FOREWORD
SafetyNotice
ImportantSafetyNotice
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.Thecautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.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..
00
WARNING!Nevermodify,weld,cut,ordrill onanypartofaROPS structure.Doingsomay weakenthestructurewhich couldleadtopossiblefailurein arolloversituation
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.
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.Gasolineorotherfuelsshouldneverbeusedtocleanparts.Cleanpartwithappropriatesolvents.
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.Whenjumpstartingthemachine,onlyuseamachineofsimilarsizeandvoltage.Neveruseaarcwelderorotherelectrical generatingequipmenttojumpstartthemachine.Carefullyreviewthesafetyandproceduresforjumpstartingthe machine.
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesureyou understandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.For easeofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeachmain groupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel,coolantand lubricantspecificationcharts.
STRUCTURE,FUNCTIONANDMAINTENANCESTANDARD
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingofthe structure,butalsoservesasreferencematerialfortroubleshooting.Inaddition,thissectiongivesthejudgementstandards wheninspectingdisassembledparts.
STANDARDVALUETABLE
Thissectionexplainsthestandardvaluesfornewmachineandjudgementcriteriafortesting,adjustingand troubleshooting.Thisstandardvaluetableisusedtocheckthestandardvaluesintestingandadjustingandtojudgeparts introubleshooting.
TESTINGANDADJUSTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemadeat completionofthechecksandrepairs.
TROUBLESHOOTING
Troubleshootingchartscorrelating“Problems”to“Causes”arealsoincludedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeachcomponent, aswellasprecautionstobetakenfortheseoperations.
DIAGRAMSANDSCHEMATICS
Thissectionhasthefoldoutdrawingsforthemachine.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvancenotice.Contact yourKomatsudistributorforthelatestinformation.
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:
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
Caution
Weight
Tightening torque
Specialsafetyprecautionsare necessarywhenperformingthe work.
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems. Cautionnecessarywhenselecting hoistingwireorwhenworking postureisimportant,etc.
Placesthatrequirespecial attentionfortighteningtorque duringassembly.
CoatPlacestobecoatedwithadhesives andlubricantsetc.
Oil,waterPlaceswhereoil,waterorfuel mustbeadded,andthecapacity.
Drain
Placeswhereoilorwatermustbe drained,andquantitytobe drained.
12 HOISTINGINSTRUCTIONS
Hoisting
WARNING!Heavyparts(25kgormore) mustbeliftedwithahoistetc. IntheDISASSEMBLYAND ASSEMBLYsection,every partweighing25kgormoreis 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.
2.Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausetheropeto slipoffthehookduringhoisting,andaseriousaccident
canresult.Hookshavemaximumstrengthatthemiddle portion.
3.Donotslingaheavyloadwithoneropealone,butsling withtwoormoreropessymmetricallywoundontothe load.
WARNING!Slingingwithoneropemay causeturningoftheloadduringhoisting,untwistingofthe rope,orslippingoftherope fromitsoriginalwindingpositionontheload,whichcan resultinadangerousaccident
4.Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.Whenhoistingaloadwith twoormoreropes,theforcesubjectedtoeachropewill increasewiththehangingangles.Thetablebelow showsthevariationofallowableload(kg)whenhoistingismadewithtworopes,eachofwhichisallowedto slingupto1000kgvertically,atvarioushangingangles. Whentworopesslingaloadvertically,upto2000kgof totalweightcanbesuspended.Thisweightbecomes 1000kgwhentworopesmakea120°hangingangle.On theotherhand,tworopesaresubjecttoanexcessive forceaslargeas4000kgiftheyslinga2000kgloadata liftingangleof150°.
12 PUSHPULLCOUPLER
WARNING!Beforecarryingoutthefollowingwork, releasetheresidualpressurefromthe hydraulictank.Fordetails,seeTESTING ANDADJUSTING,Releasingresidual pressurefromhydraulictank.
WARNING!Eveniftheresidualpressureisreleasedfrom thehydraulictank,somehydraulicoilflows outwhenthehoseisdisconnected.Prepare anoilreceivingcontainer.
Type1
Disconnection
1.Releasetheresidualpressurefromthehydraulictank.Fordetails, seeTESTINGANDADJUSTING,Releasingresidualpressurefrom hydraulictank.
2.Holdtheadapter(1)andpushthehosejoint(2)intothemating adapter(3).Theadaptercanbepushedinabout3.5mm.Donothold therubbercapportion(4).
3.Afterthehosejoint(2)ispushedintotheadapter(3),pressthe rubbercapportion(4)againsttheadapteruntilitclicks.
4.Holdthehoseadapter(1)orhose(5)andpullitout.Sincesome hydraulicoilflowsout,prepareanoilreceivingcontainer.
Connection
1.Holdthehoseadapter(1)orhose(5)andinsertitinthemating adapter(3),aligningthemwitheachother.Donotholdtherubber capportion(4).
2.Afterinsertingthehoseinthematingadapter,pullitbacktocheck itsconnectingcondition.Whenthehoseispulledback,therubber capportionmovestowardthehoseabout3.5mm.Thisdoesnot indicateanabnormality.
Type2
Disconnection
1.Holdthemouthpieceofthetighteningportionandpushbody(2)in straightuntilslidingpreventionring(1)contactscontactsurfaceaof thehexagonalportionatthemaleend.
2.HoldintheconditioninStep1,andturnthelever(4)totherightclockwise.
3.HoldintheconditioninSteps1and2,andpulloutthewholebody (2)todisconnectit.
1.Holdthemouthpieceofthetighteningportionandpushbody(2)in straightuntilslidingpreventionring(1)contactssurfaceaofthe hexagonalportionatthemaleendtoconnectit.
12 Type3
Disconnection
1.Holdthemouthpieceofthetighteningportionandpushthebody(2) instraightuntilslidingpreventionring(1)contactssurfaceaofthe hexagonalportionatthemaleend.
2.HoldintheconditioninStep1,andpushuntilthecover(3)contacts surfaceaofthehexagonalportionatthemaleend.
3.HoldintheconditioninSteps1and2,andpulloutthewholebody (2)todisconnectit.
Connection
1.Holdthemouthpieceofthetighteningportionandpushthebody(2) instraightuntiltheslidepreventionring(1)contactssurfaceaofthe hexagonalportionatthemaleendtoconnectit.
12 COATINGMATERIALS
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
Adhesives
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 Usedatjointportionssubjecttohightemperature.
LG-1790-129-9010200gTubeUsedasadhesiveorsealantforgasketsand packingofpowertraincase,etc.
Features:Resistancetoheat
Usedassealantforflangesurfacesand boltsathightemperaturelocations;usedto preventseizure.
LG-3790-129-90701kgCan
Usedassealantforheatresistantgasketfor athightemperaturelocationssuchas enginepre-combustionchamber,exhaust pipe.
Gasket sealant
