Page 1

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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Komatsu wa500 1 wheel loader service repair manual sn:10001 and up  
Komatsu wa500 1 wheel loader service repair manual sn:10001 and up  
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