PC450-6 Shop Manual
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Transcript of PC450-6 Shop Manual
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1
SEBM014508
MACHINE MODEL SERIAL NUMBER
PC400-6 32001 and up
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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
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‡ 00- 1 (8)
00- 2 (2)
‡ 00- 2-1 (8)
‡ 00- 2-2 (8)
‡ 00- 2-3 (8)
‡ 00- 2-4 (8)
‡ 00- 2-5 (8)
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00 12
10-65
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10 82
10-39
10-40
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10-44
10-45
10-46
10-46-2 (5)
10-46-3 (5)
10-48
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10-52
10-53
10 55
Mark Indication Action required
fi 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 actions
be taken to these pages according to the table below.
Pages having no marks are those previously revised
or made additions.
LIST OF REVISED PAGE
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LIST OF REVISED PAGES
01- 1
01- 2 (5)
01- 3 (4)
01- 3-1 (5)
01- 4 (5)
01- 5
01- 6
01- 7
01- 7-1 (5)
01- 7-2 (5)
01- 8 (5)
01- 9
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01 12 (4)
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10-16 (4)
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20-119-1 (4)
20-119-2 (4)
20-120 (4)
20-121 (4)
20-122 (1)
20-123 (1)
20-124 (1)
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20-128 (4)
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20-201 (6)
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20-10 (1)
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20-12 (6)
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20-16 (1)
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20-103 (4)
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LIST OF REVISED PAGES
10-192
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10-197 (6)
10-198
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10-173 (6)
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10-179 (6)
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LIST OF REVISED PAGES
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20-639 (4)
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30- 7 (3)
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30- 9 (3)
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30-9-3 (6)
30-10 (2)
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30-11 (2)
30-11-1 (3)
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30-12 (2)
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30-19 (2)
30-20 (2)
30-21 (2)
30-22 (2)
30-23 (2)
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LIST OF REVISED PAGES
30-37 (2)
30-38 (2)
30-39 (2)
30-40 (2)
30-41 (4)
30-42 (2)
30-43 (2)
30-44 (2)
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30-46 (4)
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30-61-1 (6)
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LIST OF REVISED PAGES
30-108 (2)
30-109 (2)
30-110 (2)
30-111 (2)
30-112 (2)
30-113 (2)
30-114 (2)
30-115 (2)
30-116 (2)
30-117 (4)
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30-119 (4)
30-120 (2)
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30-122 (2)
30-123 (2)
30-124 (2)
30-125 (2)
30-126 (2)
30-127 (2)
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‡ 40- 1 (8)
40- 2
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40- 8
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fi 40- 9-1 (8)
fi 40- 9-2 (8)
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40-38 (4)
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40-41
40-42 (5)
40-43
40-43-1 (5)
40-44 (5)
40-45
40-45-1 (5)
40-45-2 (5)
40-46
40-47
40-48
90-15 (5)
90-17 (5)
90-19 (5)
90-21 (5)
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SAFETY SAFETY NOTICE
SAFETYSAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbolk 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 actions
to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual care-
fully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
• Always wear safety glasses when hitting
parts with a hammer.
• Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the work.
When carrying out welding work, always wear
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 work-
ing.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from fall-
ing. In addition, be sure to lock all the control
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SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK
11.When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out.
Before disconnecting or removing components
of the oil, water or air circuits, first remove the
pressure completely from the circuit.
12.The water and oil in the circuits are hot when the
engine is stopped, so be careful not to get
burned.
Wait for the oil and water to cool before carry-
ing out any work on the oil or water circuits.
13.Before starting work, remove the leads from the
battery. Always remove the lead from the nega-
tive (–) terminal first.
14.When raising heavy components, use a hoist or
crane.
Check that the wire rope, chains and hooks are
free from damage.
Always use lifting equipment which has ample
capacity.
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 hoist
or crane.
15.When removing covers which are under internal
pressure or under pressure from a spring,
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17 When removing piping stop the fuel or oil from
19.Be sure to assemble all parts again in their origi-
nal places.
Replace any damaged parts with new parts.
• When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being
operated.
20.When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when install-
ing tubes for high pressure circuits. Also, check
that connecting parts are correctly installed.
21.When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate 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 fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24.Take care when removing or installing the tracks
of track-type machines.
When removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
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FOREWORD GENERAL
FOREWORD
GENERALThis shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-ther divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLYThis section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
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FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMESShop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series
Electrical volume:
Attachments volume:
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chas-
sis, engine, electrical and attachment volumes be
available.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will besent to KOMATSU distributors. Get the most up-to-
date information before you start any work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show how to read the page
number.
Example 1 (Chassis volume):
10 - 3
Item number (10. Structure and
Function)
Consecutive page number for each
item.
Example 2 (Engine volume):
12 - 5
Unit number (1 Engine)
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 REVISED
PAGES next to the CONTENTS page.
SYMBOLS
So that the shop manual can be of ample practical
use, important safety and quality portions are
marked with the following symbols.
Symbol Item Remarks
k Safety
Special safety precautions
are necessary when per-
forming the work.
a Caution
Special technical precau-
tions or other precautions
for preserving standards
are necessary when per-forming the work.
4 Weight
Weight of parts of sys-
tems. Caution necessary
when selecting hoisting
wire, or when working pos-
ture is important, etc.
3Tightening
torque
Places that require special
attention for the tighteningtorque during assembly.
2 Coat
Places to be coated with
adhesives and lubricants,
etc.
Pl h il t
}·
Each issued as one
volume to cover all
models
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FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
k Heavy parts (25 kg or more) must be lifted
with a hoist, etc. In the DISASSEMBLY
AND ASSEMBLY section, every part
weighing 25 kg or more is indicated clearly
with the symbol
• If a part cannot be smoothly removed from the
machine by hoisting, the following checks
should 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 ROPES
1) Use 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 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 symmetrically
wound onto the load.
k 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 hook.When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
when hoisting is made with two ropes, each of
which is allowed to sling up to 9.8 kN {1000 kg}
vertically, at various hanging angles.
When two ropes sling a load vertically, up to
19.6 kN {2000 kg} of total weight can be sus-pended. This weight becomes 9.8 kN {1000 kg}
when two ropes make a 120° hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 39.2 kN {4000
kg} if they sling a 19.6 kN {2000 kg} load at a
Rope diameter Allowable load
mm kN tons
10
11.5
12.5
14
1618
20
22.4
30
40
50
60
9.8
13.7
15.7
21.6
27.535.3
43.1
54.9
98.1
176.5
274.6
392 2
1.0
1.4
1.6
2.2
2.83.6
4.4
5.6
10.0
18.0
28.0
40 0
4
SAD00479
41%71%79%88%100%
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FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
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 hydraulic
tank.
k Even if the residual pressure is released from
the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
l ic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic 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 it
clicks. (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.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter
perfectly, pull it back to check its connecting
condition. (See Fig. 5)
Type 1
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FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
D i s a s s e m b l y
1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn
lever (4) to the right (clockwise).
3) Hold in the condition in Steps 1) and 2), and
pull 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 of
the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and push
until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre
• Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre
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FOREWORD COATING MATERIALS
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, featuresr
Adhesives
LT-1A 790-129-9030 150 g Tube• Used to prevent rubber gaskets, rub-
ber cushions, and cock plug fromcoming out.
LT-1B 790-129-905020 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 gPolyethylene
container
• Features: Resistance to heat andchemicals
• Used for anti-loosening and sealantpurpose for bolts and plugs.
LT-3
790-129-9060(Set of adhesiveand hardening
agent)
Adhesive:
1 kgHardeningagent:500 g
Can
• Used as adhesive or sealant for met-
al, glass and plastic.
LT-4 790-129-9040 250 gPolyethylene
container
• 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 gPolyethylene
container
• 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 ccPolyethylene
container
• Resistance to heat, chemicals• Used at joint portions subject to high
temperatures.
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
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FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
Molybdenumdisulphidelubricant
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 or shrink fitting.
• Used as lubricant for linkage, bear-ings, etc.
Grease
G2-LI
SYG2-400LI
SYG2-350LISYG2-400LI-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.
Molybdenum
disulphidegreaseLM-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 WhiteGrease 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 G2B
G2-BT (*)*: For hightemperatureand large load
SYG2-400BSYGA-16CNBSYG2-400BT (*)SYGA-16CNBT (*)
400 g16 kg
Bellows typeCan
• Since this grease is decomposed
by bacteria in short period, it hasless effects on microorganisms,animals, and plants.
Primer
SUNSTARPAINT PRIMER580 SUPER
417-926-3910
20 mlGlass
container
e s i v e f o r c a b g l a s s
• Used as primer for cab side(Using limit: 4 months)
SUNSTARGLASS PRIMER580 SUPER
20 mlGlass
container
• Used as primer for glass side(Using limit: 4 months)
Adhesive
SUNSTARPENGUINESEAL 580SUPER "S" or "W"
320 mlPolyethylene
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 Polyethylene • Used as adhesive for glass
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FOREWORD STANDARD TIGHTENING TORQUE
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
Thread diameter of bolt
Width acrossflats
Tightening torque
mm mm Nm kgm
6
8
10
12
14
10
13
17
19
22
11.8 – 14.7
27 – 34
59 – 74
98 – 123
153 – 190
1.2 – 1.5
2.8 – 3.5
6 – 7.5
10 – 12.5
15.5 – 19.5
16
18
20
2224
24
27
30
3236
235 – 285
320 – 400
455 – 565
610 – 765785 – 980
23.5 – 29.5
33 – 41
46.5 – 58
62.5 – 7880 – 100
27
30
33
36
39
41
46
50
55
60
1150 – 1440
1520 – 1910
1960 – 2450
2450 – 3040
2890 – 3630
118 – 147
155 – 195
200 – 250
250 – 310
295 – 370
Thread diameter of bolt
Width acrossflats
Tightening torque
mm mm Nm kgm
6
8
10
12
10
13
14
27
5.9 – 9.8
13.7 – 23.5
34.3 – 46.1
74.5 – 90.2
0.6 – 1.0
1.4 – 2.4
3.5 – 4.7
7.6 – 9.2
Sealing surface
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FOREWORD STANDARD TIGHTENING TORQUE
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
10
12
16
14
17
22
59 – 74
98 – 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
02
03, 04
05, 06
10, 12
14
14
20
24
33
42
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
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
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FOREWORD STANDARD TIGHTENING TORQUE
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 SCREWS
Use 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
6
8
10
12
10 0 2
24 0 4
43 0 6
77 0 12
1.02 0 0.20
2.45 0 0.41
4.38 0 0.61
7.85 0 1.22
Thread diameter Tightening torque
mm Nm kgm
6
8
10
12
14
8 0 2
10 0 2
12 0 2
24 0 4
36 0 5
0.81 0 0.20
1.02 0 0.20
1.22 0 0.20
2.45 0 0.41
3.67 0 0.51
Thread diameter Tightening torque
inch Nm kgm
1 / 16
1 / 8
1 / 43 / 8
1 / 2
3 / 4
1
3 0 1
8 0 2
12 0 215 0 2
24 0 4
36 0 5
60 0 9
0.31 0 0.10
0.81 0 0.20
1.22 0 0.201.53 0 0.41
2.45 0 0.41
3.67 0 0.51
6.12 0 0.92
Nominal sizeof hose
Width acrossflats
Tightening torque (Nm {kgm})Taper seal
typeFace seal type
Range TargetThread size
(mm)
Nominal threadsize - Threads per inch, Thread series
Root diameter (mm) (Reference)
02 19 34 63 {3 5 6 5} 44 {4 5} 14 14 39
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FOREWORD ELECTRIC WIRE CODE
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)
Currentrating
(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, signaletc.
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
1Pri-
mary
Code W B B R Y G L
Color White Black Black Red Yellow Green Blue
2
Code WR — BW RW YR GW LW
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
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FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this asA, then draw a horizontal line
fromA.
(2) Locate the number 5 in the row across the top, take this asB, then draw a perpendicular line down
fromB.
(3) Take the point where the two lines cross asC. This pointC 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 theleft) 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
0
10
20
30
40
50
60
70
80
0
0.394
0.787
1.181
1.575
1.969
2.362
2.756
3.150
0.039
0.433
0.827
1.220
1.614
2.008
2.402
2.795
3.189
0.079
0.472
0.866
1.260
1.654
2.047
2.441
2.835
3.228
0.118
0.512
0.906
1.299
1.693
2.087
2.480
2.874
3.268
0.157
0.551
0.945
1.339
1.732
2.126
2.520
2.913
3.307
0.197
0.591
0.984
1.378
1.772
2.165
2.559
2.953
3.346
0.236
0.630
1.024
1.417
1.811
2.205
2.598
2.992
3.386
0.276
0.669
1.063
1.457
1.850
2.244
2.638
3.032
3.425
0.315
0.709
1.102
1.496
1.890
2.283
2.677
3.071
3.465
0.354
0.748
1.142
1.536
1.929
2.323
2.717
3.110
3.504
B
A
C
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FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
Kilogram to Pound
1 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
0
22.05
44.09
66.14
88.18
110.23
132.28
154.32
176 37
2.20
24.25
46.30
68.34
90.39
112.44
134.48
156.53
178 57
4.41
26.46
48.50
70.55
92.59
114.64
136.69
158.73
180 78
6.61
28.66
50.71
72.75
94.80
116.85
138.89
160.94
182 98
8.82
30.86
51.91
74.96
97.00
119.05
141.10
163.14
185 19
11.02
33.07
55.12
77.16
99.21
121.25
143.30
165.35
187 39
13.23
35.27
57.32
79.37
101.41
123.46
145.51
167.55
189 60
15.43
37.48
59.53
81.57
103.62
125.66
147.71
169.76
191 80
17.64
39.68
61.73
83.78
105.82
127.87
149.91
171.96
194 01
19.84
41.89
63.93
85.98
108.03
130.07
152.12
174.17
196 21
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FOREWORD CONVERSION TABLE
Liter to U.S. Gallon
1l = 0.2642 U.S. Gal
Liter to U.K. Gallon
1l = 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
0
2.200
4.399
6.599
8.799
10.998
13.198
0.220
2.420
4.619
6.819
9.019
11.281
13.418
0.440
2.640
4.839
7.039
9.239
11.438
13.638
0.660
2.860
5.059
7.259
9.459
11.658
13.858
0.880
3.080
5.279
7.479
9.679
11.878
14.078
1.100
3.300
5.499
7.969
9.899
12.098
14.298
1.320
3.520
5.719
7.919
10.119
12.318
14.518
1.540
3.740
5.939
8.139
10.339
12.528
14.738
1.760
3.950
6.159
8.359
10.559
12.758
14.958
1.980
4.179
6.379
8.579
10.778
12.978
15.178
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FOREWORD CONVERSION TABLE
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
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FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/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
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
32 1
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
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
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
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
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
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
33
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
33 1
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
338
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
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FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4
–37.2
–34.4
–31.7
–28.9
–28.3
–27.8
–27.2
–26.7
–26.1
–25.6
–25.0
–24.4
–23.9
–23.3
–22.8
–22.2
–21.7
–21.1
–20.6
–20.0
–19.4
–18.9
–18.3
–40
–35
–30
–25
–20
–19
–18
–17
–16
–15
–14
–13
–12
–11
–10
–9
–8
–7
–6
–5
–4
–3
–2
–1
–40.0
–31.0
–22.0
–13.0
–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
–11.7
–11.1
–10.6
–10.0
–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
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
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
7.8
8.3
8.9
9.4
10.0
10.6
11.1
11.7
12.2
12.8
13.3
13.9
14.4
15.0
15.6
16.1
16.7
17.2
17.8
18.3
18.9
19.4
20.0
20.6
46
47
48
49
50
51
52
53
54
55
56
57
58
59
0
61
62
63
64
65
66
67
68
69
114.8
116.6
118.4
120.2
122.0
123.8
125.6
127.4
129.2
131.0
132.8
134.6
136.4
138.2
140.0
141.8
143.6
145.4
147.2
149.0
150.8
152.6
154.4
156.2
27.2
27.8
28.3
28.9
29.4
30.0
30.6
31.1
31.7
32.2
32.8
33.3
33.9
34.4
35.0
35.6
36.1
36.7
37.2
37.8
40.6
43.3
46.1
48.9
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
105
110
115
120
117.8
179.6
181.4
183.2
185.0
186.8
188.6
190.4
192.2
194.0
195.8
197.6
199.4
201.2
203.0
204.8
206.6
208.4
210.2
212.0
221.0
230.0
239.0
248.0
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FOREWORD UNITS
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}
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ENGINE MOUNT
MAINTENANCE STANDARD ENGINE MOUNT
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MAINTENANCE STANDARD FINAL DRIVE
No. Check item Criteria Remedy
Standard clearance Clearance limitBacklash between No. 1
1 sun gear and No. 1 planet0.20 – 0.61 1.00gear
Backlash between No. 12 0.24 – 0.70 1.10
planet gear and ring gear
Backlash between No. 23 0.06 – 0.24 —
planet carrier and motor
Backlash between No 2
Unit: mm
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Backlash between No. 24 sun gear and No. 2 planet 0.20 – 0.63 1.00
MAINTENANCE STANDARD SPROCKET
SPROCKET
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MAINTENANCE STANDARD SPROCKET
SPROCKET TOOTH SHAPE OF REAL DIMENSION
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MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING
TRACK FRAME AND RECOIL SPRING
fl The diagram shows the PC400-6.
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Unit: mm
2
1
3 SAP00410
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+2T k f 148 152
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