SEBM00231
Printed in Japan
-1 (01)
00-1 (1 )
LIST OF REVISED PAGES
Notice of revision 11th revision The affected pages are indicated by the use of the following marks. It is requested that necessary actions must be taken to these pages according to the list below.
2019/07 Mark
Indication
Action required
Q
Page to be newly added
Add
q
Page to be replaced
Replace
()
Page to be deleted
Discard
List of revised pages Mark
Page
q
00-1 00-2 00-2-1 00-2-2 00-2-3 00-2-4 00-2-5 00-3 00-4 00-5 00-6 00-7 00-8 00-9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 00-19 00-20 00-21 00-22 00-23 00-24 00-25 00-26 00-27 00-28 00-29 00-30 00-31 00-32 00-33 00-34 00-35 00-36
q q q q
Revision number (11) (11) (11) (10) (11) (11) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7)
Mark
Page
Revision number
00-37 00-38 00-39 00-40 00-41
(7) (7) (7) (7) (7)
01-1 01-2 01-3 01-4 01-5 01-6 01-7 01-8 01-9
(2) (2) (2) (2) (2) (2) (2) (2) (2)
10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-7-1 10-7-2 10-8 10-10 10-11 10-11-1 10-11-1-1 10-11-2 10-12 10-13 10-14 10-15 10-16 10-17 10-18 10-19 10-20 10-21
(2) (2)
(2) (2) (2) (2) (2) (4) (9) (9) (2) (6) (4) (6) (4) (2)
Mark
Page 10-22 10-23 10-24 10-25 10-26 10-27 10-28 10-29 10-29-1 10-29-2 10-29-3 10-29-4 10-29-5 10-29-6 10-29-7 10-29-8 10-29-9 10-29-10 10-29-11 10-29-12 10-29-13 10-29-14 10-30 10-31 10-31-1 10-31-2 10-31-3 10-31-4 10-31-5 10-31-6 10-32 10-33 10-34 10-35 10-36 10-37 10-39 10-40 10-41 10-42 10-43
Revision number
(2) (4) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (4) (2) (4) (4)
(2) (2) (2) (2) (6) (6) (2)
Mark
Page 10-44 10-45 10-46 10-47 10-48 10-49 10-50 10-51 10-51-1 10-51-2 10-51-3 10-52 10-52-1 10-53 10-54 10-55 10-57 10-58 10-59 10-60 10-61 10-62 10-63 10-64 10-65 10-66 10-67 10-68 10-69 10-70 10-71 10-72 10-73 10-74 10-75 10-76 10-77 10-78 10-79 10-79-1 10-79-2
Revision number (2) (2) (2) (2)
(2) (4) (6) (6) (2) (2)
(2) (2)
(4) (4)
(2) (2) (2) (2) (2) (2) (2)
00-2-1 (11)
LIST OF REVISED PAGES
Mark
Page 10-79-3 10-79-4 10-80 10-80-2 10-80-3 10-80-4 10-80-6 10-80-7 10-80-8 10-80-10 10-80-11 10-80-12 10-81-1 10-81-2 10-81-3 10-82 10-83 10-84 10-85 10-86 10-87 10-88 10-89 10-90 10-91 10-92 10-93 10-94 10-95 10-96 10-97 10-97-1 10-97-2 10-98 10-99 10-100 10-100-1 10-100-2 10-100-3 10-100-4 10-101 10-102 10-103 10-104 10-105 10-106 10-107 10-108 10-109 10-110 10-111 10-112
00-2-2 (11)
Revision number (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (1) (1) (1) (2)
(2)
(2) (2) (2) (2) (2)
(2) (2) (2) (2) (2)
(2) (2) (2) (2) (2) (2) (2)
Mark
Page 10-113 10-113-1 10-113-2 10-113-3 10-113-4 10-114 10-115 10-116 10-117 10-118 10-119 10-120 10-120-1 10-120-2 10-120-3 10-120-4 10-121 10-122 10-123 10-123-1 10-124 10-125 10-126 10-127 10-128 10-129 10-130 10-131 10-132 10-134 10-135 10-136 10-136-1 10-137 10-138 10-140 10-141 10-141-2 10-142 10-142-1 10-143 10-144 10-145 10-146-1 10-146-3 10-146-5 10-146-7 10-146-9 10-146-11 10-147 10-148 10-149
Revision number
Mark
(2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (6) (6) (6) (6) (6) (6) (6) (6) (6) (2) (2) (2) (2) (2) (2) (2) (2) (2) (4) (4) (6) (6) (2) (2) (4) (2) (6) (4) (6) (6) (6) (2) (6) (6) (6) (6) (6) (6) (2) (2) (2)
q
Page
Revision number
10-150 10-151 10-152 10-153 10-154 10-155 10-155-1 10-155-2 10-155-3 10-156 10-156-1 10-157 10-158 10-159 10-160 10-161 10-162 10-163 10-164 10-165 10-166 10-166-1 10-166-2 10-167 10-168 10-169 10-170 10-171 10-172 10-173
(2) (2) (2) (4) (2) (2) (4) (4) (4) (6) (6) (2) (2) (2) (2) (2) (2) (2) (2) (2) (4) (6) (6) (2) (2) (2) (4) (6) (6) (6)
20-1 20-2 20-3 20-3-1 20-4 20-5 20-6 20-7 20-7-1 20-8 20-9 20-10 20-11 20-12 20-13 20-13-1 20-14 20-15 20-16 20-17 20-18
(10) (2) (9) (11) (3) (3) (3) (3) (5) (5) (2) (2) (2) (2) (2) (5)
(9)
Mark
Page 20-19 20-19-1 20-19-2 20-19-3 20-20 20-21 20-22 20-23 20-23-1 20-24 20-25 20-26 20-27 20-28 20-29 20-30 20-31 20-32 20-33 20-34 20-35 20-36 20-37 20-38 20-39 20-40 20-41 20-42 20-43 20-45 20-46 20-47 20-48 20-49 20-50 20-51 20-52 20-53 20-54 20-55 20-55-1 20-56 20-57 20-58 20-59 20-59-1 20-59-2 20-60 20-60-1 20-60-2 20-60-3 20-60-4
Revision number (10) (10) (10) (10)
(2) (5) (5) (5)
(6) (6)
(5)
(2) (2) (2) (2) (2) (2) (6) (2) (2) (5) (2) (2) (5) (5) (5) (5) (5) (5) (5) (5) (5) (2) (2) (4) (2) (4) (4) (2) (2) (2) (2) (4)
LIST OF REVISED PAGES
Mark
Page
Revision number
20-60-5 20-60-6 20-60-8 20-60-9 20-60-10 20-60-49 20-60-50 20-60-51 20-60-52 20-60-53 20-60-54 20-60-55 20-60-56 20-60-57 20-60-59 20-60-60 20-60-61 20-60-62 20-60-63 20-60-64 20-60-65 20-60-66 20-60-67 20-60-68 20-60-69 20-60-70 20-60-71 20-60-72 20-60-73 20-60-74 20-60-75 20-60-76 20-60-77 20-60-78 20-60-79 20-60-80 20-60-81 20-60-82 20-60-83 20-60-84 20-60-85 20-60-86 20-60-87 20-60-88 20-60-89 20-60-90 20-60-91 20-60-92 20-60-93 20-60-94 20-60-95 20-60-96
(2) (2) (4) (4) (4) (4) (4) (4) (6) (4) (4) (6) (6) (6) (6) (6) (6) (6) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7)
Mark
Page 20-60-97 20-60-98 20-60-99 20-60-100 20-60-101 20-60-102 20-60-103 20-60-104 20-60-105 20-60-106 20-60-107 20-61 20-62 20-63 20-64 20-65 20-66 20-67 20-68 20-69 20-70 20-71 20-72 20-73 20-74 20-75 20-76 20-77 20-78 20-79 20-81 20-82 20-83 20-84 20-85 20-85-1 20-86 20-87 20-88 20-89 20-90 20-90-1 20-91 20-92 20-92-1 20-93 20-94 20-95 20-96 20-97 20-98 20-99
Revision number (7) (7) (7) (7) (7) (5) (5) (5) (5) (5) (5) (2)
(2)
(4) (4) (4) (4) (4) (4) (4) (4)
(4)
Mark
Page
Revision number
20-101 20-102 20-103 20-104 20-105 20-105-1 20-106 20-107 20-108 20-109 20-110 20-110-1 20-111 20-112 20-112-1 20-113 20-114 20-115 20-116 20-151 20-152 20-153 20-153-1 20-153-2 20-154 20-155 20-156 20-157 20-158 20-159 20-160 20-161 20-162 20-163 20-164 20-165 20-166 20-167 20-168 20-169 20-170 20-171 20-172 20-173 20-174 20-175 20-175-1 20-176 20-177 20-178 20-179 20-180
(2) (2) (2) (2) (4) (4) (2) (4) (4) (2) (4) (4) (2) (4) (4) (2) (2) (2) (2) (8) (8) (2) (8) (8) (2) (8) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (4) (4) (4) (4) (2) (4) (4) (4) (4)
Mark
Page
Revision number
20-181 20-182 20-183 20-184 20-185 20-186 20-187 20-188 20-189 20-190 20-191 20-192 20-193 20-194 20-195 20-196 20-197 20-198 20-201 20-202 20-204 20-205 20-206 20-207 20-208 20-209 20-210 20-211 20-212
(4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (8) (8) (8) (8) (8) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2)
30-1 30-1-1 30-1-2 30-1-3 30-1-4 30-1-5 30-1-6 30-2 30-3 30-4 30-4-1 30-4-2 30-5 30-6 30-7 30-8 30-9 30-10 30-11 30-12 30-13 30-14
(9) (6) (7) (7) (6) (6) (6) (6) (6) (2) (2) (2) (2) (2) (2) (1) (1) (1) (1) (1) (1) (1)
00-2-3 (10)
LIST OF REVISED PAGES
Page
Revision number
30-15 30-16 30-17 30-18 30-18-1 30-19 30-20 30-21 30-22 30-23 30-24 30-25 30-26 30-27 30-28 30-28-1 30-29 30-30 30-31 30-32 30-33 30-34 30-35 30-36 30-37 30-38 30-39 30-40 30-41 30-42 30-43 30-44 30-45 30-45-1 30-45-2 30-45-3 30-45-4 30-45-5 30-45-6 30-45-7 30-45-8 30-46 30-47 30-48 30-49 30-50 30-51 30-52 30-53 30-54 30-55 30-56
(1) (1) (1) (2) (2) (1) (1) (1) (1) (1) (1) (1) (1) (1) (2) (2) (1) (1) (1) (1) (1) (1) (2) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (2) (2) (2) (2) (2) (2) (2) (2) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)
Mark
00-2-4 (11)
Mark
Page
Revision number
30-57 30-58 30-59 30-60 30-61 30-62 30-63 30-64 30-65 30-66 30-67 30-68 30-69 30-70 30-71 30-72 30-73 30-74 30-75 30-76 30-77 30-78 30-79 30-80 30-81 30-82 30-83 30-84 30-85 30-86 30-87 30-88 30-89 30-90 30-91 30-92 30-93 30-94 30-95 30-96 30-97 30-98 30-99 30-100 30-101 30-102 30-103 30-104 30-105 30-106 30-107 30-108
(1) (1) (4) (4) (4) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (4) (4) (4) (4) (1) (1) (1) (4) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (10) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (10) (1) (1)
Mark
Page
Revision number
30-109 30-110 30-111 30-112 30-113 30-114 30-115 30-116 30-117 30-118 30-119 30-120 30-121 30-122 30-123 30-124 30-124-1 30-125 30-126 30-127 30-128 30-129 30-130 30-131 30-131-1 30-131-2 30-131-3 30-131-4 30-132 30-133 30-134 30-135 30-136 30-137 30-138 30-139 30-140 30-141 30-142 30-143 30-144 30-145 30-146 30-147 30-148 30-149 30-150 30-151 30-152 30-153 30-154 30-155
(1) (1) (1) (10) (1) (1) (1) (1) (1) (1) (1) (1) (9) (6) (6) (6) (6) (1) (1) (1) (1) (1) (1) (1) (9) (9) (9) (9) (1) (10) (1) (1) (1) (2) (1) (1) (2) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)
Mark
Page
Revision number
30-156 30-157 30-158 30-159 30-160 30-161 30-162 30-163 30-164 30-165 30-166 30-167 30-168 30-169 30-170 30-171 30-172 30-173 30-174 30-175 30-176 30-177 30-178 30-179 30-180 30-181 30-182 30-183 30-184 30-185 30-186 30-187 30-188 30-189 30-190 30-191 30-192 30-193 30-194 30-194-1 30-194-2 30-194-3 30-194-4 30-194-5 30-194-6 30-194-7 30-194-8 30-194-9 30-194-10 30-195 30-196 30-197
(1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (2) (1) (1) (1) (1) (1) (1) (2) (1) (1) (2) (1) (1) (1) (1) (1) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (1) (1) (1)
This is the sample of the manual Click on the download link for complete manual
Download Link
LIST OF REVISED PAGES
Mark
Page
Revision number
30-198 30-199 30-200 30-201 30-202 30-203 30-204 30-205 30-205-1 30-205-2 30-205-3 30-205-4 30-205-5 30-205-6 30-205-7 30-205-8 30-206 30-207 30-207-1 30-207-2 30-208 30-209 30-210 30-211 30-212 30-213 30-214 30-214-1 30-214-2 30-214-3 30-214-4 30-214-5 30-214-6 30-214-7 30-214-8 30-215 30-215-1 30-216 30-217 30-218 30-219 30-220 30-221 30-222 30-223 30-223-1 30-223-2 30-223-3 30-223-4 30-223-5 30-224 30-225
(1) (1) (1) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (2) (2) (2) (2) (2) (1) (1) (2) (2) (2) (2) (6) (2) (2) (2) (2) (2) (2) (2) (2) (2) (10) (2) (1) (2) (1) (2) (2) (2) (2) (2) (2) (6) (2) (2) (1)
Mark
Page
Revision number
30-226 30-227 30-228 30-229 30-230 30-231 30-232 30-233 30-234 30-235 30-236 30-237 30-238 30-239 30-240 30-241 30-242 30-243 30-244 30-245 30-246 30-247
(1) (1) (1) (2) (2) (2) (2) (2) (2) (2) (2) (2) (6) (5) (5) (6) (6) (6) (6) (6) (6) (6)
40-1 40-2 40-3 40-3-1 40-3-2 40-3-3 40-3-4 40-4 40-5 40-6 40-7 40-8 40-9 40-9-1 40-9-2 40-10 40-10-1 40-11 40-12 40-13 40-14 40-15 40-15-1 40-15-2 40-16 40-17 40-18 40-19 40-20
(2) (4)
Mark
Page
Revision number
40-21 40-21-1 40-21-2 40-22 40-23 40-23-1 40-23-2 40-24 40-26 40-27 40-27-1 40-27-2 40-28 40-29 40-29-1 40-29-2 40-30 40-31
(2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (6)
(9) (6) (9) (9) (4) (6) (4) (2) (2) (2) (2) (2) (2) (6) (4) (6) (6)
(2) (2)
00-2-5 (11)
Safety notice
(Rev. 2008/08)1
Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is 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. 1.
General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) 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, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) 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 hitq ting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 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 warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7)
8) 9)
If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld ing work , alwa y s we ar w eldin g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5
Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work 7
Wearing protective goggles (for cleaning or grinding work)
8
Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation 10
Precautions against work which you are not used to or you are used to too much
00- 3 (7)
2.
Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock 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. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) 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 m a c h i n e . N ev e r j u m p o n o r o f f t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
3.
Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engin e (measuring oil pressure , revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
00- 4 (7)
6)
When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused 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 operated. 11) 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. In addition, check t h a t c o n n e c t i n g pa r ts a re co r re c t ly installed. 12) When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a rly ca re f ul t o c h e c k t h at t h ey ar e installed correctly. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are correctly assembled. 15) 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. 16) If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
4.
Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 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. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. After the wire ropes are stretched, q stop the crane and check the condition of the slung load, wire ropes, and pads.
00- 5 (7)
If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
q
5.
6.
Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.
00- 6 (7)
7.
Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2)
a
Example of O-ring (Fitted to every joint of hoses and tubes)
a
For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a ) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings.
00- 7 (7)
How to read the shop manual q q q
1.
1
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) Chassis volume q This section gives hydraulic circuit diagrams and electrical circuit diagrams. Engine volume q This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
00- 8 (7)
3.
4.
Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q
Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)
q
Revisions Revised brochures are shown in the shop manual composition table.
Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
k
Safety
Special safety precautions are necessary when performing work.
a
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
4
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Tightening torque
Places that require special attention for tightening torque during assembly.
2
5.
Coat
5
Oil, coolant
6
Drain
Remarks
Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
00- 9 (7)