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KOMATSU WA350-1 WHEEL LOADER Service Repair Manual SN:10001 and up







This is the Highly Detailed factory service repair manual for theKOMATSU WA350-1 WHEEL LOADER, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.KOMATSU WA350-1 WHEEL LOADER Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

Service Repair Manual Covers:
Engine
Power train
Steering system
Brake and air system
Work equipment system
Electric and electronic system
Others
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader

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KOMATSU WA350-1 WHEEL LOADER Service Repair Manual SN:10001 and up

  1. 1. SEBM04230107 KOMATSU WA3504 MACHINE MODEL SERIAL No. WA350- 1 10001 and up l This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. l WA350-1 mount the S6Dll O-l engine. For details of the engine, see the 110 Series Engine Shop Manual. 05-90(03)03561 oo-1 a
  2. 2. CONTENTS 10 ENGINE No. of page 11 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 l-l 12 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 13 DISASSEMBLY AND ASSEMBLY.. . . . . . . . . . . . . . . . . . . 13-1 20 POWER TRAIN 21 STRUCTURE AND FUNCTION ............................................... 21-1 22 TESTING AND ADJUSTING ................................................. 22-l 23 DISASSEMBLY AND ASSEMBLY ............................................. 23-l 24 MAINTENANCE STANDARD ................................................. 24-l 40 STEERING SYSTEM 41 STRUCTURE AND FUNCTION ............................................... 41-1 42 TESTING AND ADJUSTING ................................................. 42-l 43 DISASSEMBLY AND ASSEMBLY ............................................. 43-l 44 MAINTENANCE STANDARD ................................................. 44-l 50 BRAKE AND AIR SYSTEM 51 STRUCTURE AND FUNCTION ............................................... 51-1 52 TESTING AND ADJUSTING ................................................. 52-l 53 DISASSEMBLY AND ASSEMBLY ............................................. 53-l 54 MAINTENANCE STANDARD ................................................. 54-l 60 WORK EQUIPMENT SYSTEM 61 STRUCTURE AND FUNCTION ............................................... 61-1 62 TESTING AND ADJUSTING ................................................. 62-l 63 DISASSEMBLY AND ASSEMBLY ............................................. 63-l 64 MAINTENANCE STANDARD ................................................. 64-l 80 ELECTRIC AND ELECTRONIC SYSTEM 81 STRUCTURE AND FUNCTION ............................................... 81-1 82 TESTING AND ADJUSTING ................................................. 82-l 83 DISASSEMBLY AND ASSEMBLY ............................................. 83-l 90 OTHERS 91 STRUCTURE AND FUNCTION ............................................... 91-1 93 DISASSEMBLY AND ASSEMBLY ............................................. 93-l 97 GEAR PUMP ................................................................ 97-l 00-2 0 WA350-1
  3. 3. The affected pages are indicated by the use of the following marks. It is requested that necessary actions Mark Indication must be taken to these pages according to the list below. Action required 0 Page to be newly added Add 0 Page to be replaced Replace ( 1 Page to be deleted Discard Pages having no marks are not revised at this time. LIST OF REVISED PAGES Mark Page Revision number oo- 1 @ oo- 2 0 00- 2-l @ oo- 2-2 @ 00- 2-3 @ 00- 2-4 @ oo- 3 oo- 4 00. 5 00- 6 oo- 7 00- 8 oo- 9 oo- 10 00-11 0 00-12 @ II- 1 II- 2 11- 3 II- 4 II- 5 12- 1 12-2 0 12-3 @ 12-4 @ 12-5 @ 12-6 @ 12-7 @ 12-8 @ 12-9 0 12-10 0 12-11 0 12-12 0 12-13 @ 12-14 @ 13- 1 0 13-2 @ 13-3 0 13-4 0 13-5 0 lark Page Revision number l3- 6 @ 13-8 @ 13-g @ 13-10 @ 13-11 @ 13-12 @ 13-13 @ 13-14 @ 13-15 @ 13-16 @ 13-17 0 13-18 @ 13-19 @ 13-20 @ 13-21 @ 13-22 @ 13-23 @ 13-24 @ 13-25 @ 13-26 @ 13-27 @ 13-28 @ 13-29 0 13-30 0 13-31 0 13-32 @ 13-33 0 13-34 @ 13-35 0 13-36 @ 13-37 0 13-38 @I 13-39 0 13-40 0 13-41 0 13-42 @ 13-43 0 13-44 0 13-45 0 13-46 @ dark Page Revision number 13-47 21- 1 21- 2 2l- 3 21- 4 21- 5 21- 6 21- 7 21- 8 21- 9 21-10 21-11 21-!2 21-13 21-14 21-15 21-16 21-17 21-18 21-19 21-20 21-21 21-22 21-23 21-24 21-25 21-26 21-27 21-28 21-29 21-30 21-31 21-32 21-33 21-34 21-35 21-36 21-37 21-38 Aark Page Revision dark Page Revision number number 21-40 @ 21-41 @ 21-42 @ 21-43 @ 21-44 21-45 @ 21-46 @ 21-47 @ 21-48 21-49 22- 1 @ 22- 2 @ 22- 3 0 22- 4 @ 22- 5 @ 22- 6 @ 22- 7 @ 22- 8 @ 22- 8-l @ 22- 8-2 @ 22- 9 @ 22-11 @ 22-12 0 22-13 @ 22-14 @ 22-15 @ 22-16 @ 22-17 @ 22-18 8 22-19 @ 22-20 @ 22-21 @ 22-22 0 23-l @ 23- 2 @ 23- 3 @ 23- 4 @ 23- 5 @ 23- 6 @ 23- 7 @ 23- 8 @ 23- 9 @ 23-10 @ 23-11 @ 23-12 @ 23-13 @ 23-14 @ 23-15 @ 23-16 @ 23-17 @ 23-18 @ 23-19 0 23-20 @ 23-21 @ 23-22 @ 23-23 0 23-24 @ 23-25 @I 23-26 @ 23-27 @ 23-28 @ 23-29 0 23-30 @ 23-31 @ 23-32 @ 23-33 @ 23-34 @ 23-35 @ 23-36 @ 23-37 @ 23-38 @ 23-39 0 23-40 @ 23-41 @ 23-42 @ 23-43 @ 23-44 @ 23-46 @ 23-47 @ 23-48 @ WA350-1 00-2 -1 0
  4. 4. Mark Page Revision number /lark Page Revision number Aark Page Revision Page Revision number Aark number 23- 49 @ 23-105 @ 41-21 23- 50 @ 23-106 @I 41-22 23- 51 @ 23-107 @I 41-23 23- 52 @ 23-108 @ 41-24 23- 53 @ 23-109 0 41-25 23- 54 @ 23-110 @ 42- 1 23- 55 @ 23-111 @ 42- 2 23- 56 @ 23-112 @ 42- 3 23- 57 @ 23-113 @ 42- 4 23- 58 @ 23-114 @ 42- 5 23- 59 @ 23-Cl5 @ 0 42- 6 23- 60 @ 23-116 @ 0 42- 7 23- 61 @-- 23-117 @ 42- 8 23- 62 @ 23-118 @ 42- 9 23- 63 @ 23-119 0 42-10 23- 64 @ 24- 1 42-11 23- 65 @ 24- 2 @ 42-12 23- 66 -0 24- 3 43- I 23- 67 @ 24- 4 43- 2 23- 68 @ 24- 5 43- 3 23- 69 @ 24- 6 43- 4 23- 70 @ 24- 7 @ 43- 5 23- 72 @ 24- 8 43- 6 23- 73 @ 24- 9 @ 43- 7 23- 74 @ 24- IO 43- 8 23- 75 @ 24- 11 @ 43- 9 23- 76 @ 24- 12 @ 43-10 23- 77 @ 24- 14 43-11 23- 78 @ 24- 15 43-12 23- 79 @ 24- 16 @ 43-13 23- 80 @ 24- 17 @ 43-14 23- 81 @ 24- 18 @ 43-15 23- 82 @ 24- 19 43-16 23- 83 @I 24- 20 @ 43-17 23- 84 @ 24- 21 @I 43-18 23- 85 @ 41-1 0 43-19 23- 86 @ 41-2 @ 43-20 23- 87 @ 41- 3 0 43-22 23- 88 @ 41- 4 0 43-23 23- 89 @ 41-5 8 43-24 23- 90 @ 41- 6 @ 43-25 23- 91 @ 41- 7 0 43-26 23- 92 @ 41- 8 @ 43-27 23- 93 @I 41- 9 0 43-28 23- 94 @ 41- 10 43-29 23- 95 @ 41- II 0 43-30 23- 96 @ 41- 12 0 43-31 23- 97 @ 41- 13 0 43-32 23- 98 @ 41- 14 0 43-33 23- 99 @ 41- 15 43-34 23-100 @ 41- 16 43-35 23-101 @ 41- 17 0 43-36 23-102 @ 41- 18 @ 43-37 23-103 @ 41- 19 0 43-38 23-104 @ 41- 20 @ 44- I 00-2 -2 0 44- 2 44- 3 44- 4 44- 6 44- 7 44- 8 44- 9 44-10 44-11 44-12 44-13 44-14 44-15 51- I 51- 2 51- 3 51- 5 51- 6 51- 7 51- 8 51- 9 51-10 51-11 51-12 51-13 51-14 51-15 51-16 51-17 51-19 51-20 51-21 51-22 51-23 51-24 51-25 52- I 52- 2 52- 3 52- 4 52- 5 52- 6 52- 7 52- 8 52- 9 52-10 52-11 52-12 52-13 52-14 52-15 52-16 52-17 52-18 52-19 lark Page Revision number 52-20 53- I 53- 2 53- 3 53- 4 53- 5 53- 6 53- 7 53- 8 53- 9 53-10 53-11 53-12 53-13 53-14 53-15 53-16 53-17 53-18 53-19 53-20 53-21 53-22 53-23 53-24 53-25 53-26 53-27 53-28 53-29 53-30 53-31 53-32 53-33 53-34 53-35 53-36 53-37 53-38 53-39 53-40 53-41 53-42 53-43 53-44 53-45 53-46 53-47 53-48 54- 1 54- 2 54- 3 54- 4 54- 5 54- 6 @ WA350-1
  5. 5. Mark Page Revision number 54- 7 @ 54- 8 54- 9 0 61- I @ 61- 2 61- 3 61- 4 @ 61- 5 @ 0 6l- 5-l 0 6l- 5-2 @ 6l- 6 @ 6l- 7 -.6l- 8 6l- 9 61-10 61-11 61-12 @ 61-14 @ 61-15 61-15-I @ 61-15-2 @ 61-16 61-17 61-18 @ 61-19 61-20 61-21 @ 61-22 61-23 61-24 61-25 61-26 @ 62- 1 @ 62- 2 @ 62- 3 @ 62- 4 @ 62- 5 @ 62- 6 @ 62- 7 @ 62- 8 @ 62- 9 @ 62-10 @ 62-11 @ 62-13 @ 62-14 @ 62-15 @ 62-16 @I 62-17 @ 62-18 @ 62-19 @ 62-20 @ 63- I @ 63- 2 @ 63- 3 @ 63- 4 @ WA350-1 /lark Page Revision Jlark Page Revision number number 63- 5 63- 6 63- 7 63- 8 63- 9 63-10 63-11 63-12 63-13 63-14 63-15 63-16 63-17 63-18 63-19 63-20 63-21 63-22 63-23 63-24 63-25 63-26 63-27 63-28 63-29 63-30 63-31 63-32 63-33 63-34 63-35 63-36 63-37 63-38 64- 1 l 64- 2 64- 3 64- 3-l 64- 3-2 64- 4 64- 5 64- 6 64- 7 64- 8 64- 9 64-10 8l- I 8l- 2 8l- 3 8l- 5 8l- 5-2 8l- 6 8l- 7 8l- 8 81- 9 81-10 81-11 81-12 81-13 81-14 81-15 81-16 81-17 81-18 81-19 81-20 81-21 81-22 81-23 81-24 81-25 81-26 81-27 81-28 81-29 81-30 81-31 81-32 81-33 81-34 81-35 81-36 81-37 81-38 81-39 81-40 81-41 82- I 82- 2 82- 5 82- 6 82- 8 82- 9 82-10 82-11 82-12 82-13 82-14 82-15 82-16 82-17 82-18 82-19 82-20 82-21 82-22 82-23 82-24 82-25 82-26 lark Page Revision lark Page Rewsion number number 82-27 82-28 82-29 82-32 82-33 82-34 82-35 82-36 82-37 82-38 82-39 82-40 82-41 82-42 82-43 82-44 82-45 82-46 82-47 82-48 82-49 82-50 82-51 82-52 82-54 82-55 82-56 82-57 82-59 82-60 82-61 82-62 82-63 82-64 82-65 82-66 82-67 82-68 82-69 82-70 82-71 82-72 82-73 82-74 82-75 82-76 82-77 82-78 82-79 82-80 82-81 82-82 82-83 82-84 82-85 82- 86 @ 82- 87 @I 82- 88 @I 82- 89 0 82- 90 @ 82- 91 Cj) 82- 92 0 82- 93 @ 82- 94 @ 82- 95 @ 82- 96 @ 82- 97 @ 82- 98 0 82- 99 @ 82-100 @ 82-102 @ 82-103 @ 82-104 @ 82-105 @ 82-106 @ 82-107 @ 82-108 @ 82-109 @ 82-110 @ 82-111 @ 82-112 @ 82-113 @ 82-114 @ 82-115 @ 83- I @ 83- 2 @ 9l- I @ 91- 2 9l- 3 @ 9l- 4 @ 9l- 5 91- 6 9l- 7 93- I @ 93- 2 @ 93- 3 @ 93- 4 @ 93- 5 @ 93- 6 @ 93- 7 @ 93- 8 @ 93- 9 0 93- IO @ 97- 1 @ 97-001 @ 97-002 @ 97-003 @ 97-004 @ 97-005 @ 97-006 @ 00-2 -3 a
  6. 6. Mark Page Revisior number 97407 97-008 97-101 97-102 97-103 97-104 97-105 97-106 97-107 97-108 97-109 97-110 97-111 97-112 97-113 97-114 97-115 97-116 97-117 Aark Page Revision dark Page Revision number number Aark Page Revfsion Mark Page Revision number number 00-2 -4 a WA350-1
  7. 7. A IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols A *&and 4 are used to mark safety pre- cautions 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 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 op- erating 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 and learn the 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. PREPARATIONS FOR WORK 7. Before adding oil or making any 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, sup- port 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. 00-3
  8. 8. 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 compo- nents 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 car- rying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-1 terminal first. 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 hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal 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 mini- mum of gasoline when washing electrical parts. 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. l When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful 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 in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track. 00-4
  9. 9. 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 or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5
  10. 10. HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carry- ing out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume Attachments 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 neces- sary that chassis, engine, electrical and attach- ment volumes are ready. DISTRIBUTION 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. FILING 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): IO-3 % Item number (IO. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12-410 F 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 in- dicated by a hyphen (-1 and number after the page number. File as in the example. Example: 1o-4 12-203 REVISED EDITION MARK (@)a@ -.--) When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol Item A *& * * Safety Caution Weight Tighten- ig torque Coat Xl, water Drain ? Remarks Special safety precautions are necessary when performing the work. 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. Weight of parts or systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water must be drained, and quantity to be drained. 1o-5 12-204 00-6
  11. 11. HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly 1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: . Check for removal of all bolts fastening the part to the relative parts. . Check for existence of another part causing interference with the part to be rem-oved. 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 ropes without galvanizing) Rope diameter (mm) Allowable load (tons) 10 1.o 11.2 1.4 12.5 1.6 14 2.2 16 2.8 ia 3.6 20 4.4 22.4 5.6 30 10.0 40 Ia.0 50 28.0 60 40.0 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. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion. 100% 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. A 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”. 30” 60” go* 120’ 150” Lifting angle : 01 FSO065 00-7
  12. 12. STANDARD TIGHTENING TORQUE m STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of “Disassembly and Assembly”. Thread diameter of bolt (mm) 6 .. 8 10 12 14 - 16 18 20 22 24 27 30 33 36 39 Width across flat (mm) I km I Nm 10 1.35kO.15 13.2* 1.4 13 3.2kO.3 31.4k2.9 17 6.7 f 0.7 65.7k6.8 19 11.5*1.0 112t9.8 22 18.0t2.0 177*19 24 28.5*3 279&29 27 3924 383?39 30 56*6 549*58 32 76+8 745278 36 94.5* 10 927*98 41 135+15 1320+ 140 46 175220 1720-r 190 50 225&25 221 Ok240 55 28Ok30 27502290 60 335t35 3280&340 This torque table does not apply to the bolts with which nylon ferrous metal washers are to be used, or which require tightening torque. Sr Nm (newton meter): 1Nm + 0.1 kgm packings or other non- to otherwise specified 2.TlGHTENlNG TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread: gtl,eter (mm) 10 12 16 Width across flats (mm) 14 17 22 Tightening torque kgm Nm 6.7kO.7 65.7 k6.8 II.521 112t9.8 28.5t3 279t29 00-8
  13. 13. STANDARD TIGHTENING TORQUE Sealing surface 3.TlGHTENlNG TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared. Thread diameter Width across flats of nut part of nut part (mm) (mm) r km 14 19 2.5kO.5 18. 24 522 22 27 822 24 32 1423 30 36 1823 33 41 20*5 36 46 2525 42 55 30&5 Tightening torque COATING MATERIALS Nm 24.5 k4.9 49* 19.6 78.5 f 19.6 137.3k29.4 176.5229.4 196.1 &49 245.2+49 294.2*49 The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenclature Adhesives Komatsu code LT-1 A LT-18 LT-2” LT-3 Applications Used to apply rubber pads, rubber gaskets, and cork plugs. Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong seal is needed. Preventing bolts, nuts and plugs from loosening and leaking oil. Provides an airtight, electrically insulating seal. Used for aluminum surfaces. Gasket sealant Antif riction com- pound (Lubricant including molybde- num disulfide) Grease (Lithium grease) Vaseline LG-1 LG-3 LG-4 LG-5 LM-P G2-LI - Used with gaskets and packings to increase sealing effect. Heat-resistant gasket for precombustion chambers and exhaust piping. Used by itself on mounting surfaces on the final drive and trans- mission cases. (Thickness after 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. Applied to bearings and taper shafts to facilitate press-fitting and to prevent sticking, burning or rusting. Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and facilitation of assembling work. Used for protecting battery electrode terminals from corrosion. lLT-2 is also called LOCTITE in the shop manuals. 00-9
  14. 14. 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: 5WB indicates a cable having a nominal number 5 and white coating with black stripe. CLASSIFICATION BY THICKNESS Nominal number Number str_ands Copper wire _ Cable O.D. (mm) Applicable circuit Dia. TF;ands Cross section (mm2) 0.85 1 11 1 0.32 1 0.88 1 2.4 1 12 1 Starting, lighting, signal etc. 2 1 26 1 0.32 / 2.09 I 3.1 I 20 1 Lighting, signal etc. 5 65 0.32 5.23 4.6 37 Charging and signal 84 0.45 13.36 7.0 59 Starting (Glow plug) 85 0.80 42.73 1 1.4 135 Starting 15 40 60 100 127 217 0.80 0.80 63.84 109.1 13.6 17.6 178 230 Starting Starting CLASSIFICATION BY COLOR AND CODE Circuits Class+ fication ChTng / GrTd Signal Other ity 1 G I L White Black 2 Code Color Code WR - White & Red - WB &xi_ “‘Or liary t White & Black Code WL - Color White&Blue - 3 4 5 Code t-Color / Code 6 (GLI 1 - Color (Green & Blue) 1 - 00-l0
  15. 15. GENERAL WEIGHT TABLE WEIGHT TABLE A This weight table is a guide for use when transporting or handling components. Engine assembly 700 700 Radiator assembly 105 105 Torque converter assembly 160 160 (Unit: kg) ‘3Yl7 11118 and up Lift cylinder (I piece) Dump cylinder 185 185 Engine hood 134 134 Rear drive shaft 12 I 12 Front frame 1,250 I 1,308 Front axle assembly ) 1,129 1 1,129 Rear frame I 1,040 1,021 Rear axle assembly 1,109 1,109 Bucket link 52 52 Front differential assembly 191 191 Tilt lever 248 248 Rear differential assembly 176 176 P~;t&rr~carrier assembly I 68 1 68 I ! Planetary hub assembly (I piece) I 73 ( 73 Axle pivot Front/Rear 1 61183 ( 61183 Wheel (1 piece) 1 100 1 100 Tire (I piece) 210 210 Steering valve 32 32 Steering cylinder (1 piece) 27 27 Brake (1 piece) 111 111 ) Fuel tank 204 204 Battery (1 piece) 44 44 Operator’s seat 37 37 Floor plate 75 75 CAB 310 310 WA350-1 l : with teeth. l * :with bolt on cutting edge. 00-l 1 0
  16. 16. GENERAL TABLE OF OIL AND COOLANT QUANTITIES TABLE 0 RESERVOIR Engine oil pan Brake Transmission case Hydraulic system Axle (Front and rear) Fuel tank Cooling system : OIL AND COOLANT QUANTITIES See NOTE (4) each 45 each 45 oiese, fue, LASTPAD975 No. 1 Water Add antifreeze 52 - NOTE: (1) When fuel sulphur content is less than 0.5%. change oil in the oil pan every periodic mainte- nance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%. Above 1.0% I l/4 of regular interval (2) (3) (4) When starting the engine in an atmospherric tem- perature of lower then 0°C. be sure to use engine oil of SAEIOW, SAEIOW-30 and SAEI 5W-40, even though an atmospheric temperature goes up to 10°C more or less in the day time. Use API classification CD as engine oil and if API classification CC, reduce the engine oil change in- terval to half. For axle oil, use only recommended oil as follows. SHELL: DONAX TT or TD CALTEX: RPM TRACTOR HYDRAULIC FLUID CHEVRON: TRACTOR HYDRAULIC FLUID TEXACO: TDH OIL MOBIL: MOBILAND SUPER UNIVERSAL * It is possible to substitute engine oil CLASS-CD SAEBO for axle oil. ASTM: American Society of Testing and Material SAE: 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. 00-12 0 WA350- 1
  17. 17. ENGINE 11STRUCTURE AND FUNCTION Engine mount .............................. 11-2 Radiator .................................. 11-3 Fueltankandpiping ........................ 11-4 Engine control ............................. 1 1-5 WA350-1 11-1
  18. 18. STRUCTURE AND FUNCTION ENGINE MOUNT ENGINE MOUNT 423FOO5 . The engine, torque converter, transmission, and transfer are each joined together. . There are rubber mounts at the engine end and transfer end. 1. Transmission mount 2. Engine mount View 2 11-2 WA350-1
  19. 19. STRUCTURE AND FUNCTION RADIATOR RADIATOR Section X-X I. Radiator 2. Coolant level sensor 3. Fan guard 4. Hydraulic oil cooler 5. Torque converter oil cooler A. Coolant inlet port 6. Coolant outlet port 423FOO6 Specifications Core type: G6 type Total heat dissipating area: 52.57 m2 Cross-sectional area of water tubes: 138 cm2 WA350- 1 11-3
  20. 20. STRUCTURE AND FUNCTION FUEL TANK AND PIPING FUEL TANK AND PIPING The fuel level sensor is installed 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
  21. 21. STRUCTURE AND FUNCTION ENGINE CONTROL ENGINE CONTROL F4230002 WA350-1 1. Accelerator pedal 2. Injection pump 11-5
  22. 22. ENGINE 12 TESTING AND ADJUSTING Standard value table . . . . . _. . . 12- 2 Tool list for testing and adjusting . 12- 3 Adjusting valve clearance . . . . . 12- 4 Measuring compression pressure . . . . 12- 5 Testing and adjusting fuel injection timing . . 12- 6 Measuring engine oil pressure and temperature . . 12- 8 Measuring blow-by pressure . . . . . 12- 9 Testing and adjusting fan belt tension . 12-l 0 Measuring exhaust gas color . . . . . . . . 12-l 1 Measuring accelerator pedal operating force and operating angle . . . . . . 12-l 2 Adjusting fuel cut solenoid . . . . . . . . 12-l 4 * 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 standard values in these tables for judgement when troubleshooting are estimated values based on the standard values for the machine when shipped from the plant, and on the results of various tests. Therefore, they should be used as reference in combination with repair and operating records when making judgements. 3. These standard value tables must not be used for standard values when judging claims. In addition, do not use these values alone to make simple judgements. WA350-1 %’
  23. 23. TESTING AND ADJUSTING STANDARD VALUE TABLE STANDARD VALUE TABLE rEngine Komatsu S6Dll O-l Cate gory Item Condition Unit Standard Permissible value value 2,350 - 2,450 2,430 - 2,530: 650-750 (680-780) Min. 150 Min. 100 Max. 300 Max. 50 Max. 650 Max. 5.0 (Max. 6.5) Max. 1 .O (Max. 2.5) 0.25 0.45 Min. 30 [300 - 3501 Max. 150 3.5-5.5 Min. 1.5 80-I 10 - - - Min. 150 Min. 100 Max. 635 Max. 75 Max. 650 6.5 (8.5) 2.0 (3.5) 0.25 0.45 13002-43501 300 2.5 1 .o 120 Max. 0.5 250 16 70-90 74.5 - 78.5 90 9.5-10.5 7.5 4-7 CYI45 cY,33 42 15-25 15-25 136-146 1 .o 200 16+1 100 74.5 - 78.5 90 9.5 - 10.5 5-10 Max. 10.5 - High idling speed rpm Low idling speed rpm Engine speed Necessary starting 0°C vm speed . - 20°C (using starting aid) rpm Intake resistance All speed mmH,O Exhaust pressure All speed mmHg Exhaust temperature All speed (intake air temp. 20°C) “C At abrupt acceleration Bosch index At high idling Bosch index Exhaust gas color Valve clearance Intake valve mm (When engine is cold) Exhaust valve mm u” mo Oil temperature 40 - 60°C kg/cm2 [engine speed1 [rpml Compression pressure Blow-by pressure At high idling, oil temoerature min. 60°C mmH,O Oil pressure (SAE30 oil temperature: min. 8d’C) At high idling kg/cm2 At low idlino ko/cm2 Oil temperature Whole speed range (inside oil pan) I “C Oil consumption ration At continuous rated horsepowe (oroportion to fuel consumption) 1 % Fuel injection pressure Nozzle tester kg/cm2 Fuel injection timing Before top dead center degree Coolant temperature Whole speed range (at engine outlet) I OC Valve cracking temperature “C Temperature when fully open “C Lift when fully open mm Thermostat function Fan belt tension (Alternator-Fan pulley) Operating force Deflection when pushing with finger force approx. 6 kg mm kg degree mm mm mm mm Operating angle cy Operating travel L Stopper height L, Stopper height Lz Rod length X 12-2 0 ( 1: Serial No. 1 1 1 18 and up WA350-1
  24. 24. TESTING AND ADJUSTING TOOL LIST FOR TESTING AND ADJUSTING TOOL LIST FOR TESTING AND ADJUSTING Tool Part No.No. I Testing and measuring item Remarks Digital display 60-I 9,999 rpm 1.100 - 1.300 -5 - -50°C 0 - 200°C 0 - 1,ooo”c 0 - 10 kg/cm2 0 - 20 kg/cm2 0 - 1,500 mmHg 0 - 1,000 mmH,O - 1,000 - 0 mmH,O 0 - 70 kg/cm2 0 - 500 mmH,O 0.25,0.45 mm Discoloration 0 to 70% standard color (Discoloration %x l/l O=Bosch index) Water content 0.1%. 0.2% in standard sample PH. nitrous acid ion concentration 0 - 2 kg/cm2 0 - 300 kg/cm2 Current, voltage, resistance Commercially available 0 - 25 kg 7~1 Engine speed 799-203-8000Tachometer 2 Battery specific gravity 3 Coolant freezing temperature 4 Water temperature, oil temper- ature, intake temperature 795-500-1000Battery coolant tester 790-500-I 300 or 799-l 01-6000 Thermistor temperature gauge 5 Exhaust temperature Lubricating oil pressure6 7 Fuel pressure Engine presssure measuring kit Intake pressure, exhaust pressure Blow-by pressure 799-203-20028 - 9 ~ I_ 10 Intake resistance 795-502-I 20411 Compression gaugeCompression pressure Blow-by pressure Blow-by checker12 - 13 799-201-I 503 795-l 25-l 330 Commercially available Feeler gauge Smoke meter Engine oil checker Water quality tester Valve clearance 14 Exhaust gas color 15 Fuel on water mixed in oil 16 Coolant quality 17 Leakage from cooling system 18 Fuel injection pressure Nozzle injection condition 799-201-6000 799-202-7001 799-202-9001Cap tester Nozzle tester Tester Commercially available Commercially available 7AO-262-0020 19 Electrical circuit Accelerator pedal force Push-pull scale20 m A A A When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, insert the safety pins and block the tracks. 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. WA350 1 12-3 al
  25. 25. TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE ADJUSTING VALVE CLEARANCE * Condition: Engine is cold. * Adjust clearance between valve and rocker lever as follows. Unit: mm Intake valve I Exhaust valve Cold 0.25 0.45 Special tool -- Part number Part name Q’ty A 1 795-125-1330 1 Feelergauge I 1 1. 2. 3. Remove air cleaner assembly and intake connector, then remove cylinder head cover (I ). Rotate the crankshaft in the normal direction to align pointer (2) with the 1.6 TOP mark on crank- shaft pulley. When rotating, check the movement of the valves. When the pointer is in line with the 1.6 TOP mark, No.1 cylinder should be at com- pression top dead center. When No. 1 cylinder is at compression top dead center, adjust the valve marked l . When No.6 cylinder is at compression top dead center, adjust the valves marked 0. 4. To adjust, insert tool A between rocker lever (3) and valve stem (4) and turn adjustment screw (5) until clearance is a sliding fit. Then tighten lock nut (6) to hold adjustment screw in position. m Lock nut: 3.2 * 0.3 kgm 5. Next, rotate crankshaft one turn in the normal di- rection and adjust the valve clearance of the re- maining valves marked o. t After adjusting No.1 cylinder at compression top dead center, it is also possible to turn the crankshaft 120” each time and adjust the valve clearance of each cylinder according to the firing order. l Firing order: l-5-3-6-2-4 Zr After tightening the lock nut, check the clear- ance again. r I 423F301 12-4 a WA350-1
  26. 26. TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE MEASURING COMPRESSION PRESSURE * Measurement condition l Coolant temperature: Inside operating range. l Engine valve clearance: Standard value. l Engine speed: 360 to 380 rpm Unit: kg/cm2 Item Standard value Permissible value Compression pressure Min. 28 Min. 19.5 Special tools 1 Part number 1 Part name IQ’ty Al--- 1795 502-I 204 Compression gauge I ’ B 799-203-8000 Tachometer 1 * If performance tests or troubleshooting that the piston, piston ring or cylinder liner worn, measure the compression pressure. shows may be mWhen measuring the compression pressure, be careful not to touch the exhaust manifold or muffler, or to get caught in rotating parts. 1. Adjust valve clearance. t For details, see ADJUSTING VALVE CLEAR- ANCE. 2. Warm up engine (oil temperature 40°C) 3. Remove nozzle holder assembly. 4. Install adapter A in mount of nozzle holder assembly, and connect pressure gauge. 5. Set engine tachometer B in position. 6. Disconnect fuel CUT-OFF solenoid valve connector. Crank engine with starting motor and measure compression pressure. Zr Measure the compression pressure at the point where the pressure gauge indicator remains steady. * When measuring the compression pressure, measure the engine speed to confirm that it is within the specified range. * Installing the nozzle holder assembly after measur- ing the compression pressure. WA350-1 12-5 @
  27. 27. TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING TESTING AND ADJUSTING FUEL INJECTION TIMING * Measurement condition l Coolant temperature: Inside operating range. Unit: degree Item Standard Permissible value value m-~ B.T.D.C. 16 ( 16+ 1 TESTING FUEL INJECTION TIMING 1. Disconnect fuel injection pipe (1) of No. 1 cylinder. 2. Remove delivery valve holder (2). then remove delivery valve (3) and spring (4). and install delivery 3. 4. 5. * valve holder (2) again. Place fuel control lever at FULL position. Operate priming pump and rotate crankshaft slowly in normal direction. Check point where fuel stops flowing from delivery valve holder (2). Check that 16” I.J. line on crankshaft pulley (5) and pointer 16) are aligned at point where fuel stops flowing. * BEYOND injection timing line: Timing RETARDED Sr BEFORE injection timing line: Timing ADVANCED If the test shows that the fuel injection timing is incorrect, adjust as follows. /j&v 423F302 12-6 0 WA350-1
  28. 28. TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING ADJUSTING FUEL INJECTION TIMING BY DELIVERY CHECK 1. Turn crankshaft back 30 - 40” from top dead center. 2. Rotate cankshaft to align 16” I.J. line on crank- shaft pulley and pointer correctly. 3. Loosen nut (7) on the injection pump mounting flange bolt, and rotate the flange on the pump side little by little by operating the priming pump (9) until no fuel flows out of the delivery valve holder. 4. Tighten nut (7) in oblong hole of mountijng flange of fuel injection pump. + After-tightening the bolt, check again that the fuel stops flowing from the delivery valve holder at the point where the pointer is aligned with the line on the crankshaft pulley. 5. Remove delivery valve holder (2). assemble deliv- ery valve (3) and spring (41, then install delivery valve holder (2) again. w Delivery holder: 3.3 -C 0.2 kgm 6. Connect fuel injection pipe (I). m Sleeve nut: 2.4 + 0.1 kgm WA350-1 12-7 0
  29. 29. TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE AND TEMPERATURE MEASURING ENGINE OIL PRESSURE AND TEMPERATURE 1. Measuring engine oil pressure. t Measurement condition l Coolant temperature: Inside operating range. Unit: kg/cm* ~~ Special tool Part number Part name Q’ty A 799-203-2002 Engine pressure measuring kit 1 A When measuring, be careful not to get caught A in rotating parts. Install and remove the plug and oil pressure gauge with the engine stopped. t Measure the engine oil pressure when the oil tem- perature is at the specified temperature. 1) Remove plug (I 1. 2) Install oil pressure gauge A (25 kg/cm? * Install the oil pressure gauge so that it is af- fected as little as possible by the engine vibration. 3) Start engine and measure oil pressure. 2. Measuring oil temperature. * Measurement condition l Coolant temperature: Inside operating range. Item Standard value Permissible value Oil temperature 190- 110°C I 120°C 12-8 WA350-1 0
  30. 30. TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE MEASURING BLOW-BY PRESSURE * . . Measurement condition Coolant temperature: inside operating range. Engine valve clearance: Standard valve Unit: mm H,O Item Standard I Permissible value value Blow-by pressure Max. 150 300 Special tool ~ r P&t number 1 Part name A 1 799-201-1503 1 Blow-by checker 1 1 2. Precautions when measuring blow-by It Blow-by may vary greatly according to the con- dition of the engine, so if there is any abnormali- ty in the reading, check for any problem related to defective blow-by, such as excessive oil consumption, defective exhaut gas color, or early deterioration or contamination of the oil. WA350-1 12-9 0
  31. 31. TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION TESTING AND ADJUSTING FAN BELT TENSION Testing fan belt tension Check the amount the fan belt deflects when pushed with a force of approx. 6 kg at a point midway between the fan pulley and the alternator pulley. Unit: mm Measuring procedure 1. Push the V-belt with a force of 6 kg, at a point midway between the pulley and the alternator. 2. Use a scale to measure the amount the V-belt deflects. Adjustment procedure 1. Loosen mounting bolt (1) of the alternator assembly, and the mounting bolt of adjustment plate (2). 2. Insert a stick or bar between the alternator mounting bolt and the cylinder block, then raise the alternator to the outside. Qf If the alternator is moved to the inside with the 3. 4. hands, there is danger of catching and insuring the fingers. Adjust the belt (3) tension and temporarily tighten mounting bolt. Check that the belt tension is correct then tighten all mounting bolts fully. Fan pulley Alternator pulley 423F303 12-10 0 WA350-1
  32. 32. TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR MEASURING EXHAUST GAS COLOR t Measurement condition l Coolant temperature: Inside operating range. l Valve clearance: Standard value. Unit: Bosch index ~ Special tool Part number Part name Q’ty A Commercially available Smoke meter 1 * When measuring the exhaust color; be careful not to touche the exhaust pipe. 1. Insert probe @ in outlet of exhaust pipe (I) and secure to exhaust pipe with clip. 2. Connect probe hose, connector hose @of accel- erator switch and air hose to smoke meter A. * 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 ON 6. Accelerate engine suddenly. At the same time, depress accelerator pedal, 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. WA3561
  33. 33. MEASURING ACCELERATOR PEDAL OPERATING TESTING AND ADJUSTING FORCE AND OPERATING ANGLE MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE * Measurement condition l Coolant temperature: Inside operating range. Unit: kg Item Operating force of accelerator oedal Standard Permissible value value 4-7 Max. 10.5 Special tool _- Part number Part name Q’ty A 7AO-262;0020 Push-pull scale 1 OPERATING FORCE 1. Measuring procedure I) 2) Put push-pull scale A in contact with the accel- erator pedal at point 150 mm from pedal ful- crum “a”. * The center of push-pull scale A must be in contact with a point 150 mm from the pedal fulcrum. Start the engine, push the pedal in the direction of operation and measure the maximum value when pushing from idling to the end of the pedal travel (high idling). 2. Testing and adjusting I) Stop the engine. 2) Disconnect the cable at the bottom of the ac- celerator pedal, and check that the linkage and ball joint at the bottom of the pedal move smoothly. 3) Connect the cable at the bottom of the pedal, then disconnect at the connection for the injec- tion pump, and check that the cable moves smoothly. * When carrying out this inspection, adjust or replace parts as necessary. Measure the operating force again and check that it is within the standard range. a 423 F304 12-12 0 WA350-1
  34. 34. MEASURING ACCELERATOR PEDAL OPERATING TESTING AND ADJUSTING FORCE AND OPERATING ANGLE OPERATING ANGLE OF ACCELERATOR PEDAL Unit: mm Operating travel I I L 42 Installed height of accelerator pedal stopper Installed length X of rod 136-146 - I 1. Measuring procedure 1) Stop the engine. 2) Measure the operating angle cyl, cxz, put the angle gauge in contact with the accelerator pedal it is operated from low-idling and high idling. 2. Adjusting procedure 1) Remove the cover under the cab, open the engine hood and fit the safety lock. 2) Loosen nut (I) and adjust installed length X of rod (2) until it is 160 f 5 mm. 3) Release the accelerator pedal, loosen nut (5) and adjust the height L, of the stopper bolt (6) until it is 18 +- 5 mm. 4) Depress the accelerator pedal, loosen nut (3) and adjust the height 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 in- jection pump governor lever contacts the high idle stopper. t After making the above adjustments, take all measurements again and check that they are within the standard value. w 423 F305 WA350-1 12-13
  35. 35. TESTING AND ADJUSTING ADJUSTING FUEL CUT SOLENOID ADJUSTING FUEL CUT SOLENOID 1. 2. 3. Confirm that stop lever (2) of the fuel injection pump (I 1is at the STOP position. (Usually, the return spring holds the stop lever at the STOP position.) Adjust rod so that the solenoid has a maximum stroke. Adjust rod so clearance “b” is 0.4 * 0.1 mm between injection pump stopper lever (2) and stopper (3). Stroke-“a” = 12 mm Turn on the engine starting key and confirm that the solenoid stroke “a” is the standard dimension. 4. Tighten nuts (5) and (6) of rod (4). 423F338 12-14 0 WA350-1
  36. 36. ENGINE 13 DISASSEMBLY AND ASSEMBLY . . STARTING MOTOR ASSEMBLY Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . ALTERNATOR ASSEMBLY Removal . . . . . . . . .._........_....__ Installation . . . . . . FUEL INJECTION PUMP ASSEMBLY Removal . . . ..__..._.........._.... Installation . . . . . WATER PUMP ASSEMBLY Removal . . . . . . _.........__..,_.... Installation . . . . . NOZZLE HOLDER ASSEMBLY Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . CYLINDER HEAD ASSEMBLY Removal _....__...__..._...__..... Installation . . . TURBOCHARGER ASSEMBLY Removal . .._........._. Installation . . . . . . . COMPRESSOR ASSEMBLY Removal . . . . . . Installation . . . . . , . 13- 2 13- 2 13- 3 13- 3 13- 4 13- 4 13- 5 Removal . . . . 13-44 13- 5 Installation . . . . . . 13-46 13- 6 13- 6 13- 8 13-14 13-22 13-22 13-23 13-23 RADIATOR ASSEMBLY Removal . . . . 13-24 Installation . . , . , . , _, . . . . . . . . 13-27 OIL COOLER ASSEMBLY Removal ..__..__..._........._........ 13-29 Installation . . . . . . . . . 13-29 ENGINE ASSEMBLY Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30 Installation . . . . . . . 13-37 FUEL TANK ASSEMBLY Sr Take the following method for air bleeding when you start to operate hydraulic cylinders after reassembling cylinders, pumps and pipings. 1. Start engine, keep idling. 2. Operate hydraulic cylinder 4 - 5 cycles, but do not exceed beyond 100 mm of stroke end. 3. Continued to operate cylinder 3 - 4 cycles until stroke end. 4. After finishing above steps, keep normal engine speed. NOTE: After long storage, same procedure is required. WA350-1 13-I 0
  37. 37. DISASSEMBLY AND ASSEMBLY STARTING MOTOR REMOVAL OF STARTING MOTOR ASSEMBLY A Disconnect the cable from the negative (-1 terminal of the battery. 1. Remove catch, then open hood. 2. Disconnect wire (I) and connector (2). 3. Remove ground connection (3). then remove start- ing motor assembly (4). __ INSTALLATION OF START- ING MOTOR ASSEMBLY 1. Fit O-ring and install starting motor assembly (41, then tighten together with ground connection (3). 2. Connect connector (2) and wire (1). 3. Close hood, then lock with catch. 4. Connect cable to negative (-1 terminal of battery. 13-2 0 WA350-1
  38. 38. DISASSEMBLY AND ASSEMBLY ALTERNATOR REMOVAL OF ALTERNATOR ASSEMBLY n Disconnect the cable from the negative (-1 terminal of the battery. 1. 2. 3. 4. 5. Remove catch, then open hood. Disconnect wires (I), (2) and (3). Remove bolt (4) of adjustment plate, then loosen mounting bolt and nut (5). Move alternator assembly towards cylinder block to loosen belt tension, then remove belt (6). Remove mounting bolt and nut, then remove alter- nator assembly (7). INSTALLATION OF ALTERNATOR ASSEMBLY 1. Install alternator assembly (71, then partially tight- en 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 cylin- der block, raise alternator assembly and adjust ten- sion 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
  39. 39. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP REMOVAL OF FUEL INJECTION PUMP ASSEMBLY 1. Remove catch, then open hood. 2. Disconnect control rods (I 1and (2). 3. Disconnect boost compensator hose (3). 4. Disconnect fuel hoses (4) and (5). 5. Disconnect fuel supply hose (6). 6. Remove lubrication tubes (7) and (8). 7. Disconnect 6 fuel injection tubes (9). 8. Remove coupling bolt (10). 9. Remove 4 mounting bolts, then pull out fuel injec- tion pump assembly (I 1) to rear to remove. INSTALLATION OF FUEL IN- JECTION PUMP ASSEMBLY 1. Place fuel injection pump assembly (1 I) on bracket, and set in position. Partially tighten 4 mounting bolts, then tighten coupling bolt (IO). 2. Rotate crankshaft and align pointer (13) with line on crankshaft pulley (I 2). t If the timer line is not at the front, rotate the crankshaft one more turn. 3. Align line A on fuel injection pump with line B on timer side, then tighten mounting bolts of pump uniformly in turn. 4. Connect 6 fuel injection tubes (9). and tighten nuts. w Sleevenut: 2.4kO.l kgm 5. Fit gaskets and install lubrication tubes (8) and (7). 6. Fit gasket and connect fuel supply hose (6). 7. Fit gaskets and connect fuel hoses (51 and (4). 8. Connect boost compensator hose (3). 9. Connect control rods (2) and (I ). IO. Close hood, then lock with catch. 13-4 0 WA350-1
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