MOTORGRADER
ThismaterialisproprietarytoKomatsuAmericaCorp/andisnottobereproduced,used,ordisclosedexceptinaccordance withwrittenauthorizationfromKomatsuAmericaCorp.
Itisourpolicytoimproveourproductswheneveritispossibleandpracticaltodoso.Wereservetherighttomakechangesor addimprovementsatanytimewithoutincurringanyobligationtoinstallsuchchangesonproductssoldpreviously.
Duetothiscontinuousprogramofresearchanddevelopment,periodicrevisionsmaybemadetothispublication.Itis recommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision.
10STRUCTUREANDFUNCTION
20TESTING,ADJUSTINGANDTROUBLESHOOTING.
30DISASSEMBLYANDASSEMBLY.
40MAINTENANCESTANDARD
90OTHER.
PRODUCTPUBLICATIONSINFORMATION
VariousproductPartsandServicePublicationsareavailabletoallKOMATSUconstructionequipment owners,includingoperationandmaintenancemanuals,partsbooksandservicemanuals.
Specialpublications,suchasservicetool,airconditioningandturbochargerservicemanualsarealso availableaswellasselectedOperationandServicemanualsinforeignlanguages.
ThePublicationslistedbelowareavailableforthisparticularmachine(s).
DESCRIPTIONFORMNUMBER
PARTSBOOK-PAPER:
ChassisandEngine830B/C...................................BEPB002801
ChassisandEngine850B/C...................................BEPBG58612
ChassisandEngine870B/C...................................BEPBG78100
OPERATIONANDMAINTENANCEMANUAL:
ChassisandEngine.........................................CEAM009800
SHOPMANUAL
Chassis..................................................CEBM011200 Engine114E-2Series.......................................CEBM000601 Engine102E-2Series........................................SEBM010016
SAFETYMANUAL
Machinespecific.............................................1085960R2
PartsandServicePublicationscanonlybeacquiredbyauthorizedKOMATSUdistributorsusingthe KomatsuAmericaCorp.ExtranetLiteratureOrderingSystem.
IftheExtranetLiteratureOrderingSystemisnotavailableatthedistributorlocation,thenthefollowing RequisitionforTechnicalServicePublicationsandServiceFormscanbeused.FormKDC91Eisshown onthereversesideofthispage.KomatsuAmericaCorp.reservestherighttoaddasurchargetoallfax orders.
COMPLETEFORM ANDRETURNTO
DataKomPublicationsandTrainingDivision
440NorthFairwayDrive
VernonHills,IL60061-8112U.S.A.
Attn:ServicePublications
FaxNo.(847)970-4186
TelNo.(847)970-5887
IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERAND MACHINESERIALNUMBERMUSTBESHOWN.
QTY.PUBLICATIONFORMNO.PARTSBOOKPUBLICATION DESCRIPTION
P-Paper M-Microfiche
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.Thecautions accompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise, firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONS
Mistakesinoperationareextremelydangerous.ReadtheOPERATION&MAINTENANCEMANUALcarefullyBEFORE operatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,readalltheprecautionsgivenonthedecalswhicharefixedtothemachine.
2.Whencarryingoutanyoperation,alwayswearsafetyshoesandhelmet.Donotwearlooseworkclothes,orclotheswith buttonsmissing.
Alwayswearsafetyglasseswhenhittingpartswithahammer.
Alwayswearsafetyglasseswhengrindingpartswithagrinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained,experiencedweldercarryoutthework.Whencarryingoutwelding work,alwayswearweldinggloves,apron,glasses,capandotherclothessuitedforweldingwork.
4.Whencarryingoutanyoperationwithtwoormoreworkers,alwaysagreeontheoperatingprocedurebeforestarting. Alwaysinformyourfellowworkersbeforestartinganystepoftheoperation.Beforestartingwork,hangUNDER REPAIRsignsonthecontrolsintheoperator'scompartment.
5.Keepalltoolsingoodconditionandlearnthecorrectwaytousethem.
6.Decideaplaceintherepairworkshoptokeeptoolsandremovedparts.Alwayskeepthetoolsandpartsintheircorrect places.Alwayskeeptheworkareacleanandmakesurethatthereisnodirtoroilonthefloor.Smokeonlyintheareas providedforsmoking.Neversmokewhileworking.
PREPARATIONSFORWORK
1.Beforeaddingoilormakingrepairs,parkthemachineonhard,levelground,andblockthewheelsortrackstopreventthe machinefrommoving.
2.Beforestartingwork,lowerblade,ripper,bucketoranyotherworkequipmenttotheground.Ifthisisnot possible,insertthesafetypinoruseblockstopreventtheworkequipmentfromfalling.Inaddition,besuretolockallthe controlleversandhangwarningsignsonthem.
3.Whendisassemblingorassembling,supportthemachinewithblocks,jacksorstandsbeforestartingwork.
4.Removeallmudandoilfromthestepsorotherplacesusedtogetonandoffthemachine.Alwaysusethehandrails, laddersorstepswhengettingonoroffthemachine.Neverjumponoroffthemachine.Ifitisimpossibletousethe handrails,laddersorsteps,useastandtoprovidesafefooting.
PRECAUTIONSDURINGWORK
1.Whenremovingtheoilfillercap,drainplugor hydraulicpressuremeasuringplugs,loosenthemslowlytopreventtheoilfromspurtingout.Before disconnectingorremovingcomponentsoftheoil,wateroraircircuits,firstremovethepressurecompletelyfromthe circuit.
2.Thewaterandoilinthecircuitsarehotwhentheengineisstopped,sobecarefulnottogetburned.Waitfortheoiland watertocoolbeforecarryingoutanyworkontheoilorwatercircuits.
3.Beforestartingwork,removetheleadsfromthebattery.ALWAYSremovetheleadfromthenegative(-) terminalfirst.
4.Whenraisingheavycomponents,useahoistorcrane.Checkthatthewirerope,chainsandhooksarefreefromdamage. Alwaysuseliftingequipmentwhichhasamplecapacity.Installtheliftingequipmentatthecorrectplaces.Useahoistor craneandoperateslowlytopreventthecomponentfromhittinganyotherpart.Donotworkwithanypartstillraisedby thehoistorcrane.
5.Whenremovingcoverswhichareunderinternalpressureorunderpressurefromaspring,alwaysleavetwoboltsin positiononoppositesides.Slowlyreleasethepressure,thenslowlyloosentheboltstoremove.
6.Whenremovingcomponents,becarefulnottobreakordamagethewiring,Damagedwiringmaycauseelectricalfires.
7.Whenremovingpiping,stopthefueloroilfromspillingout.Ifanyfueloroildripsontothefloor,wipeitupimmediately. Fueloroilonthefloorcancauseyoutoslip,orcanevenstartfires.
8.Asageneralrule,donotusegasolinetowashparts.Inparticular,useonlytheminimumofgasolinewhenwashing electricalparts.
9.Besuretoassembleallpartsagainintheiroriginalplaces.Replaceanydamagedpartwithnewparts.
Wheninstallinghosesandwires,besurethattheywillnotbedamagedbycontactwithotherpartswhenthemachine isbeingoperated.
10.Wheninstallinghighpressurehoses,makesurethattheyarenottwisted.Damagedtubesaredangerous,sobeextremely carefulwheninstallingtubesforhighpressurecircuits.Alsocheckthatconnectingpartsarecorrectlyinstalled.
11.Whenassemblingorinstallingparts,alwaysusethespecifiedtighteningtorques.Wheninstallingprotectivepartssuchas guards,orpartswhichvibrateviolentlyorrotateathighspeed,beparticularlycarefultocheckthattheyareinstalled correctly.
12.Whenaligningtwoholes,neverinsertyourfingersorhand.Becarefulnottogetyourfingerscaughtinahole.
13.Whenmeasuringhydraulicpressure,checkthatthemeasuringtooliscorrectlyassembledbeforetakingany measurements.
14.Takecarewhenremovingorinstallingthetracksoftrack-typemachines.Whenremovingthetrack,thetrackseparates suddenly,soneverletanyonestandateitherendofthetrack.
12 GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesureyou understandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.For easeofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeachmain groupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel,coolantand lubricantspecificationcharts.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingofthe structure,butalsoservesasreferencematerialfortroubleshooting.
TESTING,ADJUSTINGANDTROUBLESHOOTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemadeat completionofthechecksandrepairs.TroubleshootingchartscorrelatingProblemstoCausesarealsoincludedinthis section.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeachcomponent, aswellasprecautionstobetakenfortheseoperations.
MAINTENANCESTANDARD
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvancenotice.Contact yourdistributorforthelatestinformation.
12 HOWTOREADTHESHOPMANUAL
REVISIONS
Shopmanualsareissuedasaguidetocarryingoutrepairs. Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel
Enginevolume:Issuedforeachengineseries
Electricalvolume:Eachissuedasonetocoverallmodels
Attachmentvolume:Eachissuedasonetocoverallmodels
Thesevariousvolumesaredesignedtoavoidduplicationof information.Thereforetodealwithallrepairsforanymodel, itisnecessarythatchassis,engine,electricalandattachment beavailable.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbesentto yourdistributors.Getthemostup-to-dateinformationbefore youstartanywork.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage.Filethe pagesincorrectorder.
2.Followingexamplesshowhowtoreadthepagenumber: Example: 10-3
Itemnumber(10.StructureandFunction)
Consecutivepagenumberforeachitem
3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.Fileas intheexample. Example:
RevisedpagesareshownattheLISTOFREVISEDPAGES betweenthetitlepageandSAFETYpage.
SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwiththe followingsymbols.
SymbolItemRemarks
Safety
Specialsafetyprecautionsare necessarywhenperformingthe work. Caution
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weight
Tightening torque
Weightofpartsorsystems. Cautionnecessarywhen selectinghoistingwireorwhen workingpostureisimportant, etc.
Placesthatrequirespecial attentionfortighteningtorque duringassembly.
CoatPlacestobecoatedwithadhesivesandlubricantsetc.
Oil,waterPlaceswhereoil,waterorfuel mustbeadded,andthecapacity.
Drain
Placeswhereoilorwatermust bedrained,andquantitytobe drained.
Whenamanualisrevised,aneditionmark( )is recordedonthebottomoutsidecornerofthepages.
12 HOISTINGINSTRUCTIONS
HOISTING
WARNING!Heavyparts(25kgormore) mustbeliftedwithahoistetc.In theDISASSEMBLYAND ASSEMBLYsection,everypart weighing25kgormoreis indicatedclearlywiththesymbol
Ifapartcannotbesmoothlyremovedfromthemachine byhoisting,thefollowingchecksshouldbemade:
1.Checkforremovalofallboltsfasteningtheparttothe relativeparts.
2.Checkforexistenceofanotherpartcausinginterface withtheparttoberemoved.
WIREROPES
1.Useadequateropesdependingontheweightofpartsto behoisted,referringtothetablebelow:
Wireropes (StandardZorStwistropeswithoutgalvanizing)
Theallowableloadvalueisestimatedtobe1/6or1/7of thebreakingstrengthoftheropeused.
2.Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausetheropeto slipoffthehookduringhoisting,andaseriousaccident
canresult.Hookshavemaximumstrengthatthemiddle portion.
3.Donotslingaheavyloadwithoneropealone,butsling withtwoormoreropessymmetricallywoundontothe load.
WARNING!Slingingwithoneropemay causeturningoftheloadduring hoisting,untwistingoftherope, orslippingoftheropefromits originalwindingpositiononthe load,whichcanresultinadangerousaccident
4.Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.Whenhoistingaloadwith twoormoreropes,theforcesubjectedtoeachropewill increasewiththehangingangles.Thetablebelow showsthevariationofallowableload(kg)when hoistingismadewithtworopes,eachofwhichis allowedtoslingupto1000kgvertically,atvarious hangingangles.Whentworopesslingaloadvertically, upto2000kgoftotalweightcanbesuspended.This weightbecomes1000kgwhentworopesmakea120° hangingangle.Ontheotherhand,tworopesaresubject toanexcessiveforceaslargeas4000kgiftheyslinga 2000kgloadataliftingangleof150°
