SAFETY
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforsafemachineoperation.Theserviceand repairtechniquesrecommendedbyKomatsuanddescribedinthismanualarebotheffective andsafe.SomeofthesetechniquesrequiretheuseoftoolsspeciallydesignedbyKomatsufor thespecificpurpose.
Topreventinjurytoworkers,thesymbolisusedtomarksafetyprecautionsinthismanual. Thecautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise,firstconsidersafety,andtakethenecessaryactions todealwiththesituation.
GENERALPRECAUTIONS
Mistakesinoperationareextremelydangerous. ReadtheOperationandMaintenanceManualcarefullyBEFOREoperatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,read alltheprecautionsgivenonthedecalswhichare fixedtothemachine.
2.Whencarryingoutanyoperation,always wearsafetyshoesandhelmet.Donotwear looseworkclothes,orclotheswithbuttons missing.
•Alwayswearsafetyglasseswhenhitting partswithahammer.
•Alwayswearsafetyglasseswhengrinding partswithagrinder,etc.
3.Ifweldingrepairsareneeded,alwayshavea trained,experiencedweldercarryoutthework. Whencarryingoutweldingwork,alwayswear weldinggloves,apron,handshield,capand otherclothessuitedforweldingwork.
4.Whencarryingoutanyoperationwithtwoor moreworkers,alwaysagreeontheoperating procedurebeforestarting.Alwaysinformyour fellowworkersbeforestartinganystepofthe operation.Beforestartingwork,hangUNDER REPAIRsignsonthecontrolsintheoperator's compartment.
5.Keepalltoolsingoodconditionandlearnthe correctwaytousethem.
6.Decideaplaceintherepairworkshoptokeep toolsandremovedparts.Alwayskeepthetools andpartsintheircorrectplaces.Alwayskeep theworkareacleanandmakesurethatthereis nodirtoroilonthefloor.Smokeonlyintheareas providedforsmoking.Neversmokewhileworking.
PREPARATIONSFORWORK
7.Beforeaddingoilormakinganyrepairs,parkthe machineonhard,levelground,andblockthe wheelsortrackstopreventthemachinefrom moving.
8.Beforestartingwork,lowerblade,ripper,bucket oranyotherworkequipmenttotheground.If thisisnotpossible,insertthesafetypinoruse blockstopreventtheworkequipmentfromfalling.Inaddition,besuretolockallthecontrol leversandhangwarningsignsonthem.
9.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbefore startingwork.
10.Removeallmudandoilfromthestepsorother placesusedtogetonandoffthemachine. Alwaysusethehandrails,laddersorstepswhen gettingonoroffthemachine.Neverjumponor offthemachine.Ifitisimpossibletousethe handrails,laddersorsteps,useastandtoprovidesafefooting.
PRECAUTIONSDURINGWORK
11.Whenremovingtheoilfillercap,drainplugor hydraulicpressuremeasuringplugs,loosen themslowlytopreventtheoilfromspurtingout. Beforedisconnectingorremovingcomponents oftheoil,wateroraircircuits,firstremovethe pressurecompletelyfromthecircuit.
12.Thewaterandoilinthecircuitsarehotwhenthe engineisstopped,sobecarefulnottoget burned.
Waitfortheoilandwatertocoolbeforecarryingoutanyworkontheoilorwatercircuits.
13.Beforestartingwork,removetheleadsfromthe battery.Alwaysremovetheleadfromthenegative(–)terminalfirst.
14.Whenraisingheavycomponents,useahoistor crane.
Checkthatthewirerope,chainsandhooksare freefromdamage.
Alwaysuseliftingequipmentwhichhasample capacity.
Installtheliftingequipmentatthecorrectplaces. Useahoistorcraneandoperateslowlytopreventthecomponentfromhittinganyotherpart. Donotworkwithanypartstillraisedbythehoist orcrane.
15.Whenremovingcoverswhichareunderinternal pressureorunderpressurefromaspring, alwaysleavetwoboltsinpositiononopposite sides.Slowlyreleasethepressure,thenslowly loosentheboltstoremove.
16.Whenremovingcomponents,becarefulnotto breakordamagethewiring.Damagedwiring maycauseelectricalfires.
17.Whenremovingpiping,stopthefueloroilfrom spillingout.Ifanyfueloroildripsontothefloor, wipeitupimmediately.Fueloroilonthefloor cancauseyoutoslip,orcanevenstartfires.
18.Asageneralrule,donotusegasolinetowash parts.Inparticular,useonlytheminimumof gasolinewhenwashingelectricalparts.
19.Besuretoassembleallpartsagainintheiroriginalplaces.
Replaceanydamagedpartswithnewparts. •Wheninstallinghosesandwires,besure thattheywillnotbedamagedbycontact withotherpartswhenthemachineisbeing operated.
20.Wheninstallinghighpressurehoses,makesure thattheyarenottwisted.Damagedtubesare dangerous,sobeextremelycarefulwheninstallingtubesforhighpressurecircuits.Also,check thatconnectingpartsarecorrectlyinstalled.
21.Whenassemblingorinstallingparts,alwaysuse thespecifiedtighteningtorques.Wheninstalling protectivepartssuchasguards,orpartswhich vibrateviolentlyorrotateathighspeed,beparticularlycarefultocheckthattheyareinstalled correctly.
22.Whenaligningtwoholes,neverinsertyourfingersorhand.Becarefulnottogetyourfingers caughtinahole.
23.Whenmeasuringhydraulicpressure,checkthat themeasuringtooliscorrectlyassembledbefore takinganymeasurements.
24.Takecarewhenremovingorinstallingthetracks oftrack-typemachines. Whenremovingthetrack,thetrackseparates suddenly,soneverletanyonestandateither endofthetrack.
FOREWORD
GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemanan accurateunderstandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesureyouunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaservice workshop.Foreaseofunderstanding,themanualisdividedintothefollowingchapters;thesechaptersarefurtherdividedintotheeachmaingroupofcomponents.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingofthestructure,butalsoservesasreferencematerialfortroubleshooting.
Inaddition,thissectionmaycontainhydrauliccircuitdiagrams,electriccircuitdiagrams,andmaintenancestandards.
TESTINGANDADJUSTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentsto bemadeatcompletionofthechecksandrepairs.
Troubleshootingchartscorrelating"Problems"with"Causes"arealsoincludedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheproceduresforremoving,installing,disassemblingandassemblingeachcomponent,aswellasprecautionsforthem.
MAINTENANCESTANDARD
Thissectiongivesthejudgmentstandardsforinspectionofdisassembledparts. ThecontentsofthissectionmaybedescribedinSTRUCTUREANDFUNCTION.
OTHERS
Thissectionmainlygiveshydrauliccircuitdiagramsandelectriccircuitdiagrams. Inaddition,thissectionmaygivethespecificationsofattachmentsandoptionstogether.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutany advancenotice.Usethespecificationsgiveninthebookwiththelatestdate.
HOWTOREADTHESHOPMANUAL
VOLUMES
Shopmanualsareissuedasaguidetocarryingout repairs.Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel
Enginevolume:Issuedforeachengineseries
Electricalvolume: Attachmentsvolume:
Eachissuedasone volumetocoverall models
Thesevariousvolumesaredesignedtoavoidduplicatingthesameinformation.Therefore,todealwith allrepairsforanymodel,itisnecessarythatchassis,engine,electricalandattachmentvolumesbe available.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbe senttoKOMATSUdistributors.Getthemostup-todateinformationbeforeyoustartanywork.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage. Filethepagesincorrectorder.
2.Followingexamplesshowhowtoreadthepage number.
Example1(Chassisvolume): 10-3
Itemnumber(10.Structureand Function)
Consecutivepagenumberforeach item.
Example2(Enginevolume): 12-5
Unitnumber(1.Engine)
Itemnumber(2.TestingandAdjusting)
Consecutivepagenumberforeach item.
3.Additionalpages:Additionalpagesareindicated byahyphen(-)andnumberafterthepage number.Fileasintheexample. Example: 10-4
10-4-1
10-4-2 10-5
Addedpages
REVISEDEDITIONMARK
Whenamanualisrevised,aneditionmark ((1)(2)(3)....)isrecordedonthebottomofthepages.
REVISIONS
RevisedpagesareshownintheLISTOFREVISED PAGESnexttotheCONTENTSpage.
SYMBOLS
Sothattheshopmanualcanbeofamplepractical use,importantsafetyandqualityportionsare markedwiththefollowingsymbols.
SymbolItemRemarks
Safety
Caution
Weight
Tightening torque
Coat
Oil,water
Drain
Specialsafetyprecautions arenecessarywhenperformingthework.
Specialtechnicalprecautionsorotherprecautions forpreservingstandards arenecessarywhenperformingthework.
Weightofpartsofsystems.Cautionnecessary whenselectinghoisting wire,orwhenworkingpostureisimportant,etc.
Placesthatrequirespecial attentionforthetightening torqueduringassembly.
Placestobecoatedwith adhesivesandlubricants, etc.
Placeswhereoil,wateror fuelmustbeadded,and thecapacity.
Placeswhereoilorwater mustbedrained,and quantitytobedrained.
HOISTINGINSTRUCTIONS
HOISTING
Heavyparts(25kgormore)mustbelifted withahoist,etc.IntheDISASSEMBLY ANDASSEMBLYsection,everypart weighing25kgormoreisindicatedclearly withthesymbol
•Ifapartcannotbesmoothlyremovedfromthe machinebyhoisting,thefollowingchecks shouldbemade:
1)Checkforremovalofallboltsfasteningthe parttotherelativeparts.
2)Checkforexistenceofanotherpartcausing interferencewiththeparttoberemoved.
WIREROPES
1)Useadequateropesdependingonthe weightofpartstobehoisted,referringto thetablebelow:
Wireropes (Standard"Z"or"S"twistropes withoutgalvanizing)
Slingingneartheedgeofthehookmaycause theropetoslipoffthehookduringhoisting,and aseriousaccidentcanresult.Hookshavemaximumstrengthatthemiddleportion.
Theallowableloadvalueisestimatedtobeonesixthorone-seventhofthebreakingstrengthof theropeused.
2)Slingwireropesfromthemiddleportionofthe hook.
3)Donotslingaheavyloadwithoneropealone, butslingwithtwoormoreropessymmetrically woundontotheload.
Slingingwithoneropemaycauseturning oftheloadduringhoisting,untwistingof therope,orslippingoftheropefromits originalwindingpositionontheload,which canresultinadangerousaccident.
4)Donotslingaheavyloadwithropesforminga widehanginganglefromthehook. Whenhoistingaloadwithtwoormoreropes, theforcesubjectedtoeachropewillincrease withthehangingangles.Thetablebelow showsthevariationofallowableloadkN{kg} whenhoistingismadewithtworopes,eachof whichisallowedtoslingupto9.8kN{1000kg} vertically,atvarioushangingangles.
Whentworopesslingaloadvertically,upto 19.6kN{2000kg}oftotalweightcanbesuspended.Thisweightbecomes9.8kN{1000kg} whentworopesmakea120°hangingangle. Ontheotherhand,tworopesaresubjectedto anexcessiveforceaslargeas39.2kN{4000 kg}iftheyslinga19.6kN{2000kg}loadata liftingangleof150°.
METHODOFDISASSEMBLING,
METHODOFDISASSEMBLING,CONNECTINGPUSH-PULLTYPECOUPLER
Beforecarryingoutthefollowingwork,release theresidualpressurefromthehydraulictank. Fordetails,seeTESTINGANDADJUSTING, Releasingresidualpressurefromhydraulic tank.
Eveniftheresidualpressureisreleasedfrom thehydraulictank,somehydraulicoilflowsout whenthehoseisdisconnected.Accordingly, prepareanoilreceivingcontainer.
Disconnection
1)Releasetheresidualpressurefromthehydraulictank.Fordetails,seeTESTINGAND ADJUSTING,Releasingresidualpressurefrom hydraulictank.
2)Holdadapter(1)andpushhosejoint(2)into matingadapter(3).(SeeFig.1)
Theadaptercanbepushedinabout3.5 mm.
Donotholdrubbercapportion(4).
3)Afterhosejoint(2)ispushedintoadapter(3), pressrubbercapportion(4)against(3)untilit clicks.(SeeFig.2)
4)Holdhoseadapter(1)orhose(5)andpullitout. (SeeFig.3)
Sincesomehydraulicoilflowsout,prepare anoilreceivingcontainer.
Connection
1)Holdhoseadapter(1)orhose(5)andinsertitin matingadapter(3),aligningthemwitheach other.(SeeFig.4)
Donotholdrubbercapportion(4).
2)Afterinsertingthehoseinthematingadapter perfectly,pullitbacktocheckitsconnecting condition.(SeeFig.5)
Whenthehoseispulledback,therubber capportionmovestowardthehoseabout 3.5mm.Thisdoesnotindicateabnormality, however.
Type1
Disassembly
Type2Type3
1)Holdthemouthpieceofthetighteningportion andpushbody(2)instraightuntilslidingpreventionring(1)contactscontactsurfaceaof thehexagonalportionatthemaleend.
1)Holdthemouthpieceofthetighteningportion andpushbody(2)instraightuntilslidingpreventionring(1)contactscontactsurfaceaof thehexagonalportionatthemaleend.
2)HoldintheconditioninStep1),andturn lever(4)totheright(clockwise).
2)HoldintheconditioninStep1),andpush untilcover(3)contactscontactsurfaceaof thehexagonalportionatthemaleend.
Connection
3)HoldintheconditioninSteps1)and2),and pulloutwholebody(2)todisconnectit.
3)HoldintheconditioninSteps1)and2),and pulloutwholebody(2)todisconnectit.
•Holdthemouthpieceofthetighteningportion andpushbody(2)instraightuntilslidingpreventionring(1)contactscontactsurfaceaof thehexagonalportionatthemaleendtoconnectit.
•Holdthemouthpieceofthetighteningportion andpushbody(2)instraightuntilslidingpreventionring(1)contactscontactsurfaceaof thehexagonalportionatthemaleendtoconnectit.
COATINGMATERIALS
Therecommendedcoatingmaterialssuchasadhesives,gasketsealantsandgreasesusedfordisassembly andassemblyarelistedbelow.
Forcoatingmaterialsnotlistedbelow,usetheequivalentofproductsshowninthislist.
CategoryKomatsucodePartNo.Q’tyContainerMainapplications,features
LT-1A790-129-9030150gTube•Usedtopreventrubbergaskets,rubber cushions,andcockplugfromcomingout.
LT-1B790-129-905020g(2pcs.) Polyethylene container
•Usedinplacesrequiringanimmediately effective,strongadhesive. Usedforplastics(exceptpolyethylene, polyprophylene,tetrafluoroethleneand vinylchloride),rubber,metalandnonmetal.
LT-209940-0003050gPolyethylene container
•Features: Resistancetoheatandchemicals
•Usedforanti-looseningandsealant purposeforboltsandplugs.
LT-3
Adhesives
790-129-9060 (Setofadhesive andhardening agent)
Adhesive: 1kg Hardening agent: 500g Can
LT-4790-129-9040250gPolyethylene container
•Usedasadhesiveorsealantformetal, glassandplastic.
•Usedassealantformachinedholes.
Holtz MH705790-126-912075gTube•Usedasheat-resistingsealantfor repairingengine.
Threebond1735790-129-914050gPolyethylene container
•Quickhardeningtypeadhesive
•Curetime:within5sec.to3min.
•Usedmainlyforadhesionofmetals, rubbers,plasticsandwoods.
•Quickhardeningtypeadhesive
Aron-alpha201790-129-91302gPolyethylene container
•Quickcuretype (max.strengthafter30minutes)
•Usedmainlyforadhesionofrubbers, plasticsandmetals.
•Resistancetoheat,chemicals
Loctite 648-5079A-129-911050ccPolyethylene container
•Usedatjointportionssubjecttohigh temperatures.
LG-1790-129-9010200gTube•Usedasadhesiveorsealantforgaskets andpackingofpowertraincase,etc.
LG-5790-129-90801kgCan
LG-6790-129-9020200gTube
LG-7790-129-90701kgTube
•Usedassealantforvariousthreads,pipe joints,flanges.
•Usedassealantfortaperedplugs, elbows,nipplesofhydraulicpiping.
•Features:Siliconbased,resistanceto heat,cold
•Usedassealantforflangesurface,tread.
•Usedassealantforoilpan,finaldrive case,etc.
•Features:Siliconbased,quickhardening type
•Usedassealantforflywheelhousing, intakemanifold,oilpan,thermostat housing,etc.
Threebond1211790-129-9090100gTube•Usedasheat-resistingsealantfor repairingengine.
Threebond1207B419-15-18131100gTube
•Features:Siliconetype,heatresistant, vibrationresistant,andimpactresistant sealingmaterial
•Usedassealingmaterialfortransfercase
Gasket sealant
CategoryKomatsucodePartNo.Q’tyContainerMainapplications,features
Molybdenum disulphide lubricant
Grease
LM-G09940-0005160gCan•Usedaslubricantforslidingportion(to preventfromsqueaking).
LM-P09940-00040200gTube
SYG2-400LI
SYG2-350LI
G2-LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
SYG2-400CA
SYG2-350CA
G2-CA
Molybdenum disulphide grease
LM-G(G2-M)
HyperWhite GreaseG2-T G0-T(*) *:Forusein colddistrict
BiogreaseG2B G2-BT(*) *:Forhigh temperature andlargeload
SUNSTAR PAINTPRIMER
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
SYG2-400M
SYG2-400M-A
SYGA-16CNM
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A(*)
SYG0-16CNT(*)
SYG2-400B
SYGA-16CNB
SYG2-400BT(*) SYGA-16CNBT(*)
580SUPER 417-926-3910
SUNSTAR GLASSPRIMER 580SUPER
Primer
SUNSTAR PAINTPRIMER 435-95
SUNSTAR GLASSPRIMER 435-41
SUNSTAR SASHPRIMER GP-402
SUNSTAR PENGUINE SUPER560
Adhesive
VariousVarious
VariousVarious
400g×10 400g×20 16kg
Bellowstype Bellowstype Can
400g 16kg
Bellowstype Can
400g 16kg
Bellowstype Can
•Usedtopreventseizureorscufflingofthe threadwhenpressfittingorshrinkfitting.
•Usedaslubricantforlinkage,bearings, etc.
•Generalpurposetype
•Usedfornormaltemperature,lightload bearingatplacesincontactwithwateror steam.
•Usedforheavyloadportion
•Seizureresistanceandheatresistance higherthanmolybdenumdisulfidegrease •Sincethisgreaseiswhite,itdoesnot standoutagainstmachinebody.
•Sincethisgreaseisdecomposedby bacteriainshortperiod,ithaslesseffects onmicroorganisms,animals,andplants.
•Usedasprimerforcabside (Usinglimit:4months)
20mlGlasscontainer•Usedasprimerforglassside (Usinglimit:4months)
22M-54-2723020mlGlasscontainer•Usedasprimerforpaintedsurfaceon cabside (Usinglimit:4months)
22M-54-27240150mlCan
•Usedasprimerforblackceramiccoatedsurfaceonglasssideandfor hardpolycarbonate-coatedsurface (Usinglimit:4months)
22M-54-2725020mlGlasscontainer•Usedasprimerforsash(Alumite). (Usinglimit:4months)
22M-54-27210320ml Ecocart (Special container)
SUNSTAR PENGUINE SEAL580 SUPER“S”or “W”
417-926-3910320mlPolyethylene container
SikaJapan, Sikaflex256HV20Y-54-39850310mlPolyethylene container
SUNSTAR PENGUINE SEALNo.2505
Caulking material
SEKISUI SILICONE SEALANT
GETOSHIBA SILICONES TOSSEAL381
417-926-3920320mlPolyethylene container
20Y-54-55130333mlPolyethylene container
22M-54-27220333mlCartridge
•Usedasadhesiveforglass. (Usinglimit:6months)
•“S”isusedforhigh-temperature season(April-October)and“W”for low-temperatureseason(NovemberApril)asadhesiveforglass. (Usinglimit:4months)
•Usedasadhesiveforglass. (Usinglimit:6months)
•Usedtosealjointsofglassparts. (Usinglimit:4months)
•Usedtosealfrontwindow. (Usinglimit:6months)
•Usedtosealjointofglasses. Translucentwhiteseal. (Usinglimit:12months)
