SMC-150FA
Shop Manual
150A 150FA CRANE SERIAL NUMBERS
150A -09695 - 10827 150FA -09695 - 10827
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
October 2002
Copyright 2002 Komatsu DataKom Publishing Division
GRADER d PLANER ROLLER CRANE d
C6 R O S S P OW E R STEERING GEAR APPLICABLE GRADER MODELS
104A 104B 104C
160C 160L
07245 thru 07600 07601 thru 10750 10751 thru 12013 07245 thru 07600 07601 thru 10750 10751 thru 12013 07245 thru 07619 07620 thru 10693 02155 thru 02714 02715 thru 03029 02121 thru 03083 02601 thru 07994 02944 thru 07994 01501 thru 02535
APPLICABLE ROLLER MODEL§
SERIAL
APPLICABLE CRANE MODELS
SERIAL NUMBER§
PTR 9-Wheel R o l l e r
80 90 thru 125 thru 125A 125F 140F 150A
CONTENTS
SERIAL NUMBERS-..
00101 thru 05678
01001 thru 03131 01150 thru 08774 02006 thru 08774 07247 thru 08774 07990 thru 08774 07571 thru 08774 02832 a n 3 Up 07305 and Up 09401 and Up
Page Torque S h e e t Back o f Cover . . , , , 1 Disassembly S e r v i c e t o Cam and A c t u a t o r Assembly , . 9 , . , S e r v i c e t o Lever S h a f t and S t ud Assembly . 10 . . . . . . . S e r v i c e t o Valve Assembly 11 14 Reassembly Installation A djus tme nt o f Valve Assembly . 22 , . . Lubricant S p e ci fi c at i o n s 25 25 . . . Troubleshooting . . ,
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ON ALL
COMPONENTS MUST B E PROPERLY SUPPORTED DISASSEMBLY AND ASSEMBLY.
ALL
JACKING, HOISTING, AND GENERAL WORKSHOP EQUIPMENT REQUIRED FOR THIS OPERATION MUST B E IN GOOD WORKING ORDER.
EXTREME SAFE
The following General Torques are to be used
CAUTION INJURY.
BE OBSERVED AT A L L TIMES TO PREVENT
WORKSHOP PRACTICES ARE A MUST.
ail cases where SPECIFIC TORQUES
not given.
NOTE: Torque Values listed throughout this manual are Lubricated (Wet) Threads; values should be increased treated material Grade 5
for Non-Lubricated (Dry) Threads.
Grade 8 Grade 8 (6 radial dashes on bolt or cap screw head)
Foot Pounds
SHOP MANUAL DISASSEMBLY:
1 Remove a d j u s t i n g screw l o c k n u t .
2 Remove small cap screws f r o m c ov e r .
3 Remove n u t s and washers f r o m ends o f l a r g e r c o ve r b o l t s (beneat h s t e e r i n q g ea r mountina pad), i f so equipped.
1
SHOP MANUAL 4 Remove equipped.
co ve r r e t a i n i n o b o l t s : if so
5 On p r e v i o u s models ( w i t h sh im - a d ju s t ed l e v e r s h a f t ) , c o ve r may now be 1i f t e d o f f . Proceed t o Step 9 on page 4. On l a t e r models ( w i t h s cr e w - a d ju s t ed l e v e r s h a f t ) , use s c r e w d r i v e r t o t u r n a d j u s t i n g screw c l oc k w is e . T hi s wil lift co ve r fr o m housinq. Screw must be t u r n e d a l l t h e way th r o ug h t h e housing. Proceed t o Step 6 on 3.
Some p r e v i o u s model motor graders and a l l r o l l e r s and cranes w i t h t h e Ross u n i t a r e equipped w i t h a one- piece s t e e r i n g s h a f t . The pitman arm i s s p l i n e d t o t h e l o w e r end o f the - lever s h a f t i n th e s e models.
To remove t h e pitman arm from t h e l e v e r s h a f t ,
remove n u t and washer from s p l i n e d end. Raise l e v e r s h a f t and i n s e r t wood b l o c k under s p l i n e d end t o r a i s e s t u d r o l l e r b e a r i n g away from cam. T hi s p re v e nt s damage t o s t u d r o l l e r b e a r i n g and cam. Then d r i f t pitman arm from s h a f t .
2
FILE SECTION
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SHOP MANUAL 6
Pry staked portion of a dju st i nq screw lock n u t from s l o t i n l e v e r s h a f t .
7 Remove a dj ust i ng screw lock n u t .
8
L i f t adj us t ing screw from pocket i n l e v e r s h a f t .
3
FILE SECTION
SHOP MANUAL 9 (with shim-adjusted l e v e r On s h a f t ) , remove l e v e r s h a f t and shim pack from gear housing. Keep shim pack i n t a c t . This s t e p i s normally done only i f t o replace s h a f t , bushings or s e a l . I f none of t he se replacements a r e r eq uir ed, s l i d e l e ver s h a f t u p , rotate and r e s t l e v e r on back of case.
10
On l a t e r models (with screw- adjusted l e ve r s h a f t ) , no shim pack i s used t o a d j u s t l e v e r s h a f t stud r o l l e r t o cam. Adjustinq screw holds l e ve r s h a f t in pos it i on. Remove l e ve r s h a f t only i f t o replace s h a f t , bushings or s e a l . I f n o t required, then s l i d e lever shaft up, rotate and r e s t l e ve r on back of case.
11
Remove four ( 4 ) socket head cap screws holding valve, valve s pa c er , and cover t o control ( or a c t u a t o r ) housing. Actuating l e v e r , pi n, seal and washer w il l be removed with t h e valve. Previous valve configuration i s pictured. Service t o t h i s assembly i s i l l u s t r a t e d on page 1 1 .
4
FILE SECTION
SHOP MANUAL 12
On orevious models (with one-piece control or a c tu a tor housing) remove f ou r ( 4 ) cap screws, cover, shims, and qaskets. tube can now be removed. Insp ect bearings a n d s p l i n e s f o r serviceability. On models wi t h two-piece ( se p a r a t e upper cover proceed t o and actuator) actuator o n page 7 .
18
Wheel tube bearings can be replaced by removing r e t ai ni n g snap r i n q s . I t appears t h a t each bearing i s missing one b a l l - - t h i s i s c o r r e c t . Balls must be replaced by s e t s only .
14
Remove cap screws, control housina, a n d qask et. Insoect control housing f o r i nte r n a l bearing race wear.
5
FILE SECTION
FILE,
15 Remove cap screws, shims, qa s ke t s, sleeve r e t a i n e r , a n d end cover. Cam assembly can now be removed.
16 Remove cam assembly.
Inspect case a t mountinq f o r wear or breakage. Inspect l ev e r s h a f t bushing f o r wear or damaqe and replace as required . Proceed t o Step 24 cn paae 9 .
6
A
MANUAL 18 On models w i t h two-piece ( s e p a r a t e upper cover and a c t u a t o r ) a c t u a t o r housinq, remove cover ( 1 ) and gasket ( 2 ) .
19 Remove a c t u a t o r r e t a i n e r screw and washer, then remove a c t u a t o r housinq and ga sket.
20 Remove cam and a c t u a t o r assembly.
7
FILE
SECTION
SHOP MANUAL 21 I f cam assembly r e qu ir e reolacement, remove end cover and gasket.
22
Reassemble needle bearings i n t o housing. t o l oc a ti n g with extreme c a r e .
Press
23 Inspect case a t mountinq f o r wear or breakape. l e ve r s h a f t bushina f o r wear or ace as requ ired.
an d
FILE SECTION
1-20
SHOP MANUAL S E R V I C E T O CAM
A C T U A T O R ASSEMBLY
24
Later models with two-piece a c t u a t o r housing employ an a c t u a t o r u n i t assembled on t he cam. Remove a dj ust i ng n u t a f t e r st r a ig ht eni ng bent prong o n lock washer.
25 Remove lock washer tongued washer thrust washers needle bearing and upper cent e r i n g washer ( 5 ) from above a c t u a t o r . Do not l o s e springs ( 7 ) i n a c tua t or . Remove lower centering washer thrust washer and needle bearing ( 4 ) a f t e r removing actuator ( 6 ) .
26 Inspect cam f o r and excessive wear. Check cam qroove f o r chipping, sc or i ng, or bri nnell inq. Check cam bearinq su r f a ce s and s p l i n e s . Wearina away o f copper p l a t i n a i s natural a n d will come i n time t o 1 cams. Pictured i s the cam assembly used i n previous u n i t s with one- piece control housing. Spring assemblies a r e not a d j u s t a b l e . They a r e f ac t or y s e t . The smaller race o f t he t h r u s t bearing should be located next t o the cam. O n l a t e r models with two-piece ac t ua t or housinq, reassemble a c t u a t o r assembly on cam wheel tube assembly and a d j u s t . P r i o r t o assembly, make s u r e t h a t threads a r e s t r a i g h t a n d t h a t n u t can be run down by f i n g e r torque a l l t h e way. Assemble i n order shown in Step 25. Tighten n u t t o 10 torque. Then back o f f or 5/32" ( t h e width of a lug o n t h e lockinq nut washer). This adjustment must r e s u l t i n a l i g h t preb u t allow NO end o f a c tua t or load on on s h a f t . 9
FILE SECTION
SHOP MANUAL SE RVI CE TO L E V E R SHAFT
27
Check s h a f t spl i ne s an d threads on l e ver s h a f t . Reolace i f needed.
28 Check stud f o r f l a t s p o t s , ni c ks , o r
29
Adjustment of stud r o l l e r bearinq must be s e t t o t hr e e inch-pounds preload f o r c o r r e c t o oer at i on.
10
STUD ASSEMBLY
FILE
SECTION,
FILE
S E R V I C E TO V A L V E ASSEMBLY
30
Remove water seal r e t a i n e r , water s e a l , valve spool cover, and valve cover "0" r i by removinq can screws.
31 some previous model valve assemblies, d r i f t o u t pin with small punch a n d remove a c t u a t i ng l ev e r from swivel bearing rod and valve body.
32
Remove c l e v i s o r swivel bearing rod from end o f by removinq c o t t e r pi n , loosening n u t , and unscrewing r od from spool.
11
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