Doosan DH170 Excavator Operation & Maintenance Manual - PDF DOWNLOAD

DH170 Operation and Maintenance Manual 2022-7052

Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment.

This documentation may include attachments and optional equipment that is not available in your machine's package. Please call your distributor for additional items that you may require.

Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item.

2022-7052 Operation and Maintenance Manual

Copyright 1999 Daewoo

DH17D OPERATION

MANUAL

PART NO.: 2022-7052 HEMF22-2406

TO THE CUSTOMERS This operation manual is designed to serve as a reference for DHl'S customers and distributors who wish to gain basic product knowledge on OHi DH170, Hydraulic excavator.

To maintain the excavator in potimum condition and retain maximum performance for a long time, CORRECT OPERATION and PROPER MAINTENANCE are essential.

Therefore, Keep this manual in the operator's seat pocket so that you may refer to it at any time you want.

The descriptions in this manual may be subject to changes without prior notice.

If you have any questionaire or recommendation in connection with this Manual, please do not hesitate to contact our head office, dealers or authorized service shop.

DAEWOO HEAVY INDUSTRIES LTD.

PRECAUTIONS 1. In order to operate excavators, you must get excavator operation license in accordance with relevant laws, regulations and decrees.

2. When you operate the excavator, please keep in mind that safety is the first.

3. Before and after operation, inspect and check the excavator.

Especially followings are essental.

-Inspect and check level of cooling water and oil.

-Replace periodically every oils and elements.

-Check, clean and replace the air cleaner elements.

4. Precaution·s in handling a new excavator.

All DHI DH170 are thoroughly adjusted and inspected before they leave factory.

However, it is important to perform a break-in operation for the first 50 hours in order to protect shortening life of the equipment 5. The diesel engine and all the hydraulic component have been inspected and correctly adjusted before leaving factory, and should not be disturbed in field.

If any abnormality is found, have them repaired at nearliest DHI dealer or authorized service shop.

Do not attempt to adjust components by yourself.

. - - - - - - - - FOR SAFER EXCAVATOR OPERATION-------,

X .)~:.\ =-: ~-::·· ,•·-

Never get under the excavator while jacking up.

When parking the excavator on a slope, for a short period of time. lower the bucket to the ground, place wedges under the tracks and put all control levers in neutral position.

0 Always lower the bucket to the ground when ever you Ieave the cab.

Should the engine stall on a slope, lower the bucket to the ground immediately and then put all control levers in neutral.

Provide a head guard on the cab if the falling of stone is expected.

While working, be sure to make all persons or things are away from the working area.

Never get on or off the excavator while travelling or working.

This equipment is only for excavator, do not use it as a crane.

CONTENTS

• TO THE CUSTOMERS • FOR SAFER EXCAVATOR OPERATION 1. Specifications·································•··•··•··•··•··•··•··•········•··•··•··•··•··•··•··•··•··•··•··•··•·· 2. Construction 2. 1 2. 2 2. 3

General ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· · ·· ··· ··· ··· ··· ··· · ·· ··· ··· ··· ··· ··· ··· ··· ··· · ·· ··· · 3 Hydraulic System ··· ··· ··· ··· ··· ········· ··· ··· ··· ··· ··· ······ ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ······ ··· ··· · 4 Electrical System ··· ··· ··· ··· ··· ······ ··· ··· ··· ··· ······ ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ······ ··· ··· · 7

3. Operation 3. 1 3. 2 3. 3 3. 4 3. 5 3. 6 3. 7

Precautions in handling a new excavator ······ ··· ··· ··· ··· ··· ··· ··· ...... ······ ······ ··· ··· ··· · 9 Operation of each system ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ······ ··· ··· ··· ··· · 9 Starting the engine ··· ··· ··· ... ··· ··· ··· ··· ··· ··· ··· ··· ... ··· ··· ··· ··· ··· ··· ··· ··· · ·· ··· ··· ··· ··· ··· ··· · 24 Stopping the engine····················································································· 24 Warming up the excavator ······ ··· ··· ··· ··· ······ ··· ··· ······ ··· ······ ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ·24 Precautions in cold weather ··············· ········· ································· ··············· ·25 Precautions during operation········································································ ·26

4. Inspection, maintenance and adjustment 4. 1 Periodic inspection and maintenance ··················· .. ··································· ..... 29 4. 2 Caution tor periodic inspection and maintenance····················· ... ····················· ·29 4. 3 Inspection and maintenance table··································································· 30 4.4 Inspection and maintenance ·········································································34 5. Transportation

·· · · · · ·· · ·· · · · · · ·· · ·· · ·· · · · ··· · · · · ·· · ·· · ·· · ·· · ·· · ·· ··· ··· · · · ··· · · · · ·· · ·· · ·· · · · ··· ··· · · · · ·· ··· · · · · ·· 52

6. Trouble shootings 6.1 Engine···························· .. ·········································································53 6. 2 6. 3 6.4

Electrical System · ·· · ·· ·· · ··· · · · · ·· ··· · · · · ·· ··· · · · ·· · ·· · · · · · · · ··· ·· · · ·· · ·· · ·· · ·· · ·· · ·· ..... · · ·· · · · ..... · · 54 Heater ......... ········· ...... ··· ............... ······ ............... ··· ............ ··· ...... ··· ... ······ ... · 54 Hydraulic System ........................................................................................ 55

7. Engine 7. 1 General information ... · .. · .. · .. · .......... · .. · .. · · ·· ·· · · · · · .. · ·· ......... · · · .. · .............. · · .. · ·· · ·· · 57 7.2 Engine views ········································ .. ···· ................................................ 59 7. 3 Introduction tor operation ······ .. ···· ................................................................ 50 7. 4 7. 5 7. 6 7. 7

Preventive maintenance · ·· ··· ... · ·· ... ··· ··· ··· ··· ··· ··· ... · ·· ··· ··· ··· ··· ··· ··· ··· ··· · ·· · ·· ......... · 62 Engine fluids ··· ··· ·· · ··· ··· · ·· ··· ··· · ·· ··· ··· ··· ··· ··· ··· ··· ··· · ·· ··· ··· ··· ··· ··· ··· ··· ··· ... · ..... ··· ··· · 69 Fault diagnosis ··· ··· ... ··· · ·· ··· ··· · ·· ··· ··· ··· ··· ··· ··· ··· ··· · ·· ··· ··· ··· ··· ··· ··· · ·· ··· · ·· ··· ··· ··· ··· · 72 Engine Preservation ..................................................................................... 74

7. 8 7. 9

Parts and service ··· ··· ··· ··· ... ··· ··· ··· ··· ··· ... ··· ··· ... ··· ... ··· ·· · ··· ··· · ·· · ·· · .. ··· ··· ··· ··· ... ··· · 75 Engine date ······························································································76

1.

SPECIFICATION

DH170

m Weight

16,900 kg

• Gross Weight

Performances• Bucket Capacity (CECE, STD)

0.61 m'(heaped) 1,095 mm (W/side cutter)

• Bucket width (STD)

1,085mm(W/0 side cutter)

• Propelling Speed

High

5,2 km/hr

Low

3.8 km/hr

• Swing Speed

12.5 rpm

• Gradeability

70% (35°)

• Swing Radius at Rear

2,450 mm

Track Shoes • Shoe Width

Engine

600 mm (Standard) 510 mm (Option) 700 mm (Option)

• Ground Pressure

0.40 kg/cm (with 600 mm shoe) 0.47 kg/cm (with 510 mm shoe) 0.35 kg/cm (with 700 mm shoe)

• Engine Type

Perkins 1006 -6HR

• Rated Output

103 ps/2,200 rpm

• Total Displacement

5,985 cc

• Fuel Tank Capacity

280 Q

Electrical System• Circuit Voltage

24 V

• Battery

12 V - 150 AHX2

• Starting Motor

24 V, 7.8 kW

• Generator

24 V, 55 A

• Dimensions for transportation (unitimm)

8660 ·-·-·---:==

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1600 . ______ 1630 . .,. 400r ·~---____..

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4030

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• Working Range

(2.6 m arm)

M

F

G

D

H

J C

------ I ----i---------

B --------

--------A-------A

Max. digging reach

9,045 mm

B

Max. digging reach (ground)

8,870 mm

C

Max. digging depth

6,110 mm

Max. loading height

5,945 mm

E

Min. loading height

2,195 mm

F

Max. digging height

8,675 mm

G

Max. bucket pin height

7,410 mm

H

Max. vertical wall

4,860 mm

I

Max. radius vertical

6,080 mm

J

Max. depth to 8' line

5,880 mm

K

Min. radius 8' line

2,295 mm

L

Min. digging reach

280 mm

M

Min. swing radius

D I

3,335 mm

2

2.

CONSTRUCTION

2. 1 General

SUPERSTRUCTURE 1. Cab 2. Control Valve 3. Tool Box 4. Engine 5. Muffler 6. Air Cleaner 7. Pump 8. Counter weight 9. Radiator 10. Oil Cooler 11. Hydraulic Tank 12. Fuel Tank 13. Swing Device 14. Battery 15. Center Joint

FRONT AND ATTACHMENT

16. Boom 17.

18.

19.

20.

21.

22.

23.

Boom Cylinder Arm Arm Cyliner Bucket Bucket Cylinder Point Head Light

3

UNDERCARRIAGE 24. Swing Bearing 25. Front Idler 26. Track Spring 27. Lower Roller 28. Upper Roller 29. Travel Device 30. Shoe 31. Track Link

2. 2 Hydraulic System The hydraulic system is the means through which all the operations of swing motor, propelling motors and front attachment (Arm, Boom and Bucket) are carried out.

And the control valves are also operated by hydraulic system (The discharged oil from the 3rd pilot pump is directed through operation levers to control valves).

That is, the excavator has a total hydraulic operation system.

1) The discharged oil from the 1st pump and 2nd pump is directed through the control valve to the swing motor, left travel motor, bucket, arm, boom, right travel motor.

2) The discharged oil from the 3rd pump moves the spool in the control vales through remote control valves located in the cabin.

Therefore, if the operator operate the remote control valve, the discharged oil from the pumps (1st and 2nd) is directed to each cylinder and motor.

3) A new, patented hydraulic system is applied to DH170, called the Electronic Power Optimizing System ( E. P. 0. S ).

It offers following advantages.

-independent movement of combined operation.

-shock free operation for excellent inching performance. (very good control sensitivity).

-very low power losses because pump supplies only the required flow.

4) The boom and the arm are operated in two stages. when each working device is solely operated, the work can be carried out more efficiently, because each cylinder moves in double speed.

5) A spare spool, spare pilot vavle, spare front piping are provided for additional attachments such as hydraulic breaker.

6) In the hydraulic circuit, safety valves are provided in the right and left control valve, pilot circuit, full-flow filter and oil cooler circuit respectively, to protect the circuit from damage due to exces-sive pressure or clogging.

7) The propel parking brake is put ON and OFF automatically by the travel motor drive pressure.

It is released by operating the propel lever and is applied by releasing lever to neutral position.

8) The swing parking brake is interlocked with the safety lever and engine.

9) This machine is equipped with an accumulator, which allows to move the frontend attachment for several time after the engine has stopped. As it contains high pressure gas, never detach it from the machine body, dismantle it or throw it into flames.

10) All hydraulic components have been inspected and correctly adjusted before leaving factory and should not be disturbed in field. If any abnormality is found, have them repaired at nearest OHi dealer or anthorized service shop.

4

• HYDRAULIC LINKAGE

I I I

j

---

1 2 3 4 5 6 7 8 9 10 11 12 13

Bucket cylinder Arm cylinder Boom cylinder Travel pilot valve Left pilot valve Right pilot valve Safety valve Solenoid valve Accumulator Solenoid valve Hydraulic oil tank Strainer Full flow filter

-

14 15 16 17 18 19 20 21 22 23 24 25 26

-- - - - -

--

- ------

Air breather Center joint Swing motor Control valve Spool (swing) Spool (arm) Spool (travel - right) Block Spool (travel - left) Spool (spare) Spool (bucket) Spool (boom) Front pump

5

~

Supply line Suction line ,•.••••••· Return line Actuator line Drain and pilot line

-

27 28 29 30 31 32 33 34 35 36 37

Rear pump Pilot pump Engine Radiator Oil cooler pilot filter Mode selection cylinder Travel Motor By pass valve By pass valve Drain filter

2. 3. Electrical system

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FAN SWITCH

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STM:lER SWITCH

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WIPEJI TIMER SWITCH

ORQJJT Bf:IEAICER

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21JI l.250r 211-

HEATER RCSISTOII:

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3.

OPERATION

3. 1 Precautions in handling a new excavator All machines are thouroughly inspected and adj usted prior to shipping. Howerver, it is necessary to perform the following break-i,n operation. This care given during the initial break-in period determines the future longevity of your equipment.

• Duration (Hour Meters) -Initial 50 hours : Approx. 80% load (Fuel lever stroke 75%) -After initial 50 hours: Full load possible Note that full load operation during the break-in period may cause minor ·scratches or seizures on very small parts in the cylinders, bearing and so forth, which will greatly affect the future longevity and safe operation of the excavator.

3. 2 Operation of each system 1) Monitor

The monitoring system is composed of the gauges, check lamps, warning lamps and indication lamps. This system checks the condition of the machine using sensors installed at various places. When the starting switch turned to "ON" or "HEAT" position, all lamps will light up and the alarm buzzer sounds for 2 seconds. If there is any lamp which does not light at this time, it denotes that the lamp filament is burnt out. lhe monitor illumination lamp will be lit when you switch on the lamp switch.

1.

2.

3.

4.

Tachometer Engine coolant temperature gauge Voltmeter Fuel gauge

5. Hour meter 6. Hydraulic oil level ~

7.

8.

9.

10.

11.

12.

13.

14.

15.

Q)

@

,~

Engine coolant level

:;J--

Eng;ne 0;1 pcessoce Charge Eng i,ne coolant overheat Air cleaner clogging High speed Auxiliary mode Preheating completion Head light

~Check lamp

Warning lamp

Indicating lamp

(1) Gauge

CD Tachometer -This shows the engine speed in RPM.

TACHOMETER RPM

9

@ Engine coolant temperature gauge -Green zone indicates normal running temperature.

-After engine start up, warm up the engine until the pointer moves into green zone.

-If the pointer moves from green into red range, run the engine at low idle speed until water temperature goes down.

WATER TEMP

@ Voltmeter -Green zone is normal in starter switch "ON" position.

-If the pointer is in the red zone, please check charging system.

-In case of preheating and for 15 seconds after starting the engine is cold weather, the pointer moves into the red zone, but this in not abnormal.

L

VOLT

®

Fuel gauge

-This gauge indicates the amount of fuel in the fuel tank.

-Before the pointer arrives at the empty point, please refill fuel.

F

E

FUEL

@ Hour meter -This meter shows the total operation hours of the machine.

The hour meter advances while the engine is running even if the machine is not being operated.

-While engine is running, indicator rotates to show the hour meter advances.

10

HOUR METER

IoIoIoIoIo11{o@J

(2} Check lamp (check before starting) • If there is any abnormality, the appropriate lamp will be lit in start switch "ON" or "HEAT" position before starting the engine.

• When the engine is started, these check lamps will go OFF even if there are abnormalities.

• Park the machine on level ground before check.

®

Hydraulic oil level

-This lamp is lit when the hydraulic oil level is abnormal.

When the lamp is on, check the oil level and replenish the oil.

HYD OIL LEVEL

Radiator coolant level -The lamp is lit when the coolant in radiator is insufficient.

When this lamp is lit, check the coolant level of the reserve tank and replenish the coolant if necessary.

WATER LEVEL

(3) Warning lamp

Engine oil pressure -When the engine oil pressure lower, the lamp is lit and the buzzer sounds at the same time.

In that case, stop the engine and check the engine.

-Meanwhile, it is normal that the lamp is lit before starting engine.

(Starting switch : ON position)

ENG OIL PRESS

Charge -When charging system fails, the lamp is lit.

Inspect and check charging circuit when the lamp is lit It is normal that the lamp is lit before engine starting.

(Starter switch : ON position)

CHARGE

Engine coolant overheat -When the engine cooling water is overheated, the lamp is lit and the buzzer !Sounds at the same time. When the lamp is lit, keep the engine idle until the pointer moves into green zone of the engine coolant temperature gauge.

11

WATER TEMP

@ Air cleaner clogging -This lamp is lit when the intake of air cleaner is abnormal.

Disassemble the air cleaner element (the exterior one) and clean or replace it.

AIR CLEANER

(4) Indicating lamp

@ High speed -This lamp is lit in case of high speed travelling.

HIGH SPEED

@ Auxiliary mode -When aux mode switch is turned on in case of EPOS (Electronic Power Optimizing System) failure, this lamp will be lit.

AUX. MODE

@I Preheat -When the starter switch is turned to -HEAT" position at coolant temperature below 10°C, this lamp will light up after about 19 seconds to show that the preheating is completed.

-When you turn starter swicth to "HEAT" position at coolant temperature above 10°C, this lamp will ligt up immediately to show that the preheating is not needed.

PRE HEAT

@Headlight -When you turn on the lamp switch, head lamp and this indicating lamp will be lit at the same time.

HEAD LIGHT

12

2) Switch

(a) Starter switch -OFF Key insertion-withdrawal position.

Engine stop, room lamp, car stereo and fuel transfer pump operations are available.

-ON Electrical system operating position.

-START At this position, the starting motor will crank the engine.

Even though you hold starter switch at "START" position continuously , the starting motor does not work as soon as engine is started.

-HEAT Used this position when starting in cold weather. Release the key to allow it to return automatically to "OFF" position as soon as HEAT lamp is lit and then turn it to START.

~

~

Swicth OFF

Preheat

C,

<t

Starter ON

(b) Mode select switch -This switch is used to change the mode H : For heavy digging at full engine speed S : Standard mode F : Fine control mode

s

~

~

(c) Lamp swich -With lamp switch in position head lamp will be lit In position

I , monitcr panel lamp and

II, working lamps in boom also lit.

13

Swithc ON

(d) Heater switch -This switch is used to heat the operator's compartment.

The flow rate of the hot air can be set to two levels.

L: Low H : High

(e) Wiper switch -This switch is used to operate wiper in the front window.

ON : Wiper is continuously operated .

W : Cleaning liquid is injected.

OFF

ew

~N

(f) Intermittent wiping switch If you turn this switch on while wiper is working the windshield wiper will work every 5 seconds.

(g) Auto idle switch -ON : Even if the fuel control lever is set in high idling position, the auto idle device will reduce the engine speed to medium about 4 seconds after all working levers are put into neutral.

-OFF : Use this position when you do not want the engine speed to slow down automatically. (h) Travel speed select switch Use this switch to select HIGH or LOW speed to suit the operating conditions. (i)

Fan switch Use this switch to operate a electric fan install,ed in front of the monitor.

{j)

Circuit Breaker Circuit breaker minimize the danger of fires in electrical wiring and system by providing efficient and reliable protection against overload and short conditions.

At the same time this is convenientliy resettabl1e once the fault has been cleared.

(k) Horn switch -This switch is located above right pilot control lever, and the horn sound, when the switch is pressed.

-Breaker switch located above left pilot control lever can be also used as horn switch when breaker selection switch is in "OFF" position.

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14

(I)

Breacker selection switch -This switch form the hydraulic circuit for a breaker.

-Turn thi's switch on when using the breaker as a attachment

(n)

I

\m) Breaker switch -Use this switch to operate the hydraulic breaker.

-Breaker is operated during pressing this switch when breaker Selection switch is in "ON" position (n) Cigarette lighter Depress the knob and wait for several seconds until it is returned antomatically to its origiinal position.

Then, the cigarette lighter is ready to use. (o) Room lamp switch This switch is located rear, upper ringht hand side of the cabin, it is used for lighting the cabin during night work.

15

'

3) Fuse box •Fusebox prevent the fires in electrical elements and electrical wiring by providing efficient and reliable protection against over load and short con dlitions.

• Use fuse remover when removing fuses.

• Th1ere are spare fuses (Two 10A fuse and two 15A fuse) in fuse box cover.

[NOTE] Put the key switch at off position when exchang1ing fuses.

0

0

Arrangement of fuse

Circuit Name

Fuse No.

C U1rrent

1

10A

Gauge panel, Control unit

2

10A

Wiper, Intermittent w iiper, Window washer

3

10A

Heater

4

10A

Travel speed solenoid, Preheat controller

5

10A

EPOS

6

10A

Aux-mode

7

10A

Room lamp, Car stereo

8

10A

Auxiliary

9

15A

Head lamp, Gauge panel light

10

15A

Electric Fan

11

15A

Horn, Breaker

12

15A

Cigar lighter

13

15A

Fuel filler pump

14

15A

Auxiliary

16

4) Car stereo (1 ) Controls and indicator

2

5

7

6

8

11

12

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4

1.

2.

3.

4.

5.

6.

7.

8.

9.

9

18

ON/OFF (Volume) control Fader control Balance control Tone control Program button Cassette tape door Rewind fast Forward/Eject buttons Rewind fast Forward/Eject buttons Display

17

10.

11.

12.

13.

14.

15.

16.

17.

18.

10

Tunning button Band selector (FM/AM) Local button Metal button Seek button Freq button Memo button Preset station button (1 -6) Tape indicator

(2) Operating instructions

1. ON/OFF (Volume) control -Power ON/OFF The power is turned OFF when the control is rotated counter clockwise as tar as it will go ; it is turned ON when the control is rotated clockwise.

-Volume adjustment When the control is rotated clockwise past the point at which the power is turned on, the volume will be increased. Conversely, When it is rotated counter clockwise, it will be reduced.

2. Fader control While the unit is being used with a 4-speaker system, this control is used to adjust the volume balance between the front two and rear two speakers.

To achieve the desired balance between the front and rear speakers, rotate the control clockwise when the volume of the front two speakers is low and, conversely, rotate is counter clockwise when the volume of the rear two speakers is low.

There are two rear speakers in our machine.

3. Balance control Rotate the knob counter clockwise when the volume at the 1 l eft is low or rotate it clockwise when the volume at the right is low adjust the balance between the left and right channels. Normally the control is kept at its center (cl ickstop) position. After having performed the adjustment, release the control.

17

4. Tone control Rotate the knob clockwise to increase high and counterclockwise to increase low response.

5. Program button Pushing this button during tape playback will reverse the direction of the tape play and change the tape direction indicator on the display.

6. Cassette tape door This is where you load your tapes. Load the cassette tape with the side of the tape visible to the right. Once you insert the tape, it will automatically start playing.

7. 8. Rewind fast Forward/Eject buttons ( <j <1 or "'\) Pressing the button indicates the same direction ( <1 <1 or [> [>) as the tape run direction, which is shown by the TAPE indicator, sets the tape to the fast forward mode.

Conversely, pressing the button corresponding to the other direction sets tape to the rewind mode. To release either the fast forward or rewind mode, press the button which has not been depressed and this will return the tape to normal playback. Pressing both buttons at the same time ("'\)during tape playback will cause the tape to be ejected from the loading slot.

The ""'\," mark denotes tape "eject".

9. Display The display comes with the following functions.

-Frequency display The reception frequency is indicated in MHz units for the FM band and in KHz units for the AM band.

-Preset channel display The preset station number is indicated while a program from a station preset in one of the preset station buttons is being received.

-Time The time will be displayed in hours and minutes during tape play back.

10. Tuning button This is used to tune the broadcasting stations. When right side of the button is pressed, the frequencies of the station to be received increase ; when left side is pressed, the frequency of it decrease.

11. Band selector (FM/AM) Push this button to switch from AM to FM or vice versa.

12. Local button This is used to change the tuning stop level during tuning by seeking.

The LOCAL mode is established when the button is pressed to its ON position.

At this position stations with weak transmission signals are skipped and only the stations wiht relatively strong signals are tuned in. This function makes it possible to seek quickly all those stations capable of providing stable reception. Press the button again to its OFF position to seek stations with week siganls.

13. Metal button (MTL) Set this button ON, when the tape to be played back is high-position type like a metal tape, a chrome tape, etc.

Set this button OFF for a normal-position type.

18

14. Seek button When this button is pressed during broadcast reception. SEEK tuning will start. Stations are tuned in automatically. Pressing this button again will stop seek tuning.

15. Freq button When you wish to know the time during a radio broadcast reception, depress this button. The time will be indicated in hours and minutes for a period of 8 seconds. The display will then return to this frequency of the radio station to which the unit is currently tuned.

16. Memo button (ME) Use this button to memorize the frequency of the station currently tuned in into one of the preset station buttons. The CH indicator in the display will flash on approximately 8 seconds. Pressing one of the preset station buttons while the indicator is lighting will memorize the frequency of the station currently tuned in into that button. In addition, this button is used when setting the time display.

17. Preset station buttons (1-6) A total of 6 AM station:; and a total of 6 FM stations can be preset into the six preset station buttons. when any one of these buttons is pressed within 8 seconds after the MEMO button has been pressed, the station received at that time will be preset into that button.

18. Tape indicator The tape indicator operates as follow in accordance with the tape travel.

* Time setting Only when the display mode on LCD is in clock mode, you can adjust time.

So if the display is showing frequency, press the FREQ button once, in order to have time shown on display.

Then you press ME button and TUNNING button you can adjust hour and minutes. Pressing the right side tuning button will increas the hour and pressing the left side TUNING button will increase minute while you hold 'ME' button pressed.

(3) How to install and remove the unit

Installation 1. Push the unit into the mounting frame, and install it in the housing case.

Removal 1. Detach two side covers from the unit.

2. Insert two hooks in the holes.

3. Pull out the unit.

4. Detach two hooks from the unit.

19

(4) Broadcast reception • Basic operation 1. Turn the unit on by means of the ON/OFF control, and adjust it to obtain the desired volume.

2. Press BAND selector to change the radio mode from AM to FM or vice versa.

3. Press the TUNING button to tune in the desired station.

When this is pressed to the right, the reception frequency is increased, while pressing it to the left reduces the reception frequency.

-MANUAL Tuning Hold the TUNING button pressed in the right or left direction ; when you approach the desired reception frequency, press the button and tune it once at a time in the appropriate direction to tune in the desired station accurately.

-SEEK Tuning When the SEEK button is pressed, tuning starts, and station will be tuned in automatically and held for 8 seconds each. When the desired station is tuned in, press this button again to stop seek tuning.

4. Use the VOLUME, BALANCE, FADER and TONE controls to adjust the set to your liking. * Your set is in the tape play mode if a cassette tape is in the tape deck.

• Presetting stations Your can recall stations whose programs you listen to frequently with a push of a button if you preset the frequencies of the stations beforehand in the preset stations beforehand in the preset station buttons.

1. Tune in the station which is to be preset in the following steps of basic operation.

2. Use this button to memorize the frequency of the station currently tuned in into one of the preset station buttons.

The "CH" indicator in the display will flash on approximately 8 seconds.

Pressing one of the preset station buttons while the indicator is flashing will memorize the frequency of the station currently tuned in into that button.

3. The preset stations can be selected simply by pressing the BAND button and preset button 1 through 6.

-When another station is preset into a button position that has already memorized a station, the previously memorized station is erased.

This unit features a last station memory function which stores the station which was heard before the power was switched off. This function serves to automatically recall the same station when the power is switched on again.

(5) Tape playback 1. Rotate the OFF/VOL control clockwise and switch on the power.

2. Insert the cassette tape into the loading slot.

If it is loaded with the exposed tape on the right, the top side wi II be played.

3. To listen to the reverse side, press the program button, this will reverse the tape run direction so that the bottom side will be played.

4. When a tape has been fast forwarded to the end, the tape run direction is switched and the reverse side is played back automatically.

When a tape has been rewound to the begining, the whole side will played back automatically.

5. Adjust the volume and sound quality, and sit back and enjoy the tape program.

20

-a

I~· 0

//§

lffil

6. When one side has been played and the end of the tape is reached, the tape run direction is automatically reversed to that the other side is played.

7. To stop the tape playback, simply press the eject button ◄ ►" and the tape will stop playing and will be ejected from the insertion slot and FM or AM reception will be enabled.

M

(6) Maintenance and precautions

1. Cleaning the head When the unit has been used for a long time, deposits of magnetic dust and dirt build up on the surface of the head which makes the sound unstable, produces noise and impairs the sound quality. When your unit has been working for a long time, obtain a cleaning tape from your audio dealer to clean the head.

-When using a cleaning tape, read through the accompanied instructions and for cleaning the head once, simply run the tape through once. Running the tape through again and again accelerate head wear.

2. Precautions for tape handling -The cassette shell and tape may be deformed if left in a location whose temperature is high or which is exposed to direct sunlight. Tapes which are not being used should be housed in their cassette cases and stored in a low-temperature location.

-Any tape slack should be taken up before use. Loading a slack tape can result in the tape being jammed around the capstan or pinch roller which can make it unusable -Use casette tapes up to C-90(90minutes). C-120(120minutes)tapes are thin and thus liable to snap or be extended or they can cause problems with transport, and so should not be used.

C-~C-6hmC-9ffmtl ~l~t!$JJ 3. Power supply connection -Do not connect the power supply cord to the 24V battery (+)terminal directly.

The rated voltage of this car stereo is 12V.

21

S) EPOS Controller (1) Self-Diagnostic function

EPOS controller has a self-diagnostic function, you can see an english character through the sight glass of the controller. This character shows if the machine is normal, or indicates the system which is the cause of the abnormality.

H.

H-MODE

5.

S-MODE

,-..-

A.

t I

'-'· ,-n.

ENG. SPEED SENSOR

Lf

MODE SELECT SWITCH

.,

F-MODE

.-

AUTO IDLE

C

'

L

c,I

ENG. LIMIT SWITCH

PROPORTIONAL SOLENOID VALVE F-MODE SOLENOID VALVE AUTO IDLE SOLENOID VALVE POWER SOURCE

(2) Auxiliary circuit If the controller breaks down, switch on the auxiliary circuit so that constant current may flow to the electronic proportional reducing valve for the resistor just as when using the S-mode.

The aux. switch is located inside left control stand. If the aux. switch is on, the aux. mode lamp on the monitor will light up.

6) Operator seat adjustment -Forward and backward adjustmet If you pull the lever (D, you can move the seat forward or backward. The adjustable distance is about 1,20mm -Height adjustment There are four steps adjustable wiht the pin@.

-Reclining The back seat can be adjusted to wanted reclining if you pull upward the reclining l ever@.

7) Operating levers

(1) Swing lock lever -This lever is for locking the upper structure into the under carriage (a) Position : Locked (bl Position : Released -Put the lever into lock position wh,en you propel on a slope or put on a slope or put on a transportation vehicle.

-When you lock the upper structure into undercarriage, align them properly before you put the lever into locking position.

22

(2) Engine control lever -This lever is for control of engine rpm . (a) Position : Low speed (rpm) (b) Position : High speed (rpm)

.

·-

.

.. .

(3) Lock lever

-This lever is installed below the left hand side control lever and disable all work. (a) Position : Work (b) Position : Work stop -Before you leave the cabin , lower the bucket to ground and put the lock lever to (b) position.

(4) Propel levers -This excavator is equipped with both propel levers and pedals. The lever and ped-

al are stuck each other and control the left and right propel motors.. (a) Position Travel forward. Push down the front of both levers to travel forward. (b) Position Travel in reverse. Push down the rear -of both pedals or pull backward both levers to travel in reverse.

(N) Position : Neutral - Nlever put your foot on pedals except necessity.

-If you want , the l evers can be taken off by disassembling bolts in the side of the pedals.

23

.

--

.·

~ -

. '. ~

(5) Left control lever (ISO pattern)

-This lever i,s the swing and arm control lever. (a) Position : Arm roll out (b) Position : Arm roll ,in (c) Position : Swing right (d) Position : Swin g. left -When you release the lever, it will return to neutral.

The swing and arm will stay in p osition.

-The operation i1nstruchon of the above is based on standard machine only.

Confirm by yourself the instructions on the plate attached to the cab wall.

(6) Right control lever

-This lever is the boom and bucket control lever (a) Position : Boom 11ower (b) Position : Boom raise (c) Position : Bucket roll-out (d) Position : Bucket rol 11-i,n -When you release the lever, i,t will return to neutral.

Boom and bucket will stay in position.

3. 3 Starting the Engine Start the engine in following procedures.

1) Make sure all control levers are in their neutral position .

2) Put the engine control lever in "LOW IDLE" position.

3) In cold weather, rotate the starter switch counter clockwise to "HEAT" and hold it there for about 19 seconds until the pre-heat lamp is lit 4) Put the starter switch to "START" to actuate the starting motor.

5) As soon as the engine start , release the starter switch.

(CAUTIONS) Don't crank engine longer than 20 seconds.

Wait 1 minute before you try again.

3. 4 Stopping the engine Stop the engine by the following procedures.

1) Put the eng ine control lever to idling position for 5 minutes.

2) Put the starter switch to "OFF" position.

3. 5 Warming the excavator The hydraulic system is designed to be operated satisfactorily when heated to 50±5 °C. If the oil temperature is below 20°C , the hydraulic components (motors, valves or pipings, etc.) are easy to be damaged when making a sharp turn. Before starting the operation, be sure to perform full warm up operation so as to raise the hydraulic oil temperature above 20 °c. The procedures are as follows.

1) Run the engine at idle speed for 5 minutes.

24

2) Pull the engine control lever to medium position and run the engine for about 5 minutes with the bucket lever in roll-in position.

(Do not operate the levers other than the bucket lever.)

3) Run the engine at high speed for 5-10 minutes with the bucket and arm levers in either roll-out or roll-in position.

(Do not use the levers other than the bucket and arm levers).

Especially be sure to warm excavator in winter or cold weather.

*

3. 6 Precautions in cold weather.

In cold weather, it is easy to bring about starting failure or cooling water freeze.

1) Fuel and lubricants.

Replace the fuel and lubricants with the special cold weather fuel and lubricants.

2) Anti-freeze Mix antifreeze in coolant water in order to prevent freezing. At that time mix the anti-freeze with water in accordance with following table on the basis of the temperature which is 10°C lower than the lowest one in the past of the operating region.

Anti-freeze vs water Min. Temp.

I

-5

Capacity Anti -freeze Water

-10

-15

-20

-25

8

9

11.5

13

14.5

23

22

19.5

18

16.5

3) Battery When the weather becomes cold, the battery performance is lowered to decrease the charging rate and the battery electrolyte is easy to be frozen. Maintain the charging rate to 100% if possible and take every measure to keep the batteries warm so that the excavator can be operated on the next morning.

The battery charging rate can be conversed from specific gravity of the battery electrolyte using following table.

~

Temp. (°C)

.

20

0

-10

-20

100

1.28

1.29

1.30

1.31

90

1.26

1.27

1.28

1.29

80

1.24

1.25

1.26

1.27

75

1.23

1.24

1.25

1.26

Charging rate (%)

~

25

3. 7 Precautions during operation 1) Prior to operation, always keep out for any obstacles or men adjacent to the excavator to insure safety.

2) When you propel on the rough ground, _decrease the engine speed and propel with low speed.

3) When applying the boom and arm to support the machine, press the ground with the round base of the bucket as shown in figure. The angle between the boom and the arm should be 90'~ 110°.

4) Pay attention to the followings when propelling on slopes.

(1) Prior to propelling up or down the slope, make sure the direction of the track and ground condition, and try to drive as straight as possible.

(2) Keep the bucket 20~30cm raised off the ground when going up or down the slope.

If the excavator tends to slip or come to be unstable, lower the bucket immediately to the ground.

(3) When the engine stalls on slope, lower the bucket to the ground and place the control levers in neutral.

Then, restart the engine.

(4) When parking the excavator on slope even for a short, put the control lever to the neutral position, and block the tracks with wedges.

20-30 cm

\

•

5) The excavator can be propelled in water up to the upper edge of the carrier roller.

The river bed should be taken into consideration so that the excavator may not sink deep.

The Surface of water

6) In the even that the swing bearing and/or center joint are submerged in water or mud, contact your local DHI dealer. If the excavator is used after being submerged, these parts will wear prematurely.

26

7) Operate the machine so that a little stroke may remain at both stroke ends of each cylinder. The front attachment may be damaged if the machine is operated with the cylinder fully retracted.

8) Avoid propelling the excavator with the bucket thrusted in the ground or digging by using the weight of the excavator.

Keep in mind these cautions to protect the machine from excessive force.

9) On a soft or muddy ground, always pay attention to the lower parts of the machine because the mechine may sunk gradually in the soft ground.

1 O) Make sure that the machine is always on firm ground, expecially when working close to an edge. At such times, the machine should be positioned with the propelling motors at the rear as shown.

11) Make sure that the worksite footing has sufficient strength to firmly support the machine.

12) Serious injury of death can result from contact with electric I ines.

27

13) During operating in the cave, be careful not to front part hit the ceiling of the cave.

14) For deep excavation, be careful so as not to strike the boom sides or the bucket cylinder hose against the ground.

/~,, .

15) Never level the ground or hit things using swing force. And do not use the bucket as a hammer or pile driver. Such operations will damage the excavator and shorten it's life.

16) Avoid digging diagnoally the track frame, as the tooth end may hit the track link.

SPECIAL ATTENTION FOR CRANE USE The hydraulic excavator is specifically designed for excavation work.

It has no built-in safety devices for crane operation CAUTION : When you use machine for crane operation, contact your OHi dealer to get safe information of lifting capacity.

28

f

'

~

:, ~,,::·

~

,5:.,1 ~..;;..-

4.

INSPECTION, MAINTENANCE AND ADJUSTMENT

4. 1 Periodic inspection and maintenance Periodic inspection and maintenance are essential for the satisfactory and efficient operation and for the longevity of excavator.

Inspects as follows and defect any irregularities, immediately repair then to prevent them from developing into serious condition.

(Table 4. 1) Periodic Maintenance Schedule Daily Services

Inspect and maintain before and after day's work

50 hours services

Inspect and maintain every 50 hours

150 hours services

Inspect and maintain every 150 hours

500 hours services

Inspect and maintain every 500 hours

1,000 hours services

Inspect and maintain every 1,000 hours

2,000 hours services

Inspect and maintain every 2,000 hours

4. 2 Cautions for periodic inspedion and maintenance 1) Use of recommended genuine parts Use recommended genuine DAEWOO parts in accordance with parts list in case of replacement of parts.

2) Oil When you refill or replace the oil, use the recommended oil conforming to atmospheric temperature.

3) Cleaning the excavator Keep the excavator clean in order to discover easily the irregularities.

4) Clean oil & grease Use clean oils and grease. And use the clean vessel to prevent from mixing with dust.

5) Prevention of dust mixture When inspecting or replacing oil, prevent dust mixture by choosing clean circumstances.

6) Notice board Place a notice board "under inspection and maintenance" on the cab door or control lever so as to prevent starting engine while the oil or cooling water is removed.

7) Cleaning of assembly surface The surface where o-ring and gaskets are assembled to protect leakage of fuel or oil should be clean before replacement.

8) Protection of eledrical system When cleaning the excavator, take care not to wet the electrical system with water.

9) Cautions during work in dust -Check from time to time by dust indicator whether the air cleaner is clogged on or not.

-Clean in shorter intervals the radiator core so as to preclude the clog.

-Clean and replace in shorter intervals the fuel filter.

-Clean the electrical components especially the starting motor and the generator.

1O) Deflation of air After maintenance of hydraulic pipes, hydraulic equipments and hydraulic circuits, deflate air out of them.

(1 )Deflation out of hydraulic pumps -Remove the air vent plug and fill the pumps with recommended hydraulic oil -If you don't deflate the air from the hydraulic pumps, the pumps will be abnormally heated and their lite will be shortened.

29

(2)Deflation out of cylinders.

- lln order to release the air, operate the engine in low speed, reciprocate each cylinder 4~5 tiimes to an d from 100mm pos i1tion from the end oi stroke and 3~ 4 times to and from the end of stroke.

(J)Deflation out of pilot line - While the eng i1ne is running, remove (a) and (b) to deflate air from pilot line according to the following procedure.

Roll in the arm (to the stroke end) remove (a)(b)-tighten(a)(b) -put the arm control lever neutral pos i,tion.

Repeat the same procedure untill air is not de!lated from(a)(b).

4. 3 !Inspection and Ma1intenance Ta ble Services

Interval

I

'

Daily

I 30 hours :I

-Check fuel llevel -Drain water and sediments from the sedimentor -Check hydraulic oil level and fill it -Drain water and sediments from oil tank -Check the engine oil level and fill it -Check the cooling water and fill it -Check engine fan belt for looseness and damages -Grease bucket pin -Check the wear of bucket teeth and side cutters -Check oil leaks of each system -Check bolts and nuts in loose and missing -Check operation of switches -Check operation of lights lamps -Check operation of monitors -Check engine for smooth starting, exhaust color and abnormal noise -Check operation of control levers -Check tracks for looseness -Check bollts for looseness of track parts !links, shoes, rollers, idlers) -Replace engine oil and oil filter element (only for the first service)

I

50 hours

References

-Grease pins of the front attachments -Grease swing bearing -Check wear of the upper and lower rollers -Replace the filter elements of hyd. oil return circuit (only for the first service) -Dra i1n the foreign particles and water of fuel filter

30

I

Services

Interval

References

-Replace engine oil and oil filter element -Replace the fuel filter element -Clean the outer element of air cleaner 250 hours

-Grease swing reduction device (only for the first service) -Replace gear oil of swing device (only for the first service) -Check and fill electrolyte level of battery -Replace filter

element of hydraulic oil return circuit

-Check wear of pins and bushings of front attachments -Clean the exterior and interior of the radiator -Replace gear oil of travel device (only for the first service) 500 hours

-Exchange cooling water -Replace grease of swing gear -Replace the element of hyd. oil drain filter -Replace the element of hyd. oil pilot filter ->Grease center joint -Grease swing device

1,000 hours

-Replace gear oil of travel device -Replace gear oil of swing device -Replace hydraulic oil -Replace suction filter of hydraulic oil -Replace suction filter of fuel -Replace elements of the air cleaner

1,500 hours

(both outside & inside ones) -Check generator and starter -Check anti-vibration rubbers of engine -Performance inspection and precise inspection

31

Autorized A/S shops

-Table of Recommended Lubricants Do not use lubricants other than those recommended.

Oil for

Kinds of lubricants

Hydraulic oil

Caltex oil

Engine crankcase fuel injection Pump and governor

-20~ 1-10~ 0°C 40°C

Less

More

32

than

than

than

~

32°C

0°C

32°C

0°C

Caltex RPM Delo

oil

300 oil SAE 40

Telleso

than Multi-purpose van EP90

I

'

SAE 30

SAE

2

10W

0

"1

I

I Nebla EP

Esso gear oil

Standard fleet

GP90 or standard gear oil

No. NUTO H32

40

No.

I

I

30

No. 1

No. 10W

Daphne super \Aporoil Diesel Hydraulic motive S-300

SAE90

Daphne coronex

Aporoil gear

grease

HE90

fluid 46WR

340 I 330 I 320 Mobil Mobil delevac

IDTE24 Super

High diesel

Seikiyu

highland

engine oil S-3

S26

I

32

SAE 40

engine

I SAE

I

30

series Mobilube HD80W class 3

I 46 I Lipanoc grease 47

SAE

No.2 I No.1

45

90

I No.O SP90 or EP90

10W

Shell rymla XS

Shell alvania

Shell spirax

K32

oil

EP grease 2

EP90

Total

Total

Multis EP

Transmission

Grease 2

DA85W90

I 30

Total

Total

Equivis ZS46

Man, 2920

SAE # 30

Niseki gearlube

Shell tellus

40

Remarks

No. 2 Mobil prex

1340 I "1330 I 1310

Nippon

Total

Diesel oil

Mobil oil

Shell oil

Rollers, idler

I 0°C

oil

Kosan

floating

I Less

Multifac EP

Esso lube HD

standard oil

Idemitsu

Gear oil

Swing gear, Swing unit and Swing bearing propelling unit Swing reduction gear

More

Catex land

HD32 Esso

Bearing grease

seal

Where to be Hudraulic applied system

Manufacturer

Engine oil

120120w

Normal(both summer and winter): SAE No. 30 equivalents Tropical zone : SAE No. 40 equivalents Freezing zone : SAE No. 1OW equivalents

NOTE

-Those products encircled by bold line are shipped together with the main product.

-Do not mix different oils in the sytem when you refill the lubricants, especially hydraulic oil.

32

• REPLACEMENT OF LUBRICANT AND FILTER ELEMENTS

®

© ®®@®@

0:

D.: Greasing

Lubrication points (Replacing points)

D: Cleaning

Replacing

Lubricant (Element)

30

CD

Grease

,:?)

Swing bearing

Grease

3

@

Swing gear

Grease

1

@

Center joint

Grease

1

Swing device

Grease

@

Engine oil pan

Engine oil

20 Q

(J)

Swing device

Gear oil

5Q

® ®

Travelling device

Gear oil

2X3Q

Oil tank

Hydraulic oil

215 Q

@

Fuel tank

Diesel

280Q

@

Radiator

Soft water

31 Q

®

Full-flow filter

Element

Hyd. oi I suet. filter

Strainer

1

Pilot line filter

Element

1

@

Hyd. oil drain filter

Element

1

®

Fuel suction filter

Strainer

1

® ©

Fuel filter

Element

2

Engine oil filter

Element

1

Element (outer)

1

Element (inner)

1

500

1000

1500

£::,. £::,.

&,.

®

£::,.

0

® ®

0 0 0

[Q]

®

2

®

250 £::,.

1

©

Air cleaner

50

6 (NOTE)

17

@

* :First replacement only lnterval(hrs)

Q'ty

Front joint pin

(B)

G)

0 0 0 0 □ 0

®

0

□

I

0 0

NOTE) In case of digging in water, be sure to apply lubricant to the front pins before and after operation.

33

4. 4 Inspection & maintenance 1) Engine (1) Engine oil -Check the oil level before starting the engine.

If the oil level is anywhere between H and L of the oil level gauge A, it is normal.

-Replacing or refilling oil, fill the oil through the oil filler opening B and recheck the oil level.

-Replacing engine oil, refill the oil after draining all the before-used oil through drain hole C. At that time, the el,ement of oil filter should be replaced.

-The interval of the first oil replacement is 30 hours, 250 hours afterwards.

A05II

(2) Engine oil filter -Engine oil filter element should be replaced at the same time with the engine oil.

-Replace oil filter element every 250 hours (initial 30 hours).

-For the details concerning replacement of oil filter element, refer to the engine operation manual.

34

(3) Fuel filter

-Replace fuel filter element every 250 hours.

-Periodically drain water and sediments removing the drain water and sediments removing the drain plug of bottom.

-Be sure to eliminate air from the fuel system.

-For the details concerning replacement of filter element and deflation of air . refer to the engine operation manual.

(4) Adjustment of fan belt tension -When you push the middle parts of the

fan belt with thumb, it should be pushed about 10mm -When adjustment is necessary, loosen the adjusting bolts ::D, ®, adjust the tension and retighten the bolts.

-Two belts must be renewed at the same time.

2) Radiator (1) Cooling water -Check the level of cooling water at the reserve tank A. If the water level is anywhere between FULL and LOW. it is nor-

mal.

rfr~ ~

'. i------.J, Ji -·- -··= FULL

'i ~Jw

u -When you replace cooling water, open the drain cock C at the bottom of the radiator to drain throughly, remove sediments and then refill the cooling water, through the filler B after the drain.

-Use soft or city water as free as possible from scale forming minerals.

35

(2) Anti -freeze -When t,h e outside temperature is anticipated to fall below freezing point, sufficient amount of anti-freeze should be used 1in the cooling system to prevent freezing. In cold season, the anti-freeze is mixed with water prior to shipping fro m factory.

-The anti-freeze should be mixed with water according to paragraph 3-6.

(3) Cleaning of core -Clean the radiator cores with stream or water.

3) Air cleaner

(1) Dust indicator -If the air cleaner element is clogged with dust, a warning lamp in the monitor by the operation of dust indicator A is turned into red.

-If the dust indicator lamp is turned red, clean the elements throughly by blowing compressed air or replace them.

(2) Elements -There are two elememts in air cleaner.

Dust of outside elements should be swept off every 250 hours.

-Rep~ l ace both inside and outside elements at the same time every 1,500 hours.

-1,f the cleaning or r eplacement of the elements is not done in time, the engine is overstrained during operation and decrease the performances of excavator.

(3) lnspedion of air intake system -Check periodically air intake system(all hoses, and pipes) for loose joints or connections.

4) Fuell tantk

(1) Fuel -Replenish the fuel at the end of each day's operation.

-This machine is provided with a motor driven fuel suction pump. After assembling the suction hose to the inlet of the pump, put other end into fuel drum and put the switch for the pump in the battery box in ON and fuel is sucked into the tank. At that time, watch the visual tuel gauge A.

36

-Before starting operation, check fuel gauge A and replenish fuel if necessary.

-The capacity of fuel tank is 280 Q.

(2) Dra.i ning water -Drain water and sediments d'aily by removing tne drain plug of sedimentor and occasionally by removing the drain plug at the bottom of fuel tank.

-The purpose of the draining water is to

drain water and sediments etc. So, it is better to drain water after rest and before operation.

(3) Suction strainer

-Replace the fuel suction strainer after 1,000 hours operation.

-Remove the cover at the bottom of the fuel tank and replace the suction filter.

S) Hydraulic oil tank

(1.) Hydraulic oil -Before you check hydraulic oil level, place the excavator in even place and set it in the posture shown in the right picture.

-Check the oil level by the oil gauge.

When the oil level is anywhere between red lines, it is normal.

-When you repl·ace or repl1enish hydraulic oil, use the same recommended oil with the existing oil. If you use other kind of oil, replace all the oil of oil tank and oil circuit.

37

(2) Draining water -Drain water and sediments by loosening the drain cock at the bottom of the tank.

-It is better to drain water before operation in the morning.

(3) Fuel flow filter el'e ment replacement -Replace the filter element for the first 50 service hours and there after every 250 service hours.

-Before replacement, clean the filter case and around it so that the dust may not get in the case.

-Remove the cover on the top of the tank replace the elements and observe if there are foreign materials such as debris of copper alloy , al uminum allioy or others in the old elements. In case there are foreign materials, inform OHi A/S shop in order to pursue its causes and preclude damages in advance.

(4) Hydraulic oil pilot filter -The pilot Mter is located at side of the hydraulic pump.

-Replace the filters after removing filter covers, and observe if there are any foreign materials.

-When replacing the elements, be sure to replace the o-ring at the same time and take care not to damage the o-ri:n g during assembl ing.

-Don 't loose nut in the center of frlter cover when replacing the fi.lters.

(5) Hydraulic oil drain filter -Precaution and procedure in replacement of filter element are same as those of hydraulic oil pi lot filter.

-When you change filter element, inspect the old element for foreign matters such as debris of copper alloy , or others in case there are foreign matters, inform OHi A/S shop to pursue its cause and preclu de damage in advanec.

38

(6) Hydraulic oil suction filter -The suction filter is located at the bottom of the hydraulic tank.

-Replace this filter when replacing hydraulic oil.

-Remove the upper cover when replacing filter without replacing hydraulic oil, the filter is connected with the upper cover by the connection rod.

6) Swing device (1) Check of oil level -Check the oil level by the A which is located at the swing un1it.

(2) Replacement of oil : every 1,000hrs (initial 250hrs) -When you replace the swing unit oil, drain the oil by removing the drain plug C which is located under part of the gear box. Retighten the plug and refill the oil through the fi'lller B located at the upper part of the gear box.

(3) Greasing : every 1,000hrs (initial 250hrs) -When greasing, remove the air deflation plug in the opposite side of filler port.

7) Travel device (1) Check of the oil level -Set the excavator so t1h at the fil ling plug B and drain plug A can be located like photograph and remove the plug C in order to check the oil level. If the gear oil flows out through the plug hole C, it is normal.

-If the oil is insufficent, replenish oil through filling plug B until oil flows out from the pl ug hole C.

(2) Replacement of oil -Drain all oil through drain plug A, retighten the plug A and pour fresh oil through filling plug B. -The replacement interval is 500 hours for the first service, and 1,000 hours afterwards.

39

8) Swing bearing (,) Swing bearing

-There are three fittings for swing bearing.

-Grease the bearing every 250 hours through these fittings.

(2) Replacement of grease of swing gear

-Replace the girease when the gears are wet with water or contaminated with foreign materials.

The peni odic replacement interval is 500 hours.

-Disassemble the under cover and remove old grease and apply new grease after remove the upper cover.

-Apply grease to the gear teeth with a putty !kn ife or the llike while the upper structure are being swing.

J

9) Center joint -Apply the

every

grease 1,000 hours.

through

fitting

40

110) Adjusting track link tension

Valve

(1) Adjustment method.

-When the track thension is too ti,ght, loosen the grease cylinder valve to blead out grease. When the track link tension is too loose, pump grease to the cylinder through the fitting in valve.

-Jack up the machine and check the track tension by measuring, the deflection " L" (midway between the idler and the

-Track tension capacity

sprocket).

(2) Criteria

-Tension is normal if the deflection " L" measures: • On average ground : 260~270mm • On swampy or marshy soil : 270~340mm

\.\..__A"ri::i""c'TT"F'F.F'F.F"!"r~W--+_,

Shoe lnside

• On grabbl'es, sand, snow and rough ground : about 340mm

11) Battery

-Check level of electrolyte after removing the battery cap.

- H the level is low, add distilled water to raise level' up to 10~12mm above plates.

-You can check the state of charge of battery by measuring the gravity of electrolyte, the criteria refer to paragraph 3.6 (Precaution in cold weather).

12) Lubrication of front attachment -Supply grease to the points marked in the figures.

-Pump the grease after cleaning the grease fittings.

©

®

Side Frame Lower

@

®

I

I

I

®

©

41

@ . Boom cylinder foot pins (2 points)

@. Boom foot pin (3 points)

©·. Boom cylinder rod

end (2 points) -

@. Arm cylinder foot pin (1 point)

®·

joint pin of boom and arm (2 points)

42

- - ---

®·

Arm cylinder rod end (1 point)

@. Bucket cylinder foot pin(~ Point)

®·

Joint pin arm and link (1 point)

(D. Joint pin of links (1 point)

Q). Joint pin of arm and bucket (1 point)

®-

Joint pin of bucket and link (1 point)

©-

Bucket cylinder rnd end (1 point)

43

13) Bucket point (tooth) replacement *Important When installing and removing Helilok teeth, always work safely and use proper equipment to avoid injury.

Observe these precautions : -Wear approved hardhat, safety glasses, gloves and steel-toed shoes.

-To avoid inadvertent injury to others, be sure other people are out of the way.

Only one peroson is needed to remove or install Helilok teeth.

(1) Installation -The Helilok point(A) threasds onto the adapter (B) and is secured by the U-shaped Quadrilok (C). The tools required for installation and removal are 4-pound hammer(D) and an ESCO Quadrilok removal tool(E).

-Clean the adapter nose to make sure the point will seat fully.

-Twist the point on with a quarter turn to contact the square end of the adapter nose.

44

-Insert the Ouadrilok with the side marked "FRONT" facing the front of the point.

Always use a new Quadrilok when changing points.

"FRONT" Facing Forward

-Center the Ouadrilok between the point ears. Then hit the top of the U-shaped lock to seat it fully into the groove.

-To complete installation, check that the hooks on both legs of the Ouadrilok are fully secured under the point ears.

Point Ear '

45

(2) Removal

*Caution The ESCO Removal Tool is designed only for use with Helilok points and adapters.

During the removal of a Quadrliok, make sure there is room behind you because the Quadrilok may release suddenly, causing a possible loss of footing.

-Hammer the sides of both point ears to loosen fine material which may have packed in around the Quadrilok.

-Use a screwdriver to clean the recess slot in the center front of the Quadrilok.

-Insert the small hooked end of the removal tool under the Quadrilok and apply a sharp downward tug to initiate removal.

46

-At mid-point of lock removal, insert the large jaw-end of the removel tool under the Quadrilok to obtain extra leverage.

Additional blows on the point and downward pressure on the tool will aid in lock removal.

-If the Quadrilok binds, complete the removal by tapping the lock on both sides while maintaining pressure.

-Remove the Quardrilok, Complete removal by pulling the point off the adapter with a 1 /4 twist.

47

14) Retightening bolts and nuts.

(1 )Tighten bolts and nuts of every part in accordance with the torque chart.

Before or after daily operation, check them if they are loosend or lost.

When they are loosened, retighten them and when they are lost, immediately assembly new ones. The bolts and nuts are to be tightened to proper torque for the first 50 hours and, thereafter, every 250 hours.

• Torque chart

No.

Item to be retightened

Dia.

Q'ty

Tool

Torque (kgf-m)

16(H) 12(H) 10(H)

12 8 16

24 19 17

21 9 5

1

Engine mounting tightening bolt

2

Oil tank tightening bolt

16(H)

4

24

21

3

Fuel tank tightening bolt

16(H)

4

24

21

4

High pressure hose union

PF 3/4 PT 3/4 PF 1 10(T) 12(T)

35 29 41 L-wrench L-wrench 27 32 36

18 7 21 6.5 11 9.5 14 18

I

High presssure hose ; flange High presssure hose ; ORFS

I

20(T)

4

L-wrench

55

Control valve tightening bolt

12(T)

4

L-wrench

11

7

Swing device tightening bolt

20(T)

11

30

55

8

Battery tightening bolt

1 0(H)

2

17

5

9

Cabin tightening bolt

16(H)

4

24

21

10

Swing bearing tightening bolt

20(T)

72

30

55

11

Travel motor tightening bolt

16(T)

60

24

23

12

Sprocket tightening bolt

16(T)

42

24

23

13

Upper roller tightening bolt

12(H)

16

19

9

14

Lower roller tightening bolt

16(T)

64

24

27

15

Shoe bolt

16(T)

392

24

38

16

Front idler tightening bolt

16(T)

8

24

21

5

Pump tightening bolt

6

Note; -When tightening, clean rust, sand and dust from bolts, nuts and surrounding areas or parts.

-Apply "Lock tight 262" to the threads of the attaching bolts of swing bearing, swing unit, travel device, sprockets and lower rollers.

-Consult nearest OHi dealer or service shop if the counterweight attaching bolts are loosened.

48

*REMARKS Torque is twisting or turning effort and is measured in kgf-m for instane, 118N-m (12kg-m) torque would be applied if you pulled on a 1m spanner with 118N(12kg) force.

If you use a 25cm spanner, force required to exert this torque would be : 118N-m(12kgf-m)X110/25 = 472N(48kg).

1S) Precautions in part repairs

(1) Never touch the engine setting(governor setting), pump regulator setting, and main relief setting for control valve.

(2) Never disassemble the hydraulic components, rollers, idlers. Have them inspected and repaired at nearest DHI dealer or authorized service shop.

(3) When replace the parts, refer to the parts list and use genuine DHI parts. Expecially, blots, nuts for hydraulic components and travel device are of special type. Never use unauthorized parts which may break to endanger men or excavator. Proper tightening is essential because these bolts and nuts must withstand extreme load during operation.

(4) Take special care to protect hydraulic joints from scores, scratches, mud and othere air borne abrasives.

-After cleaning, wipe off solvent thoroughly from pipes, rubber hoses, oil tank and their surroundings using a clean and link free clothes.

-Don't use o-ring scored, scratched or cracked. Take care not to damage o-ring during assembling.

-Warp threaded parts of pipes and hose joints with sealing tape.

1 to 2 pitches to be left.

Take care not to wrap them more than necessary and leave one to two pitches from the end of the each joint or pipe. In the mean time, wrap the tape in the opposite direction to tightening like the figures.

0 -Tighten the low pressure hose clamps to a torque of 0.6~0.7kg-m(5.9~6.9N-m)

49

16) Maintenance services under unusual conditions

Conditions Operation in mud,

Maintenance service I

-After operation : Clean entire excavator and check for

water, rain or snow I

Operation in seaside

-Before operation : Check plugs and cocks for tightness.

cracked, damaged, loosened, lubricate each points.

-Before operation : Check plugs and cocks for tightness.

-After operation : Flush with fresh water any part in actual contact with salt water. Pay particular attention to electric parts and take necessary measures to protect them from the corrosion.

Operation in dust and grit

-Air cleaner: Clean element more frequently than under usual condition.

-Radiator : Flush with fresh water to remove embedded dust and grit from core.

-Fuel system : Clean strainer and filter element more frequently than under usual condition.

-Electrical accessaries : Clean starter and generator commutators.

Operation in rocky terrain

-Tracks : Check for damages to tracks, rollers, idlers and thumblers. Check for loosened, damaged or missing bolts and nuts. Have track tension more loosened than under usual condition.

-Front attachment : Over load to standard front attachment may bring about damages.

When the excavator is to be operated under tough conditions, use proper attachment or reinforce it as necessary.

Operation with

-Cab head guard : Install head guard *

danger of falling stones Operation in extreme cold

-Fuel, lubricating oil : Use cold weather type of good quality fuel and oil.

-Cooling water : Use sufficient antifreeze in radiator.

-Battery : Recharge more frequently than under normal conditions. If the battery is not sufficiently charged, electrolyte may be frozen.

-Track: Remove accumulated mud and take necessary measures to protect from freezing.

*If there are any damage of falling stones, be sure to use head guard.

Consult nearest OHi dealer or service shop to install.

50

17) Precaution in long storage

Item Cleaning

Maintenance services Wash thoroughly lower parts of excavator.

Check track parts and repair it it necessary.

Lubrication

Lubricate all grease points and oiling points. Apply a thin coating of oil to all exposed metal surfaces, if necessary. (cylinder rod etc.)

Battery

Dismount, recharge and store battery in cool and dry place, or remove terminals from battery.

Cooling system

When there are any possibility of freeze, add sufficient anti-freeze or drain water throughly. In case of draining water, attach a tag "NO WATER".

Protection against

Store the excavator in dry garage. Protect engine from

dust and moisture

moisture with a suitable covering and cover the operation seat.

Tool box

Store tools in tool box after taking measures against rust.

Lubrication operation

Once a month, start the engine and operate the excavator

(In low speed with no

to distribute oil to pistons, cylinders, bearings and so

load for a few minutes)

forth. (Don't forget checking cooling water before starting)

*NOTE -Lubrication operation refers to operation which repeat the motion including warming, propelling, swinging and digging 2 or 3 times.

-Lubricant is also reduced during storages.

Replenish sufficient lubricant when you operate the excavator after storage.

18) Bucket linkage clearance Check the bucket clearance "A".

If necessary adjust it as follows.

• Remove bolt A and plate B. • Remove shims C according to clearance ·'a''.

• Fit plate B to pin and tighten bolt A. • There are two kinds of shims in thickness; 0.5mm and 1.0mm.

®

Bucket

Pin Arm

Bucket

I

®

Clearance "a"

©

m age clearance part.

51

5.

Transportation

S. l . Transportation The excavator of standard specification can be transported an a 24 tons trailer without disassembling.

When the excavator is loaded onto, unloaded from a trailer by its own power, use a ramp of a sufficient capacity to support the weight of the excavator. Never jack up the excavator to get on or off the trailer. The appropriate slope of the ramp is up to 10°-15°. If the ramp is wet with water, place straw mats on it. When the front attachment is removed, since the gravity center of the excavator is closer to the end, drive with the counter weight foremost.

After placing the excavator on the trailer, be sure to apply the swing lock, wedge the track link with wooden block and strap the excavator to the deck by using the tie rods and wire ropes. Examine in advance obstacles on the road to pass especially over road bridge etc.

Weight and dimension for transport

DH170

Overall Height

Overall Width

Overall Length

Overall Weight

Reference

About 2,950mm

About 2,800mm

About 8,660mm

About 16.9tons

Standard Specification

i

(Precautions) -When loading or unloading the excavator with its own power, be sure to use a ramp and reduce the speed of engine as low as possible.

-The ramp should have sufficient strength to endure the weigth of excavator.

-Take correct direction before crawling, never steer the machine once it gets on the ramp way.

-Use the bucket to reduce movement of the machine to the minimum, because the center of the gravity of the machine will shift abruptly when riding over the ramp and walking on to the trailer.

ramp

Do not use to jack-up

S. 2. Dimension of transportation

8660

2450

1250.

0

L')

Ol N

4030

52

1225

6.

Trouble shooting

6. 1 Engine Trouble Engine hard to start, will not start

Cause

Remedy

-Wrong fuel -Low battery power -Plugged line or nozzle -Resistance in starting circuit

-Use correct fuel -Charge or install battery -Clean line or nozzle -Clean and tighten battery and starter connection -Use correct oil -Remove air from fuel system Clean fuel tank strainer -Check fuel system connections -Check electrical system

-Wrong engine oil -Water, dirt or air in fuel system or plugged filters -Leaks in fuel system -Engine stop solenoid failure Engine knocks, runs irregularly or stops

Engine has little power

-Engine oil low -Plugged air intake sytem - Injection pump out of time -Plugged fuel filters -Low coolant temperature

-Add oil -Clean filter and system -Consult with your dealer -Install new filters -Thermostat not working correctly or too ~cool"

-Water, dirt or air in fuel system -Plugged filters or injection nozzles dirty or faulty -Engine stop solenoid failure

-Remove air from fuel system Clean fuel tank -Consult with your DHI dealer for injection nozzle service -Check electrical system

-Air intake system plugged -Plugged fuel filters -Injection nozzles dirty or faulty

-Check air intake system -Change filters -Consult with your DHI dealer for injection nozzle service -Consult with your DHI dealer

-Speed control linkage out of adjustment -Wrong oil -Injection pump out of time -Engine is too hot -Wrong valve clearance

-Use correct oil -Consult with your DHI dealer -See below -CHeck and adjust valves.

See perkins manual

Coolant tern perautre too high

-Low coolant level -Thermostat faulty -Radiator cap faulty -Radiator core or oil cooler core plugged -Injection pump out of time -Air cleaner plugged -Fan belts loose or faulty -Cooling system passages dirty -Temperature gauge faulty

-Check coolant level -Consult your DHI dealer -Install new cap -Clean radiator core and oil cooler core -Consult with your DHI dealer -Clean air cleaner -Tighten or install new belts -Clean cooling system -Install new gauge

Coolant Temperature too low

-Thermostat faulty -Temperature gauge faulty

-Consult with your DHI dealer -Install new gauge

53

Remedy

Cause

Trouble Low engine

-Low oil level

-Add oil to correct level

oil pressure

-Plugged oil filter

-Install a new oil filter

-Oil leaks or engine temperature

-Check for leaks. Check cooling

too high Engine uses

system

I -Wrong oil

-Use correct oil

-Oil leaks or engine temperature

too much

too high

oil

-Check engine oil drain plug Check cooling system

-Plugged air cleaner

-Clean element or install new element

-Plugged or dirty air intake

Engine uses

-Clean air intake system

system

too much

-Fuel injection nozzles dirty or

fuel

-Consult with your DHI dealer

faulty -Injection pump out of time

-Consult with your DHI dealer

Exhaust gas

-Wrong fuel

-Use correct fuel

is black

-Plugged or dirty air intake or

-Clean air intake and exhaust

exhaust system

system

Exhaust gas

-Injection pump out of time

-Consult with your DHI dealer

is little

-Injection nozzle dirty or faulty

-Consult with your DHI dealer

Exhaust gas

-Wrong fuel

-Use correct fuel

is white

-Cold engine

-Run engine until warm

-Thermostat faulty or too "cool"

-See your DHI dealer

-Injection pump out of time

-See your DHI dealer

6. 2 Electric system Cause

Trouble

Remedy

Batteries

-Loose or corroded connections

-Clean and tighten

will not

- Low battery power

-Install new batteries

take a

-Alternator belt loose or faulty

-Tighten or install new belt

charge

-Alternator turn on speed wrong

-Consult with your DHI dealer

Starter does

-Loose or corroded connections

-Clean and tighten

not work or

-Low battery power

-Check specific gravity of

-Wrong engine oil

-Use correct oil

-Electrical system failure

-Consult with your DHI dealer

electrolyte

turns slowly

6. 3 Heater Trouble

I

Remedy

Cause

Heater will

-Thermostat faulty

-Consult with your DHI dealer

not heat

-Heater hose valve closed

-Open valve

54

6. 4 Hydraulic system Trouble Parts con trolled by hydraulic system move too slowly

Cause

Remedy

-Cold oil -Wrong oil -Engine speed too low -Worm pump

- Operate hydraulic system to normal operating temperatures -Use correct oil -Consult with your OHi dealer -Consult with your OHi dealer

Oil temperature too high

-Wrong oil -Oil lines plugged -Plugged filters -Worn pump -Plugged radiator or oil cooler -Oil cooler faulty -Relief valve faulty -Dirty oil -Worn propel motors

-Use correct oi I -Consult with your OHi dealer -Install new filters -See your DHI dealer -Clean, make fins straight -See your DHI dealer -See your DHI dealer -Drain oil and install correct oil -See your DHI dealer

Oil foams

-Air sucked in line from reservoir to pump -Kinks or dents in oil lines -Wrong oil -Water in oil -High or low oil level

-Check line -Check lines -Use correct oil -Change oil -Make level correct

Low or no oil pressure

-Wrong oil -No oil in system -Worn cylinder packings -Relief valve faulty

-Use correct oil -Fill with correct oil -See your DHI dealer -See your OHi dealer

All actuators don't work.

(Big noise from pumps)

-Hydraulic pump failure -Lack of hydraulic oil level -Damage of suction line

-See your OHi dealer -Add oil -Repair or replace

All actruators have little power

-Wear of pump -Set pressure down of main relief valve -Hydraulic oil level low -Foreign matters on suction filter -Sucked air through pump suction side

-See your DHI dealer -See your DHI dealer

-Low function of relief valve -Damage of pipe or hose -Loose pipe fittings -Damaged o-rings in the pipe fittings -Damaged hydraulic pump -Damaged remote control valve

- See your DHI deal er -Repair or replace -Retorque -Install new o-rings -See your DHI dealer -See your OHi dealer

One side lever motions don't work

55

-Add oil -Clean filter and system -Retorque

I

Cause

Trouble

Remedy

Only one

-Control valve spool faulty

-See your OHi dealer

actuator

-Foreign matters clogged in the

-Repair or replace

dosen't work

valve spool -Damage of pipe or hose

-Repair or replace

-Loosen pipe fittings

-Retorque

-Damage of o-ring in the pipe

-lsntall new o-ring

fitting -Damaged remote control valve

-See your OHi dealer

One cylinder

-Oil seal faulty

-Repair or replace

doesn't work

-Oil leak caused by damaged

--Repair or replace

or has little

cylinder rod

power Both propels

I -Center joint faulty

-See your OHi dealer

don't work One side

-Propel motor faulty

-See your OHi dealer

propel

-Parking brake release faulty

-See your OHi dealer

No swing

-Swing brake faulty

-See your OHi dealer

motion

-Damage of swing motor

-See your OHi dealer

Traveling

-Too tight or loose track tension

-Re-adjust

is not

-Lack of oil in the idlers or rollers

-Refill oil

smooth

-Deformed track frame

-Repair or replace

-Meshed stones etc

-Remove and repair

-Parking brake scratch

-See your OHi dealer

doesn't work

Swing does

-Worn swing gear

-See your OHi dealer

not work

-Damaged swing bearing and/or

- See your OHi deal er

smoothly

balls -Lack of grease

-Charge grease

56

7. ENGINE 7. 1 General information 1) Introduction

The 1000 Series family of industrial and agricultural engines is the latest devel opment from Perk,i ns Engines Umited', a world leader in the design and manufacture of high performance diesel engines.

1

More than fi,fty years of diesel production experience, together with the latest technology, have been applied to the manufacture of your engine to give you reliable and economic power.

To ensure that you use the relevant information for your specific engine type , refer to "Engine identification".

2) How to care for your engine

This hanctbook has been written to assist you to maintain and operate your engine correctly.

To obtain the best performance and the longest life from your engine, you must ensure that the maintenance operations are done at the intervals indicated in "Preventive maintenance". If the engine works in a very dusty environment or other adverse conditions, certain maintenance intervals will have to be reduced. Renew the filter el'e ments and lubricating oil regularly in order to ensure that the inside of your engine remains clean.

Ensure that ai'I adj'ustments and repa.irs are done by personnel who have had the correct training. DHI distributors have this type of personnel available.

You can also obtain parts and service from your DHI distributor. H you do not know the address of your nearest distributor , enquire at one of the DAEWOO companies.

The left and right sides of the engine are as seen from the rear.

~~i;!l,,llki':;-.,L-, ..

Read the "Safety precautions" and remember them.

They are given for your protection and must be applied at all times.

57

.

i---,. .

"·

3) Safety precautions These safety precautions are important. You must refer also to the local regulations in the country of use. Some items only apply to specific applications.

• Only use these engines in the type of application for which they have been designed.

• Do not change the specification of the engine.

• Do not smoke when you put fuel in the tank.

• Clean away fuel which has been spilt.

Material which has been contaminated by fuel must be moved to a safe place.

• Do not put fuel in the tank while the engine runs(unless it is absolutely necessary).

• Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training ; even then extreme caution must be used to prevent injury).

• Do not make adjustments that you do not understand.

• Ensure that the engine does not ;-un in a location where it can cause a concentration of toxic emissions.

• Other persons must be kept at a safe distance while the engine or equipment is in operation.

• Do not permit loose clothing or long hair near moving parts.

• Keep away from moving parts during engine operation. A~ention : The fan cannot be seen clearly while the engine runs.

• Do not operate the engine if a safety guard has been removed.

• Do not remove the filler cap of the cooling system while the engine is hot and while the coolant is under pressure, because dangerous hot coolant can be discharged.

• Do not use salt water or any other coolant which can cause corrosion in the closed cooling circuit.

• Do not allow sparks or fire near the batteries(especially when the batteries are on charge)because the gases from the electrolyte are highly flammable.

The battery fluid is dangerous to the skin and especially to the eyes.

• Disconnect the battery terminals before a repair is made to the electrical system.

• Only one person must control the engine.

• Ensure that the engine is operated only from the control panel or from the operator's position.

• If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.

• Diesel fuel and lubrication oil(especially used lubricating oil)can damage the skin of certain persons. Protect your hands with gloves or a special solution to protect the skin.

• Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated with oil into the pockets.

• Discard used lubricating oil in a safe place to prevent contamination.

• Do not move mobile equipment if the brakes are not in good condition.

• Ensure that the control lever of the transmission drive is in the "out-of-drive"position before the engine is started.

• The combustible material of some components of the engine(for example certain seals)can become extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with the eyes.

• Fit only genuine Perkins parts.

58

The engine number is stamped on a label which is fastened to the left side (D , or rear ® , of the cylinder block. An example of an engine number is YA80515.

If you need parts, service or i,nformation for your engine, you must give the complete engine number to your DHl's distributor.

7. 2 Engine views Front and left side view of YA engine ·

CD Filler cap for ® Fuel Mter (t @ @ @ (f)

lubricating oil

Lubricating oil cooler Fuel injection Pump Lubricating oil dipstick Drain plug for lubricatiing oil Crankshaft pulley

® Fan ®

Water pump

@ Front I ifting bracket

CID Water outlet @ Atomiser

Rear and right side view of YA engine

@ @ @ @ @ @ @ @

-~=~-~'='~------,@

----®

59

Alternator Lubricating oil filter Drive belts Starter motor Lubricating oil sump Drain plug for lubricating oil Flywheel housing Flywheel ® Fuel lift pump @ Exhaust manifold @ Induction manifold

7. 3 Introduction for operation 1) How to start the engine Several factors affect engine start, for example : The The The The

power of the batteries. performance of the starter motor. viscosity of the lubricating oil. installation of a cold start system.

Diesel engines need a cold starting aid if they are, to start in very cold conditions.

Normally, your vehicle or your machine will be fitted withthe correct equipment for your region of operation.

Perkins engines can be equipped with various cold starting systems. For the 1000 Series engines these systems are : Fuelled starting aid : An electrically operated device which ignites a specific amount of diesel fuel in the induction manifold in order to heat the induction air.

Port heaters : These electrical devices are fitted in the induction manifold and heat the induction air.

They are operated automatically when the starter motor is engaged. When these devices are fitted, the start procedure for a cold engine is the same as that given for a cold engine start without starting aids.

Start Pilot : A hand pump is used to inject a cold start fluid into the induction manifold through an atomiser. The cold start fluid ignites at a lower temperature than diesel fuel. The cold start fluid is contained in a separate reservoir. Certain models use a push button to actuate a solenoid which releases the cold start fluid from an aerosol container.

KBi : This system uses an aerosol container filled with cold start fluid. The fluid is released by a solenoid, which is operated by a push button. The cold start fluid is sprayed into the induction manifold through a nozzle. The cold start fluid ignites at a lower temperature than diesel fuel.

Attention: If the engine has not run for several weeks, see "Attention" on paragraph "7-7".

How to start a warm engine 1 Adjust the engine speed control to the low idle position.

2 Turn the start key to the "START" position (A)to engage the starter motor.

3 Allow the start key to return to the "ON"position, as soon as the engine starts.

Always ensure that the engine and starter motor are stationary before the starter motor is engaged again.

60

OFF

I

HEAT '\

I

ON

I

• ~__:'TART

How to start a cold engine with the fuelled starting aid

1 Turn the start key to the "HEAT" position (A) and keep it there for 19 seconds until the preheat lamp is lit.

2 Adjust the engine speed control to the maximum speed position.

3 Turn the start key to the "START"position, in order to engage the stater motor. Allow the start key to return to the "ON" position, when the engine starts. Then adjust the engine speed control to give an even idle speed.

4 If the engine does not start, turn the start key to the "HEAT"position and hold it there for 19 seconds.

Then engage the starter motor again.

Ether type fuels must not be used at the same time as a fuelled starting aid.

2) How to stop the engine

Turn the engine start key to the "OFF" position.

3) Adjustment of engine speed range

The idle or maximum speed settings must not be changed by the engine operator because this can damage the engine or transmission. The warranty of the engine can be affected if the seals on the fuel injection pump are broken during the warranty period by a person who is not approved by Perkins.

4) Running-in

A gradual running-in of a new engine or POWER EXCHANGE engine is not necessary. Prolonged operation at light loads during the early life of the engine is not recommended. Maximum load can be applied to a new engine as soon as the engine is put into service and the coolant temperature has reached a minimum of 60°C(140°F).

Do not operate the engine at high speeds without a load.

Do not overload the engine.

5) Altitude

If the naturally aspirated engine is to run at an altitude above 600 m (2,000ft), the fuel delivery can be changed to reduce fuel consumption and smoke. Perkins can give the percentage of fuel reduction necessary if details of engine application and ambient conditions are given.

Changes to the settings of the fuel injection pump must be made by a Perkins distributor or by an approved distributor for the fuel injection pump.

61

7. 4 Preventive main tenance 1) Preventive maintenance periods These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is installed. If necessary, use the shorter periods. When the operation of the engine must conform to the local regulations these periods and procedures may need to be adapted to ensure corredt operation of the engine.

It is good preventive maintenance to check for leakage and loose fasteners at each service.

These maintenance periods apply only to engines that are operated with fuel and lubricating oil which conform to the specifications given in this handbook.

2) Schedules The schedules which follow must be applied at the interval(hours or months)which occurs first First service at 20/40 hours Every day or every 8 hours Every 200 hours or 6 months Every 400 hours or 12 months Every 800 hours Every 1,200 hours Every 2,000 hours Operation

• • • • • • • • • • • • •

Check the amount of coolant

• • • • • • • • • • • • • • • • •

Clean the sediment chamber and the strainer of the fuel lift pump

• •

Check the drive belt(s)

Check for water in the fuel pre -filter* Renew the fuel filter element(s) Ensure that the atomisers are checked Ensure that the idle speed is checked and adjusted, if it is necessary* Check the amount of lubricating oil in the sump

• • • • • • • • • • • • • • • • •

Check the lubricating oil pressure at the gauge

• • • • • • • • • • I • •• •• • •

Clean the air cleaner or empty the dust bowl of the air filter

Renew the lubricating oil Renew the Canister(s) of the lubricating oil filter

-extremely dusty conditions -normal conditions Clean or renew the air filter element, if this has not been indicated earlier

• •

Ensure that the valve tip clearances are checked and adjusted, if it is necessary*

•

Ensure that the alternator, starter motor etc. are checked*

Ensure that the exhauster is checked*

* By a person who has had the correct training.

62

3) How to drain the cooling system Attention : Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous coolant can be discharged.

1 Ensure that the machine is on level ground.

2 Remove the filler cap of the cooling system.

3 Remove the drain plug from the side of the cylinder block(A or B) in order to drain the engine.

Ensure that the drain hole is not restricted.

4 Open the cock at the bottom of the radiator in order to drain the radiator.

5 If necessary, flush the system with clean water.

6 Fit the drain plugs and the filler cap.

Close the radiator cock.

4) How to check the drive belt(s)

Renew belts if it is worn or damaged.

Twin belts must be renewed together.

To ensure maximum belt life, it is recommended that a belt tensioner gauge is used to check the belt tension. Fit the gauge (A) at the centre of the longest free length and check the tension. If a "Burroughs" gauge is used, the correct tension is 355N(80 lbf) 36kgf. If the tension is 220N(50 lbf) 22kgf or below, adjust it to 355N(80 lbf) 36kgf as indicated below.

If a gauge is not available, press down the belt with the thumb at the centre of the longest free length and check the deflection(B). With moderate thumb pressure-45N(10 lbf)4,5kgf-the correct deflection of the belt is 10 mm(3/8 in).

Check/ adjust the tension on the tighter belt of the two.

63

How to adjust the belt tension

1 Loosen the pi1vot fastenersG) of the alternator and the adjustment link fasteners@.

2 Change the position of the alternator to give the correct tension. Tighten the pivot fasteners of the alternator and the adjustment link fasteners.

3 Check the belt tension again to ensure that It is still correct. If new belts is fitted, the belt tension must be checked again after the first 20 hours of operation.

S) How to clean the gau1ze strainer of the fuel lift pump 1 Remove the cover arnd jointG) from the top of the fuel lift pump@ arnd remove the gauze strainer@.

2 Carefu llly wash all the sediment from the lift pump body.

3 Clean the gauze strainer, joint and cover.

4 Assemble the lift pump. Use a good joint and ensure that the lift pump body and the cover are fitted together correctly because leakag1e at this point will let air into the fuel system.

5 Eliminate the ai r from the fuel system through the filter vent po i1nt.

6) Fuel pre-filter(Sedimentor) This will normally be fitted between the fuel tank and the engine. Check the filter bowl for water at regular intervals and drain as necessary.

7) How to renew the filter element(s)of the fuel filter The separate element type where the filter element is held between the filter head and the bottom cover(B).

Attention : It is important that only the genuine Perkins fuel filter element is used. The use of a wrong element can damage the fuel injection pump.

-

=====---:k

'----

~~

64

--7

It)~

How to renew the filter element of the separate element type.

The filter have two elements. Two elements must be renewed at the same time.

2

3 4 5 6 7

8

Clean the outside surfaces of the fuel filter assembly. If a drain tap is fitted to the filter bowl, drain the fuel from the filter(A).

Hold the bottom cover of the filter element and release the setscrew which is fitted through the filter head above the centre of each element.

Lower the bottom cover of the filter(B).

Remove the element and discard it.

Clean the inside surfaces of the filter head and of the cover.

Renew the seals and lightly lubricate them with clean fuel.

Put the bottom cover under the new element and hold the element squarely to the filter head. Ensure that the element is fitted in the centre against the joint in the filter head. With the assembly in this position, engage and tighten the setscrew.

Eliminate the air from the fuel filter.

8) Atomiser fault An atomiser fault can cause an engine misfire. In order to find which atomiser is defective, operate the engine at a fast idle speed. Loosen and tighten the union nut of the high-pressure fuel pipe at each atomiser. When the union unt of the defective atomiser is loosened, it has little or no effect on the engine speed.

Ensure that the fuel does not spray onto your skin.

9) How to renew an atomiser

1 Remove the fuel leak-off pipe.

2 Remove the union nuts of the high -pressure pipe from the atomiser arid from the fuel injection pump. Do not bend the pipe. If necessary, remove the pipe clamps.

3 Remove the atomiser flange setscrews and remove the flange(D, the atomiser@ and its seat washer@. Remove the dust seal@ and the spacer@ and fit the spacer and a new dust seal onto the new atomiser.

65

4 Put the new atomiser in position with its spacer, new dust seal and a new seat washer.

Ensure that the fuel leak-off connection is not toward the engine. Fit the flange and engage the flange setscews. Ensure that the atomiser is not tilted and tighten the flange setscrews evenly and gradually to 12 Nm(9 lbf ft) 1,2kgf m.

5 Fit the high -pressure fuel pipe and tighten the union nuts to 18 Nm(14 lbf ft) 1,9 kgf m.

If necessary, fit the pipe clamps.

6 Renew the aluminium washers and fit the leak -off pipe.

7 Operate the engine and checK for teakage of fuel and air.

10) How to eliminate air from the fuel system If air enters the fuel system, it must be eliminated before the engine can be started.

Air can enter the system if : • The fuel tank is drained during normal operation.

• The low-pressure fuel pipes are disconnected.

•Apart of the low-pressure fuel system leaks during engine operation.

In order to eliminate air from the fuel system, proceed as follows.

1 Loosen the vent plug on the top of the twin element fuel filterG).

2 Operate the priming lever on the fuel I ift pump(C) until fuel, free from air, comes from the filter vent point Tighten the vent plug. If the drive cam of the fuel lift pump is at the point of maximum cam lift, it will not be possible to operate the priming lever.

In this situation, the crankshaft must be turned one revolution.

3 Turn the start key to the "ON" position.

4 Loosen the vent screw in the lock screw of the hydraulic head@ and the vent screw on the governor cover of the fuel injection pump@.

66

5 Operate the priming lever of the fuel lift pump until fuel, free from air, comes from the vent screw(s).

Tighten the vent screw(s).

6 Loosen the union nut@ at the fuelled starting aid and operate the lift pump until fuel, free from air, comes from the connection. Tighten the union nut at the starting aid.

7 Loosen the union nuts of the high-pressure

pipes@ at two of the atomisers. Operate the starter motor until fuel, free from air, comes from the pipe connections. Tighten the high-pressure pipe connections.

8 The engine is now ready to start If the engine runs correctly for a short time and then stops or runs roughly, check for air in the fuel system. If there is air in the fuel system, there is probably a leakage in the low pressure system.

11) How to renew the lubricating oil

1 Operate the engine until it is warm.

2 Stop the engine, remove the sump drain plug(D and its "O" ring and drain the lubricating oil from the sump. Ensure that the "o" ring is not damaged. Fit the drain plug and its "O" (ing and tighten the plug to 34 Nm(25 lbf ft) 3,5kgf m.

3 Fill the sump to the "MAX" mark on the dipstick@ with new and clean lubricating oil of an approved grade, see paragraph "7 -5 ".

67

112) How to renew the canister of the lubricating oi l filter 1 Put a tray under the filter to retain spilt lubricating oil.

2 Remove the filter canister with a strap wrench or simi llar tool. Ensure ttnat tine adaptor(D is secure in the fillter head. Then discard the canister.

3 Clean the filter head.

4 Add clean engine lubricati1ng oil to the new canister. Allow the oil enough time to pass through the filter element.

5 Lubricate the top of the canister seal with clean engine lubricating oil.

6 Fit the new can1ister and tig,hten i1t by hand only.

Do not use a strap wrench.

7 Ensure that there is lubricating oil in the sump.

8 Operate the engine and check for leakage from the filter. When the engine has cooled, check the oi ll level on tine dipstick and put more oil into the sump, if necessary.

Attention :The canister contains a valve and specia l! tube to ensure that ll!Jbricating oil does not drain from the filter. Therefore, ensure that the correct Perkins POWERPART canister is used.

13) How to check the valve tip cl'earances 1

These are checked between tine top of the valve stem and the rocker levedA), with the engine cold. The correct clearances are 0,20 mm(0.008 in) for inlet valves and 0,45 mm(0.018 in)for exhaust valves.

The valve positi1ons are shown at (B).

Attention : Number 11 cy llinder is at the front of the engine.

68

2 3 4 5 6

Turn the crankshaft in the normal direction of rotation until the inlet valve of number 6 cylinder has just opened and the exhaust valve of the same cylinder has not closed completely. Check the clearances of the valves of number 1 cylinder and adjust them, if necessary.

Set the valves of number 2 cylinder as indicated above for number 6 cylinder.

Then check/adjust the clearances of the valves of number 5 cylinder.

Set the valves of number 4 cylinder. Then check/adjust the clearances of the valves of number 3 cylinder.

Set the valves of number 1 cylinder. Then check/adjust the clearances of the valves of number 6 cylinder.

Set the valves of number 5 cylinder. Then check/adjust the clearances of the valves of number 2 cylinder.

Set the valves of number 3 cylinder. Then check/adjust the clearances of the valves of number 4 cylinder.

7. S Engine Fluids 1) Fuel specification

To get the correct power and performance from your engine, use good quality fuel.

The recommended fuel specification for Perkins engines is indicated below : Cetane number : Viscosity Density Sulphur Distillation

45 minimum 2.5/4.5 centistokes at 40°C 0,835/0,855 kg/I itre 0.5 % of mass, maximum 85 % at 350 °C

Cetane number indicates ignition performance. A fuel with a low cetane number can cause cold start problems and affect combustion.

Viscosity is the resistance to flow and engine performance can be affected if it is outside the limits.

Density :A lower density reduces engine power, a higher density increases engine power and exhaust smoke.

Sulphur :A high sulphur content(not normally found in Europe, North America or Australasia)can cause engine wear. Where only high sulphur fuels are available, it is necessary to use a highly alkaline lubricating oil in the engine or to renew the lubricating oil more frequently.

Distillation : This is an indication of the mixture of different hydrocarbons in the fuel. A high ratio of light-weight hydrocarbons can affect the combustion characteristics.

Low temperature fuels Special winter fuels may be available for engine operation at temperatures below 0°C. These fuels have a lower viscosity and also limit the wax formation in the fuel at low temperatures. If wax formation occurs, this could stop the fuel flow through the filter.

Aviation kerosene fuels These fuels can be used but they can affect engine performance. It is recommended that you consult the Perkins Technical Service Department at Peterborough, especially if JP4 fuel is to be used. These fuels are more flammable than diesel fuel and need careful storage and careful management.

If you need advice on adjustments to an engine setting or to the lubricating oil change periods which may be necessary because of the standard of available fuel, consult your nearest OHi distributor.

69

2) Lubricating oil specification: API CD/SE MIL-L-2104C CCMC D2 Use only a good quality lubricating oil to the relevant specification.

Attention : The type of lubricating oil to be used may be affected by the quality of the fuel which is available. For further details see "Fuel specification".

Always ensure that the correct viscosity grade of lubricating oil is used for the ambient temperature range in which the engine will run as shown in the chart below.

Recommended SAE viscosity grades fNi

I

I

I

5W20

I

I

I

t0W30

I

15W40

20W50

I

20

I 30

I

I -30 -22

-20 - 4

-10 14

0 32

10 50

I 40

I 20 68

30 86

40 104

50"C 122°F

Ambient temperature

3) Coolant specification The quality of the coolant which is used can have a great effect on the efficiency and life of the cooling system. The recommendations indicated below can help to maintain a good cooling system and to protect it against frost and/or corrosion.

If the correct procedures are not used. Perkins cannot be held responsible for frost or corrosion damage.

1 If it is possible, use clean soft water in the coolant.

2 If antifreeze mixture, other than Perkins POWERPART, is used to prevent frost damage, it must have an ethanediol base(ethylene glycoi)with a corrosion inhibitor. It is recommended that the corrosion inhibitor is of the sodium nitrite or sodium benzoate type. The antifreeze mixture must be an efficient coolant at all ambient temperatures and it must provide protection against corrosion.

It must also have a specification at least as good as the requirements of the standards below:

United Kingdom : BS.6580 : 1985 : "Specification for corrosion inhibiting, engine coolant concentrate(antifreeze) ".

United states of America : ASTM D3306-74: "Ethylene Glycol Base Engine Coolant".

Australia : "AS 2108-1977 : Antifreeze Compounds and Corrosion Inhibitors for Engine Cooling Systems".

70

Perkins POWERPART antifreeze exceeds the requirements of the above standards. The quality of the antifreeze coolant must be checked at least once a year, for example, at the beginning of the cold period. The coolant must be renewed every two years. The antifreeze mixture must consist of equal quantities of antifreeze and water. Concentrations of more than 50% of antifreeze must not be used because these can affect adversely the performance of the coolant.

3 When frost protection is not necessary, it is still an advantage to use an approved antifreeze mixture because this gives a protection against corrosion and also raises the boiling point of the coolant.

If an antifreeze is not used, add a correct mixture of corrosion inibitor to the water. Renew the mixture of water and corrosion inhibiter every six months or check it according to the inhibitor manufacturer's recommendations.

Attention : Certain corrosion inhibitor mixtures contain soluble oil which can have an adverse effect on certain types of water hose.

71

7. 6 Fault diagnosis 1) Problems and possible causes

Possible causes

Problem

Checks by the Checks by the user

workshop personnel

The starter motor turns the engine too slowly

1, 2, 3,4

The engine dose not start

5, 6, 7, 8, 9, 10, 12, 13,

34, 35, 36, 37, 38, 42,

14, 15, 17

43,44

5, 7, 8, 9, 10, 11, 12,

34, 36, 37, 38, 40, 42,

13, 14, 15, 16, 17, 19

43,44

8, 9, 10, 11, 12, 13, 16,

34, 36, 37, 38, 39, 42,

17, 18, 19, 20, 21

43,44

8, 9, 10, 12, 13, 15, 20,

34, 36, 37, 38, 39, 40,

22

41, 43

11, 13, 15, 17, 18, 19,

34, 36, 37, 38, 39, 40,

21, 22

42, 43, 44,

11, 13, 15, 17, 19, 21,

34, 36, 37, 38, 39, 40,

22

42, 43, 44, 61

4,15,21,23

36, 37, 38, 39, 42, 44,

The engine is difficult to start

Not enough power

Misfire

High fuel consumption

Black exhaust smoke

Blue or white exhaust smoke

45, 52, 58 The pressure of the lubricating oil is too low

4, 24, 25, 26

46,47,48, 50, 51,59

The engine knocks

9, 13, 15, 17, 20, 22, 23

36, 37, 40, 42, 44, 46, 52,53, 60

The engine runs erratically

Vibration

7, 8, 9, 10, 11, 12, 13,

34, 38, 40, 41, 44, 52,

15, 16, 18,20, 22,23

60

13, 18, 20, 27, 28

34, 38, 39, 40, 41, 44, 52, 54

The pressure of the lubricating oil is too high

4, 25

49

The engine temperature is too high

11, 13, 15, 19, 27, 29,

34, 36, 37, 39, 52, 55,

30, 32

56,57, 64

Crankcase pressure

31,33

39,42,44, 45, 52

Bad compression

11, 22

37, 39, 40, 42, 43, 44, 45,53, 60

The engine starts and stops

10, 11, 12

72

2) Code list of possible causes

1 Battery capacity low.

32 Insufficient coolant in system.

2 Bad electrical connections.

33 Vacuum pipe leaks or fault in

3 Fault in starter motor.

exhauster.

4 Wrong grade of lubricating oil

34 Fault in fuel injection pump.

5 Starter motor turns engine too slowly.

35 Broken drive on fuel injection pump.

6 Fuel tank empty.

36 Timing of fuel infection pump is

7 Fault in stop control.

incorrect.

8 Restriction in a fuel pipe.

37. Valve timing is incorrect.

9 Fault in fuel lift pump.

38 Bad compression.

10 Dirty fuel filter element.

39 Cylinder head gasket leaks.

11 Restriction in air filter/cleaner or

40 Valves are not free.

induction system.

41 Wrong high-pressure pipes.

12 Air in fuel system.

42 Worn cylinder bores.

13 Fault in atomisers or atomisers of an

43 Leakage between valves and seats.

incorrect type.

44 Piston rings are not free or they are

14 Cold start system used incorrectly.

worn or broken.

15 Fault in cold start system.

45 Valve stems and/or guides are worn.

16 Restriction in fuel tank vent.

46 Crankshaft bearings are worn or

17 Wrong type or grade of fuel used.

damaged.

18 Restricted movement of engine speed

47 Lubricating oil pump is worn.

control.

48 Relief valve does not close.

19 Restriction in exhaust pipe.

49 Relief valve does not open.

20 Engine temperature is too high.

50 Relief valve spring is broken.

21 Engine temperature is too low.

51 Fault in suction pipe of lubricating oil pump.

22 Incorrect valve tip clearances.

23 Too much oil or oil of a wrong

52 Piston is damaged.

specification is used in wet type air

53 Piston height is incorrect.

cleaner.

54 Flywheel housing or fiywheel is not.

24 Not enough lubricating oil in sump.

aligned correctly

25 Defective gauge.

55 Fault in thermostat or thermostat is of

26 Dirty lubricating oil filter element.

an incorrect type.

27 Fan damaged.

56 Restriction in coolant passages.

28 Fault in engine mounting or flywheel

57 Fault in water pump.

58 Valve stem seal is damaged(if there is

housing.

one fitted).

29 Too much lubricating oil in sump.

30 Restriction in air or water passages of

59 Restriction in sump strainer.

radiator.

60 Valve spring is broken.

31 Restriction in breather pipe.

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7. 7 Engine preservation 1) Introduction

The recommendations indicated below are desingned to prevent damage to the engine when it is withdrawn from service for a prolonged period. Use these procedures after the engine is withdrawn from service. The instructions for the use of POWERPART products are given on the outside of each container.

2) Procedure

1 Completely clean the outside of the engine.

2 When a preservative fuel is to be used, drain the fuel s~1 stem and fill it with the preservative fuel.

POWERPART Lay-Up 1 can be added to the normal fuel to change it to a preservative fuel.

If preservative fuel is not used, the system can be kept full with normal fuel but the fuel must be drained and discarded at the end of the storage period together with the fuel filter element(s).

3 Operate the engine until it is warm. Then correct leakages of fuel, lubricating oil or air.

Stop the engine and drain the lubricating oil from the sump.

4 Renew the canister(s) of the lubricating oil filter.

5 Fill the sump to the full mark on the dipstick with new and clean lubricating oil and add POWERPART Lay-Up 2 to the oil to protect the engine against corrosion. If POWERPART Lay-Up 2 is not available, use a correct preservative fluid instead of the lubricating oil. If a preservative fluid is used, this must be drained and the lubricating oil sump must be filled to the correct level with normal lubricating oil at the end of the storage period.

6 Drain the cooling system. In order to protect the cooling system against corrosion, it is better to fill it with a coolant that has a corrosoin inhibitor. If protection against frost is necessary, use an antifreeze mixture. If protection against frost is not necessary, use water with an approved mixture of corrosion inhibitor.

7 Operate the engine for a short period in order to circulate the lubricating oil and the coolant in the engine.

8 Clean the engine breather pipe(if one is fitted)and seal the end of the pipe.

9 Remove the atomisers and spray POWERPART Lay-Up 2 into each cylinder bore. If this is not available,clean engine lubricating oil will give a degree of protection. Spray into the cylinder bores 140 ml(0.25 pint) of lubricati,)g oil divided evenly between the four/six cylinders.

10 Slowly turn the crankshaft one revolution and then fit the atomisers with new seat washers and new dust seals.

11 Remove the air filter. Then, if necessary, remove the pipe(s) installed between the air filter and induction manifold or turbocharger. Spray POWERPART Lay-Up 2 into the induction manifold or turbocharger. It is recommended that the spray time for the turbocharger is 50% longer than the spray time for the manifold, which is indicated on the container label. Seal the manifold or the turbocharger with waterproof tape.

12 Remove the exhaust pipe. Spray POWERPART Lay-Up 2 into the exhaust manifold or the turbocharger. It is recommended that the spray time for the turbocharger is 50% longer than the spray time for the manifold, which is indicated on the container label. Seal the manifold or the turbocharger with waterproof tape.

13 If the lubricating oil filler is fitted onto the rocker cover, remove the filler cap. If the lubricating oil filler is not fitted onto the rocker cover, remove the rocker cover. Spray POWERPART Lay-Up 2 around the rocker shaft assembly. Fit the filler cap or rocker cover.

14 Disconnet the battery. Then put the battery into safe storage in a fully charged condition. Before the battery is put into storage, protect its terminals against corrosion. POWERPART Lay-Up 3 can be used on the terminals.

15 Seal the vent pipe of the fuel tank or the fuel filler cap with waterproof tape.

16 Remove the drive belts and put them into storage.

74

17 In order to prevent corrosion, spray the engine with POWERPART Lay-Up 3.

Do not spray the area inside the alternator cooling fan.

Attention :After a period in storage, but before the engine is started, operated the starter motor with the engine stop control in the "stop" position until oil pressure is indicated. Oil pressure can be indicted either by a gauge or when a low pressure warning light is extinguished. If a solenoid stop control is used on the fuel injection pump,it must be disconnected for this operation.

If the engine protection is done correctly according to the above recommendations, no corrosion damage will normally occur. Perkins are not responsible for damage which may occur when an engine is in storage after a period in service.

7. 8 Parts and service l) introduction If problems occur with your engine or with the components fitted onto it, your DHI distributor can make the necessary repairs and will ensure that only the correct parts are fitted and that the work is done correctly.

Certain components can be supplied by your DHI distributor through the Perkins POWER EXCHANGE system. These will enable you to reduce the cost of certain repairs.

2) Service literature Workshop manuals and other service publications are available from your DHI distributor at a nominal cost.

3) Training Local training for the correct operation, sefvice and overhaul of engines is available at certain DHI distributors. If special training is necessary, your DHI distributor can advise you how to obtain it at the Perkins Product Education Department, Peterborough, or other main centres.

4) POWERPART consumable products Perkins have made available the products indicated below in order to assist in the correct operation, service and maintenance of your engine and your machine. The instructions for the use of each product are given on the outside of each container. These products are available from your DHl'S distributor.

POWERPART Antifreeze : Protects the cooling system against frost and corrosion.

POWERPART De-icer: Removes frost.

POWERPART Easy Flush : Cleans the cooling system.

POWERPART Easy Seal: Stops leakages from the cooling system.

POWERPART Foam Action Gasket Remover: Allows easy and rapid removal of old gaskets and joints.

POWERPART Hylomar: Universal jointing compound which seals joints.

75

POWERPART Hylosil : Silicone rubber sealant which prevents leakage through gaps.

POWERPART Inhibitor: Protects cooling system against corrosion when antifreeze is not used.

POWERPART Lay-Up 1 : A diesel fuel additive for protection against corrosion.

POWERPART Lay-Up 2: Protects the inside of the engine and of other closed systems.

POWERPART Lay-Up 3 : Protects outside metal parts.

POWERPART Moisture Dispersant and Rust Penetrant : Dries damp equipment and gives protection against corrosion. Passes through dirt and corrosion to lubricate and to assist removal of components.

POWERPART Retaining Compound: Retains components which have a transition fit or an interference fit, for example, pulleys, bushes etc.

POWERPART Studlock : Secures threaded fasteners. Recommended for fasteners which, normally, are not removed.

POWERPART Threadseal : Seais threads and pipe connections. Low pressure systems can be used immediately.

7. 9 Engine Data.

Engine data Number of cylinders······················ ....................... 5 Cylinder arrangement .......................................... In line Cycle·················· .. ····· ...................................... Four stroke Induction system YA························· .. ················ .................... Naturally aspirated YC .. ································ ............................. Altitude compensated Combustion system························· .. ····· ............. Direct injection Nominal bore····· .. ····································· ....... •··100 mm (3.937 in) Stroke············ .. ········································ .. ······· 127 mm (5.00 in) Compression ratio YA, YC·········· ..... ······ ··· ········ ......................... 16. 5 : 1 Cubic capacity YA, YC········ ................................................. 6 litres (365 in 3 ) Firing order ...... ··· ··· ······ ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· •·· 1, 5, 3, 6, 2, 4 Valve tip clearances(cold) Inlet ··· ··· ··· ... ··· ··· ... ··· ··· ··· ··· ··· ··· ······ ··· ......... ··· 0.20 mm (0.008 in) Exhaust·············· ........................................... 0.45 mm (0.018 in) Lubricating oil pressure(minimum at maximum engine speed and normal engine temperature) Engines without piston cooling jets········ .... ···•·· •··207kN/m 2 (30 lbf/in 2 )2.1 kgf/ cm' Engines with piston cooling jets ........................ 280kN/m 2 (40 lbf/in 2 )2.5kgf/cni Direction of rotation········· ... ······ ...... ··············· ... ··· Clockwise from the front(fan)

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