Issuu

CEBM001400

HYDRAULIC CRANE

SERIAL NUMBERS

and UP

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. 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 add 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, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.

September 2004 Printed in USA

FOREWORD 12

BOOK SECTIONS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1

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

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1

TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

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

OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

00-2

150A/FA

PRODUCT PUBLICATIONS INFORMATION Various product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals. Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and Service manuals in foreign languages. The Publications listed below are available for this particular machine(s).

DESCRIPTION

FORM NUMBER

PARTS BOOK - PAPER: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB003601

OPERATION AND MAINTENANCE MANUAL: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAMC20081

SHOP MANUAL Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM001400 Engine 102E-2 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEBM010019

SAFETY MANUAL CIMA Crane machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1085 961 R2

Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America Corp. Extranet Literature Ordering System. If the Extranet Literature Ordering System is not available at the distributor location, then the following Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this page. Komatsu America Corp. reserves the right to add a surcharge to all fax orders.

150A/FA Crane Publinfok.fm

9/27/04

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM AND RETURN TO

DataKom Publications and Training Division 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887

COMPANY NAME

SHIP TO

PURCHASE ORDER NO.

ATTN.

TYPE or PRINT ONLY

STREET ADDRESS

ORDER DATE

CITY, STATE, ZIP CODE COUNTRY

PHONE NO.

FAX NO.

SHIPPING METHOD

DISTR/BRANCH CODE

IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. QTY.

PUBLICATION FORM NO.

KDC91E 071403

PARTS BOOK P-Paper M-Microfiche

PUBLICATION DESCRIPTION

MODEL NUMBER

CURRENT PRICES WILL BE CHARGED

SERIAL NUMBER

FOREWORD

SAFETY

12 SAFETY

SAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions 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.

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous. Read the OPERATION & 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.

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 operating 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.

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

Before adding oil or making 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, support the machine with blocks, jacks or stands before starting work.

150A/FA

00-3

FOREWORD 4.

SAFETY

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.

PRECAUTIONS DURING WORK

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.

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 carrying out any work on the oil or water circuits.

Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.

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 hitting any other part. Do not work with any part still raised by the hoist or crane.

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.

When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.

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.

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

Be sure to assemble all parts again in their original places. Replace any damaged part 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.

10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 11. 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. 12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 14. 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.

00-4

150A/FA

This is the sample of the manual if you need complete manual

Click Here to download

FOREWORD

SAFETY

12 ASBESTOS AND NON-ASBESTOS FIBERS

WARNING! ASBESTOS FIBER WARNING The procedures for servicing brakes are recommended to reduce exposure to asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are available from Meritor Heavy Vehicle Systems, LLC; 2135 West Maple Road; Troy MI. 48084 HAZARD SUMMARY Because some brake linings contain asbestos, workers who service brakes must understand the potential hazards of asbestos and precautions for reducing risks. Exposure to airborne asbestos dust can cause serious and possibly fatal diseases, including asbestosis (a chronic lung disease) and cancer, principally lung cancer and mesothelioma (a cancer of the lining of the chest or abdominal cavities). Some studies show that the risk of lung cancer among persons who smoke and who are exposed to asbestos is much greater than the risk for non-smokers. Symptoms of these diseases may not become apparent for 15, 20 or more years after the first exposure to asbestos. Accordingly, workers must use caution to avoid creating and breathing dust when servicing brakes. Specific recommended work practices for reducing exposure to asbestos dust follow. Consult your employer for more details. RECOMMENDED WORK PRACTICES 1.

Separate Work Areas. Whenever feasible, service brakes in a separate area away from other operations to reduce risks to unprotected persons. OSHA has set a maximum allowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average and 1.0 f/cc averaged over a 30-minute period. Scientists disagree, however, to what extent adherence to the maximum allowable exposure levels will eliminate the risk of disease that can result from inhaling asbestos dust. OSHA requires that the following sign be posted at the entrance to areas where exposures exceed either of the maximum allowable levels: DANGER: ASBESTOS CANCER AND LUNG DISEASE HAZARD AUTHORIZED PERSONNEL ONLY RESPIRATORS AND PROTECTIVE CLOTHING ARE REQUIRED IN THIS AREA Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, beginning with the removal of the wheels. Procedures for Servicing Brakes. A. Enclose the brake assembly within a negative pressure enclosure. The enclosure should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts. B. As an alternative procedure, use a catch basin with water and a biodegradable, non-phosphate, water-based detergent to wash the brake drum or rotor and other brake parts. The solution should be applied with low pressure to prevent dust from becoming airborne. Allow the solution to flow between the brake drum and the brake support or the brake rotor and caliper. The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth. C. If an enclosed vacuum system or brake washing equipment is not available, employers may adopt their own written procedures for servicing brakes, provided that the exposure levels associated with the employer’s procedures do not exceed the levels associated with the enclosed vacuum system or brake washing equipment. Consult OSHA regulations for more details. D. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use with asbestos when grinding or machining brake linings. In addition, do such work in an area with a local exhaust ventilation system equipped with a HEPA filter. E. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents, flammable solvents, or solvents that can damage brake components as wetting agents.

150A/FA

00-5

FOREWORD 4.

SAFETY

Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter with care. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not shake or use compressed air to remove dust from work clothes. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste disposal.

REGULATORY GUIDANCE References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United States, are made to provide further guidance to employers and workers employed within the United States. Employers and workers employed outside of the United States should consult the regulations that apply to them for further guidance. WARNING! NON-ASBESTOS FIBERS WARNING The following procedures for servicing brakes are recommended to reduce exposure to non-asbestos fiber dust, a potential cancer and lung disease hazard. Material Safety Data Sheets are available from Meritor Heavy Vehicle Systems, LLC; 2135 West Maple Road; Troy MI. 48084 HAZARD SUMMARY Most recently manufactured brake linings do not contain asbestos fibers. These brake linings may contain one or more of a variety of ingredients, including glass fibers, mineral wool, aramid fibers, ceramic fibers and silica that can present health risks if inhaled. Scientists disagree on the extent of the risks from exposure to these substances. Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous lung disease. Silicosis gradually reduces lung capacity and efficiency and can result in serious breathing difficulty. Some medical experts believe other types of non-asbestos fibers, when inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic fiber dust are known to the State of California to cause lung cancer. U.S. and international agencies have also determined that dust from mineral wool, ceramic fibers and silica are potential causes of cancer. Accordingly, workers must use caution to avoid creating and breathing dust when servicing brakes. Specific recommended work practices for reducing exposure to non-asbestos dust follow. Consult your employer for more details. RECOMMENDED WORK PRACTICES 1. 2.

Separate Work Areas. Whenever feasible, service brakes in a separate area away from other operations to reduce risks to unprotected persons. Respiratory Protection. OSHA has set a maximum allowable level of exposure for silica of 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-asbestos brake linings recommend that exposures to other ingredients found in non-asbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average. Scientists disagree, however, to what extent adherence to these maximum allowable exposure levels will eliminate the risk of disease that can result from inhaling non-asbestos dust. Therefore, wear respiratory protection at all times during brake servicing, beginning with the removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA) filter approved by NIOSH or MSHA, if the exposures levels may exceed OSHA or manufacturer’s recommended maximum levels. Even when exposures are expected to be within the maximum allowable levels, wearing such a respirator at all times during brake servicing will help minimize exposure. Procedures for Servicing Brakes. A. Enclose the brake assembly within a negative pressure enclosure. The enclosure should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts.

150A/FA

00-6

FOREWORD

SAFETY

B. As an alternative procedure, use a catch basin with water and a biodegradable, non-phosphate, water-based detergent to wash the brake drum or rotor and other brake parts. The solution should be applied with low pressure to prevent dust from becoming airborne. Allow the solution to flow between the brake drum and the brake support or the brake rotor and caliper. The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth. C. If an enclosed vacuum system or brake washing equipment is not available, carefully clean the brake parts in the open air. Wet the parts with a solution applied with a pump-spray bottle that creates a fine mist. Use a solution containing water, and, if available, a biodegradable, non-phosphate, water-based detergent. The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth. D. Wear a respirator equipped with a HEPA filter approved by NIOSH of MSHA when grinding or machining brake linings. In addition, do such work in an area with a local exhaust ventilation system equipped with a HEPA filter. E. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents, flammable solvents, or solvents that can damage brake components as wetting agents. 4.

Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA, if the exposure levels may exceed OSHA or manufacturers’ recommended maximum levels. When you replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter with care. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not shake or use compressed air to remove dust from work clothes. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste disposal.

150A/FA

00-7

FOREWORD

GENERAL

12 GENERAL

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 the following sections. These sections are further divided into each main group of components.

00 - INTRODUCTION This section contains general maintenance safety procedures, general torque values and conversion charts. 01 - GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. 10 - STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 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. In addition, this section also gives the judgement standards when inspecting disassembled parts. 20 - TESTING, ADJUSTING AND TROUBLESHOOTING 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. 30 - 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. 90 - OTHER This section has all “FOLDOUTS” listed in the other sections.

NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.

00-8

150A/FA

FOREWORD

HOW TO READ THE SHOP MANUAL

12 HOW TO READ THE SHOP MANUAL

VOLUMES

REVISIONS

Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.

Chassis volume: Engine volume:

SYMBOLS

Issued for every machine model Issued for each engine series

Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available.

DISTRIBUTION AND UPDATING

FILING METHOD 1. 2.

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

Remarks

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.

Tightening torque

Places that require special attention for tightening torque during assembly.

Coat

Places to be coated with adhesives and lubricants etc.

Oil, water

Places where oil, water or fuel must be added, and the capacity.

Drain

Places where oil or water must be drained, and quantity to be drained.

Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work. 00

See the page number on the bottom of the page. File the pages in correct order. Following examples show how to read the page number: Example: 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item

Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example:

10-4 10-4-1 10-4-2

Added pages

10-5

REVISED EDITION MARK When a manual is revised, an edition mark ( recorded on the bottom outside corner of the pages.

150A/FA

…) is

00-9

FOREWORD

GENERAL MACHINE HOISTING INSTRUCTIONS

12 GENERAL MACHINE HOISTING INSTRUCTIONS

GENERAL MACHINE HOISTING

can result. Hooks have maximum strength at the middle portion.

WARNING! 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

1. 2.

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 interface with the part to be removed.

GENERAL MACHINE WIRE ROPES 1.

WARNING! 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

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) Rope diameter

Allowable load

tons

9.8

1.0

11.2

13.7

1.4

12.5

15.7

1.6

21.6

2.2

27.5

2.8

35.3

3.6

43.1

4.4

22.4

54.9

5.6

98.1

10.0

176.5

18.0

274.6

28.0

392.2

40.0

Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.

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 (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 subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°.

The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident

00-10

150A/FA

FOREWORD

COATING MATERIALS

12 COATING MATERIALS

The recommended coating materials prescribed in the shop manuals are listed below.

Adhesives

2004 KOMATSU 150A FA Service Repair Shop Manual PDF Download