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    13 views820 pages

    PDF Komatsu 95 Series Diesel Engine Shop Manual PDF Download Compress

    Uploaded by

    Fulani Saifulloh

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    Sh SEBE61460114 DIESEL ENGINE ‘This material is proprietary to Komatsu America Intemational Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Intemational Company. {tis our poley to improve our products whenever I fs possible and practical 10 do so. We reserve the right to make ‘changes or add improvements at any ime without incurring any obigetion to install such changes on products sold previously. ‘Due to this continuous program of research and development, periodic revisions may be made to this publication. Itis recommended that customers contact their distributor for information on the latest revision. January 1998 Copyright 1998 Koratsu Amica Intemational Compary 0-1 @ 01 11 12 13 14 15 CONTENTS No. of page + 01-001 GENERAL .... STRUCTURE AND FUNCTION... TESTING AND ADJUSTING .. DISASSEMBLY AND ASSEMBLY ....... MAINTENANCE STANDARD... ++ 14-001 REPAIR AND REPLACEMENT ++ 16-001 95 SERIES UST OF REVISED PAGES LIST OF REVISED PAGES ‘The affected pages are indicated by the use of the following marks. tis requested thet necessary actions Mark Indication Action required be taken to these pages according to the table below. © | Pageto be newly added | Add © | Page to be replaced Replace { }| Page to be deieted Discard Pages having no marks are those previously revised ‘or made additions. LIST OF REVISED PAGE wore rege TT nae rage THT ark rage MOT wank rage MEF] tak Pa e 01 ® ore ® | 0 craesze @ own @ aon @ 2 @ ors @® | 0 rasze @ oo @ aon @ © w21 ® 10051 ® | O or0627 ® ore @ ovon2 @ © wm ® cros2 @ | O oro @ ove oor @ © w2s @ oaes cae @ oom @ oo © 24 @ ova ao © a0 ® ous © w2 @ ovoss cae @ ao @ oon @ oo e106 evo @ cas @ oro @ oe ovens? vane cvs @ our @ os oes @ evais2 oars? @ cos @ os os B cos ® ome @ coe 07 ov09590 cose © na @ con® os aoe @ now © nae © coe 0-8 ovon82 B aon @ oa @ co ota ov0053 B aor © ae @ oa oo or0054 @ oon @ oom @ non @ conz ora515 @ eos © oa @ oz @ cons oreo @ ovose @ oo @ aos @ cone coro. 16 cons © oes @ case @ cons covans1621 aos © oon @ aos @ cons © 10057 B wos @ oo @ cae @ cow © as18 @ rons @ ori @ crass @ coo © 01 ® cou @ oor @ oor @ cons ee) cos norr @ crass @ © c100521 & a) oasr2 om @ © oo @ fe m2 @ oon @ oo 00 @ oom @ |e oes @ aro @ ores ov0801 @ ovo @ | @ oro @ ce) oro @ or0802 @ 95 SERIES 00-2-1 @ LST OF REVISED PAGES LUST OF REVISED PAGES wan Pane TT 3] wane rose MES] ware Page TLS! wate Fase THES'] wane age Tot eras ®@ 108 ® new @ nor @ r080 @ ear @ noe @ ne ® i081 @ not @ eon @ now @ now @ 1082 @ na @ wae nove @ oe @ soa @ sr @ o10881 @ n08s @ n081 © no @ i004 @ e102 @ now @ n0u2 @ nos @ 108 @ v0 ® 08s @ 108 ® noms @ ne @ o105 @ nos @ 1084 © n087 @ non © O mas: @ 1097 ® 108 ® nome ® n0871 @ oes @ nove @ 108 @ or) n072 © a) no © no @ tome @ noma @ n001 ® 108 @ w091 @ nome @ no @ n002 @ 108 @ w08-2 @ 1108975 @ nena @ nome ® en) 1108 © 0878 @ none © s0m4 @ or) s108 © n087 @ 02 @ r10205 B 0811 @ 070 ® 110878 @ an) news @ nosi2 @ non @ noe @ noe © now @ seas @ non @ 138740 @ 1195 © non nr) nna @ 08 © 10% @ no i108 @ ra 120 @ 07 @ nD ne @ 11093 ® s1090 @ 1108 ® 10 108 @ no ® sto @ oD 08 OD i081 ® none @ nm @ i082 ® noe @ 11082 © iw ® no ® now @ ner @ 108 ® no ® nome @ non @ s1020 @ 110897 @ nom @ no @ no @ i072 @ 108 @ 10882 @ noe io -® nn ® n081 @ i088 @ 105 @ no @ naw @ n082 @ 084 @ 110051 @ io ® no01 ® toa @ 11085 ® 110082 ® s0181 ® r002 @ 11089 @ 11088 ® n1082 ® s10182 i @ nO n087 @ roe @ nasa @ 2 @ no @ rons @ 110855 @ rows @ ne @ 08 @ n089 @ nos @ 08s nD 06D 11.075-10 @ 11.0057 @ 086s @ 105 @ 110631 @ 1975-11 @ 0858 @ n0%7 @ noe ® nome @ noe ® noe @ a) 11081 ® noe @ non @ ner © no ® 11002 ® 108 @ 108 @ ne62 ® oo) 07 @ n08 ® no @ ne @ 00-2-2 95 SERIES @ LIST OF REVISED PAGES LST OF REVISED PAGES, Mark Page OH] atone Page TOT tor Page TMT wank Page TF mark Page Teme of 110864 @ now @ ran © nome @ reares02 @ 110965 noi @ nae @ nase @ reaz2-103 @ rr0868 now @ ran © one D rear0 @ 0807 @ wos @ rae D nares @ sacaa05 @ va868 non @ roa © nme @ naar. @ 087 @ wor @ nena ® nome @ ons ® i108 @ no no © nae @ rao @ 10881 @ vow O nam @ none @ ran ® 002 nas @ nan ® nan @ | 0 ven ® r10%9 @ now @ nena ® non ® non ® sro @ new @ ssessca @ nom & w08 1108 @ new @ nes ® non @ 1205 @ sr0801 @ rawr ® rears ® non @ v0 s10802 @ nowe ® rar38 ® non @ nox @ sroe3 @ | @ wows @ r2ar298 @ non @ no @ ns @ ne @ nen @ non @ noe @ ir @ wa @ nance © norm @ | @ 2082 @ nen @ a2 @ seme @ 200 @ © 20 202 @ raze @ roe @ 12001 @ v2002 @ rea @ ran @ nome @ 2002 1203 © na2 O rare ® none ® noes @ v2008 nos @ reas @ nos @ e004 @ 12005 @ nena & nau @ ros B rons @ 12008 @ ras @ rears ® e085 @ rans 207 @ noe ® noe ® roe ® 007 2008 @ nar @ nee @ none ®@ none 20001 @ nome © reevass @ noes ® none © v.09 @ nea rea @ nome ® reasoa0 ® 00 @ ra210 @ 202250 @ 0299 snows © 001 non @ raens1 © rome @ now ® 12002 © none ® nos @ noe & nen @ vows wenn vanes © woz @ naw @ 004 @ ra @ rarest rears @ 20015 @ rows @ nas @ ans @ nae @ rans ® ros @ 20218 @ reaz286 @ 202298 @ nao @ 007 @ 027 @ reazs7 © noe @ | O ro @ 2008 ® s202218 @ nose © norm @ | @ a0 @ r009 @ nents ® reas @ nove @ 11209020) izor010 @ none rea @ reores00® | @ rea02 & non @ nea ® nae ® ro @ | @ race @ 95 SERIES 0-2-3 LIST OF REVISED PAGES. LIST OF REVISED PAGES Mark Pome me tT mare Page THE! atk Pope TE] ma Pane Tet] acc Page Ti © 1200020 @ reas0 soo © non @ vs058 © 20002 @ var D ra00119 © nou @ ssase © 120002 @ ve @ 1300120 © nos 3088 @ © 200028 @ 208 @ rsa0r22 © woe reas © 200027 @ 12058 sea023 ® nov @ vas © 1200028 @ 0 rsaovas ® woe wa © 1209029 12088 ss40125 © sso 13058 © 1200050 @ nos @ ss40126 @ 100 13058 @ © 1200031 ® 1200 ssaorzt © ss01 @ 1300 «® © 120022 @ not @ rs40128 ® no @ 130601 @ © 2m @ noe @ s800129 © 0 @ 2081 @ © 203034 ® 08 @ ssaor30 © non @ 13062 @ © 208035 2068 ssansn © 30D 13068 @ © 200036 @ nos rst ® n08 @ 13068 @ © 208037 ® 1206 @ r300189 © 30261 @ 13065 © 20039 2067 soo. © non @ 3068 @ © 2009 @ 12068 @ 300138 © 108 i307 @ oO wm @ 208 @ 1200136 @ wo @ 3068 O04 & now @ rs0097 @ won @ ao @ ro non sao © won non @ © 2000 @ noe @ ssoorse @ won @ wor @ wan @ rso040 @ was @ aos @ van D rsa ® ss0041 @ wn @ now @ vas D rsa0r ® ss0042 @ nas @ nos nae @ ssa ® sso @ re v0 ssans © sooo @ wor @ won @ nae DO rear @ rso045 @ v0 @ 002 v0 ® ssa8 © ss00149 @ nC) 400s @ 008 0018 © rs00047 @ 00 O 40034 @ use D 30017 © ss002 @ won 40082 @ 200 D ssa © 13003 @ 1302 woe @ ue 009 © 108 @ 1308 08 @ nen @ rso0r10 @ v0 | @ rao @ woe @ ras @ ss0011 @ s306 @ was wor @ noe @ ss00r2 @ 13007 @ r308 woe nos rso0r3 @ 3008 @ wor 40081 @ now DO ® v2000 an) eon? nar ® woo 13050 @ was nae @ wor @ wo @ wow D nae ss007 @ now @ soe @ um @ 24 95 SERIES LUST OF REVISED PAGES LIST OF REVISED PAGES Moe Pose Te [are Pose TE] maa fae Te] wrk Pane [wank Page TO! wor © oe) woe ® wor 031 © wo @ woz © 08 @ uo © a) ro) won wis © won @ ores © won @ uner @ wou @ ua wo wow wow @ naar @ wor B owe @ woe ® woes @ uno @ co @ wor ® wae D un @ won ® uae ues wae! ® 40262 wor wo @ wa @ 00 @ uo @ woe ues @ eo @ was @ wor @ wor B 15003 ® 5000 @ sos @ 95 SERIES 0-2-5 SAFETY ‘SAFETY NOTICE SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manuat are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol \ is used to mark safety precautions in this. manual. The cautions accompanying these symbols should always be followed care- fully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. GENERAL PRECAUTIONS Mistakes In operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always ‘wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. ‘+ Always wear safety glasses when hitting parts with a hammer. + Always wear safety glasses when grind- ing parts with a grinder, ote. 3. If welding repairs are needed, always have a trained, experienced welder carry out the ‘work. When carrying out welding work, al- ways wear welding gloves, apron, hand shield, cap and other clothes suited for weld- ing work. 4. When carrying out any operation with two or more workers, always agree on the oper- ating procedure before starting. Always in- form your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 8. Keep all tools in good condition and learn the correct wey to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oll on the floor. ‘Smoke only in the areas provided for smok- ing. Never smoke while working PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving, 8, Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warn- ing signs on them. ‘8. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oll from the steps or other places used to get on and off the ma- chine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3 PRECAUTIONS DURING WORK 11, When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 12, The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oll and water to cool before carrying out any work on the oil or water circuits. 13, Before starting work, remove the leads from. the battory. Always remove the lead from the negative (-) terminal first. 14, When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capaci Install the places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pres- ‘sure, then slowly loosen the bolts to remove, 16. When removing components, be cereful not to break or damage the wiring. Damaged witing may cause electrical fires. 17. When removing piping, stop the fue! or oil from spilling out. If any fuel or oil drips onto ‘the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires 18. As a general rule, do not use gasoline to wash parts. In particular, use only the mini mum of gasoline when washing electrical parts. 00-4 19. 20. a 22. 23. 24, SAFETY NOTICE Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. « When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is be- ing operated ‘When installing high pressure hoses, make sure that they are not twisted. Darnaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. ‘When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. ‘Take care when removing or installing the tracks of track-type machines. ‘When removing the track, the track sep- rates suddenly, so never let anyone stand at either end of the track FOREWORD GENERAL GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided inta the following chapters; these chapters are further divided into the each main group of components. STRUCTURE AND FUNCTION This section explains the structure and funetion of each component. It serves not only to give ‘an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the cheoks and repairs. Troubleshooting charts correlating "Problems" to "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or ‘assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date. FOREWORD HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one volume to cover all models ‘These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is neces- sary that chassis, engine, electrical and attach- ment volumes be available. Eloctrical volume: Attachments volumé DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the ‘most up-to-date information before you start any work, FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume}: 10-3 |__rem number (10. Stucture and Funetion) | __Consecutive page number for each fem. Example 2 (Engine volume): 5 Unit number (1. Engine) | Item number (2. Testing and Adjusting) Consecutive page number for ‘each item. 3, Additional pages: Additional pages are indi cated by a hyphen (-) and number after the page number. File as in the example. Example: eS ae eR Ate poss Cte a te 00-6 HOW TO READ THE SHOP MANUAL REVISED EDITION MARK When 2 manual is revised, an edition mark (OBE...) is recorded on the bottom of the pages. REVISIONS. Revised pages are shown in the LIST OF RE- VISED PAGES next to the CONTENTS page. SYMBOLS So that the shop manual can be of ample prac- tical use, important safety and quelity portions are marked with the following symbols. Symbol Remarks ‘Special safety precautions are nececeary when performing the work, Safery ‘Special technical precautions oF other precautions for pro- serving standards are neces: sary when performing the work. Caution Weight of parts of systems. Caution necessary when se- Feeting hoisting wire, or when Weight ‘working posture is important, atoning] sn eg ara torque | torque during Places to be coated with ad- Coat | hesives and lubricants, etc. Places where ol, water or fuel Joi, weter| must be added, and the ca- pacity Places where oil of water Drain | must be drained, and quan- tity to be drained, FOREWORD. HOISTING INSTRUCTIONS HOISTING Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISAS- SEMBLY AND ASSEMBLY section, every part weighing 25 kg or more, is indicated clearly with the symbol = If @ part cannot be smoothly removed from the machine by hoisting, the following checks. should be made: 1) Check for romoval of all bolts fastening the part to the relative parts. 2) Check for existence of another part caus- ing interference with the part to be re moved. WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard °Z" or "S" twist ropes without galvanizing) Rope diameter Allowable load mm kN tons 10 98 10 2 137 1 125 197 16 “4 216 22 16 28 28 18 363 38 20 43.4 Aa 22.4 549 56 30 98.1 10.0 40 1765 18.0 50 2146 28.0 60 3922 40.0 The allowable load value is estimated to be one-sixth or one-seventh of the break: ing strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. HOISTING INSTRUCTIONS Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can re~ sult. Hooks have maximum strength at the middle portion. baad 100% 88% 79% «= 71% «41% 3) Do not sling a heavy load with one rope ‘alone, but sling with two or more ropes symmetrically wound onto the load. B Sinsing with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can re- sult in a dangerous accident. 4) Do not sling a heavy load with ropes form- ing a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allow- able load KN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 8.8 KN (1000 kg) vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg) of total weight can be suspended. This weight becomes 9.8 kN (1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 KN (4000 ka} if they sling 2 19.6 kN (2000 kg} load at a lifting angle 3 > ise FOREWORD COATING MATERIALS + The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. + For coating materials not listed below, use the equivalent of products shown in this list. COATING MATERIALS Komatsu code | Part No. = Gry | conniner | Main apicotns, features ["Uned to preven ber gota alba? crim freon] sooo | tune |” Unit Masta Seria Used i placosrequing an immedi ative, erp sate. Urea fr par t-18 — |790-129-9050| 209 |Polvethylene} 1:3. (excapt polyethylene, polyprophylene, = winer | tetrafluorcethlene and vinyl chloride), rub- toma and nonnt Features: Raitnce to hel ond chon Povstyena|” ese a one 0] S09 container |+ Used for anti-loosening and sealant pur- poe or ste and a 0-12-2000 | Adhesive: Ved sees or alot ort lane ‘en oteene | te nd pec ura |theand” laderng| — can rardening. [spent oon | B03 Advasive — tr |ra0-tea-ao%o] 20g Polyester! Ties, [ensorm| Wo | tae | eda bone or > ic hardening type echo The bond povettsn|= ure aos fae 3 1735 aa-328-0140 | Bg! container |* Used mainly for adhesion of metals, rub- bors lasts ord wos Fuck hardering type adhesive ‘lone ymthyna|* Dick Coe typ Un Stent ar 30 mi- Aronsione |rep-szs-o] 29 Povtivra|” fs + Used mainly foradhsin of rubbers, pla evant eta, Features Resource to het corneas vost Joe Lostte rea-rasario| acc [Povtvee|: Used aan orion subj to mph tem paren 161 [eomsoro| awa | roe | Sede aero sn gost > Fearn: Resstance fo hot > Gu cede ft hong sueste and Gost Sots a Hightampraare esos, wed = ves freorssom| tug | con | tovrerontteuue Used as sealant for hoat resistance gasket {or high temperature locations such as en- gine precombustion chamber, exhaust bipe, etc. FOREWORD COATING MATERIALS: Category [Komatsu code| PartNo. | ary | Container Features: Resistance to water, oll “+ Used as sealant for flange surface, thread. c-4 frsotzasnzo| 2009 | tune | Alo posto uo sealant for forges |+ Used as sealant for mating surfaces of fi- nal drive caso, transmission case. = Used as sealant for various threads, pipe Polyethylene| joints, flanges. 46-5 (790-129-9080) 1 ka | "concainer | Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. |+ Features: Silicon based, resistance to heat, Gasket ‘cold sealant tos | ogso-c0011 | 250g | Tube | Used as sealant tor flange surtace, tread. J+ Used as sealant for cl pan, final drive case, ote. + Features: Silicon based, quick hardening type. LG-7 | 09920-00150 | 150g | Tube |. Used as sealant for flywheel housing, in take manifold, oil an, thermostat housing, etc. Toes bond Tiso.129- 5060] 1009 | Tune | Used as heat vesting seat for repang engine. , + Used as lubricant for sliding portion (to pre- LMG | 09940-00051 609 con | vant rom squeaking) + Used to prevent seizure or scutfling of the twee — | eaaco-00040 | 2009 | Tube | thread when press fitting or shrink fting |+ Used as lubricant for linkage, bearings, ete. Isvcz-400u + General purpose type 'Syc2-350L! 'S¥G2-40011-8 | Various | Various 'sya2-160L1 'S¥GA-1600NLI |- Used for notmal temperature, light loat reas |sve2aooca bearing a places in contact wih water of |syG2.50ca pr c2ca —|syGz400ca-A| Various | Various |syo2-t00ca [SreAetcncal | Molybdenum 400 9 | Used for places with heavy loa« disulphide | SYG2-400M | (10 per [Relows type!” U**4 TOF Places with heavy load lubricant case) FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS Use these torques for metric bolts and nuts. (Always use torque wrench). Thread diameter Width @& @e I © ‘of bolt across flats — mm mm Nm kom 6 10 crrvary 7352018 8 13 3153 32203 10 7 e527 7207 2 9 13510 wget u 2 wea 182 16 2 279-30 pasta 8 Z 382239 | 3924 20 30 543259 55=6 2 22 75283 75285 24 36 927 103 9455105 7 a 3202140 135215 30 ry 1720 190 175120 8 50 2210240 225425 38 55 2750 290 280330, 38 60 3290 340 335.35 Thread diameter Width of bolt across flats mm mm Nm kom @ 70 7.852 196 ] 08202 8 3 1a6+49 13805 10 4 40.2259 41208 2 2 82354785 Basos TIGHTENING TORQUE OF HOSE NUTS Use these torques for hose nuts. Nominal No, |Thtead diameter | Width across flat | __Tightening torque mm mm Nm I kom 0 14 78 Zass43 25205 03 18 26 492186 42 04 2 2 7852196 8x2 05 es 2 13738294 143 06 20 36 17652204 13 10 B 0 196.1448 2035 2 6 6 245.2548 25:5 “ 2 5 2302843 5028 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter | Width across flat Tightening torave mm mm Nm kom 70 ry aT=08 e7=07 12 7 12+98 vset 16 2 27929 73523 FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE OF O-RING BOSS CONNECTOR Use these torques for O-ring boss connector Nominal No, |_Thfead diameter | Width across flat Tightening torque mm mm Nm kgm oe “ ase 49 35205 03, 04 20 \Varies depending on| 93.1598 9521 05, 06 24 ype of connector. vazssi96 =| 14532 10, 12 33 4356 te 2 99.54 13.5 TIGHTENING TORQUE OF O-RING BOSS CONNECTOR, Use these torques for O-ring boss con nector Thread diameter. Width across flat Tightening torque Nominal No. mm mm Nm kgm) 08 8 | « 7352 147 075%0.15 10 10 v zs 147 1.154 0.15 2 2 9 17.64 1.98. 18402 4 14 2 22.542 1.96 23402 16 16 24 29.4249 3405 18 18 27 39.2249 4405 20 20 30 49249 5405 24 24 2 62.6298 741 30 30 32 107.82 147 nes 33 33 = 12744196 1342 36 36 36 151.92 24.5, 155425 2 a = 210.729.4 21.543 82 52 - 323.42 48.1 Sth TIGHTENING TORQUES OF FLARE NUT Use these torques for O-ring boss connector ‘Thread diameter | Width across flat Tightening torque. mm mm Nm | kgm ry 9 1 245249 25205 18 ry 492 19.6 ‘B42 2 7 78.52 19.6 B22 2 32 13734294 4x3 30 36 1765+29.4 | 183, 3 a 196.14 49 205 36 6 245.2449 2525 a 55 | 294.2449 305 FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS) Use these torques for metric bolts and nuts of 102 Series Engine. Thread diameter Tightening torque mm Ne kgm 6 1022 1.02 + 0.20 a mst 245 £041 10 as6 433 £061 2 £2 785 +122 TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS) Use these torques for metric eye joints of 102 Series Engine. ‘Thread diameter Tightening torque mm Nm kom 6 e22 i 081 + 020 8 1022 1.02 + 0.20 10 222 3.22 £020 12 meh 245 = 0.41 4 3625 367 051 ‘TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS) Use these torques for inches tapered scrows of 102 Sorice Engi Thread diameter Tightening torque inches Nm. kgm 1116 Fray 03% + 0.10 18 a42 oat +020, a4 1242 1.22 £0.20 3/8 1542 153 £041 2 244 245 £0.41 ay4 3645 | 367 +051 1 wore 6.12 +082 FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS, Example: SWB indicates a cable nal number § and white coating with black stripe CLASSIFICATION BY THICKNESS Coppers Cable 0.0. |Current rating} Apoticable circuit i nl oom [ nf om | om [ae |v _| Sermo thin wipaioc 2 [| ee) am | a | a tating wine [| em [nae [re | rng tw 40 85 0.80 4273 na 136 Starting _ || om [mae | me | ve | ng cLASSIrcATION BY COLOR AND CODE a Prior- Charging | Ground | Starting | Lighting | Instrument | signal Other = a | Color] _ White Black Black Red Yellow Green Blue Teme] [| ew [ew | [ew co eat] —— a ion a wife fon fae wi >| ele [| » | = | « | «| a cst ie aa] —— ea Yow awa on wd] Bi al gc a Go eka] — [Rk aad fs aoa Gero 8 fie Yn caf we [=] - | = |» | @ | : [Color] White & Greer] — aes [Red & Green [Yellow & Blue|Green & Black] Blue & Black a a a SC FOREWORD CONVERSION TABLE CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section Is pro det led to enable simple conversion of figures. For Is of the method of using the Conversion Table, see the example given bolow. EXAMPLE ‘+ Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 60 in the vertical column at the left side, take this as @, then draw a horizontal line from @. {2) Locate the number § in the row across the top, take this as @, then draw a perpendicular line down from ®. (3) Take the point where the two lines cross as ©, This point © gives the value when converting from milimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 850 mm into inches. (1) The number 550 does not appear In the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2,165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. Millimeters to inches 1mm = 0.03937 in ° 1 2|3 | 4 5} 6 | 7]s |e o jo 0.039 | 0.079 | 0.118 | 0.157 | 0.197'| 0.296 | 0.276) 0.315 | 0.354 10 | 0.394 | 0.433 | 0.472 0.512 0.551 | 0.591'| 0.630 | 0.669 | 0.709 | 0.748 20 | 0.787 | 0.827) 0.866 | 0.906 | 0.945 | 0.984'| 1.024 | 1.063] 1.102] 1.142 30 | 1.181 | 1.220| 1.260 | 1.299 | 1.339 | 1.378!| 1.417 | 1.457 | 11496 | 11536 40 | 1.575) 1.614| 1.654 | 1.693 | 1.732 | 1.772:| 1.811| 1.850 | 1.890] 1.929 2.205 | 2.244] 2283| 2.323 % 2588 | 2638| 2677 | 2.717 70 | 2.756) 2.795} 2.835 | 2.874 | 2913 2.953| 2.992] 3.032) 3.071 | 2.110 ao | 2150) 2199) 2.298 | 3.268 | 3207 | 2346 | 3396 | 3.425 | 3.465 | 2.504 90 | 3543) 3.583 | 3.622 | 3.661 | 3701| 3740 | 3780| 3.819/ 3.e68| 3.808 00-14 FOREWORD Millimeters to Inches CONVERSION TABLE ‘mm = 0.03937 in 0 1 2 3 4 5 6 7 8 9 0 ° 0.039 | 0.079 | 0.118 | 0.157 | 0.197 | 0.296 | 0.276 | 0.315 | 0.954 10 0.394 | 0.433 | 0.472 | 0.512 | 0.551 | 0.591 | 0.630 | 0.669 | 0.709 | 0.748, 20 0.787 | 0827 | 0.866 | 0.906 | 0.945 | 0.984 | 1.024 | 1.063 | 1.102 | 1.142 30 att | 1.220 | 1.260 | 1.299 | 1.339 | 1.378 | 1.417 | 1.487 | 1.496 | 1.536 40 1.575 | 1.614 | 1.654 | 1.693 | 1.732 | 1.772 | 1811 | 1.850 | 1.890 | 1.929 50 rge9 | 2008 | 2.047 | 2087 | 2.126 | 2165 | 2205 | 2.244 | 2.283 | 2.928 60 2262 | 2.402 | 2.441 | 2.490 | 2.520 | 2.589 | 2598 | 2638 | 2677 | 2.717 70 2.766 | 2.795 | 2.835 | 2.874 | 2.913 | 2953 | 2992 3.032 | 3.071 | 3.110 80 3.150 | 3.189 | 3.228 | 3.268 | 3.307 | 3.246 | 3.986 | 3.475 | 3.405 | 3.504 90 asaz | ase3 | 3.622 | 3681 | 3.701 | 3.740 | 3.780 | 3a19 | 3.ase | seca Kilogram to Pound kg = 2.2066 Ib ° 1 2 3 4 5 6 7 8 9 o 0 220| 441| 661| saz] 1102] 1323) 15.43| 17.64| 19.84 10 22.05| 2425| 26.46| 28.66) 3086] 3307| 3527 3748| 39.68 41.99 20 4409| 4630] 4850/ 50.71) 5191| 55.12| 5732| 5953| 6173 63.93 30 66.14| 6334| 7055| 72.75) 7496| 77.16| 7937| 81.57| 83.78 95.98 40 gig} 90.39] 9259] 9480] 97.00] 99.21) 101.41 103.62 | 105.82 108.03 so | 110.28 | 112.44 | 114.64 | 116.85 | 119.08 | 121.25 | 123.48 | 125.86 | 127.87 | 130.07 60 | 132,28 | 134.48 | 136.69 | 138.89 | 141.10 | 143.30 | 145.51 | 147.71 | 149.91 | 152.12 70 | 184.32 | 156.53 | 158.73 | 160.94 | 163.14 | 165.35 | 167.55 | 169.76 171.96 | 174.17 80 | 176.37 | 178.57 | 180.78 | 182.98 | 185.19 187.39 189.60 | 191.80 194.01 | 196.21 90 198.42 | 200.62 | 202.83 | 205.03 | 207.24 | 209.44 | 211.64 | 213.85 | 216.05 218.26 FOREWORD Liter to U.S. Gallon CONVERSION TABLE 1 = 0.2642 US. Gal o 1 2 3 a 5 6 7 a 9 ° 0.264 | 0.528 | 0.793 | 1.057 | 1.321) 1.585 | 1.849 | 2.113 | 2378 10 2.642 | 2.906 | 3.170 | 3.434 | 3.698] 3.963 | 4.227) 4.491} 4.755 | 5.019 5.283 | 5548 | 5.812) 6.076 | 6.340 | 6604 / 6869 | 7.133 7.397 | 7.661 30 7.928 | 8.19] 8.454 | 8.718 | 8982] 9.246 | 9.510 | 9.774 | 10.039 | 10.303 40 | 10.567 | 10.831 | 11.095 | 11.380 | 11.624 | 11.988 | 12.152 | 12.416 | 12.680 | 12.944 50 | 13.209 | 13.473 | 13.737 | 14.001 | 14.265 | 14.529 | 14.795 | 15.058 | 15.322 | 15.586 60 | 15.850 | 16.115 | 16.378 | 16.043 | 16.907 | 17.171 | 17.495 | 17.700 | 17.964 | 19.228, 70 | 18.492 | 18.756 | 19.020 | 19.285 | 19.549 | 19.813 | 20.077 | 20.341 | 20.605 | 20.870 80 21.134 | 21.398 | 21.662 | 21.926 | 22.190 | 22.466 | 22.719 | 22.983 | 23.247 | 23.511 90 | 23.778 | 24.040 | 24.304 | 24.568 | 24.832 | 25.096 | 25.361 | 25.625 | 26.889 | 26.153, Liter to UK. Gallon 7 0 1 2 3 4 5 6 7 8 9 ° ° 0.220 | 0.440} 0.660 | 0.880 | 1320 | 1540 | 1760) 1.980 20 4399 | 4619) 4939 | 5.059 | 5.279 5.719 | 5.939 6.159 | 6.379 30 6599 | 6.819 | 7.039 | 7.259 | 7.479 7913 | 2.139| 8359 | 9.579 40 8799 | 9.019 | 9.239] 9.459 | 9.679 10.119 | 10.339 | 10.559 | 10.78 80 | r0.998 | 19.281 | 11.438 | 17.858 | 11.878 | 12.098 | 12.318 | 12.528 | 12.758 | 12.978 60} 13,198 | 13.418 | 13.638 | 13.858 | 14.078 | 14.298 | 14.518 | 14.738 | 14.958 | 15.178 70 | 16.398 | 15.618 | 15.838 | 16.058 | 16.278 | 16.498 | 16.718 | 16.938 | 17.158 | 17.378 20 | 17.898 | 17.818 | 18.037 | 18.257 | 18.477 | 18.697 | 18.917 | 19.137 | 19.367 | 19.577 90 | 19.797 | 20.017 | 20.237 | 20.457 | 20.677 | 20.897 | 21.197 | 21.937 | 21.987 | 21.777 FOREWORD CONVERSION TABLE kgm to ft. Ib 1 kgm = 7.233 ft. Ib ° al 2 3 4 5 6 7 8 8 0 0 72| 145] 217| 289| 362| 434) so6| 579| 65.1 0 723} 796| 868] 940] 1013| 1085 | 1157 | 1230 | 130.2 | 197.4 20 1447 | 1519] 169.1 | 1664 | 1736 | 1808 | 1881 | 1953 | 2025 | 2098 30 217.0 | 2242 | 2315 | 298.7 | 245.9 | 253.2 | 260.4 | 267.6 | 2749 | 282.1 40 2003 | 2066 | 2038 | 311.0 | 3183 | 3255 | 3327 | 340.0] 3472 | 3544 50 3617 | 3689 | 3761 | 383.4 | 3906 | 397.8 | 405.1 | 4123] 4195 | 4268 60 434.0 | 4412 | 4485 | 458.7 | 462.9 | 470.2 | 477.4| 4846 | 4918) 499.1 70 5063 | 5135 | 5208 | 5280 | 535.2 | 5425 | 49.7 | 5569 | 5642 | 571.4 80 578.6 | 5859 | 5931 | 6003 | 607.6 | 6148 | 6220 | 629.3 | 6365 | 6437 90 651.0 | 658.2 | 665.4 | 672.7 | 679.9 | 687.1 | 6944 | 7016 | 7088 | 716.1 100 7233 | 7305 | 737.8 | 745.0 | 752.2 | 7595 | 7667 | 7739 | 781.2 | 7884 10 795.6 | 8029 | 810.1 | 817.3 | 8246 | 9318 | 8390 | s463| 635 | 860.7 120 868.0 | 875.2 | 882.4 | 999.7 | 9969 | 9041 | 911.4] 9186] 9258) 9331 130 940.3 | 9475 | 9548 | 962.0 | 969.2 | 9765 | 983.7 | 990.9 | 998.2 | 1005.4 140 | 10126 | 1019.9 | 1027.1 | 1034.3 | 1041.5 | 1048.8 | 1056.0 | 1063.2 | 1070.5 | 1077.7 | 150 | 1084.9 | 1092.2 | 1099.4 | 1106.6 | 11139 | 1121.1 | 1128.3 | 11386 | 11428 | 1150.0 eo | 1187.3 | 11645 | 1171.7 | 1179.0 | 11862 | 1193.4 | 1200.7 | 1207.9 | 1215.1 | 1222.4 170 | 1128.6 | 12368 | 1244.1 | 1251.3 | 12585 | 1265.8 | 1273.0 | 1280.1 | 1287.5 | 1294.7 180 | 1301.9 | 1308.2 | 1316.4 | 1323.6 | 13309 | 1338.1 | 1345.3 | 1352.6 | 1359.8 | 1367.0 190 | 1374.3 | 1381.5 | 1388.7 | 1396.0 | 1403.2 | 1410.4 | 1417.7 | 1424.9 | 1432.1 | 1499.4 FOREWORD CONVERSION TABLE kg/em? to Ibfin? Uglem? = 14.2233 Ibfin? ° 1 2 3 4 5 6 7 8 8 ° 0 | 142) 284] 427| s69| 71.1] 853| 996] 1138] 1280 10 1422 | 1985 | 1707 | 1849 | 1991 | 2134] 227.6 | 241.8 | 2560 | 270.2 20 2845 | 2987 | 3129 | 327.1 | 3414) 3556 | 3698 | 384.0 | a983 | 4125 30 4267| 4409) 455.1 | 469.4 | 4936 | 497.8] 512.0| 5263 | 5405 | 554.7 40 sesa| 5932 | 5974) e116 | 268} 640.1 | 6543 | 6605 | c027 | coco 50 7112 | 725.4 | 7396 | 7538 | 768.1 | 7823) 7965 | 8107 | 925.0 | 939.2 60 e534 | 9676 | 9818 | 9961 | 9103 | 9245 | 998.7 | 950.0] 967.2 | 901.4 70 9956 | 1010 | 1024 | 1038 | 1053 | 1067 j 1081 | 1095 | 1109 | 1124 go 113s [1452 | 1168 jais1 [1195 | 1209 | 1223 | 1237 | 1252 | 1266 90 | 1280 | 1294 | 1309 | 1328 | 1337 | 1351 | 1985 | 1380 | 1294 | 1408 oo 1422 | 1437 | 1451 | 1465 [1479/1493 | 1508 | 1822 | 1636 | 1850 110 |1565 | 1579 | 1593 |1607 | 1621 | 1636 | 1650 | 1664 | 1678 | 1693 120 |a707 1721 |4795 [1749 | 1764 | 1778 J 1792 | 1808 | 1821 | 1835 130 |1e49 | 1963 | 1877 |1e92 | 1906 | 1920 1934 | 1949 | 1963 | 1977 140 }1991 | 2005 | 2020 | 2034 | 2048 | 2062 2077 |2091 | 2108 | 2119 150 [2134 |2148 | 2162 [2176 | 2190 | 2205 | 2219 | 2233 | 2247 | 2262 160 2276 |2290 | 2304 | 2318 | 2333 | 2347 |2361 | 2375 | 2389 | 2404 170 |2aig |24s2 | 24s | 2480 | 2475 | 24a9 | 2503 | 2518 | 2592 | 25408 eo |2560 2574 | 2589 | 2603 | 2617 | 2631 | 2646 | 2660 | 2674 | 2688 190 |2702 [2717 | 2731 |2745 | 2759 |2773 | 2788 | 2802 | 2816 | 2830 200 | 2845 | 2859 | 2873 | 2887 | 2901 [2916 | 2930 | 2048 | 2958 | 2973 210 |2987 | 3001 |3015 [3030 | 3044 | 3068 | 3072 | 3086 | 3101 | 3115, 220 |arza {ares | arse |a172 |a1e6 | 3200 |a214 |a229 |a24a | 2257 230 |s271 |s2e6 | 3300 [3314 [3328 | 3343 | 3387 |3371 | 3385 | 2399 240 3414 | 3428 | 3442 | 3456 | 3470 | 3485 | 3499 | 3513 | 3527 | 3542 00-18 FOREWORD CONVERSION TABLE Temperature Fahrenheit Centigrade Conversion simple way to convert» Fahronhe't temperature reading into & Centigrade tempera: ‘ure reading or vice verse is to enter the accompanying table i the canter or boldface column of figuras. ‘These figures rofer to the tomparatre in ether Fahrenheit of Centigrade degrees. If i ie desiced to convert from Fahrenhelt to Centigrade degrees, consider the center column as a table of Fahrenheit ‘temperatures and read the correspencing Centigrade temperature in the eoluran a the le fit is desired to conver from Centigrace to Fahrenheit degrees, consider the corte column asa tabla of Centigrado valuas, ‘and read the corresponding Fahronheit temperature on the right 1-236 *c « | + | | oF soa |4o | oo] -r7| | sie | re | as | vas | 272 ms sz | as | no | a | wz | 536 | 53 | a7 | ries | 278 1798 sua | 30 | 220 | 0s | 13 | ssa | 89 | as | ange | 283 wet s17 | 25 | 130 | oo | a | 572 | 94 | 49 | i202 | 259 13.2 -03 | 20 | 40] 4 | 15 | 550 | 100 | so | i220 | 28 1059 3 |-19 | 22] 29] 1 | cos | 0s | s1 | 1238 | 300 | 86 | 1068 are | | 4] 23] 7 | o26| a1 | se | r250| 300 | o7 | 186 sa |o7 | a4 | aa] w | see | ony | ss | za] aia | oe | r908 “07 | “se | 22 | 72] 1 | 662] 122) sa | 1202 | 317 | 9 | 1022 asi |-1s | so] -67| 2 | 680 | 128 | 55 | tao | 322| 9 | 1940 6 |-4 | 6a] s1| 2 | cos | rss | 56 | ts | szs| ov | 1958 50] | e6| 36] 2 | m6] 139 | 57 | 16 | 333) 92 | 976 sa | 2 | oe] 50] 23 | 734 | ise | 5a | ta84 | 339 | 93 | 1908 sag om | zz | 44] 2 | 752 | aso | 59 | tas2 | 38s | 96 | 2or2

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