Komatsu WA180-1LC 75001 and up Wheel Loader Shop Manual - PDF DOWNLOAD

CEBMW17020

SHOP MANUAL

WA1 80-I

LC

WHEEL LOADER MACHINE

MODEL

WA1 80-I LC

SERIAL

NUMBERS

75001 and up

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.

MAR 92

PRODUCT PUBLICATIONS INFORMATION VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS.

SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, ANDTURBOCHARGER SHOP MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS IN FOREIGN LANGUAGES.

THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).

DESCRIPTION

FORM NUMBER

PARTS BOOK - PAPER: Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEPBW17021

PARTS BOOK - MICROFICHE: Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION

& MAINTENANCE

BEPMW17021

MANUAL:

Chassis.......................................................

SEAMU417KDlO

SHOP MANUAL: Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CEBMW17020

Engine: Shop Manual . . _...........................................

Alternative Repair Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CEBM61 OSMO CEBM61 OAR0

SAFETY MANUAL

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

1066 663 R3

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PUBINFO.KOM

100791

~~OuisiTloN FOR TECHNICAL SERVICE PuBLKX~~N~

AND SERVICE FORMS

COMPLETE FORM

Komatsu America International Company

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CONTENTS No. of page

10 ENGINE 11 STRUCTURE AND FUNCTION ................................................ ..................................................

13 DISASSEMBLY AND ASSEMBLY ..............................................

11-l 12-1 13-1

12 TESTING AND ADJUSTING

20 POWER TRAIN 21 STRUCTURE AND FUNCTION ................................................

22 TESTING AND ADJUSTING ..................................................

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

23 DISASSEMBLY AND ASSEMBLY ..............................................

24 MAINTENANCE STANDARD .................................................

40 STEERING SYSTEM 41 42 43 44

STRUCTURE AND FUNCTION ................................................

TESTING AND ADJUSTING ..................................................

DISASSEMBLY AND ASSEMBLY ..............................................

MAINTENANCE STANDARD .................................................

41-1 42-l 43-l 44-1

50 BRAKE SYSTEM 51 52 53 54

STRUCTURE AND FUNCTION ................................................

TESTING AND ADJUSTING ..................................................

DISASSEMBLY AND ASSEMBLY ..............................................

MAINTENANCESTANDARD .................................................

60 WORK EQUIPMENT 61 62 63 64

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

SYSTEM

STRUCTURE AND FUNCTION ................................................

TESTING AND ADJUSTING ..................................................

DISASSEMBLY AND ASSEMBLY ..............................................

MAINTENANCESTANDARD .................................................

61-1 62-1 63-1 64-l

80 ELECTRIC AND ELECTRONIC SYSTEM 81 STRUCTURE AND FUNCTION ................................................

83 DISASSEMBLY AND ASSEMBLY ..............................................

81-l 83-1

90 MISCELLANEOUS 91 CAB AND AIR CONDITIONER STRUCTURE AND FUNCTION 97 GEAR PUMP ............................................................

99 METRIC CONVERSIONS ....................................................

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

91-1 97-l 99-1

00-l

SAFETY

A

WARNING!

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose.

To prevent injury to workers, the symbols A and *q are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

A

SAFETY

GENERAL PRECAUTIONS

PREPARATIONS

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.

7.

Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.

a.

Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.

9.

When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.

10.

Remove all mud and oil from the steps or other places used to get on and off the machine.

Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

1.

2.

Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.

When carrying out any operation, always safety shoes and helmet. Do not wear loose clothes, or clothes with buttons missing.

Always wear safety glasses when hitting with a hammer.

Always wear safety glasses when grinding with a grinder, etc.

wear work

l

parts

l

parts

3.

If welding repairs are needed, always have a trained, experienced welder carry out the work.

When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.

4.

When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.

5.

Keep all tools in good condition correct way to use them.

6.

Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

00-2

PRECAUTIONS

FOR WORK

DURING WORK

11.

When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out.

Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.

12.

The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned.

Wait for the oil and water to cool before carrying out any work on the oil or water circuits.

and learn the

SAFETY

13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first.

23.

When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.

14. When raising heavy components, use a hoist or crane.

Check that the wire rope, chains and hooks are free from damage.

Always use lifting equipment which has ample

24.

Take care when removing or installing the tracks of track-type machines.

When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

CapaCity.

Install the lifting equipment at the correct places.

Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

16. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.

17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.

18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

19. Be sure to assemble all parts again in their original places.

Replace any damaged part with new parts.

When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. l

20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.

21 When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.

22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught

VITON SEALS The maximum operating temperature of our hydraulic system is 220“ F (104°C). Under abnormal conditions, the operating temperature can reach 265°F (129°C).

“VITON” fluorine rubber material is rated to operate at 450” F (232” C).

When “VITON” fluorine rubber material is subjected to an open flame or temperatures exceeding 599°F (315°C) it will produce highly corrosive “Hydro-Flouric Acid” when subjected to temperatures exceeding 599” F (315°C). The resulting contamination can have extremely harmful consequences to human tissue. It is almost impossible to remove after contact.

Therefore, we recommend the following procedures be utilized when it is necessary to inspect or repair any equipment that has been subjected to high temperatures from causes such as fire, extreme operational overheat, etc.

1.

Visually inspect for any gaskets, seals or o-rings which have suffered from heat; they will appear black and sticky.

2.

If this is confirmed, DO NOT TOUCH!

3.

Make inquiries to determine the suspect material composition. If the material is a Flouro-Elastomer, (Viton, Flourel or Tecmoflon), it should be considered dangerous. However, if the material is found to be “Natural Rubber” or “Nitrile” it can be considered non-hazardous.

4.

If Flouro-Elastomer parts have been used, the affected area must be decontaminated before undertaking further work.

5.

Disposable heavy duty gloves made of Neoprene must be worn throughout the decontamination process. Decontaminate the affected area by washing thoroughly with limewater, a Calcium Hydroxide solution.

in a hole.

00-3

6.

Any cloths and residue as well as the gloves worn during decontamination must be safely discarded after use.

00-4

NOTE:

Burning of discarded items is not recommended except in an approved incineration process where the dangerous products are treated by Alkaline scrubbing.

MEMORANDA

00-5

FOREWORD This service manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This service manual mainly contains the necessary technical workshop.

information

for operations

performed

For ease of understanding, the manual is divided into chapters for each main group of components; are further divided into the following sections.

in a service

these chapters

STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.

Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.

DISASSEMBLY

AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling assembling each component, as well as precautions to be taken for these operations.

MAINTENANCE

STANDARD

This section gives the judgement standards when inspecting disassembled

00-6

parts.

or

HOW TO READ THE SERVICE MANUAL

HOW TO READ THE SERVICE

MANUAL

VOLUMES

REVISIONS

Service manuals are issued as a guide to carrying out repairs. They are two manuals for each machine,

Revised pages are shown on a LIST OF REVISED PAGES which is located between the section contents page and SAFETY pages.

Chassis volume and Engine volume.

These volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, both chassis and engine volumes are needed.

SYMBOLS

DISTRIBUTION

So that the service manual can be of ample practical use, important places for safety and quality are marked with the following symbols.

AND UPDATING

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

FILING METHOD 1.

2.

See the page number on the bottom of the page.

File the pages in correct order.

Following number:

examples

show how to read the page

Symbol

Item

A

Special safety precautions are necessary when performing the work Safety

A4

iY

Example 1 (Chassis volume): *

r5lkn

Example 2 (Engine volume): Refer to the pertinent engine manual.

3.

Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number.

File as in the example.

&

Q

Example:

Caution

Weight

Weight of parts or systems.

Caution necessary when selecting hoisting wire or when working posture is important, etc.

Tightening torque

Places that require special attention for tightening torque during assembly.

Coat

Oil, water

21-4 $$l

Drain

Added pages

Extra special safety precautions are necessary when performing the work because it is under internal pressure.

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

Section and sub-section number (11. Engine Structure and Function) Consecutive page number for each sub-section

Remarks

Places to be coated with adhesives and lubricants etc.

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

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

21-5 REVISED EDITION MARK ([l]

[2] [3] ....)

When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages.

00-7

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

A

1 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

6 100%

L

as%

71%

79%

41% FSW64

1.

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: l

l

2.

Check for removal of all bolts fastening the part to the relative parts.

Check for existence of another part causing interface with the part to be removed.

3)

A

Wire ropes 1)

Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:

Wire ropes (Standard ‘7” or “S” tw.;;.s;opes without galvanizRope diameter (mm) 10.0 11.2 12.5 14.0 16.0 18.0 20.0 22.4 30.0 40.0 50.0 60.0

1 Allowable load (tons) 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.

4)

WARNING! 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.

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 subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150”.

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 from the middle portion of the hook.

300

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.

00-8

So’ Lifting

So” angle

:

120”

150’

a FSW05

STANDARD

TIGHTENING

TORQUE

STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening “Disassembly and Assembly”.

Thread diameter of bolt (mm)

torques of bolts and nuts. Exceptions

are given in sections of

08

Width across flat (mm)

6 8 10 12 14

1.3520.15 3.2t0.3 6.7t0.7 11.5kl.O 18.Ok2.0

13.2k1.4 31.4k2.9 65.726.8 11229.8 177*19

16 18 20 22 24

24 27 30 32 36

28.5*3 39-t4 56-t6 76?8 94.5?10

279 f 29 383 ? 39 549+58 745 + 78 927-c98

27 30 33 36 39

41 46 50 55 60

135+15 175220 225 +25 280230 335+35

1320?140 1720+190 2210+240 2750 + 290 3280 + 340

This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or which require tightening to otherwise specified torque. + Nam (newton meter): 1 Nom 5 0.1 kgm

2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts.

Thread diameter of bolt (mm)

Width across flats (mm)

kgm

N-m

10 12 16

14 17 22

6.7kO.7 11.5&l 28.5+3

65.7k6.8 112k9.8 279229

Tightening

torque

00-9

STANDARD TIGHTENING

TORQUE

3. TIGHTENING TORQUE FOR NUTS OF FLARED FITTINGS Use these torques for nut part of flared.

Thread diameter of nut part (mm)

Width across flats of nut part (mm)

Tightening

torque

kgm

N*m

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

2.5kO.5 5k2 8+2 1423 1823 20+5 25+5 3Ok5

24.5 f 4.9 49219.6 78.5k19.6 137.3229.4 176.5 + 29.4 196.1149 245.2 f 49 294.2*49

COATING MATERIALS The recommended

Nomenclature

Code

Adhesives

I Liquid gasket

Antifriction compound (Lubricant including molybdenum disulfide) Grease (Liihium grease) Vaseline

coating materials prescribed in the service manuals are listed below.

Applications

LT-1 A

Used to apply rubber pads, rubber gaskets, and cork plugs.

LT-1 B

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

LT-2*

Preventing bolts, nuts, and plugs from loosening and leaking oil.

LT3

Provides an airtight, electrically insulating seal.

Used for aluminum surfaces.

LG-1

Used with gaskets and packings to increase sealing effect.

LG-3

Heat-resistant gasket for precombustion I pioina.

chambers and exhaust

LG-4

Used by itself on mounting surfaces on the final drive and transmission cases. (Thickness after tightening: 0.07 - 0.08 mm).

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.

LM-P

Applied to bearings and taper shafts to facilitate press-fitting and to prevent sticking, burning or rusting.

G2-LI

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

___

Used for protecting battery electrode terminals from corrosion.

* LT-2 is also called LOCTITE in the service manuals.

00-l 0

parts when a

rust

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example:

05WB indicates a cable having a nominal number 05 and white coating with black stripe.

CLASSIFICATION

BY THICKNESS

CLASSIFICATION

BY COLOR AND CODE

00-l 1

WEIGHT TABLE

A

WEIGHT TABLE This weight table is a guide for use when transporting

or handling components.

Unit: kg

441

Engine assembly Radiator assembly

43

Torque converter assembly Transmission

with torque converter assembly

37

Center drive shaft

420 11

Front drive shaft

10.5

Rear drive shaft Front axle assembly

5.5 - dry

Rear axle assembly - dry

466 465

Rear axle pivot Wheel - each: For 15.5 X 25 tire - 1 piece type

85

For 15.5 X 25 tire - 3 piece type For 17.5 X 25 tire - 1 piece type

92

For 17.5 X 25 tire - 3 piece type

116

Tire - each: 15.5X25-12plyL2 15.5 X 25 - 12 ply L3

89

15.5 X 25 - 12 ply XHAT 17.5X25-12plyL2

111

17.5 X 25 - 12 ply L3

133

17.5 X 25 - 12 ply XHAT Steering valve Steering cylinder

18

Brake master cylinder

11

Hydraulic tank - dry

66

Hydraulic loader and steering pump Equipment control valve: Two spool

10

Three spool Lit cylinder - each

00-12

7

21 27 76 75

Dump cylinder Engine hood

135

Front frame

765

Rear frame

758

Bucket link Bucket tilt lever

30 142

Lii arm with bushings

636

WEIGHT TABLE

Unit: kg

Bucket with cutting edge: General purpose bucket

1,450

Excavating

1,400

bucket

Light material bucket

1,675

Counterweight: Standard

850

Additional

680

Fuel tank - empty

75

Battery - each wet

30

Operator’s seat Rigid type Suspension type

37 41

Floor plate ROPS cab - If equipped

109 430

00-l 3

LUBRICANTS,

FUEL AND COOLANT

LUBRICANTS, FUEL AND COOLANT PROPER RESERVOIR

Engine with filter

FLUID TYPE

-22 -30

AMBIENT TEMPERATURE 68 86 14 32 50 -10 0 10 20 30

’ Engine oil See NOTE 2

r

122°F 50°C

Specified

4.9 gal (18.5 P)

1.0 qt (1 4 ,.,,s&$:sw::,‘y,..,, i,,i:;:,::y::,: ~.j,‘~~‘::.::.‘.::~:::.:.‘l,~j:::~,~:::::,~:::. ,::.:: ,:~,,,:::,:::,:;: ,.,\, :,,.,:‘:::j,::. .::::., .c.:.,..:. ,,T:::.::$: ..>..,., ,...., ..,\., ,. .,.......,... .::,.,.: ..:.:.:.:.:.:.:.:.::.. :: j:.:.:.:.:.::: .................:).~,.:.:,...:...:..,.:..I\ . ... ..: ;:..:::;:,:.,,. .. .. ...:.. : .::.:.::: ...... .:....>.:.:. .::.. .. .:..::... \:.. ........:.

19.0 gal .. .. :‘:;:’‘.. “:‘:‘:ii:,ii,:i,‘SAE~1OW: ;:‘:,,: “,j.‘:‘:..::~:.‘/. .:.::. j::‘.‘,‘,: :I::::‘.‘ii::.:I,.::j’i::i:;: .::.: ....::. ..,,:.. ........./..I. ....,,.. ,., :...:: 1 (72 Q) .‘.Y\::.:: ....‘.~‘.g..f .. ::., .: :, ,“:‘::;,::,j’::‘::;.. : : :..,..,. ,,,., ,,,, :,.:.,.:.

12.9 gal (49 @)

4.5 gal

4.5 gal

See NOTE 4

Fill as instructed

--

Diesel fuel

See NOTE 5

37.0 gal (140 P)

--

Coolant

See NOTE 6

5.3 gal (29 4)

--

See NOTE 3

All lubrication fiiings

Grease

Fuel tank Cooling system

American Petroleum Institute American Society of Testing and Material Society of Automotive 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.

00-l 4

Refill

>......: ,..,\.,., :.: :.,.: ..,...,...,. ,.:::‘,.S~E:il O,j,,: ;,:,;$;i:j::,:ii.:f; :::+j:. ,. ..,.:>,..,:..,::..:..:,,, ..,..,..,.,:...,.:...,.

Axle oil

API: ASTM: SAE:

CAPACITY 104 40

6.0 gal . .. ... ..::.: .., .:.,.,..,.,.,.. .:.:.: .,.,.,..: ,..,,.. .,., ,.,.,., :.,>:: ,..,.,.,.,.,.,.,. ..‘.‘...~...~.~.~..~...~...~~.. .:::,:~,SAE:,OW~:::~~,,~~:~,::,~::.l,:i..,’ ;;:X,; 1 (23 4) :; j:x ::.:j:j,::y .‘.: ,.’ :.:.,.:...: ,jji, :j,.

1: :.,:.;: :::::,,::;: ,.,. ,::: :.,.: :,:, .,. ,. : . . :. . . . . . . : . : .,.. ,..., : .,..... .>. .:.::. .:. ,.,.,.,.,.,.,., ,.., .,..,..,.,. .,,..,,.,. .,.,.,.,.,. .::’::.:::.::j,y-

Hydraulic system

Drive axles Front & rear

TABLE

Engine oil See NOTE 1

Torque converter & Transmission

Service brakes

-4 -20

SELECTION

LUBRICANTS,

FUEL AND COOLANT

Arctic Operation

NOTES:

If an engine is operated in ambient temperatures consistently below -10°F (-23°C) and there are no provisions to keep the engine warm when it is not in operation, use a synthetic CE/SF or CD/SF engine oil with adequate low temperature properties such as SAE 5W-20 or 5W-30.

1. ENGINE OIL Normal Operation Oil performance recommendations

are as follows:

The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are critical factors in maintaining engine performance and durability.

The oil supplier must be responsible for meeting the performance service specifications.

IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals can decrease engine life due to factors such as; corrosion, deposits and wear.

SAE 15W4.0 multi-viscosity oil meeting the American Petroleum Institute (API) Classification of CE/SF is recommended. CD/SF oil may be used in areas where CE/SF oil is not available.

Additional information regarding lubricating oil availability throughout the world is available in the “E.M.A. Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines.” The data book may be ordered from the Engine Manufacturers Association, One Illinois Center, 111 East Wacker Drive, Chicago, IL U.S.A. 60601. The telephone number is (312) 644-6610.

A sulfated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption control. The sulfated ash must not exceed 1.65 mass percent. The sulfated ash limit of 1.85 mass percent has been placed on all engine lubricating oils recommended for use in the engine.

Higher ash oils can cause valve and/or piston damage and lead to excessive oil consumption.

2. ENGINE OIL The API service symbol displays the following information. The upper half of the symbol displays the appropriate oil categories; the lower half may contain words to describe oil energy conserving features. The center section identifies the SAE oil viscosity grade.

Oil viscosity recommendations

Use API classification CE engine oil. If API classification CD is used, reduce the oil change interval to half.

3. AXLE OIL For axle oil, use only the recommended follows:

are as follows:

The use of a multi-graded lubricating oil has been found to improve oil consumption control and improve engine cranking in cold temperatures while maintaining lubrication at high operating temperatures.

SHELL: CALTEX: CHEVRON: TEXACO: MOBIL:

While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the previous chart for oil viscosity recommendations for extreme climates. * Limited use of low viscosity oils, such as SAE 1OW30 may be used for easier starting and providing sufficient oil flow at ambient temperatures below +23” F (-5°C). However, continuous use of low viscosity oils can decrease engine life due to wear.

Do not use special “break-in” lubricating oils for a new or rebuilt engine. Use the same type of oil during the “break-in” as specified for normal operation.

oil as

DONAX TT or TD RPMTRACTOR HYDRAULIC FLUID TRACTOR HYDRAULIC FLUID TDH OIL MOBIL AND SUPER UNIVERSAL

It is possible to substitute engine oil SAE 30W API classification CD for axle oil. If noise comes from the brake, it is no problem of durability.

4. GREASE The recommended lubricating grease is No. 2 multipurpose lithium grease with 3% molybdenum disulfide.

00-l 5

WARNING! Do not mix gasoline or alcoho! with diesel fuel. This mixture can cause an explosion.

antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel formation can occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive. DO NOT use methanol or alcohol as an antifreeze because of its low boiling point.

IMPORTANT: Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of dirt or water.

Dirt or water in the system can cause severe damage to both the injection pump and nozzles.

Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to maintain corrosion protection.

5. DIESEL FUEL

A

The use of ASTM No. 2-D diesel fuel with a minimum Cetane number of 40 is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent misfires and excessive smoke.

At operating temperatures below +32”F (OOC), acceptable performance can be obtained by using a blend of No. 2-D and No. 1-D fuels. The use of lighter fuels can reduce fuel economy.

Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel temperature. Cloud point is the temperature at which crystals begin to form in the fuel.

The viscosity of the fuel must be kept above 1.3 cSt to provide adequate fuel system lubrication.

6. COOLANT Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additives. Supplemental coolant additive recommendations are included in the Operation and Maintenance Manual. The coolant should be changed at the specified service interval shown in the Operation and Maintenance Manual.

DCA4 is recommended cooling system.

to inhibit corrosion

formulated with methoxy propanol, or glycol, is not recommended for this

NOTE:

Do not mix types of antifreeze solutions.

Mixed solutions make it impossible to determine the protection against freezing. Antifreeze containing sealer or antileak additives should NOT be used in this system. Sealer or anti-leak additives will cause plugging problems in the cooling system.

Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient protection against freezing.

Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited water must meet the following standards: Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount will cause scale deposits to develop in the engine.

Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.

in the

In climates where the temperature is above -34°F (37”C), use a coolant mixture that contains 50 percent antifreeze. Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is required. Never use more than 68 percent antifreeze under any condition.

Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali metasilicate. Low silicate

00-l 6

Antifreeze propylene system.

Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.

Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits, scale deposits, corrosion or a combination of these.

If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water supplies meet these standards, water samples can be tested by water treatment laboratories. “Softened” water that is prepared using common salt (sodium chloride) contains

MEMORANDA

MEMORANDA

00-l8

ENGINE 11

STRUCTURE

ENGINEMOUNTING

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

RADIATORANDOILCOOLER FUELTANKANDPIPING ENGINECONTROL

AND FUNCTION

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

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

2 3 4 5

11-l

STRUCTURE AND FUNCTION

ENGINE MOUNTING

ENGINE MOUNTING Power for the machine is supplied by a KDC Model 610T Diesel Engine. For further information on the engine that is not covered in this manual, refer to the pertinent engine manual.

VIEW

A-A

VIEW

B-B

L12AD041

OUTLINE .

The engine, torque converter and transmission are each joined together.

There are rubber mounts at the engine and transmission ends. l

11-2

1.

2.

Transmission mount Engine mount

STRUCTURE AND FUNCTION

RADIATOR AND OIL COOLER

RADIATOR AND OIL COOLER OUTLINE The radiator and oil cooler is cushion mounted to the rear frame of the machine. It is located between the grille and the engine.

The radiator and oil cooler consists of a core, top and bottom tanks and side channels. The radiator core is a straight tube and flat fin type. The bottom tank incorporates the oil cooler.

l

l

VIEW

VIEW

A-A

.

Oil which comes out from the torque converter outlet port is at a high temperature because of the energy used in transmitting motive force. The torque converter oil passes through oil inlet port (A) and enters the oil cooler. Here it is cooled by the engine coolant in the lower portion of the radiator. The oil then flows out from oil outlet port (B), lubricates the transmission and returns to the sump in the transmission case.

VIEW B-B

C-C VIEW Z

Q’

LO6AH031 SPECIFICATIONS Radiator core type . . . . . . . . . . . . . . . . . . . . . CD-4 Total heat dissipating area . . . . . . . . . . . . 32.36 m* Cross-sectional area of cooling tubes . . . . 38.4 cm* Minimum air pressure test without leakage 1.0 kg/cm* Filler cap opening pressures: Pressure relief _ . . . _ _ . _ _ . . . 0.7 + 0.1 kg/cm* Vacuum relief . . . . . . . . . . . . . 0 - 0.046 kg/cm*

1. Radiator 2. Filler cap 3. Fan guard 4. Torque converter oil cooler 5. Coolant recovery tank A. Oil cooler inlet port B. Oil cooler outlet port

11-3

FUEL TANK AND PIPING

STRUCTURE AND FUNCTION

FUEL TANK AND PIPING I--

I

-1

i

VIEW B-B

VIEW C-C

VIEW A-A

r ---

-

-._

L12BH014

OUTLINE The fuel tank is mounted at rear of the machine, below the radiator.

The fuel tank piping is located between the tank and the engine. The fuel supply line incorporates an in-line fuel strainer. .

The fuel level sensor is installed in the top left of the tank. l

l

1.

2.

3.

4.

5.

6.

SPECIFICATIONS Fuel tank capacity

11-4

Fuel filler cap Fuel tank Fuel drain valve Fuel supply line In-line fuel strainer Fuel return line

. . . . . . . . . . _ _ . . . . . . . . . 140 0

ENGINE CONTROL

STRUCTURE AND FUNCTION

ENGINE CONTROL

VIEW Z VIEW A-A

_/ ,’

,‘A)

__

__

---I-----

9

f--q-

Low Idle

High Idle

J

,’

Ii

/ /

----;--\ ___(L_____ /

_____------

L12BV029

OUTLINE .

The engine accelerator pedal is located on the right side floor frame in the operator’s compartment. .

A control cable connects the accelerator pedal to the operating lever on the fuel injection pump.

1.

2.

3.

4.

Accelerator pedal Accelerator control cable Pump operating lever Fuel injection pump

11-5

STRUCTURE AND FUNCTION

MEMORANDA

11-6

MEMORANDA

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