LOGGINGEXCAVATOR
ThismaterialisproprietarytoKomatsuAmericaCorp.andisnottobereproduced,used,ordisclosedexceptinaccordance withwrittenauthorizationfromKomatsuAmericaCorp.
Itisourpolicytoimproveourproductswheneveritispossibleandpracticaltodoso.Wereservetherighttomakechangesor addimprovementsatanytimewithoutincurringanyobligationtoinstallsuchchangesonproductssoldpreviously.
Duetothiscontinuousprogramofresearchanddevelopment,periodicrevisionsmaybemadetothispublication.Itis recommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision. SERIALNUMBERSandUP
PRODUCTPUBLICATIONSINFORMATION
VariousproductPartsandServicePublicationsareavailabletoallKOMATSUconstructionequipment owners,includingoperationandmaintenancemanuals,partsbooksandservicemanuals.
Specialpublications,suchasservicetool,airconditioningandturbochargerservicemanualsarealso availableaswellasselectedOperationandServicemanualsinforeignlanguages.
ThePublicationslistedbelowareavailableforthisparticularmachine(s).
DESCRIPTIONFORMNUMBER
PARTSBOOK-PAPER:
SHOPMANUAL
SAFETYMANUAL
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
SHIPTO
COMPANYNAME
ATTN.
TYPEorPRINT ONLY
PURCHASEORDERNO.
STREETADDRESSORDERDATE
CITY,STATE,ZIPCODE
COUNTRY
PHONENO.FAXNO.SHIPPINGMETHODDISTR/BRANCHCODE
IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERAND MACHINESERIALNUMBERMUSTBESHOWN.
QTY.PUBLICATIONFORMNO.PARTSBOOKPUBLICATION DESCRIPTION
MODELNUMBERSERIALNUMBER P-Paper M-Microfiche
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.Thecautions accompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise, firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONS
Mistakesinoperationareextremelydangerous.Readthe OPERATION&MAINTENANCEMANUALcarefully BEFOREoperatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,readallthe precautionsgivenonthedecalswhicharefixedtothe machine.
2.Whencarryingoutanyoperation,alwayswearsafety shoesandhelmet.Donotwearlooseworkclothes,or clotheswithbuttonsmissing.
Alwayswearsafetyglasseswhenhittingpartswitha hammer.
Alwayswearsafetyglasseswhengrindingpartswitha grinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.Whencarrying outweldingwork,alwayswearweldinggloves,apron, glasses,capandotherclothessuitedforweldingwork.
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure beforestarting.Alwaysinformyourfellowworkers beforestartinganystepoftheoperation.Beforestarting work,hangUNDERREPAIRsignsonthecontrolsin theoperator'scompartment.
5.Keepalltoolsingoodconditionandlearnthecorrect waytousethem.
6.Decideaplaceintherepairworkshoptokeeptoolsand removedparts.Alwayskeepthetoolsandpartsintheir correctplaces.Alwayskeeptheworkareacleanand makesurethatthereisnodirtoroilonthefloor.Smoke onlyintheareasprovidedforsmoking.Neversmoke whileworking.
PREPARATIONSFORWORK
1.Beforeaddingoilormakingrepairs,parkthemachine onhard,levelground,andblockthewheelsortracksto preventthemachinefrommoving.
2.Beforestartingwork,lowerblade,ripper,bucketorany otherworkequipmenttotheground.Ifthisisnot possible,insertthesafetypinoruseblockstoprevent theworkequipmentfromfalling.Inaddition,besureto lockallthecontrolleversandhangwarningsignson them.
3.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbeforestarting work.
4.Removeallmudandoilfromthestepsorotherplaces usedtogetonandoffthemachine.Alwaysusethe handrails,laddersorstepswhengettingonoroffthe machine.Neverjumponoroffthemachine.Ifitis impossibletousethehandrails,laddersorsteps,usea standtoprovidesafefooting.
PRECAUTIONSDURINGWORK00
1.Whenremovingtheoilfillercap,drainplugor hydraulicpressuremeasuringplugs,loosenthemslowly topreventtheoilfromspurtingout.Before disconnectingorremovingcomponentsoftheoil,water oraircircuits,firstremovethepressurecompletelyfrom thecircuit.
2.Thewaterandoilinthecircuitsarehotwhentheengine isstopped,sobecarefulnottogetburned.Waitforthe oilandwatertocoolbeforecarryingoutanyworkon theoilorwatercircuits.
3.Beforestartingwork,removetheleadsfromthebattery. ALWAYSremovetheleadfromthenegative(-) terminalfirst.
12 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.Neveruseflammableliquidstocleanpart.Alwaysuseapprovednon-flammablesolventstocleanparts.
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.
15.Whenmakingrepairsoradjustmentsonelectronically-controlledengines,avoidanyphysicalcontactwithinjectionsystemwiringharnesswhileengineisrunning.Duetothehighvoltageandamperageinthesystem,seriousinjurymay result.
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.Troubleshootingchartscorrelating“Problems”to“Causes”arealsoincludedinthis section.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeachcomponent, aswellasprecautionstobetakenfortheseoperations.
MAINTENANCESTANDARD
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvancenotice.Contact yourdistributorforthelatestinformation.
12 HOWTOREADTHESHOPMANUAL
VOLUMES
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: REVISEDEDITIONMARK
Whenamanualisrevised,aneditionmark(…)is recordedonthebottomoutsidecornerofthepages.
REVISIONS
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.
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 (Standard“Z”or“S”twistropeswithoutgalvanizing)
Theallowableloadvalueisestimatedtobe1/6or1/7of thebreakingstrengthoftheropeused.
3.Donotslingaheavyloadwithoneropealone,butsling withtwoormoreropessymmetricallywoundontothe load.
WARNING!Slingingwithoneropemay causeturningoftheloadduring hoisting,untwistingoftherope, orslippingoftheropefromits originalwindingpositiononthe load,whichcanresultina dangerousaccident
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°
2.Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausetheropeto slipoffthehookduringhoisting,andaseriousaccident canresult.Hookshavemaximumstrengthatthemiddle portion.
Therecommendedcoatingmaterialsprescribedintheshopmanualsarelistedbelow.
CategoryCodePartNo.QuantityContainerMainapplications,features
LT-1A790-129-9030150gTubeUsedtopreventrubbergaskets,rubber cushionsandcorkplugsfromcomingout
Usedinplacesrequiringanimmediately effective,strongadhesive.
LT-1B790-129-905020g(2pes.)
Polyethylene container
LT-209940-0003050gPolyethylene container
Usedforplastics(exceptpolyethylene, polypropylene,tetrafluoroethylene,and vinylchloride),rubber,metaland non-metal.
Features:Resistancetoheat,chemicals Usedforanti-looseningandsealant purposesforboltsandplugs.
LT-3
790-129-9060 (Setofadhesive andhardening agent)
Adhesive: 1kg Hardening agent: 500g CanUsedasadhesiveorsealantformetal,glass orplastic.
LT-4790-129-9040250gPolyethylenecontainerUsedassealantformachinedholes.
Holtz MH705790-126-912075gTubeUsedasheat-resistingsealantforrepairing engine.
Three bond 1735 179-129-91402gPolyethylene container
Aronalpha 201 790-129-913050gPolyethylene container
Loctite 648-5079A-129-911050ccPolyethylene container
Quickhardeningtypeadhesive.
Curetime:within5sec.to3min.
Usedmainlyforadhesionofmetals, rubbers,plasticsandwoods.
Quickhardeningtypeadhesive.
Quickcuretype(max.strengthafter30 minutes).
Usedmainlyforadhesionofrubbers, plasticsandmetals.
Features:Resistancetoheat,chemicals Usedatjointportionssubjecttohigh temperature.
LG-1790-129-9010200gTubeUsedasadhesiveorsealantforgasketsand packingofpowertraincase,etc.
Features:Resistancetoheat
LG-3790-129-90701kgCan
Usedassealantforflangesurfacesandbolts athightemperaturelocations;usedto preventseizure.
Usedassealantforheatresistantgasketfor athightemperaturelocationssuchasengine pre-combustionchamber,exhaustpipe.
CategoryCodePartNo.QuantityContainerMainapplications,features
Features:Resistancetowater,oil
LG-4790-129-9020200gTube
LG-5790-129-90801kgPolyethylene container
Usedassealantforflangesurface,thread. Alsopossibletouseassealantforflanges withlargeclearance.
Usedassealantformatingsurfacesoffinal drivecase,transmissioncase.
Usedassealantforvariousthreads,pipe joints,flanges.
Usedassealantfortaperedplugs,elbows, nipplesofhydraulicpiping.
Features:Siliconbased,resistanttoheat, cold.
LG-609940-00011250gTube
LG-709920-00150150gTube
Three bond 1211
Usedassealantforflangesurface,thread. Usedassealantforoilpan,finaldrivecase, etc.
Features:Siliconbased,quickhardening type.
Usedassealantforflywheelhousing,intake manifold,oilpan,thermostathousing,etc.
790-129-9090100gTubeUsedasheat-resistingsealantforrepairing engines.
MolybdenumdisulphidelubricantLM-G09940-0005160gCanUsedaslubricantforslidingparts(to preventsqueaking).
LM-P09940-00040200gTube
SYG2-400LI
SYG2-350LI
G2-LI
SYG2-400LI-A
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
G2-CA
SYG2-160CA
VariousVariousGeneralpurposetype
VariousVarious
Usedtopreventseizureorscuffingofthe threadwhenpressfittingorshrinkfitting. Usedaslubricantforlinkage,bearings,etc. Grease
SYG2160CNCA
Usedfornormaltemperature,lightload bearingatplacesincontactwithwateror steam.
MolybdenumdisulphidelubricantSYG2-400M400g(10percase)BelowstypeUsedforplaceswithheavyload.
STANDARDTIGHTENINGTORQUEOFBOLTSANDNUTS
Thefollowingchartsgivethestandardtighteningtorquesofboltsandnuts.ExceptionsaregiveninDISASSEMBLYAND ASSEMBLY.
ThreaddiameterofboltWidthacrossflats mmmmNmlbfft
ThreaddiameterofboltWidthacrossflats mmmmNmlbfft
12 TIGHTENINGTORQUEOFHOSENUTS
Usethesetorquesforhosenuts.
NominalNo.
ThreaddiameterWidthacrossflatTighteningtorque mmmmNmlbfft 02141924.5±4.918.0±3.6 03182449±19.636.1±14.4 04222778.5±19.657.8±14.4 052432137.3±29.4101.2±21.6 063036176.5±29.4130.1±21.6 103341196.1±49144.6±36.1 123646245.2±49180.8±36.1 144255294.2±49216.9±36.1
TIGHTENINGTORQUEOFSPLITFLANGEBOLTS 00
Usethesetorquesforsplitflangebolts.
ThreaddiameterWidthacrossflatTighteningtorque mmmmNmlbfft
101465.7±6.848.4±5.0 1217112±9.882.6±7.2 1622279±29205.7±21.3
TIGHTENINGTORQUEFORFLAREDNUTS
Usethesetorquesforflaredpartofnut.
ThreaddiameterWidthacrossflatTighteningtorque mmmmNmlbfft
141924.5±4.918.0±3.6 182449±19.636.1±14.4 222778.5±19.657.8±14.4 2432137.3±29.4101.2±21.6 3036176.5±29.4130.1±21.6 3341196.1±49144.6±36.1 3646245.2±49180.8±36.1 4255294.2±9216.9±36.1
Inthewiringdiagrams,variouscolorsandsymbolsareemployedtoindicatethethicknessofwires.Thiswirecodetablewill helpyouunderstandWIRINGDIAGRAMS.
Example:05WBindicatesacablehavinganominalnumber05andwhitecoatingwithblackstripe.
CLASSIFICATIONBYTHICKNESS
0.85110.320.882.412Starting,lighting,signaletc. 2260.322.093.120Lighting,signaletc. 5650.325.234.637Chargingandsignal 15840.4513.367.059Starting(Glowplug) 40850.8042.7311.4135Starting 601270.8063.8413.6178Starting 1002170.80109.117.6230Starting
CLASSIFICATIONBYCOLORANDCODE
METHODOFUSINGTHECONVERSIONTABLE
TheConversionTableinthissectionisprovidedtoenablesimpleconversionoffigures.Fordetailsofthemethodofusingthe ConversionTable,seetheexamplegivenbelow.
EXAMPLE
MethodofusingtheConversionTabletoconvertfrommillimeterstoinches.
1.Convert55mmintoinches.
A.Locatethenumber50intheverticalcolumnattheleftside,takethisas,thendrawahorizontallinefrom
B.Locatethenumber5intherowacrossthetop,takethisas,thendrawaperpendicularlinedownfrom.
C.Takethepointwherethetwolinescrossas.Thispointgivesthevaluewhenconvertingfrommillimetersto inches.Therefore,55millimeters=2.165inches.
2.Convert550mmintoinches.
A.Thenumber550doesnotappearinthetable,sodivideby10(movethedecimaloneplacetotheleft)toconvertitto 55mm.
B.Carryoutthesameprocedureasabovetoconvert55mmto2.165inches.
C.Theoriginalvalue(550mm)wasdividedby10,somultiply2.165inchesby10(movethedecimaloneplacetothe right)toreturntotheoriginalvalue.Thisgives550mm=21.65inches.
Millimeterstoinches1mm=0.03937in
501.9692.0082.0472.0872.1262.1652.2052.2442.2832.323 602.3622.4022.4412.4802.5202.5592.5982.6382.6772.717 702.7562.7952.8352.8742.9132.9532.9923.0323.0713.110
803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.7013.7403.7803.8193.8583.898