Komatsu WA420-1LC Wheel Loader Shop Manual A25001 and up - PDF DOWNLOAD

CEBMW24020

SHOP MANUAL

WA4204 LC WHEEL LOADER MACHINE

MODEL

WA420-1 LC

SERIAL NUMBERS

A25001

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.

DEC 91

REQUISITION

COMPLETE

FOR TECHNICAL SERVICE PUBLICATIONS

AND SERVICE FORMS

FORM

Komatsu America International Company 440 North Fairway Drive

AND RETURN TO -

Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186 Tel No. (847) 9704887 COMPANY NAME

SHIP TO

l

ATTN.

TYPE or PRINT ONLY

STREET ADDRESS

.

CITY, STATE, ZIP CODE COUNTRY

PHONE NO.

FAX NO.

DISTR/BRANCH CODE

SHIPPING METHOD

IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), SERIAL NUMBER MUST BE SHOWN.

QTY.

PUBLICATION FORM NUMBER

KDC91 D 081696

PARTS BooK I: ~;~;pe;

PUBLICATION DESCRlPTlON

THE MODEL NUMBER AND MACHINE

MODEL NUMBER

CURRENT PRICES WILL BE CHARGED

SERIAL NUMBER

CONTENTS No. of page

10 ENGINE 12 TESTING AND ADJUSTING ..................................................

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

12-1 13-1

20 POWER TRAIN 21 22 23 24

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

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

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

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

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

40 STEERING SYSTEM 41 42 43 44

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

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

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

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

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

50 BRAKE AND AIR SYSTEM 51 52 53 54

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

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

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

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

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

60 WORK EQUIPMENT SYSTEM 61 62 63 64

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

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

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

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

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

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

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

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

81-1 82-l 83-l

90 OTHERS 93 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-l 97 GEAR PUMP 97-l 99 METRlCCONVEdSlbNiABiE’::::::::::::::::::::::::::::::::::::::::::::::: 99-1

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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 symbol shown is 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.

SAFETY PREPARATIONS

FOR WORK

GENERAL PRECAUTIONS 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.

8.

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

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

1.

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

2.

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

-Always wear safety glasses when hitting parts with a hammer.

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

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.

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PRECAUTIONS

DURING WORK

11.

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

Before disconnecting or removing 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

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

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

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 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.

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.

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

22.

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

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.

23.

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

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.

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.

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

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

This shop manual mainly contains the necessary technical information for operations performed in a service workshop.

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

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

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parts.

or

HOW TO READ THE SHOP 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, Chassis volume and Engine volume.

Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page.

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.

DISTRIBUTION

SYMBOLS So that the shop 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.

Symbol FILING METHOD See the page number on the bottom of the page.

File the pages in correct order.

Item

A

Special safety precautions are necessary when performing the work Safety

Following examples show how to read the page number:

Y

Y

$

Example 1 (Chassis volume):

Item number (21. Structure and Function) Consecutive page for each item

-rt

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

Example: I&1

21-4 21-4-1 Added pages

21-4-2 21-5

REVISED EDITION MARK ([l]

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.

number

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

Remarks

Oil, water

Drain

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.

[2] [3] ....)

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

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HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

Hooks have maximum strength at the middle portion.

1

Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassemblyand Assembly section, every part weighing 25 kg or more is indicated clearly with the symbol 103%

88%

71%

79%

41% FSOO64

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

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

l

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

3)

A

2. Wire ropes 4) 1)

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

Wire ropes (Standard ‘7” or “S” twist ropes without galvanizing) Rope diameter (mm) 10.0 11.2 12.5 14.0 16.0 18.0 20.0 22.4 30.0 46.0 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.

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.

30’

60’

so’

17.0”

150’

Lifting angle : a FSOO65

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result.

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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

Width across flat (mm)

kgm

I

Nm

14

10 13 17 19 22

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

16 18 20 22 24

24 27 30 32 36

28.5+3 39?4 56+6 7628 94.5+10

279r29 383239 549 f 58 745 + 78

27 30 33 36 39

41 46 50 55 60

135+15 175?20 225 a 25 280230 335 + 35

1320+140 1720+190 22102240 2750 + 290 3280+348

6 8 10 12

-L 13.2k1.4 31.4k2.9 65726.8 11229.8 177219

927r98

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. t Nm (newton meter): 1Nm & 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

Nm

10 12 16

14 17 22

6.720.7 11.5+1 28.5 +3

65.726.8 11229.8 279*29

Tightening torque

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STANDARD TIGHTENING

TORQUE

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

Tightening

Thread diameter of nut part (mm)

Width across flats of nut part (mm)

kgm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

2.520.5 5?2 8?2 1423 1823 20+5 25+5 30+5

torque Nm 24.524.9

49k19.6 78.5219.6 137.3 229.4 176.5k29.4 196.1+49 245.2+49 294.2 + 49

COATING MATERIALS The recommended

Nomenclature

Adhesives

Liquid gasket

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

coating materials prescribed in the shop manuals are listed below.

Code

Applications

LT-1A

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 Used for aluminum surfaces.

LG-1

Used with gaskets and packings to increase sealing effect.

LG-3

Heat-resistant gasket for precombustion piping.

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 flings and tapered screw fittings in hydraulic circuits of less than 50 mm in diameter.

LM-P

insulating seal.

chambers and exhaust

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 shop manuals.

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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: CLASSIFICATION

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

BY THICKNESS

Applicable

CLASSIFICATION

Prioritv

Classification

1

Primary

circuit

BY COLOR AND CODE Circuits Code .

Color Code

2

Color Code

3

Color Code Auxiliary

I

Color

Starting B Black BW Black 81 White BY Black & Yellow BR

Code

Lighting R Red RW

White 81Red

Red & White

WB White & Black WL

RB Red 81Black I

RY

I

I

--

I

Color

--

Code

--

Color

--

I

I

WY White & Yellow WG White & Green

I

RG Red & Green RL Red & Blue

Instrument Y Yellow YR Yellow & Red YB Yellow & Black GY YG Yellow & Gc::$ Green I GB YL I Green 81 Yellow 81 Black Blue YW GL Green & Yellow 81 Blue White Signal G Green GW Green & White GR Green & Red

Black & Red White & Blue Red 81Yellow I

t

I

Charging W White WR

I

I

Other L Blue LW Blue & White LR Blue & Red LY Blue & Yellow LB Blue & Black

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WEIGHT TABLE

GENERAL

WEIGHT TABLE

A

This weight table is a guide for use when transporting

or handling components.

Unit: kg

Engine assembly Radiator assembly Torque converter assembly Transmission assembly Center drive shaft Front drive shaft Rear drive shaft Front axle assembly Rear axle assembly Front differential assembly Rear differential assembly Wheel hub assembly (1 piece) Planetary hub assembly (1 piece) Axle pivot (Rear axle) Wheel (1 piece) Tire (1 piece) Steering valve Steering cylinder (1 piece) Brake (1 piece) Hydraulic tank Hydraulic pump Main control valve Lii cylinder (1 piece) Dump cylinder Engine hood Front frame Rear frame Bucket link Tilt lever Lii arm (with bushing) Bucket Counterweight Fuel tank Battery (1 piece) Operator’s seat Floor plate Cab Air Conditioner Unit

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655 166 165 718 30 40 20 1,173 1,186 210 185 69 68 106 216 243 24 28 128 270 45 57 170 200 128 1,470 1,220 z3 1145 1,502 885 215 45 37 115 305 40

GENERAL

LUBRICANTS, FUEL AND COOLANT PROPER

RESERVOIR

Engine with filter

Torque converter Transmission & Service brakes

FLUID TYPE

-22 -30

SELECTION

TABLE

AMBIENT TEMPERATURE (Top line “F, Bottom line “C) -4 14 32 50 68 86 104 -20 -10 0 10 20 30 40

CAPACITY lli

Specified

Refill

Engine oil See NOTE 1

Engine oil See NOTE 2

Hydraulic system (Incl. brake sys.)

,;... ~.,.j::,.:::.,.:..‘.‘. ‘:’ s~_,~~~:;,,;,~:_~~,:_:,:..~:I’.~~ .... . ,.. :; .”“: 54 e ::?X:: ,j;,:,:;,:;, .::.. :: : ::::aAE:jew. .\

47 e

.\:..::..:::.::. .. .:.: ::..:I. ::*i,Jz()yI :,,,, :j::::,.j .::,,,, :::;:,:~:,,;~,;jj:,.:~:, 165e : ..: :: :: :. :.: .. .::,..,, ... .‘...I.;i,::,: .. .... y:,..:

103 e

Drive axles Front & rear

Axle oil

See NOTE 3

55 e each

55 e each

All lubrication fittings

Grease

See NOTE 4

Fill as instrutted

--

Fuel tank

Diesel fuel

See NOTE 5

305 e

--

Cooling system

Coolant

See NOTE 6

50 e

-_

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.

American Petroleum Institute API: ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers SAE 15W-40 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.

NOTES: 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.

A sulfated ash limit of 1.O mass percent is suggested for optimum valve and piston deposit and oil consumption control. The sulfated ash must not exceed 1.85 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.

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GENERAL 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.

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

3. AXLE OIL

Oil viscosity recommendations

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.

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 lOW30 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.

Arctic Operation 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.

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.

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.

For axle oil, use only the recommended follows: SHELL: CALTEX: CHEVRON: TEXACO: MOBIL:

oil as

DONAX TT or TD RPM TRACTOR 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.

5. DIESEL FUEL

A

WARNINGI Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.

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.

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 (O’C), 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.

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GENERAL 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 section entitled “CHANGE THE COOLANT AND FLUSH THE COOLING SYSTEM”. The coolant should be changed at the specified service interval shown in the “MAINTENANCE TABLE”.

DCA4 is recommended cooling system.

to inhibit 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 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.

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.

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 excessive amounts of chlorides and should not be used.

NOTE:

Never use water alone in the cooling system because corrosion will occur.

Maintain supplemental coolant additive levels at 1 unit DCA4 per 1 U.S. gal (3.8 liters) of coolant.

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

Use antifreeze during all seasons to protect the cooling system from corrosion as well as freezing damage.

Antifreeze propylene system.

A mixture of 50% water and 50% ethylene glycol base antifreeze is required for operation of the engine in temperature environments above -34.6“ F (-37°C). A mixture of 40% water and 60% antifreeze is recommended for temperatures below 34.6“ F (-37” C).

NOTE:

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

Do nor mix types of antifreeze solurions.

Mixed so&ions make it impossible to determine the prorecrion against freezing.

Antifreeze containing sealer or anti-leak additives should NOT be used in this system. Sealer or anti-leak additives will cause plugging problems in the cooling sysrem.

In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor (Cummins liquid DCA), or an equivalent to protect the engine cooling system.

Do not operate the engine without a thermostat.

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:

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GENERAL

This page is blank.

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ENGINE 12

TESTING

STANDARDVALUETABLE

AND ADJUSTING

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

2

TOOL LIST FOR TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

VALVE CLEARANCE

7

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

FUEL INJECTION TIMING

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

ENGINE OIL PRESSURE AND TEMPERATURE BLOW-BYPRESSURE

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

8 9

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

11

EXHAUST GAS COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

ACCELERATOR PEDAL, OPERATING FORCE AND OPERATING ANGLE

13

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

+ The following precautions are necessary when using the Standard Value Tables to make judgements during troubleshooting 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 information in the Standard Value Tables are estimates, based on standards from the production plant when the machines were shipped. Therefore, when troubleshooting they should be used as reference in combination with repair and operating records when making judgements.

3.

These standard value tables must not be used for standard values when judging claims. In addition, do not use these values alone to make simple judgements.

12-1

TESTING AND ADJUSTING

STANDARD VALUE TABLE

STANDARD VALUE TABLE .

FOR ENGINE ON TEST BENCH

T

Engine Category

Item

Condition, etc.

Engine speed

High idling speed Low idling speed

Necessary starting speed

0°C -20” C (Using starting aid) Ether used

Performance

Intake resistance Exhaust pressure Exhaust temperature

Intake and exhaust system

BUY

Lubrication system

Fuel system

Cooling system

12-2

All speed At rated output All speed (Intake air temp.: 20°C)

I

Unit

614T

Standard value

Permissible value

2420 + 50 825+50 Min 150 Min 120

mmH20 mmHg “C

Max 380 Max 76 660

Max 635

Bosch index Bosch index

Max 6.5 Max 1.0

Max 7.0 Max 2.0

mm mm

0.30 0.61 None

(Turbine inlet)

Exhaust gas color

At abrupt acceleration At high idling

Valve clearance (Engine cold)

Intake valve Exhaust valve

Compression pressure

Oil temperature 4060” C (Engine speed)

kg/cm* (rpm)

Blow-by pressure Orifice size 7.67 mm

At high idling, oil temperature min. 80°C

mmH20

(:w engine)

Oil pressure (SAE 15W-40 Oil temp.: 80°C min.)

At rated speed At low idling

kg/cm* kg/cm”

2.1-3.5 0.7-2.2

Oil temperature

All speed (Inside oil pan)

“C

80-110

Max 120

Oil consumption

At continuous rated horsepower (Proportion of fuel consumption)

%

Max 0.3

Max 0.5

ratio

Fuel injection pressure

Nozzle tester

kg/cm*

209

Fuel injection timing

Before top dead center

Degree

22

Coolant temperature

Whole speed range (At engine outlet)

“C

83-95

457 (Used engine)

Max 100

STANDARD VALUE TABLE

TESTING AND ADJUSTING

614T

Engine Category

Item

Thermostat function Cooling system (Continued) Fan belt tension (Alternator-fan pulley)

Condition, etc.

Valve cracking temperature Temperature when fully open Lii when fully open Deflection when pushing with finger force approx.

6 kg

Unit

Standard value

Permissible value

“C “C

95

mm

7.5

mm

Refer to the Operation Manual

NOTE: The values given in the Testing and Adjusting data are NOT for adjustment of the output.

Do not use these values as a guide to change the setting of the fuel injection pump.

12-3

TESTING AND ADJUSTING

l

STANDARD VALUE TABLE

FOR ENGINE ON CHASSIS Engine Category

Performance

Check item

Engine speed

Conditions High idling speed Low idling speed Sudden acceleration

Exhaust gas color Intake and exhaust system

614T

I

At high idling

Unit

Standard value

wm

2420 + 50 825 + 50

Bosch index Bosch index

Max 6.5

Max 7.0

Max 1.0

Max 2.0

mm mm

0.30 0.61

rm

Valve clearance

Intake valve (20” C) Exhaust valve (20°C)

Compression pressure

Oil temp.: 4060°C Engine speed: Idle

kg/cm*

Blow-by pressure

At high idling (Water temp. inside operating range)

mmH20

Max 89 (New engine)

Oil pressure (SAE 15W-40, oil temp.: min. 80°C)

At rated speed At low idling

kg/cm* kg/cm*

2.1-3.5 0.7-2.2

Oil temp.

Whole speed range (Inside oil pan)

“C

80-110

Fuel system

Fuel injection timing

Compression

Cooling system

Alternator drive belt tension

B&Y

Lubrication system

12-4

B.T.D.C.

Permissible value

Degree

I

Max 457 (Used engine)

Max 120

22

Refer to the Operation Manual

TOOL LIST FOR TESTING AND ADJUSTING

TESTING AND ADJUSTING

TOOL LIST FOR TESTING AND ADJUSTING No.

Testing and measuring item

1

3

Water temperature, oil temperature, intake temperature

4

Digital display 60-l 9,999 rpm 1.100 - 1.300

specific gravity

Coolant freezing I temperature

Remarks

Part number 799-203-8000

Tachometer

Engine speed

2lXttery

Tool name

Battery coolant tester

Thermistor temperature gauge

795-500-l 000

-5 - -50°C

790-500-l 300

0 - 200°C

799-1oo1r-6ooo

0 - 1,ooo”c

5

Exhaust temperature

6

Lubricating

7

Fuel pressure

8

Intake pressure, exhaust pressure

9

Blow-by pressure

0 - 1,000 mmH20

10

Intake resistance

-1,000 - 0 mmH20

11

0 - 10 kg/cm2

oil pressure

Compression

0 - 20 kg/cm2

pressure

Engine pressure measuring kit

Compression

gauge

799-203-2002

0 - 1,500 mmHg

795-502-l 204

0 - 70 kg/cm2

799-201-l 503

0 - 500 mmHe0 or use 0 - 1,000 mmH20 gauge

I 12

13 14

A

Blow-by pressure

1 Valve clearance Exhaust gas color

Blow-by checker I Feeler gauge Smoke meter

When carrying out testing, adjusting or troubleshooting, and block the tracks.

795-l 25-l 330 Commercially available

Discoloration 0 to 70% standard color (Discoloration % x l/10 + Bosch index)

799-2016000

Water content O.l%, 0.2% in standard sample

799-202-7001

PH, nitrous acid ion concentration

799-202-9001

0 - 2 kg/cm2

Commercially available

0 - 300 kg/cm2

Commercially available

Current, voltage, resistance

7AO-262-0020

Commercially 0 - 25 kg

available

stop machine on level ground, insert the safety pins

12-5

TESTING AND ADJUSTING

A A A

12-6

TOOL LIST FOR TESTING AND ADJUSTING

When working in groups, use agreed signals and do not allow unauthorized

persons near the machine.

When checking the water level in the radiator, wait for the water to cool. Do not remove the radiator cap while the water is hot. Boiling water may spurt out.

Be careful not to get caught in rotating parts.

TESTING AND ADJUSTING

VALVE CLEARANCE

VALVE CLEARANCE t +

Condition: Engine is cold.

Adjust clearance between valve and rocker lever as foliows.

Unit: mm

I

Intake valve

I

Exhaust valve

0.30

Cold

0.61

Soecial tool

I A

Part number

1 795-125-1330

Part name

I

Q’ty

1 Feeler gauge

I

1

I

1.

Remove catch, then open hood.

2.

Loosen band (1) of air cleaner assembly (2), disconnect from turbocharger (3), then remove air cleaner (2). t When removing the air cleaner, remove the intake hose first.

3.

Loosen band (4) and remove bolt (5) of exhaust muffler (6). Disconnect turbocharger (3) then remove exhaust muffler (6).

4.

Remove brackets (7 and 8) of air cleaner and exhaust muffler.

5.

Remove air connector

6.

Adjusting valve clearance + For details of the engine, see the Engine Shop Manual.

(9) from engine.

12-7

TESTING AND ADJUSTING

FUEL INJECTION

FUEL INJECTIONTIMING + +

Measurement condition Coolant temperature: Inside operating range Unit: Dearee item

Standard value

Fuel injection timing

22

Permissible value

1.

Remove catch, then open hood.

2.

Disconnect control cable rod (1).

3.

Remove the fuel filter (2) and disconnect fuel tube (4). t For details of the fuel injection pump, see the Engine Shop Manual.

4.

Disconnect fuel return hose (3). Remove injection pump (5) side.

5.

Adjusting fuel injection pump timing t For details of the engine, see the Engine Troubleshooting and Repair Manual.

12-8

ENGINE OIL PRESSURE AND TEMPERATURE

TESTING AND ADJUSTING

ENGINE OIL PRESSURE AND TEMPERATURE 1.

Measuring engine oil pressure t Measurement condition Coolant temperature: Inside operating range l

Unit: kg/cm2 Item

Standard value

Permissible value

k

Special tool Part number A

799-203-2002

Part name Engine pressure measuring kit

Q’ty 1

A

When measuring, be careful not to get caught in rotating parts.

A

install and remove the plug and oil pressure gauge with the engine stopped.

t

Measure the engine oil pressure when the oil temperature is at the specified temperature.

1) Remove switch (1).

2) Install oil pressure gauge A (25 kg/cm*). t Install the oil pressure gauge so that it is affected as little as possible by the engine vibration.

3) Start engine and measure oil pressure.

12-9

TESTING AND ADJUSTING

2.

ENGINE OIL PRESSURE AND TEMPERATURE

Measuring oil temperature * Measurement condition Coolant temperature: inside operating range l

Item Oil temperature

Standard value

Permissible value

80-110°C

120°C

Special tool Part name

Q’ty

~

1)

Remove dipstick (2).

2) Insert sensor of thermistor temperature gauge in dipstick guide.

Connect sensor to thermistor temperature gauge A and measure temperature of oil in oil pan.

12-10

BLOW-BY PRESSURE

TESTING AND ADJUSTING

BLOW-BY PRESSURE *

Measurement condition Coolant temperature: Inside operating range Engine valve clearance: Standard valve Engine speed: Rated speed

l

o l

Unit: mmHa0

I Item

Standard value New engine

used engine

89

457

Blow-by pressure Soecial tools

I A

799-201-l 503

B

3375788 Cummins part number

A 1.

2.

Part number

I

Part name

I Q’ty

Blow-by checker

1

Pipe tee

1

I

When taking measurements, be careful not to touch the exhaust manifold, muffler, or to get caught in rotating parts.

Measuring blow-by 1) When measuring the blow-by, warm the engine up thoroughly. (oil temp: min. 8O“C) 2) Stop engine and install pipe tee of blow-by checker on engine breather hose (1).

3) Connect adapter and pressure gauge A (O1,000 mmHs0) to hose.

4) Run the engine at rated output and measure the blow-by pressure.

Precautions when measuring blow-by + The blow-by may vary greatly according to the condition of the engine, so if there is any abnormality in the reading, check for any problem related to defective blow-by, such as excessive oil consumption, defective exhaust gas color, or early deterioration or contamination of the oil.

Jib

III

Manometer

UACOOOB

12-11

EXHAUST GAS COLOR

TESTING AND ADJUSTING

EXHAUST GAS COLOR t

Measurement condition Coolant temperature: Inside operating range Valve clearance: Standard value

o e

Special tool Part name

Part number A

Commercially available

A

Smoke meter

Q’ty 1

When measuring the exhaust gas color, careful not to touch the exhaust pipe.

be

1.

Insert probe @ in outlet of exhaust pipe (1) and secure to exhaust pipe with clip.

2.

Connect probe hose, connector hose @of accelerator switch and air hose to smoke meter A. -or The pressure of the air supply should be under 15 kg/cm2.

3.

Connect power cord to AClOOV socket. * Check that the power switch is OFF before connecting the cord.

4.

Loosen cap nut of suction paper.

5.

Turn power switch ON.

6.

Accelerate engine suddenly. At the same time, depress accelerator pedal of smoke meter, operate relief valve and catch exhaust gas color on filter paper.

7.

Lay filter paper used to catch exhaust gas color on top of unused filter papers (10 sheets or more) inside filter paper holder, and read indicated value.

12-12

pump and insert filter

ACCELERATOR

TESTING AND ADJUSTING

PEDAL

ACCELERATOR PEDAL, OPERATING FORCE AND OPERATING ANGLE * e

Measurement condition Coolant temperature: Inside operating range Unit: ka Item Operating force of accelerator pedal

I

Standard value

Permissible value

4-8.5

Max. 10.5

Special tool Part number A

7AO-262-0020

Part name Push-pull scale

cxty 1

OPERATING FORCE 1. Measuring 1) Set push-pull gauge @ at a point 150 mm from the fulcrum of the pedal. t The center of push-pull gauge @ must contact at a point 150 mm from the fulcrum of the pedal.

2) Start the engine, depress the pedal, and measure the maximum reading from the point where the pedal is first depressed (low idling) to the end of the pedal travel (high idling).

2.

Inspection 1) Stop the engine.

2) Disconnect cable (1) at the bottom of the accelerator pedal, and check that linkage of the accelerator pedal itself moves smoothly.

3) Connect cable (1) at the bottom of the pedal, disconnect it again at the connection of the injection pump, and check that the cable moves smoothly. + Carry out the above inspection, and adjust or replace the parts if necessary, then measure the operating force again to check that it is within the standard value.

4) Check that radius of the curve in the cable is at least 260 mm.

12-13

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