REVISEDPAGES
Theaffectedpagesareindicatedbytheuseofthe followingmarks.Itisrequestedthatnecessaryactions betakentothesepagesaccordingtotablebelow.
SymbolIndicationActionrequired Q PagetobenewlyAdd q PagetobereplacedReplace
()PagetobedeleteDiscard
Pageshavingnomarksarethosepreviouslyrevisedor madeadditions.
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kIMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine. TheserviceandrepairtechniquesrecommendedbyKomatsuUtilityanddescribeinthismanualareboth effectiveandsafemethodsofoperation.Someoftheseoperationsrequiretheuseoftoolsspeciallydesigned byKomatsuUtilityforthepurpose.
Topreventinjurytoworkers,thesymbolkisusedtomarksafetyprecautionsinthismanual.Thecautions accompanyingthesesymbolsshouldalwaysbecarefullyfollowed.Ifanydangerarisesormaypossiblyarise, firstconsidersafety,andtakenecessarystepstoface.
GENERALPRECAUTIONS
Mistakesinoperationextremelydangerous.Readallthe OperationandMaintenanceManualcarefullyBEFORE operatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,readall theprecautionswrittenonthedecalswhicharesuck onthemachine.
2.Whencarryingoutanyoperation,alwayswearsafety shoesandhelmet.Donotwearlooseworkclothes,or clotheswithbuttonsmissing.
Alwayswearsafetyglasseswhenhittingparts withahammer.
Alwayswearsafetyglasseswhengrindingparts withagrinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.Whencarrying outweldingwork,alwayswearweldinggloves,apron, glasses,capandotherclothessuitedforwelding work.
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure beforestarting.Alwaysinformyourfellowworkers beforestartinganystepoftheoperation.Before startingwork,hangUNDERREPAIRsignsonthe controlsintheoperatorscompartment.
5.Keepalltoolsingoodconditionandlearnthecorrect waytousethem.
6.Decideaplaceintherepairworkshoptokeeptools andremovedparts.Alwayskeepthetoolsandpartsin theircorrectplaces.Alwayskeeptheworkareaclean andmakesurethatthereisnodirtoroilonthefloor. Smokeonlyintheareasprovidedforsmoking.Never smokewhileworking.
PREPARATIONSFORWORK
7.Beforeaddingormakinganyrepairs,parkthe machineonhard,levelground,andblockthewheels topreventthemachinefrommoving.
8.Beforestartingwork,loweroutrigger,bucketorany otherworkequipmenttotheground.Ifthisisnot possible,useblockstopreventtheworkequipment fromfallingdown.Inaddition,besuretolockallthe controlleversandhangwarningsignonthem.
9.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbeforestarting work.
10.Removeallmudandoilfromthestepsorotherplaces usedtogetonandoffthemachine.Alwaysusethe handrails,laddersorstepswhengettingonoroffthe machine.Neverjumponoroffthemachine.Ifitis impossibletousethehandrails,laddersorsteps,use astandtoprovidesafefooting.
PRECAUTIONSDURINGWORK
11.Whenremovingtheoilfillercap,drainplugor hydraulicpressuremeasuringplugs,loosenthem slowlytopreventtheoilfromspurtingout.
Beforedisconnectingorremovingcomponentsofthe hydrauliccircuitandenginecoolingcircuit,first removethepressurecompletelyfromthecircuit.
12.Thewaterandoilinthecircuitsarenothotwhenthe engineinstopped,sobecarefulnottogetburned. Waitfortheoilwatertocoolbeforecarryingoutany workonthecoolingwatercircuits.
13.Beforestartingwork,removetheleadsfromthe battery.Alwaysremovetheleadfromthenegative( )terminalfirst.
14.Whenraisingheavycomponents,useahoistor crane.Checkthatthewirerope,chainsandhooks arefreefromdamage.
Alwaysuseliftingequipmentwhichhasample capacity.Installtheliftingequipmentatthecorrect places.Useahoistorcraneandoperateslowlyto preventthecomponentfromhittinganyotherpart. Donotworkwithanypartstillraisedbythehoistor crane.
15.Whenremovingcoverswhichareunderinternal pressureorunderpressurefromaspring,always leavetwoboltsinpositiononoppositesides.Slowly releasethepressure,thenslowlyloosentheboltsto remove.
16.Whenremovingcomponents,becarefulnotto breakordamagethewiring. Damagewiringmaycauseelectricalfires.
17.Whenremovingpiping,stopthefueloroilfrom spillingout.Ifanyfueloroildripsontothefloor,wipe itupimmediately.
Fueloroilonthefloorcancauseyoutoslip,orcan evenstartfires.
18.Asageneralrule,donotusegasolinetowashparts. Inparticular,useonlytheminimumofgasolinewhen washingelectricalparts.
19.Besuretoassembleallpartsagainintheiroriginal places.Replaceanydamagepartswithnewparts. Wheninstallinghosesandwires,besurethatthey willnotbedamagedbycontactwithotherparts whenthemachineisbeingoperated.
20.Wheninstallinghighpressurehoses,makesure thattheyarenottwisted.Damagedtubesare dangerous,sobeextremelycarefulwheninstalling tubesforhighpressurecircuits.Also,checkthat connectingpartsarecorrectlytightened.
21.Whenassemblingorinstallingparts,alwaysuse specifiedtighteningtorques.Wheninstallingthe partswhichvibrateviolentlyorrotateathighspeed, beparticularycarefultocheckthattheyarecorrectly installed.
22.Whenaligningtwoholes,neverinsertyourfingersor hand.
23.Whenmeasuringhydraulicpressure,checkthatthe measuringtooliscorrectlyassembledbeforetaking anymeasurement.
24.Takesurewhenremovingorinstallingtracks.When removingthetrack,thetrackseparatessuddenly,so neverletanyonestandateitherendofthetrack.
FOREWORD
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheoperatoranaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesure youunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaservice workshop.
Themanualisdividedintochaptersoneachmaingroupofcomponents;thesechaptersarefurtherdividedintothe followingsections.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstanding ofthestructure,butalsoservesasreferencematerialfortroubleshooting.
TESTINGANDADJUSTMENTS
Thissectionsexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobe madeatcompletionofthechecksandrepairs. Troubleshootingchartscorrelating«Problems»to«Causes»arealsoincludedinthissection.
REMOVALANDINSTALLATION
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeach component,aswellasprecautionstobetakenfortheseoperations.
STANDARDMAINTENANCE
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
NOTE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutany notice. ContactyourKomatsuUtilitydistributorforthelatestinformation.
VOLUMES
HOWTOREADTHESHOPMANUAL
Shopmanualareissuedasaguidetocarryoutrepairs. Thesevariousvolumesaredesignedtoavoid duplicatingthesameinformation.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbe senttoKomatsuUtilitydistributors.Getthemostup-todateinformationbeforeyoustartanywork.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage.File thepagesincorrectorder.
2.Followingexamplesshowyouhowtoreadthepage number.
Example:
3.Additionalpages:additionalpagesareindicatedby ahyphen()andnumberafterthepagenumber.Fle asintheexample.
Example:
REVISEDEDITIONMARK
Whenamanualisrevised,aneditionmarkisrecorded onthebottomoutsidecornerofthepages.
REVISIONS
RevisedpagesareshownontheLISTOFREVISED PAGESbetweenthetitlepageandSAFETYpage.
SYMBOLS
Inordertomaketheshopmanualgreatlychelpful, importantpointsaboutsafetyandqualityaremarked withthefollowingsymbols.
SymbolItemRemarks kSafety
Specialsafetyprecautionsare necessarywhenperformingthe work.
Extraspecialsafetyprecautions arenecessarywhenperforming theworkbecauseitisunder internalpressure.
aCaution
4Weight
3Tightening torque
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems. Cautionnecessarywhenselecting hoistingwire,orwhenworking postureisimportant,etc.
Partsthatrequirespecialattention forthetighteningtorqueduring assembly.
2CoatPartstobecoatedwithadhesives andlubricantsetc.
5Oil,waterPlaceswhereoil,waterorfuelmustbeadded,andtheirquantity.
6Drain
Placeswhereoilorwatermustbe drained,andquantitytobe drained.
HOISTINGINSTRUCTIONS
kHeavyparts(25kgormore)mustbeliftedwitha hoistetc.IntheRemovalandInstallationsection, everypartweighing25kgormoreisclearlyindicated withthesymbol4
1.Ifapartcannotbesmoothlyremovedfromthe machinebyhoisting,thefollowingchecksshouldbe made:
Checkforremovalofallboltsfasteningthepartto therelativeparts.
Checkforanypartcausinginterferencewiththe parttoberemoved.
2.Wireropes
1)Useadequateropesdependingontheweightof partstobehoisted,referringtothetablebelow:
WIREROPES
(Standard«S»or«Z»twistropes withoutgalvanizing)
Ropediameter(mm)Allowableload(tons)
Theallowableloadvalueisestimatedtobeonesixthorone-seventhofthebreakingstrengthofthe ropeused.
2)Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausethe ropetoslipoffthehookduringhoisting,anda
seriousaccidentcanresult.Hookshavemaximum strengthatthemiddleportion.
3)Donotslingaheavyloadwithoneropealone,but slingwithtwoormoreropessymmetricallywound ontotheload.
kSlingingwithoneropemaycauseturningoftheload duringhoisting,untwistingoftherope,orslippingof theropefromitsoriginalwindingpositiononthe load,whichcancausedangerousaccidents.
4)Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.
Whenhoistingaloadwithtwoormoreropes,the forcesubjectedtoeachropewillincreasewiththe hangingangles.Thetablebelowshowsthe variationofallowableload(kg)whenhoistingis madewithtworopes,eachofwhichisallowedto slingupto1000kgvertically,atvarioushanding angles.Whentworopesslingaloadvertically,upto 2000kgoftotalweightcanbesuspended. Thisweightbecomes1000kgwhentworopesmake a120°hangingangle.Ontheotherhand,tworopes aresubjectedtoanexcessiveforceaslargeas4000 kgiftheyslinga2000kgloadataliftingangleof 150°.
STANDARDTIGHTENINGTORQUE
STANDARDTIGHTENINGTORQUE
Thefollowingchartsgivethestandardtighteningtorquesofboltsandnuts. Exceptionsaregiveninsectionof«DisassemblyandAssembly».
1.STANDARDTIGHTENINGTORQUEOFBOLTSANDNUT
Thistorquetabledoesnotapplytoboltsornutswhichhavetofastennylonorotherpartsnon-ferrousmetalwasher. aNm(newtonmeter):1Nm=0.102kgm
2.TIGHTENINGTORQUEFORNUTSOFFLARED
Usethesetorquesfornutpartofflared.
Threaddiameter ofnutpart (mm)
1/2-20
9/16-18
3/4-16
7/8-14
1.1/16-12 1.5/16-12
Widthacrossflats ofnutpart (mm)
Usethesetorquesfornutpartofflared.
Threaddiameter ofnutpart (mm)
9/16-18
11/16-16
13/16-16
1-14
1.3/16-12
1.7/16-12
1.11/16-12
2-12
Sealingsurface
Widthacrossflats ofnutpart (mm) TIGHTENINGTORQUE
COATINGMATERIALS
TherecommendedcoatingmaterialsprescribedinKomatsuUtilityShopManualsarelistedbelow:
FunctionCodeApplications
ASL800010Usedtoapplyrubberpads,rubbergasketsandcorkplugs.
ASL800020Usedtoapplyresin,rubber,metallicandnon-metallicpartswhenafast,strongseal isneeded.
Loctite222Usedforlowresistancelockingofscrews,checknutsandadjustmentnuts.
Loctite242
Adhesives
Gasketsealant
Topreventthelooseningofbolts,nutsandplugsandtheleakageofoil.Usedfor mediumresistancelockingofscrewsandnutsofeverytype,andforlockingkeys andbearings.
Loctite262Usedforhighresistantofthreadedpartsthatcanberemovedwithnormaltools.
Loctite270Usedforhighresistantlockingandforsealingthreadedparts,boltsandstudbolts.
Loctite542Usedforsealingtheunionthreadsforhydraulictubes.
Loctite573Usedforsealingratherexactplanesurfaceswhentheoptionofpossiblefuture dismantlingisrequired.
Loctite601Usedforhighresistantlockingofmechanicalcomponentsthatcanberemovedonly afterheating
Loctite675Usedtolockcylindricalcouplingsandforthepermanentlockingofthreadedparts, andalsotolockshaftstobearings,gears,pulleys,pins,bushings,etc.
ASL800060Usedbyitselftosealgreasefittings,taperedscrewfittingsandtaperedscrew fittingsinhydrauliccircuitsoflessthan50mmindiameter.
Loctite510Usedbyitselfonmountingflatsurface
(Clearancebetweensurfaceswithin0.2mm)
Usedbyitselfonmountingflatsurface
Loctite518
Antifrictioncompound
(Lubricantincluding Molybdenumdisulfide)
(Clearancebetweensurfaceswithin0.5mm)
ASL800040Appliedtobearingsandtapershafttofacilitatepress-fittingandtopreventsticking, burningorrusting.
Grease (Lithiumgrease)ASL800050Appliedtobearings,slidingpartsandoilsealsforlubrication,rustpreventionand facilitationofassemblingwork.
Vaseline
Usedforprotectingbatteryelectrodeterminalsfromcorrosion
ELECTRIC
Inthewiringdiagramsvariouscolourandsymbolsareemployedtoindicatethethicknessofwires. ThiswirecodetablewillhelpyouunderstandWIRINGDIAGRAMS.
Example:RN1.5indicatesacablehavinganominalnumber1.5andredcoatingwithblackstripe.
CLASSIFICATIONBYTHICKNESS
Currentrating (A) NumberstrandsØofstrands(mm)Crosssection(mm) 0.5160.200.351.553.5 1140.300.992.8011 1.5210.301.483.3514 2.5350.302.473.8020 4560.303.954.6028 6840.305.935.2037
CLASSIFICATIONBYCOLOURANDCODE
PrimaryAuxiliary
CodeAA-BA/BA-GA-NA/NA-RA-VA/V
ColourLightBlueLightBlueWhiteLightBlueYellowLightBlueBlackLightBlueRedLightBlueGreen CodeBB-GB-NB/NB-RB/R
ColourWhiteWhiteYellowWhiteBlackWhiteRed CodeCC-BC/BC-LC-NC/N
ColourOrangeOrangeWhiteOrangeBlueOrangeBlack CodeGG-NG/NG/R
ColourYellowYellowBlackYellowRed CodeHH-GH-LH-NH-RH/R
ColourGreyGreyYellowGreyBlueGreyBlackGreyRed CodeLL/BL-GL/GL-NL/NL-RL/R
ColourBlueBlueWhiteBlueYellowBlueBlackBlueRed CodeMM-BM/BM-NM-V
ColourBrownBrownWhiteBrownBlackBrownGreen CodeN
ColourBlack
CodeRR-GR-NR/NR-V
ColourRedRedYellowRedBlackRedGreen CodeSS-GS-NS/N
ColourPinkPinkYellowPinkBlack CodeVV-BV/BV-N
ColourGreenGreenWhiteGreenBlack CodeZZ-BZ-NZ/N
ColourVioletVioletWhiteVioletBlack
COMPOSITIONOFTHECOLOURS
Thecolorationoftwo-colourwiresisindicatedbythecompositionofthesymbollisted. Example:GV=Yellow-Greenwithlongitudinalcolouring G/V=Yellow-Greenwithtransversalcolouring
Thisweighttableisaguideforusewhentransportingorhandlingcomponents.
aASTMD975N.1
aaSpecialredpermanentantifreezecompatiblewithaluminiumradiators.Ifpure,dilutewithwater (50%).
ASTM:AmericanSocietyofTestingandMaterials
SAE:SocietyofAutomotiveEngineers
API:AmericanPetroleumInstitute
Firstfillingquantity: totalquantityofoil,includingtheoilforthecomponentsandpipes.
Oilchangequantity: quantityofoilnecessarytofillthesystemorunitduringthenormalinspectionandmaintenanceoperations.