SEBM033805 SHOW” IMTA\INTU A\ILs KOMATSU WA1950-5 MACHINE MODEL SERIAL NUMBER WA150-5 65001 and up + This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. + WA150-5 mounts the SAA4D102E-2 engine. For details of the engine, see the 102 Series Engine Shop Manual © 2005 KOMATSU All Rights Reserved Printed in Japan 04-05(02) 09st01 10 20 30 90 00-2 Q) CONTENTS GENERAL ec cesses STRUCTURE, FUNCTION AND MAINTENANCE STANDARD........... TESTING AND ADJUSTING... DISASSEMBLY AND ASSEMBLY .. OTHERS .. No. of page sent e014 2-20-41 230-4 WA150-5‘The affected pages are indicated by the use of the fol- lowing marks. It is requested that necessary actions Man indication Aoboriteaubed be taken to these pages according to the table below. © [Page to be newly added [Add @ |Page to be replaced —_| Replace ( ) [Page to be deleted ard Pages having no marks are those previously revised or made aditions. LIST OF REVISED PAGES Mak Page PeMSOn| mark Pago PME] Mark Pago PENS Mark Page PESO] mark Page _‘evison © 007 © 104 10-45 10-86 10-131 002 @) 105 10-46 10-88 @ 10-132 (5) © 0021 (5) 106 10-47 10-89 10-133 © 0022 (5) 10-7 10-48 10-90 10-134 © 0023 © (5) 108 10-49 10-91 10-135 © 0024 (5) 109 10-50 10-92 10-136 © 003 10-10 10-51 10-94 10-137 © 004 10-11 10-52 10-98 10-138 © 005 10-12 1053, 10-96 10-139 © 006 10-13 1054 10.97 10-140 © 007 10-14 10-55 10-98 10-141 © 008 10-18 10-56 10-100 10-142 (4) © 009 10-16 1057 10-401 10-144 © 00-10 10-17 1058 8) 10-102 10-145 (3) © 0011 e101 6) 10:59 10-103 10-146 © 00-12 e101 6) 10-80 10-104 10-147 © 00-13 10-20 1081 @) 10-105 10-148 © 00-14 10-21 10-62 10-106 10-149 (3) © 00-15 10-22 10-63 10-107 10-150 © 0016 10-28 10-84 10-108 10-451 © 0017 10-24 10-85 10-109 10-152 © 0018 10-25 1086 3) 10-110 10-153 © 0019 10-26 1087 10-411 10-154 © 00-20 10-27 10-68 10-112 10-155 © 0021 10-28 10-69 10-113 10-156 © 00-22 10-29 10-70 10-114 10-157 10-30 10-71 10-115 10-158 (4) ort 10:31 10-72 10-118 10-159 ore 10-32 10-73, 10-117 10-160 01-3 10-33 10-74 10-118 10-161 @ 014 ©) 10-34 10-75 10-119 10-162 (3) 01s 10-35 10-76 10-120 10-163 016 1036 10-77 10-121 10-164 O17 1037 10-78 10-122 10-165 © ore 6) 10:38 10-7 10-123 10-165 @ 019 6) 1038 10-80 10-124 10-167 (01-10) 10-40 10-81 10-125 10-168 10-41 10-82 10-126 10-169 104 10-42 10-83, 10-127 10-170 10-2 10-43 10-84 10-128 10-171 103 10-44 10-85 10-130 30-172 WA150-5 00-2-1 6)Mark Page Raver Mark Page Raven Mark Page Rois] van Page Raven Mark Page numer fume ra rie fue 10-173 20-119 (1) 20-169 (4) 20-248 (1) 20-508 (1) 10-174 20-120 (1) 20-170 (3) 20-250 (1) 20509 (1) 10-175 20-121 (1) 20-171 (1) 20-251 (1) 20510 (1) 10-176 20-122 (1) 20-201 (1) 20-252 (1) 20511 (1) 10-17 20-123 (4) 20-202 (1) 20-253 (1) 20-512 (1) 10-178 20-124 (1) 20-203 (1) 20-254 (1) 20513 (1) 10-179 20-125 (1) 20-204 (1) 20-301 (1) 20514 (1) 10-180 20-126 4) 20-205 (1) 20-302 (1) 20515 (1) 10-181 20-127 (1) 20-206 (1) 20-303 (1) 20516 (1) 10-182 20-128 (1) 20-207 (1) 20-304 (1) 20517 (1) 10-183 (3) 20-129 (4) 20-208 (1) 20-305 (1) 20518 (1) 10-184 20-130 (1) 20-209 (1) 20-306 (1) 20519 (1) 10-185 20-131 (1) 20-210 (1) 20-307 (1) 20520 (1) 10-186 20-132 (1) 20-211 (1) 20-308 (1) 20522 (1) 10-187 20-133 (4) 20-212 © (1) 20-309 (1) 20523 (1) 10-188 20-134 (1) 20-213 (1) 20-310 (1) 20-524 (1) 10-189 20-138 (1) 20-214 (1) 20-311 (1) 20526 (4) 10-190 20-136 (1) 20-215 (4) 20-312 (1) 20527 (1) 10-191 20-137 (1) 20-216 (4) 20-313 (1) 20528 (1) 10-192 20-138 (1) 20-218 (1) 20-314 (1) 20528 (1) 10-193 20-139 (1) 20-219 (1) 20-315 (1) 20530 (1) 10-194 20-140 (1) 20-220 (1) 20-316 (1) 20531 (1) 10-195 20-141 4) 20-221 (1) 20317 (1) 20532 (4) 10-196 20-142 (4) 20-222 © (1) 20-318 (1) 20533 (1) 20-143 (1) 20-223 (1) 20-319 (1) 20534 (1) 20-1 () 20-144 (1) 20-224 (1) 20-320 (1) 20535 (1) 20-2 () 20-145 (1) 20-225 (1) 20-321 (1) 20536 (1) 20-3 () 20-146 (1) 20-228 (1) 20-322 (1) 20537 (1) 20-4 () 20-147 (1) 20-227 (4) 20-323 (1) 20538 (1) 20-5 () 20-148 (1) 20-228 (1) 20-324 (1) 20539 (1) 20-6 () 20-149 (3) 20-229 (1) 20-325 (1) 20540 (1) 20-7 () 20-150 (1) 20-230 (1) 20-326 (1) 20542 (1) 20-101 (1) 20-151 (4) 20-231 (1) 20-327 (1) 20543 (1) 20-102 (4) 20-152 (1) 20-232 (1) 20-328 (1) 20544 (1) 20-103 (4) 20-153 (1) 20-233 (1) 20-328 (1) 20545 (1) 20-104 (4) 20-154 (1) 20-234 (1) 20-330 (1) 20546 (1) 20-105 (1) 20-155 (4) 20-235 (1) 20-401 (1) 20547 (1) 20-106 (4) 20-196 (1) 20-236 (1) 20-402 (4) 20548 (1) 20-107 (1) 20-197 (1) 20-237 (1) 20-403 (4) 20549 (1) 20-108 (1) 20-158 (1) 20-238 © (1) 20-404 (1) 20550 (1) 20-109 (4) 20-159 (4) 20-238-1 (4) 20-405 (1) 20551 (1) 20-110 (4) 20-160 (4) 20-239 (1) 20-406 (1) 20552 (1) 20-111 (1) 20-161 (1) 20-240 (1) 20-407 (4) 20553 (1) 20-112 (1) 20-182 (4) 20-241 (4) 20-501 (1) 20554 (1) 20-113 (1) 20-183 (4) 20-243 (1) 20-502 (1) 20585 (1) 20-114 (1) 20-164 (1) 20-244 (1) 20-503 (1) 20556 (1) 20-115 (1) 20-185 (4) 20-245 (1) 20-504 (1) 20557 (1) 20-116 (1) 20-166 (4) 20-246 (1) 20-505 (1) 20558 (1) 20-1177 (1) 20-167 (4) 20-247 (1) 20-506 (1) 20559 (1) 20-118 (4) 20-168 (4) 20-248 (1) 20-507 __(1) 20.560__(1) 00-2-2 WA150-5 (5)Mak Page Foison Mark Page Revisor Mark Page Rois Mak Page Rogan Mark Page Rov fbr ‘ene ‘nee ft ‘ener 20-601 (1)| 20853 (1) | 20-723 (1) [| 3023 (2)| OTB (2) 20-602 (1)| 20654 (1) | 20-728 «(ty | 30-24 = (2) | 30-74 (2) 20-603 (1)| 20685 (1) | 20-801 (1) | 3028 = (2)| 30-75 (2) 20-604 (1)| 20656 (1) | 20-802 (1) | 30-26 = (2) | 30-78 (2) 20-606 a) 20-657 qa 20-803 (a) 30-27, (2) 30-77 (2) 20-607, a) 20-658 qa 20-804 qa) 30-28 (2) 30-78 (2) 20-608 a) 20-659 qa 20-805 qa) 30-29 (2) 30-79 (2) 20-610. a) 20-660 qa) 20-806 (a) 30-30 (2) 30-80 (2) (20-611 q) (20-661 a) (20-807 a) 30-31 (2) 30-81 (2) 20-612 q) 20-662 a) 20-808 a) 30-32, (2) (30-82 (2) 20-613 Q) 20-663 a) 20-809 a) 30-33, (2) 30-83 (2) 20-614 (4) 20-664 a) 20-810 a) 30-34 (2) (30-84 (2) 20-615 q) 20-665 a) 20-811 a) 30-35, (2) 30-85 (2) 20-616 q) 20-666 a) 20-812 a) 30-36, (2) 30-86 (4) 20-617 a) (20-667 a) 20-813, (a) 30-37, (2) 30-87 (2) 20-618 (1) 20-668 (1) 20-814 (1) 30-38 © (2) 30-88 (2) 20619 (1)| 20669 (1) | 20.815 (1) | 30-39 (2) | 30-892) 20-620 (1)| 20670 (1) | -20:816 (1) | «30-40 (2) | 30-80 (2) 20621 (1)| 20671 (1) | 20.817 (ty | 30-41 (2) | 30-012) 20-622 a) 20-672 qa) 20-818 qa) 30-42 (2) 30-92 (2) 20-623, a) 20-673, qa) 20-819 (4) 30-43 (2) 30-93 (2) 20-624 a) 20-674 qa) 20-820 (4) 30-44, (2) 30-94 (2) 20-625, a) 20-675, qa) 20-821 (a) 30-45 (2) 30-95 (2) 20-626 q) 20-676 a 20-822 (a) 30-46, (2) 30-96 (2) 20-627 q) (20-677 a) 20-823 a) 30-47 (2) 30-97 (2) 20-628 q) (20-678 a) (20-824 a) 30-48 (2) 30-98 (2) 20-629 q) (20-679 a) 30-49 (2) 30-99 (2) 20-630 (1) 20-680 (1) 30-50 (2) 30-100 (2) 20-631 (1)| 20-701 (1) | 30-1 4) | 80-512) | 30-401 (2) 20-632 (1) 20-702 (1) 30-2 @) 30-52 (2) 30-102 (2) 20-633 (1)| 20-703 (1) | 30-3) | 30532) | 30-103 (2) 20-634 a) 20-704 qa) 30-4 @) 30-54 (2) 30-104, (2) 20-635, a) 20-705 qa) 30-5 @) 30-55 (2) 30-105, (2) 20-636, a) 20-708 qa) 306 @) 30-56 (2) 30-106, (2) 20-637, a) 20-707 qa) 30-7 (4) 30-57 (2) 30-107, (2) 20-638 q) (20-708 a 30-8 a 30-58 (2) 30-108, (2) 20-639 q) 20-709 a) 30-9 @) 30-59 (2) 30-109, (2) 20-640 q) 20-710 a) 30-10 @) 30-60 (2) 30-110, (2) 20-641 q) (20-711 a 30-11 @) 30-61 (2) 30-111 (2) 20-642 q) 20-712 a) 30-12 ) 30-62, (2) 30-112, (2) 20-643 q) 20-713 a) 30-13, ) 30-63, (2) 30-113, (2) 20-644 q) 20-714 a) 30-14 ) 30-64 (2) 30-114, (2) 20-645 (1) 20-715 a) 30-15, 2) 30-65, (2) 30-115, (2) 20-648 © (1) 20-716 (1) 30-16 (2) 30-66 (2) 30-118 (2) 20-647 (1)| 20-717 (1) | 30-17) | 3067 (2) | 30-117 (2) 20648 © (1)| 20-718 (1) | 3018 =) | 30-88 = 2) | 80-118 (2) 20-649 (1)| 20-719 (1) | 30-19») | 30692) | 30-119 (2) 20-650 a) 20-720 qa 30-20 2) 30-70 (2) 30-120, (2) 20-651 qa) 20-721 qa) 30-21 ) 30-71 (2) 30-121 (2) 20-652, a) 20-722 a 30-22 @) 30-72 (2) 30-122, (2) WAt50-5 00-2-3 6)Raver Raven Ravn] Rasen Mark Page RNAL"] Mak Pago OEE] Mark Page RSIGRY| Mark Page SSL] Mark Page Re? 30-123 (2) | 80-2T 30-124 (2) | 90-23 30-125 (2) | 90-25 30-126 (2) | 90-27 30-127 (2) | 90-29 30-128 (2) | 90-31 30-128 (2) 30-130 (2) 30-131 (2) 30-132 (4) 30-133 (2) 30-134 (2) 30-135 (2) 30-136 (2) 20-137 (2) 20-138 (2) 20-139 (2) 20-140 (2) 20-141 (2) 30-142 (2) 30-143 (2) 30-144 (2) 30-145 (2) 30-146 (2) 30-147 (2) 30-148 (2) 30-149 (2) 30-150 (2) 30-151 (2) 30-152 (2) 30-153 (2) 30-154 (4) 30-155 (2) 30-156 (4) 30-157 (2) 30-158 (2) 30-159 (2) 30-180 (4) 20-1 0-3 © (4) 90-5 90.7 90-9 90-11 90-13 90-15 90-17 90-19 WA150-5 00-2-4 (5)SAFETY SAFETY NOTICE SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for rep: the specific purpose. To proventinjury to workers, the symbo! diy is used to mark safety precautions in this manual. ‘Tho cautions accompanying these symbols should always be followed caretully. I any danger ous situation arises or may possibly arise, first consider safety, and take the necessary actions {to deal with the situation. GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual care- fully 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, hand shield, 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. Aways 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, companment. 5. Keep all tools in good condition and lear 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 ro ditt or oll on the floor. Smoke only in the areas provided for smoking. Never smoke while work- ing, 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 fal ing. 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 pro- Vide safe footing. 00-3SAFETY SAFETY NOTICE 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 got burned. Wait for the oil and water to cool before carry- ing 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 naga- tive (-) 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 i capacity. Install the liting equipment at the correct places. Use a hoist or crane and operate slowly to pre- vent the component from hitting any other part. Do not work with any part still raised by the hoist, orcrane. equipment which has ample 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel oF oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor an cause you to slip, or can even star fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. 00-4 19.Be sure to assemble all parts again in their origi- nal places, Replace any damaged parts 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, 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when install- ing 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 instaling protective parts such as guards, or parts which vibrate violently or rotate at high speed, be par- ticularly careful to check that they are installed correctly 22.When aligning two holes, never insert your fin- ‘gers or hand. Be careful not to get your fingers, ‘caught in @ hole, 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.FOREWORD GENERAL FOREWORD GENERAL 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 judge- ments. 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 the following chapters; these chapters are fur- ther divided into the each main group of components, STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an under- standing of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte- nance standards. 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" with "Causes" are also included in this section, DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each com. ponent, as well as precautions for them MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. ‘The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date. 00-5FOREWORD HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES ‘Shop manuals are issued as a guide to carrying out repairs. They are divided as follows’ Chassis volume: Issued for every machine model Engine volume: issued for each engine series Each issued as one volume to cover all models Electrical volume: Attachments volums These various volumes are designed to avoid dupli- cating the same information. Therefore, to deal with all repairs for any model , it is necessary that chas- sis, engine, electrical and attachment volumes be avaiable, DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. 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 show how to read the page number. Example 1 (Chassis volume} 10-3 tem number (10. Structure and Function) Consecutive page number for each item, Example 2 (Engine volum 12-5 u Unit number (1. Engine) Item number (2. Testing and Adjust- {___ ing) Consecutive page number for each item, 3. Additional pages: Additional pages are indicated by a hyphen () and number after the page number. File as in the example. Example: 10-4 12-203 10-4-1 12-2034 19-4-2_I—~Addes panes 12-203-2 10-5 12-204 00-6 REVISED EDITION MARK When a manual is revised, an edition mark ((1)(2)(Q)...) is recorded on the bottom of the pages. REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page. SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols. Symbol Item Remarks ‘Special safety preceutons A Satety | are necessary whan per forming the work Special technical precau tions or other precautions for preserving standards are necessary when per: forming the work. * Caution Weight of parts of sys . tems, Caution necessary T= | weight | when selecting hoisting \wiro, oF winen working pos {ure is important, ote. fering | Places that require spocial SS | TARND | attention forthe tightening dia torque during assembly. Places to be coated with AD | Coat | adhesives and lubricants, etc Places where ol, water or {Ee | Ollwater | tue! must be added, and the capacity, Places where cil or water Drain | must be drained, and quantity to be drained.FOREWORD HOISTING INSTRUCTIONS, HOISTING INSTRUCTIONS HOISTING AX Heavy parts (25 kg or mora) must be lited with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part welghing 25 kg or more is indicated clearly with the symbol ==> + Ifa part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 4) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existance of another part causing interference with the part to be removed. WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "2" or "S" twist ropes without galvanizing) Rope diameter Allowable load mm iN tons 10 98 10 18 13.7 14 125 157 168 14 21.6 22 16 278 28 18 353 36 2 43.1 44 22.4 54.9) 56 30 98.1 10.0 40 1785 18.0 50 2746 280 60 392.2 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. 3) 4) 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 max- imum strength at the middle portion. LO 100% = «88K Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically Wound onto the load. Slinging with one rope may cause tuming of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which ‘ean result in a dangerous accident. Do not siing 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 kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sing a load vertically, up to 19.6 KN (2000 kg} of total weight can be sus- pended. This weight becomes 9.8 KN {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 39.2 kN {4000 kg} if they sling a 19.6 KN {2000 kg} load at a lifting angle of 150°. 3 hom 2 2000) i = ig -—200_ (1700) = 000) 48 (1000) Lowe 08 3 ORD Lifting anele terres) 9803002 00-7FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER Ai Belore carying out the following work, release Type 1 the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Flat Releasing residual pressure from hydraulic 4 tank « Ac ven it the residual pressure is released from the hydraulic tank, some hydraulic oil lows out when the hose is disconnected. Accordingly, in prepare an oil receiving container. Disconnection 4) Release the residual pressure from the hydrau- lic tank. For details, see TESTING AND fea ADJUSTING, Releasing residual pressure from 1 hydraulic tank. $2 2) Hold adapter (1) and push hose joint (2) into 5 ‘mating adapter (3). (See Fig. 1) + The adapier can be pushed in about 3.5 Ly mm, + Do not hold rubber cap portion (4). = 3) Alter hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (8) until it licks. (See Fig. 2) Fie3 4) Hold hose adapter (1) or hose (5) and pul it out. oe ee Fig. 3) (] Since some hydraulic oil flows out, prepare 4 Lt an oil receiving container. Connection 4) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each Flas other. (See Fig. 4) %* Do not hold nubber cap portion (4). - 2) After inserting the hose in the mating adapter A perfectly, pull it back to check its connecting +i | condition. (See Fig. 5) %* When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, i 1 4 however Flies cnio701 00-8FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER Type2 Type3 y Hold the mouthpiece of the tightening portion and push body (2) in straight unti siding pre- vention ring (1) contacts contact surface a of the hexagonal portion at the male end. 7) Hold the mouthpiece of the tightening portion and push body (2) in straight until siding pre~ vention ring (1) contacts contact surtace a of the hexagonal portion at the male end. G) Reo 2) Hold in the condition in Step 1), and push 2) Hold in the condition in Step 1), and tum lever (4) to the right (clockwise) Until cover (3) contacts contact surface a of the hexagonal portion at the male end. § Le —_— 3 3 - cessor = s coueses 3) Hold in the condition in Steps 1) and 2), and | 3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it > > a corence si ries + Hold the mouthpiece of the tightening portion | + Hold the mouthpiece of the tightening portion’ and push body (2) in straight unti sliding pre- | and push body (2) in straight until sting pre- vention ring (1) contacts contact surface a of | vention ring (1) contacts contact surface a of the hexagonal portion at the male end to con- | _ the hexagonal portion at the male end to con- rect it rect it 5 T é 00-9FOREWORD COATING MATERIALS COATING MATERIALS The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. 4 For coating materials not listed below, use the equivalent of products shown in this ist Category Komatsu code Part No, ay Container Main applications, features aa 790-129-8030 1509 Tube * Used to provent rubber gaskets, rubber ‘cushions, and cock plug from coming out mB 790-129-8050 209 (2pcs.) Polyethylene container * Used in places requiring an immedately effective, strong adhesive. Used for plastics (except polyethylene, Polyprophylene, tetrafiuoroethiene and Vinyl ehlonde),tubber, metal and non- Le 09940-00020 509 Polyethylene container * Features: Resistance to heat and chemicals + Used for anti-loosaning and sealant purpose for bolts and plugs. Adhesives La 790-129-9080 (Set of adhesive ‘and hardening agent) ‘Adhesive: kg Hardening agent: 300.9 can * Used as adhesive or sealant for metal, glass and plastic. ira 790-129-9040 2509 Polyethylene container * Used as sealant for machined holes Holtz MH 705 790-128-9120 59 Tube * Used as heal-resisting sealant for repairing engine. Three bond 1735 790-129-9140 50g Polyethylene container * Quick hardening type adhesive + Cure time: within 9 sec, to 3min, + Used mainly for adhesion of metals, rubbers, plastics and woods. Aron-alpha, 201 790-129-8130 29 Polyethylene container * Quick hardening type adhesive + Quick cure type (max. strength after 90 minutes) + Used mainly for adhesion of rubbers, plastics and metals. Loctite 648-50 79A-129-9110 Dee Polyethylene container * Resistance to heat, chemicals + Used at joint portions subject to high temperatures. Let 790-129-8010 200g Tube * Used as adhesive or sealant for gaskets and packing of power train case, etc. Les 790-129-8080 1g can * Used as sealant for various threads, pipe joints, flanges. + Used as sealant for tapered plugs, ‘elbows, nipples of hydraulic piping, Gasket Les 790-129-8020 200g Tube * Features: Silicon based, resistance 10 heat, cold + Used as sealant for flange surface, tread. + Used as sealant for oll pan, final drive ase, etc. sealant lev 790-129-8070 1g Tube + Features: Silicon based, quick hardening type. + Used as sealant for flywheel housing, intake manifold, ll pan, thermostat housing, ete. ‘Three bond Tait 790-129-8090 1009 Tube + Used as heat resisting sealant for repairing engine. 00-10 ‘Three bond 12078 419-15-18131 1009 Tube + Features: Silicone type, heal resistant, vibration resistant, and impact resistant sealing material | + Used as sealing materia for transfer caseFOREWORD COATING MATERIALS Category | Komatsu code | Pan No ay | container Main applications, features wwe | o8040-00061 | 609 | can _ | Used as ubean fr siding orion fo wpe ~ Used to prevent seizure or sclfing ofthe ‘hvoad when prose fiting or sink itn Mivteant | UMP 09940-00040 | 2009) Tube |. {ed ae ubeant for inkage bearings a SYa240011 ~ General pupose pe /SYG2-350LI p um geu — |[SyG2-400L-a | various | various S¥G2-160l1 SYGA-160GNLI IS¥G2-400CA * Used Tor normal temparatur, light oad S¥G2.35008 bparng a places in contact with water or Geca —|§vG2-4000A-8 | various | Various | stoam: S¥G2-18008 SYGA-160GNCA Movbdenan |syap.nom 400g » 10] Botowe ype|* Vee Feavy lad prion Grease | Sage S¥G2400M-A 4009 » 20) Bellows ype Be oy) [SYGATEONM —"IBky™ | Can Hyper White 5 ~ Seizure resislance and heat resistance Grease G2T higher than molyodenum disulfide grease s¥a2-400r-a SEFC" (RISSIEENT | dane [Peters Shoes amen aula does “For vse in Q siand out against machine bo Botddouer _[S¥G0-180NT C) | ; pane Biogresse G28 |eyeg9-4008 + Since his graase decomposed by G2BT (*) bacteria in short period, it has less effects: raha, (SSSI@R. | Bho fPelegnee| osmccoganom ana endprs tomporate |SVGA-16CNBT (+) SUNSTAR a + Used as priner Tor cab sido PAINT PRIMER 20m Seis (Using limit: 4 months) eT 417-928-8810 = SUNSTAR, ams ~ Used as primer for glass ede GLASSPRMER 20m ri (Using limit: 4 months) 580 SUPER: phat SUNSTAR, clas ~ Used as primer for painted surface on primer |PAINTPRIMER | 22msa-z72a0 | 2om | Glass, | |” cab sige 49595 {Using mt: 4 montns) + Used as primer for back ceramic: SUNSTAR, GLASSPRMER| 22Ms4-27240 | 150m | Can comet sures on dase see ars “eat (Using limt: 4 monins) SUNSTAR Glass | @ |” Used as primer for sash (Alumite). SASH PRIMER | 22M.54-27250 | 20 mi lass | 8) Using limit: 4 months) eee container | SUNSTAR, Ecosat | 8 |> Used as adhesive for ass PENGUINE | 2eMs4-272I0 | s20mi | (Special | 5)” (Usnglint:6 montna) SUPER 550 comrainen) | 3 Bee 1) SE Shas |” saacon (Apt Octobor) and “Wor adhesive | SEAL 560 417-928-3910 | 3e0mi |Povettylene| 3] jow-temperature season (November ‘SUPER “S’ or container April) as adhesive tor glass. w (Using tints 4 months) ‘Sika Japan, Polyethylene + Used as adhesive for glass. Sikafiex 256Hv | 20¥54-39850 | 310m! |" container (Using limit: 6 months) SUNSTAR ~ Used to seal joints of glass parts. PENGUINE _ | 417-925-8920 | 20m [Pobettptene| |” Gngtini: 4 monnss SEAL No. 2505 SEKISUI 7 Used seal front window. Caulking | SILICONE 2ov-sa-s5130 | 333mi |Pobethylene) |” (Using limit: 6 months) SEALANT GE TOSHIBA + Used seal joint of glasses SILICONES | 22M-54-27220 | 333mi | Carbidge Translucent white seal. TOSSEAL 381 (Using limit: 12 months) 00-11FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) Inthe case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. _ wm | “=~ | SOSSO0O = TABLE OF TIGHTENING TORQUES FOR FLARED NUTS + In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter Width across fat Tightening torque mm mm Nm kgm 14 19 24.5449 25405 18 24 492198 522 22 27 78.5419.6 ese 24 32 197.3294 1443 30 36 176.5 29.4 1843 33 a 198.1 £49 2045 26 45 245.24 49 2545 42 55 296.2 + 49 305 00-12FOREWORD STANDARD TIGHTENING TORQUE TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS In the case of split lange bolts for which there is no special instruction, tighten to the torque given in the table below. ‘Thread diameter Width across flat Tightening torque mm mm Nm kom 10 14 59-74 6-75 12 "7 98-123 10-125 16 22. 235-285 235-235 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS. Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Norminal No. Tightening torque (Nm {kgm)) 03, 08 05, 06 10, 12 14 Thread diameter | With across flat mm mm 14 20 Varies depending 24 ontype of 33 ‘connector. 42 Range 35-83 (9.56.5) 84-132 (8 5-13.5} 128 ~ 185 {13.0 ~ 19.0} 363 — 480 {37.0 -49.0} 746 ~ 1010 {76.0 - 103} Target 44 {4.5} 103 {10.5} 157 (160) 422 (439) 883 (90.0) ‘TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS Unless there are special instructions, tighten the O-ring boss plugs to the torque below. Thread diameter | Wiath across flat Tightening torque (Nm {kgm)) Norminal No. mm mm Range Target 08 08, 14 5.88 — 8.82 (0.6-0.9} 7.38 (0.75), 10 10 17 9.8-12.74 (1.0-1.3) 14.27 (1.15} 12 2 19 147-196 {15-20} 17.84 {18} 14 4 22 49.6 - 24.5 {2.0-2.5} 22.54 (2.3), 6 16 24 24.5 ~ 34.3 (2.5-3.5} 29.4 {3.0} 18 18 27 343-441 {95-45} 39.2 (4.0) 20 20 30 441-539 {45-55} 48.0 {5.0} 26 24 32 58.8 - 78.4 {6.0-8.0} 68.6 (7.0, 30 30 32 93.1 ~ 1225 (9.5 12.5) 107.8 {11.0} 33 33 = 107.8 ~ 147.0 {11.0~15.0} 124.4 (19.0) 38 36 36 127.4 ~ 176.4 {13.0 ~ 18.0} 151.9 (155) 42 42 = 181.3 240.1 {18.5 ~24.5) 210.7 (21.5) 82 62 = 274.4 ~ 367.5 (28.0 ~37.5} 328.4 (93.0} 00-13FOREWORD TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS. Use these torques for bolts and nuts (unit: mm) of Cummins Engine STANDARD TIGHTENING TORQUE ‘Thread dameter Tightening torque mm Nov kam 6 1002 1020 0.20 8 2404 2.450 0.41 10 4306 4.38.0 0.61 12 77012 7850 1.22 2) EYE JOINTS, Use these torques for eye joints (unit: mm) of Cummins Engin. ‘Thread dameter Tightening torque mm Nov kam 6 aoe 0.81.0 0.20 8 1002 4.020 0.20 19 1202 1.220 0.20 12 2404 2.450 0.41 14 3605 3.670 0.51 3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine, ‘Thread dameter Tightening torque inch Nin kom 116 301 0.310 0.10 8 aoe 0.810 0.20 14 1202 1.220 0.20 3/8 1502 1.530 0.20 V2 2404 2.450 0.41 3/4 360.5 36700051 1 6009 6.1200 0.92 TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) 4 Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. 4 Apply the following torque when the threads are coated (wet) with engine cil Tightening torque (Nm {kam | T#PeE see! Face sealtype vegas netazon ToneaT ga 1082 's Thread size Root diameter Foray Twat | Ment See Reg a toon ‘ 08 ig 34-54 (35-55) 4 {4.5} 7g ~ 18UN 14.3 wees wee | a : : i 7 sissma5) | 7475) eon 24 59 ~ 98 (6.0 - 10.0) 78 {8.0} 18 a = 04 27 (84 - 182 (8.5 - 13.5) 103 {10.5} 22 20.6 05, 32, 128 — 186 [13.0- 19.0) | 157{16.0} a4 25.4 | a | v7r-auie0-as0) |areiean| na Go| a ras wo ao) | aeTwO| —w E - (@_| a8 | 497-201 oe ano essa) | : = (14) 55 246 — 343 (25.0-35.0) | 294{30.0} 42 - = 00-14FOREWORD 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: Copper wire ‘amber woe | eet | Se Coble o.0 a Agpkcable creuit (mm?) (mm?) 08s 1" ase oss 24 12 | Sattng, tghting, signal 2 28 ose 209 sa 20 Lighting. egralet. 5 3s ase 5a 48 a Charging ae signal 15 ae as 1398 70 2 Saing (Glow plus) «0 35 080 ans 114 135 Stating Ps 127 080 cae 136 176 Staring 160 217 080 108.1 76 230 Staring CLASSIFICATION BY COLOR AND CODE 7 Circus at Charging |Ground| Starting | Lighing | Instument | signal | Other ten | pa [ome] 8 8 f ¥ @ L NY | Color White Black Black Red Yellow: Green Blue cose) wh | — | Bw rw vA ow w ° Color | White &Red| — [White & Black| Red & White | Rellow & Red Green & White Blue & White. cote) we | — | ev Fe v8 cA iF . Color |wite& tack) — lace & Volou| Rea Blak Nlow & Back Green & Red Blu & Yotow cote] om | — | 8A RY ve oy ir 4 fen Yelows | Goons Coor| mites Bue] — | Blas Red {rods vaow| Yetow® | 410208 | pie & Yotow co] wa | — |) — Re ve 38 ie . Color White & Green| — - Red & Green Yellow & Blue Green & Black) Blue & Black Code - - - RL Yw GL @ . Color - - - Red & Blue [Yellow & White Green & Blue | @ 00-15,FOREWORD CONVERSION TABLE CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE ‘The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE + Method of using the Conversion Table to convert rom milimeters to inches, 1. Convert §5 mm into inches. (1) Locate the number 50 in the vertical column at the lett side, take this as (A), then draw a horizontal line from (A) (2) Locate the number 5 in the row across the top, take this as (B), then draw @ perpengicular line down from (B). (8) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2, Convert §50 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (8) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to retum to the original value. This gives 650 mm = 21.65 inches. ©) Millimeters to inches 1 mm = 0.03997 in 6 7 8 9 o jo 0.039 | 0.079 | 0.118 | 0.157 | 0.197;| 0.236 | 0.276 | 0315 | 0.354 10 | 0.994 | 0.433 | 0.472 | 0.512 | 0.551 | 0.991;| 0.630 | 0.669 | 0.709 | 0.748 20 | 0.787 | 0.827 | 0.866 | 0.906 | 0.945 | 0.984:| 1.024 | 1.063 | 1.102 | 1.142 30 | 1.181 | 1.220 | 1.260 | 1.299 | 1339 | 1.978;| 1.417 | 1.457 | 1.496 | 1.536 49 | 1S | 1814 | 4.654 | ‘Capa | 1792 | i772!) 18H | 1.980 | 41800 | 1529 w& 50 | 1.969 | 2.008 | 2.047 | 2.087 | 2.126 |[2.165]| 2.205 | 2.244 | 2283 | 2.323 60 | 2.362 | 2.402 | 2441 | 2.480 | 2520 2559 | 2598 | 2.638 | 2677 | 2.717 70 | 2.756 | 2.795 | 2835 | 2.874 | 2913 | 2.953 | 2.992 | 3.032 | 3.071 | 3.110 go | 3.150 | 3.189 | 3.228 | 3.268 | 3307 | 3.346 | 3.386 | 3.425 | 3.465 | 3.504 90 | 3543 | 3583 | 3622 | 3.681 | 3701 | 3740 | 3.780 | 38i9 | 3858 | 3.808 00-16FOREWORD CONVERSION TABLE Millimeter to Inches 1 mm = 0.03997 in si 0 1 2 3 4 5 6 7 8 9 0 ° 0.039 | 0.079 | 0.118 | 0.157 | 0.197 | 0236 | 0.276 | 0.315 | 0.354 10 0.394 | 0.433 | 0472 | 0.512 | 0.551 | 0.591 | 0.630 | 0.669 | 0.709 | 0.748 20 0.787 | 0.827 | 0866 | 0.906 | 0.945 | 0.984 | 1.024 | 1.063 | 1.102 | 1.142 30 1.181 | 1.220 | 1260 | 1.299 | 1.339 | 1.978 | 1.417 | 1.457 | 1.496 | 1.536 40 1.975 | 1.614 | 1.654 | 1.693 | 1.732 | 1.772 | 1.811 | 1.850 | 1.890 | 1.929 50 1.969 | 2.008 | 2.047 | 2.087 | 2126 | 2165 | 2205 | 2.244 | 2.283 | 2.923 60 2.362 | 2402 | 2441 | 2480 | 2.520 | 2559 | 2598 | 2.638 | 2.677 | 2.717 70 2.756 | 2.795 | 2835 | 2874 | 2.913 | 2953 | 2992 | 3.032 | 3.071 | 3.110 80 3.150 | 3.189 | 3228 | 3268 | 3307 | 3.46 | 3.986 | 3.425 | 3.465 | 3.504 90 3.543 | 9.683 | 3.622 | 3.661 | 3.701 | 3.740 | 3.780 | 3.819 | 3.858 | 3.898 Kilogram to Pound kg = 2.2046 lb 0 1 2 3a 4 5 6 7 8 9 ° ° 220 441 | 661) 82 | 1102 | 1323) 1543| 17.64] 1984 10 22.05 | 24.25 | 26.46 | 28.66 | 30.86 | 33.07 | 35.27) 3748) 39.68] 41.89 20 |44.09 | 4630 | 4850 | 50.71 | Stat | 55.12 | 5732| 5a53| 61.73] 6393 30 |66.14 | 68.34 | 70.55 | 72.75 | 74.96 | 77.16 | 79.37) 81.57| 83.78] 8598 40 |ga.18 | 90.39 9259 | 94.80 | 97.00 | 99.21 | 101.41 | 103.62 | 105.82 | 108.03 50 |110.23 | 112.44 | 114.64 | 116.85 | 119.05 | 121.25 | 129.46 | 125.66 | 127.87 | 130.07 60 | 192.28 | 134.48 | 136.69 | 138.89 | 141.10 | 143.30 | 145.51 | 147.71 | 149.91 | 152.12 70 | 184.82 | 156.53 | 158.73 | 160.94 | 163.14 | 165.35 | 167.55 | 169.76 | 171.96 | 174.17 80 | 176.37 | 178.57 | 180.78 | 182.98 | 185.19 | 187.39 | 189.60 | 191.80 | 194.01 | 196.21 90 — | 198.42 | 200.62 | 202.83 | 205.03 | 207.24 | 209.44 | 211.64 | 213.85 | 216.05 | 218.26 00-17FOREWORD CONVERSION TABLE Liter to U.S. Gallon 10 =0.2642 US. Gal —— 0 1 2 3 4 5 6 7 8 9 ° 0 0.264 | 0.528) 0.793 | 1.057 1.585| 1849] 2113] 2978 10 2642) 2.906| 3.170) 3.434] 3.698 4227) 4.491| 4.795| 5.019 20 5283 5.548| 5812| 6076| 6.340 6.869) 7.133| 7.397] 7.661 30 7.925) 8.189| 8.454| 8718] 8.962 9.510 | 9.774 | 10.039 | 10.303 40 10.567 | 10.831 | 11.095 | 11.359 | 11.624 | 11.888 12.152 | 12.416 | 12.680 | 12.944 50 19.209 | 13.473 | 13.737 | 14.001 | 14.265 | 14.529 | 14.795 | 15.058 | 15.922 | 15.586 60 15.850 | 16.115 | 16.379 | 16.643 | 16.907 | 17.171 | 17.435 | 17.700 | 17.964 | 18.228 70 18.492 | 18.756 | 19.020 | 19.285 | 19.549 | 19.813 | 20.07 | 20.341 | 20.605 | 20.870 80 21.134 | 21.998 | 21.662 | 21.926 | 22.190 | 22.455 | 22.719 | 22.983 | 23.247 | 23.511 90 23.775 | 24.040 | 24.904 | 24.568 | 24.832 | 25.096 | 25.361 | 25.625 | 25.889 | 26.153 Liter to U.K. Gallon = 0.21997 UK. Gal 0 1 a 3 4 5 6 7 8 9 — 0 0 0.220} 0.440) 0.660} 0.880) 1.100) 1.320) 1.540] 1.760| 1.980 10 2200} 2420| 2640| 2860) 3080] 3300| 3520) 3740| 3950| 4179 20 4399) 4.619 | 4.939 5.059] 5279| 5a99/ 5.719) 5.939] 6159| 6.379 30 6599) 6.819 | 7.039, 7.259) 7.479| 7989| 7.919) 8.139| 8359| 8579 40 8799) 9.019) 9239) 9459| 9.679) 9899 | 10.119 | 10.339 | 10.559 | 10.78 50 10.998 | 11.281 | 11.438 | 11.658 | 11.878 | 12.098 | 12.318 | 12.528 | 12.758 | 12978 60 13.198 | 13.418 | 13.638 | 13.858 | 14.078 | 14298 | 14.518 | 14.738 | 14.958 | 15.178 70 15.398 | 15.618 | 15.838 | 16.058 | 16.278 | 16.498 | 16.718 | 16.938 | 17.158 | 17.978 80 17.598 | 17.818 | 18.037 | 18.267 | 18.477 | 18.697 | 18.917 | 19.137 | 19.357 | 19.677 90 19.797 | 20.017 | 20.237 | 20.457 | 20.677 | 20897 | 21.117 | 21.937 | 21.557 | 21.777 00-18FOREWORD CONVERSION TABLE kgm to ft. Ib 1 kgm = 7.283 ft b 0 1 2 3 4 5 6 7 8 8 0 0 72 | 145 | 217 | 289 362] 434 | 506) 579 | 65.1 10 723 | 796) 968 | 940 | 101.3 | 1085 | 157 | 123.0 | 1302 | 197.4 20 1447 | 1519 | 159.1 | 1664 | 1736 | 1808 | 188.1 | 195.3 | 2025 | 2098 30 217.0 | 224.2 | 231.5 | 238.7 | 245.9 | 253.2 | 260.4 | 267.6 | 274.9 | 2821 40 2093 | 2066 | 303.8 | 3110 | 3183 | 3255 | 332.7 | 340.0 | 347.2 | 3544 50 3617 | 368.9 | 376.1 | 383.4 | 390.6 | 3978 | 405.1 | 412.3 | 4195 | 4268 60 434.0 | 441.2 | 448.5 | 4557 | 4629 | 4702 | 477.4 | 4846 | 491.8 | 4901 70 5063 | 513.5 | 520.8 | s2a0 | S352 | 5425 | 549.7 | 556.9 | 5e42 | 571.4 80 578.6 | 585.9 | 593.1 | 600.3 | 607.6 | 614.8 | 622.0 | 629.3 | 6365 | 643.7 90 651.0 | 658.2 | 665.4 | 672.7 | 679.9 | 6871 | 694.4 | 701.6 | 7088 | 7161 100 | 7233 | 7305 | 737.8 | 745.0 | 7522 | 7595 | 766.7 | 773.9 | 781.2 | 7084 110 | 7956 | 8029 | 810.1 | 8173 | ge46 | 8318 | 839.0 | 846.3 | 8535 | 860.7 120 | 8680 | 975.2 | 8824 | 989.7 | e969 | 904.1 | 911.4 | 918.6 | 9258 | 9931 130 | 9403 | 947.5 | 954.8 | 9620 | 969.2 | 9765 | 983.7 | 990.9 | 9982 | 1005.4 140 | 1012.6 | 1019.9 | 1027.1 | 1034.3 | 1041.5 | 1048.8 | 1056.0 | 1063.2 | 10705 | 1077.7 150 | 1084.9 | 1092.2 | 1099.4 | 1106.6 | 1113.9 | 1121.1 | 1128.3 | 113546 | 11428 | 1150.0 160 | 1157.3 | 1164.5 | 1171.7 | 1179.0 | 1186.2 | 1193.4 | 12007 | 1207.9 | 1215.1 | 1222.4 170 | 1129.6 | 1236.8 | 1244.1 | 1251.3 | 12585 | 12658 | 1273.0 | 1280.1 | 12875 | 1294.7 180 | 1301.9 | 1309.2 | 13164 | 1323.6 | 1330.9 | 1338.1 | 13453 | 1382.6 | 1359.8 | 1967.0 190 | 1974.3 | 1381.5 | 1388.7 | 1996.0 | 1403.2 | 1410.4 | 14177 | 1424.9 | 1492.1 | 1439.4 00-19FOREWORD CONVERSION TABLE kg/cm? to Ibvin? tkgiem? = 14.2233 loin? “S| 2 1 2 3 4 5 6 7 8 9 o 0 142) 284 427] 569] 71.1) 85.3, 99.6] 113.8] 1280) 10 142.2| 1565| 170.7) 1849] 199.1] 213.4) 227.6) 241.8] 256.0| 270.2 20 284.5) 2987) 3129) 327.1] 341.4] 355.6, 369.8 384.0/ 3983| 4125) 30 426.7| 4409) 455.1] 469.4] 4836) 497.8, 512.0| 526.3| 5405| 5547 40 868.9) 583.2) 5974 611.6] 6258| 640.1) 654.3, 668.5] 6827| 696.9 50 7i12| 728.4) 7396) 753.8) 768.1! 782.3) 796.5) 9810.7| 825.0] 639.2 60 853.4) 867.6) 861.8, 896.1] 910.3] 924.5, 938.7, 953.0/ 967.2| 981.4) 70 995.6, 1010 | 1024 | 1038 | 1053 | 1067 | 1081 | 1095 | 1109 | 1124 80 1138 | 1152 | 1166 | 1181 | 1195 | 1209 | 1223 | 1237 | 1252 | 1266 90 12a0 | 1294 | 1309 | 1323 | 1337 | 1351 | 1365 | 1380 | 1394 | 1408 400 1422 | 1437 | 1451 | 1465 | 1479 | 1493 | 1508 | 1522 | 1536 | 1550 110 1865 | 1879 | 1583 | 1607 | 1621 | 1636 | 1660 | 1664 | 1678 | 1693, 120 1707 | 1721 | 1735 | 1749 | 1764 | 1778 | 1782 | 1806 | 1821 | 1835 130 1e49 | 1863 | 1877 | 1892 | 1906 | 1920 | 1934 | 1949 | 1963 | 1977 140 1991 | 2005 | 2020 | 2034 | 2048 | 2062 | 2077 | 2091 | 2105 | 2119 150 2134 | 2148 | 2162 | 2176 | 2190 | 2205 | 2219 | 2233 | 2247 | 2062 160 2276 | 2290 | 2304 | 2318 | 2333 | 2347 | 2361 | 2375 | 2389 | 2404 170 zaig | 2432 | 2446 | 2460 | 2475 | 2489 | 2503 | 518 | 2532 | 2546 180 2560 | 2574 | 2589 | 2603 | 2617 | 2631 | 2646 | 2660 | 2674 | 2688 190 2702 | 2717 | 2731 | 2745 | 2759 | 2773 | 2788 | B02 | 2816 | 2830 200 zeas | 2859 | 2873 | 2687 | 2901 | 2016 | 2930 | 2o44 | 2058 | 2973 210 2987 | 3001 | 3015 | 3030 | 3044 | 3058 | 3072 | 3086 | 3101 | 3115 220 3129 | 3143 | 3158 | 3172 | 3186 | 3200 | s2t4 | 3229 | 3243 | 3257 230 se71_ | se86 | s300 | 3314 | 3328 | 3343 | 3367 | 3371 | 3365 | 3399 240 3414 | 3428 | 3442 | 3456 | 3470 | 3485 | s499 | 3513 | 3627 | 3542 00-20FOREWORD CONVERSION TABLE Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen- tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col umn of figures. ‘These figures refer to the temperature If itis desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit tamperatures and read the corresponding Centigrade temperature in the column at the left. IFitis desired to convert trom Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right, either Fahrenheit or Centigrade degrees, 190 =338F Oy e | e | * | + 40.4 | -40 | 400] -11.7] 1 | 518] 78 | 46 | 148] 272 | a1 | 1178 -972| -95 | -310]-111| 12 | 536] 83 | 47 | 166 | 278 | 92 | 1796 -344| -30 | -220]-106| 13 | 554] 89 | 48 | 1184] 283 | 83 | 1814 -317 | -25 |-130]-100] 14 | 572] 94 | 49 | 1202] 29 | 4 | 1832 -289| -20 | -40] -94| 15 | 590| 100 | s0 | 1220] 294 | 85 | 1850 -23| -19 | -22|] -39| 16 | sos] 105 | 51 | 1238] 300 | 96 | 1868 -278| -18 | -04] -83| 17 | 626] 114 | 52 | 1256] 306 | 87 | 1886 -272| -17 | 14] -78| 18 | 644] 7 | 53 | 1274] 31.1 | 98 | 1904 -%7| -16 | 32] -72| 19 | se2| 122 | sa | 1292] 317 | 99 | 1922 -26.1| -15 | 50} -67| 2 | 680} 128 | 55 | 131.0] 322 | 90 | 1940 -26| -14 ] 68] -61| 21 | 698] 133 | 56 | 1328] s28 | 97 | 1958 -25.0| -13 | s6| -s6| 2 | 716] 139 | 57 | 1346] 333 | 92 | 1976 -m44| -12 | 104] -50| 23 | 734] 144 | 58 | 1364] 339 | 93 | 1994 -239| -11 | 122] -44| 2 | 752] 150 | 59 | 1382] 344 | 94 | 2012 -233| -10 | 140] -39| 25 | 770] 156 | 0 | 1400] 35.0 | 95 | 2030 -28| -9 | 158] -33| 2 | 7as| 161 | 61 | 1418] 356 | 96 | 2048 -222| -8 | 176] -28| 27 | 806] 167 | 62 | 1436] 361 | 97 | 2066 -217| 7 | 194] -22| 2 | 824] 172] 63 | 1454] 367 | 98 | 2084 aii} 6 | 212] -17] 29 | 842] 178 | 64 | 1472] 37.2 | 99 | 2102 -26| -5 | 230] -11| 30 | 860] 183 | 65 | 149.0] 37.8 | 100 | 2120 -20.0| 4 | 248] -06| 31 | 878] 189 | 66 | 1508] 406 | 105 | 221.0 -194| -3 | 266] 0 | 32 | 896] 194 | 67 | 1526] 433 | 110 | 2300 -199| -2 | 284] o6| 33 | 914] 200 | 68 | 1544] 461 | 115 | 239.0 -103| = | soz] 11] 34 | 932] 2065 | 69 | 1562] 489 | 120 | 2480 -178| 0 | 320] 17] 35 | 950] 211 | 70 | 1580] 51.7 | 125 | 2570 -172| 1] 338] 22] 36 | 968] 217 | 71 | 1598] 544 | 130 | 2660 -167| 2] 356] 28] 37 | 986] 222 | 72 | 1616] 57.2 | 135 | 2750 16.1 3 | 374] 33] 38 | 1004] 228 | 73 | 1634] 60.0 | 140 | 2840 -156| 4] 392] 39] 39 | 1022] 233 | 74 | 1652] 627 | 145 | 29030 -150| 5 | 41.0] 44] 4 | 1040] 239 | 75 | 167.0] 656 | 150 | 3020 -144| 6 | 428] 50] 41 | 1058] 244 | 76 | 1688] 683 | 155 | 311.0 -139| 7 | 446] 56] 42 | 1076] 250 | 77 | 1706] 71.1 | 160 | 3200 -133| 8 | 464] 61] 43 | 1094] 256 | 78 | 1724| 739 | 165 | 3290 -128| 9 | 482] 67] 44 | 112] 261 | 79 | 1742] 767 | 170 | 3380 -122| 10 | soo} 72] 48 | 1130] 267 | 80 | 1760| 794 | 175 | 3470 00-21FOREWORD UNITS UNITS In this manual, the measuring units are indicated with Intematinal System of units (SI) As for reference, conventionally used Gravitational System of units are indicated in parentheses { }. Example: N {ko} Nm {korn} MPa (kg/om?} kPa {mmH-0} kPa {mmHg} kWWérpm (HP/tpm) g/kWh (g/HPh) 00-22 04-0501 GENERAL GENERAL ASSEMBLY DRAWINGS 01-2 SPECIFICATIONS 01-3 WEIGHT TABLE. 01-7 LIST OF LUBRICANT AND COOLANT. 01-9 WA150-5, 01-1GENERAL, GENERAL ASSEMBLY DRAWINGS GENERAL ASSEMBLY DRAWINGS 0 ' i c 8 6 te item Unit WAI80-5 Operating weight (with BOC) ho TA Rated load KN (koh 23.5 (2.400) Bucket capacity (piled) (With BOC) me 18 Engine model = KOMATSU SAAD 102-2 Diesel engine Flywheel horse power OV (HPH tm 71 (96) 12,000 ‘A_[ Overall length (With BOC) mm 6,820 B | Overall height mm 3,035 © | Overall height when buckets raised mm 4.690 D | Overall wath mm 2,260 E | Min. ground dearance mm 200 F_[ Bucket with mm 2,390 [Dumping dearance __| Tip of bucketiTip of BOG mm 2785/2.705 H | Dumping reach Tip of bucket/Tip of BOC mm 8407 970 [Bucket dump angie ae. 45 Tip of bucket/Tip of BOC mm 5165/6, 185 Min. turning radius Center of outside whee! mm 4470 Ft nih 46-180 F2 en Th 30 FS kn Th 200 ‘Travel speed tal nih 280 Ri kn Th 46-130 R2 en Th 30 R3 nh 200 [Ra kn Th 380 01-2 WA150-5GENERAL SPECIFICATIONS SPECIFICATIONS Machine model WAI50-5 Serial No 65001 and up = [Operating weight (th BOO) Kg 7A B istibution (ront) SAE travel posture kg 2975 © [bistrivution (rear) SAE travel posture ka 4450 Bucket capacity (ples) (With BOO) ™ 15 Rated load KN 23.5 (2.400) FTravel speed ‘FORWARD ‘st kin 46-120 FORWARD 2nd km/h 130 FORWARD 31d kmh 200 FORWARD 4th kos 38.0 3 REVERSE tt kesh 46-130 5 REVERSE 2nd km/h 130 5 REVERSE rd km 200 @ REVERSE 4th ksh 38.0 Max. rimpull FORWARD KN ho} 63.7 46.500) REVERSE KN (ho) 63.7 (6,500 JGradeabitiy og. 5 Min. turning rads (Genter of outside | yy 4470 ftpottuekertpotBoc) Mel) mm 168 /5.185 [Overall Ienath (with BOC) mm 6320 Overall width (chassis) mm 2.250 Bucket width (with BOO) mm 2390 Overall height (op of cab) mm 3.035 Overaneaht Bucket eporo. 28631 | ayy oo Wheel base mm 2600 2 |Tresa mm 4780 |Min, ground clearance mm 400 Fox nophtor bucket hinge pin om ass [Dumping cearance (i of bucketTip of B0C)| mm 2,765 12,705 Dumping reach (Tip of bucevTp of BOC) mm 9401970 steering angle 0. 40 Bucket tit angle (vavel posture) 609. 46 Bucket it angle (max. height) 09. 66 Bucket dump angle (max. height) cog. 46 Digging depth (10° dump) wt 220 1255 (Tip of bucket/Tip of BOC) WAt50-5 01-3GENERAL SPECIFICATIONS Machine model Waiso-5 Serial No. 85001 and up ‘Mode! SANDTOE? a eon ee talegooled. ened, rect injection with turbocharcer, aif-cocled aftr cooler 'No. ofcyinders -bore x stroke mm 4~102x 120 Piston displacement (cc) 2.92 (2,920) Flywhel horsepower RV pm 717 2,000 (HP pm) {96 2,000) Maximum torque Nmv/ipm 402 11,300, a {kom J rpm) (411,300) 'Min. fue! consumption ratio 19 / kWh fg HPay 219 (163 High idle speed tom 2,250 Low idle speed tom 825 ‘Saring motor Ba SBKW ‘Atemator 24 35, Batory 1) 24 92 Ah x2 pos. HST pump Variable displacement swash plate type piston pump HST motor 1 Variable displacement bent axis type piston motor |MST moter 2 Variable displacement bent axis type piston motor & || Teansier. ‘Multiple shaft planetary compound-type, sour gear 3 Constant meshelype, 2 altomnative power systems € Reduction gear ‘Spiral bevel gear, splash lubrication type ferential ‘Straight bevel gear ype, torque portioning Final chive Planetary gear 1-slaye, splash lubrication type Drive type Frontand eer whe! drive $ |Frontaxte Fe fram, smitostng pe Rear axle Center pin support, semiloating type Tee size 168-24-10PR (12) g |Rimsize isl x 24 F inflation pressure Front tre kPa {kg fom?) 235 (2.4) Rear tire Pa kg om?) 236 (2.4) anager “heel baking, Font nd ear wheeindpendont = ewok Brake type Enclosed wet mutiple dsc type . (Operation method ydrautcaly controted g contro! metnod Hydraulic power servo assisted brake & {Braking system Speed change gear output shaft braking Brake type Wet multiple cise ype Parkingbrake operation method Mechanical type {contol metnod Hand lever ype “i Battery capacity (Ah) shows the rate of 5 hours, 01-4 (5) WA150-5GENERAL SPECIFICATIONS Machine model WAi50-5 Serial No 65001 and up type Ariculated steering contrat Hydeaulie conto! Wik quant and Soong pap “Type oa ype + Thacrota copacty emtrev aa E [Brake and cooling fan pump | te ear ype | + rhearacl capac emeoy 10s * [Transfer lubrication pump “Type oor ype + Theorie cepecty emtrev oa [ee Recprocatig piston vee e | | 3 [eviinderiner diameter rn 56 3 & | piston rod dlametar _ 20 5 Stroke mm 375 2 )| | Moc tng powsen ps im 1,020 z i. encthbotwoen pins xm cas Type Rocprocating piston ype «,|exnce ner amater rm 110 3 & [ston ou diameter rn 6 5 = [sree tm 28 5 ‘tax. tngthbotwon pins on 1.059 is. ann between pins . 1.01 Type ezprocatng pion Wee Cyindor ner samen rm 10 Paton rod dameter tm ss srke rm 42 Max. engh between pins rm 1307 in. ont botwoan pins rm ons WAt50-5 01-5GENERAL, SPECIFICATIONS Mechine model wate0-s Sea No. 6001 and up |Work equipment control valve | te sarees ‘ £ | 3] - setpressue MPa {ka Jem’) 20.6 (210) & | 8 lance 218]. tine omit ype 3 + Sot pressure MPa {kg Jem") 186 (190) 3 [e22ira tan moter 2] + tw. Fined iplaariont stn ype “eJ lUnktpe Shale ink 2. 2 3 louchet edge oe Flat blade with op BOC 01-6 WA150-5GENERAL WEIGHT TABLE WEIGHT TABLE Ad This weight table is a guide for use when transporting or handling components. Unit kg Machine model WA150-5 Seral Numbers 9001 and up Engne (winow coolant and of) 250 Cooling assembly (without coolant) 1 Cooling fan metor 6 Damper 3 AST pum % HST motor 1 28 HST motor2 % Transfer 158 Front drive shot “4 Rear dive shat 4 Front axle 410 Rear axle 360 ‘Axle pivot rear axe) 6 Wheel each) 3 Tre (each) ot ofbial vane 7 Priory vane 6 Steering cyinder assembly (each) 8 Brake vane 0 yer tank without hydrauke a) ® Seger pump unt 20 Work equiment PPC vale 3 Work equipment contolvave 8 Lit onder assembly (each) es Bucket onder assembly % Engine nood (with side pane!) 140 Front fame 83 Rear ame 573 WA150-5, 01-7GENERAL, WEIGHT TABLE Unit: kg Machine model WAts0-5 Serial Numbers {65001 and up Li arm (including bushing) aur Bucket (1.5m, including BOC) 595 Boll crank +08 Bucket tink 7 Counterwaight 660 ‘Additional counterweight (1 piece) +00 Fue! tank (without fue!) 70 Battery each) 23 Operator's Cab (Including air conditioner and interior parts) 755 Operator's seat a 01-8 WA150-5 (5)GENERAL LIST OF LUBRICANT AND COOLANT LIST OF LUBRICANT AND COOLANT For details of the notes (Note 1, Note 2, the table, see the Operation and Maintenance Manual. ‘Ambient Temperature Reservoir Fuidtype [22-414 92 50 68 06 104 122°F| pom nacs +30 -20 -10 9 10 20 30 40 50% TT T_T 1 T Komatsu | } EO10W30-0H | APICH-4 i APICI-A Engine Oil Pan | Engine oil i efomae ' ‘APICH-4 | APICI-4 i Komatsu i E030-DH Powertrain oil Transfer case nee) | Tot Hydraulic System | Engine oi! i meet Axle oll f (Note.2) noe Axle + Engine oil | E050-CD Hyper grease | 7, G22 (Nod : G27, G2-TE Grease titting : Lithium EP grease | | aati ‘Supercoolant i Cooling system | ANI E y AF-NAC. i ASTM No.2-D Fuel tank Diese! fuel | Wi ASTM No.1-D Reservoir! Engine oll | Transfer | Hydraulic Aate Fuel tank | cooling Capacity pan cee system | Front | Rear system Liters 4 48 so | 140) 145] 133 7 Specified | 1 | us gal | 3.70 1.27 2378 | 3.70 | 383) 35.14 4.49 tiers | 125 44 a7 | 140 | 145 = = Refill usgal | 3.30 1.16 1242 | 3.70 | 383 = - WA150-5, 01-9 (5)10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE MOUNT AND TRANSFER MOUNT 10- 2 DAMPER, 10-3 COOLING SYSTEM. 10-4 POWER TRAIN 10-5 POWER TRAIN SYSTEM DIAGRAM vcs. 10° 6 DRIVE SHAFT (PROPELLER SHAFT) .wanc.. 10" 8 HST HYDRAULIC PIPING DIAGRAM. 10-9 HST PUMP 10-10 HIGH-PRESSURE RELIEF VALVE 10-12 LOW-PRESSURE RELIEF VALVE. 10-14 HST CHARGE PUMP 10-15 ‘SPEED-RELATED VALVE (DA VALVE) ..... 10-16 HIGH-PRESSURE CUT-OFF VALVE 10-17 HST MOTOR 10-18 EP SERVO VALVE 10-24 HA SERVO VALVE 10-22 FORWARD-REVERSE SHUTTLE VALVE .... 10-23 TRANSFER. 10-24 CLUTCH SOLENOID VALVE su 10-95 AXLE... svenntneneee 10°36 DIFFERENTIAL 10-38 LIMITED-SLIP DIFFERENTIAL 10-44 FINAL DRIVE. 10-48 AXLE MOUNTING AND. CENTER HINGE PIN sus 10-50 STEERING PIPING wesc 110-55 STEERING COLUMN: 10-56 PRIORITY VALVE 10-57 ORBIT-ROLL VALVE 10-60 STEERING CYLINDER 10-68 EMERGENCY STEERING PIPING 10-70 EMERGENCY STEERING VALVE... 10-71 BRAKE PIPING. 10-74 BRAKE VALVE 10-75 INCHING VALVE 10-79 CHARGE VALVE. csisawrauses 10-80 ACCUMULATOR (FOR BRAKE) 10-84 SLACK ADJUSTER nso 10-85 BRAKE 10-88 PARKING BRAKE CONTROL 10-91 PARKING BRAKE 10-92 HYDRAULIC PIPING 10-94 WORK EQUIPMENT LEVER LINKAGE........ 10-96 HYDRAULIC TANK. 10-97 WAt50-5 3-GEAR PUMP UNIT. 40-100 ACCUMULATOR (FOR PPC CIRCUIT)......10-102 LOCK VALVE 10-103 ECSS. VALVE 10-104 ACCUMULATOR (FORE.C.S.S.) 10-107 HYDRAULIC PIPING OF COOLING SYSTEM. 10-108 COOLING FAN MOTOR 40-109 WORK EQUIPMENT CONTROL VALVE.....10-110 WORK EQUIPMENT PPC VALVE 10-123 WORK EQUIPMENT LINKAGE. 10-130 BUCKET een oN O-132 BUCKET POSITIONER AND ‘BOOM KICK-OUT 10-133 WORK EQUIPMENT CYLINDER 10-139 AIR CONDITIONER 10-140 MACHINE MONITORING SYSTEM 10-141 MACHINE MONITOR 10-151 LIST OF ITEMS DISPLAYED ‘ON MONITOR... 0-192 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM) 10-178 HST CONTROLLER 10-182 ENGINE START CIRCUIT. 10-183 ENGINE STOP CIRCUIT. 0-185 PREHEATING CIRCUIT... ne 10486 PARKING BRAKE CIRCUIT... 10-187 ELECTRONICALLY CONTROLLED ‘SUSPENSION SYSTEM 40-190 SENSORS, 10-191 10-1STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE MOUNT AND TRANSFER MOUNT ENGINE MOUNT AND TRANSFER MOUNT 59-74Nn (8-7, 5kem) 98-1230 98-123Nn (io-12 Sken) (10-12, Skenl 96-123Nn (10-12. Shem! 236-205Nn 235-265Na 59-74Ne 123. 5-29" skon \. 1235-29" Skenl (6-7. Shon! sugora0e 10-2 WA150-5STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DAMPER 123M 110-12, Skea! DAMPER. 245-309Ne 125-31. Skea! 5. 8-73. Nn ig (6 0-7. Stam 44, 1°53. Ne fC 45-5. Bkom eo J \ Ne 100-120Nn . (0, 2°12" 24m 4 5 a 6 20m tt 4 ri Ty Z it TE vf v ba veoiee7 Unit: mm No. Check tem Criteria Remedy Standard size Repair init 1 [Distance between HST pump z — mounting face ard end of ub ae a8 2 [Wear of lange and insert Repairlimit: 10 Replace 3. Flange Outline 4. HST pump input shaft + The damper reduces the torsional. vibration 5. Hub caused by fluctuation of the engine torque to pro- 6. Cover tect the drive system after the engine from the 7. Flywheel torsional vibration 8. Insert +The power from the engine is transmitted through flywheel (7) to flange (3), which absorbs the tor- sional vibration, and then transmitted through hub (5) to the HST pump. WAt505 10-3STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING SYSTEM COOLING SYSTEM svena10 4. Oil cooler 4, Reservoir tank 2. After cooler 5. Cooling fan 3. Radiator 6. Cooling fan motor Specification a Radiator Ol cooler Afr cooler Core type AL WAVE-4 C404 ALWAVE Fin pitch (mm) 35/2 35/2 4012 ‘Total heat radiating area (m) 20 5.12 5.75 Pressure valve opening pressure 686 _ _ (kPa {kaiem?}) {0.7} Vacuum valve opening pressure 0-49 (kPa (kglem?)) {0 ~ 0.05) 10-4 WA150-5STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN POWER TRAIN ‘001253 Engine Damper HST pump 3-gear pump unit High-pressure hose HST motor 1 HST motor2 Transfer Front drive shaft 10. Front axle 11, Rear drive shaft 12, Rear axle eenoorens WA150-5, 10-5STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM POWER TRAIN SYSTEM DIAGRAM suaniane 10-6 WA150-5STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM Senouhena 10. 1". 12, 13, 14, 18, 16. 17. 18, 19, 20. 2 22. 23. 24, 26. Engine Damper HST pump Work equipment and Steering pump Brake and cooling fan pump Transfer lubricating oil pump High-pressure hose HST motor 4 HST motor 2 Emergency steering valve (If equipped) Transfer Transfer clutch Parking brake Front drive shaft Front axle Differential Wet multiple disc brake Final drive Front tire Rear drive shaft Rear axle Differential Wet multiple disc brake Final drive Rear tire WAt50-5 Outline The power of engine (1) is transmitted to HST pump (3) through damper (2) which is installed to the flywheel and which absorbs the torsional vi- bration of the power, The power of engine (1) is also transmitted to HST pump (3), HST charge pump built in HST pump (3), work equipment and steering pump (4) connected to HST pump (3), brake and coaling fan pump (5), and transfer lubricating oil pump ©. HST pump (8) is equipped with the forwarc-re- verse shifting valve and servo piston, which changes the discharge direction and discharge rate of HST pump (3) continuously by changing the swash plate angle. HST motors (8) and (9) are installed to transfer (11) and connected to HST pump (3) by high- pressure hose (7). The turning direction and speed of HST motors (8) and (9) are changed by the hydraulic power of HST pump (3) to contro! the travel direction and travel speed of the machine. The power of HST motor 1 (6) is transmitted through transfer clutch (12) in transfer (11) to the output shatt The power of HST motor 2 (9) is transmitted through the gear in transfer (11) to the output shaft Parking brake (13) is installed on the rear side in transfer (11). Itoperates the wet multiple disc brake to stop the machine according to the oper- ation of the parking brake lover. The power for the front side is transmitted through front drive shaft (14) to front axle (15). The power for the rear side Is transmitted through rear drive shaft (20) to rear axle (21) The power transmitted to axles (15) and (21) is reduced in speed by the pinion gears of diferan- tials (16) and (22), and then transmitted through the sun gear shaft to the sun geer. The power of the sun gears reduced in speed by the planetary mechanisms of final drives (18) and (24), and then transmitted through the axle shaft and wheels to tires (19) and (25). 10-7STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE SHAFT DRIVE SHAFT 52-7400 {50-7 5kan) sumerane 1. Front axle Outline 2, Front drive shaft + The power from the output shaft of the transfer is 3. Transfer transmitted through front drive shaft (2) and rear 4, Rear drive shaft drive shaft (4) to front axle (1) and rear axle (5). 5. Rearaxie + When the machine is articulated or it receives an impact from the road during travel or a working impact, the positions of the transfer and front and rear axles change. The drive shafts can change their angles and lengths by means of the univer- sal joints and sliding joints so that the power will be transmitted without damaging any part even when the positions of the components change because of the impacts. 10-8 WA150-5STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST HYDRAULIC PIPING DIAGRAM HST HYDRAULIC PIPING DIAGRAM susos9n1 1. Hydraulic tank 2. HST pump 3. Clutch solenoid valve 4. HST oil filter 5. HST motor 1 6. HST motor 2 WA150-5, 10-9STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST PUMP HST PUMP ‘HST: Abbreviation for Hydro Static Transmission 1 0 4 8 auynatai8 1. Forward-reverse shifting solenoid valve Specifications 2. High-pressure cut-off valve 3. Speed-related valve (DA valve) mea eaerinn 4. Charge pump b Varizoiecspiacarnent awash 5. Low-pressure reliof valve vs plate-ype piston pump 8. Servo cylinder aiid eal 7. High-pressure relief valve oe on 8. Control plate ——____| 9. Cylinder block Set pressure of hgh pressure soz 10. Piston rele vaive (MPa ken?) 11. Swash plate Setpossue othighpressure | Ettectve dferntal pressure cutotvaive (MPa {hgfon?) 40.2(410) Set pressure of low-pressure rol valve (MPa kale) cual 10-10 WA150-5STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST PUMP Operation Flow of power ‘The HST pump is installed to the coupling which is installed to the engine fiywheel ‘The power of the engine is transmitted from the flywheel through the coupling to the HST pump. The HST pump is equipped with forward-reverse shifting solencid valve (1) and servo cylinder (6) If the operator operates for forward or reverse travel, forward-reverse shifting solenoid valve (1) ‘operates and swash plate (11) in the HST pump, slants to reverse the oil ow. Cylinder block (8) and pistons (10) in it rotate to- gether with drive shaft (12) and the tips of pistons, (10) slide on swash plate (11) which does not ro- tate. The pump has 9 pistons (10) init. aooia18 WAt50-5 Flow of oil ‘As swash plate (11) of the HST pump stants, pis- tons (10) in contact with its surface reciprocate and work as pumps to suck and discharge the oil in cylinder block (8). As a result, high-pressure oil flows in a constant direction into the HST motor. If swash plate (11) slants in the opposite direc- tion, the sucking and discharging directions of the oll are reversed, that is, the oll flows in the oppo- site direction. While swash plate (11) is in neu- tral, pistons (10) do not reciprocate, thus they do not discharge any ol The strokes of pistons (10) are changed to con- trol the travel speed by increasing or decreasing inclination (angle) of swash plate (11). Ifthe quantity of the oil in the low-pressure circuit (the return circuit from the motor to the pump) be- Comes insufficient because of leakage from the HST pump, HST motor, and control valve, the charge pump adds oil through speed-related valve (3) and check valve of high-pressure relief valve (7) suction Delivers Delivers Suction Nevieal 001 140 10-11STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HIGH-PRESSURE RELIEF VALVE HIGH-PRESSURE RELIEF VALVE Nut Locknut Poppet spring Check spring Main piston Valve seat Pilot poppet Adjustment screw PNOMaEnS 10-12 ig )B01141 Function The high-pressure relief valve is installed to the HST pump. If the cil pressure in the high-pres- sure circuit between the HST pump and HST mo- tor rises higher than the set pressure, the high- pressure relief valve drains the oil into the low- pressure circuit. The high-pressure relief valve controls the maxi- mum pressure in the circuit to protect the circuit with this function. Ifthe quantity of the oilin the circuit becomes in- sufficient, the high-pressure valve leads oil in from the HST charge pump to prevent cavitation, WA150-5STRUCTURE, FUNCTION AND MAINTENANCE STANDARD Operation Port A is connected to the high-pressure circuit of the HST pump and ports C and D are connected to the low-pressure circuit of the HST pump. The oil fills chamber B through the orifice of main piston (5) Pilot poppet (7) is seated on valve seat (6). pypo142 WAt50-5 HIGH-PRESSURE RELIEF VALVE {fhe oil pressure in port A and chamber B reach- es the set pressure of poppet spring (3), pilot poppet (7) opens and the oll in chamber B flows through chamber D to port G, and the oll pressure in chamber B lowers consequent. If the oil pressure in chamber B lowers, a pres- sure difference is made between port A and chamber B by the orifice of main piston (6). Asa result, main piston (5) is pushed open and the oil in port A flows into port C to relieve the ebnomal pressure. SSSR auonas The set pressure can be adjusted by increasing cr decreasing the tension of poppet spring (3) To adjust the set pressure, remove the nut and loosen the locknut. If the adjustment screw is tightened, the set pressure is heightened. if the former is loosened, the latter is lowered 1f the oil pressure in port A lowers below that in port C, check spring (4) pushes back main piston (8) and the oll in port G flows through chamber D into port A so that the quantity ofthe oil in port A will not become insufficient. 10-13STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LOW-PRESSURE RELIEF VALVE LOW-PRESSURE RELIEF VALVE Operation ae 3 \ ouani14s, 1. Locknut 2. Adjustment screw 3. Piston 4. Spring Function + The low-pressure relief valve is installed to the HST pump. If the oil pressure in the low-pressure circuit between the HST pump and HST motor rises higher than the set pressure, the low-pres- sure reliof valve drains the oil into the hydraulic tank. The low-pressure relief valve controls the pres- sure in the HST pump charge circuit to protect the circuit with this function 10-14 Port A is connected to the HST pump charge cir- cuit and port B is connected to the drain circuit. Ifthe oll pressure is below the set pressure, the oll does not flow into port B. Ifthe pressure in port A reaches the set pressure for some reason, piston (3) opens and the oil in port A flows into port B, and the oil pressure in port A lowers consequently. The set pressure can be adjusted by increasing or decreasing the tension of spring (4). To adjust the set pressure, loosen locknut (1) and turn adjustment screw (2). If the adjustment screw is tightened, the set pressure is height- ened. If the former is loosened, the latter is low- ered art a evan 1148, WA150-5STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST CHARGE PUMP HST CHARGE PUMP Cover bolt Pump gear Key Coupling Drive shat Plate Charge pump cover Crescent divider board suction 801147 Gear pump (inscribed type) 196 Function Outline + The HST charge pump is built in the HST pump. and driven together with the HST pump tosupply oil to the HST speed-elated valve and low-pres- sure relief valve of the HST pump. + The HST charge pump sucks in oil from the hy- draulic tank. WAt50-5 ‘The HST charge pump is connected to drive shaft (5) of the HST pump and rotated by coupling (4). The HST charge pump has pump gear (2) and crescent divider board (8)in it and sucks and dis- charges the oil in the direction shown in the above figure. 10-15STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPEED-RELATED VALVE (DA VALVE) SPEED-RELATED VALVE (DA VALVE) Locknut Adjustment screw Poppet spring Spring seat Pilot poppet eaeNe Function + The speed-related valve is installed to the HST pump and used to divide the oil from the HST charge pump into two parts. One part flows through a throitle valve to the forward-reverse shifting solenoid valve of the HST pump and the ther part flows to the low-pressure relief valve of the HST pump. Operation + Port Ais connected to the HST pump charge cir- cuit. Port D is connected to the low-pressure re- lief valve circuit. Port € is connected to the forward-reverse shifting solenoid valve circuit. + The oil from the HST charge pump always flow through the throttle valve of pilot poppet (5), chamber B, and port D to the low-pressure relief valve. As the hydraulic pressure from the HST charge pump is applied a differential pressure is gener- ated between port A and chamber B because of the throttle vaive of pilot poppet (5). Since this df- ferential pressure moves pilot poppet (5), the oil flows from chamber B through port C to the for- ward-reverse shifting solenoid valve. + Pilot poppet (5), poppet spring (3), and spring seat (4) are used as a set. To change the set pressure, loosen locknut (1) and tum the adjust- ment screw (2). If the adjustment screw is tight- ened, the set pressure is lowered. If the former is loosened, the latter is heightaned. 10-16 su801 148 9va01 180 WA150-5STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HIGH-PRESSURE CUT-OFF VALVE HIGH-PRESSURE CUT-OFF VALVE i i 3 4 5 ‘ 7 t 1201181 Adjustment screw Locknut Spring Spool Piston Barrel Shuttle spoo! Valve seat @regsens Function + The high-pressure cut-off valve is installed to the HST pump. If the oil pressure in the high-pres- sure circuit between the HST pump and HST mo- tor rises higher than the set pressure, the high- pressure cut-off valve drains the oil from the ser- ge vo cylinder circuit into the hydraulic tank to con- trol the maximum pressure in the HST pump. 4 S circuit. oH Operation + Port Ais connected to the high-pressure circuit 1s during reverse travel. Port B is connected to the 1 EE Tc high-pressure circuit during forward travel. Port _ Pc is connected to the speed-ralated valve, and 5 port T is connected to the drain circuit. + If the pressure on the port A side rises high for aD some reason, shuttle spool (7) is pushed down and the circuit on port B side is closed. At the at same time, piston (5) is pushed up by the hydrau- Ito lic pressure on port A side and spring (3) is com- aa pressed and spool (4) is also pushed up. Than, cd ports Pe and T are opened and the hydraulic oil in the speed-related valve circuit flows into the suportse drain port ‘Asa resutt, the oil pressure in port Pe lowers and, the swash plate angle of the HST pump raducas, and consequently the discharge reduces and the abnormal pressure in the HST pump circuit low- ers. WA150-5, 10-17STRUCTURE, FUNCTION AND MAINTENANCE STANDARD. HST MOTOR HST MOTOR ‘HST: Abbreviation for Hydro Static Transmission HST motor 1 3 4 5 sunonis7 1. Drive shaft Specifications 2, Piston _—___ 3, Cylinder block = TE ae = 4. Port plate ee ante displacement baa 5. EP servo valve ‘axis type piston motor 10-18 (5) “Theoretical capacity (corey) Set pressure of high-pressure relief valve (MPa fkgiem?}) Set prossure of high-pressure cutoff valve (MPa {kglom?}) Set pressure of low-pressure reliet valve (MPa fkglem?}) ° 43.2 (441) Etfoctve aereniial pressure 40.2 {410} 25 (25) WA150-5STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HsT MOTOR HST motor 2 3 ‘ MrT Vat ATI f= 4 I 5 ana aupoiise 1. Drive shaft Specifications 2. Piston 3. Cylinder block i | _ ae 4. Part pie, im Variable icant bert Sen wale ‘ans type piston motor &. Forwerd-reversé shuttle vane ‘Theorticaleapacty crew) | 785-65 Set pressure of igh-pressure e2uan roi valve (MPa glen?) Sel pressure of igh pressure | Efecive dterental pressure ‘utestvahe (MPa (kalo) 40.2410) Set pressure of n-pressire telief valve (MPa (kg/cm?) ae) WA150-5, 10-19 (5)STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST MOTOR Principle + Lot's assume that a shaft of a disc is supported and the disc can rotate freely. force F is applied bias to this disc, itis divided into component force F1 at right angles to the disc and component force F2 in the peripheral direction of the disc. Component force F2 rotates the disc to the right. + If force F', not force F, is applied to the disc, itis divided into component forces Ft’ and F2 simi- larly to the above and force F2" rotates the disc to the left ‘901158 Structure + There are 7 pistons (2) installed to the disc por- tion of the drive shaft (1) as if they are spherical joints. They are set in cylinder block (3) at a cer- tain angle to drive shaft (1) + As the extemal load on the HST motor is in- creased by servo valve (5) and forward-reverse shuttle valve (6), inclination of pistons (2) is in- creased. As a result, the revolving speed is low- ered but the torque is increased. eugene 10-20 Operation The hydraulic ol sent from the HST pump flows in the inlet port of the HST motor and gives hy- draulic pressure to the back side of pistons (2) Accordingly, drive shatt (1) rotates because of in- lination of pistons (2) and cylinder block (3). The ollfrom the HST pump flows between the for- ward-reverse shifting solenoid valve and servo ‘ylindor into forward-reverse shuttle valve (6) of the HST motor. The oil from the forward or re- verse high-pressure discharge side of the HST motor flows into forward-reverse shuttle valve (6). Ita load is applied to the motor connected to servo valve (5) in the HST motor, the ol flows into the servo cylinder of the HST motor because of the pressure difference from forward-reverse shuttle valve (6) side, thus cylinder block (3) is in- clined more. 00) 161 WA150-5STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EP SERVO VALVE i Motor 1 solenoid valve EP servo valve Spring Servo cylinder Function + The EP servo valve is installed to the rear part of, HST motor 1 and used to change the displace- ment of the motor according to the current given to motor 1 solenoid valve (1). WAt50-5 EP SERVO VALVE sug 163 Operation Suction force F1 of motor 1 solenoid valve (1) and force F2 of spring (3) are applied to EP servo vaive (2) If the current given to motor 1 solenoid valve (1) is Iitle (F1 F2), EP servo valve (2) leads the hydraulic pressure to the large diameter (L) side. As a result, servo cylinder (4) moves toward the max side because of the area differance between tho small diameter (S) side and large diameter (L) side. The force of spring (3) changes according to the position of servo cylinder (4) (the displacement of the motor). Accordingly, the displacement of the motor is controlled by the current given to motor 1 sole noid valve (1) so that suction force F1 will be bal- anced with spring force F2. 10-21STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HA SERVO VALVE HA SERVO VALVE 1. Motor 2 solenoid valve 2. HA servo valve 3. Servo cylinder Function + The HA servo valve is installed to the rear part of HST motor 2 and used to control the position of servo cyfinder (3) (the displacement of the motor) to meet the motor output to the extemal load on the motor. The displacement is controlled with the hydraulic pressure in the circuit selected by the forward-reverse shuttle valve. 10-22 1011s Operation ‘When the load on the machine is small, HA servo valve (2) leads the hydraulic pressure on the side selected by the forward-reverse shuttle vaive to the small diameter (S) side of servo cylinder (3) and releases the hydraulic pressure on the large diameter (L) side into the tank (motor housing) to minimize the displacement of the motor. When a large load is applied to the machine on a Uphill, etc., HA servo valve (2) leads the hydraulic, pressure to the large diameter (L) side. As a ro- sult, servo cylinder (3) moves toward the max side because of the area difference between the small diameter (S) side and large diameter (L) side. Atthis time, the displacement of the motor becomes largest and the motor generates large torque. Fmotor 2 solenoid valve (1) is energized, HA ser- vo vale (2) leads the hydraulic pressure to the large diameter (L) side and the displacement of the motor becomes largest, regardless of the load on the machine. WA150-5Thank you very much for your reading. Please Click Here Then Get More Information.