parts. * Measure the comprossion pressure with the engine warmed up. (Oil temporature 40 - 60°C} 1. Adjust the valve clearance. * For details, see ADJUSTING VALVE CLEARANCE, 2. Remove the spill pipe, then disconnect the fuel injection tube. 3. Remove the nozzle holder assembly from each cylinder. Be careful not to let any dirt or dust get side. % When removing the nozzle holder as- sembly, replace the seat gasket. 4. Install the adapter (1) into the nozzle holder mount of the cylinder to be measured, and tighten to the specified torque. Gre=] Adapter :4.41 4 4.9 Nm (4.5 + 0.5 kgm) 5. Connect compression gauge A to the adapter. 6. Place the fuel control level in the NO INJEC: TION position. Crank the engine with the starting motor and measure the compres- sion pressure at the point where the gauge indicator remains steady. AAI the fue! control lever is not placed at the NOINJECTION position, fuel will spurt out. ‘* If the adapter mount is coated with a ‘small amount of oil, it will help to pre. vent leakage. %* For details of the standard values for the compression pressure, see TESTING AND ADJUSTING, Standard Value Ta- ble. 62210112-004 ® 622101 FUEL SYSTEM TESTING AND ADJUSTING FUEL INJECTION TIMING The following methods are used for testing and adjusting the fuel injection timing of the injec- tion pump. + Ifthe injection pump has not been repaired and it is reassembled to the same engine, use the match mark method. + If the injection pump has been repaired or replaced, use the delivery valve method when assembling the pump. * With the delivery valve method, it is nec- essary to replace the delivery valve cop- per gasket O-ring with a new part, so prepare a new part before starting the operation. 4 Set the No.1 cylinder at the compres sion top dead center befor carrying out testing and adjusting. For details, see ADJUSTING VALVE CLEARANCE. TESTING AND ADJUSTING INJECTION TIMING BY MATCH MARK METHOD 1, Rotate the crankshaft 30 - 40° in the reverse direction from the No.1 cylinder TOP posi- tion, 2. Rotate it slowly in the normal direction, and align pointer (2) with the fuel injection tim ing line on crankshaft pulley (1). 3. Check that line @ on the injection pump and line b on the injection pump drive case are aligned. 4 if the lines are not aligned, loosen nut (3) in the oblong hole and pump mount: ing nut (4), then move the fuel injection pump to align the line, and tighten the rut. Gorm Nut : 66.2 + 7.4. Nm (6.75 + 0.75 kam) TESTING AND ADJUSTING BY MATCH MARK METHOD (LAMINATED COUPLING TYPE) 1, Carry out Steps 1 and 2 above for the fiange type. 2. Check that ine fa) on the injection pump is aligned with the line on the coupling block (weight) % If tho lines aro not aligned, loosen the bolts of the front laminated and flange couplings, align the lines, then tighten the bolts. Goa= Bolt: 88.3 - 83.2 Nm (9.0 ~9.5 kam) Injection pump. flange Injecton pump drive case |G); Lt} 6100172 no @ a & I ‘coupling i rec0011712-005 ® TESTING AND ADJUSTING BY DELIVERY VALVE METHOD 1, Disconnect fuel injection tube (5) from the No.1 cylinder. 2. Remove delivery valve holder (7). 3, Take out spring (8) and delivery valve (9) from inside the delivery valve holder, then assemble the delivery valve holder again. 4, Set the fuel control lever at the FULL posi- tion, then operate the priming pump and rotate the crankshaft slowly in the normal direction, Check the point where the fuel stops flow- ing from the delivery valve halder 5. Check that the injection timing line of the crankshaft pulley (1) and the pointer (2) are aligned at the point where the fuel stops flowing, ‘* BEYOND injection timing line : Timing RETARTED. %* BEFOR injection timing line : Timing AD- VANCED ‘if the test shows that the injection tim- ing is incorrect, adjust the fuel injection timing as follows. After testing and adjusting, do not for- get to reassemble the spring and deliv- ery valve. 1) Rotate the crankshaft 30 - 40° in the re- verse direction from the No.1 cylinder TOP position. 2), Rotate it slowly in the normal direction, and align pointer (2) with the fuel injec- tion timing ling on crankshaft pulley (1). 3) Loosen nut (3) in the oblong hole in the mounting flange of the fuel injection pump, and pump mounting bolt (4), then ‘operate the priming pump and rotate the pump flange a littie at a time. Stop. at the point where the fuel stops flow- ing from the delivery valve holder. sere Injection pump flange Injection pump drive case 2210112-006 @ 4) Tighten the nut in the oblong hole in the mounting flange of the fuel injection pump, and the pump mounting bolt. Check the injection timing again to con- firm that the timing is correct. 5) Make match mark (a) and (b). 622101ADJUSTMENT FUEL CUT SOLENOID LINK Stop tho engine, connect solenoid (1) and injection pump (3) with rod (2), and assem. ble temporarily Pull the rod fully by hand to the solenoid end, and adjust the length of the rod so that there is a clearance of 0.5 - 1.0 mm between stop lever (4) and stopper (5) at the STOP end. Pass electricity through the solenoid and adjust the rod finally so that the clearance between the stop lever and the stopper at the STOP side is dimension a. % Dimension a: 0.5 - 1.0 mm Stop and start the engine 2 - 3 times, and check that the solenoid moves smoothly and works properly. If the movement is not smooth, adjust the linkage to improve the movement. + Problems caused by impropar adjustment of solenoid. 12.007 2 Injection pump STOP stoppor Problem: + Winen electricity is passing, clearance between stop lever and stopper at STOP side is 0 burns out. “Excessive current flows to solenoid, and solenoid coil + Injection pump governor is bent and causing scuftuing (Evcessive force is brought to bear on laver) + + When frae, clearance between stop lever and stopper at FULL sideistoo + Amount of fuel injected drops, 50 engine output drops. 2210112-008 @PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE 1. Temporarily install ball joint (3) to cable (2) of engine stop motor (1) (tighten fully, then tum back approx. 1/2 turns), then install @ ball joint to the stop lever of the fuel injec- tion pump. 2. Pull injection pump stop lever (4) by hand to the ENGINE STOP (NO INJECTION) posi- tion, and temporarily fix the cable to the bracket. When doing this, put stop lever (4) in con- tact with ENGINE STOP stopper (5), and tem- porarily fit the cable to the bracket using the holding nut. %* Engine stop motor (1) is delivered with cable (2) pulled (engine stop position). %* Stop lever (4) of the fuel injection pump is at the RUN position when the lever is free. (It is pulled to the RUN position by a spring.) 3. Adjust so that clearance a between stop le- ver (4) of the fuel injection pump and STOP stopper (5) is 1 - 2 mm. Carry out the adjustment with nut (6) hold- ing the cable to the bracket, or make fine adjustments by changing the amount that ball joint (2] is screwed in. = exes Pere eal 62210112-010 622101 @ Tighten all bolts and nuts. ‘Turn the engine starting switch ON and OFF repeatedly, and check that engine stop mo- tor (1) and the cable move smoothly. Then check the following points again. 1) When the engine is running, check visu ally that there is slack in cable (2) of engine stop motor cable (1), and that stop lever (4) of the fuel injection pump is fully returned to the RUN position. 2) Check again that the clearance between stop lever (4) and STOP stopper (5) is 7 2m When the engine is stopped. % Engine stop motor (1) has limit switches built in on both sides of the cable stroke % Engine stop motor stroke: 35mm Fuel injection pump stop lever stroke: 300m % When the engine is running, there is slack in cable (2) of engine stop motor (1), and the RUN position is maintained by the action of a spring (this is fre- quently built into the fuel injection pump). * There is a loose spring inside engine stop motor (1), and this absorbs the tol- erance of stop motor (1) when the en- absorbed by the loose spring of engine stop motor (1), force is applied to the injection pump, so de- pending on the model, this may be im- possible, With such models. if the clearance be- tween stop lever (4) and the STOP stop- per is mado 0 when the engine is stopped, there is a risk that problems may occur with the injection pump. +x Problems caused by defective adjustment of the engine stop motor cable. ~ When the clearance botwoon the stop lever| and STOP stoppar is excessive with the engine stop motor cable pulled + When the clearance |+ Fue! injection amount between the stop lever| drops, causing loss of and the RUN stopper | engine output power is excessive at the free| “Engine does nat stop12-011 @ ADJUSTING ENGINE SPEED SENSOR (MECHANICAL GOVERNOR) 1. Sctew in until tip of sensor (1) contacts ring gear (2). 2. After sensor (1) contacts gear (2), turn the gear back one turn. 3. Tighten with locknut (3). % Be careful to arrange the sensor wiring so that no excessive force is brought to bear on the wiring, ‘* Be careful not to scratch or get metal Particles on the tip of the sensor. 622101622101 12-012 ® PER RUNMING 1M IMANCE TEST STANDARD 4 Load ara given for the case of the dynamometer arm length is 716 mm. ‘This lst shows the standard on condition that the fan is removed. T ws wc Output kW CHP} {0} 20.0 (26.8) | $2.0 469.7} | 88.1 (118) | 131 (176) — ee ‘Output wep) 00) | 25.0 99.4) | 62:7 (way | 109 (rae | 159 (213) soe: Running time | min, | Engine speed | rpm Loea Nt) ‘output lew iH) Running eme | min Engine speed | rpm Load No) Output cn (HP Runaing time | mia, Engine speed | rpm Load \n a9? Output lew oF) ‘Running time | min. Engine speed | rpm Load | w deat Output hw 4212-013 @ Load ao gen forthe cate of ho dynamomotor am ength i 716 mm. 3% Thi shows the candor on contin tet the fa ie rmoved. Sells ne oe ve # 2 a 4 5 6 Tngian ep eT : | éngine seed | wm | 700 | 1220 | rs | a700 | 1980 reso tora [wer] 01 | za5 ene | 0 enor | ere ten |r.00 cry oun —_aveie] 01) [aso 001|e75,0605| roe ten | 188219 Ranenatne | cam) ee Engine seed | mm | 160 | rae0 | sats | tse0 | 2200 waszos eae N49] 010) | 288 609 | 520.630 | 775 70.0 | 100 (08) ouput weir] 0) | as0.5381|er0@56| rs ci6a | 170 220 cigwaam [Moegtne| wm] e | | we | ow |e |e ae ee ne ee eee AUSTRALIA| ood [aia] 01m | as0-e00n| ore con | a2 ons) | ox7 coos | ves 0a soeot “sees Output Jew ¢HP} 0 (0) 44.0 (69.2) | 86.0 (116) | 113 (151) | 149 (192) | 177 {2374 s Sugarcane |Forning time | min | & 0 10 8 6 5 s RETERT in| Ervine soced | rom | 750 | 1200 | 1400 | 1900 | 2180 | 2400 § AUSTRALIA| ows |vaah] 010) | are en | cen on. | veu cra) | obo. | os 07.9 [ RE? ca ‘Output, |KWIMP) 0 {0} 45.0 (60.0} | 68.0 {116} | 115 (154) | 145 (194) | 179 {240 sao | nomemel aa 2 |? | ws Senarmor |Engine speed | rom | 160 | tao | samo | yeu | 1400 EG1858--1 Engine speed) tr st al WorALGERA| Lond vat] 01 | st3 eso | es 70.09 | 00018 | 1.3704 uot _hwwoin] 0 | 2903005] 300.6000) s27 470) | 105 240 Running ine | win amie | wi eave | ts Sener | engine seed | op Scare Load N (kg) Output |kWy {HE} | Runring ine Racinrmped | om saeorsean a - el « - tore —— [wai] ithe patormance aca ong inp huv resin ioe | sav ceed | ai toss oui _avor12-013-1 ®PERFORANCE TEST CRITERIA # The values in the table are the standard values for machines with the muffler installed, alr cleaner installed, cleaner installed, alternator under no load, and air compressor opened (if installed). * The load for the dynamometer are at an arm's length of 718 mm 2 864-1059 (101 — 108) 60 He) 1490 ~ 1,180 (181 - 120 to Hen 5010 1,000 703-108) 00 Hed 190 = 120 (198 = 122 0 re) Engine | Applicable Engine speed] Dynamometer model machine Tart item, Specified value Irpm) AN tka) Fiywhesl horsepower | 993 KW (13S HPY1800 rom | 1686-1805 | _735— 760 ‘Net ea 795) | Maximum torque | 818m 3.0 4g7m1,400 rpm | 1200-11600 | 995-036 PSTey: (Not) (90.2 - 95.5) Hioh iting specs 2,050 2,150 pm 2080 ~ 2,180 - Low iaiag speed 800 — B80 rpm 800 ~ 860 - | Fivwneo hewsepower | 121 KW (63 HP12.380 rpm | 2976-20806 | TOI —7ay ‘not 1578.81 Maximum torque 647 Nm {66.0 kgm}/1,600 rpm | 1,500 ~ 1,700 896 - 978 WARIS (Neth {91.6 ~ $9.7) High iting soeed 2880 - 2.610 mm 2.860 = 2,810 - Low iting speed 780 - 690 rpm 700 - 890 s Fliwheo! horsepower | 140 RW (137 HPV2.200 wpm | 2195-2208 | a00-911 inet r= 329) Maximum toque | 806 Nem (82.0 kam.800 rpm | 400-800 | 1.100 —1,180 wase0-9 ino) ina — tao | High idling speed 2,450 - 2.550 rpm 2,450 - 2,550, - Low icing speed 800 ~ 850 rpm ‘00-860 - Rated ero HP 11,500 rpm (50 H2)|1,495 ~ 7,505 (60 Hab, 7 feet horsepower |134 KW {180 HPY300 fp (60 Fa 9 —ae DF) ‘at | anerator | Maximum 1281 (171 HPV" 00 rpm (60 Ha)]1495—nocs He) ESiSOBS's | Hywnoe! oreeponer | 162 kW i204 HPY/00 fp (60 F199 ate a 300108: ‘te | Senerator foroem High iting soeed | max. 1575 1pm (Raced. 50 Hs) mo vasiestil tas 1890 rpm (Rated 0 Ha) ox 130 3 : Low idling enced 100 ~ 800 rom 700 - 200 “ Flirmheel horsepower | Maximum torque High idling spead | Low iting spece Fivatieel horsepower | Moximum torque High ioting speed Low idling opoee Fiywheel horsepower Maximum torque High ieling epeed Low idling speed 622101622101 12-014 Q 4 For fuel, use ASTM D975 No. 1 oF No. 2. + For lubricant, use SAETEW.-40 or SAE3O oil 3 12 - 119 (149 ~ 160) 150 Ha) 196 — 143 (182 ~ 192) [60 Ha) “4 327 ~ 134.170 ~ 179) (80 He) 153 — 162 (205 - 217) (60 Had ie Mpa Fiywnee! horsepower] Torque _ [Fuel consumption] ye ocrarire | Lubsesting ot || tubrieatng of tev HPD) com tkgmy) | Tseed200c0) REERU | smporature CO] ude Teateme) 105 — 177 (Grose) : minasa | 70-90 | 90-110 03-05 (at 143 80-50) - 60-671 (Gross . yo-90 | 90-110 03-05 (46 - 684) 0-50) x . 93-08 . x 2 = ro-30 | so-10 | 93-98, ~ = 23 ro-90 | 90-110 {minora tmin 12) Z 125 ~ 132 (Gross) : min. 200 70-90 | sp-110 03-08 max. 600 ‘G68 201) 0250) im est - 100 arcs - yo-90 | 90-110 “ (eau 7) 2s = = yo-90 | 90-110 - - z e = 70-90 | min. _|min 0.12 fin 12) : 142 — 160 (Grose) = min.aa | 70-90 | 90-110 03-05 max. 600 190 ~ 202) 30-50, 7 41-700 (Gree : yo-90 | 90-110 ~ mex, 670 feet ra 2 - - | r-90 | 90-110 - - : - - 70-90 | _min.80 _|min. 012 tin 12 - “3 — [min 23216080) a0-90 | 90-110 |os-o8 (30-0) max e70 > [mins fas led Ha}| 2-80 | S02 110 |as-a8G0-50) max e70 “ 7 so-so | 90-110 os-o5 0-50] max 700, 80-80 | 0-110 [o3-08(0-s0] max 700 | » ss ‘ so-so | so-10 jos-o5 (30-50) 7 : - so-so | S0-110 [o3-05G0-s0 7 - - so-so | 0-110 [min 0-2 min 121 x12-015 4% The values in the table are the standard values for machines with the muffler installed, air cleaner installed, air cleaner installed, alternator under no load, and air compressor opened {if installed), ‘* The load for the dynamometer are at an arm's lenath of 716 mm. 5 “6 1,200 - 1,280 (122 ~ 190) 180 Ha) 1,320 - 1,400 (135 ~ 143) (50 He) 1.200 = 1/280 (122 - 130) @0 Ha) 1320 ~ 1,390 {135 - 142) (60 Ha) Engine | Applicable P i Engine speed | Dynamometer model | machine Test item ‘Srecied value (cpm) UN tg) Flywheel horsepower | 154 KW (207 HPi/1.950 rom | 1.985~ 1,955 | 7,080- 1,170 (wet) ino7 — 113) Pca00-5 Maximum torque 814. Nm (83.0 kgmi/600 pm | 1,400 1,800 | 1,090 ~ 1,140 pedootibs | Wet) in0= 117) cs High idling speed 2,15 ~ 2.235 rpm 2115 - 2.235 - Low Idling epee 700 - 750 rpm 700 - 750 - Flywheel horsepower | 162 kW (217 HPY2,200 rpm | 2195 -2,208 | 971 - 1,070, Wed) (98.0 - 109), Maximum toraue {847 Nm (86.6 kgmi/1.500 pm | 1,400 1,800 | 1,170 - 1,280 wasz0-3 (weo) {120 123) High idling speed 2,425 - 2.525 rpm 2.4085 - 2,525 - Low idling soved 700 - 780 rom 700 ~ 750 « Flywheel horsepomer | 178 kW/ (240 HPY2.400 rpm | 2.995-2405 | 946 - 1,040 (New (96.4 107), Maximum torque 784 Nem {80.0 kgmy/,600 rpm | 1,800 1,700 | 1,040 - 1,180 (Net) (06-147) (Engine No, High idling speed 2,580 ~ 2,640 rpm 2860 - 2,640 - 10001 ~ 10926) Low idling speed 860 - 1,050 rpm 960 - 1,050 - Flywneet horsepower | 160 Ki (247 HPY2,500 rpm | 2495-2,605 | 905-904 Sowers | (Net) (95.4 ~ 100), AUSTOFT in| Maximum torque 824 Nm {84.0 kamy/1,600 rpm | 1,800- 1,700 | 1,200 - 1,210 AUSTRALIA (Net) ina 13) 3A60108-1 | (Engine Nia. ing epee 2,780 rpm 7 - eaare Noy | High iating speed 2,100 ~ 2,750 ep 2,700 - 2,760 Low idling speed 350 ~ 1.950 rpm 950 - 7,050 z Long time 136 kW (182 HPY1.500 ypm | 1495-1605 | 1,200 1,280 fiymheel horsenower (Net i122 130), 180 kW (201 HP},500 rpm | 1498-1605 | 1,920- 1,490 1 horsapow Net! (135 - 133) (for ALGERIA) ling speed mae. 1575 ¢pm - Low idling speed 7100 - 750 rpm - Rated 196 ki (182 HPY/,600 cpr (50 Hz] 495 1.50 0H flywheel horsepower |1E2 KW {217 HPY 800 ram (60 H:)/1795- 05 (60H Maximum 150 KW (201 HPY/.500 rpm (60 He) |1495 1505 (80 Hl] 6 Generator flywheel horsepower | 178 KW (289 HPY//8C0 rpm (60 Hs)|1.795 — 1806 €0 Hl] DENYO OcatEo (Net) High idling speed | max. 1.875 cpm (Rated, 50 Ha). [mo 1575 Aaa 5 - ‘max. 1.870 pm (Rated, 60 Ha) |rax 180 fad, 6H - Low idling speed 700 ~ 800 rpm | = Maximum horsepower | 309 KW (420 HPI/2,700 rpm [sas cise SABD108-M-1 High idting spec 2.920 - 3,120 rpm 2,920 - 3,120 = Low ialing speed 1100 - 750 rpm 700 - 750 - 622101