SEBM04250107
KOMATSU
WA5004 MACHINE
WA5004
MODEL
SERIAL
10001
No.
and up
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. WA500-1 mount the S6D140-1 engine; For details of the engine, see the 6D140-1
Series Engine Shop Manual.
00-l 05-91(02)03261
a
CONTENTS 10 ENGINE 11 - 12
No. of page
STRUCTURE TESTING
AND FUNCTION
.........................................
AND ADJUSTING
13
DISASSEMBLY
........................................... AND ASSEMBLY ......................................
14
MAINTENANCE
STANDARD
20
POWER
21
STRUCTURE TESTING
23
DISASSEMBLY
24
MAINTENANCE
AND
FUNCTION
.........................................
AND ADJUSTING
........................................... AND ASSEMBLY ...................................... STANDARD ...........................................
STEERING
SYSTEM AND FUNCTION
41
STRUCTURE
42
TESTING
43
DISASSEMBLY
44
MAINTENANCE
.........................................
AND ADJUSTING
........................................... AND ASSEMBLY ...................................... STANDARD ...........................................
50 BRAKE AND 51
STRUCTURE
52
TESTING
53
DISASSEMBLY
54
MAINTENANCE
60 WORK
AND FUNCTION
.........................................
........................................... AND ASSEMBLY ...................................... STANDARD ...........................................
EQUIPMENT
61
STRUCTURE TESTING
AND
FUNCTION
.........................................
63
DISASSEMBLY
........................................... AND ASSEMBLY ......................................
64
MAINTENANCE
STANDARD
81
STRUCTURE
82
TESTING
83
DISASSEMBLY
22-1 23-l 24-1
41-1 42-l 43-1 44-l
AND
...........................................
ELECTRONIC
AND FUNCTION
51-l 52-1 53-l 54-l
SYSTEM
AND ADJUSTING
ELECTRIC
21-1
AIR SYSTEM
AND ADJUSTING
62
80
14-1
13-l
TRAIN
22
40
...........................................
11-l
12-1
61-l 62-l 64-l
63-1
SYSTEM
.........................................
AND ADJUSTING
........................................... AND ASSEMBLY ......................................
81-1 82-l 83-1
90 OTHERS 91 93 97
OTHERS..
............................................................ DISASSEMBLY AND ASSEMBLY ...................................... GEAR PUMP ........................................................
Ok2
91-1 93-1 97-101
WA500-
1
01 GENERAL
(THIS SECTION IS NOT USED IN THIS MANUAL) m
10 ENGINE
20 POWER TRAIN
40 STEERING
SYSTEM
m
50 BRAKE AND AIR SYSTEM
60 WORK EQUIPMENT
80 ELECTRICAL
90 OTHERS
SYSTEM
AND ELECTRONIC
SYSTEM
m
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WA5bO- 1
A
IMPORTANT
Proper service and repair is extremely The
service
and repair techniques
manual are both effective
important
injury to workers,
cautions
in this manual.
followed
carefully.
If any dangerous
safety, and take the necessary
by Komatsu
of operation.
of your machine.
and described
in this
Some of these operations
re-
by Komatsu for the purpose.
the symbols
The cautions
NOTICE
for the safe operation
recommended
and safe methods
quire the use of tools specially designed To prevent
SAFETY
A
iY
and
accompanying
situation
are used to mark safety pre* these symbols should always be
arises or may possibly arise, first consider
actions to deal with the situation.
A SAFETY GENERAL
6. Decide
PRECAUTIONS
a place
in the repair
keep tools and removed Mistakes Read
in operation
the
carefully
are extremely
Operation
dangerous.
and Maintenance
BEFORE operating
Manual
the tools Always
and parts in their correct
read
all
the
precautions
or repairs,
given
places.
sure that there is no dirt or oil on the floor.
the machine.
out any greasing
to keep
keep the work area clean and make
Smoke 1. Before carrying
workshop
parts. Always
on
only
smoking.
in
the
areas
provided
for
Never smoke while working.
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, missing.
with buttons
.
Always
or clothes
wear safety
Always
glasses when
hitting
trained, work.
wear
safety
glasses
when
experienced
always wear welding cap
and
welder
carrying
other
out
carry
out the
welding
work,
gloves, apron, glasses,
clothes
suited
for
welding
work. 4.When
carrying
inform
out any operation
work,
always
procedure your fellow
any step
agree
before
UNDER
workers REPAIR
controls in the operator’s 5. Keep all tools
in good
with two on the op-
starting.
of the operation.
hang
oil or making
any
repairs,
on hard, level ground, and
the wheels
8. Before
starting
or tracks
to prevent
the
before Before
to the
If this
equipment to
lock
warning
is not
possible,
insert
the
port
the
In addition,
control
levers
be sure
and
hang
signs on them. disassembling
the
machine
or assembling, with
blocks,
sup-
jacks
or
stands before starting work.
starting starting
machine.
and learn
lower
from falling. all
other
on the
work,
safety pin or use blocks to prevent the work
10. Remove
compartment.
the correct way to use them.
ripper,
Always
signs
condition
blade,
or any other work equipment
ground.
9. When
or more workers, erating
block
bucket
repairs are needed, always have a
When
adding
machine from moving.
grinding parts with a grinder, etc. 3. If welding
7. Before
FOR WORK
park the machine
parts with a hammer. l
PREPARATIONS
or
steps
machine. If
it
all mud and oil from
places
used
Always
to get
the steps or
on and off
use the handrails,
when
getting
on
or
the
ladders off
the
Never jump on or off the machine.
is impossible
to
use
the
handrails,
ladders or steps, use a stand to provide safe footing.
00-3
PRECAUTIONS 1 1. When or
DURING
removing
the oil filler
hydraulic
loosen
pressure
them
spurting
slowly
19 Be sure to assemble
WORK cap, drain
measuring
to prevent
plug
places.
Replace
any damaged
.
plugs,
of the
remove
oil,
the
or removing
water
pressure
compo-
or air circuits, completely
from
the
20 ‘. When
the
engine
when
oil
in the
circuits
is stopped,
are
hot
so be careful
that
rying
out
any
work
to cool before
on
the
oil
car-
or
water
starting
battery.
14 When
work,
remove
Always
the negative
(-1
remove
terminal
raising
Check
that
heavy
the
parts
lead
from
high
first.
rope,
are free from
damage.
use
lifting
ample
capacity.
Install
the
places.
use
a
equipment
a hoist
other
covers
ternal
pressure
or
spring,
always
sides. Slowly loosen
bolts
components,
removing
the floor, on the
any
in-
from
a on
the pressure,
the
piping,
be careful wiring.
not
Damaged
fires. stop
the fuel
or oil
out. If any fuel or oil drips on to
wipe
floor
with
the bolts to remove.
or damage
spilling
hit-
in position
release
it up immediately.
can cause
you
Fuel or oil
to slip, or can
even start fires. 18. As
a general
wash.parts. mum parts.
00-4
of
rule,
do
In particular, gasoline
when
not
use gasoline
to
use -only the miniwashing
not
which speed,
hoses,
twisted.
make
Damaged
so be extremely
check
for
that
high
care-
pressure
connecting
or installing tightening
protective
parts
two
fingers
caught
always When
violently
be particularly
or hand.
parts, torques.
parts such as guards,
vibrate
aligning
or
rotate
careful
or at
to check
correctly. holes,
never
Be careful
insert
your
not to get your
in a hole.
electrical
measuring the
24. Take
hydraulic
measuring
bled before
from
are under
pressure
may cause electrical
17 When from
under
leave two
removing
wiring
operate
which
the ma-
installed.
fingers
that
by the hoist or crane.
removing
break
correct
and
Do not work
when
has
at the
the component
15 When
opposite
which
or crane
part.
part still raised
then slowly
and hooks
equipment
to prevent any
chains
be by
pressure
that they are installed
23. When
lifting
Use
slowly
to
Also,
the leads from
components,
wires,
be damaged
parts
tubes
assembling
22. When
the wire
Always
16 When
are
installing
are correctly
installing
hoist or crane.
ting
high
use the specified
13 Before
not
other
they
ful when
21 When
circuits.
the
will
are dangerous,
circuits.
not to get burned. Wait for the oil and water
with
installing
sure and
they
new parts.
and
chine is being operated.
tubes water
hoses
in their
first
circuit. 12 The
that
again
parts with
installing
contact
disconnecting
nents
When sure
the oil from
out.
Before
all parts
original
care
taking when
tracks
of track-type removing
either
pressure,
check
is correctly
assem-
any measurements. removing
When
rates suddenly,
tool
or installing
the
machines. the
track,
so never
end of the track.
the
track
let anyone
sepa-
stand
at
FOREWORD
This shop serviceman
manual
has been prepared
an accurate
understanding
repairs and make judgements.
as an aid to improve
of the product
the quality
and by showing
Make sure you understand
of repairs
by giving the
him the correct way to perform
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
components;
of
understanding,
these chapters
STRUCTURE
AND
This
section
adjustments
This
section
assembling MAINTENANCE
into
chapters
for
each
main
group
of
sections.
the structure
of the structure,
and function
of each component.
but also serves as reference
It serves not only to give
material for troubleshooting.
ADJUSTING explains
checks
to be made
to be made at completion
Troubleshooting DISASSEMBLY
is divided
FUNCTION
an understanding AND
manual
are further divided into the following
This section explains
TESTING
the
charts correlating
AND
before
and after
performing
repairs,
as well
as
of the checks and repairs.
“Problems”
to “Causes”
are also included in this section.
ASSEMBLY
explains
the order to be followed
each component,
when
as well as precautions
removing,
installing,
disassembling
or
to be taken for these operations.
STANDARD
This section gives the judgement
standards
when inspecting
disassembled
parts.
NOTICE The
specifications
contained
in this
shop
time
and without
any advance
notice.
Contact
latest
manual your
are
subject
KOMATSU
to change
at any
distributor
for the
information.
00-5
HOW
TO READ THE SHOP
MANUAL
HOW
TO READ THE SHOP
MANUAL
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages.
volume:
Engine volume:
Issued for every machine model Issued for each engine series
Electrical volume Attachments volume
: :
I
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 necessary that chassis, engine, electrical and attachment volumes are ready. DISTRIBUTION
MARK
-... )
REVISED
Chassis
EDITION
(a@@
VOLUMES
AND
UPDATING
Any changes Get the you start
amendments or other additions, will be sent to KOMATSU distributers. most up-to-date information before any work.
FILING
METHOD
REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page.
SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols.
Symbol
1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples shows how to read the page number. Example 1 (Chassis volume):
1 Item
Remarks Special safety precautions are necessary when performing the work.
A Safety
Extra special safety precautions are necessary when performing the work because it is under internal pressure.
YY 9
IO-3
17_
Item number (I 0. Structure and Function) Consecutive page number for each item.
Special technical precautions other precautions for preserving standards are necessary when performing work.
Caution
*
Example 2 (Engine volume):
T
Weight
3. Additional pages: Additional pages are indicated by a hyphen (-1 and number after the page number. File as in the example. Example:
?
4 4
1 o-4
12-203
1 o-5
12-204
00-6
Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants
Oil, water
A
Drain
the
Weight of parts or systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
12-410 Unit number (I. Engine) Item number (2. Testing and Adjusting) Group No. (4. Fuel system) Consecutive page No. (Page 10 of Group 4)
or
etc.
Places where oil, water or fuel must be added, and the capacity. Places where oil or water must be drained, and quantity to be drained.
HOISTING
INSTRUCTIONS
HOISTING
INSTRUCTIONS
A Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and Assembly section, every part weighing 25 kg or more is indicated clearly with the symbol &
1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: . Check for removal of all bolts fastening the part to the relative parts. . Check for existence of another part causing interference with the part to be removed.
2. 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
(mm)
Allowable
load (tons)
10
1 .o
11.2
1.4
12.5
1.6
14
2.2
16
2.8
18
3.6
20
4.4
22.4
5.6 10.0
30 40
18.0
50
28.0
60
40.0
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
as%
79%
71%
41% FSO064
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. Slinging 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 result in a dangerous accident.
A
4) Do not sling a heavy load with ropes forming 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 allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 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 4000 kg if they sling a 2000 kg load at a lifting angle of 150”. A
A
The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes of the hook.
from
the middle
portion Lifting
angle
: a FSO065
00-7
STANDARD
TIGHTENING
TORQUE
STANDARD 1. STANDARD
TIGHTENING
TIGHTENING
TORQUE
OF BOLTS
The following charts give the standard tightening sections of “Disassembly and Assembly”.
Thread diameter of bolt (mm)
AND torques
TORQUE NUTS of bolts and nuts. Exceptions
are given in
Width across flat (mm)
kgm
Nm
6
10
1.35kO.15
8
13
3.2kO.3
31.4t2.9
10
17
6.7f0.7
65.7k6.8
12
19
11.5+1.0
112k9.8
14
22
18.0~2.0
177r19
16
24
28.5t3
279+29
18
27
39I+4
20
30
56+6
13.22
383t39 549k58
22
32
76-t8
745r+78
24
36
94.5*10
927*98
27
41
30
46
33
50
36
55
39
60
1.4
This torque table does not apply to the bolts with which nylon packings or other nonferrous metal washers are to be used, or which require tightening to otherwise specified torque. *
Nm (newton
2. TIGHTENING
meter):
TORQUE
INm
& 0.1 kgm
OF SPLIT
FLANGE
BOLTS
Use these torques for split flange bolts.
Threa$
00-8
gtlyeter
Tightening
torque
(mm)
Width across flats (mm)
10
14
12
17
11.5&l
112k9.8
16
22
28.5+3
279229
kgm 6.71~0.7
Nm 65.7k6.8
.
STANDARD
TIGHTENING
TORQUE
Sealing surface
3.TlGHTENlNG Use these
TORQUE torques
FOR
NUTS
OF
FLARED
for nut part of flared.
T
Tightening
Thread diameter of nut part (mm)
Width across flats of nut part (mm)
14
19
2.520.5
18
24
5k-2
Nm
kgm
24.5 24.9 49k19.6
22
27
8k2
24
32
14k3
137.3k29.4
30
36
1823
176.5 k29.4
33
41
2OC5
196.1
36
46
25+5
245.2*49
42
55
3OA5
294.2249
COATING The recommended
coating
Nomenclature
materials
I
Grease (Lithium grease)
249
MATERIALS in Komatsu
Shop
Manuals
are listed
below.
Applications
LT-1A
Used to apply rubber pads, rubber gaskets, and cork plugs.
LT-IB
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong seal is needed.
LT-2’
Preventing
LT-3
Provides an airtight, electrically Used for aluminum surfaces.
LT-4
Used to coat plugs (plate shaped, bowl shaped) and holes, and mating portion of shaft.
LG-1
Used with gaskets and packings to increase sealing effect.
LG-3
Heat-resistant gasket for precombustion and exhaust piping.
LG-4
Used b itself on mounting surfaces on the%al drive and transmission cases. YThrckness after tightening: 0.07 - 0.08 mm)
LG-5
Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittinas in hvdraulic circuits of less than 50 mm in diameter.
Sealant gasket
Antifriction compound (Lubricant including molvbdenum disulfide)
prescribed
78.5 f 19.6
Komatsu code
Adhesives
Vaseline
torque
LG-6
bolts, nuts and plugs from loosening and leaking oil. insulating seal.
1 Srlrcon ‘. base type used in combination
chambers -
with LG-1 and LG-4.
LG-7
Has a shorter curing time than LG-6, and is easier to peel off.
LM-P
Applied to bearings and taper shafts to facilitate prevent sticking, burning or rusting.
G2-LI
Applied to bearings, sliding parts and oil seals for lubrication, prevention and facilitation of assembling work.
-
Used for protecting
battery electrode
press-fitting
and to
rust
terminals from corrosion.
“LT-2 is also called LOCTITE in the shop manuals
00-9
ELECTRIC WIRE
CODE
ELECTRIC In the wiring
diagrams,
various
colors
and symbols
This wire code table will help you understand Example:
5WB
indicates
CLASSIFICATION
a cable
having
a nominal
Number
Dia. Tp$nds
to indicate
the thickness
of wires.
DIAGRAMS.
number
5 and white
coating
with
black stripe.
Cross section
Cable O.D.
Current rating
(mm)
(A)
2.4
12
Applicable
circuit
(mm*)
11
0.85
CODE
BY THICKNESS
strands 0.32
0.88
Starting,
lighting, signal etc.
2
I
26
1
0.32
1
2.09
1
3.1
1
20
1
Lighting,
signal etc.
5
1
65
1
0.32
1
5.23
1
4.6
I
37
(
Charging
and signal
15
84
0.45
13.36
7.0
59
Starting
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
217
0.80
230
Starting
I
100
CLASSIFICATION
1
are employed
WIRING
Copper wire
Nominal number
Prioritv
WIRE
I\
BY COLOR
109.1
AND
CODE
Charging
Starting
Ground
Lighting
I
I tPri-
I
Circuits
Classk fication
marY
17.6
(Glow plug)
Code Red
Color
RW White&
Red
WB White & Black
I
-
I
Black&White BY Black &Yellow
Red & White RB Red & Black RY
YB
I
GR
Yellow & Black 1 Green & Red YG
I
GY
I
LR
1
Blue & Red
I
LY
Red & Yellow RG
00-l 0
Red & Green
Yellow & Blue
RL
YW
(GL)
Red & Blue
Yellow & White
(Green & Blue)
-
WEIGHT
A
TABLE
This weight table is a guide for use when transporting
or handling components. Unit.
Machine Model
WA500- 1
Machine Model
Serial Number
10001 -
Serial Number pump
I
WA500-1 10001 -
Engine assembly
1453
Hydraulic
Radiator
assembly
285
Steering and POC pumps
Torque converter assembly
193
Switch pump
I
13
Transmission assembly
980
POC valve
I
5
I
Damper
91
Machine control valve
Upper drive shaft
18
Lift cylinder
Center drive shaft
33
Dump cylinder
Front drive shaft
44
Engine hood
Rear drive shaft
42
Front frame
Front axle assembly
2028
Rear axle assembly
1776
Front differential
288
Rear differential
assembly assembly
282
Planetary carrier assembly (1 piece)
80
Planetary hub assembly (1 piece)
102
Axle pivot (Rear axle)
(1 piece)
Lift arm (with bushing)
20
90 279 283 43
I
1996
931119
I
Tire (1 piece)
421
Battery (1 piece)
Steering valve
55
Cab assembly
47
Air conditioner
Brake (1 piece)
170
Hydraulic
156
WA500-1
I
13
2486
Fuel tank
tank
I
I
240
(1 piece)
I
I
Wheel (1 piece)
Steering cylinder
kg
328 53 305
unit
I
115
Operator’s seat
I
40
Floor plate
I
131
0°2’
TABLE OF OIL AND
QUANTITIES
AMBIENT
KIND OF .FLUID
RESERVOIR
COOLANT
_22 -30
-1014
-240
320
CAPACITY
TEMPERATURE 50 10
‘2
68 20
Engine oil pan
Specified
‘$E
Refill
I ! 32
~~~,~~~~~~~,~~ !... ,.,,I,,,..,.....,.:_.,.,.,,,., ‘., .(.,,,.,..,.... -l-‘““”
IQ)
I
28.5
Engine oil
Brake
Transmission case
Hydraulic system Axle (Front and rear)
See NOTE
1
each 75
(4)
each 75
Fuel tank
Water
Cooling system
Add antifreeze
ASTM:
American
SAE:
Society of Automative
API:
American
Society of Testing and Material Petroleum
Specified capacity: Refill capacity:
_
80
Engineers Institute
Total amount of oil including oil for components and oil in piping.
Amount
of oil needed to refill system during normal inspection and maintenance.
NOTE: (I)
When change
fuel
sulphur
oil in the
content
nance hours described Change
oil according
sulphur content
is less
oil pan every
than
periodic
0.5%,
to 10°C (3)
I
Above 1 .O%
I
the engine
(4) l/2 of regular interval
l/4 of regular interval
SAElOW-30
and
an atmospheric
Use API classification
SAE15W-40,
temperature
goes up
CD as engine
CC, reduce
the
oil and if API
engine
oil change
to half.
For axle oil, use only recommended SHELL:
DONAX
CALTEX:
RPM TRACTOR TRACTOR
TEXACO:
TDH OIL
MOBIL:
MOBILAND
* It is possible
oil as follows.
TT or TD
CHEVRON:
SAE30
HYDRAULIC
HYDRAULIC
to substitute
SUPER
FLUID
FLUID
UNIVERSAL
engine
oil CLASS-CD
for axle oil.
If noise comes
from the brake,
it is no problem
durability.
0°i2
tem-
more or less in the day time.
classification interval
in an atmospheric
of lower than O°C, be sure to use engine
even though
if fuel
Change interval of oil in engine oil pan
~
starting
oil of SAElOW, table
is above 0.5%.
Fuel sulphur content
When
perature
in this manual. to the following
I
0.5 to 1.0%
(2)
mainte-
WA500-
1
of
PRECAUTIONS
4. Bearing
FOR
DISASSEMBLY
AND
ASSEMBLY
separator
5. Hook wrench A hook wrench
has a claw which
turning
of round nuts. The wrench
defined
sockets by the
turned.
The
wrench
designed
different
outer
diameter
accompanying
of the
figure
for use with
hooks
into the size is
round
shows
nut
a hook
round nuts of two
sizes.
FSOOl4
FSOO 13
:’ FSOO15
Removal
and Installation
of the Sprocket
Wheel
02P-023
FSOO16
00-l 3
PRECAUTIONS
FOR
S.CLEARANCE Store
DISASSEMBLY
AND
ASSEMBLY
12. CENTERING
ADJUSTMENTS
each set of shims or washers
can be installed
in their
original
so that they
condition
at the
time of reassembly.
Centering power
is very important
train
-
for example,
and
the
transmission
bevel
gear
shaft
centering deviation
parts,
between and
the stresses
so always
is within the specified
in the
the engine
between
and the final drives.
only increases
the turning
for interfaces
make
the
Incorrect acting
on
sure that the
limits.
Engine
10. LINK
RODS
1) If it is necessary
to change
the length
of the
link rod in order to remove
it, first record
original
rod can
length
reassembled 2) Remove
so that
the
in its original condition.
the link rod at the pins.
Rod
w
r-l�----�
Correct
n
o]
0
0
Transmission
the
be easily
0
Yoke
Pin FSOOI
7
Transmission
11 .SHIMS 1) Shims adjust
AND
WASHERS
are
used
the action
very carefully 2) Record
the
adjustment
center
of the
the
bevel
engine gears.
as they get deformed numbers
and
Handle
Correct
easily.
and positions
to speed
after reinstallation.
3) Do not reuse deteriorated,
to
any shims damaged,
or washers
that
are
bent or deformed.
4) Insert thin shims between
thicker ones.
FSOO18
00-14
MEASURING
INSTRUCTIONS
MEASURING PREPARATIONS 1. Cleaning Wash
BEFORE
INSTRUCTIONS
CHECKING
BLOCK
To bring two blocks into contact,
of parts
parts to be checked.
Special
paid to thoroughly
remove
surfaces
measurements
on which
care should be
dust and dirt from
the
are to be made
repair
Remove
of part surfaces
scratches,
be checked. ments
and rust from
If the surface
will
surface,
dents
be careful
parts to
When
smoothing
not to use an oilstone
paper coarser than the finished
benzene
wipe
with
to remove
a clean cotton
the other,
causing
wash each block
rust-preventing
oil and
cloth. Put one block on
a sliding or twisting
movement
the two.
If the
contact
apply
a fine-grade
their edges.
between
two
oilstone
blocks to’ the
feels
rough,
blocks
(Do not try to rub thecontact
along surface
of the blocks.)
are rough, the measure-
be inaccurate.
with
between
so that possible errors can be eliminated. 2. Minor
GAUGES
any
or sand
Do not leave the blocks in contact Long-time separate
surface.
contact
for a long time.
will make the blocks difficult
to
or cause black rust to appear on the con-
tact surfaces. 3. Preparation Clean
the tools
dirt from the
of measuring
and thoroughly
the surfaces
tools
for
adjustment.
When
tools
which
proper
Remedy
remove
contact
function
dust and
parts. Check
and
storing
Handle
of measuring
all tools
subject
them
which
with
to
can affect
odically
check
necessary,
sufficient
their delicate the
tools
calibrate
them.
their cases and return locations
whenever
care
and do not
force
or shocks
construction.
for
accuracy
by force
them.
or strike
gauge, coat
wipe
with
off
moisture,
a rust-preventing
such as Vaseline, and put the gauge back
Periand,
if
them
to their fixed
VERNIER
CALIPERS
At the start
storage
not in use. It is recommended
of measuring
slide or twist
apart,
Put the tools back into
to assign a person to be responsible storage
blocks,
in its case.
tools
unreasonable
a block
dirt and fingerprints,
any abnormality.
lubricant 4. Maintenance
two
them with a mallet. When
zero-point
separating
Do not try to pull them
for the proper
is no clearance
tween
and that
the jaws
graduation
tools.
of measurement,
check that there
is in exact
close the jaws
and
(due to wear)
be-
the “zero”
alignment
with
point of the the “zero”
point of the vernier scale.
MEASURING Repeat
TOOLS
each
eliminate
measurement
possible
necessary,
Measuring
if
two
or three
errors. Further
there
is a
large
times
an outer
diameter
to
repetition
will be
variation
in the
readings. When
measuring
a cylindrical measuring angles
the inside or outside
object, device
take put
two
in two
to each other. Repeat
diameter
readings
with
directions
of the
at right
this at several
points
along the overall length of the object. Along may
eye-measurement be used for
two approximately racy
of
such
considered At
the
for judging allowable
below
the unit of a scale
a comparison
equal measurements,
eye-measurements
between the accu-
should
not
be a
as reliable.
start
measuring
making
of
device whether limit.
each
measurement,
select
having
an accuracy
appropriate
the measurement
reaches
Correct
its FSOO 19
00-l 5
MEASURING
l
INSTRUCTIONS
Measuring
DIAL
an inner diameter
GAUGES
Carefully to
be
put the gauge contact-point
measured
to
protect
the
on a surface delicate
gauge
against shock. Set the zero-point
@ Correct
the
movement
of the gauge of
the
with care to keep
contact-point
within
its
stroke during measurement. Careless
setting
spindle
to
making
-
The
Correct
l
Measuring
measurement
minute
by
extend
pointer
‘of of
errors)
through
the the
are
protrusions,
probe
does
thus
gauge
are
errors
because
mechanism
dial using
can not
unit on the scale.
depressions
so that vertical
not exceed
(and
by the
of eye measurements
Measuring
zero-point
the
limit,
contact-point
below the minimum
the
dial
indicated
be assured
Set the
its
large
an expanding
gears. The reliability
may cause
to
impossible.
relatively
variations
accompanying
a depth
or
measurements
accompanied FSOOZO
of the zero-point
retract
or steps movement
its stroke
limits,
of and
slide the base of the gauge on a fiat surface.
Correct
Wrong
FSOO21
MICROMETERS Put the anvil onto an object turn in the spindle the object. two
or
Rotate three
at a right angle
until it comes the ratchet idle
into contact
stop until there
rotations,
then
and with
read
are the
FSO023
measurement. When
reading a measurement,
right angle to the graduation To turn back the spindle,
keep your eyes at a
Measuring
bending
on the sleeve. rotate
the thimble
with
your fingers.
Wrong
Correct
FSO022
Read
the
moving When
storing
ance between
a micrometer,
leave
a slight
the anvil and the spindle.
clear-
Indicator
object
Turn
the
the
difference
minimum
00-l 6
Total
the
object
back
Reading and
forth
one complete between
indications
the
(T.I.R.)
while
or vertically.
rotation
and read
maximum
of the gauge pointer.
and
MEASURING
Measuring
INSTRUCTIONS
end play,
looseness
or deviation
l
Measuring
gear backlash
Lever and fulcr
dial gauge
FSO025
Read the T.I.R. while
moving
the object
1) Fully mesh one of two gears and place the dial
back and
gauge
forth or vertically. Measuring
face runout
or radial
runout
contact-point
on a tooth
of the
other
gear. Swing
the free gear within the limits of its
play in the
rotational
directions,
and read the
T.I.R. 2) Use of the lever and fulcrum recommended point
type dial gauge
for this purpose
placed
is
as the contact-
on the gear is moved
tangentially
to the gear pitch circle. 3) The lever and fulcrum for
use
measurement
Radial runout
type dial gauge is suitable
in a narrow
space
which
contact-point
or for
requires
on an object
a special
placing
at an angle
the to the
spindle of the gauge. Since FSOO26 1) Read runout
complete
at six or more positions
rotation
point at the middle the spindle
during one
fully checked
movement.
Be careful
range
for contact
of gauge (usually
should
3
be care-
with the object during
of
not to con-
fuse positive and negative readings of runout.
CYLINDER l
‘)
GAUGES
Install
a contact-point
mately
equal to the cylinder
on the cylinder test indicator cylinder
gauge.
having
a length
Set the zero-point
to the bore diameter
measured
with
approxi-
bore to the measured
a reference
of the
of the standard ring gauge
or
a micrometer.
When the pointer is to the left of “0”
3) When
range
measurement.
set the zero-
of the assumable
of this type
measuring
mm or less), the contact-point
of the object.
2) At the start of each measurement,
the contact-point
has a very narrow
measuring
contact-point
_
face
runout,
+
place
the
on the object along a circle 2 or 3
mm smaller in diameter ter of the object.
than the outside diameContact-point \
Measuring
point
FSO028
00-17
PARTS
l
CHECKING
INSTRUCTIONS
Insert the gauge into the bore to be measured read the minimum while
giving swings
the detachable l
indication
When
the
and
of the test indicator
to the gauge
about
the tip of
rod used as the fulcrum.
minimum
reading
right side of the zero
is obtained
on the
point of the test indicator,
and the reading to the standard
value to which the
zero point is set. When
the minimum
reading
side of the zero point, the standard
is obtained
subtract
Check
from
value.
PARTS l
on the left
the reading
disassembled
CHECKING
parts to see if they are reusa-
INSTRUCTIONS 3. PITTING
ble or need repair. If the part failed due to an external
source,
before
determine
the
cause
and
correct
1) Pitting
by cavitation
In most
assembly.
cases,
chemical
scale, carefully 1. GENERAL
PRECAUTIONS
l
When
Visually
inspect
rosion,
scoring,
inspection,
every
parts
for
cracks,
ridging
etc.
part
should
To be
pitting,
cor-
ensure
proper
clean
before
If the cause of the defect great
help to analyze
the defect
can be found,
it will be a
l
whether
l
the part condition;
will progress
Knowing
l
the cause of the defect,
can give good advice
the service
to the customer
man
to prevent
him from having the same trouble again. l
Visual
inspection
damage.
Other
can
not find
methods
of
minute
or hidden
inspection
are
as
follows; a)
Water-pressure
b)
Color check or magnetic
or air-pressure damage
test test
2. CRACKS l
If
the
part
inspection, l
is found
to
be
it should be replaced
cracked
If the length or depth of crack exceeds thickness
by
visual
or repaired. 113 of the
of the part, it should be replaced
instead
of repaired. l
A part having an internal crack should be replaced.
00-l 8
removing
rust
by or
within the
limit, replace the part. is not deep,
removing
the rust and scale.
due to removal
resurface
the part after
of surface
If ball bearing is pitted, replace it. If more
than
l/3
of the contact
face
is pitted,
the part should be replaced.
or not, and the possibility
of future trouble.
is accompanied
inspect the depth of pitting.
If pitting
2) Pitting
inspection. l
l
After
the pitting can not be repaired
allowable l
cavitation
corrosion.
If pitting is not serious, resurface
the part.
PARTS
HANDLING
PARTS
HANDLING
1. OIL SEALS 3) Use a suitable
in the
proper
direction,
as shown
in the
press to press fit the oil seal into
the housing.
1. Direction Be careful to install the oil seal with its lips facing
.
When
installing
the
oil seal flush
with
the
.
housing surface..
figure
below. Oil seal nominal outside
Oil
pressure
side
Main lip
&.t
lip
FSO031 FSO029
.
2. Inspection prior to installation 1) Keep the oil seals free from
dust,
rust
and
scratches. Take
special
care to prevent
on the lips. slide
a wire
across
its
surface.
gently
If the
replace the oil seal with a new one.
+
sure that
the wire
the
oil
seal
inside
the
outside diameter l.O)mm
I
outside diameter l.O)mm
wire
catches, Make
installing
housing.. Oil seal nominal Oil seal nominal outside diameter + (0.5 I - (0.5 - l.O)mm Oil seal nominal - (0.5 t-L-7
rust or scratches
2) To check the oil seal lip for smoothness,
When
used for this test
does not scratch the lip surface. 3) Do
not
would
use the
come
oil seal
into contact
on a shaft
where
it FSO032
with rust or scratches
FSO033
on the shaft surface. 4) When
removing
damage 3. Installing 1) Coat
the
oil seal, take
not to
4) After
press-fitting
the oil seal, check that it has
not been installed at an angle to the housing.
the oil seal the surface
to which
applied with a lubricant +
care
the housing or shaft surfaces.
If the lip should double being proper
fitted place
over by
the oil seal is to be
or grease.
the
over as the oil seal is shaft,
rotating
return the
it to its
shaft
and
pulling the oil seal slightly backwards. 2) When with
installing a
keyway,
an oil seal on a shaft splines,
suitable jig to protect
or
machined
threads,
use
a
Max. permissible oil seal slant (H, -
the lip.
HI)/2 S l/400 FSO034
Lip protectton jig
FSOO30
00-l 9.
PARTS
HANDLING
4. Applying grease to the lips Before installing an oil seal, coat it with grease according to the following procedure to prevent friction from burning the seal surfaces while the machine is being started. 1) Single-lip oil seal Place a flat, uniform coating of grease on the surface away from the sealing surface.
‘Grease FSO035
2) Double-lip oil seal Coat the entire surface between the two lips with grease in the manner shown in the accompanying figures.
Grease
2. FLOATING
SEALS
1. Handling floating seals 1) Keep each pair of floating seals bundled together with tape to avoid mix-ups when they are reinstalled. 2) Discard the old O-rings. Always use new ones when installing the floating seals. 3) Replace a floating seal if its contact surface is rusted.
2. Installing floating seals 1) Remove all rust and dust from the mounting surfaces of the seal. Use sandpaper to remove any rust that might come into contact with the O-ring. 2) When installing the floating seal, coat the mounting surfaces with oil. Then install the O-ring, taking care not to twist it. * Do not coat the O-ring with oil. * The floating seal has been correctly installed if the seal ring rotates. 3) After installing the O-ring and seal rings in both housings, mate the two together.
Grease
I
FSO036
Housing
Seal ring FSO037
5. Applying adhesives Take special care when applying adhesives. to the outer surface of oil seals. Adhesive on the surface of the lip or shaft leads to oil leakage. * Since any adhesives on the surface of the press jig will soon transfer to the oil seal lips, clean the jig before use.
4) An installer is recommended for inserting the O-rings. t Using a screwdriver or other pointed object risks scarring the O-ring. 5) Attempting to mate the two housings together without the O-rings and seal rings in place can damage the O-rings and lead to oil leakage.
O-ring
I
Housing
Seal ring FSO038
00-20
PARTS
HANDLING
4. GASKETS
3. O-RINGS
1. Handling
1. Handling 1) Discard
any O-ring
that has been in storage
too
2) Use only the O-rings for
rings
used
parts, where
materials
prescribed
for the part in
BOOK. This is especially
those
engine
with
important
USE
NEW
2) Make
packings,
gaskets
and copper
with new ones.
sure that there
on the contact
are no scratches
surfaces
or burrs
of the gasket.
high-temperature
heat-resistant
and durable
2. Installing
gaskets
I) Make
such as silicon are required.
3) ALWAYS
replace
packings
long or has hardened. the PARTS
gaskets
I) Always
sure that
the holes in the gasket
those in the mating
O-RINGS.
2) Apply
gasket
match
part.
sealant
to the joints so specified
in the SHOP MANUAL. 2. O-ring
types
KOMATSU as shown
O-rings
are marked
in the accompanying
with colored
dots
3. Precautions gasket 2) Coat
Material
Part Number
Marking
Application
One blue spot
07000-0
..... Nitrile rubber
For low-pressure
Two blue spots
07000-1
..... Nitrile rubber
For high-pressure
One green spot
07000-3
..... Fluorine rubbel
For low-pressure
07000-2
Fluorine rubbel
07000-4
One red spot
..... Nitrile rubber
For high-pressure For low-pressure in cold weather
all scratches,
the specified
07000-5
Two red spots
,..., Nitrile rubber
applying
a new coat.
area evenly
and let dry for
several minutes. 3) Assemble sealant
the
mating
parts
when
the
gasket
is stickly to the touch.
5. BEARINGS
1) Shield
bearings the
bearings
from
dust
and dirt;
the tiniest speck rapidly accelerates +
Leave
the
packaging
bearings until just
in
their
before
even
wear. protective
they
are to be
installed. 2) Protect
For high-pressure in cold weather
dirt, paint, grease and old
sealant before
1. Handling Two green spots
for using liquid gasket
1) Remove
chart.
a bearing
from
excessive
force
and
compressed
air
shocks. *
Never
dry
a bearing
with
after cleaning. 07000-6
Orange spot
..... Silicon rubber
For low-pressure in hot weather
2. Installing
bearings
I) Never drive a bearing onto a shaft by pounding on
the
outer
pounding produces 3. Inserting After
O-rings
coating
so as not
the O-ring
to damage
2) When with
oil, insert
it. Silicon
rubber
carefully O-rings
race
on the
into
an
race.
Such
opening
by
pounding
dents in the tracks in the races.
a bearing
with some
or
inner must
interference,
with the jig shown
be fitted press-fit
onto
a shaft
the inner race
in the accompanying
figure.
require special care since they tear easily. Jig
Press fit
FSO039
00-2 1
PARTS
HANDLING
6. PRESS
3) If the shaft ference, *
of opening
has considerable
heat the bearing before
with
a non-separable interference
the jig shown
BUSHINGS
Do not drive in a bushing
installing.
Use a press so that
Do not heat above 120°C.
4) When
FITTING
inter-
bearing
must
for both races,
be fitted
press-fit
in the accompanying
with
1) If no press is available, a
distributed
I
with a hammer.
is uniform
over the
entire circumference. using
figure.
directly
pressure
driving
tool
hammer so
that
in the bushing the
force
is
evenly.
Jig I
Press fit
FSOO40
5) Thoroughly
coat
the
bearing
with
oil before
installing. 6) Install
the
chamfered
bearing, surface
spacer
or washer
with
its
facing the step on the shaft.
a
2) If the bushing
has an oil hole, bring the hole into
exact alignment
with the oil hole in the housing.
Rear face of
To injection
FSO043
3) When
Correct
burrs FSO041
a bushing and
has been removed,
foreign
matter
from
the
remove
all
mounting
hole, and then clean.
7. REMOVING I) Use snap
SNAP
RINGS
ring pliers to remove
rings. Do not overexpand
or install snap
them-especially
the
smaller ones. 2) After
installing,
check
to make
sure that
snap ring is firmly in place within its groove.
00-22
the
PARTS
HANDLING
8. HYDRAULIC
2. Installing
PIPING
the hydraulic
I) Thoroughly B
Precautions ment
for
hydraulic
I) Lower
servicing
the
work
equip-
equipment
to the ground
and
the oil filler cap to relieve
the hydraulic 3) Operate eliminate
pressure
in
3
to
control
levers
hydraulic
2
pressure
or
times
remaining
in the
the
work
equipment
prevent
it
removed
and the hydraulic
1. Removing
from
falling
the hydraulic
1) Disconnect tubes
by
male
side
loosening
hydraulic holding
remove
all
with compressed
air.
when
the
pressure
and
4) Install
the
piping
so that
piping!
alt the identification
tags match. a pipe
must
be joined
at
both
ends,
to
tightening
only one end at a time may make
is
too short.
First fit both ends by hand and then
piping
is released.
it
tighten the ends by turns. (See figure.)
piping nut on the
joint)
one
on a stand
a oil,
tubes from hoses or other
the
of the the
and
with
light
dents are too large, replace.
5) When
piping to be disassembled. 4) Support
trichloroethane)
traces of detergent
of piping
example,
3) Do not use gasket sealant for hydraulic
oil tank.
the
piece
(for
2) Repair the sealing faces or, if the scratches
turn off the engine. 2) Loosen
piping
each
detergent
kerosene,
system
the work
suitable
clean
with
on the
spigot
a wrench
socket
(the
(the while
female
side).
Tighten gradually and alternately the both ends. FSO045
6) To ensure tight-fitting 80%
then tighten FSO044
7) After engine
2) Seal
the ends
hoses
and
equipment matter.
oil
ports
For the same
reason,
the
tubes
and
hydraulic
neath to catch
Then
idling
levers check
90°,
and
of
all speed the
connections, and
operate
run
the
hydraulic
all the
attachments.
the oil level in the hydraulic
tank
and add oil as necessary.
tape.
containers
the hydraulic
control
the nuts to
loosen
to the full torque.
completing at
torque,
seal the ports of
tank with adhesive
appropriately-sized
out when
to
with blind plugs to keep out foreign
the hydraulic 3) Have
of the disconnected
the
seals, tighten
of the specified
under-
fluid that will flow
the piping is disconnected.
Clean
up
all spills immediately. 4) When
working
yourself 5) Tag
under
the
machine,
position
out of the way of the oil shower.
the ends of all piping
removed
as well as
the ports to which they were attached.
00-23
PARTS
HANDLING
3. Handling
high-pressure
hoses
I) Do not try to shorten the accompanying
Shorting
under
/
the hose. A hose shorter
than the specified
length is subject
to the defects
shown
in
figures.
pressure
increases
the tension.
Too
sharp
a bend
damages
FSO046
2) Make sure the hose is not twisted The
FSO047
after it is installed.
letters
printed
on the
hose
soon
reveal
any twists.
FSO048
3)
Similarly,
the hose must not twist as it moves.
FSO049 Improper the pipe
connection
causes
the
hose
to twist
as
moves. FSOO50
4) The last figures on this page are examples
of poor connections.
e must
have
it to contract
FSO05
Rubbing
FSO053
00-24
1
sufficient under
play pressure
FSOO52
PARTS
HANDLING
4. Handling
hoses with
self-seal
1) Do
attempt
to connect
not
coupling
without
hydraulic
pressure.
*
The gushing
first
use
relieving
hydraulic
also damage
or disconnect the
or
internal
fluid will not only soil
but the high flow rate may
the O-ring
a hammer
halves
tighten
them
tightly
together,
distance
the surroundings, 2) Never
2) Press the two
couplings
they
equivalent
the fastening pathway
completely
uniformly.
If they will
to the
together
and
are
held
separate
clearance
bolts and their
not
by
a
between
holes, forming
a
for oil leakage.
of the coupling.
to tighten
or loosen
a
coupling. *
Such
sharp
leading
to
blows oil
can deform
leakage
the coupling,
or cracking
of
the
coupling. 3) Protect
the
intrusion
disconnected
of
dust
disconnected
for
necting
to another
and
dirt
some coupling
piping
from
the
! If it is to remain time,
seal
by
or by fitting
cona dust FSO057
cap or a blind plug to each end. 6. Using sealing 1) To
tape
prevent
around
oil
leakage,
the tapered
thread
wind
sealing
before
inserting
tape the
plug into the plug hole. 2) Wrap then
all but the first 1.5 threads force
fingernail. “I.4
During
�
FSOO54
1) Follow
Wind
tape
into
the
at the tip and
threads
with
the tape in the same direction
as the threads.
storage
FSO055
5. Handling
the
ave 1.5 threads
FSO058
split flanges the
bolt
bare.
tightening
sequence
given
in
the figure.
FSO056
00-25
a
PARTS
HANDLING
9. SPRING Judging
ll.PUMP
WASHERS
I) After
suitability
I) Discard
the spring
washer
if the overlapping
assembly
pump
with
and before
oil
through
installation, the
intake
fill the port
to
provide initial lubrication.
portion is worn or damaged.
2) Before
installing
shaft
by
hand
smoothly
the to
without
pump,
make
turn
sure
the
that
drive
it turns
any catching.
* Inlet -
If
J
FSO059
2) Discard if the distance P is more than 2t/3.
FSO062
3) Test
run the
installed
pump
and
check
for
unusual noises and leakage.
12. SEAL I) Seal FSOO60
RINGS rings
are very
delicate,
so handle
and
store carefully.
2) Do not reuse rubber seal rings. 3) Avoid excessive stretching when fitting a seal 10. SPRING
(ROLL)
ring
PINS
over
a shaft;
it decreases
the
ring’s
fitting
a seal
performance. Handling
spring
4) Remove
pins
all sharp
edges
before
ring into a slot on an abutment. 1)
A spring
pin performs
the split is placed
facing
somewhat
better
the load instead
when of at a
right angle to the load.
Check for sharp edges and scratches
FSOO61
Seal ring
00-26
HOISTING
INSTRUCTIONS
HOISTING
INSTRUCTIONS Slinging
near the edge of the hook may cause
A
Heavy parts (25 kg or more) must be lifted
the
with
a hoist etc. In the Disassembly
and As-
and a serious
25 kg or
maximum
strength
100%
88%
sembly
section,
every
more is indicated
1. If a part
cannot
machine
part weighing
clearly with the symbol
be smoothly
by hoisting,
removed
the following
Check
.
Check
for
removal
from
checks
of all bolts
to slip off the accident
hook
during
hoisting,
can result. Hooks
the
should
fastening
the
79%
71%
41% FSOO64
part to the relative parts. for
interference
existence
of another
part
causing
with the part to be removed.
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound
2. Wire
Q
ropes
I) Use adequate of
parts
ropes
depending
to be hoisted,
(
referring
on to the load. Slinging
with one rope may cause turning
of the load during
hoisting,
the rope, or slipping
on the weight
original
to the table
winding
untwisting
of
of the rope from
its
position
on
which can result in a dangerous
below:
When
galvanizing)
hoisting
the force Rope diameter
(mm)
load,
Allowable
load (tons)
with
a load with two
subjected
the
hanging
shows the variation hoisting
1 .o
10
angles.
to sling up to 1000
1.4
various hanging angles.
12.5
1.6
When
2.2
16
2.8
18
3.6
two
becomes
make a 120” ropes
as large
4.4
20
ropes
ropes,
table
below
load (kg) when kg vertically,
sling a load vertically,
kg of total weight
weight two
The
of allowable
11.2
2000
or more
to each rope will increase
is made with two ropes, each of which
is allowed
14
a
wide hanging angle from the hook.
“Z” or “S” twist ropes
without
the
accident.
4) Do not sling a heavy load with ropes forming
Wire ropes (Standard
have
at the middle portion.
&
be made: l
rope
1000
at
up to
can be suspended.This kg when
two
ropes
hanging angle. On the other hand,
are subjected
as 4000
to an excessive
kg if they
force
sling a 2000
kg
load at a lifting angle of 150”. 5.6
22.4
10.0
30
The
40
18.0
50
28.0
60
40.0
allowable
one-sixth strength
or
load
value
one-seventh
is estimated of
the
to be breaking
of the rope used. 30"
2) Sling wire ropes from the middle hook.
portion
of the
60"
Lifting angle
SO'
120"
1500
: cy FSO065
00-27
HOISTING
.
INSTRUCTIONS
Approximate
reduction
of
allowable
load
for
3. Hanging
bolts
wire ropes at various hanging angles.
Hanging
91”
a
-
angle
I
Reduction
120”
I
50%
in %
02P-02 Hanging angles should not exceed
I
150”.
5) When hoisting several parts as a unit, be careful not to allow any part of the unit to fall. Use a suitable container when hoisting many small parts at a time. 6) Select the most suitable hoisting a specially-shaped
sling device object.
when
Part Number
d
04530-0815
Cylinder head
7) When using a hoist to turn over a heavy part, observe the following instructions: l Clear as much of the area surrounding the part as possible. .
When
the ropes from slackening
changes. Gradually
slacken sure
that
the the
wire part
ropes
after
is completely
Slackening
the
ropes
before
complete
of the part may cause the part to fall
back to its original position.
80
018
10
1.5
18
150
04530-l
222
12
1.75
22
220
04530-l
628
16
2.0
28
450
04530-2030
20
2.5
30
630
04530-2438
24
3.0
38
950
04530-3045
30
3.0
45
1500
04530-3655
36
3.0
55
2300
04530-4625
46
3.0
25
3400
04530-487C
48
3.0
70
4500
* The
allowable
load
maximum
static
withstand.
The
in the
table
these
values
should
safety
in the
load
table
which
actual
hoisting
in the
table
factors
reduced,
means
the
bolt
can
load given taking
the
into consideration,
as
operation.
are applicable
from a hoist.
the
of allowable be
bolts will be subjected
vertically
00-28
15
04530-l
necessary
turned over. turning
1.25
Allowable load (kg)
and the
part from slipping when the center of gravity
making
L
turning the part over, take special care
to prevent
.
8
Pitch
to shocks
The
allowable
to the
bolts
during loads slung
STANDARD
TIGHTENING
TORQUE
STANDARD 1. STANDARD
TIGHTENING
The following “Disassembly
TIGHTENING
TORQUE
charts give the standard
OF
BOLTS
tightening
AND
torques
TORQUE
ml4
NUTS
of bolts and nuts. Exceptions
are given in sections
and Assembly”.
Thread diameter of bolt (mm)
Width across flat (mm)
07
0
z Nm
kgm 6
10
8
13
10
17
12
19
1 1.5 f
14
22
18.Ok2.0
16
24
28.523
279*29
18
27
39*4
383239
20
30
56?6
549t58
22
32
76a8
745278
24
36
94.5&10
927+98
27
41
135+15
1320&140
30
46
175220
1720&l
33
50
225&25
22102240
36
55
280*30
2750+290
39
60
335235
3280?340
1.35*0.15
This torque table does not apply to the bolts with which to be used, or which *
of
Nm (newton
2.TlGHTENlNG
require tightening
meter):
TORQUE
1 Nm f
OF
to otherwise
13.2+
3.2 a0.3
31.422.9
6.7 20.7
65.7t6.8
1 .o
112k9.8 177*19
nylon packings
specified
1.4
or other non-ferrous
90
metal washers
are
torque.
0.1 kgm
SPLIT
FLANGE
BOLTS
Use these torques for split flange bolts.
Threatf difi;eter
Tightening
torque
(mm)
Width across flats (mm)
10
14
12
17
11.5*1
11229.8
16
22
28.523
279+29
kgm 6.7kO.7
Nm 65.7k6.8
00-29
STANDARD
TIGHTENING
3. TIGHTENING
TORQUE
TORQUE
Use these torques
FOR
NUTS
OF
Sealing surface
FLARED
for nut part of flared.
FSOO68
Thread diameter of nut part (mm)
Width across flats of nut part (mm)
14
19
T
Tightening
torque Nm
kgm 2.5 F0.5
24.5 t4.9
18
24
522
22
27
812
24
32
1423
137.3t29.4
30
36
1823
176.5t29.4
49tlS.6 78.5 k 19.6
33
41
2Ok5
196.1
36
46
2525
245.2*49
42
55
3oi5
294.2a49
COATING The recommended
coating
Nomenclature
materials
prescribed
r+49
MATERIALS
in Komatsu
Shop
Manuals
Komatsu code
are listed
below.
Applications
LT-1A
Used to apply rubber pads, rubber gaskets, and cork plugs.
LT-1B
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong seal is needed.
LT-2’
Preventing
LT-3
Provides an airtight, electrically Used for aluminum surfaces.
LG-1
Used with gaskets and packings to increase sealing effect.
LG-3
Hea;t-resistant
Adhesives
bolts, nuts and plugs from loosening insulating
gasket for precombustion
and leaking oil.
seal.
chambers
and exhaust piping
Liquid gasket
I
LG-4
I
Used by itself on mounting surfaces on the final drive and transmission (Thickness after tightening: 0.07 - 0.08 mm)
cases
LG-5
Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings in hydraulic circuits of less than 50 mm in diameter.
Antifriction compound (Lubricant including molybdenum disulfide)
LM-P
Applied to bearings and taper shafts to facilitate prevent sticking, burning or rusting.
Grease (Lithium grease)
G2-LI
Applied to bearings, sliding parts and oil seals for lubrication, prevention and facilitation of assembling work.
Vaseline
-
‘LT-2
00-30
Used for protecting
is also called
LOCTITE
battery electrode
in the shoo manuals
press-fitting
terminals from corrosion.
and to
rust
ELECTRIC WIRE
CODE
ELECTRIC In the wiring
diagrams,
various
colors
and symbols
This wire code table will help you understand Example:
05WB
indicates
CLASSIFICATION
a cable having
WIRE are employed
WIRING a nominal
the thickness
of wires.
number
05 and white
coating
with
black stripe.
BY THICKNESS
Number strands
Dia. of strands (mm)
_
Cable O.D. (mm)
Cross section (mm?
Current rating (A)
Applicable circuit
01
11
0.32
0.88
2.4
12
Starting, lighting, signal etc
02
26
0.32
2.09
3.1
20
Lighting, signal etc.
05
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
j7a
Starting
100
217
0.80
17.6
230
Starting
CLASSIFICATION
1
to indicate
DIAGRAMS.
Copper wire Nominal number
CODE
BY
COLOR
109.1
AND
CODE
Instrument
Other
Code
6
W
R
G
Y
L
Color
Black
White
Red
Green
Yellow
Blue
YR
LW
Yellow & Red
Blue & White
GR
YB
LR
Green & Red
Yellow & Black
Blue & Red
GY
YG
LY
Yellow & Green
Blue &Yellow
Primary
BW 2
I
WR
I
Black & White
I
RW
I
White & Red
Red &White
Green &White
3 Auxiliary 4 Black & Red
1 White
&Blue
1 Red &Yellow
Green &Yellow
Code
-
WY
RG
GB
YL
LB
Color
-
White &Yellow
Red & Green
Green & Black
Yellow & Blue
Blue &Black
Code
-
WG
RL
GL
YW
Color
-
White &Green
Red & Blue
Green &Blue
Yellow &White
00-3 1
WEIGHT
TABLE
This weight table is a guide for use when transporting or handling components.
a
(Unit: kg) Engine assembly
1453
Radiator assembly Torque converter assembly Transmission assembly
I I
Steering cylinder (I piece)
285
Brake (1 piece)
193
Hydraulic tank
980
Main control valve
47 170
I
90
Damper
91
Lift cylinder (I piece)
279
Center drive shaft
33
Dump cylinder
283
44
Engine hood
42
Front frame
2486 2012
Front drive shaft
I
Rear drive shaft
I
Front axle assembly
2028
Rear frame
Rear axle assembly
1776
Bucket link (with bushing)
Front differential assembly
I
43
94
288
Tilt lever (with bushing)
1::
Lift arm (with bushing)
1996
Planetary carrrer assembly (I prece)
Bucket with teeth
2351
Planetary hub assembly (I piece)
Counterweight
Rear different:
assembly
I 1
Axle pivot (Rear axle) Wheel (I piece) Tire (1 piece) Steering valve
WA500-
1
92 (I 19)
I
Fuel tank
240
Battery (I piece)
421
Operator’s seat
55
Floor plate
I
457
880
I I
328 53 40 131
0°if3
TABLE OF OIL AND
RESERVOIR
T
KIND OF FLUID
COOLANT
QUANTITIES
CAPACITY (PI
AMBIENT TEMPERATURE -22 -30
-2
-1014
320
50 10
;:
::
‘g
‘g$E
Specified
Refill
,,,,.,. ,,,, :.:.:.:.:.:.:c:<.:;:.:.:. ,, ,.,,,,,......,, ~~~~~~~~~ii.i~~~~~~~~~ .:<.:.:.y..:.:.:<.:.:<.>,,,& ..,,._ (1. *, ,n ,.,,,,. .,.:,,.,............ Engine oil pan
28.5
Engine oil
Brake
2.4
62
Transmission case
150
Hydraulic system AMa (Front and rear)
Fuel tank
SW NOTE (4)
Diesel fuel
ASTM: SAE:
each 75
435
Add antifreeze
Water
Cooling system
each 75
80
American Society of Testing and Material Society of Automative Engineers
Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity:
Amount
of oil needed to refill system during normal inspection and maintenance.
NOTE: (I) When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%. Change interval of oil in engine oil pan
Fuel sulphur content
0.5 to 1.O%
Above 1.O%
I I
l/2 of regular interval
l/4 of regular interval
(2) When starting the engine in an atmospheric temperature of lower than O”C, be sure to use engine oil of SAEl OW, even though an atmospheric temperature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce-the engine oil change interval to half. (4) For axle oil, use only recommended oil as follows. DONAX TT or TD SHELL: RPM TRACTOR HYDRAULIC FLUID CALTEX: CHEVRON: TRACTOR HYDRAULIC FLUID TEXACO: TDH OIL MOBILAND SUPER UNIVERSAL MOBIL: * It is possible to substitute engine oil CLASS-CD SAE30 for axle oil. If noise comes from the brake, it is no problem of durability.
o”634
WA500- 1
10 ENGINE
VHEEL â&#x20AC;&#x2122; n4DER
ENGINE 11 STRUCTURE
AND
FUNCTION
Engine mount ............................. Radiator .................................. Fuel tank and piping ........................ Engine control .............................
WA500-
1
11-2 11-3 11-4 11-5
11-l
ENGINE MOUNT
Section A - A
Section B - B
425FOO7
.
The engine is mounted
separately from the torque
converter and transmission.
.
Both front and rear have rubber mounts.
1. Rear mount 2.
11-2
Front
mount
WA500-
1
RADIATOR
Section A - A
5
1.
Radiator
2.
Coolant level sensor
3.
â&#x20AC;&#x2DC;4
Fan guard
425FOO8
Specifications Core type: Total
Cross-sectional 4.
G7 type
heat dissipating
area:
area of water
89.9
cm2
tubes:
193.8
cm2
Torque converter oil cooler
5.
Hydraulic oil cooler
A.
Coolant inlet port
B. Coolant outlet port C. Wind
WA500-
1
11-3
FUEL TANK
AND
PIPING
The fuel level sensor is installed in the fuel tank.
11-4
1.
Fuel level sensor
2.
Drain valve
3.
Injection pump
WA500-
1
ENGINE
CONTROL
F42101002
WA500-
1
1.
Accelerator pedal
2.
Accelerator cable
3.
Injection pump
1 l-5
ENGINE
12 TESTING
AND
ADJUSTING ................... ........... Adjusting valve clearance ................ Measuring compression pressure ........... ......... Testing and adjusting fuel injection Measuring blow-by pressure .............. Testing and adjusting belt tension .......... Measuring exhaust gas color .............. Standard value table
Tool list for testing and adjusting
Measuring engine oil pressure and temperature Adjusting fuel cut solenoid
...............
12- 2 12- 3 12- 4 12- 5 12- 6 12- 8 12- 9 12-10
. . 12-l 1 12-12
Measuring accelerator pedal operating force
..................
and operatin angle
*
The following
precautions
12-13
are necessary when using the Standard Value Tables to make judgement
during trouble-
shooting or during testing and adjusting. 1.
The values in these tables are based on the values for new machines leaving the plant, so they should be used as target values when repairing or when estimating wear after a period of use.
2.
The standard
values in these tables for judgement
when troubleshooting
are estimated
values based on the
standard values for the machine when shipped from the plant, and on the results of various tests. Therefore,
they should be used as reference in combination
with repair and operating
records when making
judgements. 3.
These
standard
these values
WA500-
1
value
alone
tables
to make
must simple
not be used for standard values
when
judging
claims.
In addition,
do not use
judgements.
12-1 0
STANDARD
VALUE TABLE Engine
Cate-
KOMATSU Condition
Item
S6D140-1
Unit
Standard value
Permissible value
rpm
2250 - 2350
-
slow
High idling speed
I-----
E
Engine speed
: E b ‘= a”
. Necessary
660 - 720
I
-
starting speed
Intake resistance
6
z > 0l
Exhaust temperature
5 2 !z 0 :
Exhaust gas color
Oil pressure (entine water tempwrature green range
E r t
All speed (intake air temp. 2O’C
OC
Oil temperature
5
+
i
1 Oil consumption ratio
Bosch index
Max. 4.0
5.0
At high idling
Bosch index
Max. 1 .O
2.0
Intake valve
mm
0.43
-
Exhaust valve
mm
0.80
-
Oil temperature 40 - 60°C (engine speed: 160 - 200 rpm)
kg/cm’
Min. 32
22
At high idling
mmH,O
Max. 100
200
kg/cm’
3.5 - 5.5
2.0
Min. 1.0
0.7
Min. 1 .O
0.7
At high idling At low idling
SAE30
Coolant temperature
kg/cm’
Whole speed range (inside oil pan)
OC
At continuous rated horesepower (proportion
‘rg
110
120
Max. 0.5
1 .o
80-
%
to fuel consumption)
Nozzle tester
kg/cm2
Before top dead center
degree
27
27 * 1
“C
70 - 95
100
74.5 - 78.5
74.5 - 78.5
Whole speed range (at engine outlet)
250*
E t; ?;
10
250 c 10
90
90
Thermostat function
.-r” 5 s
Max. 650
At abrupt acceleration
SAEIOW
.-5
Max. 650
9.5 Fan belt tension (Tension pulley-
9.5 -
10.5
6 I
I
I
I
kg
8-9
Max. 13.5
I i
/
0
z & z s
Operatinganglea
Stopper height L,
-
o1 45 os 30
15-25
-
14-24
-
136 -
12-2 0
10.5
-
146
WA500-1
TOOL LIST FOR TESTING NO
Testing and measuring
item
AND
Tool Name
2
Battery
specific gravity
3
Coolant
freezing temperature
4
Water temperature, oil temperature, intake temperature
Battery
5
Exhaust temperature
6
Lubricating
7
Fuel pressure
8
Intake pressure, exhaust pressure
9
Blow-by
coolant
Thermistor temperature
Part No.
Remarks
I
xx
Digital display 60-19999
Tachometer
Engine speed
ADJUSTING
tester
rpm
gauge 799-l 01-6000
T
0 -
oil pressure
Engine pressure measuring kit
799-203-2002
10 kg/cm’
2 0 - 1000 mmH,O
pressure
10 11
Compression
12
Blow-by
13
Valve clearance
Feeler gauge
795-l 25-1210
0.43, 0.80 mm
14
Exhaust gas color
Handy smoker checker
799-2 1O-9000
Discoloration (Discoloration
15
Fuel on water mixed in oil
Engine oil checker
799-201-6000
Water content 0.1%. 0.2% in standard sample
16
Coolant
Water quality
799-202-7001
PH. nitrous
17
Leakage from cooling
Cap tester
799-202-9001
0 - 2 kg/cm’
18
Fuel injection pressure Nozzle injection condition
Nozzle tester
Commercially available
0 - 300 kg/cm’
19
Electrical
Tester
Commercially available
Current,
20
Accelerator
Push-pull scale
79A-262-0020
Commercially
Compression
pressure
Blow-by
pressure
quality
circuit
pedal force
system
gauge
checker
tester
0 to 70% standard color %x l/10 = Bosch index)
acid ion concentration
voltage, resistance
available 0 - 25 kg
-
n!
When carrying out testing, adjusting or troubleshooting,
Qf
When working in groups, use agreed signals and do not allow unauthorized
n!
When checking the water level in the radiator wait for the water to cool.
Qt
Be careful not to get caught in rotating parts.
stop the machine on level ground, insert the safety pins
and block the tires.
the water is hot.
WA500- 1
persons near the machine. Do not remove the radiator cap while
Boiling water may spurt out.
12-3 0
ADJUSTING *
Condition:
*
Adjust
VALVE CLEARANCE
Engine is cold.
clearance
between
crosshead
and rocker
lever
as follows. Unit:
I
mm
Intake valve
Exhaust valve
0.43
0.80
Cold
Special tool Part No. A
Part Name Feeler gauge
795-l 25-1210
Remove cylinder Rotate
the
align
pointer
(2) with
shaft
pulley.
When
1.6 TOP
1
head cover (1).
crankshaft
of the valves.
Qâ&#x20AC;&#x2122;ty
in the
normal
rotating,
to
on crank-
check the movement
When the pointer
mark,
direction
the 1.6 TOP mark
is in line with
No. 1 cylinder
should
the
be at com-
pression top dead center. When
No.
1 cylinder
is at compression
center, adjust the valve marked When
No.
6 cylinder
is at compression
center, adjust the valves marked Cylinder No.
1
I,
I-
Intake valve
Exhaust valve
4.
To
adjust,
I,
insert
tool
clearance
is a sliding
5.
Lock nut:
Next,
rotate
crankshaft
and adjust
maining
valves marked
After
adjusting
top dead center, shaft
120â&#x20AC;?
ance
of
0
0
0
Then
0
0
rocker
adjustment fit.
6
I II
0
lever
(3)
screw
(5)
tighten
lock
screw in position.
one turn
the
valve
in the normal
clearance
of the
dire-
0.
No.
1 cylinder
at compression
it is also possible to turn crank-
each time and adjust
each
dead
6.0 ? 0.6 kgm
rection *
top
5
II
A between
nut (6) to hold adjustment m
4
I
0
l
(4) and turn
deal
0. 3
I,
l
0
l
and crosshead until
2 l
top
0.
cylinder
the valve clear-
according
to the
firing
order.
- Firing order: *
After
tightening
l-5-3-6-2-4 the
lock
nut,
check
the clear-
ance again.
615OF201
12-4 0
WA500-
1
MEASURING *
Measurement
COMPRESSION
PRESSURE
condition
* Coolant temperature: Inside operating range. * Engine valve clearance: Standard value. * Engine speed: 160 to 200 rpm Unit: Item
kg/cm*
Standard value
Permissible value
Min. 32
22
Compression pressure
Special tools Part No.
Compression gauge
I
1
510
/ 1
Adapter
I
1
520
/
Plate
I
1
Tachometer
I
1
1
795-502-I
204
4
/
795-502-I
A,
1 I
795-502-I
A
8 *
799-203-8000 1
If performance the piston,
tests
piston
or troubleshooting
ring or cylinder
When
1.
measuring
the
compression
pressure,
be
the
manifold
or
not
muffler,
or to get caugh t in rotating
Adjust
touch
exhaust
careful
*
to
shows that
liner may be worn,
pressure.
measure the compression
a
I Oâ&#x20AC;&#x2122;tv
Part Name
parts.
valve clearance.
For
details,
see ADJUSTING
VALVE
CLEAR-
ANCE. 2.
Warm up engine (oil temperature
3.
Remove nozzle holder *
40 to 6Oâ&#x20AC;&#x2122;C).
assembly.
For details, see REMOVAL
OF NOZZLE
HOLD-
ER ASSEMBLY. 4.
Install
tool A, AI
assembly,
and Az in mount
and connect
5.
Set engine tachometer
6.
Disconnect
B in position.
fuel CUT-OFF
Crank engine with
of nozzle holder
pressure gauge. solenoid
valve connector.
motor
and measure com-
starting
pression pressure. *
Measure where
the the
compression pressure
pressure
gauge
at the point
indicator
remains
steady. *
When
measuring
measure within *
Installing
the
the specified the
nozzle
ing the compression For
the
engine
details,
see
compression
speed to confirm
pressure, that
it is
range. holder
assembly
after measur-
pressure. INSTALLATION
HOLDER
ASSEMBLY.
WA500-
1
OF
NOZZLE
TESTING *
AND
ADJUSTING
FUEL INJECTION
TIMING
Measurement condition
- Coolant temperature:
Inside operating range. Unit:
Fuel injection timing
TESTING
B.T.D.C.
FUEL
1.
Disconnect
2.
Remove delivery
Permissible value
Standard value
Item
degree
27
27 + 1
/
INJECTION
TIMING
fuel injection pipe (1) of No. 1 cylinder.
delivery
valve
holder
(2),
then
remove
valve (3) and spring (4). and install deliv-
ery valve holder (2) again. 3. 4.
Place accelerator pedal at FULL Operate slowly
priming in normal
pump
position.
and
direction.
rotate Check
crankshaft point
where
fuel stops flowing from delivery valve holder (2). 5.
Check that 27â&#x20AC;? I.J. line on damper (5) and pointer (6) are aligned at point where fuel stops flowing. *
BEYOND
injection timing line:
Timing *
BEFORE
RETARDED
injection timing line:
Timing ADVANCED *
If the test shows that the fuel injection
timing
is
incorrect, adjust as follows.
12-6 0
WA500- 1
ADJUSTING FUEL INJECTION BY DELIVERY CHECK 6.
Turn
crankshaft
TIMING
back 30 to 40â&#x20AC;?
from
top
dead
center. 7.
Rotate
crankshaft
to align 27â&#x20AC;&#x2122;
I.J. line on crank-
shaft pulley and pointer correctly. 8.
Loosen nut
(7) on the
injection
flange
and
the
bolt,
rotate
side little
by little
(8)
no fuel
until
pump mounting
flange
on the
pump
by operating the priming pump flows
out of the
delivery
valve
holder. 9.
Tighten
nut (7) in oblong hole of mounting
flange
of fuel injection pump. *
After
tightening
the nut, check again that the
fuel stops flowing at the point
from the delivery valve holder
where
the pointer
the line on the crankshaft IO.
Remove
delivery
ery valve (3)
is aligned with
pulley.
valve holder
(2), assembly deliv-
and spring (41, then install delivery
valve holder (2) again. w 11.
Delivery holder:
3.3 f 0.2 kgm
Connect fuel injection pipe (1). w
Sleeve nut:
WA500- 1
2.4 i 0.1 kgm
12-7 0
MEASURING *
BLOW-BY
PRESSURE
Measurement condition
- Coolant tempe*ure: Inside operating range. * Engine valve clearance: Standard value. * Engine oil temperature: Min. 60°C Unit:
Permissible value
Standard value
Item
Blow-by pressure
Max. 100
I
mmH,O
Max.200
I
Special tool Part Name
Part No.
1
A
Q f
799-201-l
Blow-by checker
503
When taking measurements, the exhaust
Oâ&#x20AC;&#x2122;ty
manifold
I
1
be careful not to touch
or muffler,
or to get caught
When measuring the blow-by,
warm the engine
in rotating parts. 1.
Measuring blow-by up thoroughly. Stop
engine
and
install
adapter
of
blow-by
checker on engine breather hose (1). Connect
adapter
mmH,O)
to hose.
and
blow-by
A
(0 to
500
Run the engine at high idling and measure the blow-by pressure. 2.
Precautions when measuring blow-by *
The
blow-by
should
be
measured
with
the
engine running at rated output.
- When measuring in the field, a similar value can be obtained at stall speed.
- If it is impossible to check at rated output or stall speed, measure at high idling. In this case, the blow-by value will be about 80% of the value at rated output. *
Blow-by
may
vary
greatly
according
to
the
condition
of the engine, so if there is any ab-
normality
in the reading,
lem
related
cessive
to
oil
gas color,
defective
consumption, or
early
check for blow-by,
defective
deterioration
any prob-
such as exexhaust
or contami-
nation of the oil.
12-8 0
WA500-
1
TESTING TESTING TENSION
AND AND
ADJUSTING
ADJUSTING
BELT TENSION
FUN
BELT Approx. 6 mm
Unit:
Standard value
Item
mm
Permissible value
I Deflection of belt
.
6
Testing fun belt tension Check the amount the fan belt deflects when pushed with a force of approx.
6 kg at a point mid-way
between the fun pulley and tension pulley. Use a scale to measure the amount the V-belt deflection.
.
Adjusting fun belt tension 1)
Loosen lock nut (I) of tension pulley.
2)
Adjust
the belt tension
of adjusting bolt
(2),
tighten lock nut of tension pulley.
TESTING AND ADJUSTING BELT TENSION
ALTERNATOR Approx.
Unit: mm Standard value
Item Deflection of belt
15 mm
Alternator pulley
Permissible value -
15
Approx. 6 kg Testing alternator
belt tension
*
Check the amount the alternator pushed with mid-way
a force
between
of approx.
the alternator
belt deflects when 6 kg at a point pulley
and water
pump pulley.
Water pump pulley 425F202
Use a scale to measure the amount the V-belt deflection. Adjusting alternator 1)
belt tension
Loosen alternator
mount bolt, nut (I) and bolt
(2) of adjusting plate. 2)
Use a bar, rise alternator tension adjusting
of
belt
(3),
plate
as
assembly and adjust
and tighten first,
tighten
bolt
(2)
of
alternator
mount bolt, nut (1).
WA500- 1
12-9 0
MEASURING * . .
Measurement
EXHAUST
GAS COLOR
condition
Coolant temperature: Valve clearance:
inside operating range.
Standard value. Unit: Standard value
Permissible value
Acceleration
Max. 4.0
5.0
High idling
Max. 1 .o
2.0
I
Part Name
O’ty
Smoke meter
1
Item
Exhaust color
Bosch index
Special tool
I
Part No. Commercially available
A
Q f
*
When measuring the exhaust color,
be careful
not to touch the exhaust pipe.
When measuring the exhaust color, warm the engine up thoroughly
(oil temperature
6O’C).
1.
Insert probe A rn outlet of exhaust pipe (I) 0’ secure to exhaust pipe with clip.
2.
Connect
probe hose, connector
switch and air hose *
and
hose of accelerator
to smoke meter A.
8 The pressure of the air supply should be under 15 kg/cm2.
3.
Connect power cord to socket. t
Check
that
the power
switch
is OFF
before
connecting the cord. 4.
Loosen cap nut of suction
pump and insert filter
paper. 5.
Turn power switch ON.
6.
Accelerate
engine suddenly.
press accelerator
At the same time, de-
switch of smoke meter, operate re-
lief valve and catch exhaust gas color on filter paper. 7.
Lay filter top
of
paper used to catch exhaust gas color on
unused
filter
papers (IO
sheets or more)
inside filter paper holder, and read indicated value,
12-10 0
WA500-
1
MEASEURING
ENGINE
MEASURING
ENGINE
* .
condition
Measurement Coolant
OIL
temperature:
OIL PRESSURE
TEMPERATURE
PRESSURE
Inside operating
range. Unit:
Item
AND
Standard value
kq/cm*
Permissible value
Oil pressure High idling
1
Low idling
I
Min. 1 .O
0.7
Special tool
I
Part No.
A
Part Name
I
Engine pressure measuring kit
799-203-2002
n n !
When measuring, rotating
O’ty
be careful
not to get caught in
parts.
Install
and
remove
the
plug
and oil
pressure
gauge with the engine stopped. *
1.
Measure
the engine
perature
is at the specified
Disconnect plug
2.
oil pressure when
connector
of
the oil tem-
temperature. wiring
(I),
then
remove
(2).
Install oil pressure gauge A (20 kg/cm2). *
Install
the oil pressure gauge so that it is affect-
ed as little as possible by the engine vibration. 3.
Start engine and measure oil pressure.
MEASURING
OIL
TEMPERATURE
*
Measurement
condition
.
Coolant
temperature:
Item
Inside operating
Standard value
Oil temperature
range
Permissible value
80-llO°C
120°c
Special tool
A Al 1. 2.
I I
Part No.
Part Name
799-l016000
Thermister temp. gauge
799-l 01-6140
sensor
Q’ty
Remove dipstick
(1).
Insert sensor A,
of thermistor
temperature
gauge in
sensor to thermistor
temperature
gauge A
dipstick Connect
guide.
and measure temperature
WA500- 1
of oil in oil pan.
12-11 0
ADJUSTING
1.
FUEL CUT SOLENOID
Adjust rod 15) while pulling rod (5) in the running direction so that there is clearance of 0.4 kO.1 mm between stop lever (4) and stopper (7).
2.
Turn
on the engine starting
solenoid
key and confirm
that the
has a stroke of 12 mm and clearance of 0.4 *
0.1 mm. 3.
After
turning
reconfirm
on and off the key two or three times,
that solenoid works smoothly and engine runs
v;
or stops completely. *
If the solenoid does not work coil
burns
flywheel
in the
horsepower
cause of
smoothly,
solenoid
excessive current
or
downs in the cause of dropp-
ing fuel injection volume.
is
_1
4
IL -.
621OFlll
12-12 0
WA500-
1
MEASURING ACCELERATOR AND OPERATING ANGLE *
PEDAL OPERATING
FORCE
Measurement condition
- Coolant temperature:
Inside operating range.
Unit: Item
Permissible value
Standard value
Operation force of accelerator pedal
kg
13.5
8-9
Special tool Part No.
Part Name
a’ty 423F304
A
OPERATING 1.
Push-pull scale
79A-262-0020
1
FORCE
Measuring procedure 1)
Put push-pull celerator
scale A in contact
pedal at point
150
with the ac-
mm from
pedal
fulcrum “a”. *
The
center
contact
of
push-pull
with a point
scale A must be in
150 mm from
the pedal
fulcrum. 2)
Start tion
the engine, push the pedal in the direcof operation
and measure the maximum
value when pushing from
idling to the end of
the pedal travel (high idling). Testing and adjusting 1) 2)
Stop the engine. Disconnect
the cable (1) at the bottom
accelerator
pedal,
of the
and check that the linkage
(2) and ball joint (3) at the bottom of the pedal move smoothly. 3)
Connect then
the cable at the bottom
disconnect
injection
pump,
at
the
of the pedal,
connection
for
the
and check that the cable (4)
moves smoothly. *
When
carrying
out
this
inspection,
or replace parts as necessary. operating
force
adjust
Measure the
again and check that
it is
within the standard value.
WA500-
1
12-13 0
OPERATING
ANGLE
OF ACCELERATOR
PEDAL
423F305C
1.
Measuring procedure 1) 2)
Stop the engine. Measure the operating pedal
it is operated
a2, put the
angle q,
angle gauge A in contact
with
from
the accelerator
low-idling
and high
idling. 3) 2.
Measure installed
length X of rod (1).
Adjusting procedure
1) 2)
Remove cover under cab. Loosen
nut
X of the 3)
Loosen
4)
L1
of
Loosen
nut (3) and adjust L2
Adjust
the
injection
length pump
high idling (high
idling)
stopper
value.
pedal
stopper
is
bolt so that installed
accelerator
the standard
length
value.
height
of
installed
the standard
bolt so that installed
accelerator
the standard
within 5)
so that
(1) is within
nut (2) and adjust
height within
and adjust
rod
pedal
stopper
is
value. of the governor
rod
(4) so that
lever
contacts
the the
when the pedal is depressed
and still
tighten
stopper
bolt
(3)
half turn.
12-14 0
WA500- 1
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