SHOU IM CAIN AIL KOMATSU GD510, GD520 SERIES MACHINE MODEL GD521A-1 GD522A-1 GD523A-1 GD525A-1 GD511A-1 GD513A-1 GD521R-1 GD523R-1 GD511R-1 GD513R-1 GDS510R-1 GDS515A-1 GD525A-1C GD525A-1A GD525A-1B SERIAL No. 10001 and up 20001 and up 30001 and up 50001 and up 10001 and up 30001 and up 10001 and up 30001 and up 10001 and up 30001 and up 15001 and up 50001 and up 60001 and up 50001 and up 55001 and up J COMPONENT TYPE A ZEerxcranmoow See table of poi le components. SEBMG5250107 @ component and parts for the GDS 10R-1, with the exceptions of the transmission and main. ) ‘are interchangeable with those of the GD511R-1 © 1993 MOMATSU All Rights Reserved Printed in Japan 02-93(01)03961 00-1 @CONTENTS No. of page 10 ENGINE 12. TESTING AND ADJUSTING .........00000:0cceeeee 12-1 13 DISASSEMBLY AND ASSEMBLY : we 1341 20 POWER TRAIN 21 STRUCTURE AND FUNCTION : 214 22. TESTING AND ADJUSTING fe 22-1 23 DISASSEMBLY AND ASSEMBLY . «23-1 24 MAINTENANCE STANDARD .......-2.000ccc00cccecseeeeesseeeeeseeeeesses 26-1 40 STEERING SYSTEM 41 STRUCTURE AND FUNCTION ........ ee ait 42 TESTING AND ADJUSTING «02... 0 ...0ccccsceeeceeeeeeeeeerseee 424 43 DISASSEMBLY AND ASSEMBLY 43-1 44 MAINTENANCE STANDARD .. cee tseteeeseeeees cece AGT 50 BRAKE SYSTEM 51 STRUCTURE AND FUNCTION 51-1 52 TESTING AND ADJUSTING cca 52-1 53 DISASSEMBLY AND ASSEMBLY ....... Se 7 53-1 54 MAINTENANCE STANDARD en es 54-1 60 HYDRAULIC SYSTEM 61 STRUCTURE AND FUNCTION ceeeee cee eveeeeneees 61-1 63 DISASSEMBLY AND ASSEMBLY 63-1 64 MAINTENANCE STANDARD cobb ceteeeveeteeseeeeeeee 64-1 70 WORK EQUIPMENT 71 STRUCTURE AND FUNCTION ..... na 72 TESTING AND ADJUSTING ...00.....000ccccceeessseeeeteteeesseeee 721 73 DISASSEMBLY AND ASSEMBLY eccegaet 74 MAINTENANCE STANDARD 74-1 80 ELECTRIC AND ELECTRONIC SYSTEM 81 STRUCTURE AND FUNCTION ceeee 81-1 82 TESTING AND ADJUSTING 82-1 00-2 GD510, 520 SERIESLIST OF REVISED PAGES LIST OF REVISED PAGES. ‘The affected pages are indicated by the use of the following marks. It is requested that necessary actions be Mark Indication ‘Action requi taken to these pages according to the table below. pian © | Page to be newly added Aad © | Page to be replaced | Replace (| Page to be deleted Discard Pages having no marks are those previously revised or made additions LIST OF REVISED PAGES Mark Page Tm | Mark Page Tmeot] ark Page TINE OF | mark page Time of | sary page Time of + 01 ® a4 12 aR 9 21 8 o2 wa 4 a3 21233 m2 = ma ® ws 6 anata 2243 m3 1 + 22 © we 4 mag 22813 me + 23 @ a7 4 as na 3 B56 1 + 24 @ | a6 21263 mae 1 «03 29 4 a7 23 ar + oa i190 ae 3 21.28 28 4 + os wn 6 281 3 21.29 23-9 + 6 wiz a9 3 2120 aa0 +07 yas 2-92 3 nam 4 nar ae wie 21-10 23123 zr + os wis 4 an 2132 243 + oot a) aaa asa ata 2 oon | 132 aaa} ai was © ose isa zisa 3 22 @ 216 +0013 41 aaa as @ nar + con 35 1 2118 24 218 os 6 4 m6 3 2s 6 219 ore wT a7 261 @ 23201 ow @ we ae 252 @ war cor 38 1 2194 263 @ 2322001 ° 02 @ 1310 2120 4 64 4 a3 © coat wa na 4 26 4 2323-1 @ 14a nam 2 ar @ 2323-2 2 o wt ® a3 2212 2 me 4 223.3 2 14 o m1 @ 2213 2 29 @ 223.4 2 22 4 a1 @ 22142 104 2323-5 @ GD510, 520 SERIESLIST OF REVISED PAGES LIST OF REVISED PAGES Mark Page Time! mark Pape THEO | mark Page Fmect | mark Page TEST | Mark Pave pine 2323-6 2 23.2347 2335 m3 8 446 2323-7 2 23.23.48 23361 mar 2 47 23.23. 8 23.23.49 237 ma2 2 2323-8 @ 222960 © mae 233 2 ai ¢ 232810 2 232361 2339 wa 2 a2 @ 2941 2 232352 8 2340 we 8 a3 4 232812 2 232353 8 var 25 aa 6 222343 2 23.2358 maz 2513 a5 4 232314 @ 23.2355 5) as 2452 3 a6 4 232315 2 73.2356 9) mae we 3 232316 2 pass S 245 wer 9 22047 2 nase mae wr 8 ai 2218 2 232359 8 var m8 a2 232319 2 232360 8) maa! 29 as 23.2320 2 aes zag! mos 3 aa 232321 2 232362 8) 23500 | 292 3 as 232322 2 232363 5) sr! 203 ae 232323 2 23.2364 9) sz! per 3 a7 O 232224 2 73.2065 5 282 | 242 ae 4 232325 2 2323668 5) nse err ao 232326 2 nae 255 | 2aas a0 4 22027 2 232368 5 256 | mia 3 aan 222328 2 232360 287 | mas 3 az 222929 2 232370 mse aa 0 232390 2 aan 8 259 | © 1 @ aia 232331 8 nan 8 2360 | at 15 22332 8 nan 5 ze | 164 2233 2008 me | aid 232334 8 22375 5 mes | aie 4 nas 6) 232376 ne | 2 a9) 232336 8 m2 | nes | a 4320 23.2337 8 2325 | nes | a7 wad 232338 8 2328 | ner! ae 4 2 23.2339 8 mart nes! a9 3 4323 2323-40 5 m2 m6! aot 3 aaze masa 8 mae 440 4925 282 © za0 0 aun 23.2343 8) aa wi og an? 232348 8 2a2 w2 @ ans 444 23.2345 5 nas) m2 8 aa “2009 22346 8 ws 2422 3 ans 3 0-2-2 > D510, 520 SERIESLIST OF REVISED PAGES sT OF REVISED PAGES Mork Pose Fearon | Mork Pave TAmEST | mark page TOK mark Page Te | srk age Time of aor 8 se ee 3 ee 4 e451 3203 m2 4 eres os 4 e451 aa 30 oe 3 66 4 e474 sea 4 ere 3 67 4 o m1 @ es 4 e103 ee 1 ont see! oun se | ea 512 7 ez 4 40 eae sis set eii3 en Cn Bia s3 ea e121 we 6 518 so ons 3 eu 645 516 sont e765 one see 3 sey 3 e121 ee 3 ors or 2 she 3 19 e181 3 ea18 one 81 3 sua e119 e174 ete 51103 5315 61202 14 Coane) pu 516 era Ce su 17 6122 6320 Cn 5143 | soi 6123 on 1 e133 Sead sor 61.24 622 sis 3 $320 61.25 a2 4b) | o m1 @ site 3 sa 617513 ez ma su e322 61252 63251 nea sie 3 5323 61255 6251 na 4 518 53242 e127 oar yf ea 51203 61283 028 ms 4 sit e129 2 3204 ne size 6130 630 eee S123 3 oe ort oa ne 3 5128 st? sista saz a oad 51253 sea 3 oraz e331 7410 51263 sea 3 e133 esa nay sean 2 6136 6335 mr 3 ss 6138 351 mas 3 sr 4 6196 wort naa s2 4 | o 1 @ 6137 ose sea ont e383 eso mr 4 wet 6.2 40 nme 4 e254 ers 3 ear 7a 6 4 erat 6 oer 4 ea ma 4 5274 61 3 e241 eas | oo ma @ os 3 es 4 eae m5 4 D510, 520 SERIES 00-23 7LIST OF REVISED PAGES LIST OF REVISED PAGES Merk Pose Tm@F | wrk page TNEOt | mark Page TIMES! | mark Page Tus | Mark Pee [sion 26 6@ eit a7 oe m7 @ ang ease er a ne @ aie e209 e200 ne @ e138 soa ee nwo @ aie e241 6 ms @ a7 ea 4 m1 e243 m2 4 a1 @ ao me 22 @ e24s 4 naa 23 @ eas 4 a5 @ 24 @ e474 met ae 9 aoa m7 ar 4 soap me ea 4 wso 4 we ae 4 as 4 mo eno oso 4 mn @ an 4 oss 4 8212 « 8254 a ass e255 4 74 wx ess 4 142 eis esr 4 149 a1 4 na a ms 8 a 4 eso 4 m5 8 ae 008 ms 4 asa ao a mr e220 @ e262 48 ea 4 ws | me 9 an 4 aoeeg e224 ag 4 2225 @ wes at e226 ae @ er? an @ nes | aa 2 e220 oo; ane 220 @ a0 as 230 @ an 4 a6 ma an @ a7 sa on a oe an @ ae ae 4 mas a aoa 23s ag en 22.08 an @ | 0-2-4 60810, 620 SERIES @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 symbol i is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed care fully. 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, ete. 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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 (—) 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 00-4 19, Be sure to assemble all parts again in their original 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 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.a 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 inspécting 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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 Issued for each engine series Each issued as fone volume to cover all models Engine volume: Electrical volume Attachments volume 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): 10-3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume) 12-410 Unit number (1. Engine) tem 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 (-) and number after the page number. File as in the example. Example: 10-4 12-203 10-4-1 12-203-1 10-4-2-}~ Added pages L 13.203-2 10-8 12-204 00-6 REVISED EDITION MARK ( 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 Remarks ‘Special safety precautions are A _| Satery | necessary when performing the work. ‘Special technical precautions or other precautions for preserving standards are necessary when performing the work, | caution Weight of parts or systems. Caution necessary when CE | wish | Sletng helsing ite, o winen warning pate is toon te [Paces tet rule special Go | Tahom | Menon forthe sohaning "248 | torque during assembly. Places tobe costed with a Coat adhesives and lubricants, etc. Places where oil, water or il, water | fuel must be added, and the capacity. Places where oil or water Drain | must be drained, and quantity to be drained.HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS Ay Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and Assembly section, every part weigh- ing 25 kg or more is indicated clearly with the symbol >) 1. If 2 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 removed 2. 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 (mm) | Allowable load (tons) 10 10 11.2 14 125 16 14 22 16 28 18 36 20 44 224 5.6 30 10.0 40 18.0 50 28.0 60 40.0 LS] 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% 9% 1% 195 Fs006e 3)Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. Ay Singing 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 @ wide hanging angle from the hook. When hoisting 2 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°. > | 3 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, 4 Fg > -4 80085 00-7STANDARD TIGHTENING TORQUE 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 Width of bolt across flat (mm) (mm) _—— ee | kgm 6 10 1,350.15 13.2414 8 13 3.2+03 314429 10 7 6.7407 65.7+68 12 19 11.5+1.0 112498 14 22 18.0+20 177419 16 24 28.543 279429 18 27 3944 383+39 20 30 56+6 549+58 22 32 16+8 745+78 24 36 94.5410 927+98 27 a 135415 1320+140 30 46 175+20 1720+190 33 50 225425 2210+240 36 55 280+30 2750+290 39 60 335+35 3280+340 This torque table does not apply to the bolts with which nylon packings or other non- ferrous metal washers are to be used, or which require tightening to otherwise specified torque. * Nm (newton meter): 1Nm 20.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width Tightening torque of bolt across flats | | ——— Uc eeeseeeeee (mam) (ram) kgm Nm 10 14 67207 65.7+68 12 7 11.541 112498 16 22 28.543 27929 00-8STANDARD TIGHTENING TORQUE 3. TIGHTENING TORQUE FOR NUTS OF FLARED pareve reals erereeere er Use these torques for nut part of flared, et ry Thread diameter | Wiath across flats Tightening torque of nut part ‘ofnut part (nn) (nen) kgm Nm 14 19 25+05 245249 18 24 52 4919.6 22 27 a2 785196 24 32 1423 13732294 30 26 1823 1765294 33 a1 2025 196.1449 36 46 255 245.249 42 55 3025 294.249 COATING MATERIALS The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenclature Komatsu eal Applications ura Used to apply rubber pads, rubber gaskets, and cork plugs 7 | Usedo opply resin rubber metalic and ie non-metal parts when a fast, song seals needed Adhesives ure Preventing bolts, nuts and plugs from loosening and leaking oil [ars | Provides an airighr, elactncaty iauiating seal us Used fr aluminum surtaces. = a Used to coat plugs [plate shaped, bow shapedl and holes, and a ‘mating portion of shat tet Used with gaskets and packings to increase sealing effect r Teat-resisiantgaaket Yor precombustion chambers ee iss and exhaust piping pene ies Used by itself on mounting surfaces on the final drive and transmission cases. (rhickness after tightening, G07 — O08 mis Used by ise to sea] grease fittings tapered screw fitngs and Tapered ee Screw fitings in hyaraute ercute ot less than 80 tm in Samnater 16-6 Silicon base type usedin combination with LG-1 and LG-4 Wasa shorter curing time thanlG-6, ands easier ‘Aniiction compound ied to bearings and taper shafts to facilitate press-fiting and to (Uubrcant ncucing um Applied to bearings and taper shafts to facitate press-iting and ees prevent sticking, Burning or rusting Grease ur] Applied o bearings, siding parts and ol seals for UBTCaTOn Fst iUinwum grease) eau prevention and fecitation of assembing work Vaseline = Used for protecting battery electrode terminals from corrosion *LT-2 ig also called LOCTITE in the shop manuals. 00-9ELECTRIC WIRE CODE aay 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: SWB indicates @ cable having a nominal number § and white coating with black stripe. CLASSIFICATION BY THICKNESS Co CLASSIFICATION BY COLOR AND CODE Greute Prior | cigs3h cherging | Ground | Starting Lighting | instrument Signal omer "7 | fication | [ew Leese] 8 e ® ¥ S v mary | color Block ‘Black ea Yellow ‘Green Blue Code = ew aw va ow iw 2 Cor| WhieaAed | — | Blacks wnite | Red& Whe | Yolow& Red | Groendi White | Blue & White cose] We = BY ro v8 oF i © | oac| Color] white Black | __— [Black Votow| Rede Block [Velows Black| Greenanea | Bes Red Non Teed] we 5 aR RY ve 7 2 Color] Whites | — Black Red | Red Yelow | Yellow & Green ‘Blue & Vatlow codep WO zi 7 AG vo 1 . Calor] White &Green | — 7 Red& Green | Yalow & Ble [iGreen & Black | (Blue & Black) cose] = 7 RL we 120 = : color] - = Red Give [Yellow & White | (Groen & Blue) . 00-10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 from mi 1. Convert 55 mm into inches, (1) Locate the number 50 in the vertical column at the left side, take this as. @, then draw a horizontal line from @). {2) Locate the number § in the row across the top, take this as @), then draw perpendicular line down trom ® (3) Take the point where the two lines cross as ©. This point © gives the volue when converting from millimeters to inches, Therefore, 55 mm = 2.165 inches imeters to 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 came procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal oint one place to the right) to return to the original value. This gives 650 mm = 21.65 inches, Millimeters to inches ® 1 mm = 0.03937 in Cas [s]el7fe [° ° 0039 | 0079 | o118 | 0187 | 01971] 0236 | 0276 | oats | ose 10 | 0304 | 049 | ouz2 | ostz | 038: | 0581.) oea0 | ogee | O09 | ona 20 | 0787 | 0827 | o86s | 0908 | 0945 | 0984) 1.024 | 1.063 ties | ase 30 | 1181 | 1.220 | 1.260 | 1.298 | 1.339 | 1.a7e!| 1417 | 1457 | 1496 | 1836 40 | 1575 | 1614 | 1654 | 1693 | 1.732 eo" | 1.811 | 1.850 | 1.890 | 1.929 70 | 2756 | 2795 | 2835 | 2874 | 2913 | 2953 | 2992 | 3032 | 3071 | 3110 80 | 3.150 | 3189 | 3228 | 3268 | 3307 | 3346 | 3386 | 3425 | 3.465 | 3504 90 _| 3843 | 3683 | 3622 | aes: | 3701 | 3740 | 2.700 | aero | aes | 3.000 00-11CONVERSION TABLE 11 mm = 0.03937 in limeters to Inches PEPE EEPET at T acer) — 0 0.03 | 0079 | 018 | 0187 | 097 | 0296 | 0.276 0315 | 0.254 10 0.394 | 0.433 | 0472 | 0512 | 0.551 | 0.591 | 0.630 0.669 | 0.709 | 0.748 20 oer | 0827 | 0866 | 0906 | 0945 | 0984 | 1024 | 1063 | 1.102 1.142 oo | saan | 1220 | 1260 | 1.29 | 0 tare | arr | vasr | 1496 | 1596 wo | vss | ers | vost | 1603 | 1992 | v7 | an | va | 1990 | 1920 50 1969 2008 | 2047 | 2087 | 2.126 | 2165 | 2205 | 2244 | 2283 2.923 co | 2362 | 2402) 24a1 | 2490 | 2520 | 2559 | 2596 | 2698 | 2677 | 2717 70 2756 | 2795 | 2835 | 2974 | 2913 | 2953 | 2992 | 3022 | 2071 | 3.110 80 3180 3189 | 3228 | 3268 | a307 | 3346 3386 | 3425 | 3.465 | 3504 90 3.543 | 3.583, | 3.622 3.661 3.701 3.740 | 3.780 | 3.819 | 3858 3.898 EE eee eee | Kilogram to Pound 1kg © 2.2046 Ib ous | 220 | 441 | oor) aga | 1102 | 1929 | 1543 | 104 | 1984 10 2205 | 2425 | 2646 | 2866 | 30.86 | 3307 | 95.27 | 37.48 39.68, 41.89 zo | 4400 | ean | «nso | sori | sia | 56:2 | s7ae | sosa | 6173 | 30s 30 se | ase | ross | 7275 | 7499 | 7716 | 7037 | e157 | 8078 e508 | | | | | | so |s029 | vr24e | 114.64 | 11605 | 11908 | 121.25 | 12946 | 128.66 | 127.87 | 12007 ro | vseaz | esa | 1sa72 | rae s6are | 10525 16795 | 10078 | 17.96 | 17417 so | r76a7 | 17857 | 180.78 | 18298 | 185.19 | 187,99 | 189.60 del ae | 196.21 80 twa | 20082 | 20282 | o500 | 20724 |rooas | aint | 21308 | 21605 | 218.26 | Heel lene 00-12CONVERSION TABLE Liter to U.S. Gallon 1 &= 0.2642 US. Gal ] Ea ° 1 ete 4 5 ef? 8 9 | | | | + | 264 0528 | 0.703 1057 | 1321 | 1506 | ia 213} 2978 2 2906 3170 | s438| 3608 ase | 4227 aaor | 4755] Soro 20 5283) 5548) 6812/ 6076 | 6340| 6.604 6.869 | 7133 | 7.397 | 7.661 30 7925 | 8169/8454) e718 | 8.982) 9.246 | 9810 | 9774 | 10.039 | 10.303 | | 40 10.567 | 12.4152 | 12.416 | 12.680 | 12.994 10.931 | 11.095 | 11.359 | 11.624 | 11.888, | so | saan | ss4ra | 13707 | sos 14.266 | 14529 | 14.795 | 15.058 15.322 | 15.586 co | 15350 | re15 | 16270 | sect vesor | r.47 | aap 00 798 | 28 70 | rea92 | 18756 19020 | 19205 | 19549 19813 | 20077 20381 | 20.605 | 20870 s | 21.194 | 21.398 | 21.602 | 21926 | 22.190 | 22485 | 22.719 22983 | 20287 | 23511 90 ad 24.040 | 24.908 | 24.568 | 24.852 | 25.096 | 25.361 | 25.625 25889 26.152 | a | Liter to U.K. Gallon 1 £ = 0.21997 U.K. Gal i o 1 2 ba fw sb oe J 7 le - — | 02%) o4so| oss | o8e0| 1100] 1320] 1500] 1.760] 1990 10 2.200 2420) 2640, 2860| 3090) 3300, 2520/ 3740) 3950) 4.179 20 | 4300) 4619) aea9| soso! 5279/ s.4e0| s.719| 5030| 6150/ 6.279 20 | 6500/ sere| 7020| 7280| 7470| 7960] 7010| 9190| 50/ a570 40 | 799 9019 9209 9489 9679 9.899 | 10.119 1099) 10559 10.778 el | ee ll. e | 13198 13418 | 13698 | 13058 | 14078 | 14298| 14.518 | 14738] 14.958 | 15.178 7 | 15.296 15610 | 15.228 | 18088 | 16276 | 16496 | 16718 16938 | 17.158 | 17.378 80 17898 | 17.818 | 18037 | 18257 | 18.477 | 18697 | 18.017| 19.137 | 19.357 | 1957 20 i i i 20.457 | 20.677 | 20.897 | 21.117 | 21.337 | 21.557 | 21.777 00-13CONVERSION TABLE kgm to ft.lb kgm = 7.233 ftlb 72| 1a5| 27 | 289 | 362] 434 | 506 | 579) 65.1 to | 723] 706) sce} o40| rors | soes | 1157 | r2a0 | 1902 | ra78 mo | wer | sro | sso | rosa] 796 | 1008 | r861 | 1063 | 2008 | 2000 wo | aro | 222 | zais | 2307 | 2450 | 2582 | 2604 | 2676 | 2740 | 202: wo | ama | ame | sone | aa | area | ozss | soar | a0 | 072 | asa | so | 2017 | 2009 | sor | sea | s008 | sore | 4051 | arza | a195 | azse co | ono, aera | aaas | 4557 | 4620 | 4702 | 4774 | e046 | 4018 | 4001 70 5063 | 5135 | 5208 | 5280 | 535.2 | 5425 | 5497 | 5569 | 564.2 | 5714 co | sve0 ses | 5031 coos | sors | san | s220 | sma | exes 6137 90 651.0 | 658.2 | 6654 672.7 | 6799 | 687.1 694.4 | 701.6 | 7088 | 716.1 | wo | 7203 | 7008 | 2978 | vas0 722 | 2505 | 7607 | 7709 | 7012 7004 110 7956 | 8029 810.1 | 8173 | 8246 | 831.8 8390 | 8463 | 8535 8607 vo | oo90 | 0752) a2 0007 | e959 081 ona | o195 | 9258 | 9991 190 | e403 | 9475 | e548 | o6z0 | o6a2 | o7es | 0827 | sco0 | o00. | 100s 140 10126 | 10199 | 1027.1 | 1034.3 | 1041.5 | 1048.8 | 10560 | 1063.2 | 10705 | 1077.7 | | | 150 1084.9 | 1092.2 | 1099.4 | 1106.6 | 11139 | 1121.1 | 1128.3 | 1135.6 | 1142.8 | 1150.0 160 1157.3 | 1164.5 | 1171.7 | 1179.0 | 1186.2 | 1193.4 | 1200.7 | 1207.9 | 1215.1 | 12224 170 1129.6 | 12368 | 1244.1 | 1251.3 | 12585 | 1265.8 | 1273.0 | 1280.1 | 1287.5 | 1294.7 180 1301.9 | 1309.2 | 1316.4 | 1323.6 | 1330.9 | 1338.1 | 1345.3 | 1352.6 13588 | 13670 190 1374.3 | 1381.5 | 13887 | 1396.0 | 1403.2 | 14104 | 1417.7 | 1424.9 | 1432.1 [s a 00-14CONVERSION TABLE kg/cm? to Ib/in? T 10 | 1422 | 1565 | 1707 | 1849) 1991 | 2134 | 2276 | 2618 | 2560 | 2702 20 | 2085 2907 3129 307.1 | sera | 3556 | 2690 | ae40 | 3003 | ar25 30 4267 4409 | 455.1 | 4694 4836 | 4978 | 5120 | 5203 | sas | 5547 40 | 5089 5692 | sora | ore | e258 | e401 | esa | esas | 6227 | cose | so | m2) 7264 | 72068 7508 | 7601 7623) 7965 | o107 | e250 | e002 so | essa cor | apie sees aio | o2as | oxe7 | osa0 | 9672 | eta 70 995.6 1010 1024 | 1081 1095 1109 1124 80 1138 | 1152 1166 1223 1237 1252 1266 90 1280 | 1294 | 1309 1365 | 1380 | 1304 | 1408 woo [raze jaar | tas | ges | 1479 | 1493 | 1608 | 1522 | 1536 | 1860 110 | 15551579 1592 | 1607 1621 1636 | 1650 | 1664 | 1678 | 1609 120 1707) 1721 | 1735, 1749 1764 | 1778 | :1792 1806 1821 1835, 190 | ve49 1963 | 1877 | 1892 | 1906 | 1920 | 934 | ro49 | 1063 | 077 | 140 1991 | 2005 =| 2020-2034 «= 2048)» 2062_-/| 2077: «| 2091:«| 2105 =| 2119 | | 150 2138/2148 21622176 2190-2205 | 2219 | 2233 | 2247 | 2062 | 160 2276 ©2290 | 2308 2318 2333, | 2347 | 2361 | 2375 | 2380 | 2404 170 2418 | 2432, | 2406. | 2460 | 2475 | 2489 | 2503 (| 2518 «= 2532 2546 180 2560 2574 | 2589 2603 2617/2631 | 2646 | 2660 | 2674 2688 wo faroz |ar7 | 27a | ares | a758 | 2773 | 2708 | 2002 | 2016 | 2020 | | 200 | 2015 | 20so 20702887 | 20012016 | 2030 | zose | 2058 | 2072 210 2987 3001 3015 | 3030 3044 | (3058 3072 3086 3101 3115 220 3129 | 3143 3188-3172 | 3186 3200 3214 3229 3243 3257 v0 a2 |szes | 3300 | sara | a328 eS ee 240 | gana Ie 3442 | 3456) 3470 3485 | 3499 | 3613 | 2527 | 3542 | 00-15CONVERSION TABLE ‘Temperature Fahrenheit-Centigrade Conversion, —A simple way to convert a Fahrenheit temperture reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If i is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit ‘temperatures and read the corresponding Centigrade temperature in the column at the left If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right | ce + |‘ * | a Tae | a | wo | az |v | ows | oa | we | ame | ome | oo | se To | ae | te | ans | iz | soe | sa] a | nes | ae | a2 |] v8 Sta | So | Tea | Soe | 42 | cee | se | ae | sme | zea | a | sot 317 -25 13.0 100 | 14 87.2 94 49 120.2 zo | 183.2 28.9 -20 40 ee 59.0 10.0 50, 122.0 20.4 85 185.0 aa) 19) -22 | 09 | 16 | os | 106 | 1 | rane | 200 | a | t099 Ta | ce | can | ceo | 7 | oe | va | ae | tase | ans | or ] sos Tha | a | aa | ae | te | cea | any | se | tare | on a | 08 Ter | ce | az | oz | we | cea | 122 | se | rasa | arr | a | 22 mi [ais | so] 97 | 2 | ooo | sa | as | rao | azz | oo | sso 25.6 14 68 an joa 698 133 86) 1328 328 oo 195.8 ceo || as | se | 2 | me | ma | 8 | se | 292 | 92 | 76 Tua | uaz | sea | oso | 2s | x04 | tea | se | tase | ase | ao | t004 me jon | a2 | ae | ze | rez | vse | se | raz | ata | oe | aoe Tea | uo | wo] a0 | a | mo | ise | oo | soo | aso | os | 2000 -na| -s| we | 3 | | m0 | ter | or | mre | ose | a | 2008 cha cg | tre | 28 | ov | os | wer | 62 was | 251 | o7 | 2000 m7 | 7 | we | 22 | a | soe | rz | os | tase | nr | oe | ane at 6 2 7 2 B42 78 64 147.2 a2 | 9 210.2 -206 “5 230 a 30, 86.0 13 | 65 149.0 378 100 2120 200 | 4 24.8 06 nu 878 189 66 150.8 406 105, 221.0 Toa | <9 | we | o- | se | ose | wea | or | sas | waa | sto | 2000 132) 2 | me | 06 as | ara | oo | oe | ree | aor | nis | zas0 ssa | | ma | ta | me | a2 | aos | oe | sse2 | sao | sm | ato cae | 0 | seo | 17 | a | eso | ann | mo tse0 | siz | ras | 2570 cna | 1 | aus | 22 | as | soa | avr | rm | tooo | see | 0 | 2050 cer | 2 | ase | 28 | a | see | 222 | 72 | wore | v2 | 105 | 2750 cer | 3 | ara | a3 | 36 | ra0e | 22a | 79 | wou | oo | 100 | 2000 Tee | 4 | sez | se | a | tox | za | m | 1652 | 27 | sas | 2000 Teo | s | ao] aa | ao | toco | 220 | rs | toro | se | 190 | 020 ce | ae | so | a | tose | 2a | me | rene | cos | 155 | onto >) me | se | a2 | wore | a0 | 77 | v8 | ma | seo | 2200 o | ae] er | a |) toe | se | ve | wee | tao | vee | 3200 o | m2 | er | a | ame | ar | 7 | ama | rez | rm | a0 | ef oe | | rae | me | wm | me | me | ne | ane 00-16WEIGHT TABLE Bi Ts woight tate guid foruse when traneportng or hanling components Model JA. 8, C,D,G,H Type] E,F, J. K Type LType Engine assembly (dry) 580 410 456 Radiator assembly (dry) 80 80 66 Fuel tank and hydraulic tank assembly (dry) 146 146 149 ‘Main clutch assembly - - 136 Transmission (dry) 620 620 295 Final drive assembly 555 420 420 ‘Tandem drive assembly (each) 780 746 746 Front axle assembly 440 430 430 Frame assembly 2160 2095 2778 Front frame assembly 1230 1190 - Rear frame assembly 930 905 - Operator's compartment assembly linc. control) 270 225 290 Low profile 790 = ROPS cab assembly Full height 840 a zi Drawbar assembly 722 722 722 Blade assembly 640 640 640 Circle rotation assembly 78 78 78 ‘Wheel assembly 133 143 143 Blade lift cylinder assembly (each) 37 37 37 Drawbar shift cylinder assembly 28 28 28 Blade shift cylinder assembly 34 34 34 ‘Articulate cylinder (each) 20 20 - ‘Scarifier assembly (If equipped) 610 610 610 ‘Scarifier cylinder assembly {If equipped) 27 27 27 Ripper assembly (if equipped) 900 = = Ripper cylinder assembly (If equipped) 4a sy ~ 00-18 D510, 520 SERIESUnit: kg cos258-18 MType | Typo, GDS25A-14 580 580 80 80 146 146 583 620 359 555 750 790 437 437 2095 2160 1190 1230 905 930 270 270 790 730 840 240 722 722 640 640 78 78 133 133 37 37 28 28 34 34 20 20 610 610 27 27 = 900 = aa GD510, 520 SERIES 00.19LIST OF LUBRICANT AND WATER A,B,C, E,F,G,H, J. K, L Type ‘AMBIENT TEMPERATURE. CAPACITY (0) RESERVOIR NDE ue eee ty soecities | Refill =10. O00" SE 30 [sae TOW Engin oil pan Enaine oi r " 9 SAE 10030, wn (ay [SAE Tawea0 - E £ “Transmission care AE 3O azis) | 341251 “Tandem ease (each) Engine oi! 6 39 Final drive care TT sae Tow 13 a Circe cotation gear ease Gear oi z TSAE 80 z 4 4 E Hydraulic system Engine oi zi TISAE iow, Tw 30 i " t t — 08 Brake Brake tuia SAE LTO = oa ere t { t ASTM B76 Not Fue sank Diese fue 27 - Cooling system Water ‘Auld antitroze 34 s + ASTM D975 No. 1 CE ABCGH Type Ub L Tyee ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers Specified capacity: Total amount of oil including oil for components and cilin piping Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance, NoTE: (1) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric tem- change oil in the oil pan every periodic mainte- perature of lower than 0°C, be sure to use engine nance hours described in this manual oil of SAETOW, SAE1OW-30 and SAE15W-40, Change oil according to the following table if fuel even though an atmospheric temperature goes up sulphur content is above 0.5% t0 10°C more or less in the day time. Peaaneracneaaenaeare| (3) Use API classification CD as engine oil and if API ‘Change interval of ollin Fuel sulphur content ‘Stginecilpan. classification CC, reduce the engine oil change in- ieee terval to halt 05 101.0% 1/2 of regular interval Above 1.0% 1/4 of regular interval GD510, 520 SERIESD, M, N Type, GD525A-1A, GD525A-1B ‘AMBIENT TEMPERATURE. CAPACITY (£) RESERVOIR Prue (poe FLUID 250 wae a (qe Species | Rati TLL nen a ‘SAE TOW Engine ol pan Engine ai 2 ™ TL ISAE 103, ee c TL TSAE 1sab | “Teansmision case sae 30) 42 (26) (421 |4 (x6) (28) “Tandem ease (each) Engine ot Ld 45 140)(37-5)] 39 40)137.5) Final rive case se ow Ta] 13110118) |12 (116) Gree catationgear case Gear oi EE ee iz 4 4 Hydraulic system Engine oi TL SAE Tow, cy 30 ra TSIM DENTE Fuel tank Diese fue 2 ~ Cooling system ater ‘Add antifreeze 34 - ‘# ASTM D975 No.1 TV: M Type (J: Type (4) API categories The API categories are categories of quality deter- mined by AP! [American Petroleum Institute) corre- sponding to the conditions of use of the ol CD: Oil for diesel engine in heavy-duty conditions This oil is for use with high-speed, high-output tur- bocharged diesel engines, used in conditions which demand powerful wear and sludge inhibiting ability. (equivalent to MIL-L-451998) CC: Oilfor diesel engine in medium conditions This oil is for use with diesel engines operated in medium or heavy-duty conditions which demand the ability to prevent high temperature sludge in low-turbocharged diesel engines. (equivalent to MIL-L-21048) When using CC class olin the engine on Komatsu construction equipment, reduce the oil change in- terval by half as explained in the previous Note (3), €BCA: Oil for diesel engine used in light to medium conditions This oil is for diesel engines used in light to medium operating conditions, so do not use it for the engines of Komatsu construction equipment. GD510, 520 SERIES 00-21 )10. ENGINE TABLE OF APPLICABLE COMPONENTS 12. TESTING AND ADJUSTING Name of component or item Applicable component GD525A-1A GD525A-1B Table of judgement standard value * For engine on test bench N N Table of judgement standard value * For engine on chassis N N Adjusting valve clearance Measuring compression pressure Testing and adjusting fuel injection timing Engine speed control zi/z/z|2z2 zi/ziz\z GD510, 520 SERIESENGINE 12 TESTING AND ADJUSTING Table of judgement standard value Testing and adjusting tool list Adjusting vaive clearance Measuring compression pressure Testing and adjusting fuel injection timing Bleeding air-from fuel system Engine speed control ccheck the safety pin and chock. the machine. to prevent the risk of being scalded by hot water which may spurt out if the engine is hot. ‘Take great care to avoid getting caught in rotating parts such as the fan, etc. | a D510, 620 SERIES Before performing inspection, adjustment or faultfinding, park the machine on level ground and When performing joint work, make appropriate signals and allow only authorized personnel near When checking the water level, allow the engine to cool down before removing the radiator cap 12-2 12-6 12-7 12-9 12-11 12-14 12-15 12-1TABLE OF JUDGEMENT STANDARD VALUE * FOR ENGINE ON TEST BENCH MType Engine s00105-1 — stom Condition, et Unit Standard Permissible valve Fiywheet norsepower Hep 12672800 = | Maximum torque kominm | 48/1580 . : Tow ing ‘7m 760 ~ 850 = 5 | engine spoos High og tom _|_ 2050-2750 - Necessary bs ‘pm Min. 150 = starting speed 20°C (Using staring aid ‘om Min. 100 7 Take vesatonce ‘Aspeed mmni,o ax 300 ‘wax 702 £ | exnovetpressre Al speea mm : : eee ana Aspe 7 | eshausttemperaie papel ees c Max. 650 Max. 700 i ‘Giick acceleration Mex 60 wan 78 3 | exhaust gos color Buch rd Atrated speed Max 40 Max. 50 | voweceorance at Tnake valve oy 028 z a bau Exhaust valve mm 045 = Oitemperatre: 40 — 80°C koient Min 29 in 20) % | Compression pressure & [Engine speed) (pnt (320 - 360) (320 - 360) = z ‘vated speed oo mm,0 Max, 100, Max. 200 a ssanial Oil temperature: Min. 70°C © | orp gazzoos | Dah ao toon" 35-60 in 25 | temperature: 80°C min) | atiowicing kofomt Min. Min 07 5 [onremperture ‘Aspeed (in pan *e 0-110 ax 120 3 ne Ratio to fuel consumption) * Max 08 ote lijection pressure loz es om! 30 ae ~g_[ Fuetinectionm Nozzle tester i nas th tn 200 3: 25 [Fuetinecton oming BT06 Deoree 121 1st Cootant empertare ‘Aepeed at engine ave ES 70-80 ax 100 Vatve cracking temperate e . = fg _| Thermostat tuncion Fl opening tm “e . - § pening & Fullopening ht om 7 7 | etree ier pressure! oiem | 07504 075 +01 ea Fan speed At high idling speed pm 1793 + 45, 1793 + 45 Fan bat tesion Detect when pushed wha (Alternator) force of 6 kg ae am isdaite Note: The values given in the Testing and Adjusting data are NOT for adjustment of the output. Do not use these values as a guide to change the setting of the fuel injection pump. GD510, 520 SERIESNType Engine '500105-1 po tem Condition ete Unit Standord value | Permissible value Fywneet horsepower HP rom 13512500, ~ | Maximum torque amir | 51/1880 - : Tow iaing ‘om 750 — 850 = E | engine speed : High ing ‘om - . . oc rom Min 150 Necessary ° : Starting speed ~ 20°C Using starting a ‘om Min 100 Intake resistance ‘speed nto Max 300 Wax 762 5 § | emoust pressure ‘Al spees stig = - 3 ye A speed 7 E [Expat iemperare Cee ey < Max. 050 ox. 700 : {uick acceleration Max 60 Max 80 3 | exnaust ges color Poach 2 Atralate speed sale Max. 40 Max. 50 ee inte vane ow 025 028 ot aoe Exhaust vane om oa 04s i Ottemperatre 40 ~ 60° igen? Min 29 Min 20 3 | compresion pressure i {Eooine speed) tom | a20-260 | 1820-280) 2 z ‘Arvated speed & | siow-ny pressure z immo Max. 100 Max. 200 tBAEa0) Oiitemperature: Min. 70°C er rs orem 35-60 Min 28 | temeerare: 20°C min) | actow ting oem Min 1s Min 07 & | oivenpersure Ailspeed (iin pal *e eo- 10 Max 120 a peer 3 | oiconsum {Revo to fel consumption) ‘ os em : “Ho | rostinecton pressure | Nozze tester oem? atl Min. 200 3 _| Foatiecton uming etc Degree 121 121 Covent temperature “Aspeed ot engine oe °c 70-80 ‘Max 100 Vote cracking verperatre e = = g_| Tremostttncton Full opening temperature c 7 7 i Fell opening itt em _ 7 2 | Roda pressure pening pressure : : * £ | vate tneton {Giterenfa pressure) kolo os Cie! ST ranapeca Atigh ing speed ‘em 200 = 50 2100 = 50 Fan bet tesion Detect when pushed wth @ ae i. ae latternator force ot 8g Note: The values given in the Testing and Adjusting data are NOT for adjustment of the output. Do not use these values as a guide to change the setting of the fuel injection pump. D510, 520 SERIES* FOR ENGINE ON CHASSIS A,B, C,D,G,H, M,N Type Engine 3601081 = Standard Pormisie tem Conditions sit a ia ih ing ‘om 2700 = 60 - Engine speed Low iting i 00 +88 . crated peed ‘om 2500 . ‘Sudden secretion ouch index Wax 60 80 Exhaust color thigh iting Boschindox ox 40 50 Take vove 20°C) om 028 z Vat earnce Exhaust valve 20°C) 7 04s : oitemp: 40 — 6o-e noe mo Compression pressure | (" "Engine speed pen : 7 Sele Tom (280 S00 (220 360) Note Note (water temperate inside Slow-by pressure | operating ng smah,0 100 200 signing SAE ot iwatertemperstureinsige Sperting nce Oi pressure aerating kofeme as-60 as Atlow ing (SAE20, min 80°0) | kglome 15 o7 ‘Atlom iting (SAEIOW, min 80°C) | kg/m! 10 o7 Otemperance | Whesped ange “c 80-110 20 Fostinection timing | Compression 87.06 Degree tert test Tonbet rnin | Slack when pushed wih finger . (Alternator) force of 6 kg oe Note: Values at rated speed. 12-4 @ D810, 520 SERIESE,F,J.K.L Type Engine sesst-1 tte Condione Une nid Pormielite High iting om 3100 * 50 - Engine specs Low iting ‘om 900 + 50 - ‘At rated speed fom : = Sudden acceleration Bosch index Max. 70 80 Exhaust color At high iting Bosch index Max.1.0 20 Intake vive (20°C) mm 036 7 Volve clearance Exhaust valve (20°C) mm 080 - Oiitemp. 40 — 60°C. kgiem* Mex. 28 20 ‘Compression pressure | 1 Engine speed ee ‘tom 820 360 (320 = 360), Note Note) (water temperate nse Blow-by pressure | operating ange) sm. 100 200 ‘Athign ting SAE3O of (water tempereture inside eperstng range) Oiipressuce thigh ting oven 35-55 28 [At low ing (GAE3O, min. 80°C) ko/em* 10 | 07 Atfow ing (GAETOW. min. 80°C) | kg/em! 7 7 aa ‘Whote speed ange : Or teperan {aide of pa’ 7 ad Fuelinecton timing | Comeression BTD-. Degree 72 +1 Fan belt tension ‘Slack when pushed with finger " (aiterator force oF hg oe s a Note: Value is at rated speed. GD510, 520 SERIES 12-5 @TESTING AND ADJUSTING TOOL LIST No.] — checkitem Tool PartNo Remarks 1 [ensinespecd | Mutitachometer | 799-209-8000 | Digalaspiny 4; 69 ~ 2000cpm_ (Clamp set) (799-203-8900), Water oitandintke_ | permistor i ae a. | Wetec an Thermistorkit 799-101-6000 | 60 ~ 1200°¢ Analog hvareutic | 799.101.5000 | 25, 60, 400, 600 kg/em! 2. | Lubricant pressure Digital hydrautic 790-261-1100 | 500 kg/cm? too Compression gouge | 795-502-1690 | 0 JO4eRE 05 oe sthateeeatl tates '95-502-1370 | For S6D95L-1 795-602-1870 |For SoD9sL- Adapter 795-502-1330 | For S6D105-1 5 | Blow-by pressure | Blow-by checker | 799-201-1504 | 0 500 mmH,0 6 | vavecteorence | Feelergeuge 796-126-1370 | 05, 050 mm Discoloration 9 — 70% 7 ‘| Exhaust color ‘Smoke checker 799-201-9001 | With standard color (Discoloration %x 1/10 = Bosch index) 12-6 @ D510, 520 SERIESADJUSTING VALVE CLEARANCE A,B,C, D,G,H,M,N Type % Adjust clearance between valve and rocker lever as follows Unit: mm At20°C Remove cylinder head cover. 2. Rotate crankshaft in normal direction while watching valve to align "1.6 TOP” mark on crankshaft pulley with pointer (2) when No. 1 cylinder is at compres sion TOC. 3. When No. 1 cylinder is at compression TDC, adjust the valves marked @ in the table below When No. 6 cylinder is at compression TDC, adjust the valve marked * Valve arrangement crinaerno. J 1 ] 2 etakevave fo] fo | 4, Insert feeler gauge A between rocker arm (3) and valve stem (4) and adjust adjustment screw (5) until feeler gauge A is a sliding fit. Tighten lock nut (6) =) Lock nut: 32 + 0.3kgm 5. Next, rotate crankshaft one turn in the normal direc: tion and adjust the valves marked + itis also possible to adjust as follows. ‘Adjust valve clearance of No. 1 cylinder when it is at compression TDC, then turn crankshaft 120° each time and adjust valve clearances fol: lowing firing order © Firing order) 1-5-3-6-2~4 * After tightening lock nut, confirm valve clearance 60510, 520 SERIESE,F,J,K,L Type + Adjust clearance between valve and rocker lever as follows Unit: een Intake valve Exhaust valve At 20°C 038 050) 1, Remove cylinder head cover (1) 2. 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 isin line with the 1.6 TOP mark, No. 1 cylinder should be at com: Pression top dead center. 3. When No. 1 cylinder is at compression top dead center, adjust the valve marked e. When No. 6 cylinder is at compression top dead center, adjust the valves marked vingerno [1 | 2 | Exhaust valve l 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. Lock nut: 4.5 + 0.5 kgm 5. Next, rotate crankshaft one turn inthe normal di rection and adjust the valve clearance of the re- maining valves marked ‘After adjusting No.1 cylinder at compression top dead center, is also possible to turn crankshaft 120° each time and adjust the valve cleerance of each eylinder according to the fring order + Firing order: 1-5—3-6-—2~4 4 4 5 5 % After tightening the lock nut, check the clearance again a20F301 12-8 GD510, 520 SERIESMEASURING COMPRESSION PRESSURE A,B,C, D,G,H, M,N Type + If performance tests or troubleshooting shows that the piston, piston ring or cylinder liner may be worn, measure the compression pressure. Bi wien measuring the compression pressure, be care- ful not to touch the exhaust manifold or mutter or to get caught in rotating parts 1. Adjust valve clearance * For details, see ADJUSTING VALVE CLEAR- ANCE 2. Warm up engine (oil temperature: 40 ~ 60°C) 3. Remove nozzle holder assembly * For details, see 30 REMOVAL OF NOZZLE HOLDER ASSEMBLY. 4. Install compression gauge A in mount of nozzle holder assembly. 5. Set engine tachometer in position 6. Place fuel control lever in NO INJECTION position. Crank engine with starting motor and measure com: pression pressure. Measure the compression pressure at the paint 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. # Install the nozzle holder assembly after measuring the compression pressure. For details, see 30 INSTALLATION OF NOZZLE HOLDER ASSEMBLY. GD510, 520 SERIES 12-9E,F, J, K,H Type ‘* If performance tests or troubleshooting shows that the piston, piston ring or cylinder liner may be worn, measure the compression pressure AA Wren measuring the compression pressure, be careful not ot touch the exhust maniolé or mut. fer, oro get cought in otating parts 1. Adjust valve clearance, + For details, see ADJUSTING VALVE CLEAR- ANCE 2. Warm up engine (oil temperature 40 — 60°C). 3. Remove nozzle holder assembly, For details, see 30 REMOVAL OF NOZZLE HOLDER ASSEMBLY 4. Install adapter A, in mount of nozzle holder assembly, and connect pressure gauge A. 5. Set engine tachometer in position. 6. Disconnect fuel cut solenoid connector. Crank engine with starting motor and measure com- pression pressure %* 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 measuring the compression pressure, for details, see 30 IN- STALLATION OF NOZZLE HOLDER ASSEMBLY 12-10 GD510, 520 SERIES @TESTING AND ADJUSTING FUEL INJECTION TIMING A,B,C, D, G, H, M,N Type % Measurement condition % Coolant temperature: Inside operating range. a Siavd ] Porm : ue promt) Foetjecton | erocie 1821 tng cis | TESTING FUEL INJECTION TIMING 1. Disconnect fuel injection pipe (1) of No 1 cylinder 2. Remove delivery valve holder (2), then remove deliv- ery valve (3) and spring (4), and install delivery valve holder (2) again. 3, Place fuel control lever at FULL position. 4. Operate priming pump and rotate crankshaft slowly in normal direction, Check point where fuel stops flowing from delivery vaive holder (2 5. Check that 18° IJ. line on crankshaft pulley (5) and pointer (8) are aligned at point where fuel stops flowing %* BEYOND injection timing line Timing RETARDED % BEFORE injection timing line Timing ADVANCED GD510, 520 SERIES: 12-11ADJUSTING FUEL INJECTION TIMING BY DELIVERY CHECK Turn crankshaft back 30 — 40° from top dead center. 2, Rotate crankshaft to align 18° IJ. tine on crankshaft pulley and pointer correctly, 3. Loosen nut (7) on the injection pump mounting flange slot, and rotate the flange on the pump side little by little by operating the priming pump until no fuel flows out of the delivery valve holder 4. Tighten nut (7) in oblong hole of mounting flange of fuel injection pump. %* After tightening the bolt, check again that the fuel stops flowing from the dalivery valve holder at the point where the pointer is aligned with the line on the crankshaft pulley, 5. Remove delivery valve holder (2), assemble delivery valve (3) and spring (4), then install delivery valve holder (2) again 52) Delivery holder: 3.3 + 0.2 kgm 6. Connect fuel injection pipe (1), SSE) Sleeve nut: 2.4 + 0.1 kgm 12-12 a GD510, 520 SERIESTESTING AND ADJUSTING FUEL INJECTION TIMING E,F,J,K,H Type * Measurement condition + Coolant temperature: Inside operating range. nit: degree ic Standard Permissible ™ value value, [Fuel injection timing [_etpe2z 2241 ‘TESTING FUEL INJECTION TIMING 1. Disconnect fuel injection pipe (1) of No.1 cylinder 2. Remove delivery viave holder (2), then remove detiv- ery valve (3) and spring (4), and install delivery valve holder (2) again, Delivery viave holder: 4.25 + 0.2 kgm 3. Place accelerator pedal at FULL position 4. Operate priming pump and rotate crankshaft slowly in normal direction. Check point where fuel stops flowing from delivery valve holder (2) 5. Check that 22° |v. line on crankshaft pulley (6) and pointer (6) are aligned at point where fuel stops flowing # BEYOND injection timing line Timing RETAROED. 4% BEFORE injection timing line ‘Timing ADVANCED ADJUSTING FUEL INJECTION TIMING + If the test shows that the fuel injection timing is incor rect, adjust as follows. 1. Loosen nut (7), (8) on the injection pump mounting bolt. linside, outside each 2 boits) 2. Move injection pump towards OUTSIDE to RETARD timing. Move injection pump towards CYLINDER BLOCK to ADVANCE timing D610, 520 SERIES 4236302 12-13BLEEDING AIR FROM FUEL SYSTEM 1. Loosen air bleed plug (1) of the fue! filter operate priming pump, and when no more bubbles come out with fuel, tighten the plug. 2. Operate the priming pump another 10 — 15 times to bleed the air from the fuel injection pump. + The pump is not fitted with an air bleed plug When the priming pump is operated, the check ball inside the joint bolt on the return side opens and the air escapes to the tank 12-14 GD510, 520 SERIESENGINE SPEED CONTROL CHECKING ENGINE CONTROL Using convex scale A, measure the distance traveled by accelerator pedal (1) from the point where it starts to be depressed to the point where it stops. Adjusting travel of accelerator pedal. ADJUSTING ENGINE CONTROL 1. Adjust dimension A of rod (2) of the intermediate lever and accelerator pedal to V mm. 2. Adjust dimension B of cable (3) of the intermedi- ate lever to W mm, 3. Set dimension D for the height of stopper bolt (a) of the accelerator pedal to X mm, then adjust 0 that the engine is at full speed at this position, (As a guide, when the engine is stopped, adjust dimension C of the cable to Y mm.) Dimension E for the pedal height when the engine is stopped is Z mm. D510, 520 SERIES 118 +10 F23aH01200 12-15ENGINE 13 DISASSEMBLY AND ASSEMBLY RADIATOR Removal 13-2 Installation 13-2 RADIATOR ASSEMBLY Removal 13-4 Installation 13-4 FUEL TANK (incl. HYDRAURIC TANK) ASSEMBLY Removal 13. Installation 13-6 GD510, 520 SERIES 13-1REMOVAL OF RADIATOR A,B,C, G,H Type 1. Loosen drain valve (1) and drain coolant. (See P1) % If the coolant contains antifreeze, dispose of correctly, fey Coolant: Approx. 2. Remove hood. 3. Remove radiator gril (2). (See P2) so) Radiator grille: Approx. kg 4. Remove hoses (3), (4), (5) and (6). (See P1, P3) 5. Remove fan guard (81. (See Pa) 6. Remove radiator assembly (9), (See PS) ty) Radiator: Approx. kg INSTALLATION OF RADIATOR 1. Install radiator (9), [See PS) 2. Install fan guard (8). (See P4) 3. Install hoses (3), (4), (6) and (6). (See P1, P3) 4. Install radiator grile (2). (See P2) 5. Tighten drain valve (1), (See P1) 6. Add water through water filler (10) to the speci- fied level. (See 6) * Run the engine to circulate the water through the system, Then check the water level again. a Coolant: Approx. 13-2 REMOVAL OF RADIATOR E,F, J, K Type 1. Loosen drain valve and drain coolant + If the coolant contains antitreeze, dispose of itcorrectly wei $00!ant: Approx. 17 & Remove hood and battery cover. 3. Disconnect connector (1) of Water level Sensor. (See P7) 4. disconnect connector (3) of radiator grile (2) (See P8) 5. Raise radiator grille temporarily, loosen bolts (4) (See P8) 6. Raise radiator grile (2) then remove off. (See P9) 7. Remove inlet hose (6), outlet hose (7) and trans- ‘mission oil cooler hoses (8! and (9) trom radiator assembly (5) (See P10) . Remove fan guard (10). (Gee P10) ). Raise radiator assembly temporarily, remove rod (11), and mounting bolts (12). (See P10) Radiator: Approx. 30 kg ee 10. Raise radiator assembly (6) then remove off. (See P11) INSTALLATION OF RADIATOR 1. Raise radiator assembly (5) and set on main frame. (See P11) ty Radiator: approx. 30 kg 2. Install radiator mounting bolts (12) and red (11). (See P10) 3. Install fan guard (10). (See P10) 4. Connect transmission oil cooler hoses (8), and (9) and outlet hose (7), and inlet hose (6). (See Pro) 5. Raise radiator grille (2) and set on main frame (See P9} 6. Install radiator grille mounting bolts (4). (See P8) 7. Connect connector (3) of radiator grile. (See PB) 8. Connect connector (1) of water level sensor. (See P7) 9. instil battery cover and hood. 10, Tighten drain valve and add water through-water filler to the specified level * Run the engine to circulate the water through the system, then check the water level again. D510, 520 SERIESSeen: GDB10, 620 SERIESREMOVAL OF RADIATOR ASSEMBLY DType 1. Open drain valve and drain cooling water. watey Padiator: 27 ¢ ‘If the coolant contains antifreeze, dispose of it correctly. 2, Disconnect radiator guard (1) and chassis con- nection wiring connector (2). (See P1) 3. Disconnect radiator water le connector (3). (See P2) I sensor wiring 4. Raise guard and disconnect from main frame. (See P3) 5. Disconnect inlet hose (4), outlet hose (7), and hoses (8) and (9) for car heater from radiator, and inlet hose (5) and outlet hose (6) from hy- draulic cooler. (See P4) 6. Disconnect hoses (10) and (11) from radiator. (See P5) 7. Remove wire net (12). (See P5) 8. Remove radiator lock rod (13). (See PS) 9. Sling radiator, loosen bolts (14), then remove mount rubber (15). (See P5) kg) Radiator: 80 kg 10. Raise radiator and disconnect from main frame, (See P6) INSTALLATION OF RADIATOR ASSEMBLY 1, Raise radiator and set in position on main frame (See P6) tg) Raidator: 80 kg 2. Insert mount rubber (15) in radiator and mount ing bracket, and secure with bolts (14), (See P5) 3. Lock with rod (13). (See PS) 4. Install wire net (12). (See P5) 5. Connect hoses (10) and (11). (See P5) 6. Connect hoses (4), (5), (6), (7), (8) and (9). (See Pa) 7. Raise radiator guard (1), and install to main frame, (See P3) 8. Connect radiator oil evel sensor wiring connector (3). (See P2) 9. Connect radiator guard (1land chassis connec- tion wiring connector (2). (See P1) 10. Tighten drain valve and add water to the speci- fied level ‘* Run the engine to circulate the water through the system. Then check the water level again. Radiator: 27 ¢ GD510, 520 SERIESGD510, 520 SERIES 13-5REMOVAL OF FUEL TANK (Incl. HYDRAULIC TANK) ASSEMBLY A,B,C, G,H Type 1. Hood Remove air cleaner, exhaust pipe, hood and side cover. 2. Cover Remove cover, 3. Fuethose 1) Open drain valve (3) and drain fuel from fuel tank 2) Shut the fuel supply valve (4) and remove hose (5). (See P1, P2) 4, Inlet hose and outlet hose of transmission filter Disconnect inlet hose (6) and outlet hose (7) of transmission filter, then remove transmission filter assembly (8). (See P1) 13-6 Wiring Ai Disconnect the wire (8) frm the nega: tivo 2) terminalof the batory (See 3) Hydraulic tank piping Loosen oil filer cap (10) to relieve the pressure in the hydraulic oil tank. (See Pa) 1) Remove drain plug (11) of hydraulic oil tank and drain oll from hydraulic tank. (See PS) Hydraulic oll tank: Approx. 2) Disconnect hoses (12), (13) and (14). (See Ps) Fuel tank Install eyebolts (Thread dia. = 12 mm, Pitch = 1.75 mm), sling fuel tank (15) and lift off from frame. (See P6) ig”) Fueltank: Approx. kg (dry weight) GD510, 520 SERIESGD510, 520 SERIES 13-7INSTALLATION OF FUEL TANK (Incl. HYDRAULIC TANK) ASSEMBLY A,B,C, G,H Type 1, Fuel tank assembly Install eyebolts (Thread dia. = 12 mm, Pitch = 1.75 mm, sling fuel tank (15) andset in position ‘on main frame, (See P1) 2 1) Tighten drain plug (11) of hyautc ol tank (See P2) 2). Gonnect tubes (12), 18) and (14), then aed hydraute ol through hydraulic ol fir 10) to the specified level. (See P2, P3) ac ee the system. Then check the olevel again 3. Wiring Connect wire (9). (See P4) Insert the wiring and hoses securely when connecting, * Connect the lead from the negative (—) terminal of the battery. 13-8 4, Inlet hose and outlet hose of transmission Install transmission filter assembly (8) and con- nect hoses (6) and (7). (See P5) 5. Fuelhose 1) Close fuel drain valve (3). (See P5) 2) Connect hose (6) and open fuel supply valve (4). (See Ps) 3) Add diesel fuel through fuel filler (16). (See P7) by Fueltank: Approx. & 6 Cover Install cover. 7. Hood Install hood, exhaust pipe, air cleaner and side GD510, 520 SERIESGD510, 520 SERIESREMOVAL OF FUEL TANK (Incl. HYDRAULIC TANK) ASSEMBLY FJ. K Type 1. Remove side cover and hood, 2. Disconnect the cable from the negative (—) terminal of the battery 3. Open drain vaive and drain fuel from fuel tank. 4. Remove drain plug and drain hydraulic oil from hydraulic tank. sey Hydraulic oil: Approx. 25 & 5. Disconnect hoses (2) and (3) from transmission filter case (1), (See P1) 6. Disconnect fuel hose (4) and fuel return hose (5) from the engine. (See P1) 7. Disconnect hos tank, (See P2) (6), (7) and (8) from hydraulic 8. Disconnect wiring connectors (9) and (10). (See P3) 9. Disconnect wiring connectors (11), (12) and (13). See Pa) 10. Temporarily sling fuel tank and remove mounting bolts (14), (See PS) 11. Sling fuel tank and lift off from main frame. (See Pé) Tb) Fueltenk: Approx. 180 ke 12, Remove aircleaner (15), hydraulic filter (16) and transmission filter (1) from fuel tank. (See P7) 13-10 r INSTALLATION OF FUEL TANK (Incl. HYDRAULIC TANK) ASSEMBLY 1. Install transmission filter (1), hydraulic filter (16) ‘and air cleaner (15) to fuel tank. (See P7) 2, Sling fuel tank and install to main frame. (See P6) Ce) Fuel tank: Approx. 190 kg 3. Tighten fuel tank mounting bolts (14). (See PS) 4. Connect wiring connectors (11), (12) and (13) (See P4) 5. Connect wiring connectors (9) and (10). (See P3) 6. Connect hoses (6), (7) and (8) to hydraulic tank (SeeP2) 7. Install fuel hose (4) and fuel return hose (5) to the engine, (See P1) 8. Install hoses (2) and (3) to transmission filter case. (See P1) 8. Tighten drain plug and add hydraulic oll through oil filler to the specified level. 10. Close drain valve and add diese! fuel 11. Connect the cable from the negative (—) terminal of the battery, 12. Install side cover and hood. GD810, 520 SERIES