CEBM018803
HYDRAULIC EXCAVATOR SERIAL NUMBERS ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
August 2011 Printed in USA
Copyright 2011 Komatsu DataKom Publishing Division 00-1
FOREWORD
CONTENTS
12 CONTENTS
00
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
20
STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30
TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
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TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
50
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
90
DIAGRAMS AND DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2
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This is the sample of the manual Click on the download link for complete manual
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FOREWORD
SAFETY
12 SAFETY
Safety Notice
00
00
Important Safety Notice
00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbol 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.
General Precautions
00
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1.
Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.
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 hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
3.
5.
When carrying out any operation with two 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 signs on the controls in the operator's compartment. Keep all tools in good condition and learn the correct way to use them.
PC400LC-8
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 or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
Preparations For Work
00
1.
Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
2.
Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety 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 machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
WARNING! Never modify, weld, cut, or drill on any part of a ROPS structure. Doing so may weaken the structure which could lead to possible failure in a rollover situation.
4.
6.
Precautions During Work 1.
00
When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
00-3
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SAFETY
2.
The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
3.
Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
4.
5.
When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6.
When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
7.
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
8.
Never use flammable liquids to clean parts, use only non-flammable approved cleaning solutions to clean parts.
9.
Be sure to assemble all parts again in their original places. Replace any damaged part 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 being operated.
10. 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. Also check that connecting parts are correctly installed. 11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 14. 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. 15. Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit. A. Disconnection WARNING! Collect the air conditioner refrigerant gas (R134a). If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, when collecting or adding it, you must be qualified for handling the refrigerant and put on protective goggles. B. Connection i.
When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them.
ii.
When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints.
iii. Check that each O-ring is not damaged or deteriorated.
00-4
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FOREWORD
SAFETY
iv. When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings. Example of O-ring (Fitted to every joint of hoses and tubes) For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
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