AKSA Series Engines

Operation & Maintenance Manual

 Foreword
The AKSA series diesel engines are new high power engines which being
manufactured by Diesel Engine Ltd.Co. is developed with introduced and absorbed
advanced technologies both at home and abroad. The engines have compact
structures, high reliability, advanced technical characteristics, good starting
performance, easy operation and maintenance, well economics. It meets the
requirements of GB/T 1147-1987 Genera Technical Requirements of Internal
Combustion Engine.

AKSA series engines are suitable for loaders, bulldozers, excavators, cranes and etc.
Construction machineries and small size power generators, heavy trucks, it will meet
the different customers requirements in a wide ranges.

Continuing improvement and advancement of product might have caused changes to

the engine specification, structure, adapted accessories, etc. in this manual, those will
be republished this operation and maintenance manual in next edition. Pay attention to
some contents in this manual will be a little different from the engine that you owned.

This manual will not be a Quality warranty certificate to the engine, so all the date,
illustrated figures and explanations will not be based to the customer claim.

All right reserved. No part of this manual covered by the copyright hereon may be
reproduced or copied without written permission of AKSA Diesel Engine Ltd.Co.

Whenever a question arises regarding the engine, please consult any AKSA dealer for
the latest information.
Chapter I Brief Introduction
1.1 Safety Precautions and Warning
1.1.1 Before Usage
The product that you selected are conformed with the Chinese safety standards.
It will be well worth to read this manual from cover to cover prior to putting the engine
into operation. It covers important information about engine installation, use and safety
instruction.
If you not obeyed above instruction, when engine have some faults, the
manufacturer will not take any responsibility.
According to the instruction of this manual to run in the engine, use the engine and
maintenance the engine.
Not over load the engine, idle the engine not over 10 minutes.
Lubricant for the turbocharger engine should be CD grade oil or its Equivalent, when
change the oil, should not mix the new with the old one or other grade oil. In order to
avoid reduce quality dont mixed the different brands oils.
After running in, please flush the oil sump, oil elements with clean kerosene and
change the engine oil.
Running the engine without air cleaner is prohibited, air with dust will cause the
engine early wearing, result abnormal working.
Electrical circuit lines should be right and firmly connected. When alternator working,
taking down the lines are prohibited.

1.1.2 During usage

When Engine running, the operator should not close up the running parts and
teardown any parts. When Checking and adjusting the engine, should take special
cares and pay attention to the safety.
Intake pipes connectors should be checked regularly (including the pipe connecting
the turbocharger and intercooler) to avoid t power loss and abnormal parts wear.
Teardown the turbocharger with exhausting valve and support are prohibited. It will
cause the changes of working load and effect machine life.
When engine working, to avoid high temperature injure from your body, should not
touch turbocharger, exhaust pipe, muffler and radiator.
There are 20 kPa pressure in the radiator. Pay attention to the safety when adding
the coolant to the radiator. To avoid hot injure please wait the coolant temperature
lower down to 50 after engine stop.
When finding oil pressure too low or without pressure, coolant temperature too high,
crankcase having abnormal noises, stop the engine and find the causes, remove the
failures.
Keep away flame from the engine. Exhaust gas has very high temperature, installed
spark extinguish device to the muffler, if engine located nearby the flame-able
materials.
When the engine running away, cut off the fuel supply pipe or block up the intake
pipe immediately.

1.1.3 After usage

Before stopping the engine, lower the load and speed until coolant temperature
under 70. Stopping the engine is prohibited when coolant in high temperature.
If the engine need to store for a long period at the temperature below 0 ,to avoid
damage the engine, water in the cooling system should be discharged and antifreeze
should be added according to the working condition.
1.1.4 Fault appearance
Not allowed to clean the radiator and intercooler with corrosive detergent, it will
cause the engine serious damage.
All the seals on the injection pump will not allowed to remove and adjust. When have
some failures, please contact the local service centres or dealers.
Without allowed by the authority of special service centers by the manufacturer,
unload and maintain the engine by the customer is prohibited within the warranty
period.
1.2 General Description of Engine Models
For the better of production management and operation, the manufacturer classify the
model and type according to the main structures, operation purpose and
characteristics. According to the Chinese Standards, the model of diesel engine
consists of several digitals and Bopomofo. The meanings of the AKSA series engine
models are as follows:

Diesel Engine Ltd.Co. Engine Series symbol.

Cylinder No.

Cylinder diameter symbols, use A,B,C to indicate different cylinder diameters. A is

special use for 126 mm model engine, it may be omitted.

Configuration symbol, T for Turbocharged, TA for Turbocharged and Aftercooled with

air, TW for Turbocharged and Aftercooled with water.

Rated output power, kW, it may be omitted.

Matched Type

CMarine , QAutomobile GConstruction machinery

TAgricultural machinery, DGenerator
Version No.

Matched manufacturer No.

For example:
3 Transportation/Installation/Resuming engine operation
AKSA series engines are multi-purposes, can be used for moving, fixing machinery.
The structure of engine is more compact, when moving the engine, the hole holders
which fixed in front and rear of cylinder head should be used properly. Pay attention to
not touch the fuel pipes, accessories and outside parts of engine.

The engine should be firmly connected with adapted machine. For Moving
machineries, such as Mobiles, instruction machine and harvester, four-points (there
are each of two points on the cover of flywheel and engine block connect with the
adapt machine) or three-points (there are two points on the cover of flywheel and one
point on the engine block connect with adapt machine) connecting methods are
recommended. For fixing machinery should keep the engine on the horizontal base
level except firmly connected. To avoid vibration, the damping adaptor should be
installed.

For the new engine is seal packed before shipping, please check it with the purchase
contract. Clean the dust and oil on the outside of engine, and check all the accessories
(include fuel pipes) and the all the connect parts, crank the engine several revolutions
by hand to make sure the engine is in good condition.
Chapter 2 Engine Usage and Precautions
2.1 First usage

1. Read the operation and maintenance manual carefully before running, performing
and maintenance on the engine.
2. For the transportation safety, the engine oil has been drained out before ex-factory,
so fill the engine oil into the oil crankcase, injection pump before usage.
CAUTION
Before using turbocharger, add a little bit oil into the inlet of turbocharger, turn the
impeller several revolutions.
3. During the operation, never run the engine at idle speed more than 10 minutes and
turn the governor controller to full open position and work at over load.
4. Without permission of the manufacturer or special service center, all the seal parts
on the injection pump will be not allowed the customer to remove and adjust. The
electrical circuit lines should be right and firmly connected. When alternator or starter
working, taking down the lines are prohibited.
5. Running the engine with failures is prohibited. When engine works without oil
pressure or low oil pressure, high coolant temperature, some leakages in the inlet
system, abnormal noise in the engine, it is better to stop the engine immediately and
find causes. Without allowed by the authority of special service center by the
manufacturer, unload and maintain the engine by the customer is prohibited within the
warrant period.
6. When engine running, to checking and adjusting the engine should take special
cares and pay attention to the safety. Closing up the running parts and teardown some
parts are prohibited.
7. When the engine run away, cut off the
fuel supply pipe or block up the intake pipe
immediately under the safety of operator.
See the right Figure.

8. Before stopping the engine, lower the

load and speed until coolant temperature
below 70. Stopping the engine is
prohibited when coolant and oil are in high temperature.
9. If the engine need to store for a long period at the temperature below 0, if the
engine does not use antifreeze, the water in the cooling system should be discharged
to avoid damage the engine.
10. There is 20 kPa pressure in the radiator. Adding the coolant (or water) to the
radiator is prohibited. To avoid hot injure, never close up the hot parts when adding the
coolant (water)and draining the coolant (water) or engine oil.
11. Pay attention to fire prevention, keep away fire from the engine. When the engine
work in some situations, such as harvest place, install the spark extinguish device to
the muffler.
When to install, use and maintain the AKSA series engines, stepping and putting some
heavy load on outside part of engine ( such as fuel pipes, head cover, oil cooler and so
on ) are prohibited.

2.2 Engine oil grades

The AKSA series engines should use CD grade engine oil.

2.3 Engine protection

The AKSA series engines storage period is one year. If the engine has been stored
over one year, it should be checked and take some necessary measures to care.

2.4 Open new machine

When open the packing container of the engine, the user should check the engine and
spare parts with the packing list, to find out damage and loosen parts first, then do the
following jobs:
1. Clean the antirust coating and anticorrosive agent on the outside of the engine.
2. Drain out the seal oil from fuel filter and other fuel supply system, it may allowed to
let the seal oil in the system, but be sure that the normal fuel will be supply the system
when the seal oil runs out.
3. Check the water and oil plugs on the engine, the water and oil pressure sensors are
ready or not, if these sensors need user to install, then install them before starting the
engine.

2.5 Choose Fuel, lubrication, coolant and accessory materials

1. Fuel Selection
Table 2-1 lists fuel standard (China Standard: GB 252 2000 Light Diesel Fuel) which
meet AKSA series engines requirement.
 Table 2-1 Fuel Selection
Ambient
Temperature
4 -5 -5-15 -30
Fuel Grade 0 -10 -20 -35

Keep fuel clean is important to prolong the engine life. Strictly follow the principle for
using clean fuel. The special container or barrel for keeping fuel should be clean.
When fill the fuel into the engine, its better to adopt sealing method and do not fill fuel
until deposit fuel for three to seven days, take the fuel from topside of the container or
barrel. Pay attention to keep the fuel clean during the transportation, filling and usage,
to avoid the fuel be contaminated.
2. Lubricant Selection
(1) Choose the CD Grade engine oil.
(2) The engine may allowed to use over CD Grade engine oils
(3) It may use 15W/40 CD Grade engine oil when ambient temperature is over -15,
or use 5W/30 CD Grade engine oil when ambient temperature is below -15
(4) Before starting engine, check oil level on the oil sump, the oil level should reach the
upper mark on the dipstick.
CAUTION
Don t check the oil level while the engine is running!
3. Grease: Inject automobile general lithium base grease (GB/T 5671-1995) into the
water pump oil cup, fan bearing and front supporting grease fittings.
4. Coolant:
The cooling system should use long-life antifreeze. The antifreeze have some abilities
of anti-rust, anti-freeze, anti-scale, anti-erosion and anti-corrosion for the parts in the
cooling system. For the concentrations of antifreeze, please refer to Specification of
Antifreeze.
According to the different ambient temperature to choose the concentrations of
antifreeze.
CAUTION
1. Periodically to check the strength of antifreeze when the ambient temperature below
0. The long-life antifreeze may use perennially.
2. In the special case, it will be allowed to use the treated soft water which have
anti-rust and anti-scale abilities instead of the long-life antifreeze for a short period.
When the winter season come, the ambient temperature below 0, stop the engine
and drained out water from the radiator and engine.
5. Accessory Materials:
During assembling and maintaining the engine, may use following fluid sealants and
binders and Molykotte Pvlver.
The application points of the accessory materials see the following table

Tab. 2-2 Accessory Materials List

No. Name Color Application

Coating on flat metal surfaces to prevent seize, such as

1 Molykotte Pvlver Black
inner surface of cylinder sleeve and etc.

Deep Coating on some parts surface to lubricate before oil

2 Molykotte Gu.plus
grey pressure set up, such as vale stems and etc.

Coating on outside of screw thread and bearing to prevent

3 Loctite 242
4 Loctite 262
Blue loose, middle strength, such as the screw thread of main
office pressure limiting valve and etc.
Coating on outside of screw thread to lock, seal and
Red prevent loose, high strength, such as the screw thread of
cylinder head bolts and etc.

Coating on surface of pipes and joints to fix parts, such as

5 Loctite 275 Green
the outside surface of heater water outlet and etc.

Red Coating on finished metal surface to seal the parts, such as

6 Loctite 510
(Orange) the joint face between the block and crankcase and etc.

Suitable for sealing the plugs to the water lines and oil
7 Loctite 277 Red
lines, coating on the cylinder surface of bell plugs and etc.

Coating on finished metal surface to fix the parts, such as

8 Loctite 648 Green the inner hole of tensioner bearing and outside surface of
shaft and etc.

2.6 Starting and Operating

1. Pre-starting preparation
Before starting the engine, check each parts of engine, check the tighten and leakage
of fuel, oil and air pipes. Remove all the abnormal phenomena.

Check the coolant level in the radiator, fill the coolant.

Through the oil filler, fill the oil and wait 5 minutes, check the oil level on the dipstick,
make sure the oil level between the upper mark and lower mark. For the first time to
filling oil into the engine, it may to add a little bit more, let the engine run 3 to 5 minutes,
then stop the engine, after 5 to 10 minutes, recheck the oil level and make sure the
keep the oil level correctly.

Check the connections of electric system, charge the battery fully.

After checking, open the stop cock on the fuel tank, pump the priming level to escape
the air in the fuel system.

2. Normal Starting

Put the governor level to the suitable position.

Turn on the electric key switch, push the start button to make the engine start. If the
engine does not start with 5 seconds, release the button immediately to protect the
starter and battery. Wait for 1 to 2 minutes before cranking again. If the engine can not
be started over three times, the causes should be found before restart the engine.

After the engine started, release the button immediately and turn the electric key
switch to the middle position, pay attention to the reads of each gauges on the
instrument panel, especial for the oil pressure, when the engine speed at 600 r /min
the oil pressure should not less than 100 kPa. Then let the engine run about 10
minutes at speed of 600 to 700 r/min to check the engine working condition. Do not let
the cold engine to run at high speed.

3. Pre-heat Starting (equipped with electric programmed control flame preheat device)

When ambient temperature above -5, engine can be started without any assistants.
When the ambient temperature below -10, Turn on the electric key switch, the
preheat indicator light and the glow plug work, after 50 seconds the preheat indicator
will flash automatically, the temperature of glow plug is about 850 to 950 , push the
start button to turn on the starter. The magnet valve open automatically to supply the
fuel to glow plug, made the flame to preheat the engine, this device can made the
engine starting under -25. For the engine use at cold weather, should take special
measures, such as heat preservation, low temperature battery, special engine oil, fuel
and etc..

4. Engine Operation

After the engine started, reduce the throttle, keep the engine at the idle speed.
 CAUTION
Do not allow the engine to run at the idle speed for a long time.

After run the engine at idle speed for few minutes, increase the speed gradually to
1000 to 1200 r/min, then let the engine run at part load and put the engine at full load
while the coolant temperature over 60 and the oil temperature over 50. Increase
the load and speed of engine step by step to avoid suddenly increase and reduce the
load.

For the new or overhaul engine, should not operate the engine at full load at
beginning , its better to run the engine for about 60 hours at partly power (not
over 80% rated power) to improve run-in condition and reliability and usage life.

When engine match construction machine, its better let the engine run often at rated
power, it not good for the engine run at max. torque condition for a long period, it will
made engine have faults. If let the engine work at low load and speed will cause faults,
such as low efficiency, burn the oil and etc..

During the engine operation, pay attention the change of gauge reads. Check the
engine oil pressure and coolant temperature regularly. At the normal condition, coolant
temperature should be 85 to 90, oil pressure should be 294 kPa to 490 kPa. When
oil temperature reach 95 to 100, the oil pressure could be lower a little bits less
than 294 kPa.

CAUTION
The oil pressure should not be lower than 98 kPa, when it happened, should find
the cause immediately. Continue operate the engine is prohibited at the coolant
temperature below 60 or over 100.

When engine operate, pay attention to hear the abnormal noise, check the fuel lines,
water pipes, air in and out lines, if find some leakages, remove them immediately,
otherwise will cause the engine damaged.

5. Shut-off Engine

(1) Normal Shut-off

Before stopping engine, reduce load, adjust the governor level t reduce engine speed
to 600 to 1000 r/min to run few minutes, then put the shut-off handle to stop the engine.
Turn electric key to the mid position to avoid current from battery to turn back.
(2) Emergency Shut-off

In emergency or special situations, it must take emergency shut-off measure to avoid

serious damage. In this case, put the shut-off handle back, cut off the fuel supply pipe
or block up the intake pipe or exhaust pipe immediately.

Maintain the engine for storage a long time.

2.7 Preheat and idle speed

Running the engine at full open throttle is prohibited, after starting the engine increase
the speed gradually.

Excessive engine idling speed should not be over 10 minutes. Otherwise will cause
combustion chamber temperature decrease, poor combust, carbon deposit, injector
holes block, cylinder rings and valves wears.

2.8 Running in
Before operate Engine, following procedures should be complied:

(a) Warm up the engine at light load and mid-low speed.

(b) Idling the engine not over 10 minutes.
(c) Avoid run engine at constant speed.
(d) Often Obverse oil temperature and pressure, coolant temperature, keep them in
normal ranges.
(e) Often check the levels of oil and coolant.

The run-in hours of AKSA series engines is not less than 60 hours. According following
table (Tab. 2-3) to run-in the engine in proper sequence.

Tab. 2-3 Engine Running-in Procedure

Load / % Hours / min Load / % Hours / min
25(1/4) 10 75(3/4) 30
50(1/2) 15 100 5

When engine match with automobile vehicles, according to the vehicle running-in
procedure to run-in the engine. Total running-in mile is not less than 2 500 km. No-load
running is 200 km, 50% load running is 800 km, running velocity is less than 70%
corresponded the engine speed. 75% load running is 1500 km, running velocity is less
than 75% corresponded the engine speed. 75% load running is 1 500 to 25 000 km,
running velocity is less than corresponded the engine rated speed.

CAUTION
After running-in. clean and check the engine according to the following procedure:

(a) Check and adjust valve clearance, remove leakages of oil, fuel, coolant or air.
(b) Check and adjust fuel supply timing and injector pressure.
(c) Check capacity of coolant and refill it when necessary. Check the tension of fan and
dynamotor belts. Tighten the clamps of cooling pipes.
(d) Clean the screens of fuel supply pump, filler bowl and fuel filter, Replace them if
damaged or contaminated seriously.
(e) Change the oil, replace the oil filter and clean the oil sump. S series engines adopt
spin-on oil filter, it should be replace when change oil. Unscrew the oil drain plug, drain
the oil when engine is hot. Apply a thin coat of oil to the seal and install the filter by
hand until the filter contacts the filter base, tighten it by special spanner.

2.9 Periodical check & maintenance

Good maintenance is important procedure, it will keep the engine work reliable and
prolong engine life. The user should follow the maintenance items to service the
engine as follows.
1. Periods of maintenance
First Check: Engine run about 30 to 50 hours
Daily CheckP: Engine run every 250 hours
Class I MaintenanceWD 1: Engine run every 500 hours
Class II MaintenanceWD 2: Engine run every 1000 hours
Class III MaintenanceWD 3: Engine run every 2000 hours
Class IV MaintenanceWD 4: Engine run every 4000 hours
Notes: The maintenance periods is calculated by yearly working hours of 1500 hours,
if the working hour less than 500 hours per year, the periods will be half of above
periods. if the working hour more than 1500 hours per year, the periods will be 1.5 time
hours of above periods.

2. All the maintenance jobs is listed clearly in the following table (see detail in Tab.2-4)
 Tab. 2-4 Check and Service Items List of S Series Engines

1st.
Items P WD1 WD2 WD3 WD4
Check
Change engine oil (once a year)

Water pump (through the grease cup)

Replace oil filter Every time when change engine oil

Check & adjust valve clearance

Check injector opening pressure

Replace fuel filter

Clean pre filter of fuel pump

Check coolant level, fill when needed

Change coolant Every 24 months

Tighten clamps of cooling pipes

Tighten connection parts of air intake

pipes, hoses and flanges
Check service indicator lamp of air filter
Clean dust pocket of air filter (not include

auto duct type)
Clean main element of air filter When indicator lights

Replace main element of air filter

Replace safety element of air filter Clean main filter element every 5 times

Check V-belts

Check turbo-charger bearing play

Check injection pump at special service

center
Adjust idle speed

According to the models, work conditions and users experiences, the items of
maintenances may increase or reduce, anyways it should have plan, procedures to
remove and install the parts from the engine. To use proper tools to fasten the bolts
nuts and screws according to the specification of tightening torques on this manual.
Clean and coat anti-rust oil or grease on each connecting surfaces. Notice relative
positions of each removable parts and structure characteristic of unmovable parts, and
their fitting plays and adjustment methods. Keep the engine and its auxiliary
equipments clean.
3. Daily Maintenance
Daily maintenance will do the following items:
(a) Check the capacity of fuel tank, fill fuel as needed.
(b) Check the oil level on the oil sump, the oil level should be between upper mark and
lower mark of dipstick, fill the oil as needed.
(C) Check leakage and seals on fuel, oil, and air pipes and hose joints. Check the
tighten of fastening pieces.
(d) Check instruments condition, if have some faults, repair or replace them in time.
(e) Clean the outside of engine and its auxiliary equipments.

2.10 Storage & maintenance

Use the following procedures to storage the engine for over three months:
(a) Drain out the fuel, oil and coolant from engine.
(b) Crank the crankshaft several revolutions, let the oil film on all the moving parts.
(c) Remove the outside trash, dust and rust, place a thin coating of oil on the unpainted
parts and jointed points of drag bars.
(d) Plug the air intake, exhaust pipes and fuel, oil filler cap with plastic or rubber plugs.
(e) Keep the engine in the dry, clean and good ventilation room. There are no
corrosive gases nearby. Do not keep the engine in the open air. Its better to keep the
engine in the wooden box or rapped with plastic cover.
(f) Keep the engine serial No., Date of manufacturing, total working hours and
technical status record.

For long period of storage, the engine should be checked and run 3 to 5 minutes every
half year to keep the oil films on the moving parts. According to the requirements store
the engine again. Pay a special attention to the safety while starting and running the
engine. The engine should be installed firmly.
 Chapter 3 Main Parts Fitting Play and Wear Limit
Unit: mm

No. Play Fitting Play Wear Limit

1 Main bearing 0.0950.163 0.17

2 Connecting rod bearing 0.0590.127 0.16
3 Crankshaft axial 0.0520.255 0.35
4 Connecting rod big end and crankshaft 0.150.35
5 Piston skirt (Cold) 0.1430.182 0.350.4
6 Connecting rod small end bush and piston pin 0.0450.066 0.1
7 Piston pin boss and piston pin 0.0030.013
1st.ring 0.40.6 11.2
Piston ring opening (Cold) 2nd. ring 0.250.4 11.2
Oil ring 0.350.55 11.2
!st. ring
2nd. ring 0.070.12 0.28
Piston ring gap (Cold)
Oil ring 0.050.085 0.26
10 Inlet valve and stem guide 0.050.086 0.15
11 Exhaust valve and stem guide 0.030.066 0.10
Valve bottom surface recession on cylinder head plane 1.21.4
12 1.8
Inlet/Exhaust 1.25/0.95
13 Injector over top of cylinder head 3.24
14 Cylinder sleeve over top of block 0.020.07
15 Camshaft axial 0.10.4
16 Camshaft bearing 0.040.12
17 Tappet rod and guide 0.0250.089
-0.010.033
18
Cylinder sleeve and bore of cylinder block -0.020.033
19 Rockerarm and rockerarm shaft 0.040.119
20 M12 Bolts over top of cylinder block 1803
21 Valve stem guide over top of cylinder head concave plane 22
22 Piston head and cylinder head 1.0
23 Valve clearance Inlet/Exhaust 0.3/0.4
24 Gear backlash 0.150.33
Axial 0.0250.1
J92B Series turbochargers
Radial 0.0750.18
27 Backlash of timing and mid gears 0.150.33
Chapter 4 Bolt tightening torques

1. Main bearing bolts: According to the orders as following Figure 1 to tighten these
14 bolts (M18).
The tighten torque is about 30 Nm (3kgfm) at first time.
Then the tighten torque reach about 80 Nm (8kgfm) at second time.
At last, the tighten torque reach about 250+25 Nm (25+2.5kgfm) at third time.

2. Cylinder cover bolts:

(1) The tighten order is as following Figure 2.
The serial number from 1 to 21 (the circle ones) are the second bolts (M12), there are
21 bolts (these bolts may use twice).
The serial number from 22 to 45 (the hexagon ones) are the main bolts (M16), there
are 24 bolts (these bolts may use thrice).

(2) Tighten procedures:

1) Aligning the side surfaces of cylinder heads first, tighten all main and second bolts
with 30 Nm (3 kgfm) torque as tightening order.
2) Tighten all nuts of second bolts with 100Nm (10 kgfm) torque in turns.
3) Tighten all main bolts with 200 Nm (20 kgfm) torque in turns.
4) Turn all nuts of second bolts 90 degree in turns.
5) Turn all nuts of main bolts 90 degree in turns.
6) Turn all nuts of second bolts 90 degree again in turns, the torque reach from 120 to
160 Nm (from 12 to 16 kgfm), if the torque can not reach, replace the nuts.
7) Turn all main bolts 90 degree again in turns, the torque reach from 240 to 340 Nm
(from 24 to 34 kgfm), if the torque can not reach, replace the bolts.

3. Connecting rod bolts:

First tighten bolts to position by hands, then tighten the bolts symmetrically with torque
of 120 Nm (12 kgfm), finally turn all bolts 905 degree in turns, the torque reach
from 170 to 250 Nm(from17 to 25 kgfm) at same time, if the torque can not reach,
replace the bolts.
Caution: All the dismounted bolts will not be allowed to reuse again!

4. Flywheel bolts:
280Nm(2328kgfm)
First tighten bolts to position by hands, then tighten the bolts symmetrically with torque
of 60 Nm (6 kgfm), finally turn all bolts 1805 degree in turns, the torque reach from
230 to 280 Nm (from 23 to 28 kgfm) at same time, if the torque can not reach, replace
the bolts.
Caution: These bolts may use twice only!

5. Connecting bolts for flywheel casing with block:

First tighten bolts to position by hands, then tighten the bolts symmetrically with torque
of 40 Nm (4 kgfm), finally turn all bolts 1205 degree in turns, the torque reach from
110 to 140 Nm (from 11 to 14 kgfm) at same time, if the torque can not reach, replace
the bolts.
Caution: These bolts may use twice only!

6. Idle gear shaft bolts (M16)(for valve timing): Once tighten to 180+20 Nm (18+2
kgfm).

7. Idle gear bolts (M10) ( for oil pump): Once tighten to 60+5 Nm(6+0.5 kgfm).

8. Rocker seat bolts (M12): 12 bolts, Once tighten to 100 Nm (10 kgfm).

9. Tensioner bolts (M16): Once tighten to 200 Nm (20 kgfm).

10. Water pump impeller tight nut (M181.5) : Once tighten to 50 Nm (5 kgfm).

11. Hexagon socket bolts (M12) (for connect the coupling and driving shaft of
injection pump) : The tighten torque is 130 Nm (13 kgfm)

12. Tight nuts(M181.5) (for driving gear of injection pump): Once tighten to 200 Nm
(20 kgfm). Part model is 300 Nm (30 kgfm).

13. Camshaft gear bolts (M8) : 4 bolts, tighten to 35 Nm (3.5 kgfm) symmetrically.

14. Tight nuts for injector (M8): 2 nuts, tighten to 25 Nm (2.5 kgfm) symmetrically,
pay attention to consistent clearances.

15. Connecting bolts(M10) (for damper pulley with crankshaft): 8 bolts, tighten to 35
Nm (3.5 kgfm) symmetrically.

16. Fastening bolts (for injection pump with support): tighten the bolts in orders of
Figure 3 with torque of 25 Nm (2.5 kgfm).

17. Exhaust pipe bolts(M10) : 12 bolts, Tighten bolts with 50-5 Nm first, then turn the
bolts 90 degree twice, finally tighten to torque from 70 to 90 Nm (from 7 to 9 kgfm)
symmetrically.
Caution: These bolts may use twice only!

18. Fastening bolts ( for air compressor gear): tighten torque is 200 Nm (2 kgfm).

19. Fastening bolts(M10) (for mid gear): 4 bolts, tighten the bolts in orders of Figure 4
with torque of 605 Nm (60.5 kgfm), turn the bolts 90 degree in turns, the torque
reach from 100 to 125 Nm (from 10 to 12.5 kgfm) at same time.
Chapter 5 Main Components structure and checking points

Before maintain the engine or change parts, read this manual carefully. Install the
engine according to the following instruction. Check the Parts Categories of Series
Engine which model you bought, or consult your local dealer or the manufacturer.

5.1 Cylinder block, crankcase

There are two parts of the main bearing in the S series engines, the upper part of
bearing is cylinder block, the lower part of bearing is crankcase. The integral frame
have good stiffness with crankcase and seven main bearings. Between the frame and
cylinder block there is no gasket, use the Loctite 510 sealant to seal on the bottom face
of cylinder block, the color of sealant is orange (or red), the sealant paste were packed
in special containers, when coating the sealant, forced them out by hand, the laying
method see Fig. 5.

1. Bottom surface of cylinder block 2. small screws on each sides 3. Streamlines of

Loctite 510 sealant
Fig. 5

CAUTION: the streamline of Loctite 510 sealant should be uniformly and

unbroken! (Not too much, should assemble in time after coating)

Except of 14 main bearing bolts (M18) between the cylinderblock and crankcase, there
are 24 bolts (M8) on the two sides of crankcase tighten with the cylinder block to made
the engine as an integral frame, this structure is more benefits for reducing wear of
crankshaft and main bearing and lowering noise. The S series engine adopt quite
compact centre distance (150 mm) of cylinders and the thin wall (2 mm) of dry cylinder
sleeves. Before installing the sleeve, clean the greases on the cylinder holes and
external diameter of cylinder sleeves with alcohol or Loctite 755 and coat a thin
Molykotte Pvlver, press the sleeves by hand or tools. When meet difficult, should
+0.025
measure the hole diameter 130 of cylinders and external diameter of sleeves
+0.020
130 0.002 , match them with less interference value. After pressing, measure the
sleeve height over the cylinder head within the range of 0.020.07mm, check the
 +0.025
inner diameters 126 of sleeves at same time, control the cylindericity within
0.04 mm.

The main oil line on the right side of cylinder block from the front viewed of the engine.
On the left of engine, there is auxiliary oil line which connected with 6 injection nozzles
for cooling the pistons. Pay attention to the fitting pins when install the nozzles.

The main bearing is thin wall, on the surface of bearing lining have an antifriction
alloyed coating, grinding the bearing is forbidden, before installing the crankshaft, coat
the clean oil on the bearings.

5.2 Cylinder head

The structure of cylinder head adopts one cylinder having one cylinder head. Under the
exhaust valve, there is thick spring washer which welded on the cylinder head with
Loctite 648, except 4 bolts on the cylinder head, there are 3 studs (M12) and locking
nuts, together with one set of clamping block to force against two adjacent cylinder
heads. The gasket have structure of steel gasket with asbestos core, it is allowed
reapplication, but should be checked before use, replace it when it is broken. Align the
exhaust ports with the straight ruler before tighten each cylinder heads at same time,
otherwise it will cause air leakage and damage the gaskets. The taper angle of intake
valve is 110 degree and the taper angle of exhaust angle is 90 degree, the valve guides
height over the concave camber surface of cylinder head is 22 mm.

CAUTION: Pay attention to know that there are pins for fitting the cylinder heads,
gaskets and cylinder block.

Use the Loctite sealant to coat the bell covers on the cylinder heads, it will not
allowed user to loose them. Before tighten the bolts of rocker arm supports, let
the head of adjusting bolt in a suitable position to avoid damage the parts of
valve train. There are no fitting pins between rocker arm supports and cylinder
heads, before tightening the bolts, made the rocker arm proper contacting with
valve, there are no bushes on the rocker arm, coating the clean oil before
installing the rocker shaft.

5.3 Piston
See Fig. 6.
The piston is a cast aluminum parts, on the top of piston, there are type combustion
chamber and
, please notices that the circle dimension and volume of combustion chamber is
different with engine models. There is a product code on the top of piston, there is a
heat resistance loop on the 1st. groove. The piston hole is offset to the rotating direction
of crankshaft. There are fine grooves on the top bank of piston, the skirt of piston
coated with graphite layer to improve the running-in. there are two compression rings
and one oil ring, the top ring is trapezium barrel ring, on its surface there is a moly layer,
on the top of inner circle there is a inner notch, the Top mark side must face up when
installing. The 2nd ring is a taper ring, the Top mark side must face up when installing,
it will not allow to install reversely. The 3rd. ring is a chroming combined oil ring with
inner spiral spring. According to the mass of piston, the piston classify 5 groups which
marked as G1, G2, G3, G4, G5, the sets of piston used in one engine should be the same
group of mass when replace the pistons.

Before installing pistons into cylinder sleeves, coat the clean oil on the inner surface of
sleeves, skirt of piston and piston rings, made the gaps of three rings apart each other
120 degrees, and the gap of 1st. ring offset the piston pin hole 30 degrees.

Fig. 7

When installing piston with connecting rod, heat the piston to 80C and let the lower
notch of piston skirt aim at cooling nozzles.

5.4 Connecting rod

The shot blasting treated I-section alloyed connecting rod, the big end have 45 degree
cut open, the joint face adopt 60 degree tooth shape position setting. The connection
rod grouped with the mass, the difference mass is 29 grams between groups. the
connection rod classify 9 groups which marked as C, D, E, F, G, H, J, K and L. the sets
of rod used in one engine should be the same group of mass (the mass mark should be
same) when replace the them during repair work, .otherwise will cause the engine
abnormal vibration.

CAUTION: There is a mated marks on the pair of rod and cap, not make wrong
installation!
The 2 bolts (M14) of connection rod are high strength bolts which
can be used only one
time, after dismounting, it will be discarded
 There are ternary alloy layer on the surface of connection rod
bearing, grinding the bearing is forbidden!

5.5 Crankshaft

The crankshaft is forged by carbon steel or alloy steel with 12 balancing weights, the
axial journals were treated by nitrogen treatment, the crankshaft needs dynamic
balance. The silicone oil damper may installed in the front of crankshaft. Pay attention
to amounting and dismounting the front and rear oil seals, for the better sealing may
coat Loctite sealant on the stillness surface of oil seals.

Before installing the crankshaft gear and the fixing shaft sleeve, heat them to 180C
and 290C for each.

5.6 Flywheel casing and flywheel

In order to meet different makers requirement to match different torque converters, the
engine adopted different flywheels and flywheel cases. The model of 6TA/Q1 engine
adopted SAE1 flywheel case and flywheel.

5.7 Intake and exhaust system

When install the induction system, make sure the seal of all the connections. Remove
the leakages if founded. Otherwise it will cause the power reduced.

The exhaust temperature is very high (about 600), pay attention to the safety during
the operation. When need maintaining the exhaust system. Stop the engine, let it cool
enough. If the gasket damaged, the asbestos gasket is allowed to use temporarily. The
paper gasket is prohibited. The outlet of the exhaust system should be protected by
taking some procedures to keep rain out of the system.

There are three places for mounting the turbocharger of S series engines: rear
mounted, middle mounted and above rear of exhaust manifold. Among these, the
middle mounted turbocharger for most bulldozers, the exhaust manifold has three
sections. For loader and etc. the turbocharger are mounted above rear of exhaust
manifold.

The engine Model of 6TA is for turbocharged and after cooled engine, its cooler is air
cooling which located in front of the radiator, cooled by the fan.
The turbocharger is a radial flow type, forced lubrication, the structure of turbocharger
see Fig.8.

Usage points of turbocharger:

(a) Before use the new or repaired turbocharger, rotate the rotor with hand to check
the rotation and abnormal noise.

(b) Start the engine two to three times, three to five seconds per times, let the oil fill in
the floating bearing. After starting the engine, let the engine run at idle speed several
minutes before increase the speed, especially in the winter season.

(c) Do not stop the engine suddenly, let the engine run at middle speed several minutes,
gradually reduce the speed before stop the engine.

(d) Use and change the specified oil according to the maintenance intervals.

(e) Stop the engine and check the causes when the oil pressure is lower 0.2 MPa.

(f) The air outlet pipe of compressor connected with the air inlet port of turbocharger, let
the gas separated by the compressor go into the compressor. The cooling of the
compressor is bypass cooling. The gas including oil fog will not be separated totally by
the compressor, so it will cause the oil dust condensed on the inner surface of
compressor shell and vanes of compressor, it will effect the efficiency of the
compressor, let the engine performance down. After engine run some period, if found
the engine performance down, except to check and clean the air filter and fuel systems,
remove the compressor shell case, clean the shell tubes and vanes of compressor,
please take care of not hit and damage the parts.

(j) There is a low pressure warning sensor connector near the outlet port of the air filter.
Pay attention to the change of engine performance if the engine is not installed the
warning device, especially in the sand wind conditions. If the engine have black smoke,
low power and etc. after run some period, please check the block of air filter first (at
same time check the nozzle fog and advanced angle of fuel supply), if the block heavy,
clean the filter element with dry compressed air which not have oil fog and water. Some
liquid with oil or water will not be allowed to clean the filter elements.

1. Compressor housing 2. Compressor wheel 3. O-ring

4. Thrust sleeve 5. Seal ring 6. Middle housing
7. Bearing block ring 8. Floating bearing 9. Plug 10. O-ring
11. Turbine wheel 12. Turbine housing 13. Thrust bearing
14. Spring plate 15. Cover 16. Lock nut

Fig.8 Radial flow type turbocharger

CAUTION: Periodically maintain the air filter according to the Air Filter Manual,
keep the seals of intake system well.

5.8 Valve mechanism

The one of the special characters of S series engine valve train is using hollow push
rod as a oil line to supply oil to the cylinder head. There are two circular grooves on the
bottom of the tappet rod, on the upper groove, there is angling hole connecting with
spherical seat of tappet rod. The oil coming from the main oil line periodically goes to
the upper groove, the spherical seat, the hole in the spherical seat, the rocker arm, the
adjusting bolt, the hole in the rocker arm, rocker arm bearing and valve train. On the
lower groove there is a oil return line. The other characters of valve train is using united
structure to put the rocker arm shaft and seat as an unit, use side face fix of rocker arm
shaft with inner side face of cylinder head cover without do using snap ring to make
axial fix.

The valve timing phases of S series engines are as follows:

Intake valve clearance (with engine cold): 0.3 mm

Exhaust valve clearance (with engine cold): 0.4 mm

Inlet valve opens: 2 CA before TDC

Inlet valve closes: 26 CA after BDC

Exhaust valve opens: 49 CA before BDC

Exhaust valve closes: 5 CA after TDC

After setting the valve clearances while the engine is cold, recheck the valve timing
phases again to avoid wrong setting. Please pay attention that some models of engine
have valve rotator system which have different diameters of valve stem (11 mm,
others are12 mm).

Installation of timing gears and adjustment of advanced injection angle:

1. Turn the flywheel, made the OT mark on the flywheel meet the OT mark on
observation port under the flywheel case (open the port cover), let the first cylinder in
the compressed stroke, made the first cylinder piston at top of compressed
stroke(TDC).

2. Rotate the camshaft gear, made the mark on the gear meet the OT mark on the
timing gear housing, tighten the bolts of the camshaft gear to specified torque.

3. Install two idle gears (one is big, other is small), tighten the bolts of the gear on the
idle gear shafts. If the big idle gear can not mesh with the crankshaft gear and camshaft
gear at same time, move the camshaft gear slightly (only a little bit!!), made them mesh
each other well. (see Fig. 9, Fig.10, and Fig.11)

4. Install the driven gears of high pressure fuel pump and air compressor, tighten the
bolts of those gear to specified torque.

Gear of air compresor

Gear of injection pump
Big Ldle gear (big)
Gear of Camshaft
Gear of crankshaft
Idle gear (small) of oil pump
Gear of oil pump
Fig. 9 Gear Train Assembly

Fig. 10 Installation Drawing of Idler Gear

Fig. 11 Installation Drawing of Oil Pump Idler Gear

5. Adjustment of advanced injection angle:

(1) Turn the flywheel to the angle of first cylinder compressed stroke before TDC to
the degree of advance injection angle (see the fuel system matching table), turn the
flywheel according the rotation of the engine, reverse turn is not allowed.

(2) Turn the driven end of injection pump, made it to the injection position of first
cylinder. There are two ways to check this point. One is that made the mark on the
advancer meet the mark on the body of injection pump; the other is that take off the first
high pressure fuel pipe, press the feed pump by hand, check the fuel appearance over
the delivery-valve holder, when the fuel out off the valve holder, this point is the fuel
injection position of the first cylinder.

(3) Connect the high injection fuel pump with drive shaft by spring steel plate coupling.
Tighten the M12 bolts on the coupling to specified torque.

(4) Return the flywheel a little bit, then turn the flywheel to observe the fuel appear over
the outlet valve seat, recheck the advanced angle of first cylinder, if find something
wrong, readjust the advanced angle again.

5.9 Electrical system

The electrical system includes alternator, starter, water temperature sensor, oil
pressure warning sensor and etc.

1. Alternator

The alternator is three-phases AC generator, after rectifying, change to DC. The

alternator may chosen by user depend on the different requirement, the output voltage
of basic model is 28 V, and output current is 27 A. the rotated direction is right, the
allowed max. speed is 11000 r/min, rated speed is 600 r/min, the regulator is on the
alternator. The electric diagram of Alternator sees Fig.12.

The inner circuit of alternator has been done, on the end face terminals, the connecting
pole D+ to the charging indicator lamp, W to speed motor, B+ to battery positive and
load, out-shell of alternator to earthing.

Regulator
Fig. 12 Electric Diagram of Alternator

2. Starter

The starter is DC motor, voltage is 24V, power is 5.4 kW, other model may use 7.5 kW
motor, the rotation is right direction, gear number is 11. The starter used for the
construction machinery is full sealed anti-oil motor.

The electric diagram of starter sees Fig.13.

The inner circuit of starter has been done, the out terminals are as follows:

30 Terminal 30 connect to battery positive pole

31 Terminal 31 connect to earthing
50 Terminal 50 connect to solenoid switch
Fig. 13 Electric Diagram of Starter

3. Oil pressure warning sensor

The working temperature is from -25 to100 , measured range is from 0 to 500 kPa
warning pressure is from 25 to 40 kPa (the points will be closed when pressure is low),
the max. power of alarm is 5Wrated voltage is from 6 to 24 V.

4. Water temperature sensor

The working temperature is from -25 to 120, allowed external torque is 20 Nm

(2kgfm) , rated voltage is from 6 to 24 V.

5. Battery

The battery is 212V 135Ah, there are 165Ah and 195Ah batteries as options. The 7.5
kW starters should use 212V195 Ah batteries.

5.10 Fuel system

The Fuel System of KASA Series Engines include fuel tank, fuel filters, fuel injection
pump, high pressure fuel pipes, injectors and fuel delivery lines.

The diesel fuel transfer from fuel tank into the transfer pump and the fuel filter, then go
into the injection pump, the high pressure fuel delivery through the injector go into the
cylinder. The over flow fuel goes back to the low pressure fuel lines.

1. Fuel filters
There are two stages of fuel filters, the primary filter has felt elements, and the main
filter has paper elements. Change the filter elements regularly and in time. Not install
the wrong places, and let the dust go into the fuel system.

2. Fuel injection pump

The fuel injection pump is a heart of the engine, the function is that made the high
pressured fuel into the combustion chamber with actual timing and fixed quantity
through the injection nozzle. The S series engines adopt type P high pressure fuel
injection pump. See the Fig.14.

Fig. 14 Injection pump Assembly

The connector thread of delivery valve is M141.5, the connector thread of fuel inlet
and return pipe are M141.5, the connector thread of fuel inlet is M101.

The model of speed governor is RFD or RFD-K.

The P type injection pump is a reinforced in-line high pressure pump, it consists of body,
fuel feed, fuel control, driven, speed governor and etc. parts.

There are no checking ports on the each side of aluminum alloy body. The body is a
united structure which has high strength and stiffness, can bear high injection pressure.
On the side of body there is a oil supply orifice to forced oil to the pump.

The fuel system of P type fuel pump as unit which adopt pre-installed structure, the unit
put into installed holes, fastened by the bolts.

3. Governor

The amounts of supplied fuel depend on the control of speed governor. The speed
governor model of RFD or RDF-K of P type pumps has flyweight governor.

The basic structure of RFD-K speed governor is same as RFD, but the RFD-K has a
negative calibration device. When the pump speed increase, the fuel supply move
forward; when the pump speed reduce, the fuel supply move backward within
calibration ranges.

NOTE: To know the detailed structure and working principle of P type fuel pump and
RFD (RFD-K) governors, please see the Injection Pump Manuals.

4. Fuel feed pump

The function of fuel pump transfer the fuel from fuel tank, go into the low pressure
chamber of injection pump through the fuel filters. The feed pump is located on the side
of injection pump, driven by eccentric cam of pump camshaft. When the cam down, the
piston returned by spring force. The valve on the left outlet port is closed; the valve on
the right inlet port is opened. On the one side the negative pressure on the topside
piston will suck the fuel in, on the other side the pressure under the downside piston will
force the fuel out. As the fuel pressure on the outlet increase, the feed pump will stop
work while the fuel pressure on the pressured chamber is equal to the spring force on
the piston.
There is a hand pump on the feed pump to escape air in the low pressure fuel pipes, let
the fuel full charged in the fuel pipes before starting the engine. There is a screen in the
fuel inlet screw to filtrate the impurities.

5. Injector

The injector has muti-holes nozzle, matched heat insulating sleeves. The opening
pressure of injector is 22.5 MPa.

5.11 Lubrication system

The sketch map of lubrication system shows in Fig.15.

On the outside of block, there is an oil pressure warning sensor jointed with main oil
line. The engine will warn when the pressure lower 25+15 kPa on the main oil line. In
order to prevent scrap iron go into the oil pump, there is a magnetism plug to catch the
scraps. The oil gas coming from the crankcase and block pass through the deaerator,
made condensed oil return to the oil sump, made other condensed gas go into air
intake tube before turbocharger, then go into the air intake manifold.

Ensure the engine can work normally under larger inclined conditions, this series
engines adopt dual stages oil pump, or widen type of dual stage oil pump for the rated
speed under 2000 r/min. on the lubrication system there are unadjusted safety valve,
bypass valve and pressure limited valve. The oil filter is spin-on type which is unclean
and un reusable one, it will be replace according to the requirement of maintenance.

The oil cooler is located in the water chambers of cylinder block.

There is one oil gas separator in up front of engine, the air after the separator go
through the rubber hose which has 1300 mm long to the inlet of the turbocharger. When
the hose bended or blocked, the pressure of the crankcase will increase, made the oil
overflow from the oil filler and dipstick port, when it happens, check the installation of
the rubber hose first.

Open pressure of bypass valve 250175kPa

pressure of oil pump safety valve 1550150kPa
Strainer
Oil pump
Oil filter
Oil cooler
60036kPa Open pressure of bypass valve 60036kPa
50050kPa Open pressure of bypass valve 250175kPa
Main orifice
Small end of connection rod
Turbocharger
Stem rod
Rockerarm
Camshaft
Main bearing
Connection rod bearing
Subsidiary oil orifice
Air compressor
Fuel injection pump
Spray nozzle
Piston
Fig. 15

5.12 Cooling system

The sketch map of cooling system shows in Fig.15.

Heat fan
Coolant filler
Expension water tank (Auxiliary water tank)
Radiator
Thermostat
Outlet of water pipe
Cylinder head
Cylinder block
Oil cooler for chassis lube
Engine oil cooler
Water pump

Fig. 16

The cooling system uses wax thermostat, fan and radiator to adjust the temperature.
There are many specifications of blower fan for user to choose (the diameter of fan are
540670780840mm and etc.). the thermostat is an important component to
control the temperature of coolant, the opening temperature of standard type is 80,
the opening height is 0.1 mm, the height will be 10 mm while the temperature of coolant
is 95, other types opening temperature is 71. The one which has 57 opening
temperature for the engine with water mid cooled type. The water pump is in the front of
block, the outlet of water and eddy shell cast with the timing gear chamber. The water
pump driven by the V-belt. The structure of water pump see Fig.17, and the structure of
thermostat see Fig.18.

Fig. 17 Structure of Water Pump

Fig. 18 Structure of Thermostat

The water temperature sensor install on the outlet of water pipe, which connect with
water gauge to minitor the temperature of outlet water.

5.13 Air compressor

The structure of air compressor is single cylinder witch has double acting crank guide
structure , the air compressor is located in front right upside of injection pump, driven by
the gear of the fuel injection pump, the gear ratio with engine is 1.25 (adding speed).
The oil come from the second oil orifice passing through the oil pipe jointed with the
cylinder block, the oil goes into the air compressor to lube bearings, then goes back to
the timing gear housing, return to the oil sump.

The air should be filtrated before going to the air compressor, there is one pipe between
the air filter and the turbocharger connected with the inlet of the air compressor.

There are two types of air compressor for S series engines; one is air cooled, capacity
is 168 cm3, other one is water cooled, capacity is 293 cm3 .

Air inlet tube

Inlet pipe of cooling water
Outlet pipe of cooling water
Oil Inlet pipe
Connecting to cylinder block

Fig. 19 Installation of Air Compressor

5.14 Cold starting device
The S series engines have good starting ability. The engine can be started without any
assistant starting devices at ambient temperature over -5.

On the outside of air inlet pipe, there is one screw hole of M101 for installing the
Aether cold starting device. On the up face and side face of air intake elbow, there are
two screw holes of M201.5 for installing the electric preheating cold starting device,
there are two methods for user to choose. The flame preheat cold devices consist of
electric control device, solenoid valve, temperature sensor, glow plug, fuel pipe, electric
lines and etc. This device can start engine at -40. The cold start preheating process
is auto electrical controlled, the process are as follows:

The schematic diagram and outline drawing of electronic control unit see Fig. 20 and
Fig. 21.

1. Turn the start key to the first position, put the 4V DC power through terminal15, if
the resistance of temperature sensor (RT) is less 1040110 , that means the ambient
temperature is over +23 (the resistance of temperature sensor change with the
ambient temperature, the ambient temperature lower, the resistance higher.), the
electrical control device does not work.

2. When the terminal15 got 24V DC power, if the resistance of temperature sensor
(RT) is larger than 1040110 , that means the ambient temperature is under +23
(the resistance of RT is 1040110 at 20), the relay I is closed (the pre-heater will
work), the terminal L is closed to earth (the indicator DL will light), after 504 seconds,
the points of relay I continue close and the indicator lamp DL flash. At this moment, the
temperature of pre-heat plug P is about 850 to 900, the flash of indicator lamp means
the engine can be started within 60 seconds, and otherwise this device will stop to work.
under this condition, push the starting button, the terminal 50 get 24 V DC power to
starter to start the engine, the relay II closed, the points of relay I and relay II continue
close and the indicator DL constant light, the solenoid valve D closed and open the fuel
pipe, inject fuel to the glow plug and burn the fuel. The burned flame heat the air intake
manifold and let hot air go into the cylinder to increase the temperature of compressed
air, it will help the engine start at low temperature.

3. Under the state of 2, after the terminal50get off the power about 31
seconds, if the engine can not start, it means the start attempt fail, the terminal
Dhas no signal in, whole device stop work (when start successful, the power of
starter will be cut off, the device stop work too) .If the start attempt fail at first time under
 the state of 2, cut off the power of starter switch (the terminal 50power off)
within 31 seconds, the power of 24V go into the terminal D+, the relay I and Indicator
lamp DL will work again. According to the procedure above, start engine at second time,
the device will work automatically before finish the preheat process. The continuous
working time of preheat device will meet the requirement of following table.

Resistance
121.8 6.81 40.6 2.70.5 1.80.1 1.220.1
k
Continuous working period
180 145 110 85 60 45
S1%

The temperatureresistance relationship of RT sensor are as follows:

Temperature
-30 -25 -20 -15 -10 0 10

Resistance 11061 6270 4271 3200 2530 1619 1197
1814 6210 4289 3250 2542 1647 1204

4. If need to start engine again under any minutes of the state of 2or 3, cut off
the power on the terminal15for 51 seconds, then turn on the power on the
terminal 15, the device will work.

5. Usage life: Preheating plug 250 times. Electromagnetic valve 1000 times.
Controller 2500 times.

6. When the ambient temperature is between 10C and 23C, the preheating device
even work while starting the engine, under some cases, the operator can start the
engine directly, the preheating device will stop work automatically, it will not effect the
starting process.

Fig. 20 Schematic Diagram of Electronic control unit

Fig. 20 Outline Drawing of Electronic control unit

5.15 Clutch

The single plate clutch have special damping function for torsion vibration and idle
running, its main function is transfer the power to the gearbox.
The engine with SAE 1 flywheel and flywheel housing matched with SAE1 clutch cover,
the model of clutch is GF420, the diameter of driving plate is 420 mm, the diameter of
flywheel is 492 mm, the circle diameter of connecting bolts between flywheel and clutch
is 450 mm.

The engine with SAE 2 flywheel and flywheel housing matched with SAE2 clutch cover,
the model of clutch is GF380, the diameter of driving plate is 380 mm, the diameter of
flywheel is 444 mm, the circle diameter of connecting bolts between flywheel and clutch
is 410 mm.

Generally the engines matched bulldozers have special power take-off devices.

The clutch is not a basic component belong to the engine.