A\ IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols /\, and as are used to mark safety pre- cautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation, A\ SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1, Before carrying out any gr read all the precautions given on the decals which are fixed to the machine ing or repairs, 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing « Always wear safety glasses when hitting parts with a hammer. ¢ Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work, 4. When carrying out any operation with two ‘or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking, Never smoke while working. PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving, 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them, 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders ‘or steps when getting on or off the machine, Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3PRECAUTIONS DURING WORK 11, When removing the oil filer 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 fon 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 assembiing 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.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. AS: This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE ‘The specifications contained in this shop manual are subject to change at any ime and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS AN Heavy parts (25 kg oF more) must be lifted With hoist etc, In the Disassembly and As- sembly section, every part weighing 25 kg, or more is indicated clearly with the symbol r= If @ 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, » 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 toad (tons) 10 1.0 112 14 125 16 14 22 16 28 18 36 20 44 224 56 30 100 40 18.0 50 280 60 400 The allowable load value is estimated to be ‘one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have ‘maximum strength at the middle portion. 00% = 58% 79% «= T1—G 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. AN Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not siing @ heavy ivad will pes 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 vatiation 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 alifting angle of 150°, Lituing angle : a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” weeddaneter | width a of bolt across flat mm) (eam) = kgm | Nm 6 10 1.354015 13.2414 8 13 3.2+03 31.4429 10 7 67407 | 65.7468 12 19 115410 | 112+98 14 22 180420 177#19 16 24 28543 27929 18 27 3924 38339 20 30 5626 549+58 22 32 76=8 745+78 24 38 945+10 927=98 27 a 135415 1320140 30 46 17820 1720490 33 50 22525 2210240 36 55 280+30 2750290 39 60 335435 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 & 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width Tightening torque ‘of bolt across flats (mm) (om) kgm Nm 10 14 67407 65.7+68 12 7 15+1 | 112298 16 22 28543 27929, 1 00-8STANDARD TIGHTENING TORQUE 3. TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared. Fs0068 Thread diameter | Width across flats Tightening torque of nut part Ofmut part | pe (mmm) (mm) kgm Nm 4 19 25405 24.5449 18 24 5x2 49+196 22 27 ax2 785+196 24 32 1443 13734294 30 36 18+3 176.5+29.4 33 4 205 196.1249 36 46 2545 245.2+49 42 55 3025 294.2+49 COATING MATERIALS The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenciatire Komatsu code ‘Applications uaa Used to appiy rubber pads, uber gaskets and cork plus. a nonmetal bars whe 9 fast song eas needed Adhesives a ura Preventing bolt, nuts and plas from loosening ana ieaking ok = Provides an aright, elgctncaly insulating sea 3 Usedtr alumna sraces ‘Used with gaskets ad packings t inrease sealing effect. Hest-resistnt gasket for precombustion chambers and exhavst piping. Ligue gaset {Used by eet on mounting surfaces on the fina drive and transmission cases ioe [Thveknoss after ughtening 0.07 ~ 0.08 mm a (Used by toot to seal grease fitings, tapered screw fittings and tapered screw i titiogs in hydraulic eveuts of less ton 90 mm in ameter Tanitaction compound fiprscet nets ae [Applic to bearings and taner shafts to facilitate pressing and to rmolycenum cilide) preveat sticking, burning ousting. Grease i “Applied to bearings, sliding pars and ol seals for lubrication, rust {Ui greased cu prevention and foeitation of assembling work. Vaseline — Used for protecting battery electrode terminals from corrosion *LT-28 also called LOCTITE inthe shop manuals 00-9ELECTRIC WIRE CODE (aeeat TH 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: O5WB indicates a cable having a nominal number O5 and white coating with black stripe, CLASSIFICATION BY THICKNESS Copper wire Nominal i cable. | Current rating Applicable ckcuit mer Number | Oa ofstrands | Cross secton | Imm a Sande ir imo or " 032 oss 24 2 Starting, lighting, signal ete 02 26 032 208 34 20 Lighting, signal ot. os 65 sz 523 46 37 Charging and signs! 15 24 os 1336 10 59 Starting (low plug) 40 88 080 4273 118 135 ‘Starting 60 127 080 384 136 178 Starting 100 27 o80 109.1 176 230 Starting CLASSIFICATION BY COLOR AND CODE : creute Pronty a Staring | Chorging Lanting Signal Instrument omer Cisesstieator Code 8 w ® © Y v Color ‘lack Wate ea Yetow Bie cose ew wr aw ow YR ww 2 = Cor | Backs White | Whte&Aed | Rea&Wnite |Green& white | Yellow a Rea | Blue & White cose By we Re oF va iF a ‘color | Black & Yetow | Whitew Block | Rede Black | Green& Red |Velow& Black | Blu0a Red Code BR we RY ey Ye Wy 4 : Color | Bleck &Red | WhteSaiue | Red Vetlow |Green& Yellow |velow& Green | Blue & Yellow Code = wy RG 8 ve 1B 5 Color = |White &vetiow | Rea& Green [Green a Black | Yellow a Bive | Blue & Black Code = we FL ce yw 6 Color = ‘white & Green | Red&siue | Greane Bue [yotiow & White 00-10GENERAL WEIGHT TABLE AX This weight table is a guide for use when transporting or handling components, WEIGHT TABLE Unit: kg Machine model WA470-1 Serial No. 10001 — 20000 20001 and up Engine assembly Radiator assembly Torque converter assembly Transmission assembly Damper Upper drive shaft Center drive shaft Front drive shaft Rear drive shaft Front axle assembly Rear axle assembly Front differential assembly Rear dif sembly Planetary carrier assembly (1 piece) Planetary hub assembly (1 piece} Axle pivot (Rear axle) Wheel (1 piece) Tire (1 piece) Steering valve Steering cylinder (1 piece) Brake (1 piece) Hydraulic tank Hydraulic pump Switch * POC pump Switch * PPC pump, Steering pump POC valve PPC valve Main control valve 1,020 165 195 770 85 10 30 45 30 1,540 1,500 255 238 90 60 70/85 218 335 55 40 110 250 20 12 90 1,020 165 195 770 85 15 30 45 30 1,492 1,443 285 235 90 60 70/85 218 335 24 38 128 314 20 12 13 35 90 WA470-1 00-11GENERAL WEIGHT TABLE Unit: kg Machine model waa7o-1 SerialNo 10001 — 20000 20001 end up Lifteyinder (1 piece) 210 190 Dump eviner 230 220 Engine hood 65 a1 Front frame 1.580 1.749 Rear frame 1.375 1423 Bucket ink 75 80 Titever 330 440 Litt am bth bushing) 1,360 1375 Bucket with teth) 1.760 1,840 Counterweight 870 1,550 Fuel tenk 270 240 Battery (1 piece) 45 a7 Operator's seat 40 40 Floor plate 100 99 00-12 waa7o-1 @GENERAL, TABLE OF OIL TABLE OF OIL AND COOLANT QUANTITIES AND COOLANT QUANTITIES ] AMBIENT TEMPERATURE CAPACITY (\) reservoir | KIND OF eee i eee I a TSAEIO. 5 | Oe (a sar ewao es yi Teraiason con a ea z conciaccare- | 0% ©! sa: ov RS |. (10001 — 20000) fo ee eds SESAEIOW po 5 3 {Seria 20001 LEE ‘SRETOW, = 230 | 140 ve | incl. differen- NOTE (4) | tal and planetary paeaneee - - — ei [ a "ASTM D975 No.2 ae pee ASTM: American Society of Testing and Material SAE: Society of Automative Engineers Specified capacity: Total amount of oil including oil for components and oil in piping, Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. NOTE: (1) When fuel sulphur content is less than 05% change oil in the oll pan every periodic mainte- ance hours described in this manual Change oil according to the following table if fuel sulphur content is above 0.5% Change interval of oilin Fuel sulphur content pedis ost1o% | Above 1.0% 1/4 of regular interval was7o-1 (2) (3) (ay 1/2 of regular interval When starting the engine in an atmospheric tem- perature of lower than 0°C, be sure to use engine oil of SAETOW, SAE1OW-30 and SAE15W-40, ‘even though an atmospheric temperature goes up to 10°C more or less in the day time. Use API classification CD as engine oil and if API Classification CC, reduce the engine oil change in- terval to half For axle oil, use only recommended oil as follows. SHELL: — DONAX TT OR TD CALTEX: RPM TRACTOR HYDRAULIC FLUID CHEVRON: TRACTOR HYDRAULIC FLUID TEXACO: TDHOIL MOBIL: MOBILAND SUPER UNIVERSAL It is possible to substitute engine oil CLASS-CD SAE3O for axle oll. If noise comes from the brake, it is no problem of durabilityENGINE é 12 TESTING AND ADJUSTING Standard value table 12-2 Too list for testing and adjusting 12-3 Adjusting valve clearance 12-4 Measuring compression pressure 12-5 ‘Testing and adjusting fuel injection timing ... 12- 6 ‘Measuring blow-by pressure 12-8 Testing and adjusting fan belt tension 12.9 ‘Measuring exhaust gas color 12-10 Measuring accelerator pedal operating force ‘and operating angle 12-11 Testing and adjusting fuel cut solenoid 12-13 + The following precautions are necessary when using the Standard Value Tables to make judgements during ‘troubleshooting or during testing and adjusting 1. The values in these tables are based on the values for new machines leaving the plant, so they should be used as target values when repairing or when estimating wear after a period of use. 2. The standard values in these tables for judgement when troubleshooting are estimated values based on the standard values for the machine when shipped from the plant, and on the results of various tests. ‘Therefore, they should be used as reference in combination with repair and operating records when making judgements, 3. These standard value tables must not be used for standard values when judging claims. In addition, do not use these values alone to make simple judgements, WA470-1 12-1TESTING AND ADJUS’ STANDARD VALUE TABLE @ FORENGINE ON TEST BENCH STANDARD VALUE TABLE Engine S60125-1 a trem Condition ee. Unit Standard value] Permissible Fywheol horsepower wpm | 260/2,200 | — __ | Monenantoaue xsmvfpm| to7/ta00 | = z Hig ding peed tem | 2400250 | 2400250 2 | cngwespees nae ie eercms meer) 5 ow ing spec 1 8 5 é oc rpm | Min. 100 . Necessary starting speed | _ 20°c (Using starting aid) rpm Min. 85 = ¢ _| Intake resistance All speed. mmH,0 | Max.300 | Max. 762 3 | Eshoctprecsur Alepeed ‘mig | Min'380 a 2 | Bmusttomporsture | Alfepeedtrtakeairtemp:20°c) | “Se? | Max880 | Max.630 oo 5 Quick oselration Bosch | Manas | MonS6 Eg | emaustaascotr | Rtg cing tote | Manto | Mon20 = eg | Intake value as 033 = | Vavectearance at 20rc | nthe value mm | 033 7 ee | on nets eo Gor | cplensl| ants lina B | Compression pressure | (Engine speed) (pm) | (200 — 250) | (200 -250) 2] ‘vated opoed : oo . rmmt,o | Max.150 | Mox 300 Z| Ottemperature: min 70° | | Oil pressure | g | ; Athigh ding rain | 30-50 | mnza § | SAE30 On temperature: | At foe iang | SBiem | Mtns) | Mino oo ‘Alspeed : it 3 | oremporatre Alepeed c | 80-110 | 120 So | acon eonan 3 | onconsumptionratio | Atcontinuovsreted output No mcs [sao TE | Fustiiecton pressure | Nozzle tester xeiem | 2503/0 | azs £3 | Fuctinjection timing | BTDG Degree | 2421 2421 ‘Allepoed 7 Coolattemperanne | AlSpeed | 70-80 | maxi00 Valve cracking temperature “¢ | 745-768 | 745708 & | Thermostatfunction | Fullope perature °C ‘90 90 é Fpering tft mm | 10205 | 10205 3 | Redator pressurevave | Opening pressure : i 3 function (Differential pressure) kg/em’ eae 0.7520. © | Fan speed At high idling speed rpm 1,430+35 1430235 Fan bet tension Deflact when pushed with force (Alternator) of 6 kg mm 10 7 Note: The values given inthe Testing and Adjusting dat are NOT for adjustment ofthe output 12-2 Do not use these values as a guide to change the setting of the fuel injection pump. Wa470-1‘TESTING AND ADJUSTING. ¢ FORENGINE ON CHASSIS STANDARD VALUE TABLE Engine $60125-1 Machine model WAs70-1 Gate] check ite Conditions Unit Standard value | Permissible Perfor engine High idling speed rpm —_|2,300 — 2,400|2,350 — 2,450 fans | roe Low idling speed tpm | 650 — 750 | “650 — 750 g ‘At abrupt acceleration Max.6.0 80 | eee recs ‘Athigh idling Boschindex | Max. 1.5 25 ai Intake valve (20°C) mm 033 033 oe tee Exhaust valve (20°C) mm on o71 Oiltemperature: 40- 60°C | aver? Compression pressure | (" J: Engine speed lem | min 32 22 = SAE3O ol | fp 3 (Water temperature inside | Blow-by pressure operating range) mmo | Max.150 300 | ‘thigh idling, SAE3O oit a (Water temperature inside 2 oe operating range) 2 | (Sa30, oiltemperature:| At high iaing | gem | 30-55 21 3 | min 80°C) | At tow idling kgiem? | Min 15) 07 =| Whole speed range linside o | ontemperature ve c 90-110 120 ‘ee, | Fuel nection uring _| Compression 8. D.C | degree 24 2421 eee ‘Slack when pushed with finger = = system| Fan belt tensi force of 6 kg m 10 7-13 Sina 70001 = 20000. Senin | Seino | Seino | Seino. 1000: - | 20001 -| 10008 | 20001 | Operating torce is 20000, nivo| 20000 | ante | a7 | 427 | ma t08) mex 105 a 3 % a [as a = | Operating angle dogree = 2 a, | _¢2araosa|_, | eL Serial No. 20001 and up 2 u i525 |a2—s2 . Stopper height : ue om eee Rod length x hae sae) — . WAA70-1 12-2-1 ®TESTING AND ADJUSTING TOOL LIST FOR TESTING AND ADJUSTING TOOL LIST FOR TESTING AND ADJUSTING TNo,] Testing and measuring tem TTootnare Partnumber Remarks + Engine pees Tachometer 799-203-8000 | Digital display 60-19899 rpm 2 | attryspectc gravity 1-13 ater coolant tester | 798-500-1000 3 | Cootant freezing temperature = =s0"c 4[iiure tate temperature | Thormiator 700 600,4200) Oriana 5 | Exhaust temperature cere 798-101-6000 | 0 — 1000°C 6 | Lubricating ol pressure 0 — 10kg/em* 7 | uel pressure 0 20.9/em* 5 ee en 799-203-2002 | 0 ~ 1600 mmHg 9 | Blow-by pressure [oso mo ee 10[ tae resistance = 1000 = Ommi0 11] Compression pressure Compressiongauge | 795-602-1206] 0 - 7Okglem? 12 blow-by pressure Btow-by checker 798-201-1503 | 0 — 500 mmH4O 13| Valve clearance Fealer gauge 795-125-1360 | 0.33,0.71 mm 14] Exhaust gas color ‘Smoke meter Coerar | et ae eet ae 16|Fuclonwaterminedinol | Engineeilcheck 799-201-000 Water content 0.1% 0.2% 16[ Coole quaity Water quality tester | 789-202-7001 | PH, nitrous acid ion concentration 17] Leakage trom cooling system _ | Cap tester 799-202-9001 | 0 ~ 2 kg/em* 19) fumliiocton pressure | Nozaletester - (0 — 300 kg/em* 19] Electrical circuit, Tester Commercially } current, votog 20) Accelerator ps Push-pull scale 79A-268-0020 | Commercially available 0 ~ 28 kg i os Ai Wiven carving out testing austin or troubleshooting, stop the machine on level ground, inset the safety pine and block the tracks Ad when working in groups, use agreed signals and do not allow unauthorized persons near the machine. Ad Winen checking the water level in the radiator wait for the water to cool. Do not remove the radiator cap while the water is hot. Boiling water may spurt out. Babe caret otto got caughtin rotating parts WAAT70-1 12-3TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE ‘* Condition: Engine is cold. + Adjust clearance between valve and rocker lever as follows. Unit mm Intake valve | Exhaust valve Cold 0.33 on Special tool ie] epantmmber || partnene ow Partnumber | Partname [Q'ty ‘A | 795-125-1360 | _ Feeler gauge 1 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 is in ine with the 1.6 TOP mark, No. 1 cylinder should be at com- ion top dead cent pr 3. When No. 1 cylinder is at compression top deal center, adjust the valve marked e. ‘When No. 6 cylinder is at compression top dead center, adjust the valves marked c eylingero. | 1 | 2 | 3 #[s[6 Intake vale oT exraustvave fe] [ol |e| 4. To adjust, insert tool A between rocker lever (3) and crosshead (4) and turn adjustment screw (5) until clearance is a sliding fit. Then tighten lock nut (6) to hold adjustment screw in position SD Lock nut: 3.2 + 0.3 kgm 5. Next, rotate crankshaft one turn in the normal di- rection and adjust the valve clearance of the re- maining valves marked o. * After adjusting No. 1 cylinder at compression top dead center, it is also possible to turn crankshaft 120° each time and adjust the valve clearance of each cylinder according to the firing order. + Firing order: 1-5 -3-6-2-4 * After tightening the lock nut, check the 12-4 ADJUSTING VALVE CLEARANCE 6160F201 WA470-1TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE MEASURING COMPRESSION PRESSURE ‘* Measurement condition Coolant temperature: Inside operating range. + Engine valve clearance: Standard value. + Engine speed: 320 — 360 rpm vom | a Partnumber | Part name |Q’ty A | 795-502-1204 | Compression gauge | 1 [ B | 799-203-8000 Tachometer 1 * If performance tests or troubleshooting shows that the piston, piston ring or cylinder liner may be worn, measure the compression pressure. Ad wren measuring the compression pressure, be careful not to touch the exhaust manifold oF muffier, or to get caught in rotating parts. 1. Adjust valve clearance * For details, see ADJUSTING VALVE CLEARANCE, 2. Warm up engine (oil temperature 40 — 60°C) 3. Remove nozzle holder assembly. * For details, see REMOVAL OF NOZZLE HOLDER ASSEMBLY. 4. Install tool A in mount of nozzle holder assembly, and connect pressure gauge, 5. Setengine tachometer B in position, 6. Disconnect fuel CUT-OFF solenoid valve connector. Crank engine with starting motor and measure compression pressure, * Measure the compression pressure at the oint where the pressure gauge indicator re- ‘mains 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 INSTALLATION OF NOZZLE HOLDER ASSEMBLY. WA470-1 12-5TESTING AND ADJUSTING ‘TESTING AND ADJUSTING FUEL INJECTION TIMEING TESTING AND ADJUSTING FUEL INJECTION TIMING * Measurement condition + Coolant temperature: Inside operating range. Unit: degree: a Standard Permissible value value Fuetinection| gr pc.24=1 a timing TESTING FUEL INJECTION TIMING 1. Disconnect fuel injection pipe (1) of No. 1 oylinder. 2. Remove delivery valve holder (2), then remove delivery valve (3) and spring (4), and install deliv- ery valve holder (2) again. 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 24° LJ. line on damper (5) and pointer (6) are aligned at point where fuel stops flowing % BEYOND injection timing line: Timing RETARDED % BEFORE injection timing line: Timing ADVANCED If the test shows that the fuel injection timing is incorrect, adjust as follows. eemaz roel 12-6 WAAT0-1TESTING AND ADJUSTING ADJUSTING FUEL INJECTION TIMING BY DELIVERY CHECK 6. Turn crankshaft back 30 — 40° from top dead center. 7. Rotate crankshaft to align 24° IJ. line on crank- shaft pulley and pointer correctly 8. Loosen nut (8) on the injection pump mounting flange bolt. and rotate the flange on the pump side little by little by operating the priming pump (9) until no fuel flows out of the delivery valve holder. 8. Tighten nut (8) in oblong hole of mounting flange of fuel injection pump. + After tightening the nut, check again that the fuel stops flowing from the delivery valve holder at the point where the pointer is aligned with the line on the crankshaft pulley. 10. Remove delivery valve holder (2), assemble deliv- ery valve (3) and spring (4), then install delivery valve holder (2) again. SZ] Delivery holder: 3.3 + 0.2 kgm 11. Connect fuel injection pipe (1) EI Sleeve nut: 2.4 * 0.1 kgm Wa4z70-1 TESTING AND ADJUSTING FUEL INJECTION TIMING 12-7TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE MEASURING BLOW-BY PRESSURE + Measurement condition + Coolant temperature: Inside operating range. + Engine valve clearance: Standard value. Unit: me, Standard Permissible Lea value value, Blow-by ax 13x. eae Max. 150 Max. 300 Special tool Part number Partname [Q'ty ‘A | 799-201-1503 | Blow-bychecker | 1 Ai when taking measurements, be careful not to touch the exhaust manifold or muffler, oF to get caught in rotating parts, 1, Measuring blow-by 1) When ing the blow-by, warm the engine up thoroughly. 2) Stop engine and install adapter of blow-by checker on engine breather hose (1), 3) Connect adapter and blow-by A (0 — 500 mml1,0) to hose. 4) Run the engine at high idling and measure the blow-by pressure. 2, Precautions when measuring blow-by ‘* The blow-by should be measured with the engine running at rated output. + When measuring in the field, a similar value can be obtained at stall speed. + If it is impossible to check at rated output or stall speed, measure at high idling. In this case, the blow-by value will be about 80% of the value at rated output. + Blow-by may vary greatly according to the condition of the engine, so if there is any ab- normality in the reading, check for any prob- Jem related to defective blow-by, such as ex- cessive oll consumption, defective exhaust {gas color, or early deterioration or contami- nation of the oil 12-8 WA470-1‘TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION TESTING AND ADJUSTING FAN BELT TENSION Approx. 10mm Testing fan belt tension ec unt n bel 1m pusher Approx 6 k Check the amount the fan belt deflects when pushed oe ” 3 with a force of approx. 6 kg at 2 point midway be- tween the fan pulley and the alternator pulley. Unit: mm pulley faa Standard Permissible value value Deflection of belt ae ae: 4296203 Measuring procedu 1. Push the V-belt with a force of 6 kg at a point midway between the pulley and the alternator. Use @ scale to measure the amount the V-belt, deflects. Adjustment procedure 1. Loosen mounting bolt (1) of the alternator assembly, and the mounting bolt (2) of adjust- ment plate, 2. Insert a stick or bar between the alternator mounting bolt and the cylinder block, then raise the alternator to the outside. Bi. 1r the shernatr is moved to the inside withthe hand. there is danger of eatching and insuring tho tngers, 3. Adjust the belt (3) tension and temporarily tight- ‘en mounting bolt 4. Check that the belt tension is correct then tighten all mounting bolts fully WA470-1 12-9TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR MEASURING EXHAUST GAS COLOR * Measurement condition + Coolant temperature: Inside operating range. + Valve clearance: Standard valve. Unit: Bosch index ae Standard | Permissible ‘ae | Svalue Acceleration | Max6o | 80 Exhaust : . Higniding | Maxis | 26 ‘Special tool Part number Partname [Q'ty Commercially = A ee Smoke meter | 1 Bi wren measuring the exhaust color, be careful not to touch the exhaust pipe. ‘When measuring the exhaust color, warm the ‘engine up thoroughly (oll temperature 60°C) 1. Insert probe 1 in outlet of exhaust pipe (1) and secure to exhaust pipe with clip. 2. Connect probe hose, connector hose of accelera- tor switch and air hose to smoke checker A. + The pressure of the air supply should be under 15 kg/cm 3. Connect power cord to AC 100 V socket Check that the power switch is OFF before connecting the cord 4. Loosen cap nut of suction pump and insert filter paper. 5. Turn power switch ON, 6. Accelerate engine suddenly. At the same time depress accelerator pedal, operate relief valve and catch exhaust gas color on filter paper. 7. Lay filter paper used to catch exhaust gas color ‘on top of unused filter papers (10 sheets or more) inside filter paper holder, and read indicat- ed value. 7301003 12-10 WA4T70-1MEASURING ACCELERATOR PEDAL OPERATING TESTING AND ADJUSTING FORCE AND OPERATING ANGLE MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE * Measurement condition + Coolant temperature: Inside operating range. Special tool Part number Partname [Q'ty ‘A | 798-262-0020 | Push-pullscale | 1 OPERATING FORCE (Serial No. 10001 — 20000) 1. Measuring procedure 1) Put push-pull scale A in contact with the ac- celerator pedal at point 150 mm from pedal fulerum “a”, ‘+ The center of push-pull scale A must be in contact with a point 150 mm from the pedal fulcrum, 2) Start the engine, push the pedal in the direc- tion of operation and measure the maximum. value when pushing from idling to the end of the pedal travel {high idling) 2. Testing and adjusting 1) Stop the engine. 2) Disconnect the cable at the bottom of the accelerator pedal, and check that the linkage and ball joint at the bottom of the pedal ‘move smoothly. 3) Connect the cable at the bottom of the pedal, then disconnect at the connection for the injection pump, and check that the cable moves smoothly. % When carrying out this inspection, adjust or replace parts as necessary. Measure the operating force again and check that it is within the standard value. wa470-1 12-11 @MEASURING ACCELERATOR PEDAL OPERATING ‘TESTING AND ADJUSTING FORCE AND OPERATING ANGLE OPERATING FORCE {Serial No. 20001 and up) 1, Measuring procedure 1) Put push-pull scale © in contact with the accelerator pedal at point 150 mm from pedal fulcrum “a”. + The center of push-pull scale) must be in contact with a point 150 mm from the pedal fulerum, ( Floor upper side 2) Start the engine, push the pedal in the direc- tion of operation and measure the maximum. value when pushing from idling to the end of the pedal travel (high idling). 2. Testing and adjusting 1) Stop the engine. 2) Disconnect cable (1) at the bottom of the ac- celerator pedal, and check that there is no defective movement at plate (2) at the bottom of the pedal 3) Connect cable (1) at the bottom of the pedal, then disconnect again at the connec- tion of the injection pump, and check if there is any defective movement in rod (3) or ball joint (4) %* When carrying out this inspection, adjust or replace parts as necessary. Measure the operating force again and check that itis within the standard valve. 12-11-1 WA470-1 ®MEASURING ACCELERATOR PEDAL OPERATING TESTING AND ADJUSTING FORCE AND OPERATING ANGLE OPERATING ANGLE OF ACCELERATOR PEDAL (Serial No. 10001 — 20000) 1. Measuring procedure 1) Stop the engine, 2) Measure the operating angle a, a, put the angle gauge © in contact with the accelera- tor pedal it is operated from low-idling and high idling 2. Adjusting procedure 1) Remove cover under cab. 2) Loosen nut (1) and adjust so that installed length X of the rod (2) is within the standard value. 3) Loosen nut (5) and adjust bolt (4) so that stalled height L, of accelerator pedal stopper is within the standard value. 4) Loosen nut (3) and adjust bolt (6) so that in- stalled height L; of accelerator pedal stopper is within the standard value. 5) Loosen locknut (7) and adjust the length of the cable so that the injection pump governor lever contacts the high idling stopper when the pedal is depressed (high idling). wa470-1MEASURING ACCELERATOR PEDAL OPERATING TESTING AND ADJUSTING FORCE AND OPERATING ANGLE OPERATING ANGLE OF ACCELERATOR PEDAL (Serial No. 20001 and up) 1. Measuring procedure 1) Stop the engine. 2). Measure the operating angle «,, a, put the angle gauge (1) in contact with the accelera- tor pedal it is operated from low-idling and high idling, oF 2. Adjusting procedure vaoto02 1) Remove the cover at the bottom of the cab, ‘open the engine hood, and apply the safety lock. 2) Loosen nut (1) and adjust bolt (2) so that ‘mounting height L of the accelerator pedal stopper is within a range of 47 * 5 mm. 3) Loosen locknut (3) and adjust the length of the cable so that the injection pump governor lever contacts the high idling stopper when the accelerator pedal is depressed (high idling) ‘* Check that the injection pump governor lever contacts the low idling stopper when the accelerator pedal is released (low idling) * Adjust the travel of the governor lever at joint (4. ZED Cable joint nut: 1.4 * 0.1 kgm (A Cable joint nut: Thread tightener (T-2) * After completing the above adjust- ments, measure each part again to check that it is within the standard value. Wa470-1TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL CUT SOLENOID 1 Adjust rod (2) so that there is clearance of 0.4 + 0.1. mm between stop lever (4) and stopper (5), while pulling rod (2) to the running direction. ‘Turn on the engine starting key and confirm that, the solenoid has a stroke of 12 mm and the clearance of 0.4 + 0.1. mm. After turning on and off the key two or three times, reconfirm that solenoid works smoothly ‘and engine runs or stops completely, If the solenoid does not work smoothly, sol ‘oid coil burns in the cause of excessive cur- rent or flywheel horsepower downs in the cause of dropping fuel injection volume. wa470-1 FUEL SYSTEM pene Solenoid valve Rod Fuel injejction pump Stop lever Stopper 12-13ENGINE 13 DISASSEMBLY AND ASSEMBLY STARTING MOTOR ASSEMBLY Removal Installation ALTERNATOR ASSEMBLY Removal Installation FUEL INJECTION PUMP ASSEMBLY Removal Installation WATER PUMP ASSEMBLY Removal Installation NOZZLE HOLDER ASSEMBLY Removal Installation TURBOCHARGER ASSEMBLY Removal Installation % Take the following method for air bleeding when you start to operate hydraulic 13- 13- 13- 13- 13-4 13-4 13-5 13-5 13- 6-1 13- 6-2 13- 6-2 CYLINDER HEAD ASSEMBLY Removal Installation RADIATOR ASSEMBLY Removal Installation OIL COOLER ASSEMBLY Removal Installation ENGINE ASSEMBLY Removal Installation FUEL TANK ASSEMBLY Removal Installation cylinders after reassembling cylinders, pumps and pipings. 1, Start engine, keep idling, 2. Operate hydraulic cylinder 4 — 5 cycles, but do not exceed beyond 100 mm or stroke end, 3. Continue to operate cylinder 3 — 4 cycles until stroke end. 4. After finishing above steps, keep normal engine speed. NOTE: After long storage, same procedure is required. Wa470-1 13-7 13-13 13-20 13-22-1 13-23 13-23 13-24 13-30 13-34 13-34 13-1 @DISASSEMBLY AND ASSEMBLY STARTING MOTOR REMOVAL OF STARTING MOTOR ASSEMBLY Ad disconnect the cable fom the negative (=) termine! othe battery 1, Remove catch, open side cover, then remove side cover (1) Disconnect wires (2) and (3), Remove ground connection (4), then remove starting motor assembly (5) INSTALLATION OF STARTING MOTOR ASSEMBLY 1. Fit O-ring and install starting motor assembly (5), then tighten together with ground connection (4). 2. Connect wires (3) and (2). 3. Install cover, close side cover (1), then lock with catch, 4. Connect cable to negative (—) terminal of battery, 13-2 WA4T0-1DISASSEMBLY AND ASSEMBLY. REMOVAL OF ALTERNATOR ASSEMBLY A Disconnect the cable from the negative (—) termina ot the battery. Remove catch, then open side cover. 2. Disconnect wires (1), (2) and (3). 3. Remove bolt (4) of adjustment plate, then loosen mounting bolt and nut (5). 4, Move alternator assembly towards cylinder block to loosen belt tension, then remove belt (6). 5, Remove mounting bolt and nut, then remove alterna- tor assembly (7) INSTALLATION OF ALTERNATOR ASSEMBLY 1, Install alternator assembly (7), then partially tighten mounting bolt and nut (5) 2. Fit belt (6) in pulley groove and install. Partially tighten bolt (4) of adjustment plate 4. Insert a bar between alternator assembly and cylinder block. raise alternator assembly and adjust tension of belt * The belt should deflect about 10 mm when pushed with a finger pressure of 6 kg at 2 point midway between the alternator and the fen pulley 5. Tighten bolt of adjustment plate, mounting bolt and, nut 6. Connect wires (3), (2) and (1) Close hood, then lock with catch. 8. Connect cable to negative (—) terminal of battery Waa70-1 ALTERNATOR 13-3DISASSEMBLY AND ASSEMBLY REMOVAL OF FUEL INJECTION PUMP ASSEMBLY 1. Remove catch, open side cover, then remove cover a. Disconnect control rods (2) and (3). Disconnect oil hose (4) and tube (6), then remove oil filter (6) Disconnect fuel hoses (7) and (8) Disconnect fuel feed hose (9). Remove lubrification tubes (10) and (11). Disconnect 6 fuel injection tubes (12) Remove flange bolt (13) of fuel injection pump. Remove 4 mounting bolts, then pull out fuel injection pump assembly (14) to rear to remove pero me INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 1. Place fuel injection pump assembly (14) on bracket, and set in position. Partially tighten 4 mounting bolts, ‘then tighten flange bolt (13) of fuel injection pump. 2. Rotate crankshaft and align pointer with line on damper. 3. Align line A on fue! injection pump with ine B on cou- pling side, then tighten mounting bolts of pump uni- formly in turn. 4. Connect 6 fuel injection tubes (12), and tighten nuts, GD Sleove nut: 2.4 + 0.1 kgm 5. Fit gaskets and install lubrication tubes (10) and (11). 6. Fit gasket and connect fuel feed hose (9) 7. Fit gaskets and connect fuel hoses (7) and (8). 8. Remove oil filter (6), then connect oil tube (5) and hose (4). 9. Connect control rods (3) and (2). 10. Install cover (1), close cover, then lock with catch 13-4 INJECTION PUMP ‘WA470-1DISASSEMBLY AND ASSEMBLY REMOVAL OF WATER PUMP ASSEMBLY 1, Loosen drain valve (1) and drain cooling water. If the coolant contains antifreeze, dispose of it correctly. Remove catch, then open side cover. Disconnect water pump outlet hose (2) Disconnect water pump inlet tube (3) Remove tube (4) between water pump and cooler. Remove mounting bolt (5), then pull out water pump. assembly (6) moving backward. pgaenr INSTALLATION OF WATER PUMP ASSEMBLY 1. Fit O-ring and install water pump assembly (6), then tighten bott (5) 2. Fit gasket and install bube (4) between water pump and cooler. Fit gasket and connect water pump inlet tube (3) Connect water pump outlet hose (2) Close side cover, then lock with catch. Tighten drain valve (1) 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. WaA470-1 WATER PUMP 13.5DISASSEMBLY AND ASSEMBLY REMOVAL OF NOZZLE HOLDER ASSEMBLY 1. Remove catch, open side cover, then remove hood. 2. Disconnect air pipe (1), loosen clamp of hose (2), then disconnect bracket (3). Serial No. 10001 — 19999 3-1 Loosen band of pipe (4), remove air cleaner band, then remove air cleaner assembly (5). Serial No. 20001 and up 3-2 Remove air cleaner assembly (5). 13-6 + Serial No. 10001 ~ 19999 + Serial No. 20001 and up + Serial No. 20001 and up r7 fa NOZZLE HOLDER WA470-1DISASSEMBLY AND ASSEMBLY 4. Remove bolt and nut of coupling (6), remove band, then remove muffler assembly (7) 5. Remove spi pipe (8) 6. Disconnect fuel injection tube (9) at nozzle holder end 7. Screw in mounting bolt of spill pipe to nozzle holder fully, then wrench with bar @and remove nozzle holder assembly (10). When removing the nozzle holder, clean around the nozzle holder and prevent dust or dirt from entering INSTALLATION OF NOZZLE HOLDER ASSEMBLY 1. Fit O-ring, install nozzle holder assembly (10), then, tighten bolt S) Mounting bolt: 2.2 + 0.3 kgm 2. Connect fuel injection tube (9) ZED Sleeve nut: 2.3 + 0.2 kam 3. Fit gasket and instal spill pipe (8) 4, Fit seal ring, install coupling (6), install muffler assem- bly (7), then secure with band. Serial No. 10001 ~ 19999 5-1 Install air cleaner assembly (5), then tighten air clean- er band and band of pipe (4), Serial No. 20001 and up 5-2 Install air cleaner assembly (5) 6. Connect hose (21, tighten clamp, then tighten mount- ing bolt of bracket (3). Fit gasket and install air pipe , 7. Install hood, close side cover, then lock with catch, waa7o-1 TURBOCHARGER - eqDISASSEMBLY AND ASSEMBLY TURBOCHARGER REMOVAL OF TURBOCHARGER gana soo _ soe 1. Remove catch, open side cover, then remove hood, Remove bolt and nut of coupling (1), remove band, then remove muffler assembly (2). Disconnect air pipe (3). Disconnect hose (4) and sir cleaner band, remove bolt of bracket (5), then remove air cleaner assembly 6) Disconnect connector hose (7). Disconnect oil supply tube (8). Remove drain tube (9) Remove turbocharger assembly (10) ae exoe + Serial No. 20001 and up INSTALLATION OF TURBOCHARGER ASSEMBLY Fit gasket and install turbocharger assembly (10). + Fit the gasket with the TOP mark facing up. 2. Fit gasket and install drain tube (3) 3. Fit O-ring and install oil supply tube (8), 4. Connect connector hose (7) 5. Fit air cleaner assembly (6), tighten bolts of bracket (5), then connect hose (4), and secure air cleaner as- sembly with band. 6. Fitair pipe (3) 7. Fit mufier (2), band and coupling (1). 8. Fithood 13-6-2 WA470-1DISASSEMBLY AND ASSEMBLY CYLINDER HEAD REMOVAL OF CYLINDER HEAD ASSEMBLY 1. Draining water Loosen drain valve (1) and drain coolant. If the coolant contains antifreeze, dispose of it correctly 2. Hood Remove catch, open side cover, sling hood (2), then lit off. 3. Air pipe Remove air pipe (3) 4. Air cleaner assembly 1) Loosen clamp, disconnect hose (4), then remove bracket (5) WA470-1 13-7DISASSEMBLY AND ASSEMBLY. CYLINDER HEAD. + Serial No. 10001 — 19999 Serial No, 10001 — 19999, 2) Loosen band of pipe (6), remove air cleaner band, then remove air cleaner assembly (7) Serial No. 20001 and up 2) Remove air cleaner assembly (7) 5. Wiring Disconnect electrical intake air heater wirings (8) and (9). 6. Muffler assembly 1) Remove air cleaner pipe assembly (10) 2). Remove bolt and nut of coupling (11), remove band, then remove muffler assembly (12), 13-8 WA470-1DISASSEMBLY AND ASSEMBLY. CYLINDER HEAD 7. Piping Remove oil filter hose (13) and tube (14). 8. Oilfilter Remove oil filter (18). 9. Aeration hose, radiator inlet pipe 1) Disconnect aeration hose (16) 2) Loosen hose band and remove radiator inlet pipe (7. 10. Corrosion resistor hose Disconnect 2 corrosion resistor hoses (18). ¥# Disconnect clamps of corrosion resistor hose from bracket (19). 11, Connection pipe Loosen band of hose (20), then remove connection pipe (21) WA470-1 13-9 @DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 12. Fuel injection pipe, spill pipe 1) Remove 6 fuel injection pipes (22 2) Remove spill pipe (23) 13. Oil supply tube Remove oil supply tube (24). 14, Drain tube Disconnect drain tube (25). 15. Exhaust manifold, turbocharger assembly Sling exhaust manifold and turbocharger assembly (26), then lift out 16. Intake manifold Remove intake manifold (27) together with corrosion resistor assembly, 17. Water manifold 1) Disconnect water'pump outlet pipe (28). 2). Disconnect wiring (28), then remove water mani- fold (30), 13-10 waa7o-1DISASSEMBLY AND ASSEMBLY 18, Nozzle holder assembly Screw in mounting bot of spill pipe to nozzle holder fully, then wrench with bar @)and remove nozzle holder assembly (31). When removing the nozzle holder assembly. clean around it and prevent dust or dit from entering 19. Head cover Remove head cover (32). 20. Rocker arm assembly Loosen lock nut (33), loosen adjustment screw 2 to 3 turns, then remove rocker arm assembly (34). 21. Crosshead Remove crosshead (35) 22. Rocker housing assembly 1) Remove bracket (36) 2) Remove rocker housing assembly (37) Waa7o-1 CYLINDER HEADDISASSEMBLY AND ASSEMBLY 23. Push rod Remove push rod (38). 24. Cylinder head assembly 1) Remove cylinder head bolt (39). 2) Remove cylinder head assembly (40) CYLINDER HEAD WA470-1DISASSEMBLY AND ASSEMBLY INSTALLATION OF CYLINDER HEAD ASSEMBLY Special tool Part number Partname [Q'ty ‘A | 795-125-1360 _ | Feeler gauge 1 1. Cylinder head assembly 1) Make sure the mounting surface of cylinder head and the inside of cylinders are free from dust and foreign matter, and place cylinder head gasket (41) in position. * When installing the gasket, make sure the grommet is not loose. ‘mounting bolt (39) bly (40) and tighten Coat the threads and lower side of the bolt head before tightening the mount- ing bolts with lubricant {LM-P) + First screw in the mounting bolts two or three revolutions by hand, then tighten the bolts as follows. G=] Cylinder head mounting bolts. Unit ham ee Range ieee [to oni | laetaer (cea 135148 Tele ‘Mark the bolts and the cylinder head : wtateiop on and turn ne ole arate | mith fotowing dares. 80" 75 = 108 ile a7 60-78 ~ waa7o CYLINDER HEAD 13-13DISASSEMBLY AND ASSEMBLY 2. Push rod Install push rods (38). % Make sure the push rods are securely positioned in the tappet. 3. Rocker housing assembly 1) Fit gasket and install rocker housing (37), 2). Install bracket (36). 4. Crosshead Install crosshead (35) % Adjust the crosshead as follows: i) Hold down the upper surface of the cross- head lightly with a finger, and screw the ad- just ment screw. After the adjustment screw comes into con- tact with the valve stem, screw the adjust- ment screw 20 degrees. ji) Tighten the lock nut in this position. FE Lock nut: 6.76 + 0.75 kgm 5. Rocker arm assembly Fit the ball of the rocker arm to the socket of the push rod, and install rocker arm assembly (34), 13-14 CYLINDER HEAD WA470-1DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 6. Adjusting valve clearance %* Using tool A, adjust clearance between rocker arm (34) and crosshead as follows. Unit: mm Intake valve _| Exhaust valve Valve clearance nas 0.33 071 ‘For detailes, see 12 TESTING AND ADJUSTING “adjusting valve clearance”. 7. Headcover Fit O-ring and install cylinder head cover (32). 8. Nozzle holder assembly Fit O-ring and nozzle holder assembly (31), then tighten bolt. S32) Mounting bolt: 2.2 + 0.3 kgm 9. Water manifold 1) Fit gaskets and install water manifold (30), then connect wiring (29). 2). Fit water pump outlet pipe (28). 10. Intake manifold Fit gaskets and install intake manifold (27) together with corrosion resistor. WA470-1 13-15DISASSEMBLY AND ASSEMBLY 11, Exhaust manifold, turbocharger assembly Fit gaskets and install exhaust manifold and tur- bocharger assembly (26). 12, Drain tube Fit gasket and connect drain tube (25) 13. Oil supply tube Fit gasket and install oil supply tube (24) 14, Fuel injection pipe, spill pipe 1). Fit gaskets and install spill pipe (23). 2) Install 6 fuel injection pipes (22) and secure with clamp. SBD Sleeve nut: 2.3 + 0.2 kgm 18. Connection pipe Fit gasket and install connection pipe (21), then con- rnect hose (20) and tighten band 16. Corrosion resistor hose Connect 2 corrosion resistor hoses (18). ‘* Connect clamp of corrosion resistor hose to bracket (19) 13-16 CYLINDER HEAD WA470-1DISASSEMBLY AND ASSEMBLY 17. Aeration hose, radiator inlet pipe 1) Install radiator inlet pipe (17) and secure with hose band, 2) Connect aeration hose (16) 18. Oil filter Install ol filter (15). 19. Piping Connect oil filter tube (14) and hose (13). 20. Muffler assembly 1) Install muffler assembly (12) and secure with ‘band, then tighten bolt and nut of coupling (11) 2). Install air cleaner pipe (10). 21. Wiring Connect electrical intake air heater wirings (9) and (8) wa4z7o-1 CYLINDER HEAD "J 4212091DISASSEMBLY AND ASSEMBLY 22. Air cleaner assembly Serial No. 10001 ~ 19999 1) Install air cleaner assembly (7) and air cleaner band, then tighten band of pipe (6). Serial No, 20001 and up 1). Install air cleaner assembly (7). 2) Install bracket (5), then connect hose (4), then tighten clamp, 23. Air pipe Fit gasket and install air pipe (3) 13-18 a Serial No. 10001 — 19999 CYLINDER HEAD WA4T0-1DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 24. Hood Sling hood (2), install it, close side cover, then lock with catch, Lee Stuath fa : 25. Refilling with wat 1). Tighten drain valve (1). 2). 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. WA470-1 13-19 ®DISASSEMBLY AND ASSEMBLY REMOVAL OF RADIATOR ASSEMBLY A\Siop the machine on level ground and install the safety bar on the frame. Lower the bucket to the {ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving Loosen the cil filer cap slowly to release the pressure inside the hydraulic tank. Then operate the control levers several times to release the remaining pressure in the hydraulic piping Serial No, 10001 ~ 19999 + Remove plugs (1) and (2) at the top of the hydraulic tank filter, and plugs (2), (3), (4) and (5) of the pump piping ot prevent the oil inside the tank from flowing out. Serial No. 20001 and up + Remove plugs (1) and (2) at the top of the hydraulic tank filter, and cover (2A). + Remove plugs (2), (3), (3A), (4) and (5) of the pump piping to prevent the oil inside the tank from flowing out, 1. Draining water Loosen drain valve (6) and drain coolant. If the coolant contains antifreeze, dispose of it correctly. $_, Coolant: Seriai No, 10001 — 19999 ta ese Serial No, 20001 and up 66 ¢ (With subtank) 13-20 a RADIATOR + Serial No. 20001 and up et reraresd | WA470-1DISASSEMBLY AND ASSEMBLY 2. Cover Remove hood (7), side cover (8) and grille (9). Hood: Serial No. 10001 — 19999 Ca 65 kg Serial No. 20001 and up 95 ko CHES Raditororte: 48 ko 3. Radiator guard Remove radiator guard (10), then lft it off. ‘Be careful not to hit the radiator when lifting off the radiator guard. + Disconnect wiring from connector. , Radiator guard: Serial No. 10001 — 19999 61k Serial No. 20001 and up Oks 4. Radiator hoses 1) Disconnect radiator hoses (11) and (12) at the engine end. ‘Loosen clamp of hose (13) at the radiator end. 5. Fan guard, support 1) Remove radiator support (14). 2) Remove fan guard (15) from the radiator. wa4z7o-1 RADIATOR 4213057DISASSEMBLY AND ASSEMBLY 6. Cooler piping 1) Disconnect hydraulic oil cooler hoses (16) and (17) from the radiator. 2) Disconnect torque converter hoses (18) and (19) from the radiator. Sling radiator (20), remove mounting bolts, then lift off radiator (20). % Disconnect coolant level sensor wiring from connector. Radiator: 165 kg 13-22 RADIATOR 42163061 WaA4z70-1DISASSEMBLY AND ASSEMBLY RADIATOR INSTALLATION OF RADIATOR ASSEMBLY tor Raise radiator (20), set in mounting position and in- stall mounting bolts. ++ Tighten the mounting bolts partially, then tighten them fully after installing the support. + Connect coolant level sensor wiring to connector. 421P9061 2. Cooler pi 1) Connect torque converter cooler pipings (18) and (19) to radiator. + SerialNo. 10001 — 19999 Width across flats of cooler hose: 36 mm =I Cooler hose: 18 + 3 kgm + Serial No. 20001 and up ‘Width across flats of cooler hose: 41 mm GD Cooler hose: 20 + 6.0 kgm 2) Connect hydraulic oil cooler pipings (16) and (7)t0 Width across flats of cooler hose: 41. mm. =I Cooler hose: 20 + 5 kgm 3. Fan guard, support 1) Install fan guard (15) to radiator. ‘Install so that the clearances between the fen and fan guard at the left and right, and top and bottom are the same. 2). Install radiator support (14) to radiator. ‘+ Tighten the radiator mounting bolt. 421P9058] 4, Radiator hoses Connect radiator hoses (111), (12) and (13) to engine. ‘Install the clamp properly. 4 Serial No. 20001 and up. Install the two hose clamps so that the threaded portion of each is at 180° to the other. 4 Connect hose (13) to radiator. 13 14213057 waa7o-1 13-22-1 aDISASSEMBLY AND ASSEMBLY RADIATOR 6. Hood 2 Radiator guard Set radiator guard (10) in mounting position and tighten mounting bolts. * Connect wiring to connector. ‘+ Install the radiator guard without interference. ~ Install so that the clearances between the radia- tor quardandradtor at eletandrightaretne Tf ey same. t f | ustroos Install engine hood (7), side cover (8) and grille (9), Refilling with oil, water 1) Tighten drain valve and add water through water filler to the specified level. + Serial No. 10001 — 19999 Coolant: 652 + Serial No, 20001 and up * Add water to the sub-tank to the specified level ea ~—_Coolant: 66 (With subtank) Water filler ‘Oil filler 421P9062 ——_ 2). Tighten plug at the top of hydraulic tank filter and plug of pump piping, then add hydraulic oil *__ Serial No. 20001 and up through oil filler to the specified level. Run the engine to circulate the oil and water through the system, ‘Then, check the oil and water levels again. QE Plug at the top of hydraulic tank filter: 1.2 £0.1 kgm a 13-22-2 waa70-1 €DISASSEMBLY AND ASSEMBLY On COOLER REMOVAL OF OIL COOLER ASSEMBLY 1. Remove catch, open cover, then remove cover (1). 2. Loosen drain valves (2) and (3), and drain coolant. % If the coolant contains antifreeze, dispose of it correctly 3. Disconnect turbocharger drain tube (4). 4, Remove oil cooler assembly (6). INSTALLATION OF OIL COOLER ASSEMBLY Fit gasket and install oil cooler assembly (6). Fit gasket and connect turbocharger drain tube (4) Tighten drain valves (3) and (2), install cover (1), close cover (1), then lock with catch. 4. Add water through water filler to the specified level. % Run the engine to circulate the water through the system, Then check the coolant level again. WA470-1 13-23DISASSEMBLY AND ASSEMBLY ENGINE REMOVAL OF ENGINE + Serial No. 10001 ‘A Stop the machine on level ground and install the safety ber on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving “A“ Loosen the oil filler cap slowly to release the pressure * inside the hydraulic tank. Then operate the control levers several times to release the remaining pressure in the hydraulic piping % Disconnect the cable from the negative (—) terminal of the battery. Serial No. 10001 — 19999 + Remove plugs (1) and (2) at the top of the hydraulic tank filter, and the plugs (3), (4) and (5) of the pump piping to prevent the oil inside the tank from flowing out, Serial No. 20001 and up + Remove plugs (1) and (2) at the top of the hydraulic tank filter, and cover (2A) + Remove plugs (2), (3), (3A), (4) and (5) of the pump piping to prevent the oil inside the tank from flowing + Serial No. 20001 and up ae 1. Draining water Loosen drain valve (6) and drain coolant. If the coolant contains antifreeze, dispose of it correctly, Coolant: Serial No. 10001 — 19999 ese Serial No, 20001 and up 66 (With subtank) 4213053 13-24 waa7o-1 aDISASSEMBLY AND ASSEMBLY 2. Hood Serial No. 10001 — 19999 1) Remove side covers (7), (8) and (9) and grille (10). Serial No. 20001 and up 1) Remove side covers (8), (9) and grille (10). 2). Raise engine hood (11), then lftit off. [EP Engine hood: Serial No. 10001 — 19899 65 kg Serial No, 20001 and up 90kg 3. Radiator guard Raise radiator guard (12), then lft it off. Be careful not to hit the radiator when lifting off the radiator guard. + Disconnect electric wiring from connector. (ae) Radiator guard: Serial No. 10001 — 19999 61k9 Serial No, 20001 and up 78k9 Serial No, 20001 and up 4, Radiator subtank Disconnect hose (41) from radiator sub-tank (40) ‘and remove sub-tank (40) together with bracket (42) Wa470-1 ENGINE