LUBRICATED TRACKS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FAILURE SIGNS AND DIAGNOSIS FOR REUSE . . . . . . . . . . . 2
• Inspection points for parts reuse diagnosis
• Standards for reuse of track parts
• Failure signs and diagnosis for reuse
• Seals, bushings, spacers, links and pins
EXAMPLES OF FAILURE ANALYSES
OF SEALED & LUBRICATED TRACK . . . . . . . . . . . . . . . . . . 25
CONSTRUCTION AND FUNCTION . . . . . . . . . . . . . . . . . . . . . 28
• Structure of the sealed & lubricated track
• Materials and heat treatment
• Progress of wear and rebuilding of track
TECHNICAL POINTS REQUIRED
FOR AN "OIL TURN" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
• Functional requirements for lubrication of
pins, bushings, etc.
• Precautions for the sealing mechanism
• Precautions for the track link movement during travel
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 43

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Oil Management

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့HYDRAULIC ေရာ္ဘာ ပိုက္မ်ားအေၾကာင္း

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FAILURE SIGNS AND DIAGNOSIS FOR REUSE . . . . . . . . . . . 2
• Inspection Points for Parts Reuse Diagnosis
• Standards for Failure Determination
• Standards for Reuse of Hydraulic Hose Parts
EXAMPLES OF FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
• Adapter Seals
• Adapter-Hose Interface
• Hoses
STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 31
• Functions
• Hose Structure
• Adapter Structure
• Hose Brands
• Hose Parts Number
FAILURES AND THEIR CAUSES . . . . . . . . . . . . . . . . . . . . . . 34
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 35
• Maintenance
• Precautions when Storing Hoses
• Precautions when Installing Hoses
• Physical Effects of Long-Term Storage

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CYLINDER LINERS, PISTONS AND PISTON RINGS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FAILURE SIGNS, THEIR CAUSES AND DIAGNOSIS
FOR REUSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
• Inspection points for parts reusage diagnosis
• Standards for failure determination
TYPICAL EXAMPLES OF FAILURES . . . . . . . . . . . . . . . . . . . 40
• Cylinder head failures
• Piston failures
• Piston ring failures
FAILURES AND THEIR CAUSES . . . . . . . . . . . . . . . . . . . . . . 46
• Lubricating oil
• Cooling water
• Air intake (dust)
• Machine operation
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 47
CONSTRUCTION AND FUNCTION . . . . . . . . . . . . . . . . . . . . . 49
• Cylinder liners
• Pistons
• Piston rings
BASIC MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SURFACE TREATMENT FOR CYLINDER LINERS
AND PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Cylinder head and valve

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FAILURE SIGNS, THEIR CAUSES AND DIAGNOSIS
FOR REUSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
• Inspection points for parts reusage diagnosis
• Standards for failure determination
TYPICAL EXAMPLES OF FAILURES . . . . . . . . . . . . . . . . . . . 29
• Cylinder head failures
• Valve failures
FAILURES AND THEIR CAUSES . . . . . . . . . . . . . . . . . . . . . . 34
• Cooling water
• Lubricating oil
• Fuel
• Air intake
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 35
CONSTRUCTION AND FUNCTION . . . . . . . . . . . . . . . . . . . . . 36
• Cylinder heads
• Valves
BASIC MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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THE STRUCTURE AND FUNCTION OF A DOZER

ENGINES
TORQUE CONVERTERS
TRANSMISSIONS
DIFFERENTIALS
FINAL DRIVES
BRAKES
TYRES
UNDERCARRIAGE
STEERING
OPERATOR’S COMPARTMENT
HYDRAULIC SYSTEMS
LOADER RATINFS
MAINTENANCE AS A
CONSIDERATION
THE DEALER
SUMMARY






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Basic structure and function of a dozer

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REUSEABLE PARTS OF CRANKSHAFT AND BEARING

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FAILURE SIGNS, THEIR CAUSES AND DIAGNOSIS
FOR REUSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
• Inspection points for parts reusage diagnosis
• Standards for failure determination
TYPICAL EXAMPLES OF FAILURES . . . . . . . . . . . . . . . . . . . 20
• Crankshaft
• Main and connecting rod bearings
FAILURES AND THEIR CAUSES . . . . . . . . . . . . . . . . . . . . . . 30
• Air intake
• Lubricating oil
• Operation technique
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 31
CONSTRUCTION AND FUNCTION . . . . . . . . . . . . . . . . . . . . . 32
• Crankshaft
• Main and connecting rod
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SHOP MANNUAL for WA 320-3 KOMATSU LOADER

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Diesel Emisssion

Part I Operational Issues
Tools 2.
Best Practices 3.
Proactive Attitudes 5.
Typical Exhaust Gas Components
Carbon Dioxide 7.
Carbon Monoxide 7.
Oxides of Nitrogen 7.
Hydrocarbons 7.
Particulate Matter 7.
Oxides of Sulfur 7.
Smoke 8.
Engine Systems and Conditions
That Affect Diesel Emissions
Combustion Chamber Design 9.
Intake Manifold System 10.
Operating Conditions 11.
Low Turbocharger Boost Pressure 11.
High Exhaust Backpressure 12.
High Crankcase Pressure 13.
Part II Overview of Six Engine Systems
Introduction 14.
1. Intake System
Introduction 15.
Dry Type Air Cleaners 16.
Air Induction Cooling 16.
Aftercoolers 16.
Air-to-Air Aftercoolers 17.
Water Aftercoolers 17.
Intake System Recommendations 17.
Servicing the Intake System 18.
Job Aid Checklist (Intake System) 19.
2. Exhaust System
Introduction 20.
Exhaust System Recommendations 21.
Exhaust After Treatment System Maintenance 21.
Job Aid Checklist (Exhaust System) 23.
Introduction to Tools used for Exhaust System Analysis
ECOM AC+ Gas Analyser 24.
UGAS Software Application 25.
Testing Protocol 25.
Pre-test Conditions 26.
Emissions Testing Protocol 26.
Basic Emission Equipment Operation
Undiluted Diesel Particulate Measurement 27.
Measurement Interpretation 28.
Analysis of Particulate Samples 28.
Thermal Optical Method 29.
Job Aid Checklist 30.
ECOM AC+ Gas Analyser 30.
Particulate Sampling - Gilian Pump 30.
Intake Testing 31.
Intake Restrictions and Exhaust Backpressure 32.
3. Fuel Injection System
Introduction 33.
Injection Pump or Injector Failure 33.
Inadequate Fuel Supply 34.
Incorrect Injection Pump or Injector Timing 34.
Advanced Timing 34.
Retarded Timing 34.
Fuel System Types 35.
Individual Unit Jerk Pumps 35.
Inline Pump System 36.
Distributor Pump System 37.
Cummins PT Fuel System 37.
Unit Injectors 38.
Electronically controlled Fuel Injection Systems 38.
Fuel Injection System Recommendations 39.
Job Aid Checklist (Fuel System) 40.
4. Cooling Systems
Cooling System Recommendations 41.
Cooling System Maintenance 42.
Cooling Mixture 42.
Conditioner and Inhibitors 42.
Cleaning and Flushing 43.
Troubleshooting 43.
Thermostats 43.
Aeration in Coolant 43.
Radiator Cap Relief Valve 44.
Temperature Probe (Cooling System) 44.
Job Aid Checklist (Cooling System) 45.
5. Diesel Fuel and Fuel Supply Systems
Introduction 46.
Best Practice Recommendations 46.
Sulfur Content 47.
Cetane Number 47.
Viscosity 47.
Flashpoint 47.
Fuel Quality and Handling Recommendations 48.
6. Lubrication
Lubrication Recommendations 49.
Lubrication Classification 50.
Combined Service Application 51.
Lubrication System Checks 51.
Conclusion 52.


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