Komatsu wa350 1 wheel loader service repair manual sn：10001 and up by 163048

SEBM04230107

KOMATSU

WA3504 MACHINE

MODEL

SERIAL

WA350-

10001

This shop manual available items

Please

and up

attachments consult

and optional

equipment

your local Komatsu

distributor

that are not for those

you may require.

Materials

may contain

in your area.

No.

and specifications

WA350-1

mount

For details

of the engine,

05-90(03)03561

the S6Dll

are subject

O-l

to change

without

notice.

engine.

see the 110

Series

Engine

Shop Manual.

oo-1 a

CONTENTS No. of page

ENGINE 11

STRUCTURE

TESTING

DISASSEMBLY

POWER

00-2 0

AND ADJUSTING

.. . . .. . . .

AND ASSEMBLY..

........

...

. .. .

.....

. . .. .

1 l-l 12-1 13-1

TRAIN

STRUCTURE

TESTING

DISASSEMBLY

AND ASSEMBLY

MAINTENANCE

STANDARD

AND FUNCTION

AND ADJUSTING

STEERING

............................................... ................................................. .............................................

.................................................

21-1 22-l 23-l 24-l

SYSTEM

STRUCTURE

TESTING

DISASSEMBLY

AND FUNCTION

BRAKE AND

............................................... .................................................

AND ADJUSTING

MAINTENANCE

AND ASSEMBLY STANDARD

AND FUNCTION

...............................................

STRUCTURE TESTING

DISASSEMBLY

AND ASSEMBLY

MAINTENANCE

STANDARD

.................................................

AND ADJUSTING

EQUIPMENT

STRUCTURE

TESTING

............................................... .................................................

DISASSEMBLY

AND ASSEMBLY

MAINTENANCE

STANDARD

AND

STRUCTURE

TESTING

DISASSEMBLY

42-l 43-l 44-l

51-1 52-l 53-l 54-l

SYSTEM

AND ADJUSTING

ELECTRIC

.............................................

.................................................

AND FUNCTION

41-1

AIR SYSTEM

.............................................

.................................................

WORK

... .. . .

.................................................

AND FUNCTION

.............................................

.................................................

ELECTRONIC

AND FUNCTION

AND ADJUSTING

62-l 63-l 64-l

SYSTEM

............................................... .................................................

AND ASSEMBLY

61-1

.............................................

81-1 82-l 83-l

OTHERS AND FUNCTION

...............................................

STRUCTURE

DISASSEMBLY

GEAR PUMP ................................................................

AND ASSEMBLY

.............................................

91-1 93-l 97-l

WA350-1

must

pages

affected

The following

to these

be taken

are

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by the

indicated

It is requested

marks.

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that

actions

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00-2 -4 a

WA350-1

A Proper The

service

manual

and repair and

injury

to workers,

cautions

in this

followed

carefully.

safety,

designed

manual.

The cautions

If any dangerous

and take the necessary

by Komatsu

of operation.

by Komatsu

the symbols

actions

of your machine.

and

Some

described

of these

in this

operations

re-

used to mark safety

pre-

for the purpose.

and

*& are 4 these

accompanying situation

NOTICE

for the safe operation

recommended

and safe methods

specially

SAFETY

important

techniques

effective

quire the use of tools To prevent

is extremely

repair

are both

IMPORTANT

symbols

should

arises or may possibly

always

arise, first consider

to deal with the situation.

A SAFETY GENERAL

6. Decide

PRECAUTIONS

a place

keep tools Mistakes Read

in operation

the

are extremely

Operation

carefully

BEFORE

and

dangerous.

Maintenance

operating

Manual

the

tools

and

Always

carrying

read

all

decals

the

precautions

which

2.When

out any greasing are fixed

carrying

out

or repairs,

given

any

operation,

safety

shoes

and helmet.

loose

work

clothes,

or clothes

parts with .

safety

wear

grinding

always

with

3. If welding

repairs

trained,

experienced

work.

When

always

wear

and

glasses

buttons

when

hitting

glasses

a grinder,

are needed,

welding

other

carry

out

have a out

welding

gloves,

clothes

carrying

inform

suited

the

work,

apron, for

controls

any operation always

procedure your

step

work,

out

workers,

erating

5. Keep

7. Before

FOR

adding

block

the

of the

hang

8. Before ground.

provided

for

working.

safety to

welding

warning

op-

other

Before

starting on

the

condition

way to use them.

and

the

ripper, to the

levers

the

the work

In addition,

be sure and

hang

starting

oil from

get

use the

when

blocks,

impossible

the

steps

and

handrails,

getting

Never jump

sup-

jacks

work.

and

used

or steps,

assembling,

with

Always

steps

ladders

and

insert

to prevent

control

all mud

machine.

If learn

blade,

equipment

possible,

falling.

machine

places

machine.

compartment.

is not

the

before

10. Remove

repairs,

to prevent

lower work

disassembling the

starting

signs

all

any

signs on them.

stands

work,

from

lock

before

REPAIR

in good

on the

two

or tracks

pin or use blocks

glasses,

with

making

moving.

If this

equipment

port

wheels

starting

Always

operation.

in the operatorâ&#x20AC;&#x2122;s

the correct

areas while

on hard, level ground,

or any other

starting.

workers

UNDER

all tools

agree

before

fellow

places.

and make

WORK

oil

from

9. When

or more

any

PREPARATIONS

bucket

always

welder

carrying

when

etc.

work. 4.When

the

Never smoke

machine

safety

parts with

correct

area clean

Do not wear

a hammer.

Always

cap

park the machine wear

in their

the

missing. Always

to keep

to the machine.

wear

workshop

parts. Always

is no dirt or oil on the floor.

only

smoking.

repair

the work

there

Smoke 1. Before

parts

keep

sure that

the machine.

in the

and removed

off

or the

ladders off

the

on or off the machine. to

use

use a stand

the

handrails,

to provide

safe

footing.

00-3

PRECAUTIONS 11. When or

DURING

removing

the oil filler

hydraulic

loosen

pressure

them

spurting

slowly

cap, drain

measuring

to prevent

plug plugs,

Replace l

sure

the oil from

of the

remove

oil,

the

or removing

water

compo-

or air circuits,

pressure

completely

the

20. When

the

engine

when

oil

in the

circuits

is stopped,

are

hot

so be careful

rying

out

any

work

to cool before

the

oil

carwater

starting

battery.

14. When

work,

Always

the negative

(-1

that

remove

the

parts

lead

from

components,

are free from

damage.

use

lifting

ample

capacity.

Install

the

places.

use

slowly

equipment

other

covers

ternal

pressure

spring,

always

under

loosen

bolts

components, the

removing

on the

in-

from

a on

the pressure,

piping,

be careful

not

Damaged

fires. stop

the fuel

or oil

out. If any fuel or oil drips on to

wipe

floor

any

in position

wiring.

may cause electrical

the floor,

with

the bolts to remove.

or damage

spilling

hit-

are under

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

rule,

In particular,

gasoline

when

not

use gasoline

use ,only the miniwashing

the ma-

hoses,

twisted. for

that

make

Damaged

high

care-

pressure

connecting

or installing tightening

protective

parts

two

or hand.

fingers

caught

always When

violently

be particularly

aligning

parts, torques.

parts such as guards,

vibrate

speed,

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

pressure

leave two

sides. Slowly

removing

17. When from

which

when

so be extremely

check

fingers

that

by the hoist or crane.

removing

break

operate

Do not work

15. When

then slowly

correct

and

the component

has

at the

or crane

part.

part still raised

opposite

which

equipment

a hoist

to prevent any

and hooks

not

that they are installed

23. When

lifting

Use

chains

installed.

which

high

first.

rope,

wires,

be damaged

parts

tubes

assembling

22. When

the wire

Always

wiring

Also,

the leads from

hoist or crane. Check

installing

are correctly

remove

heavy

not

pressure

are

are dangerous,

when

installing

terminal

raising

16. When

high

they

use the specified

13. Before

ting

ful

21. When

circuits.

the

will other

installing

circuits.

not to get burned. Wait for the oil and water

with

that

tubes and

they

new parts.

and

first

from

sure

water

hoses

in their

chine is being operated.

circuit. 12. The

that

again

parts with

installing

contact

disconnecting

all parts

any damaged

When

out.

Before nents

19. Be sure to assemble original places.

WORK

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

FOREWORD

This

shop

serviceman repairs effect

has been

an accurate

at every

This shop

prepared

understanding

and make judgements.

a service For

manual

Make

as an aid to improve

of the product

the

quality

and by showing

sure you understand

of repairs

by giving

the

him the correct

way to perform

of this manual

and use it to full

the contents

opportunity.

manual

mainly

contains

the necessary

technical

information

for operations

performed

workshop. ease

components;

understanding,

these chapters

STRUCTURE

AND

This section

AND

This

section

explains

section

assembling MAINTENANCE This section

the structure

of the structure,

into

chapters

into the following

and function

for

each

main

group

sections.

of each component.

but also serves

explains

checks

be made

to be made at completion

Troubleshooting

This

is divided

divided

as reference

It serves

material

not only to give

for troubleshooting.

ADJUSTING

adjustments

DISASSEMBLY

manual

FUNCTION

an understanding TESTING

the

are further

charts AND

correlating

before

and

of the checks

after

performing

repairs,

as well

and repairs.

“Problems”

to “Causes”

to be followed

when

are also included

in this section.

ASSEMBLY

explains

the

order

each component,

as well as precautions

removing,

to be taken

installing,

for these

disassembling

operations.

STANDARD 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

to change

at any

KOMATSU

distributor

for the

information.

00-5

HOW

READ

THE

SHOP

HOW

MANUAL

TO READ THE SHOP

VOLUMES

REVISED

Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

When recorded pages.

Chassis

volume:

Engine volume:

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. AND

MARK

(@)a@

-.-- )

a manual is revised, an edition mark is on the bottom outside corner of the

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

UPDATING

Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up-to-date information before you start any work.

quality

Symbol

FILING

EDITION

Issued for every machine model Issued for each engine series

Electrical volume Attachments volume

DISTRIBUTION

MANUAL

METHOD

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):

are marked

with

the following

Item

symbols.

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.

*& *

IO-3

Example

Item number (IO. Structure and Function) Consecutive page number for each item. 2 (Engine volume):

Caution

Weight

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)

3. Additional pages: Additional pages are indicated by a hyphen (-1 and number after the page number. File as in the example. Example: 1 o-4

12-203

1 o-5

12-204

00-6

Special technical precautions other precautions for preserving standards are necessary when performing work.

the

Weight of parts or systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special for the tightening torque during assembly.

Tightenattention ig torque ?

Coat

Places to be coated with adhesives and lubricants

etc.

Xl, water

Places where oil, water or fuel must be added, and the capacity.

Drain

Places where oil or water must be drained, and quantity to be drained.

HOISTING

INSTRUCTIONS

HOISTING

lifted

INSTRUCTIONS

Heavy parts (25 kg or more) must be with a hoist etc. In the Disassembly

1. If a part cannot be smoothly the machine by hoisting, checks should be made: . Check for removal of all the part to the relative parts. . Check for existence of causing interference with rem-oved.

removed from the following bolts

fastening

another the part

part be

2. Wire ropes I) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:

Wire ropes (Standard “Z” or “S” twist without galvanizing) Rope diameter

(mm)

Allowable

ropes

load (tons)

1 .o

11.2

1.4

12.5

1.6

2.2

2.8

3.6

4.4

22.4

5.6 10.0

30 40

I a.0

28.0

40.0

The allowable load value is estimated be one-sixth or one-seventh of breaking strength of the rope used. 2) Sling wire ropes of the hook.

from

the

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.

middle

100%

88%

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.

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”.

to the

portion 30”

go*

60” Lifting

angle

120’

150”

: 01 FSO065

00-7

STANDARD

TIGHTENING

TORQUE

STANDARD

1. STANDARD

TIGHTENING

TORQUE

OF BOLTS AND

The following charts give the standard tightening sections of “Disassembly and Assembly”.

torques

TORQUE NUTS of bolts and nuts. Exceptions

are given in

Width across flat (mm)

Thread diameter of bolt (mm)

I ..

1.35kO.15

3.2kO.3

31.4k2.9

6.7 f 0.7

65.7k6.8

11.5*1.0

112t9.8

18.0t2.0

177*19

28.5*3

279&29

13.2*

3924

383?39

56*6

549*58

76+8

94.5*

1.4

745278 10

927*98

135+15

1320+

140

175220

1720-r

190

225&25

221 Ok240

28Ok30

27502290

335t35

3280&340

This torque table does not apply to the bolts with which nylon packings or other nonto otherwise specified ferrous metal washers are to be used, or which require tightening torque. Sr Nm (newton

2.TlGHTENlNG

meter):

1 Nm + 0.1 kgm

TORQUE

OF SPLIT

FLANGE

BOLTS

Use these torques for split flange bolts.

Thread: gtl,eter (mm)

00-8

Width across flats (mm)

Tightening kgm

torque Nm

II.521

112t9.8

28.5t3

279t29

6.7kO.7

65.7 k6.8

STANDARD

TIGHTENING

TORQUE

Sealing surface

3.TlGHTENlNG Use these

TORQUE torques

Thread diameter of nut part (mm)

for

FOR

nut part

NUTS

OF FLARED

of flared.

Width across flats of nut part (mm)

Tightening

2.5kO.5

24.5 k4.9

18.

522

49*

19.6

822

78.5 f

19.6

1423

137.3k29.4

1823

176.5229.4

20*5

196.1

2525

245.2+49

30&5

294.2*49

COATING The recommended Nomenclature

Adhesives

Gasket

torque

coating

materials

&49

MATERIALS

prescribed

in Komatsu

Shop

Manuals

are listed

below.

Applications

Komatsu code LT-1 A

Used to apply

LT-18

Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong seal is needed.

LT-2â&#x20AC;?

Preventing

LT-3

Provides an airtight, electrically Used for aluminum surfaces.

LG-1

Used with

LG-3

Heat-resistant and exhaust

LG-4

Used by itself on mounting mission cases. (Thickness

sealant

LG-5

rubber

bolts,

pads, rubber

gaskets,

nuts and plugs from

gaskets

gasket piping.

loosening

insulating

and packings

and cork plugs.

oil.

seal.

to increase

for precombustion

and leaking

sealing

effect.

chambers

surfaces on the final drive and transafter tightening: 0.07 - 0.08 mm)

Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings in hydraulic circuits of less than 50 mm in diameter.

Antif

riction

pound including

com-

(Lubricant molybde-

LM-P

Applied

to bearings

prevent

sticking,

and taper

burning

shafts

to facilitate

press-fitting

and to

or rusting.

num disulfide) Grease (Lithium Vaseline

grease)

G2-LI -

Applied to bearings, sliding parts and oil seals for lubrication, prevention and facilitation of assembling work. Used for protecting

lLT-2 is also called

LOCTITE

battery

in the shop

electrode

terminals

from

rust

corrosion.

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

WIRE are employed

WIRING

a nominal

to indicate

the thickness

of wires.

DIAGRAMS.

number

5 and white

coating

with

black stripe.

BY THICKNESS

Copper wire

Nominal number

CODE

Number str_ands

_ Cable O.D.

Dia. TF;ands

Cross section (mm2)

Applicable

(mm)

circuit

0.85

0.32

0.88

2.4

0.32

2.09

3.1

1 Lighting, signal etc.

Starting,

lighting, signal etc.

0.32

5.23

4.6

Charging and signal

0.45

13.36

7.0

Starting

0.80

42.73

1 1.4

135

Starting

127

0.80

63.84

13.6

178

Starting

100

217

0.80

17.6

230

Starting

CLASSIFICATION

BY COLOR

109.1

AND

(Glow plug)

CODE

Circuits ity

ChTng

Class+ fication

GrTd

Signal

Other

Code

(GLI

Color

(Green & Blue)

White

Black

Code

Color

White & Red

Code

“‘Or

White & Black

3 &xi_

liary 4

t Code Color

WL White&Blue

Code 5

t- Color 6

00-l 0

WEIGHT

GENERAL

WEIGHT

TABLE

This weight table is a guide for use when transporting or handling components.

(Unit: kg) 11118 and up

â&#x20AC;&#x2DC;3Yl7 Engine assembly

700

Radiator assembly

105

Torque converter assembly

160

160 Lift cylinder (I piece)

Rear drive shaft

Front axle assembly

)

Dump cylinder

185

Engine hood

134

Front frame

1,129

1 1,129

Rear frame

1,109

Bucket link

Front differential assembly

191

Rear differential assembly

176

Rear axle assembly

P~;t&rr~carrier

assembly

Tilt lever

1,250 I

1,040

1,308 1,021

248

204

)

Planetary hub assembly (I piece)

Axle pivot

1 61183

( 61183

Fuel tank

100

Battery (1 piece)

210

Operatorâ&#x20AC;&#x2122;s seat

Steering valve

Floor plate

Steering cylinder (1 piece)

CAB

310

111

Front/Rear

Wheel (1 piece) Tire (I piece)

Brake (1 piece)

100

(

WA350-1

: with teeth. * : with bolt on cutting edge.

00-l 1 0

TABLE

GENERAL

TABLE

0 : OIL AND

COOLANT

OIL

AND

COOLANT

QUANTITIES

RESERVOIR

Engine oil pan

Brake

Transmission case

Hydraulic system Axle (Front and rear)

See NOTE (4) oiese, fue,

Fuel tank

Cooling system

each 45

LASTPAD975 No. 1

Add antifreeze

Water

NOTE: (1) When

fuel

change

sulphur

oil in the

content

oil pan

nance hours described Change

oil according

sulphur content

is less

every

than

periodic

(2) When

0.5%.

oil of

in this manual. to the following

starting

perature

mainte-

table

even

if fuel

SAEIOW, though

to 10°C

is above 0.5%. (3)

the engine

of lower

in an atmospherric

then 0°C.

tem-

be sure to use engine

SAEIOW-30

and

an atmospheric

SAEI

5W-40,

temperature

goes

more or less in the day time.

Use API classification classification

CD as engine

CC, reduce

the engine

oil and if API oil change

in-

terval to half. (4)

For axle oil, use only recommended SHELL:

Above 1.0%

l/4 of regular interval

RPM TRACTOR

CHEVRON:

TRACTOR

TEXACO:

TDH OIL

MOBIL:

MOBILAND

It is possible

American

SAE:

Society

Specified

capacity:

Refill capacity:

00-12 0

Society

of Testing

of Automotive

HYDRAULIC

HYDRAULIC SUPER

to substitute

FLUID

UNIVERSAL

engine

oil CLASS-CD

for axle oil.

and Material

Engineers

Total amount

Amount

oil as follows.

TT or TD

CALTEX:

SAEBO

ASTM:

DONAX

of oil including

oil for components

of oil needed to refill system

and oil in piping.

during normal inspection

and maintenance.

WA350- 1

ENGINE

11 STRUCTURE

AND FUNCTION

Engine mount Radiator

..............................

..................................

Fueltankandpiping Engine control

WA350-1

11-2 11-3

........................

11-4

.............................

1 1-5

11-1

STRUCTURE

AND

FUNCTION

ENGINE

MOUNT

ENGINE MOUNT

423FOO5

The

engine,

transfer .

There transfer

torque

are

rubber

transmission,

mounts

at the

engine

end

mount

11-2

and

together.

end.

1. Transmission 2. Engine

converter,

are each joined

WA350-1

and

STRUCTURE

AND

FUNCTION

RADIATOR

Section X-X

423FOO6

Radiator

Coolant

Fan guard

Hydraulic

Torque

Specifications level sensor oil cooler

converter

Coolant

inlet port

Coolant

outlet port

G6 type

Cross-sectional

area:

52.57

area of water tubes:

m2 138

cm2

oil cooler

WA350-

Core type:

Total heat dissipating

11-3

STRUCTURE AND FUNCTION

FUEL TANK AND The fuel level sensor is installed

FUEL TANK AND PIPING

PIPING in the fuel tank.

F4230001

1. Connector 2. Fuel level sensor 3. Injection

pump

4. Drain cock 5. Fuel filler port

11-4

WA350- 1

STRUCTURE

ENGINE

AND

ENGINE

FUNCTION

CONTROL

F4230002

1. Accelerator pedal 2. Injection pump

WA350-1

11-5

ENGINE

12 TESTING

AND ADJUSTING

Standard

value table

Tool list for testing Adjusting

valve

Measuring Testing

and adjusting engine

Testing

The

following

precautions

troubleshooting

or during

1. The values

in these

used as target 2. The standard standard

values

repairing

in these

tables

for the machine

values

tables

using

timing

12-

. . 12-

12-l

....

12-l

fan belt tension

exhaust

Measuring

accelerator

gas color

pedal operating

angle

fuel cut solenoid

Value

. . . . 12. . . 12-

pressure

Measuring

the Standard

on the values or when

must

shipped

for new

estimating

for judgement

when

be used as reference value

when

. .

force

. ..

.. ..

Tables

to make

judgements

leaving

the plant,

so they

12-l

during

and adjusting.

are based

when

standard

use these

tables

values

they should 3. These

are necessary testing

pressure

blow-by

and operating

12-

oil pressure

and adjusting

Adjusting

. 12-

fuel injection

and temperature Measuring

. . _. .

clearance

compression

Measuring

and adjusting

when

from

in combination

with

after a period

troubleshooting

the plant,

values

when

should

of use. are estimated

and on the results

repair and operating

not be used for standard

alone to make simple

machines

wear

values

of various

records

when

judging

claims.

based

tests.

making

on the

Therefore, judgements.

In addition,

do not

judgements.

WA350-1 %â&#x20AC;&#x2122;

TESTING

ADJUSTING

AND

STANDARD

TABLE

VALUE

STANDARD

Engine Cate

Unit

Condition

Item

gory

High idling speed Engine speed

TABLE

VALUE

rpm

Low idling speed

rpm

Komatsu Standard value

O-l

S6Dll

Permissible value

2,350

- 2,450

2,430

- 2,530:

650-750 -

(680-780)

0°C

starting .

Necessary speed

- 20°C

Intake resistance pressure

Exhaust

(using starting

aid)

(When

u”

moBlow-by

Oil pressure oil temperature: (SAE30 min. 8d’C)

Oil consumption

ration

pressure

Fuel injection timing Coolant

6.5 (8.5)

Max. 1 .O

2.0

(Max. 2.5)

(3.5)

0.25

0.25 0.45

13002-43501

mmH,O

Max. 150

300

At high idling

kg/cm2

3.5-5.5

2.5

At low idlino

ko/cm2

Min. 1.5

1 .o

Oil temperature [engine speed1

60°C

min. 60°C

At continuous rated horsepowe (oroportion to fuel consumption)

“C

80-I

120

1 %

Max. 0.5

1 .o

Nozzle tester

kg/cm2

250

200

Before top dead center

degree

16+1

70-90

100

OC I

temperature when fully open

“C

74.5 - 78.5

“C

Lift when fully open

9.5-10.5

Deflection when pushing with finger force approx. 6 kg

7.5 4-7

force

Operating

angle cy

degree

Operating

travel L

cY,33

CYI45

height L,

15-25

Stopper

height Lz

15-25

136-146

9.5 - 10.5 5-10 Max. 10.5

Stopper

(

12-2 0

Max. 5.0 (Max. 6.5)

Operating

Rod length

Max. 650

0.45

Temperature

Fan belt tension pulley) (Alternator-Fan

Max.

Min. 30 [300 - 3501

Valve cracking function

Max. 650

mm -

Whole speed range (at engine outlet)

temperature

Thermostat

Bosch index

Whole speed range (inside oil pan)

Oil temperature

Fuel injection

Bosch index

Max.

kg/cm2 [rpml

At high idling, oil temoerature

pressure

Max. 635

“C

Exhaust valve

pressure

Compression

Max. 300

mmHg

Intake valve

engine is cold)

Min. 100

All speed

At high idling

Valve clearance

Min. 150

Min. 100

mmH,O

At abrupt acceleration Exhaust gas color

Min. 150

rpm

All speed

All speed (intake air temp. 20°C)

Exhaust temperature

1: Serial No. 1 1 1 18 and up WA350-1

TESTING

AND

TOOL

I 7~ No.

ADJUSTING

LIST

TOOL

FOR TESTING

Testing and measuring item

Engine speed

Battery specific gravity

Coolant freezing temperature

Water temperature, oil temperature, intake temperature

AND

Tool

LIST

FOR

TESTING

Remarks

Tachometer

799-203-8000

Battery coolant tester

795-500-1000

Digital display 60-I 9,999

790-500-I

300

1.100

-5

-50°C

0 -

200°C

0 -

1,ooo”c

temperature gauge

799-l

01-6000

Exhaust temperature

Lubricating oil pressure

0 -

10 kg/cm2

Fuel pressure

0 -

20 kg/cm2

0 -

1,500 mmHg

0 -

1,000 mmH,O

Intake pressure,

Engine presssure

exhaust pressure

measuring kit

rpm

1.300

ADJUSTING

ADJUSTING Part No.

Thermistor

AND

799-203-2002

Blow-by pressure

10 Intake resistance ~ I_

- 1,000

0 mmH,O

Compression pressure

Compression gauge

795-502-I

204

0 -

70 kg/cm2

Blow-by pressure

Blow-by checker

799-201-I

503

0 -

500 mmH,O

Valve clearance

Feeler gauge

795-l

Exhaust gas color

Smoke meter

Fuel on water mixed in oil

Engine oil checker

799-201-6000

Coolant quality

Water quality tester

799-202-7001

PH. nitrous acid ion concentration

Leakage from cooling system

Cap tester

799-202-9001

0 -

2 kg/cm2

Fuel injection pressure Nozzle injection condition

Nozzle tester

0 -

300 kg/cm2

Electrical circuit

Tester

Accelerator

Push-pull scale

When

pedal force

carrying

out testing,

adjusting

25-l 330

Commercially available

Commercially available Commercially available 7AO-262-0020

or troubleshooting,

0.25,0.45

Discoloration 0 to 70% standard color (Discoloration %x l/l O=Bosch index) Water content 0.1%. 0.2% in standard sample

Current, voltage, resistance Commercially available 0 -

stop the machine

on level ground,

25 kg

insert the safety

pins and block the tracks.

A A

When

working

When

checking

while the water

in groups,

use agreed signals and do not allow unauthorized

the water

Be careful not to get caught

WA350

level in the radiator

is hot. Boiling water

wait for the water

to cool.

persons near the machine. Do not remove

the radiator

cap

may spurt out.

in rotating

parts.

12-3 al

AND

TESTING

ADJUSTING

ADJUSTING *

Condition:

Adjust

ADJUSTING

VALVE

CLEARANCE

Engine is cold.

clearance

between

valve and rocker

lever

as follows. Unit: mm

Intake valve Cold

0.25

tool

Special

0.45

Part number

Part name

1 795-125-1330

Exhaust valve

1. Remove

air

connector,

2. Rotate

1 Feelergauge

cleaner

I 1

assembly

then remove

the

Qâ&#x20AC;&#x2122;ty

and

intake

cylinder head cover (I ).

crankshaft

in the normal

direction

align pointer

(2) with the 1.6 TOP mark on crank-

shaft

When

pulley.

of the valves. 1.6 TOP

rotating,

When

mark,

check the movement

the pointer

No.1

cylinder

is in line with the

should

be at com-

pression top dead center. No. 1 cylinder

3. When

is at compression

center, adjust the valve marked When

No.6

cylinder

is at compression

center, adjust the valves marked

4. To adjust,

insert tool A between

rocker

(4) and turn adjustment

until clearance

is a sliding

nut (6) to hold adjustment Lock nut:

3.2 *

and adjust

After

adjusting

top dead crankshaft clearance

120â&#x20AC;? of

one turn in the normal

(5) lock

clearance

di-

of the re-

No.1

center,

tighten

(3)

screw in position.

the valve

maining valves marked t

Then

lever screw

0.3 kgm

5. Next, rotate crankshaft rection

fit.

top dead

and valve stem

top dead

cylinder

at compression

it is also possible

to turn the

each time and adjust the valve

each

cylinder

according

the

firing order. l

Firing order:

Zr After

tightening

l-5-3-6-2-4 the lock nut, check

the clear-

ance again. r

423F301

12-4 a

WA350-1

TESTING

AND

ADJUSTING

MEASURING

COMPRESSION

Measurement

Coolant

Engine valve clearance:

Engine speed:

COMPRESSION

PRESSURE

condition

temperature: 360

Inside operating Standard

to 380

range.

value.

rpm Unit: kg/cm2

Item Compression pressure

Standard value

Permissible value

Min. 28

Min. 19.5

Special tools

Al---

795

502-I

performance

worn, measure

When

IQ’ty

gauge

I ’

Tachometer

tests

that the piston,

Part name

1Compression

204

799-203-8000

Part number

or troubleshooting

shows

piston ring or cylinder liner may be the compression

measuring

pressure.

the compression

careful

not to touch

muffler,

or to get caught in rotating

pressure,

manifold

the exhaust

parts.

1. Adjust valve clearance. t

For details,

see ADJUSTING

VALVE

CLEAR-

ANCE. 2. Warm

up engine (oil temperature

3. Remove

40°C)

nozzle holder assembly.

4. Install

adapter

assembly,

mount

and connect

5. Set engine tachometer 6. Disconnect

nozzle

holder

pressure gauge.

B in position.

fuel

CUT-OFF

solenoid

valve

connector. Crank

engine

compression Zr Measure where

with

starting

motor

and

measure

pressure. the compression

the

pressure

gauge

at the point

indicator

remains

steady. *

When measure

measuring

within the specified *

the

the engine

compression

speed

to confirm

WA350-1

that it is

range.

Installing the nozzle holder assembly ing the compression

pressure,

after measur-

pressure.

12-5 @

TESTING

AND

TESTING * l

AND

Measurement Coolant

TESTING

ADJUSTING

FUEL

AND

ADJUSTING

INJECTION

FUEL INJECTION

TIMING

condition

temperature:

Inside operating

range. Unit: degree

Standard value

Item

m-~

B.T.D.C.

TESTING

FUEL

1. Disconnect 2. Remove

Permissible value 16+

INJECTION

fuel injection delivery

(

TIMING

pipe (1) of No. 1 cylinder.

valve

holder

(2).

then

remove

delivery valve (3) and spring (4). and install delivery valve holder (2) again.

3. Place fuel control lever at FULL position. 4. Operate slowly

priming

stops flowing

5. Check and

pump

in normal direction.

that

and

rotate

Check

crankshaft

point where

fuel

from delivery valve holder (2). 16â&#x20AC;?

pointer

I.J. line on crankshaft

16) are

aligned

at point

pulley where

(5) fuel

stops flowing. *

BEYOND

injection

timing line: Timing

RETARDED

Sr BEFORE injection timing line: Timing ADVANCED

If the test shows incorrect,

that

the fuel injection

timing

adjust as follows.

/j&v

423F302

12-6 0

WA350-1

TESTING

AND

TESTING

ADJUSTING

ADJUSTING FUEL INJECTION BY DELIVERY CHECK 1. Turn

crankshaft

back

AND

ADJUSTING

FUEL INJECTION

TIMING

40”

from

top dead

center. 2. Rotate

cankshaft

to align

16”

I.J. line on crank-

shaft pulley and pointer correctly. 3. Loosen flange little

nut

(7) on the

by little

by operating

until no fuel flows 4. Tighten

pump

mounting

stops

hole of mountijng

the bolt, check

flowing

from

holder at the point where

the

delivery

ery valve

(9)

flange

valve

holder

(3) and spring

again that the delivery

the pointer

with the line on the crankshaft 5. Remove

pump

pump.

After-tightening fuel

the priming

out of the delivery valve holder.

nut (7) in oblong

of fuel injection +

injection

bolt, and rotate the flange on the pump side

valve

is aligned

pulley.

(2). assemble

(41, then

install

delivdelivery

valve holder (2) again. w

Delivery

holder:

3.3

-C 0.2 kgm

6. Connect fuel injection pipe (I). m

Sleeve

WA350-1

nut:

2.4 + 0.1 kgm

12-7 0

TESTING

AND

ADJUSTING

MEASURING 1. Measuring

ENGINE

engine

Measurement

Coolant

MEASURING

OIL

ENGINE

PRESSURE

OIL

AND

PRESSURE

AND

TEMPERATURE

oil pressure.

condition

temperature:

Inside operating

range. Unit: kg/cm*

Special

tool

Part number

Part name

799-203-2002

When

measuring,

in rotating A

Install

Q’ty

Engine pressure measuring kit

be careful

not to get caught

parts.

and

remove

the

plug

and

oil pressure

gauge with the engine stopped. t

Measure

the engine

perature

is at the specified

1) Remove

oil pressure

when the oil tem-

temperature.

plug (I 1.

2) Install oil pressure gauge A (25 kg/cm? *

Install the oil pressure fected

as little

gauge

so that it is af-

as possible

by the

engine

vibration. 3) Start engine and measure 2. Measuring

oil temperature.

Measurement

Coolant

Oil temperature

condition

temperature:

Item

12-8

oil pressure.

Inside operating

Permissible value

Standard value 190-

110°C

range.

120°C

WA350-1

TESTING

AND

MEASURING

ADJUSTING

MEASURING

BLOW-BY

PRESSURE

* Measurement condition . Coolant temperature: inside operating range. . Engine valve clearance: Standard valve Unit: mm H,O

Item

Standard value

Blow-by pressure

Max. 150

Permissible value

300

Special tool ~

r A

P&t

number

1 799-201-1503

Part name

1 Blow-by checker

1 1

2. Precautions when measuring blow-by It Blow-by may vary greatly according to the condition of the engine, so if there is any abnormality in the reading, to

defective

consumption,

defective

early deterioration

WA350-1

check for any problem

blow-by,

such

as excessive

exhaut

or contamination

gas

color,

oil or

of the oil.

12-9 0

TESTING

AND

TESTING

ADJUSTING

TESTING

AND

ADJUSTING

FAN

AND

ADJUSTING

FAN

BELT TENSION

Testing fan belt tension Check the amount with

a force

between

the fan belt deflects approx.

when

kg at a point

the fan pulley and the alternator

pushed

Fan pulley

midway

pulley. Unit:

Alternator

pulley

423F303

Measuring procedure 1. Push the V-belt with midway 2. Use

between

a scale

a force

of 6 kg, at a point

the pulley and the alternator.

to measure

the

Adjustment procedure 1. Loosen mounting bolt

(1)

amount

the V-belt

deflects.

assembly,

and

the

stick

mounting

the

bolt

of adjustment

alternator

plate (2). 2. Insert

mounting

the alternator Qf

bar

bolt and the

between cylinder

the block,

alternator then

raise

to the outside.

If the alternator hands, there

is moved

is danger

to the inside with the

of catching

and insuring

the fingers. 3. Adjust

the belt (3) tension

mounting 4. Check

that the belt tension

all mounting

12-10 0

and temporarily

tighten

bolt. is correct

then tighten

bolts fully.

WA350-1

TESTING

AND

ADJUSTING

MEASURING t

Measurement

MEASURING

EXHAUST

GAS

condition

Coolant temperature:

Valve clearance:

Inside operating

Standard

range.

value. Unit:

Bosch index

Special tool Part number A

Part name

Commercially available

When

Smoke

measuring

the

1. Insert probe @

in outlet

secure to exhaust

2. Connect

probe

color;

be careful

pipe. of exhaust

pipe (I)

and

pipe with clip.

hose, connector

hose @of

accel-

and air hose to smoke meter A.

erator switch

meter

exhaust

not to touche the exhaust

Qâ&#x20AC;&#x2122;ty

The pressure

of the air supply should

be under

15 kg/cm2. 3. Connect

power cord to AC1 OOV socket.

Sr Check that the power

switch is OFF before con-

necting the cord. 4. Loosen

cap nut of suction

pump

and insert filter

paper. 5. Turn power switch

6. Accelerate

suddenly.

depress

engine

accelerator

catch exhaust

pedal, operate

the

filter

papers

(10

gas color on

sheets

or more)

inside filter paper holder, and read indicated

WA3561

time,

gas color on filter paper.

7. Lay filter paper used to catch exhaust top of unused

same

relief valve and

value.

COLOR

EXHAUST

GAS COLOR

MEASURING ADJUSTING

AND

TESTING

PEDAL

ACCELERATOR MEASURING ANGLE AND OPERATING *

Measurement

Coolant

OPERATING

OPERATING PEDAL ANGLE OPERATING

FORCE

condition range.

Inside operating

temperature:

Unit:

Operating force of accelerator oedal

Permissible value

Standard value

Item

4-7

Max. 10.5

tool

Special

ACCELERATOR AND FORCE

423 F304

Part name

Part number

scale

Push-pull

7AO-262;0020

OPERATING

FORCE

1. Measuring

procedure

Q’ty 1

I) Put push-pull scale A in contact with the accelerator pedal at point 150 mm from pedal fulcrum “a”. *

of push-pull

center

The

be in

scale A must

mm from the pedal

with a point 150

contact fulcrum.

2) Start the engine, push the pedal in the direction and measure

of operation when

the maximum

value

end

of the

to the

idling

from

pushing

pedal travel (high idling).

2. Testing

and adjusting

I) Stop the engine. the cable

2) Disconnect celerator

of the ac-

at the bottom

and

pedal, and check that the linkage at

ball joint

bottom

the

move

pedal

smoothly. 3) Connect

the cable

then disconnect tion

pump,

at the bottom

at the connection

and

check

that

the

of the pedal, for the injeccable

moves

smoothly. *

When

carrying

replace operating

parts force

out this inspection, as

again

within the standard

12-12 0

necessary. and

adjust

Measure

the

that

it is

check

range.

WA350-1

MEASURING TESTING

AND

OPERATING PEDAL

ADJUSTING

ANGLE

ACCELERATOR FORCE AND

PEDAL OPERATING OPERATING ANGLE

ACCELERATOR

Unit: mm

Operating travel

423 F305 Installed height of accelerator pedal stopper

Installed length X of rod

136-146

1. Measuring procedure 1) Stop the engine. 2) Measure

the

operating

angle

gauge

pedal

it is operated

angle

in contact

cyl, cxz, put the

with

from

the

accelerator

low-idling

and high

the

open

idling. 2. Adjusting 1) Remove

procedure the

cover

under

cab,

the

engine hood and fit the safety lock. 2) Loosen

nut (I)

and adjust

rod (2) until it is 160 3) Release

the

accelerator

and adjust the height

installed

length

X of

5 mm. pedal,

loosen

L, of the stopper

nut

(5)

bolt (6)

until it is 18 +- 5 mm. 4) Depress

the

accelerator

and adjust the height

pedal,

loosen

nut (3)

Lz of the stopper

bolt (4)

until it is 17 +- 5 mm. 5) Depress

the accelerator pedal, loosen lock nut (7) and adjust the length of cable so that the injection pump governor lever contacts the high idle stopper.

After

making

measurements

the above adjustments, again

are within the standard

WA350-1

and

check

take all that

they

value.

12-13

TESTING

AND

ADJUSTING 1. Confirm pump (I

that

stop

FUEL CUT lever

FUEL

CUT

SOLENOID

(2) of the fuel

injection

1 is at the STOP position.

(Usually,

the return

the STOP

position.)

2. Adjust

ADJUSTING

rod so that

spring

holds the stop lever at

the solenoid

has a maximum

stroke. Adjust

rod

between stopper

so clearance

injection

on the engine

the solenoid 4. Tighten

is 0.4

0.1

(2)

and

key and confirm

that

stopper

lever

(3). Stroke-“a”

3. Turn

“b”

pump

12 mm

starting

stroke “a” is the standard

dimension.

nuts (5) and (6) of rod (4).

423F338

12-14 0

WA350-1

ENGINE 13 DISASSEMBLY

AND ASSEMBLY

.. STARTING

MOTOR

Removal

ASSEMBLY

Removal

13-

Installation

. . . . . . . . .._........_....__

13-

Removal

13-

Installation

13-

Removal

13-

Installation

13-

Removal

13-

Installation

13-

ALTERNATOR

. ..

Installation INJECTION

Removal

PUMP

Removal

FUEL

HOLDER

HEAD

Removal

. . , _, . . .

13-24

. . . . 13-27

ASSEMBLY ..__..__..._........._........ .

13-29

. .

. . . 13-29

ASSEMBLY

TANK

..............................

13-30

. . 13-37

ASSEMBLY

. .

13-44

13-46

13-14

.._........._.

. .

13-22

13-23

ASSEMBLY

.. ...

Removal Installation

.. .

the following

cylinders,

ASSEMBLY

COMPRESSOR

pumps engine,

2. Operate 3. Continued

WA350-1

.. .

Installation

ASSEMBLY

TURBOCHARGER

NOTE:

_....__...__..._...__.....

Installation

4. After

.. ,.

ASSEMBLY

Removal

1. Start

..........................

Installation CYLINDER

COOLER

ENGINE

ASSEMBLY

Removal

Sr Take

. . . . . . _.........__..,_....

Installation NOZZLE

. . . ..__..._.........._....

Installation WATER

OIL

ASSEMBLY

Removal

ASSEMBLY

Installation

FUEL

RADIATOR 13-

..........................

. .

method

for

air bleeding

when

you

start

to operate

hydraulic

cylinders

after

reassembling

keep idling. cylinder

to operate After

13-23

and pipings.

hydraulic

finishing

above

4 -

cylinder steps,

long storage,

5 cycles, 3 -

but do not exceed

4 cycles

keep normal

until stroke

engine

same procedure

beyond

100

mm of stroke

end.

speed.

is required.

13-I 0

DISASSEMBLY

AND

REMOVAL

Disconnect terminal

1. Remove

OF STARTING the

cable

from

the

negative

MOTOR

ASSEMBLY

(-1

of the battery.

catch, then open hood.

2. Disconnect 3. Remove

STARTING

ASSEMBLY

wire (I) and connector

ground connection

ing motor assembly

(2).

(3). then remove

start-

(4).

INSTALLATION OF STARTING MOTOR ASSEMBLY 1. Fit O-ring

and install starting

then tighten 2. Connect

together

connector

motor

assembly

with ground connection

(41, (3).

(2) and wire (1).

3. Close hood, then lock with catch. 4. Connect

13-2 0

cable to negative

(-1

terminal

of battery.

WA350-1

DISASSEMBLY

REMOVAL

AND

ALTERNATOR

ASSEMBLY

OF ALTERNATOR

ASSEMBLY

Disconnect the cable from the negative (-1 terminal of the battery.

1. Remove catch, then open hood. 2. Disconnect wires (I), (2) and (3). 3. Remove bolt (4) of adjustment plate, then loosen mounting bolt and nut (5). 4. Move alternator assembly towards cylinder block to loosen belt tension, then remove belt (6). 5. Remove mounting bolt and nut, then remove alternator assembly (7).

INSTALLATION ALTERNATOR

OF ASSEMBLY

1. Install alternator assembly (71, then partially tighten mounting bolt and nut (5). 2. Fit belt (6) in pulley groove and install. 3. Partially tighten bolt (4) of adjustment plate. 4. Insert a bar between alternator assembly and cylinder block, raise alternator assembly and adjust tension of belt. * The belt should deflect about IO mm when pushed with a finger pressure of 6 kg at a point midway between the alternator and the fan pulley. 5. Tighten bolt of adjustment plate, mounting bolt and nut (5). 6. Connect wires (31, (2) and (I ). 7. Close hood, then lock with catch. 8. Connect cable to negative (-1 terminal of battery.

WA350-1

13-3 0

DISASSEMBLY

AND

REMOVAL 1. Remove

ASSEMBLY

FUEL

OF FUEL INJECTION

PUMP

INJECTION

PUMP

ASSEMBLY

catch, then open hood.

1and (2).

2. Disconnect

control rods (I

3. Disconnect

boost compensator

4. Disconnect

fuel hoses (4) and (5).

5. Disconnect

fuel supply hose (6).

6. Remove

lubrication

7. Disconnect

hose (3).

tubes (7) and (8).

6 fuel injection tubes (9).

8. Remove

coupling

9. Remove

4 mounting

bolt (10). bolts, then pull out fuel injec-

tion pump assembly

(I 1) to rear to remove.

INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 1. Place

fuel

bracket, mounting 2. Rotate

injection

and

crankshaft

crankshaft timer

(1 I)

Partially

tighten

coupling bolt (IO).

and align pointer

(13)

with

line

line is not at the front,

rotate

the

one more turn.

line A on fuel injection side, then

uniformly

assembly

pulley (I 2).

If the timer

3. Align

pump

in position.

bolts, then tighten

on crankshaft t

set

tighten

pump with

mounting

line B on

bolts of pump

in turn.

4. Connect

6 fuel

injection

tubes

(9).

and

tighten

nuts. w

Sleevenut:

5. Fit gaskets

2.4kO.l

and install lubrication

6. Fit gasket and connect 7. Fit gaskets

kgm

and connect

fuel hoses (51 and (4).

8. Connect

boost compensator

9. Connect

control rods (2) and (I ).

IO.

tubes (8) and (7).

fuel supply hose (6). hose (3).

Close hood, then lock with catch.

13-4 0

WA350-1

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