03 wa1200-3 shop manual

1SEBM018209

2004 1All Rights ReservedPrinted in Japan 10-04(01)

00-1(9)

WA1200-3

MACHINE MODEL SERIAL NO.

WA1200-3 50001 and up

This shop manual may contain attachments and optional equipment that are not availablein your area. Please consult your local Komatsu distributor for those items you mayrequire.Materials and specifications are subject to change without notice.

WA1200-3 mount the Cummins QSK60 engine.

WA1200-300-25

CONTENTS

No. of page

01 GENERAL ........................................................................ 01-1

10 STRUCTURE AND FUNCTION ...................................... 10-1

20 TESTING AND ADJUSTING .......................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ................................. 30-1

40 MAINTENANCE STANDARD......................................... 40-1

90 OTHERS........................................................................... 90-1

00-2-1(9)

WA1200-3

00- 1 (9)00- 2 (5)

00- 2-1 (9) 00- 2-2 (9) 00- 2-3 (9) 00- 2-4 (9) 00- 2-5 (9) 00- 2-6 (9) 00- 3 00- 4 00- 5 00- 6 00- 7 00- 8 00- 9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 00-19 00-20 00-21 00-22

10-7610-7710-7810-7910-8010-8110-8210-8310-8410-8510-8610-8710-8810-8910-9010-9110-9210-9310-9410-9610-9710-9810-9910-10010-10110-10210-10310-104

10-4810-4910-5010-5110-5210-5310-5410-5510-5610-5710-5810-5910-6010-6110-6210-6310-6410-6510-6610-6710-6810-6910-7010-7110-7210-7310-7410-75

Mark Indication Action required

Page to be newly added Add

Page to be replaced Replace

( ) Page to be deleted Discard

The affected pages are indicated by the use of thefollowing marks. It is requested that necessary actionsbe taken to these pages according to the table below.

Pages having no marks are those previously revisedor made additions.

LIST OF REVISED PAGE

Time ofMark Page revisionTime ofMark Page revision


Time ofMark Page revision

LIST OF REVISED PAGES

01- 101- 201- 301- 401- 501- 601- 701- 801- 9

10- 1 (7)10- 210- 310- 410- 510- 610- 810- 910-1010-1110-1210-14 (2)10-1510-1610-1710-1810-19

10-20 (2)10-2110-2210-2310-2410-2510-2610-2710-2810-2910-3010-3110-3210-3310-3410-3510-3610-3710-3810-3910-4010-4110-4210-4310-4410-4510-4610-47

00-2-2(9)

WA1200-3

20- 1 (2)20- 2 (5)20- 3 (1)20- 4 (1)20- 5 (2)20- 6 (1)20- 7 (1)20- 8 (1)20- 9 (2)20-10 (2)20-11 (2)20-12 (2)20-13 (2)20-14 (2)20-15 (2)20-16 (2)20-17 (2)20-18 (2)20-19 (1)20-20 (2)20-21 (2)20-22 (2)20-23 (1)20-24 (1)20-25 (1)20-26 (1)20-27 (1)20-28 (2)20-29 (1)20-30 (2)

20-101 (8)20-102 (4)20-102-1 (8)20-103 (8)20-104 (1)20-105 (1)20-106 (1)20-107 (8)20-108 (8)

10-22510-22610-22710-22810-22910-23010-23110-23210-23310-23410-23510-23610-23710-238 (7)10-239 (2)10-240 (2)10-241 (2)10-24210-24310-24410-24510-24610-24710-24810-24910-25010-25110-25210-25310-25410-25510-25610-25710-25810-25910-26010-26110-262 (7)10-263 (7)

10-187 (7)10-188 (7)10-189 (7)10-190 (7)10-191 (7)10-192 (7)10-193 (7)10-194 (7)10-195 (7)10-19610-197 (7)10-197-1 (7)10-198 (7)10-199 (7)10-200 (7)10-201 (7)10-202 (7)10-203 (7)10-204 (7)10-205 (7)10-20610-207 (7)10-208 (7)10-209 (7)10-210 (7)10-211 (7)10-211-1 (7)10-212 (7)10-213 (7)10-214 (7)10-215 (7)10-216 (7)10-217 (7)10-21810-21910-22010-22110-22210-22310-224

10-10510-10610-10710-10810-10910-11010-11210-11310-11410-11510-11610-11710-11810-11910-12010-12110-12210-12310-12410-12510-12610-12710-12810-12910-13010-13110-13210-13310-13410-13510-13610-13710-13810-13910-14010-14110-14210-14310-14410-145





10-14610-14710-14810-14910-15010-15110-15210-15310-15410-15510-15610-15710-15810-15910-16010-16110-16210-16310-16410-16510-16610-16810-16910-17010-17110-17210-17310-17410-175 (7)10-17610-17710-17810-17910-18010-181 (7)10-182 (7)10-183 (7)10-184 (7)10-18510-186 (7)

00-2-3(9)

WA1200-3





20-186 (8)20-187 (8)20-188 (8)20-189 (8)20-190 (8)20-191 (8)20-192 (8)20-193 (8)20-194 (8)20-195 (8)20-196 (8)20-197 (8)20-198 (8)20-199 (8)20-199-1 (8)20-199-2 (8)20-199-3 (8)20-199-4 (8)20-199-5 (8)20-199-6 (8)20-199-7 (8)20-199-8 (8)20-199-9 (8)20-199-10 (8)20-199-11 (8)20-199-12 (8)

20-201 (2)20-202 (2)20-203 (2)20-204 (2)20-205 (2)20-206 (2)20-207 (2)20-208 (2)20-209 (2)20-210 (2)20-211 (2)20-212 (2)20-213 (2)

20-146 (1)20-147 (1)20-148 (1)20-149 (1)20-150 (4)20-151 (4)20-152 (4)20-153 (8)20-154 (8)20-155 (8)20-156 (8)20-157 (8)20-158 (8)20-159 (8)20-160 (8)20-161 (8)20-162 (8)20-163 (8)20-164 (8)20-165 (8)20-166 (8)20-167 (8)20-168 (8)20-169 (8)20-170 (8)20-171 (8)20-172 (8)20-173 (8)20-174 (8)20-175 (8)20-176 (8)20-177 (8)20-178 (8)20-179 (8)20-180 (8)20-181 (8)20-182 (8)20-183 (8)20-184 (8)20-185 (8)

20-109 (8)20-110 (8)20-111 (5)20-112 (1)20-113 (1)20-114 (8)20-115 (1)20-116 (1)20-117 (1)20-118 (4)20-119 (4)20-119-1 (4)20-120 (8)20-121 (1)20-122 (1)20-123 (1)20-124 (1)20-125 (1)20-126 (1)20-127 (8)20-128 (8)20-129 (1)20-130 (1)20-131 (1)20-132 (1)20-133 (8)20-134 (1)20-135 (8)20-136 (8)20-137 (1)20-138 (1)20-139 (1)20-140 (1)20-141 (1)20-142 (1)20-143 (6)20-144 (6)20-144-1 (6)20-144-2 (8)20-145 (1)

20-214 (2)20-215 (2)20-216 (2)20-217 (2)20-218 (2)20-220 (2)20-221 (2)20-222 (2)20-223 (2)20-224 (2)20-225 (2)20-226 (2)20-227 (2)20-228 (2)20-229 (2)20-230 (2)20-231 (2)20-232 (2)20-233 (2)20-234 (2)20-235 (2)20-236 (2)20-237 (2)20-238 (2)20-239 (2)20-240 (2)20-241 (2)20-242 (2)20-243 (2)20-244 (2)20-245 (2)20-246 (2)20-247 (2)20-248 (2)20-249 (2)20-250 (2)20-251 (2)20-252 (2)20-253 (2)20-254 (2)

20-255 (2)20-256 (2)20-257 (2)20-258 (2)20-259 (2)20-260 (2)20-261 (2)20-262 (2)20-263 (2)20-264 (2)20-265 (2)20-266 (2)20-267 (2)20-268 (2)20-269 (2)20-270 (2)20-271 (2)

20-301 (2)20-302 (2)20-303 (2)20-304 (2)20-305 (2)20-306 (2)

20-401 (2)20-402 (2)20-404 (2)20-405 (2)20-406 (2)20-407 (2)20-408 (2)20-409 (2)20-410 (2)20-411 (2)20-412 (2)20-413 (2)20-414 (2)20-415 (2)20-416 (2)

00-2-4(9)

WA1200-3





20-417 (2)20-418 (2)20-419 (2)20-420 (2)20-421 (2)20-422 (2)20-423 (2)20-424 (2)20-425 (2)20-426 (2)20-427 (2)20-428 (2)20-429 (2)20-430 (2)20-431 (2)20-432 (2)20-433 (2)20-434 (2)20-435 (2)20-436 (2)20-437 (2)20-438 (2)20-439 (2)20-440 (2)20-441 (2)20-442 (2)20-443 (2)20-444 (2)20-445 (2)20-446 (2)20-447 (2)20-448 (2)20-449 (2)20-450 (2)20-451 (2)20-452 (2)20-453 (2)20-454 (2)20-455 (2)

20-501 (2)20-502 (2)20-503 (2)20-504 (2)20-505 (2)20-506 (2)20-507 (2)20-508 (2)20-509 (2)20-510 (2)20-511 (2)20-512 (2)20-513 (2)20-514 (2)20-515 (2)20-516 (2)20-517 (2)20-518 (2)20-519 (2)20-520 (2)20-521 (2)20-522 (2)20-523 (2)20-524 (2)20-525 (2)20-526 (2)20-527 (2)20-528 (2)20-529 (2)20-530 (2)20-531 (2)20-532 (2)20-533 (2)20-534 (2)20-535 (2)20-536 (2)20-537 (2)20-538 (2)20-539 (2)

20-601 (2)20-602 (2)20-604 (2)20-605 (2)20-606 (2)20-607 (2)20-608 (2)20-609 (2)20-610 (2)20-611 (2)20-612 (2)20-613 (2)20-614 (2)20-615 (2)20-616 (2)20-617 (2)20-618 (2)20-619 (2)20-620 (2)

20-651 (2)20-652 (2)20-654 (2)20-655 (2)20-656 (2)20-657 (2)20-658 (2)20-659 (2)20-660 (2)20-661 (2)20-662 (2)20-663 (2)20-664 (2)20-665 (2)20-666 (2)20-667 (2)20-668 (2)

20-701 (2)20-702 (2)

20-703 (2)20-704 (2)20-705 (2)20-706 (2)20-707 (2)20-708 (2)20-709 (2)20-710 (2)20-711 (2)20-712 (2)20-713 (2)20-714 (2)20-715 (2)20-716 (2)20-717 (2)20-718 (2)20-719 (2)20-720 (2)20-721 (2)20-722 (2)20-723 (2)20-724 (2)20-725 (2)20-726 (2)20-727 (2)20-728 (2)20-729 (2)20-730 (2)20-731 (2)20-732 (2)20-733 (2)20-734 (2)20-735 (2)

20-801 (8)20-802 (8)20-803 (2)20-804 (2)20-805 (8)20-806 (2)

20-807 (2)20-808 (2)20-809 (2)20-810 (8)20-811 (8)20-812 (8)20-813 (8)20-814 (2)20-815 (2)20-816 (8)20-817 (2)20-818 (2)20-819 (2)20-820 (8)20-821 (8)20-822 (2)20-823 (2)20-824 (8)20-825 (2)20-826 (2)20-827 (2)20-828 (2)20-829 (2)20-830 (2)20-831 (2)20-832 (2)20-833 (2)20-834 (2)20-835 (2)20-836 (2)20-837 (2)20-838 (2)20-839 (2)20-840 (2)20-841 (2)20-842 (2)20-843 (2)20-844 (2)20-845 (2)20-846 (2)

00-2-5(9)

WA1200-3





20-847 (2)20-848 (2)20-849 (2)20-850 (2)20-851 (2)20-852 (2)20-853 (2)20-854 (2)20-855 (2)20-856 (2)20-857 (2)20-858 (8)20-859 (2)20-860 (2)20-861 (2)20-862 (2)20-863 (2)20-864 (2)20-865 (2)20-866 (2)20-867 (2)(20-868)20-869 (2)20-870 (2)20-871 (2)20-872 (2)20-873 (2)20-874 (2)20-875 (2)20-876 (2)20-877 (2)20-878 (2)20-879 (2)20-880 (2)20-881 (2)20-882 (2)20-883 (2)20-884 (2)20-885 (2)20-886 (2)

20-887 (2)20-888 (2)20-889 (2)20-890 (2)20-891 (2)20-892 (2)20-893 (2)20-894 (2)20-896 (2)20-897 (2)20-898 (2)20-899 (2)20-900 (2)20-901 (2)20-902 (2)20-903 (2)20-904 (2)20-905 (2)20-906 (2)20-907 (2)20-908 (2)20-909 (2)20-910 (2)20-911 (2)20-912 (2)20-913 (2)20-914 (2)20-915 (2)20-916 (2)20-917 (2)20-918 (2)20-919 (2)20-920 (2)20-921 (2)20-922 (2)20-923 (2)20-924 (2)20-925 (2)20-926 (2)20-927 (2)

20-928 (2)20-929 (2)20-930 (2)

20-1001 (2)20-1002 (2)20-1003 (2)20-1004 (2)20-1005 (2)20-1006 (2)20-1007 (2)20-1008 (2)20-1009 (2)20-1010 (2)20-1011 (2)20-1012 (2)20-1013 (2)20-1014 (2)20-1015 (2)20-1016 (2)20-1017 (2)20-1018 (2)20-1019 (2)20-1020 (2)

30-001 (9) 30-002 (9) 30-003 (9) 30-004 (9) 30-005 (9) 30-006 (9) 30-006-1 (9)

30-007 (5)30-008 (5)30-009 (5)30-010 (5)30-011 (5)30-012 (5)30-013 (5)

30-014 (5)30-015 (5)30-016 (5)30-017 (5)30-018 (5)30-019 (5)30-020 (5)30-021 (5)30-022 (5)30-023 (5)30-024 (5)30-025 (5)30-026 (5)30-027 (5)30-028 (5)30-029 (5)30-030 (5)30-031 (5)30-032 (5)30-033 (5)30-034 (5)30-035 (5)30-036 (5)30-037 (5)30-038 (5)30-039 (5)30-040 (5)30-041 (5)30-042 (5)30-043 (5)30-044 (5)30-045 (5)30-046 (5)30-047 (5)30-048 (5)30-049 (5)30-049-1 (5)30-049-2 (5)30-049-3 (5)30-049-4 (5)

30-050 (5)30-051 (5)30-052 (5)30-053 (5)30-054 (5)30-055 (5)30-056 (5)30-057 (5)30-058 (5)30-059 (5)30-060 (5)30-061 (5)30-062 (5)30-063 (5)30-064 (5)30-065 (5)30-066 (5)30-067 (6)30-068 (5)30-069 (5)30-070 (5)30-070-1 (5)30-071 (5)30-072 (5)30-073 (5)30-074 (5)30-075 (5)30-076 (5)30-076-1 (5)30-076-2 (5)30-076-3 (5)30-076-4 (5)30-076-5 (5)30-076-6 (5)30-076-7 (5)30-076-8 (5)30-076-9 (5)30-076-10 (5)30-077 (5)30-078 (5)

00-2-6(9)

WA1200-3





30-079 (5)30-079-1 (5)30-079-2 (5)30-079-3 (5)30-079-4 (5)30-079-5 (5)30-079-6 (5)30-079-7 (5)30-079-8 (5)30-079-9 (5)30-079-10 (5)30-079-11 (5)30-079-12 (5)30-079-13 (5)30-079-14 (5)30-080 (5)30-081 (5)30-082 (5)30-083 (5)30-084 (5)30-085 (5)30-086 (5)

30-086-1 (9) 30-086-2 (9)

30-087 (5)30-088 (5)30-088-1 (5)30-089 (5)30-090 (5)30-090-1 (5)30-091 (5)30-092 (5)30-093 (5)30-094 (5)30-095 (5)30-095-1 (5)30-095-2 (5)30-095-3 (5)30-095-4 (5)30-096 (5)

30-097 (5)30-098 (5)30-099 (5)30-099-1 (5)30-099-2 (5)30-099-3 (5)30-099-4 (5)30-100 (5)30-101 (5)30-102 (5)30-103 (5)30-104 (5)30-105 (5)30-106 (5)30-107 (5)30-108 (5)30-109 (5)30-110 (5)30-111 (5)30-112 (5)30-113 (5)30-114 (5)30-115 (5)30-116 (5)30-117 (5)30-118 (5)30-119 (5)30-120 (5)30-121 (5)30-122 (5)30-123 (5)30-124 (5)30-125 (5)30-126 (5)30-127 (5)30-128 (5)30-129 (5)30-131 (6)30-132 (6)30-133 (6)

30-134 (6)30-135 (6)30-136 (6)30-137 (6)30-138 (6)30-139 (6)30-140 (6)30-141 (6)30-142 (6)

40- 140- 240- 440- 540- 640- 740- 840- 940-1040-1140-1240-1340-1440-1640-1740-1840-1940-2040-2140-2240-2340-2440-2540-2640-2740-2840-2940-3040-32

40-3340-3440-3540-3640-3740-3840-3940-4040-4140-4240-4340-4440-4540-4640-4740-4840-4940-5040-5140-5240-5340-5440-5540-5640-5740-5840-5940-6040-6140-6240-6340-6440-6540-66

90- 190- 2 (6)90- 3 (6)90- 4 (6)90- 5 (6)

90- 790- 990-11 (7)90-13 (7)90-15 (7)90-17 (7)90-19 (7)90-21 (7)90-23 (7)

SAFETY SAFETY NOTICE

00-3

SAFETYSAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The service andrepair techniques recommended by Komatsu and described in this manual are both effectiveand safe. Some of these techniques require the use of tools specially designed by Komatsu forthe specific purpose.

To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.The cautions accompanying these symbols should always be followed carefully. If any danger-ous situation arises or may possibly arise, first consider safety, and take the necessary actionsto deal with the situation.

GENERAL PRECAUTIONS

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

1. Before carrying out any greasing or repairs, readall the precautions given on the decals which arefixed to the machine.

2. When carrying out any operation, alwayswear safety shoes and helmet. Do not wearloose work clothes, or clothes with buttonsmissing. 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 atrained, experienced welder carry out the work.When carrying out welding work, always wearwelding gloves, apron, hand shield, cap andother clothes suited for welding work.

4. When carrying out any operation with two ormore workers, always agree on the operatingprocedure before starting. Always inform yourfellow workers before starting any step of theoperation. Before starting work, hang UNDERREPAIR signs on the controls in the operator'scompartment.

5. Keep all tools in good condition and learn thecorrect way to use them.

6. Decide a place in the repair workshop to keeptools and removed parts. Always keep the toolsand parts in their correct places. Always keepthe work area clean and make sure that there isno dirt or oil on the floor. Smoke only in the areasprovided for smoking. Never smoke while work-ing.

PREPARATIONS FOR WORK

7. Before adding oil or making any repairs, park themachine on hard, level ground, and block thewheels or tracks to prevent the machine frommoving.

8. Before starting work, lower blade, ripper, bucketor any other work equipment to the ground. Ifthis is not possible, insert the safety pin or useblocks to prevent the work equipment from fall-ing. In addition, be sure to lock all the controllevers and hang warning signs on them.

9. When disassembling or assembling, support themachine with blocks, jacks or stands beforestarting work.

10.Remove all mud and oil from the steps or otherplaces used to get on and off the machine.Always use the handrails, ladders or steps whengetting on or off the machine. Never jump on oroff the machine. If it is impossible to use thehandrails, ladders or steps, use a stand to pro-vide safe footing.

SAFETY SAFETY NOTICE

00-4

PRECAUTIONS DURING WORK

11.When removing the oil filler cap, drain plug orhydraulic pressure measuring plugs, loosenthem slowly to prevent the oil from spurting out.Before disconnecting or removing componentsof the oil, water or air circuits, first remove thepressure completely from the circuit.

12.The water and oil in the circuits are hot when theengine is stopped, so be careful not to getburned.Wait for the oil and water to cool before carry-ing out any work on the oil or water circuits.

13.Before starting work, remove the leads from thebattery. Always remove the lead from the nega-tive () terminal first.

14.When raising heavy components, use a hoist orcrane.Check that the wire rope, chains and hooks arefree from damage.Always use lifting equipment which has amplecapacity.Install the lifting equipment at the correct places.Use a hoist or crane and operate slowly to pre-vent the component from hitting any other part.Do not work with any part still raised by the hoistor crane.

15.When removing covers which are under internalpressure or under pressure from a spring,always leave two bolts in position on oppositesides. Slowly release the pressure, then slowlyloosen the bolts to remove.

16.When removing components, be careful not tobreak or damage the wiring. Damaged wiringmay cause electrical fires.

17.When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips onto the floor,wipe it up immediately. Fuel or oil on the floorcan cause you to slip, or can even start fires.

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

19.Be sure to assemble all parts again in their origi-nal places.Replace any damaged parts with new parts. When installing hoses and wires, be sure

that they will not be damaged by contactwith other parts when the machine is beingoperated.

20.When installing high pressure hoses, make surethat they are not twisted. Damaged tubes aredangerous, so be extremely careful when install-ing tubes for high pressure circuits. Also, checkthat connecting parts are correctly installed.

21.When assembling or installing parts, always usethe specified tightening torques. When installingprotective parts such as guards, or parts whichvibrate violently or rotate at high speed, be par-ticularly careful to check that they are installedcorrectly.

22.When aligning two holes, never insert your fin-gers or hand. Be careful not to get your fingerscaught in a hole.

23.When measuring hydraulic pressure, check thatthe measuring tool is correctly assembled beforetaking any measurements.

24.Take care when removing or installing the tracksof track-type machines.When removing the track, the track separatessuddenly, so never let anyone stand at eitherend of the track.

FOREWORD GENERAL

00-5

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

This shop manual mainly contains the necessary technical information for operations performed in a serviceworkshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-ther divided into the each main group of components.

STRUCTURE AND FUNCTIONThis section explains the structure and function of each component. It serves not only to give an under-standing of the structure, but also serves as reference material for troubleshooting.In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-nance standards.

TESTING AND ADJUSTINGThis section explains checks to be made before and after performing repairs, as well as adjustments tobe made at completion of the checks and repairs.Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.

DISASSEMBLY AND ASSEMBLYThis section explains the procedures for removing, installing, disassembling and assembling each com-ponent, as well as precautions for them.

MAINTENANCE STANDARDThis section gives the judgment standards for inspection of disassembled parts.The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERSThis section mainly gives hydraulic circuit diagrams and electric circuit diagrams.In addition, this section may give the specifications of attachments and options together.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without anyadvance notice. Use the specifications given in the book with the latest date.

FOREWORD HOW TO READ THE SHOP MANUAL

00-6

HOW TO READ THE SHOP MANUAL

VOLUMESShop manuals are issued as a guide to carrying outrepairs. They are divided as follows:

Chassis volume: Issued for every machine modelEngine volume: Issued for each engine series

Electrical volume: Attachments volume:

These various volumes are designed to avoid dupli-cating the same information. Therefore, to deal withall repairs for any model , it is necessary that chas-sis, engine, electrical and attachment volumes beavailable.

DISTRIBUTION AND UPDATINGAny additions, amendments or other changes will besent to KOMATSU distributors. Get the most up-to-date information before you start any work.

FILING METHOD1. See the page number on the bottom of the page.

File the pages in correct order.2. Following examples show how to read the page

number.Example 1 (Chassis volume):

10 - 3

Item number (10. Structure andFunction)Consecutive page number for eachitem.

Example 2 (Engine volume):

12 - 5

Unit number (1. Engine)Item number (2. Testing and Adjust-ing)Consecutive page number for eachitem.

3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example.Example:10-410-4-110-4-210-5

REVISED EDITION MARK

When a manual is revised, an edit ion mark((1)(2)(3)....) is recorded on the bottom of the pages.

REVISIONS

Revised pages are shown in the LIST OF REVISEDPAGES next to the CONTENTS page.

SYMBOLS

So that the shop manual can be of ample practicaluse, important safety and quality portions aremarked with the following symbols.

Symbol Item Remarks

k Safety Special safety precautionsare necessary when per-forming the work.

a Caution

Special technical precau-tions or other precautionsfor preserving standardsare necessary when per-forming the work.

4 WeightWeight of parts of sys-tems. Caution necessarywhen selecting hoistingwire, or when working pos-ture is important, etc.

3 TighteningtorquePlaces that require specialattention for the tighteningtorque during assembly.

2 Coat Places to be coated withadhesives and lubricants,etc.

5 Oil, waterPlaces where oil, water orfuel must be added, andthe capacity.

6 DrainPlaces where oil or watermust be drained, andquantity to be drained.

} Each issued as onevolume to cover allmodels

12-20312-203-112-203-212-204

Added pages

FOREWORD HOISTING INSTRUCTIONS

00-7

HOISTING INSTRUCTIONS

HOISTING

k Heavy parts (25 kg or more) must be liftedwith a hoist, etc. In the DISASSEMBLYAND ASSEMBLY section, every partweighing 25 kg or more is indicated clearlywith the symbol

If a part cannot be smoothly removed from themachine by hoisting, the following checksshould be made:1) Check for removal of all bolts fastening the

part to the relative parts.2) Check for existence of another part causing

interference with the part to be removed.

WIRE ROPES1) Use adequate ropes depending on the

weight of parts to be hoisted, referring tothe table below:

Wire ropes(Standard "Z" or "S" twist ropes

without galvanizing)

The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength ofthe rope used.

2) Sling wire ropes from the middle portion of thehook.

Slinging near the edge of the hook may causethe rope to slip off the hook during hoisting, anda serious accident can result. Hooks have max-imum strength at the middle portion.

3) Do not sling a heavy load with one rope alone,but sling with two or more ropes symmetricallywound onto the load.k Slinging with one rope may cause turning

of the load during hoisting, untwisting ofthe rope, or slipping of the rope from itsoriginal winding position on the load, whichcan result in a dangerous accident.

4) Do not sling a heavy load with ropes forming awide hanging angle from the hook.When hoisting a load with two or more ropes,the force subjected to each rope will increasewith the hanging angles. The table belowshows the variation of allowable load kN {kg}when hoisting is made with two ropes, each ofwhich is allowed to sling up to 9.8 kN {1000 kg}vertically, at various hanging angles.When two ropes sling a load vertically, up to19.6 kN {2000 kg} of total weight can be sus-pended. This weight becomes 9.8 kN {1000 kg}when two ropes make a 120 hanging angle.On the other hand, two ropes are subjected toan excessive force as large as 39.2 kN {4000kg} if they sling a 19.6 kN {2000 kg} load at alifting angle of 150.

Rope diameter Allowable load

mm kN tons

1011.512.514161820

22.430405060

9.813.715.721.627.535.343.154.998.1

176.5274.6392.2

1.01.41.62.22.83.64.45.6

10.018.028.040.0

4

SAD00479

41%71%79%88%100%

FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

00-8

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, releasethe residual pressure from the hydraulic tank.For details, see TESTING AND ADJUSTING,Releasing residual pressure from hydraulictank.

k Even if the residual pressure is released fromthe hydraulic tank, some hydraulic oil flows outwhen the hose is disconnected. Accordingly,prepare an oil receiving container.

Disconnection1) Release the residual pressure from the hydrau-

l ic tank. For detai ls, see TESTING ANDADJUSTING, Releasing residual pressure fromhydraulic tank.

2) Hold adapter (1) and push hose joint (2) intomating adapter (3). (See Fig. 1) The adapter can be pushed in about 3.5

mm. Do not hold rubber cap portion (4).

3) After hose joint (2) is pushed into adapter (3),press rubber cap portion (4) against (3) until itclicks. (See Fig. 2)

4) Hold hose adapter (1) or hose (5) and pull it out.(See Fig. 3) Since some hydraulic oil flows out, prepare

an oil receiving container.

Connection1) Hold hose adapter (1) or hose (5) and insert it in

mating adapter (3), aligning them with eachother. (See Fig. 4) Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapterperfectly, pull it back to check its connectingcondition. (See Fig. 5) When the hose is pulled back, the rubber

cap portion moves toward the hose about3.5 mm. This does not indicate abnormality,however.

Type 1

FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

00-9

Type 2 Type 3D

isas

sem

bly

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turnlever (4) to the right (clockwise).

3) Hold in the condition in Steps 1) and 2), andpull out whole body (2) to disconnect it.

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

2) Hold in the condition in Step 1), and pushuntil cover (3) contacts contact surface a ofthe hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), andpull out whole body (2) to disconnect it.

Con

nect

ion

Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.

Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.

FOREWORD COATING MATERIALS

00-10

COATING MATERIALS

The recommended coating materials such as adhesives, gasket sealants and greases used for disassemblyand assembly are listed below.

For coating materials not listed below, use the equivalent of products shown in this list.

Category Komatsu code Part No. Q'ty Container Main applications, features

Adhesives

LT-1A 790-129-9030 150 g Tube Used to prevent rubber gaskets, rub-

ber cushions, and cock plug fromcoming out.

LT-1B 790-129-9050 20 g(2 pcs.)Polyethylene

container

Used in places requiring an immedi-ately effective, strong adhesive.Used for plastics (except polyethyl-ene, polyprophylene, tetrafluoroeth-lene and vinyl chloride), rubber,metal and non-metal.

LT-2 09940-00030 50 g Polyethylenecontainer

Features: Resistance to heat andchemicals

Used for anti-loosening and sealantpurpose for bolts and plugs.

LT-3790-129-9060

(Set of adhesive and hardening

agent)

Adhesive:1 kg

Hardeningagent:500 g

Can

Used as adhesive or sealant for met-al, glass and plastic.

LT-4 790-129-9040 250 g Polyethylenecontainer Used as sealant for machined holes.

HoltzMH 705 790-126-9120 75 g Tube

Used as heat-resisting sealant for re-pairing engine.

Three bond1735 790-129-9140 50 g

Polyethylenecontainer

Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals,

rubbers, plastics and woods.

Aron-alpha201 790-129-9130 2 g


Quick hardening type adhesive Quick cure type (max. strength after

30 minutes) Used mainly for adhesion of rubbers,

plastics and metals.

Loctite648-50 79A-129-9110 50 cc


Resistance to heat, chemicals Used at joint portions subject to high

temperatures.

Gasketsealant

LG-1 790-129-9010 200 g Tube Used as adhesive or sealant for gas-

kets and packing of power train case,etc.

LG-5 790-129-9080 1 kg Can Used as sealant for various threads,

pipe joints, flanges. Used as sealant for tapered plugs,

elbows, nipples of hydraulic piping.

LG-6 790-129-9020 200 g Tube

Features: Silicon based, resistanceto heat, cold

Used as sealant for flange surface,tread.

Used as sealant for oil pan, finaldrive case, etc.

LG-7 790-129-9070 1 kg Tube

Features: Silicon based, quick hard-ening type

Used as sealant for flywheel hous-ing, intake manifold, oil pan, thermo-stat housing, etc.

Three bond1211 790-129-9090 100 g Tube

Used as heat-resisting sealant for re-pairing engine.

Three bond1207B 419-15-18131 100 g Tube

Features: Silicone type, heat resist-ant, vibration resistant, and impactresistant sealing material

Used as sealing material for transfercase

FOREWORD COATING MATERIALS

00-11

Category Komatsu code Part No. Q'ty Container Main applications, features

Molybdenum disulphide lubricant

LM-G 09940-00051 60 g Can Used as lubricant for sliding portion(to prevent from squeaking).

LM-P 09940-00040 200 g Tube

Used to prevent seizure or scufflingof the thread when press fitting orshrink fitting.

Used as lubricant for linkage, bear-ings, etc.

Grease

G2-LI

SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI

Various Various

General purpose type

G2-CA

SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA

Various Various

Used for normal temperature, lightload bearing at places in contactwith water or steam.

MolybdenumdisulphidegreaseLM-G (G2-M)

SYG2-400MSYG2-400M-ASYGA-16CNM

400 g 10400 g 20

16 kg

Bellows typeBellows type

Can

Used for heavy load portion

Hyper White Grease G2-TG0-T (*)*: For use in cold

district

SYG2-400T-ASYG2-16CNTSYG0-400T-A (*)SYG0-16CNT (*)

400 g16 kg

Bellows typeCan

Seizure resistance and heat resist-ance higher than molybdenum di-sulfide grease

Since this grease is white, it doesnot stand out against machinebody.

Biogrease G2BG2-BT (*)*: For high

temperature and large load

SYG2-400BSYGA-16CNBSYG2-400BT (*)SYGA-16CNBT (*)

400 g16 kg

Bellows typeCan

Since this grease is decomposedby bacteria in short period, it hasless effects on microorganisms,animals, and plants.

Primer

SUNSTAR PAINT PRIMER 580 SUPER

417-926-3910

20 ml Glass container

Adhe

sive

for c

ab g

lass

Used as primer for cab side(Using limit: 4 months)

SUNSTAR GLASS PRIMER 580 SUPER

20 ml Glass container

Used as primer for glass side(Using limit: 4 months)

Adhesive

SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"

320 ml Polyethylene container

"S" is used for high-tempera-ture season (April - October)and "W" for low-temperatureseason (November - April) asadhesive for glass. (Using limit: 4 months)

Sika Japan, Sikaflex 256HV 20Y-54-39850 310 ml

Polyethylene container

Used as adhesive for glass.(Using limit: 6 months)

Caulking material

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920 320 ml Polyethylene container

Used to seal joints of glassparts.(Using limit: 4 months)

SEKISUI SILICONE SEALANT

20Y-54-55130 333 ml Polyethylene container

Used to seal front window.(Using limit: 6 months)

FOREWORD STANDARD TIGHTENING TORQUE

00-12

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in

the table below.

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS In the case of flared nuts for which there is no

special instruction, tighten to the torque given inthe table below.

Thread diameter of bolt

Width across flats

Tightening torque

mm mm Nm kgm

68

101214

1013171922

11.8 14.727 3459 7498 123

153 190

1.2 1.52.8 3.5

6 7.510 12.5

15.5 19.5

1618202224

2427303236

235 285320 400455 565610 765785 980

23.5 29.533 41

46.5 5862.5 7880 100

2730333639

4146505560

1150 14401520 19101960 24502450 30402890 3630

118 147155 195200 250250 310295 370

Thread diameter of bolt

Width across flats

Tightening torque

mm mm Nm kgm

68

1012

10131427

5.9 9.813.7 23.534.3 46.174.5 90.2

0.6 1.01.4 2.43.5 4.77.6 9.2

SAD00483

Sealing surface

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

1418222430333642

1924273236414655

24.5 4.949 19.6

78.5 19.6137.3 29.4176.5 29.4196.1 49245.2 49294.2 49

2.5 0.55 28 214 318 320 525 530 5


00-13

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the

table below.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

101216

141722

59 7498 123

235 285

6 7.5 10 12.5

23.5 29.5

Norminal No.Thread diameter Width across flat Tightening torque (Nm {kgm})

mm mm Range Target

0203, 0405, 0610, 12

14

1420243342

Varies depending on type of connector.

35 63 {3.5 6.5}84 132 {8.5 13.5}

128 186 {13.0 19.0}363 480 {37.0 49.0}

746 1010 {76.0 103}

44 {4.5}103 {10.5}157 {16.0}422 {43.0}883 {90.0}

Norminal No.Thread diameter Width across flat Tightening torque (Nm {kgm})

mm mm Range Target

08101214161820243033364252

08101214161820243033364252

14171922242730323236

5.88 8.82 {0.6 0.9}9.8 12.74 {1.0 1.3}14.7 19.6 {1.5 2.0}19.6 24.5 {2.0 2.5}24.5 34.3 {2.5 3.5}34.3 44.1 {3.5 4.5}44.1 53.9 {4.5 5.5}58.8 78.4 {6.0 8.0}

93.1 122.5 {9.5 12.5}107.8 147.0 {11.0 15.0}127.4 176.4 {13.0 18.0}181.3 240.1 {18.5 24.5}274.4 367.5 {28.0 37.5}

7.35 {0.75}11.27 {1.15}17.64 {1.8}22.54 {2.3}29.4 {3.0}39.2 {4.0}49.0 {5.0}68.6 {7.0}

107.8 {11.0}124.4 {13.0}151.9 {15.5}210.7 {21.5}323.4 {33.0}


00-14

TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.

2) EYE JOINTSUse these torques for eye joints (unit: mm) of Cummins Engine.

3) TAPERED SCREWSUse these torques for tapered screws (unit: inch) of Cummins Engine.

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. Apply the following torque when the threads are coated (wet) with engine oil.

Thread diameter Tightening torque

mm Nm kgm

68

1012

10 0 224 0 443 0 6

77 0 12

1.02 0 0.202.45 0 0.414.38 0 0.617.85 0 1.22


mm Nm kgm

68

101214

8 0 210 0 212 0 224 0 436 0 5

0.81 0 0.201.02 0 0.201.22 0 0.202.45 0 0.413.67 0 0.51


inch Nm kgm

1 / 161 / 81 / 43 / 81 / 23 / 4

1

3 0 18 0 2

12 0 215 0 224 0 436 0 560 0 9

0.31 0 0.100.81 0 0.201.22 0 0.201.53 0 0.412.45 0 0.413.67 0 0.516.12 0 0.92

Nominal size of hose

Width across flats

Tightening torque (Nm {kgm}) Taper seal type Face seal type

Range Target Thread size (mm)Nominal thread

size - Threads per inch, Thread series

Root diameter (mm) (Reference)

02 1934 54 {3.5 5.5} 44 {4.5} 18UN 14.3

34 63 {3.5 6.5} 44 {4.5} 14

0322 54 93 {5.5 9.5} 74 {7.5} 16UN 17.5

24 59 98 {6.0 10.0} 78 {8.0} 18

04 27 84 132 {8.5 13.5} 103 {10.5} 22 16UN 20.6

05 32 128 186 {13.0 19.0} 157 {16.0} 24 1 14UNS 25.4

06 36 177 245 {18.0 25.0} 216 {22.0} 30 1 12UN 30.2

(10) 41 177 245 {18.0 25.0} 216 {22.0} 33

(12) 46 197 294 {20.0 30.0} 245 {25.0} 36

(14) 55 246 343 {25.0 35.0} 294 {30.0} 42

916

1116

1316

316

FOREWORD ELECTRIC WIRE CODE

00-15

ELECTRIC WIRE CODEIn the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.This wire code table will help you understand WIRING DIAGRAMS.Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

CLASSIFICATION BY COLOR AND CODE

Norminalnumber

Copper wire

Cable O.D.(mm)

Current rating

(A)Applicable circuit

Number of strands

Dia. of strands(mm2)

Cross section(mm2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

Priori-ty

Circuits

Classi-fication

Charging Ground Starting Lighting Instrument Signal Other

1 Pri-mary

Code W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Auxi-liary

Code WR BW RW YR GW LW

Color White & Red White & Black Red & White Rellow & Red Green & White Blue & White

3Code WB BY RB YB GR LR

Color White & Black Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow

4

Code WL BR RY YG GY LY

Color White & Blue Black & Red Red & Yellow Yellow & GreenGreen & Yellow Blue & Yellow

5Code WG RG YL GB LB

Color White & Green Red & Green Yellow & Blue Green & Black Blue & Black

6Code RL YW GL nColor Red & Blue Yellow & White Green & Blue n

FOREWORD CONVERSION TABLE

00-16

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLEThe Conversion Table in this section is provided to enable simple conversion of figures. For details of themethod of using the Conversion Table, see the example given below.

EXAMPLE Method of using the Conversion Table to convert from millimeters to inches1. Convert 55 mm into inches.

(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal linefrom A.

(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line downfrom B.

(3) Take the point where the two lines cross as C. This point C gives the value when converting from mil-limeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the

left) to convert it to 55 mm.(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point

one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

00.3940.7871.1811.575

1.9692.3622.7563.1503.543

0.0390.4330.8271.2201.614

2.0082.4022.7953.1893.583

0.0790.4720.8661.2601.654

2.0472.4412.8353.2283.622

0.1180.5120.9061.2991.693

2.0872.4802.8743.2683.661

0.1570.5510.9451.3391.732

2.1262.5202.9133.3073.701

0.1970.5910.9841.3781.772

2.1652.5592.9533.3463.740

0.2360.6301.0241.4171.811

2.2052.5982.9923.3863.780

0.2760.6691.0631.4571.850

2.2442.6383.0323.4253.819

0.3150.7091.1021.4961.890

2.2832.6773.0713.4653.858

0.3540.7481.1421.5361.929

2.3232.7173.1103.5043.898

B

AC


00-17

Millimeters to Inches1 mm = 0.03937 in

Kilogram to Pound1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

0.394

0.787

1.181

1.575

1.969

2.362

2.756

3.150

3.543

0.039

0.433

0.827

1.220

1.614

2.008

2.402

2.795

3.189

3.583

0.079

0.472

0.866

1.260

1.654

2.047

2.441

2.835

3.228

3.622

0.118

0.512

0.906

1.299

1.693

2.087

2.480

2.874

3.268

3.661

0.157

0.551

0.945

1.339

1.732

2.126

2.520

2.913

3.307

3.701

0.197

0.591

0.984

1.378

1.772

2.165

2.559

2.953

3.346

3.740

0.236

0.630

1.024

1.417

1.811

2.205

2.598

2.992

3.386

3.780

0.276

0.669

1.063

1.457

1.850

2.244

2.638

3.032

3.425

3.819

0.315

0.709

1.102

1.496

1.890

2.283

2.677

3.071

3.465

3.858

0.354

0.748

1.142

1.536

1.929

2.323

2.717

3.110

3.504

3.898

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

22.05

44.09

66.14

88.18

110.23

132.28

154.32

176.37

198.42

2.20

24.25

46.30

68.34

90.39

112.44

134.48

156.53

178.57

200.62

4.41

26.46

48.50

70.55

92.59

114.64

136.69

158.73

180.78

202.83

6.61

28.66

50.71

72.75

94.80

116.85

138.89

160.94

182.98

205.03

8.82

30.86

51.91

74.96

97.00

119.05

141.10

163.14

185.19

207.24

11.02

33.07

55.12

77.16

99.21

121.25

143.30

165.35

187.39

209.44

13.23

35.27

57.32

79.37

101.41

123.46

145.51

167.55

189.60

211.64

15.43

37.48

59.53

81.57

103.62

125.66

147.71

169.76

191.80

213.85

17.64

39.68

61.73

83.78

105.82

127.87

149.91

171.96

194.01

216.05

19.84

41.89

63.93

85.98

108.03

130.07

152.12

174.17

196.21

218.26


00-18

Liter to U.S. Gallon1l = 0.2642 U.S. Gal

Liter to U.K. Gallon1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

2.642

5.283

7.925

10.567

13.209

15.850

18.492

21.134

23.775

0.264

2.906

5.548

8.189

10.831

13.473

16.115

18.756

21.398

24.040

0.528

3.170

5.812

8.454

11.095

13.737

16.379

19.020

21.662

24.304

0.793

3.434

6.076

8.718

11.359

14.001

16.643

19.285

21.926

24.568

1.057

3.698

6.340

8.982

11.624

14.265

16.907

19.549

22.190

24.832

1.321

3.963

6.604

9.246

11.888

14.529

17.171

19.813

22.455

25.096

1.585

4.227

6.869

9.510

12.152

14.795

17.435

20.077

22.719

25.361

1.849

4.491

7.133

9.774

12.416

15.058

17.700

20.341

22.983

25.625

2.113

4.755

7.397

10.039

12.680

15.322

17.964

20.605

23.247

25.889

2.378

5.019

7.661

10.303

12.944

15.586

18.228

20.870

23.511

26.153

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

2.200

4.399

6.599

8.799

10.998

13.198

15.398

17.598

19.797

0.220

2.420

4.619

6.819

9.019

11.281

13.418

15.618

17.818

20.017

0.440

2.640

4.839

7.039

9.239

11.438

13.638

15.838

18.037

20.237

0.660

2.860

5.059

7.259

9.459

11.658

13.858

16.058

18.257

20.457

0.880

3.080

5.279

7.479

9.679

11.878

14.078

16.278

18.477

20.677

1.100

3.300

5.499

7.969

9.899

12.098

14.298

16.498

18.697

20.897

1.320

3.520

5.719

7.919

10.119

12.318

14.518

16.718

18.917

21.117

1.540

3.740

5.939

8.139

10.339

12.528

14.738

16.938

19.137

21.337

1.760

3.950

6.159

8.359

10.559

12.758

14.958

17.158

19.357

21.557

1.980

4.179

6.379

8.579

10.778

12.978

15.178

17.378

19.577

21.777


00-19

kgm to ft. lb1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

0

72.3

144.7

217.0

289.3

361.7

434.0

506.3

578.6

651.0

723.3

795.6

868.0

940.3

1012.6

1084.9

1157.3

1129.6

1301.9

1374.3

7.2

79.6

151.9

224.2

296.6

368.9

441.2

513.5

585.9

658.2

730.5

802.9

875.2

947.5

1019.9

1092.2

1164.5

1236.8

1309.2

1381.5

14.5

86.8

159.1

231.5

303.8

376.1

448.5

520.8

593.1

665.4

737.8

810.1

882.4

954.8

1027.1

1099.4

1171.7

1244.1

1316.4

1388.7

21.7

94.0

166.4

238.7

311.0

383.4

455.7

528.0

600.3

672.7

745.0

817.3

889.7

962.0

1034.3

1106.6

1179.0

1251.3

1323.6

1396.0

28.9

101.3

173.6

245.9

318.3

390.6

462.9

535.2

607.6

679.9

752.2

824.6

896.9

969.2

1041.5

1113.9

1186.2

1258.5

1330.9

1403.2

36.2

108.5

180.8

253.2

325.5

397.8

470.2

542.5

614.8

687.1

759.5

831.8

904.1

976.5

1048.8

1121.1

1193.4

1265.8

1338.1

1410.4

43.4

115.7

188.1

260.4

332.7

405.1

477.4

549.7

622.0

694.4

766.7

839.0

911.4

983.7

1056.0

1128.3

1200.7

1273.0

1345.3

1417.7

50.6

123.0

195.3

267.6

340.0

412.3

484.6

556.9

629.3

701.6

773.9

846.3

918.6

990.9

1063.2

1135.6

1207.9

1280.1

1352.6

1424.9

57.9

130.2

202.5

274.9

347.2

419.5

491.8

564.2

636.5

708.8

781.2

853.5

925.8

998.2

1070.5

1142.8

1215.1

1287.5

1359.8

1432.1

65.1

137.4

209.8

282.1

354.4

426.8

499.1

571.4

643.7

716.1

788.4

860.7

933.1

1005.4

1077.7

1150.0

1222.4

1294.7

1367.0

1439.4


00-20

kg/cm2 to lb/in21kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

0

142.2

284.5

426.7

568.9

711.2

853.4

995.6

1138

1280

1422

1565

1707

1849

1991

2134

2276

2418

2560

2702

2845

2987

3129

3271

3414

14.2

156.5

298.7

440.9

583.2

725.4

867.6

1010

1152

1294

1437

1579

1721

1863

2005

2148

2290

2432

2574

2717

2859

3001

3143

3286

3428

28.4

170.7

312.9

455.1

597.4

739.6

881.8

1024

1166

1309

1451

1593

1735

1877

2020

2162

2304

2446

2589

2731

2873

3015

3158

3300

3442

42.7

184.9

327.1

469.4

611.6

753.8

896.1

1038

1181

1323

1465

1607

1749

1892

2034

2176

2318

2460

2603

2745

2887

3030

3172

3314

3456

56.9

199.1

341.4

483.6

625.8

768.1

910.3

1053

1195

1337

1479

1621

1764

1906

2048

2190

2333

2475

2617

2759

2901

3044

3186

3328

3470

71.1

213.4

355.6

497.8

640.1

782.3

924.5

1067

1209

1351

1493

1636

1778

1920

2062

2205

2347

2489

2631

2773

2916

3058

3200

3343

3485

85.3

227.6

369.8

512.0

654.3

796.5

938.7

1081

1223

1365

1508

1650

1792

1934

2077

2219

2361

2503

2646

2788

2930

3072

3214

3357

3499

99.6

241.8

384.0

526.3

668.5

810.7

953.0

1095

1237

1380

1522

1664

1806

1949

2091

2233

2375

2518

2660

2802

2944

3086

3229

3371

3513

113.8

256.0

398.3

540.5

682.7

825.0

967.2

1109

1252

1394

1536

1678

1821

1963

2105

2247

2389

2532

2674

2816

2958

3101

3243

3385

3527

128.0

270.2

412.5

554.7

696.9

839.2

981.4

1124

1266

1408

1550

1693

1835

1977

2119

2262

2404

2546

2688

2830

2973

3115

3257

3399

3542


00-21

TemperatureFahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-umn of figures.These figures refer to the temperature in either Fahrenheit or Centigrade degrees.If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table ofFahrenheit 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 ofCentigrade values, and read the corresponding Fahrenheit temperature on the right.

1C = 33.8F

C F C F C F C F

40.437.234.431.728.9

28.327.827.226.726.1

25.625.024.423.923.3

22.822.221.721.120.6

20.019.418.918.317.8

17.216.716.115.615.0

14.413.913.312.812.2

4035302520

1918171615

1413121110

9 8 7 6 5

4 3 2 1 0

1 2 3 4 5

6 7 8 9 10

40.031.022.013.0 4.0

2.2 0.4 1.4 3.2 5.0

6.8 8.6 10.4 12.2 14.0

15.8 17.6 19.4 21.2 23.0

24.8 26.6 28.4 30.2 32.0

33.8 35.6 37.4 39.2 41.0

42.8 44.6 46.4 48.2 50.0

11.711.110.610.0 9.4

8.9 8.3 7.8 7.2 6.7

6.1 5.6 5.0 4.4 3.9

3.3 2.8 2.2 1.7 1.1

0.6 0

0.6 1.1 1.7

2.2 2.8 3.3 3.9 4.4

5.0 5.6 6.1 6.7 7.2

1112131415

1617181920

2122232425

2627282930

3132333435

3637383940

4142434445

51.8 53.6 55.4 57.2 59.0

60.8 62.6 64.4 66.2 68.0

69.8 71.6 73.4 75.2 77.0

78.8 80.6 82.4 84.2 86.0

87.8 89.6 91.4 93.2 95.0

96.8 98.6100.4102.2104.0

105.8107.6109.4111.2113.0

7.8 8.3 8.9 9.410.0

10.611.111.712.212.8

13.313.914.415.015.6

16.116.717.217.818.3

18.919.420.020.621.1

21.722.222.823.323.9

24.425.025.626.126.7

4647484950

5152535455

56575859 0

6162636465

6667686970

7172737475

7677787980

114.8116.6118.4120.2122.0

123.8125.6127.4129.2131.0

132.8134.6136.4138.2140.0

141.8143.6145.4147.2149.0

150.8152.6154.4156.2158.0

159.8161.6163.4165.2167.0

168.8170.6172.4174.2176.0

27.227.828.328.929.4

30.030.631.131.732.2

32.833.333.934.435.0

35.636.136.737.237.8

40.643.346.148.951.7

54.457.260.062.765.6

68.371.173.976.779.4

81 82 83 84 85

86 87 88 89 90

91 92 93 94 95

96 97 98 99100

105110115120125

130135140145150

155160165170175

117.8179.6181.4183.2185.0

186.8188.6190.4192.2194.0

195.8197.6199.4201.2203.0

204.8206.6208.4210.2212.0

221.0230.0239.0248.0257.0

266.0275.0284.0293.0302.0

311.0320.0329.0338.0347.0

FOREWORD UNITS

00-22 10-04

UNITS

In this manual, the measuring units are indicated with Internatinal System of units (SI).As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.

Example:N {kg}Nm {kgm}MPa {kg/cm2}kPa {mmH2O}kPa {mmHg}kW/rpm {HP/rpm}g/kWh {g/HPh}

01 GENERAL

WA1 200-3

General assembly drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3 Weight table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6 List of lubricant and water . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8

01-l

GENERAL GENERAL ASSEMBLY DRAWING

GENERAL ASSEMBLY DRAWING Dimensions in ( 1 are for vehicles equipped with 65/65-57-62PR tires. Dimensions marked with % are for vehicles for handling rocks and those marked with *X are for vehicles for handling lime.

SJWO4720

01-2 WA1 200-3

GENERAL SPECIFICATIONS

Machine model

Serial No.

Operating weight

Distribution (front)

Distribution (rear)

Bucket capacity (piled)

Rated load

Travel speed

Max. rimpull

Gradeability

Min. turning radius I

FORWARD 1 st

FORWARD 2nd

FORWARD 3rd

REVERSE 1st

REVERSE 2nd

REVERSE 3rd

Center of outside wheel

Outside portion of chassis

Overall length

Overall width (chassis)

Bucket width

Overall height (top of ROPS cab)

Wheelbase

Tread

(Bucket raised)

Min. ground clearance

Height of bucket hinge pin

Dumping clearance (tip of edge)

Dumping reach (tip of edge)

Bucket dump angle

Bucket tilt angle (SAE carrying position)

Digging depth (IO dump) (tip of edge)

I I: with 65/65-57-62PR tires

WA1 200-3 01-3

kg

kg

kg

m3

kg

km/h

km/h

km/h

km/h

km/h

km/h

kN {kg)

deg

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

deg

deg

mm

WA1 200-3

50001 and up

205,200 [210,4001

122,220 [ 124,840l

82,950 I85,5601

20.0

36,000

6.3 i6.51

11.5 [Il.91

19.8 120.41

7.4 17.71

13.4 113.91

22.6 i23.21

1,127 {115,000~ [1,088 ~lll,OOO~l

25

12,000

14,300

18,210

5,7 10 [5,9701

6,400 (Cutting edge)

6,550 (Tire guard)

6,865 !6,9301

11,865 [I I,9301

7,100

4,300

650 [7151

8,830 [8,8951

6,735 [6,8001

2,665

49.5 (Max. height)

50

590 [5251


Machine model

Drive type

Front axle

Rear axle

Tire

Wheel rim

Inflation pressure - Main brake

1 ? a Parking brake

r I: with 65/65-57-62PR tires

Serial No.

mm

e {cc)

Model

Type

No. of cylinders - bore x stroke

Piston displacement

Fuel consumption ratio

i High idling speed

Low idling speed

Starting motor

Alternator

Battery

Torque converter

Transmission

Reduction gear

Differential

Final drive

01-4

Wrpm IHP/rpml

lmlrpm Ikgmlrpml

g/kW-h {g/HP-h}

wm

wm

kPa {kg/cm21

WA1 200-3

50001 and up

Cummins QSK60

4-cycle, water-cooled, V type, 16-cylinder direct injection, with

turbocharger, after-cooler

16-159x190

60 (60,360)

1 ,I 60/l ,900 {I ,558/l ,900)

7,830/l ,500 {798/l ,500)

214 {ISO} (at rated output, gross)

2,050

650

24 V 9.0 kW x 2

24V140A

12 V 200 Ah x 6

3-element, l-stage, single-phase (TCA51-3)

Planetary gear, multiple-disc, hy- lraulically actuated, modulation type

Spiral bevel gear

Straight bevel gear

Planetary gear, 2 reduction, oil bath

Front/rear-wheel drive

Fixed-frame, full-floating

Center pin support type, full-floating

55.5/80-57-68PR(L-5) [65/65-57-62PR(L-511

44.00 x 57i6.0 [52.00 x 57i6.01

588 (6.01

Front/rear wheel braking, separate

front/rear wheel, wet disc, hydraulically actuated

Drive shaft (Transmission output shaft) braking, multiple wet disc, hydraulically release spring apply

WA1 200-3


Machine model

Serial No.

Type

Structure

Torque converter, transmission pump

Steering pump

Hydraulic

pump Delivery

Control valve Set pressure

Cylinder

-ink type

Switch pump

PPC pump

Brake pump

Work equipment pump (I)

Work equipment pump (2)

Transmission valve

Steering valve

PPC valve

Main control valve

Steering cylinder No. - bore x stroke

3oom cylinder No. - bore x stroke

3ucket cylinder No. - bore x stroke

3ucket edge type

Umin

Umin

Umin

4Ymin

Urnin

Urnin

l?/min

MPa {kg/cm?

VlPa {kg/cm21

VlPa {kg/cm?

VlPa {kg/cm)

mm

mm

mm

WA1 200-3

50001 and up

Articulated type

Fully hydraulically power steering

817 (Gear type: SAR(4)200+SAR(4)200)

630 (Fixed capacity piston pump:

HPF160+160)

630 Variable + fixed capacity piston pump:

HPV160+HPF160)

95 (Gear type: SAR(2)50)

54 (Gear type: SAR(2)28)

630 (Variable capacity piston pump:

HPV160+160)

383 (Variable capacity piston pump:

H PV95+95)

2.65 127) (Spool type, electric control)

31.4 {320} (Spool type)

3.7 08) (2-lever type)

31.4 (320) (2-spool type)

Reciprocating piston 2 - 225 x 660

Reciprocating piston 2-360x 1,835

Reciprocating piston 2-300x 1,025

Double Z bar link

Spade nose bucket with teeth

WA1 200-3 01-5

GENERAL WEIGHT TABLE

WEIGHT TABLE

A This weight table is a guide for use when transporting or handling components. Unit: kg

Machine model I WA1 200-3

Serial No. 50001 and up

Engine 7,250

Radiator (including hydraulic oil cooler) 2,750

Torque converter I 1,404

Torque converter oil cooler I 285

Fuel cooler 338

Transmission 3,690

Damper I 359

Upper drive shaft 112

Center drive shaft 184

Front drive shaft 209

Rear drive shaft 215

Center support I 154

Front axle I 16,500

Rear axle 16,500

Front differential assembly 1,570

Rear differential assembly 1,800

Planetary carrier assembly (each) 880

Planetary hub assembly (each) I 710

Axle pivot (Rear axle) (front/rear) 6251960

Wheel (55.5 tire/65 tire) (each) 1,913/2,051

Tire (55.5 tire/65 tire) (each) 5,930/7,150

Steering valve 68

Steering cylinder (each)

Hydraulic tank (tank unit)

Work equipment pump (No.VNo.2)

Torque converter charging + PPC pump

Switch pump

Steering pump

I 589

1,366 ( 1,230)

193/I 66

70.3

189

191

Fender (one side)

PPC valve

I 140

4

01-6 WA1 200-3

GENERAL WEIGHT TABLE

Unit: kg

Machine model WA1 200-3

Serial No. 50001 and up

Main control valve (each) 95

Boom cylinder (each)

Bucket cylinder

Radiator guard

2,943

1,380

905

Front frame I 15,160

Rear frame

Bucket link (including bushing) (each) 646

Bellcrank (including bushing) (each) 2,440

Boom (including bushing) r 18,430 Bucket (with teeth) I 23,840

Rear bumper (including fuel tank) I 6,470

Fuel tank (side x 2, center x 1) side: 520 x 2, center: 609

Battery (each) 59

Cab assembly 539

Air conditioner unit I 55

Operators seat

Floor plate

ROPS support assembly I 3,238

WA1 200-3 01-7

GENERAL LIST OF LUBRICANT AND WATER

LIST OF LUBRICANT AND WATER

CAPACITY RESERVOIR

GENERAL LIST OF LUBRICANT AND WATER

REMARK When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%.

Fuel sulphur content Change interval of oil in

engine oil pan

0.5 to 1.0% I l/2 of regular interval

Above 1.0% l/4 of regular interval

When starting the engine in an atmospheric temperature of lower than OC, be sure to use engine oil of SAEIOW, SAEIOW-30 and SAE15W- 40, even though an atmospheric temperature goes up to 10C more or less in the day time.

Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.

There is no problem if single grade oil is mixed

with multigrade oil (SAEIOW-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table.

We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment

applications.

Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill sys-

tem during normal inspection and maintenance.

ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute

WA1 200-3 01-9

WA1200-3 10-1

10 STRUCTURE AND FUNCTION

Outline ......................................................... 10- 2Radiator and hydraulic oil cooler ............. 10- 4Damper ........................................................ 10- 5Torque converter and

transmission piping ............................. 10- 6Torque converter ........................................ 10- 8Main relief valve and torque converter

relief valve ............................................ 10- 17Torque converter regulator valve ............. 10- 20ECMV ........................................................... 10- 22Transmission .............................................. 10- 28Transmission control valve ....................... 10- 38Lubricating oil relief valve ......................... 10- 49Transfer ....................................................... 10- 50Torque converter oil cooler ...................... 10- 52Center support ............................................ 10- 53Axle .............................................................. 10- 54Final drive ................................................... 10- 59Axle mount ................................................. 10- 60Center hinge pin......................................... 10- 62Arrangement of steering equipment........ 10- 63AJSS (Advanced Joystick Steering

System) ................................................. 10- 64Steering pump............................................ 10- 65Switch pump .............................................. 10- 68Servo valve ................................................. 10- 71Steering demand valve ............................. 10- 75Rotary valve ................................................ 10- 86EPC valve .................................................... 10- 89Diverter valve ............................................. 10- 90Arrangement of brake equipment ............ 10- 94Brake valve ................................................. 10- 96Charge valve ............................................... 10-101Accumulator (for brake) ............................ 10-105Slack adjuster ............................................. 10-106

Brake ............................................................ 10-109Parking brake .............................................. 10-110Arrangement of hydraulic equipment......10-112Work equipment lever linkage .................. 10-114Hydraulic tank ............................................. 10-115Work equipment pump No. 1 ................... 10-118Work equipment pump No. 2 ................... 10-131PPC valve .................................................... 10-148PPC relief valve .......................................... 10-152Accumulator (for PPC valve) ..................... 10-153Main control valve ..................................... 10-154Work equipment linkage ........................... 10-168Operation of proximity switch .................. 10-170Air conditioner ............................................ 10-172Machine monitor system........................... 10-175Main monitor .............................................. 10-177CGC monitor ............................................... 10-181All-range electronic control automatic

transmission (ATM) system ................10-218Modulated clutch (MOD/C)

control system ..................................... 10-233Work equipment and joystick steering

control system ..................................... 10-237Work equipment and joystick steering

controller .............................................. 10-243Engine starting circuit ................................ 10-244Engine stopping circuit .............................. 10-248Ether injection circuit ................................. 10-249Electric parking brake control ................... 10-250Parking brake solenoid valve .................... 10-260Emergency parking brake

reset solenoid valve ............................ 10-261Kick-down switch and auto shift/

manual shift selector switch ............... 10-262

(7)

STRUCTURE AND FUNCTION OUTLINE

OUTLINE

OUTLINE The power of engine (16) is transmitted through the engine flywheel to damper (15).

The damper output shaft is connected to modulated clutch (13) through upper drive shaft (14). The output of the modulated clutch is connected to the pump of torque converter (11). The turbine of the torque converter is connected to input shaft of trans-

mission (IO). The transmission has five hydraulically op- erated clutches and generates three gear speeds each in forward and reverse direc- tions which are selected with an electric control switch. The transmission output shaft is connected

to the gear of transfer (91, then the power is transmitted to the transfer output shaft. Then, the power is transmitted from the transfer

output shaft through center drive shaft (71,

center support (321, front drive shaft (61, and rear drive shaft (31) to front axle (5) and rear axle (281, then transmitted through the

wheels to the tires.

1 o-2

SWWO4721

1. Front differential 2. Front brake 3. Front final drive

4. Front tire 5. Front axle 6. Front drive shaft 7. Center drive shaft

8. Emergency steering pump 9. Transfer (Output)

10. Transmission 11. Torque converter 12. Transfer (Input) 13. Modulated clutch 14. Upper drive shaft 15. Damper 16. Engine 17. Work equipment pump No. 1 18. Work equipment pump No. 2 19. Switching pump

20. Steering pump 21. Control pump

22. PPC pump

WA1 200-3

STRUCTURE AND FUNCTION OUTLINE

23. Torque converter, transmission pump 24. Brake cooling pump 25. Brake pump 26. Rear final drive 27. Rear tire 28. Rear axle

29. Rear differential 30. Rear brake

31. Rear drive shaft

32. Center support 33. Parking brake

SWW04722

WA1 200-3 1 o-3

STRUCTURE AND FUNCTION RADIATOR AND HYDRAULIC OIL COOLER

RADIATOR AND HYDRAULIC OIL COOLER

,______-----

I

2

3

1. Fan guard 2. Water level sensor 3. Radiator cap 4. Sub-tank 5. Upper tank 6. Hydraulic oil cooler 7. Radiator (LTC) 8. Radiator (HTC) 9. Lower tank

Y SJW04723

Specification

LTC HTC 1

Core type Modular core Modular core

Total heat dissipating area I I

m* 211.6 414.8

Cross-sectional area of water tubes cm / 1 59,042 1 88,690 /

I I I I I

1 o-4 WA1 200-3

STRUCTURE AND FUNCTION DAMPER

DAMPER

3 4 5 6

1. Shaft FUNCTION 2. Breather .

3. Rubber cushion The damper reduces the torsional vibration

4. Inner body caused by changes in the engine torque, and

5. Rubber cushion acts to protect the units of the power train

6. Outer body beyond the engine from the effects of tor-

sional vibration.

SJW04724

OPERATION . The power of the engine is transmitted from

the flywheel to outer body (6). The torsional

vibration of the engine is absorbed by rub-

ber cushions (3) and (51, passes through in-

ner body (4) and shaft (I), and is transmitted

to the upper drive shaft between the torque

converter.

WA1 200-3 1 o-5

STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION PIPING

TORQUE CONVERTER AND TRANSMISSION PIPING

SWW04725

1. Transmission 2. Transmission control valve 3. Transfer (input) 4. Torque converter oil cooler 5. Torque converter charging pump 6. Torque converter 7. Torque converter oil filter 8. Transmission oil level gauge 9. Transfer (output)

10-6 WA1 200-3

STRUCTURE AND FUNCTION TORQUE CONVERTER

TORQUE CONVERTER

(INPUT TRANSFER, PTO, MODULATED CLUTCH, TORQUE CONVERTER)

l Z

W

7

9JA00061

1 O-8 WA1 200-3


G ! H

A: B:

c: D:

E: F: G:

H: Main oil pressure pick-up port J: Torque converter relief port K: Drain port

Torque converter outlet port Outlet oil pressure pick-up port of torque converter Torque converter inlet port Lubrication port for PTO, input transfer, and modulated clutch Interconnection port Torque converter inlet port Inlet oil pressure pick-up port of torque converter

IO

F \ . . J . . v

9JBOOO62

1. Mounting port for steering pump, control pump, and PPC pump

2. Mounting port for switch pump 3. Mounting port for transmission charging

pump, torque converter charging pump, brake cooling pump, and brake pump

4. Regulator valve of torque converter outlet 5. Mounting port for work equipment pump 6. Mounting port for work equipment pump 7. Output rotation sensor of modulated clutch 8. ECMV for modulated clutch 9. Torque converter valve

10. Input rotation sensor of input transfer

WA1 200-3 1 o-9


A-A

14

9JB00063

10-10 WA1 200-3


9JBOOO64

11. Coupling 12. Drive gear (Number of teeth: 74) 13. PTO gear (Number of teeth: 68) 14. PTO gear (Number of teeth: 68)

15. Idler gear (Number of teeth: 68) 16. Modulated clutch output shaft 17. Modulated clutch piston 18. Modulated clutch outer drum

19. Modulated clutch inner drum 20. Coupling

21. Torque converter input shaft

22. Drive case 23. Turbine

24. Stator 25. Pump 26. Torque converter case 27. Transmission input shaft 28. Driven gear (Number of teeth: 58)

29. Modulated clutch disc 30. Modulated clutch plate

WA1 200-3 10-11


Specifications Model: 42C-13-11002 Type: 3-elemet, single stage, single phase Stall torque ratio: 2.23 (T3/Tl)

2.84 (T3/T2)

10-12

T3

WA1 200-3


Operation Power transmission route

l The torque converter is installed between

the damper and transmission.

The power from the damper is transmitted

through the upper drive shaft to coupling

(II). The speed of the rotation is heightened with

drive gear (121, idler gear (151, and driven

gear (28) of the input transfer, then trans-

mitted to modulated clutch inner drum (19).

If oil pressure is applied to the back of modu-

lated clutch piston (171, modulated clutch

piston (171 presses modulated clutch disc

(29) against modulated clutch plate (30) to

transfer the power to modulated clutch outer

drum (18).

9JBOOO66

The power transmitted to modulated clutch

outer drum (18) is further transmitted

through modulated clutch output shaft (16)

and coupling (20) to torque converter input

shaft (21). Since torque converter input shaft (211, drive

case (22). and pump (25) are secured with

bolts, they are rotated with the power from

the modulated clutch.

The power of pump (25) rotates turbine (23)

to drive transmission input shaft (271, using

the oil as medium. l The power of coupling (11) is used to drive

the pump, too, through drive gear (121, PTO

gear (131, or idler gear (15).

10-14 0

WA1 200-3


Flow of oil

9JBOOO67

l The oil flows through the main relief valve and its pressure is regulated below the set pressure by the torque converter relief valve, then it flows in inlet port A and merges with the oil sent from the torque converter charging pump through torque converter case (26), then the merged oil flows in pump (25). Set pressure: 1.05 MPa (IO.7 kg/cm*} The oil is given centrifugal force by pump (251, then it flows in turbine (23) and gives

its energy to turbine (23).

The oil from turbine (23) flows to stator (24) and flows in pump (25) again. At this time, a part of the oil flows through stator (24) and

outlet port B to the torque converter outlet regulator valve. The oil that flows in the torque converter outlet regulator valve flows further through the oil cooler to cool itself, then it is used to lubricate the transmission.

WA1 200-3 10-M


Outline l The modulated clutch is installed between

the input transfer and torque converter. l The clutch can be engaged or slipped by

adjusting the clutch oil pressure with ECMV. l The power transmitted to the torque con-

verter can be reduced by slipping the clutch.

Operation

When clutch is engaged l The oil sent from ECMV (1) for the modu-

lated clutch flows through the oil passage of modulated clutch case (2) to piston (3) and moves piston (3) to the right. If piston (3) moves and the clutch oil pressure rises, the pressure of piston (3) increases and presses disc (4) against plate (5) to en- gage inner drum (6) with outer drum (7). Accordingly, all of the power transmitted from inner drum (6) is transmitted to outer drum (7).

When clutch is slipped . If the controller outputs the signal to lower

the clutch oil pressure, ECMV (I) for the modulated clutch lowers the clutch oil pressure. If the clutch oil pressure lowers, the pressure of piston (3) lowers and disc (4) slips on plate (51, then outer drum (7) rotates slower than inner drum (6). As a result, the transmitted power is reduced.

9JBOOO68

l The transmitted power depends on the slip ratio of the clutch and the speed ratio of the torque converter. Slip ratio =

(I - Output rpm/lnput rpm) x 100 (%)

10-16 WA1 200-3

STRUCTURE AND FUNCTION MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE

MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE

I E 23

D 7

A-A

P4 A4

A: From pump B: To torque converter C: To transmission lubricating circuit D: Drain E: Drain F: Drain G: Drain PI: Inlet oil pressure pick-up port of torque

converter P4: Main oil pressure pick-up port

Outline . Main relief valve

The main relief valve keeps the transmission oil pressure at the set level. Set pressure: 2.65 MPa (27 kg/cm21 (At the rated engine speed)

l Torque converter relief valve The torque converter relief valve is installed

\ Pi

9JB00069

1. Valve body 2. Valve spring (Small) 3. Valve spring (Large) 4. Main relief valve spool 5. Piston spring 6. Piston 7. Valve spring 8. Torque converter relief valve spool 9. Piston spring

IO. Piston

to the torque converter inlet circuit, and it keeps the oil pressure at the torque converter inlet circuit below the set pressure to protect the torque converter from abnormally high pressure. Set pressure: 1.05 MPa 110.7 kg/cm*) (Cracking pressure)

WA1 200-3 10-17

Operation

Operation of main relief valve l The oil from the torque converter charging

pump flows through the filter into port A of spool (41, then flows through orifice a into port B. If the circuit is filled with the oil from the pump, the oil pressure starts rising.

From Pump

To torque To transmission converter lubrication

l As the oil pressure in the circuit rises, the oil in chamber B presses piston (6) and its reaction force compresses springs (2) and (3) to move spool (4) to the left to open ports A and C. Then, the oil from the pump flows through

port A and port C into the torque converter. At this time, the oil pressure at port A is 2.65 MPa 127 kg/cm21 (at the rated engine speed).

SXW04736

To torque To transmission converter lubrication

sxwo4737

lo-18 WA 1200-3

STRUCTURE AND FUNCTION MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE

Operation of torque converter relief valve l The oil from the main relief valve flows

through port C into the torque converter. It also flows through orifice b of spool (8) into chamber D. If the torque converter is filled with the oil, the oil pressure starts rising.

l As the oil pressure in the torque converter rises, the oil in chamber D presses piston (10) and its reaction force compresses valve spring (7) to move spool (8) to the right to open ports C and E. Then, the oil in port C flows through port E into the transmission lubricating circuit. At this time, the oil pressure at port C is 1.05 MPa 110.7 kg/cm? (cracking pressure).

To toraue To transmission converter lubrication

sxwo473a

WA1 200-3 10-19

STRUCTURE AND FUNCTION TORQUE CONVERTER REGULATOR VALVE

TORQUE CONVERTER REGULATOR VALVE

A: From torque converter B: To oil cooler

1. Valve body 2. Valve spring (Small) 3. Valve spring (Large) 4. Spool 5. Piston spring 6. Piston

9JBOOO73

Outline l The torque converter regulator valve is in-

stalled to the torque converter outlet circuit

to extract the full performance of the torque converter by keeping the oil pressure in the

torque converter at the set level. Set pressure: 0.88 2 0.10 MPa 19 -c 1 kg/cm?

1 O-20 0

WA1 200-3

STRUCTURE AND FUNCTION TORQUE CONVERTER REGULATOR VALVE

Operation l The oil from the torque converter flows

through port A and orifice a into chamber B. Since the oil pressure in chamber B is lower than the tension of valve springs (2) and (31, spool (4) does not move.

. If oil pressure in chamber B rises above the tension of valve springs (2) and (31, the oil in chamber B presses piston (6) and its reaction force compresses valve springs (2) and (3) to move spool (4) to the left to open ports A and C.

8 From torque converter

sxwo4739

/ ii A From torque

converter sxwo4740

WA1 200-3 1 o-21

STRUCTURE AND FUNCTION ECMV

ECMV

(For modulated clutch)

9JBOOO76

A: To clutch B: Drain C: From pump P: Clutch oil pressure pick-up port

1. Connector 2. Spring 3. Flow sensor valve spool 4. Spring 5. Fill switch 6. Proportional solenoid 7. Pressure control valve spool 8. Load piston 9. Spring

1 o-22 WA1 200-3

STRUCTURE AND FUNCTION ECMV

Outline Outline of ECMV l ECMV (Electronic Control

consists of one pressure one flow sensor valve.

. Pressure control valve

Modulated Valve) control valve and

A , E , D

This valve receives the current sent from the controller with a proportional solenoid, then converts it into oil pressure.

l Flow sensor valve This valve operates according to the trigger signals sent from the pressure control valve and has the following functions. 1)

2)

3)

Keeps open untilthe clutch is filled with oil to shorten the time to fill the clutch with oil (filling time). Closes and outputs a signal (a filling signal) to the controller to notify that filling is completed when the clutch is filled with oil.

_ _ _

t

0 w3ec MPa! to/cm) I I Time

/- c .- al zz .-al

Keeps outputting signals (filling signals) to the controller to notify that oil pressure is applied or not while oil pressure is applied to the clutch. Range A:

Before shifting gear (when draining) Range B: Fill starts (during trigger) Range C: Fill completed Range D: Pressure adjustment Range E: During filling

ECMV and proportional solenoid . For each ECMV, one proportional solenoid

is installed. The proportional solenoid generates propulsion force according to the command current from the controller as shown in the figure at right.

The propulsion force generated by the proportional solenoid is applied to the pressure control valve spool to generate the oil pressure shown in the figure at right. Accord- ingly, the propulsion force is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil.

ECMV and fill switch l For each ECMV, one fill switch is installed.

If the clutch is filled, the flow sensor valve turns on the fill switch. When this signal is output, oil pressure starts building up.

,;I ; ) 1 *Set

Time

t-l o 1 OFF 1 ON

*Set Time

sxwo474 1

Characteristics of ProPortional solenoid current-propulsion force

N (ka)

0 (A) - Current

Characteristics of proportional solenoid propulsion-oil Pressure

MPa( kg/cm)

N(kel

- Propulsion force

03 wa1200-3 shop manual

Documents

use of thefollowing

optional equipment

machine model serial

cummins qsk60 engine

shop manual

rights reservedprinted

local komatsu distributor

necessary actionsbe