HYDRAULICEXCAVATOR
SERIALNUMBERSandUP
ThismaterialisproprietarytoKomatsuAmericaCorp.andisnottobereproduced,used,ordisclosedexceptinaccordance withwrittenauthorizationfromKomatsuAmericaCorp.
Itisourpolicytoimproveourproductswheneveritispossibleandpracticaltodoso.Wereservetherighttomakechangesor addimprovementsatanytimewithoutincurringanyobligationtoinstallsuchchangesonproductssoldpreviously.
Duetothiscontinuousprogramofresearchanddevelopment,periodicrevisionsmaybemadetothispublication.Itisrecommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision.
01GENERAL
10STRUCTUREANDFUNCTION.
20TESTING,ADJUSTINGANDTROUBLESHOOTING.
30DISASSEMBLYANDASSEMBLY.
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
IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERAND MACHINESERIALNUMBERMUSTBESHOWN.
QTY.PUBLICATIONFORMNO.PARTSBOOKPUBLICATION DESCRIPTION
P-Paper M-Microfiche
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsareusedtomarksafetyprecautionsinthismanual.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.
PRECAUTIONSDURINGWORK
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 thehoistorcraneandalwaysstandclearfromwhatyouareraising.
5.Whenremovingcoverswhichareunderinternalpressureorunderpressurefromaspring,alwaysleavetwoboltsin positiononoppositesides.Slowlyreleasethepressure,thenslowlyloosentheboltstoremove.
6.Whenremovingcomponents,becarefulnottobreakordamagethewiring,Damagedwiringmaycauseelectricalfires.
7.Whenremovingpiping,stopthefueloroilfromspillingout.Ifanyfueloroildripsontothefloor,wipeitup immediately.Fueloroilonthefloorcancauseyoutoslip,orcanevenstartfires.
8.Neveruseflammableliquidstocleanparts,alwaysuseapprovednon-flammablesolventstocleanparts.
9.Besuretoassembleallpartsintheiroriginallocations.Replaceanydamagedpartwithnewparts.
Wheninstallinghosesandwires,besurethattheywillnotbedamagedbycontactwithotherpartswhenthemachine isbeingoperated.
10.Wheninstallinghighpressurehoses,besurethattheyarenottwisted.Damagedtubbingdangerous,beextremelycareful wheninstallingtubesforhighpressurecircuits.Alsomakesurepartsarecorrectlyinstalled.
11.Whenassemblingorinstallingparts,alwaysusethespecifiedtighteningtorquesandsequences.Wheninstalling protectivepartssuchasguards,orpartsthatmayvibrateorrotateathighspeeds,beparticularlycarefultochecktheir installationcarefully.
12.Whenaligningtwoholes,neverinsertyourfingersorhand.Useappropriatetoolstoalignparts.
13.Whenmeasuringhydraulicpressure,besurethemeasuringtooliscorrectlyassembledbeforetakinganymeasurements.
14.Takecarewhenremovingorinstallingthetracksontrack-typemachines.Whenremovingthetrack,thetrackseparates suddenly,neverletanyonestandateitherendofthetrack.
15.Whenmakingrepairsoradjustmentsonelectronicallycontrolledengines,avoidanyphysicalcontactwiththeinjection systemswiringharnesswhiletheengineisrunning.Duetothehighvoltageandamperageinthissystem,seriousinjury mayoccur.
16.Whenremovingthetrack,thetrackseparatessuddenly,soneverletanyonestandateitherendofthetrack.
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
00HOWTOREADTHESHOPMANUAL
VOLUMES
00
Shopmanualsareissuedasaguidetocarryingoutrepairs. Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel Enginevolume:Issuedforeachengineseries
Electricalvolume:Eachissuedasonetocoverallmodels
Attachmentvolume:Eachissuedasonetocoverallmodels
Thesevariousvolumesaredesignedtoavoidduplicationof information.Thereforetodealwithallrepairsforanymodel, itisnecessarythatchassis,engine,electricalandattachment beavailable.
DISTRIBUTIONANDUPDATING
00
Anyadditions,amendmentsorotherchangeswillbesentto yourdistributors.Getthemostup-to-dateinformationbefore youstartanywork.
00FILING
METHOD
1.Seethepagenumberonthebottomofthepage.Filethe pagesincorrectorder.
2.Followingexamplesshowhowtoreadthepagenumber: Example: 10-3
Itemnumber(10.StructureandFunction)
Consecutivepagenumberforeachitem
3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.Fileas intheexample. Example:
REVISIONS
00
RevisedpagesareshownattheLISTOFREVISEDPAGES betweenthetitlepageandSAFETYpage.
00SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwiththe followingsymbols.
SymbolItemRemarks
Safety
Caution
Weight
Tightening torque
Specialsafetyprecautionsare necessarywhenperformingthe work.
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems. Cautionnecessarywhen selectinghoistingwireorwhen workingpostureisimportant, etc.
Placesthatrequirespecial attentionfortighteningtorque duringassembly.
CoatPlacestobecoatedwithadhesivesandlubricantsetc.
Oil,waterPlaceswhereoil,waterorfuel mustbeadded,andthecapacity.
Drain
Placeswhereoilorwatermust bedrained,andquantitytobe drained.
00REVISEDEDITIONMARK
Whenamanualisrevised,aneditionmark( )is recordedonthebottomoutsidecornerofthepages.
12
00HOISTING
INSTRUCTIONS
00HOISTING
WARNING!Heavyparts(25kgormore) mustbeliftedwithahoistetc.In theDISASSEMBLYAND ASSEMBLYsection,everypart weighing25kgormoreis indicatedclearlywiththesymbol
Ifapartcannotbesmoothlyremovedfromthemachine byhoisting,thefollowingchecksshouldbemade:
1.Checkforremovalofallboltsfasteningtheparttothe relativeparts.
2.Checkforexistenceofanotherpartcausinginterface withtheparttoberemoved.
00WIREROPES
1.Useadequateropesdependingontheweightofpartsto behoisted,referringtothetablebelow:
Wireropes (StandardZorStwistropeswithoutgalvanizing)
Theallowableloadvalueisestimatedtobe1/6or1/ 7ofthebreakingstrengthoftheropeused.
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.
12
Therecommendedcoatingmaterialsprescribedintheshopmanualsarelistedbelow.
CategoryCodePartNo.QuantityContainerMainapplications,features Adhesives
LT-1A790-129-9030150gTube
Gasket sealant
LT-1B790-129-905020g(2pes.) Polyethylene container
LT-209940-0003050gPolyethylene container
Usedtopreventrubbergaskets,rubber cushionsandcorkplugsfromcomingout
Usedinplacesrequiringanimmediately effective,strongadhesive.
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 Can
LT-4790-129-9040250gPolyethylene container
Holtz MH705790-126-912075gTube
Threebond 1735179-129-91402gPolyethylene container
Usedasadhesiveorsealantformetal,glass orplastic.
Usedassealantformachinedholes.
Usedasheat-resistingsealantforrepairing engine.
Quickhardeningtypeadhesive.
Curetime:within5sec.to3min.
Usedmainlyforadhesionofmetals, rubbers,plasticsandwoods.
Quickhardeningtypeadhesive.
Aron-alpha 201790-129-913050gPolyethylene container
Loctite 648-5079A-129-911050ccPolyethylene container
LG-1790-129-9010200gTube
Quickcuretype(max.strengthafter 30minutes).
Usedmainlyforadhesionofrubbers, plasticsandmetals.
Features:Resistancetoheat,chemicals
Usedatjointportionssubjecttohigh temperature.
Usedasadhesiveorsealantforgasketsand packingofpowertraincase,etc.
Features:Resistancetoheat
LG-3790-129-90701kgCan
Usedassealantforflangesurfacesandbolts athightemperaturelocations;usedto preventseizure.
Usedassealantforheatresistantgasketfor athightemperaturelocationssuchasengine pre-combustionchamber,exhaustpipe.
CategoryCodePartNo.QuantityContainerMainapplications,features
Features:Resistancetowater,oil
Usedassealantforflangesurface,thread.
LG-4790-129-9020200gTube
LG-5790-129-90801kgPolyethylene container
Alsopossibletouseassealantforflanges withlargeclearance.
Usedassealantformatingsurfacesoffinal drivecase,transmissioncase.
Usedassealantforvariousthreads,pipe joints,flanges.
Usedassealantfortaperedplugs,elbows, nipplesofhydraulicpiping.
Gasket sealant
LG-609940-00011250gTube
LG-709920-00150150gTube
Threebond 1211790-129-9090100gTube
Features:Siliconbased,resistanttoheat, cold.
Usedassealantforflangesurface,thread.
Usedassealantforoilpan,finaldrivecase, etc.
Features:Siliconbased,quickhardening type.
Usedassealantforflywheelhousing,intake manifold,oilpan,thermostathousing,etc.
Usedasheat-resistingsealantforrepairing engines.
Usedaslubricantforslidingparts (topreventsqueaking).
LM-P09940-00040200gTube
MolybdenumdisulphidelubricantLM-G09940-0005160gCan
SYG2-400LI
SYG2-350LI
G2-LI
SYG2-400LI-A
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
G2-CA
SYG2-160CA
SYG2160CNCA
VariousVarious
VariousVarious
Usedtopreventseizureorscuffingofthe threadwhenpressfittingorshrinkfitting.
Usedaslubricantforlinkage,bearings,etc.
Generalpurposetype
Usedfornormaltemperature,lightload bearingatplacesincontactwithwateror steam. Molybdenumdisulphide
Usedforplaceswithheavyload.
Grease
BOLTSANDNUTSSTANDARDTIGHTENINGTORQUE
Thefollowingchartsgivethestandardtighteningtorquesofboltsandnuts.ExceptionsaregiveninDISASSEMBLYAND ASSEMBLY.
ThreaddiameterofboltWidthacrossflats
mmmmNmkgm
ThreaddiameterofboltWidthacrossflats
12
00
HOSENUTSTIGHTENINGTORQUE
Usethesetorquesforhosenuts.
NominalNo. ThreaddiameterWidthacrossflatTighteningtorque
SPLITFLANGEBOLTSTIGHTENINGTORQUE
00
Usethesetorquesforsplitflangebolts.
ThreaddiameterWidthacrossflatTighteningtorque mmmmNmkgm
00FLAREDNUTS
TIGHTENINGTORQUE
Usethesetorquesforflaredpartofnut.
ThreaddiameterWidthacrossflatTighteningtorque mmmmNmkgm 141924.5±4.92.5±0.5 182449±19.65±2 222778.5±19.68±2 2432137.3±29.414±3 3036176.5±29.418±3 3341196.1±4920±5 3646245.2±4925±5 4255294.2±4930±5
00O-RINGBOSSPIPINGJOINTSTIGHTENINGTORQUE
Unlesstherearespecialinstructions,tightentheO-ringbosspipingjointstothetorquebelow.
NominalNo.
Variesdepending ontypeof connector.
00O-RINGBOSSPLUGSTIGHTENINGTORQUE
Unlesstherearespecialinstructions,tightentheO-ringbossplugstothetorquebelow.
NominalNo.
12
00114ENGINESERIESTIGHTENINGTORQUE
1)BOLTANDNUTS
Usethesetorquesforboltsandnuts(unit:mm)ofCumminsEngine. Threaddiameter
2)EYEJOINTS
Usethesetorquesforeyejoints(unit:mm)ofCumminsEngine. Threaddiameter
3)TAPEREDSCREWS
Usethesetorquesfortaperedscrews(unit:inch)ofCumminsEngine. Threaddiameter
3/8 1/2 3/4 1
0.81±0.20 1.22±0.20 1.53±0.41 2.45±0.41 3.67±0.51 6.12±0.92