Komatsu wa800 1 wheel loader service repair manual (sn 10001-10499)
- 1. SEBM04280113 WA8OO42 MACHINE MODEL SERIAL NO. WA800- 1 10001-10499 WA800-2 10501 and up l This shop manual may contain attachments and optional equipment that are not availa- ble in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. l WA8OO-1 mounts the SA8V170-1 engine; WA800-2 mount the SA12V140-1 engine. For details of the engines, see the 8V170-1 Series Engine Shop Manual and 12V14O-1 Series Engine Shop Manual. 0 1996 KOMAlhJ All Rights Reserved 05-96(01)02201 00-l 0
- 2. CONTENTS 10 ENGINE 11 STRUCTURE AND FUNCTION .......... 12 TESTING AND ADJUSTING ............ 13 DISASSEMBLY AND ASSEMBLY ....... 14 MAINTENANCE STANDARD ........... 20 POWER TRAIN 21 STRUCTURE AND FUNCTION ......... 22 TESTING AND ADJUSTING ........... 23 DISASSEMBLY AND ASSEMBLY ...... 24 MAINTENANCE STANDARD .......... 40 STEERING SYSTEM 41 STRUCTURE AND FUNCTION ......... 42 TESTING AND ADJUSTING ........... 43 DISASSEMBLY AND ASSEMBLY ...... 44 MAINTENANCE STANDARD .......... 50 BRAKE AND AIR SYSTEM 5 1 STRUCTURE AND FUNCTION ......... 52 TESTING AND ADJUSTING ............ 53 DISASSEMBLY AND ASSEMBLY ...... 54 MAINTENANCE STANDARD .......... 60 WORK EQUIPMENT SYSTEM 61 62 63 64 STRUCTURE AND FUNCTION .......... TESTING AND ADJUSTING ............ DISASSEMBLY AND ASSEMBLY ....... MAINTENANCE STANDARD ........... 80 ELECTRIC AND ELECTRONIC SYSTEM No. of page ................................ 1 l-l ................................ 12-l ................................ 13-1 ................................ 14-l ................................... 21-1 ................................... 22-l ................................... 23-l ................................... 24-l . . . . . . . . . . . . . . ........ ........ ........ . . . . . . . . . . . . . . . . . . . ...... 41-l . . . ...... 42-l . . . ...... 43-l . . . . . . . . . 44-l r*1 g : ...... 51-1 ...... 52-l ...... 53-l ...... 54-l ................................ 61-1 ................................ 62-l ................................ 63-l ................................ 64-l 81 STRUCTURE AND FUNCTION ............................................... 81-l 82 TESTING AND ADJUSTING ................................................. 82-1 83 DISASSEMBLY AND ASSEMBLY ............................................ 83-l 90 OTHERS 91 STRUCTURE AND FUNCTION .......... 93 DISASSEMBLY AND ASSEMBLY ....... 97 GEAR PUMP .......................... .................................. 91-1 .................................. 93-l .................................. 97-l
- 3. A IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols A YYand * are used to mark safety pre- cautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. A SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. q 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. 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. 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. 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 8 9 IO 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. 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. When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 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
- 4. PRECAUTIONS DURING WORK Il. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before car- rying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (- 1terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts. 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. l When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21 When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24 Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track. 00-4
- 5. FOREWORD This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5
- 6. HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carry- ing out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume : Attachments volume : Each issued as one volume to cover all models These various volumes are designed to avoid duplicating the same information. Therefore to deal with all repairs for any model, it is neces- sary that chassis, engine, electrical and attach- ment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up-to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples shows how to read the page number. Example 1 (Chassis volume): IO-3 F Item number (IO. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12-410 F Unit number (I. Engine) Item number (2. Testing and Adjusting) Group No. (4. Fuel system) Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are in- dicated by a hyphen (-1 and number after the page number. File as in the example. Example: 1o-4 12-203 REVISED EDITION MARK ((ijo@ .... ) When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol Item A Y & $ * 63kg Safety Caution Weight Tighten- ng torque Coat 3il, water Drain Remarks Special safety precautions are necessary when performing the work. Extra special safety precautions are necessary when performing the work because it is under internal pressure. Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight of parts or systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water must be drained, and quantity to be drained. 1o-5 12-204 00-6
- 7. HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS A Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and Assembly section, every part weigh- ing 25 kg or more is indicated clearly with the symbol & 1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: . Check for removal of all bolts fastening the part to the relative parts. . Check for existence of another part causing interference with the part to be removed. 2. Wire ropes 11Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) 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. I !!VI! 100% 88% 79% 71% 41% FSO064 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. A Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with ropes forming a wide hanging angle from the hnnk Rope diameter (mm) Allowable load (tons) 10 1.o 11.2 1.4 12.5 1.6 14 2.2 16 2.8 18 3.6 20 4.4 22.4 5.6 30 10.0 40 18.0 50 28.0 60 40.0 The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120” hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150”. A 2000 1900 1700 ?f-y& a 1400 @ ‘r 52 u, . ,o 30” 60” 90” 120” 150” Lifting angle : 0 FSO065 00-7
- 8. STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of “Disassembly and Assembly”. Thread diameter Width of bolt across flat (mm) (mm) kgm 6 10 1.35kO.15 8 13 3.2a0.3 10 17 6.7kO.7 12 19 11.5&1.0 14 22 18.Ok2.0 f Nm 13.22 1.4 31.4IL2.9 65.726.8 112-+9.8 177*19 16 24 28.5r3 279*29 18 27 39-14 383-+39 20 30 56*6 549k58 22 32 7628 745*78 24 36 94.5r10 927298 27 41 135r15 30 46 175-+20 33 50 225+25 36 55 280&30 39 60 335*35 1320+140 1720&190 221Ok240 27502 290 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): 1 Nm k 0.1 kgm 2.TlGHTENlNG TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Threaodfg$yeter (mm) 10 12 16 Width across flats (mm) 14 17 22 Tightening torque kgm Nm 6.7kO.7 65.7k6.8 11.5&l 11229.8 28.5*3 279*29 00-8
- 9. STANDARD TIGHTENING TORQUE Sealing surface 3.TlGHTENlNG TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared. Thread diameter Width across flats of nut part of nut part (mm) (mm) T kgm 14 19 2.5kO.5 18 24 5&Z 22 27 8-t2 24 32 14k3 30 36 1823 33 41 20r5 36 46 25k5 42 55 30+-5 Tightening torque COATING MATERIALS -T- Nm I 24.5 24.9 49k19.6 78.5 +- 19.6 137.3t29.4 176.5k29.4 196.1 249 245.2 f49 294.2 +49 The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenclature Adhesives Komatsu code LT-IA LT-1 B LT-2’ Applications Used to apply rubber pads, rubber gaskets, and cork plugs. Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong seal is needed. Preventing bolts, nuts and plugs from loosening and leaking oil. LT-3 Provides an airtight, electrically insulating seal. Used for aluminum surfaces. Sealant gasket Antifriction compound (Lubricant including molybdenum disulfide) Grease (Lithium grease) Vaseline LT-4 LG-1 LG-3 LG-4 LG-5 LG-6 LG-7 LM-P G2-LI - Used to coat plugs (plate shaped, bowl shaped) and holes, and mating portion of shaft. Used with gaskets and packings to increase sealing effect. Heat-resistant gasket for precombustion chambers and exhaust piping. Used b itself on mounting surfaces on the final drive and transmission cases. Thrckness after tightening: 0.07 - 0.08 mm)Y Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings in hydraulic circuits of less than 50 mm in diameter. Silicon base type used in combination with LG-1 and LG-4. Has a shorter curing time than LG-6, and is easier to peel off. Applied to bearings and taper shafts to facilitate press-fitting and to prevent sticking, burning or rusting. Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and facilitation of assembling work. Used for protecting battery electrode terminals from corrosion. ‘LT-2 is also called LOCTITE in the shop manuals 00-9
- 10. ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe. CLASSIFICATION BY THICKNESS Nominal number 0.85 2 Copper wire Cable O.D. Current rating Number Dia. of strands Cross section (mm) (A) Applicable circuit strands (mm) (mm?) 11 0.32 0.88 2.4 12 Starting, lighting, signal etc. 26 0.32 2.09 3.1 20 Lighting, signal etc. 5 65 I I I I 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 I 17.6 230 Starting CLASSIFICATION BY COLOR AND CODE Prior- ity 2 5 6 Charging Ground Starting Lighting Instrument Signal Other Pri- Code W B B R Y G L rnav Color White Black Black Red Yellow Green Blue Code WR - BW RW YR GW LW Color White& Red - Black &White Red &White Yellow & Red Green & White Blue &White Code WB - Auxi_ Color White&Black - liary Code WL - Color White&Blue - Code WG - BY RB YB GR LR Black &Yellow Red &Black Yellow & Black Green &Red Blue & Red BR RY YG GY LY Black & Red Red & Yellow Yellow &Green Green &Yellow Blue &Yellow - RG YL (GB) (LB) 1 Color 1White &Green 1 - 1 - Red & Green 1 Yellow & Blue ) (Green & Black) 1 (Blue &Black) Code - - - RL YW (GL) - Color - Red & Blue Yellow & White (Green & Blue) 00-l0
- 11. CONVERSION TABLE CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example l Method of using the Conversion Table to convert from millimeters to inches 1, Convert 55 mm into inches. (1) 12) (3) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal line from @. Locate the number 5 in the row across the top, take this as @J, then draw a perpendicular line down from @. Take the point where the two lines cross as 0. This point 0 gives the value when converting from millimeters 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 came procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. ( 5 Millimeters to inches 1 mm = 0.03937 in 1 2 3 6 7 8 90 4 0 IO 20 30 40 50_----_ 60 70 80 90 0.039 0.079 0.118 0.157 0.433 0.472 0.512 0.551 0.827 0.866 0.906 0.945 1.220 1.260 1.299 1.339 1.614 1.654 1.693 1.732 2.008 2.047 2.087 2.126---_-_ -- __ - _ _ _---__ .----- 2.402 2.441 2.480 2.520 2.795 2.835 2.874 2.913 3.189 3.228 3.268 3.307 3.583 3.622 3.661 3.701 0.197 0.591 0.984 1.378 1.772 0 12.165 2.559 2.953 3.346 3.740 0.236 0.276 0.315 0.354 0.630 0.669 0.709 0.748 1.024 1.063 1.102 1.142 1.417 1.457 1.496 1.536 1.811 1.850 1.890 1.929 2.205 2.244 2.283 2.323 2.598 2.638 2.677 2.717 2.992 3.032 3.071 3.110 3.386 3.425 3.465 3.504 3.780 3.819 3.858 3.898 0.394 0.787 1.181 1.575 1.969---___ 2.362 2.756 3.150 3.543 @- __ 00-l 1
- 12. ENGINE II STRUCTURE AND FUNCTION Radiator and cooler ........................ 1 I-2 Engine speed control ..................... 1 l-3- 1 Servo cylinder ............................. 11-4 Engine low idling select system .............. 1 1-7 WA800-1
- 13. RADIATOR AND COOLER 1. Radiator cap 2. Water level sensor 3. Fan guard 4. Upper tank 5. Radiator 6. Hydraulic oil cooler Eng.oil cooler Thermostat r--l i ~ Radiator A 6 427F0 Specification Core type: Model G7 Total heat dissipating area: 201 .OO m2 Cross-sectional area of water tubes: 288.52 cm2 14 A. Oil inlet port B. Oil outlet port WA800-1
- 14. l WA800-2 1. Radiator cap 2. Water level sensor 3. Fan guard 4. Upper tank 5. Radiator 6. Hydraulic oil cooler -----_ ~hdiator j I /I k--__plp 550ehin 1 Hyd. ’ coolei T/C cooler 450 Plmin F4270200 Specification Core type: Model G7 Total heat dissipating area: 201 .OO m2 Cross-sectional area of water tubes: 288.52 cm2 1 A. Oil inlet port B. Oil outlet port WA800-1 11-3 !5,
- 15. ENGINE SPEED CONTROL l WASOO-1 View 2 427FOO6 1. Accelerator pedal 2. Cable 3. Servo cylinder 4. Injection pump 5. Absorber 6. Air cylinder 7. Transmission oil filler WA800-1
- 16. l WA800-2 6 View Y View Z 427FO1004 1. Accelerator pedal 2. Cable 3. Servo cylinder 4. Injection pump 5. Absorber 6. Air cylinder 7. Transmission oil filler WA800-1 112-2
- 17. SERVO CYLINDER 1 A B 2 3 4 5 View Z 427FOO7 1. Rod 2. Spring 3. Body 4. Piston 5. Yoke OUTLINE l The servo cylinder is installed to the engine linkage. This acts to reduce the operating force without changing the amount of movement of the accel- erator pedal cable and injection pump rod. A. Oil outlet port (Drain to transmission oil filler) 6. Oil inlet port (From oil filter) 11-4 WA800-1
- 18. OPERATION 1. Accelerator pedal not depressed To TIC. TIM valve Accelerator pedal (6) is not being depressed, so the servo cylinder is not actuated. The pressurized oil from the transmission filter passes through the middle of rod (3) and flows to port A. 2. Accelerator pedal depressed T/M filter 427FOO9 When accelerator pedal (6) is depressed, cable (7) moves rod (3) to the left in the direction of the arrow. The oil from the transmission filter flows from port A through the hole in piston (2) and goes to chamber B. WA800-1 1l-5
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- 20. To TIC. TIM valve 427FOlO When the oil flowing to chamber 6 reaches the specified pressure, it overcomes the force of spring (8) and moves piston (2) to the left.in the direction of the arrow. Piston (2) continues to move until the hole in piston (2) is closed. 3. Accelerator pedal released To T/C. TIM valve As a result, the length of movement of rod (3) becomes equal to the length of movement of the piston, and the operating force is reduced by the hydraulic pressure. I 427FOll When accelerator pedal (6) is released, cable (7) moves rod (3) to the right in the direction of the arrow. As a result, the oil at chamber B is drained. When this happens, piston (2) is moved to the right by spring (8) until the hole in piston (2) is closed. 11-6 WA800-1
- 21. ENGINE LOW IDLING SELECT SYSTEM OUTLINE l By using the engine low idling selector device to set the engine low idling speed to two stages, it is possible to carry out operations more eff icientiy. OPERATION Selector switch OFF When the selector switch is OFF, no electric current flows to solenoid valve (1). so the solenoid valve is not actuated and the air supply to air cylinder (2) is shut off. As a result, the air cylinder is not actuated and the engine speed is set to 650 rpm. l WA800-1 From dry air tank 427FO12 9 WA800-2 From dry air tank 427FO1005 WA800-1
- 22. Selector switch ON When the selector switch is turned ON, electric cur- rent flows to solenoid valve (I), and the solenoid valve is actuated. Air flows to air cylinder (21, and the air cylinder rod is pushed out by the air pressure. The air cylinder rod is connected by a link to accelerator pedal (3). so the accelerator pedal is depressed by an amount equal to the movement of the rod. When this happens, the engine speed is set to approximately 850 rpm. . WA800-1 427FO13 l WASOO-2 427FO1006 WA800-1
- 23. ENGINE 12 TESTING AND ADJUSTING Standard value table . . . . 12- 2 Tool list for testing and adjusting 12- 6 Adjusting valve clearance . . 12- 7 Measuring compression pressure 12- 9 Testing and adjusting fuel injection timing . 12-l 0 Measuring accelerator pedal operating force 12-I 3 Measuring accelerator pedal operating angle 12-I 7 * The following precautions are necessary when using the Standard Value Tables to make judgement 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 mark- ing 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. A When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, insert the safety pins and block the tires. A When working in groups, use agreed signals and do not allow unauthorized persons near the machine. A When checking the water level in the radiator wait for the water to cool. Do not remove the radiator cap while the water is hot. Boiling water may spurt out. A Be careful not to get caught in rotating parts. WA800-1 ‘%j’