WENBM00390
Shop Manual
SKID-STEER LOADER
SK715-8E0
SERIAL NUMBERS F10002 and up
00 Index and Foreword
SK715-8E0
00-1
Index
00 Index and Foreword
Index 00 Index and Foreword .................................................................................................................................. 00-1 Foreword, Safety, Basic Information........................................................................................................ 00-7 How to Read the Shop Manual ........................................................................................................ 00-7 Safety Notice for Operation .............................................................................................................. 00-9 Precautions to Prevent Fire............................................................................................................ 00-16 Procedures If Fire Occurs .............................................................................................................. 00-18 Precautions When You Dispose of Waste Materials ....................................................................... 00-19 Precautions When You Handle Hydraulic Equipment ..................................................................... 00-20 Precautions When You Disconnect and Connect Pipings............................................................... 00-23 Precautions When You Handle Electrical Equipment ..................................................................... 00-30 Precautions When You Handle Fuel System Equipment ................................................................ 00-32 Precautions When You Handle Intake System Equipment ............................................................. 00-33 Practical Use of KOMTRAX ........................................................................................................... 00-34 Disconnect and Connect Push-Pull Type Coupler .......................................................................... 00-35 Precautions for Disconnection and Connection of Connectors ....................................................... 00-39 How to Disconnect and Connect Deutsch Connector ..................................................................... 00-43 How to Disconnect and Connect Slide Lock Type Connector ......................................................... 00-44 How to Disconnect and Connect Connector with Lock to Pull ........................................................ 00-46 How to Disconnect and Connect Connector with Lock to Push ...................................................... 00-47 How to Disconnect and Connect Connector with Housing to Rotate .............................................. 00-49 Standard Tightening Torque Table.................................................................................................. 00-50 Conversion Table ........................................................................................................................... 00-57 Abbreviation List ............................................................................................................................ 00-62 01 Specifications............................................................................................................................................ 01-1 Table of Contents .................................................................................................................................... 01-2 Specifications.......................................................................................................................................... 01-3 Specification Drawing....................................................................................................................... 01-3 Specification .................................................................................................................................... 01-8 Weight Table .................................................................................................................................. 01-10 How to Use Fuel, Coolant and Lubricants by Ambient Temperature................................................01-11 10 Structure and Function .............................................................................................................................. 10-1 Table of Contents .................................................................................................................................... 10-2 NOx Control System ............................................................................................................................... 10-4 Function of NOx Control System ...................................................................................................... 10-4 Boot-up System ...................................................................................................................................... 10-6 Layout Drawing of Boot-up System .................................................................................................. 10-6 System Operating Lamp System...................................................................................................... 10-7 Quick Release Battery Terminal (-)................................................................................................... 10-9 Engine System...................................................................................................................................... 10-10 Layout Drawing of Engine System ................................................................................................. 10-10 Engine Control System ...................................................................................................................10-11 Component Parts of Engine System .............................................................................................. 10-14 Layout Drawing of Engine System ........................................................................................................ 10-15 Cooling System..................................................................................................................................... 10-16 Layout Drawing of Cooling System ................................................................................................ 10-16 Control System ..................................................................................................................................... 10-17 Layout Drawing of Control System ................................................................................................. 10-17 Machine Monitor System................................................................................................................ 10-18 KOMTRAX System ........................................................................................................................ 10-19 Component Parts of Control System .............................................................................................. 10-20 Hydraulic System .................................................................................................................................. 10-35 Layout Drawing of Hydraulic System.............................................................................................. 10-35 CLSS ............................................................................................................................................. 10-36 Component Parts of Hydraulic System........................................................................................... 10-38 Work Equipment System....................................................................................................................... 10-69 Layout Drawing of Work Equipment System .................................................................................. 10-69 00-2
SK715-8E0
00 Index and Foreword
Index
PPC Lock System .......................................................................................................................... 10-70 Component Parts of Work Equipment System ............................................................................... 10-71 Travel System ....................................................................................................................................... 10-81 Layout Drawing of Travel System................................................................................................... 10-81 System Diagram of Travel Control System..................................................................................... 10-82 Component Parts of Travel System................................................................................................ 10-83 Work Equipment ................................................................................................................................... 10-96 Structure of Work Equipment ......................................................................................................... 10-96 Function of Work Equipment .......................................................................................................... 10-97 Work Equipment Clearance Adjustment Shim................................................................................ 10-98 20 Standard Value Table ................................................................................................................................ 20-1 Table of Contents .................................................................................................................................... 20-2 Standard Value Table for Engine ............................................................................................................. 20-3 Standard Value Table for Machine........................................................................................................... 20-5 Machine Posture and Procedures to Measure Performance ................................................................. 20-14 30 Testing and Adjusting ................................................................................................................................ 30-1 Table of Contents .................................................................................................................................... 30-2 Engine and Cooling System .................................................................................................................... 30-4 Examine Engine Speed.................................................................................................................... 30-4 Examine Exhaust Gas Color ............................................................................................................ 30-6 Examine and Adjust Valve Clearance............................................................................................... 30-8 Examine Compression Pressure .................................................................................................... 30-10 Examine Engine Oil Pressure ........................................................................................................ 30-12 Bleed Air from Fuel System............................................................................................................ 30-13 Examine Fuel Circuit for Leakage .................................................................................................. 30-14 Handle Cylinder Cut-out Mode Operation....................................................................................... 30-15 Examine and Adjust Alternator Belt Tension................................................................................... 30-16 Frame ................................................................................................................................................... 30-18 Examine and Adjust Gear Chain Tension ....................................................................................... 30-18 Hydraulic System .................................................................................................................................. 30-19 Release Remained Pressure in Hydraulic Circuit ........................................................................... 30-19 Examine Oil Pressure of Work Equipment ..................................................................................... 30-20 Adjust Oil Pressure of Work Equipment ......................................................................................... 30-23 Examine Oil Pressure of Control Circuit ......................................................................................... 30-25 Examine and Adjust Oil Pressure of Pump Circuit.......................................................................... 30-27 Examine Outlet Pressure of Solenoid Valve ................................................................................... 30-31 Examine PPC Valve Outlet Pressure.............................................................................................. 30-33 Examine Parking Brake Release Pressure..................................................................................... 30-37 Examine and Adjust Travel Deviation............................................................................................. 30-38 Adjust Play of Work Equipment and Travel PPC Valves ................................................................. 30-41 Examine Parts Which Cause Hydraulic Drift of Work Equipment.................................................... 30-42 Bleed Air from Hydraulic System.................................................................................................... 30-43 Pressurize Hydraulic Tank.............................................................................................................. 30-45 Electrical System .................................................................................................................................. 30-46 How to Set and Operate Machine Monitor...................................................................................... 30-46 How to Start Up KOMTRAX Terminal ............................................................................................. 30-81 Handle Voltage Circuit of Engine Controller ................................................................................... 30-86 40 Troubleshooting ........................................................................................................................................ 40-1 Table of Contents .................................................................................................................................... 40-2 Abbreviation List ..................................................................................................................................... 40-5 Related Information to Troubleshooting..................................................................................................40-11 General Troubleshooting Points ......................................................................................................40-11 Sequence of Events in Troubleshooting ......................................................................................... 40-12 Troubleshooting Points for Aftertreatment System ......................................................................... 40-14 Checks Before Troubleshooting ..................................................................................................... 40-22 Inspection Procedure Before Troubleshooting................................................................................ 40-24 Test in Accordance with Testing Procedure .................................................................................... 40-26 Procedure for Troubleshooting ....................................................................................................... 40-52 SK715-8E0
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Index
00 Index and Foreword
Information Shown in Troubleshooting Table.................................................................................. 40-55 Connector Contact Identification (For 4D88E-7 Engine)................................................................. 40-57 T-Branch Box and T-Branch Adapter Table .................................................................................... 40-61 Fuse Location Table ....................................................................................................................... 40-67 Failure Code Table ......................................................................................................................... 40-69 Troubleshooting by Failure Code (Display of Code) .............................................................................. 40-78 Failure Code [989L00].................................................................................................................... 40-78 Failure Code [989M00]................................................................................................................... 40-79 Failure Code [989N00] ................................................................................................................... 40-80 Failure Code [AQ20R1].................................................................................................................. 40-81 Failure Code [AS00R2] .................................................................................................................. 40-82 Failure Code [AS00R3] .................................................................................................................. 40-83 Failure Code [AS00R4] .................................................................................................................. 40-84 Failure Code [B@BCNS]................................................................................................................ 40-85 Failure Code [D19JKZ]................................................................................................................... 40-86 Failure Code [D811MC].................................................................................................................. 40-89 Failure Code [D862KA] .................................................................................................................. 40-90 Failure Code [D8ALKA].................................................................................................................. 40-91 Failure Code [D8ALKB].................................................................................................................. 40-93 Failure Code [D8AQKR] ................................................................................................................. 40-95 Failure Code [DAF0KT].................................................................................................................. 40-97 Failure Code [DAF0MB] ................................................................................................................. 40-98 Failure Code [DAF0MC] ................................................................................................................. 40-99 Failure Code [DAF3KK].................................................................................................................40-100 Failure Code [DAFGMC] ...............................................................................................................40-102 Failure Code [DAFLKA].................................................................................................................40-103 Failure Code [DAFLKB].................................................................................................................40-105 Failure Code [DAFQKR]................................................................................................................40-107 Failure Code [DB2QKR] ................................................................................................................40-108 Failure Code [DBH0MC] ...............................................................................................................40-112 Failure Code [DBH2KK] ................................................................................................................40-113 Failure Code [DBHLKA] ................................................................................................................40-115 Failure Code [DBHLKB] ................................................................................................................40-117 Failure Code [DBHQKR] ...............................................................................................................40-119 Failure Code [F@HSZG]...............................................................................................................40-124 Failure Code [F@HSZL]................................................................................................................40-126 Troubleshooting of Electrical System (E-Mode)....................................................................................40-128 E-1 Engine Does Not Start (Engine Does Not Crank)....................................................................40-128 E-2 Engine Does Not Start (Fuel Feed Pump System)..................................................................40-134 E-3 Automatic Preheating System Does Not Operate ...................................................................40-135 E-4 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing...............40-137 E-5 Engine Coolant Temperature Monitor Comes On in White While Engine Runs.......................40-140 E-6 Charge Level Monitor Comes On in Red While Engine is in Operation...................................40-141 E-7 Fuel Level Monitor Comes On in Red While Engine Runs ......................................................40-142 E-8 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation ...........40-143 E-9 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation .........................40-144 E-10 Fuel Gauge Display Does Not Move from Minimum or Maximum .........................................40-145 E-11 Display of Fuel Gauge is Different from Actual Fuel Level.....................................................40-147 E-12 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum ...............40-148 E-13 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature..........40-149 E-14 Some Areas of Machine Monitor Screen are Not Shown ......................................................40-150 E-15 Function Switch Does Not Operate.......................................................................................40-151 E-16 Alarm Buzzer Does Not Sound .............................................................................................40-152 E-17 Alarm Buzzer Cannot be Canceled.......................................................................................40-154 E-18 Service Meter is Not Shown, While Starting Switch is in OFF Position .................................40-155 E-19 Service Mode Cannot be Selected........................................................................................40-156 E-20 Alarm Does Not Sound During Travel ...................................................................................40-157 E-21 Travel Alarm Does Not Stop When Machine Stops...............................................................40-159 00-4
SK715-8E0
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00 Index and Foreword
Index
E-22 Horn Does Not Sound...........................................................................................................40-160 E-23 Horn Does Not Stop .............................................................................................................40-162 E-24 Front or Rear Working Lamps Do Not Light Up.....................................................................40-163 E-25 When Front Wiper Switch is Operated, Front Wiper Does Not Operate ................................40-167 E-26 When Rear Wiper Switch is Operated, Rear Wiper Does Not Operate .................................40-169 E-27 When Front Wiper Switch is Operated, Front Window Washer Does Not Operate................40-171 E-28 When Rear Wiper Switch is Operated, Rear Window Washer Does Not Operate .................40-173 E-29 Travel Indicator is Not Shown Correctly with Monitoring Function.........................................40-175 E-30 Arm IN is Not Shown Normally in Monitoring Function..........................................................40-176 E-31 KOMTRAX System Does Not Operate Normally...................................................................40-177 Troubleshooting of Engine (S-Mode)....................................................................................................40-178 Information Shown in Troubleshooting Table (S-Mode) .................................................................40-178 S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position..............................40-179 S-2 Engine Cranks but No Exhaust Smoke Comes Out ................................................................40-180 S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)......40-181 S-4 Engine Startability is Unsatisfactory........................................................................................40-182 S-5 Engine Does Not Pick Up Smoothly........................................................................................40-184 S-6 Engine Stops During Operation ..............................................................................................40-186 S-7 Engine Runs Rough or is Not Stable ......................................................................................40-187 S-8 Engine Lacks Power ...............................................................................................................40-188 S-9 KDPF Becomes Clogged in a Short Time ...............................................................................40-190 S-10 Engine Oil Consumption is Excessive...................................................................................40-191 S-11 Oil Becomes Dirty Quickly.....................................................................................................40-192 S-12 Fuel Consumption is Excessive ............................................................................................40-193 S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant.............................................................40-194 S-14 Oil Pressure Drops ...............................................................................................................40-195 S-15 Fuel Mixes Into Engine Oil ....................................................................................................40-197 S-16 Water Mixes Into Engine Oil (Milky) ......................................................................................40-198 S-17 Coolant Temperature Increases Too High (Overheating) ......................................................40-199 S-18 Unusual Noise is Heard ........................................................................................................40-200 S-19 Vibration is Excessive...........................................................................................................40-201 S-20 Air Cannot be Bled from Fuel Circuit.....................................................................................40-202 50 Disassembly and Assembly ...................................................................................................................... 50-1 Table of Contents .................................................................................................................................... 50-2 Related Information on Disassembly and Assembly................................................................................ 50-4 How to Read This Manual ................................................................................................................ 50-4 Coating Materials List....................................................................................................................... 50-6 Engine and Cooling System .................................................................................................................. 50-10 Remove and Install Starter Assembly ............................................................................................ 50-10 Remove and Install Radiator Assembly...........................................................................................50-11 Remove and Install Engine and Pump Assembly ........................................................................... 50-18 Remove and Install Fuel Tank Assembly........................................................................................ 50-28 Remove and Install Alternator Assembly........................................................................................ 50-31 Remove and Install Air Cleaner Assembly ..................................................................................... 50-32 Frame ................................................................................................................................................... 50-34 Remove and Install Engine Hood ................................................................................................... 50-34 Remove and Install Heater Assembly ............................................................................................ 50-36 Raise Arm and Tilt Cab .................................................................................................................. 50-41 Fully Tilt and Rest the Cab Assembly............................................................................................. 50-44 Remove and Install Cab Assembly................................................................................................. 50-50 Remove and Install Wheel Hub Assembly...................................................................................... 50-57 Remove and Install Travel Motor Assembly ................................................................................... 50-61 Hydraulic System .................................................................................................................................. 50-66 Remove and Install Pump Assembly.............................................................................................. 50-66 Remove and Install Gear Pump Assembly ..................................................................................... 50-70 Remove and Install Pump Coupling ............................................................................................... 50-72 Remove and Install Control Valve .................................................................................................. 50-75 Remove and Install PPC Valve....................................................................................................... 50-79 SK715-8E0
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Index
00 Index and Foreword
Work Equipment ................................................................................................................................... 50-82 Remove and Install Arm ................................................................................................................. 50-82 Remove and Install Lift Cylinder..................................................................................................... 50-86 Remove and Install Bucket Cylinder............................................................................................... 50-88 Remove and Install Equipment Support Frame .............................................................................. 50-90 Electrical System .................................................................................................................................. 50-92 Remove and Install Battery ............................................................................................................ 50-92 60 Maintenance Standard .............................................................................................................................. 60-1 Table of Contents .................................................................................................................................... 60-2 Engine and Cooling System .................................................................................................................... 60-3 Maintenance Standard for PTO........................................................................................................ 60-3 Hydraulic System .................................................................................................................................... 60-4 Maintenance Standard for Control Valve (Standard Flow) ................................................................ 60-4 Maintenance Standard for Control Valve (Super Flow)..................................................................... 60-9 Maintenance Standard for Work Equipment PPC Valve ................................................................. 60-14 Maintenance Standard for Travel PPC Valve ................................................................................. 60-17 Maintenance Standard for Attachment PPC Valve ......................................................................... 60-20 Power Train........................................................................................................................................... 60-22 Maintenance Standard for Transmission ........................................................................................ 60-22 Work Equipment ................................................................................................................................... 60-24 Maintenance Standard for Work Equipment Linkage...................................................................... 60-24 Maintenance Standard for Lift Cylinder .......................................................................................... 60-26 Maintenance Standard for Tilt Cylinder .......................................................................................... 60-27 90 Circuit Diagrams........................................................................................................................................ 90-1 Table of Contents .................................................................................................................................... 90-2 How to Read the Codes for Electric Cable .............................................................................................. 90-3 Hydraulic Circuit Diagram........................................................................................................................ 90-7 Symbols Used in Hydraulic Circuit Diagram ..................................................................................... 90-7 Hydraulic Circuit Diagram................................................................................................................90-11 Electrical Circuit Diagram ...................................................................................................................... 90-13 Symbols Used in Electric Circuit Diagram ...................................................................................... 90-13 Electrical Circuit Diagram (1/6)....................................................................................................... 90-17 Electrical Circuit Diagram (2/6)....................................................................................................... 90-19 Electrical Circuit Diagram (3/6)....................................................................................................... 90-21 Electrical Circuit Diagram (4/6)....................................................................................................... 90-23 Electrical Circuit Diagram (5/6)....................................................................................................... 90-25 Electrical Circuit Diagram (6/6)....................................................................................................... 90-27 INDEX..................................................................................................................................................................1
00-6
SK715-8E0
00 Index and Foreword
How to Read the Shop Manual
Foreword, Safety, Basic Information How to Read the Shop Manual •
Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor.
•
The materials and specifications are subject to change without notice.
•
Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.
•
Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
Composition of the Shop Manual This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 Index and Foreword This section describes the index, foreword, safety, and basic information.
01 Specification This section describes the specifications of the machine.
10 Structure and Function This section describes the structure and operation of each component with respect to each system. “Structure and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 Testing and Adjusting This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for Testing and Adjusting are described in “Standard Value Table”.
40 Troubleshooting This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 Disassembly and Assembly This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 Other Information This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams This section describes hydraulic circuit diagrams and electrical circuit diagrams.
SK715-8E0
00-7
How to Read the Shop Manual
00 Index and Foreword
Symbols Important safety and quality portions are marked with the following symbols so that shop manual is used effectively. Symbol
Item
Remark
Danger
This signal indicates an extremely hazardous situation which will result in death or serious injury if it is not avoided.
Warning
This signal indicates a potentially hazardous situation which will result in death or serious injury if it is not avoided.
Caution
This signal indicates a potentially hazardous situation which will result in injury or property damage around the machine if it is not avoided.
Weight
This signal indicates the weight of parts and components, and items which requires great attention to a selection of wires and working posture for slinging work.
Tightening torque
This signal indicates the tightening torque for portions which requires special care in assembling work.
Coat
This signal indicates a place to be coated with adhesive, grease, etc. in assembling work.
Oil and coolant
This signal indicates a place to supply oil, coolant, etc. and the quantity.
Draining
This signal indicates a place to drain oil, coolant, etc. and the quantity.
Safety
This symbol indicates the works which require special caution for the machine safety when assembling.
Signal Word Signal word for notice and remark describes the following. Symbol
Item
Remark
NOTICE
Notice
If the precaution of this signal word is not observed, the machine damage or shortening of service life may occur.
REMARK
Remark
This signal word contains useful information to know.
Unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }.
00-8
SK715-8E0
00 Index and Foreword
Safety Notice for Operation
Safety Notice for Operation •
Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purposes.
•
The symbol mark
is indicated for such matters that require special precautions. The work indicated with
should be performed according to the instructions with special attention. Should a this warning mark hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every necessary measures.
Safety Considerations •
Well organized work place
•
Correct work clothes
•
Observance of work standard
•
Enforcement of hand signals
•
Prohibition against unlicensed persons operating and handling the machine
•
Safety check before starting work
•
Wear of dust glasses (for cleaning or grinding work)
•
Wear of welding goggles and protectors (for welding work)
•
Being in good physical condition, and good preparation
•
Always be alert and careful.
General Precautions k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this manual before operation. •
Read and understand the meaning of all the safety labels stuck to the machine before performing any greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Operation and Maintenance Manual.
•
Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on the floor. Smoke only in the designated areas. Never smoke while working.
•
Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
•
Always wear safety shoes and helmet when performing any operation. Do not wear loose clothes, or clothes with buttons missing.
SK715-8E0
00-9
Safety Notice for Operation
00 Index and Foreword
•
Always wear the protective eyeglasses when hitting parts with a hammer.
•
Always wear the protective eyeglasses when grinding parts with a grinder, etc.
•
When performing any operation with multiple workers, always agree on the operating procedure before starting. Be clear in verbal communication, and observe hand signals. Hang “UNDER REPAIR” warning tag in the operator's compartment Before starting work.
•
Work and operation which require license or qualification should be performed by qualified workers.
•
Welding repairs should be performed by trained and experienced welders. When performing welding work, always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
•
Warm up before starting the work with exercise which increases alertness and the range of motion in order to prevent injury.
•
Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe area.
G0000885
Precautions for Preparatory Work •
Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving before adding oil or making any repairs.
•
Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang “UNDER REPAIR” warning tag on them.
•
When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work.
•
Remove all mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed. Repair it or replace it immediately. G0000874
Precautions During Work •
For the machine with the battery disconnect switch, check before starting the work that the system operating lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position. REMARK Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type. For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) terminal first.
•
For the machine with the quick release battery terminal (-), check before starting the work that the system operating lamp is not lit. Then, disconnect the quick release battery terminal (-). REMARK For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the quick release battery terminal (-).
00-10
SK715-8E0
00 Index and Foreword
Safety Notice for Operation
•
Release the remaining pressure from the circuit before starting the work of disconnecting and removing of oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it should be done slowly otherwise the oil spills.
•
When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit.
•
The coolant and oil in the circuits are hot when the engine is shut down. Be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or coolant circuits.
G0119780
G0119782
•
Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut down the engine. When checking the machine without shutting down the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts.
•
When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, webbing slings, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
•
When removing a part which is under internal pressure or under reaction force of a spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately to release the pressure, and then remove the part.
•
When removing components, do not break or damage the electrical wiring. Damaged wiring may cause a fire.
•
When removing piping, do not spill the fuel or oil. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires.
•
Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in particular.
SK715-8E0
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00-11
Safety Notice for Operation
•
00 Index and Foreword
Install the disassembled parts again to the original position. Replace the damaged parts or the parts that cannot be used again with new ones. Before you connect the hoses or wiring harnesses, make sure that they do not touch and give damage to other parts when you operate the machine. REMARK When you replace the removed or disassembled parts with new ones, refer the parts book to find out the part number.
•
When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that high pressure hoses and tubes are correctly installed.
•
When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are installed correctly.
•
Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
•
Check that the measuring tools are correctly installed when measuring hydraulic pressure.
•
Take care when removing or installing the tracks of track-type machines. Since the track shoe may separate suddenly when you remove it, never let anyone stand at either end of the track shoe.
•
If the engine is operated for a long time in a closed place with poor ventilation, it may cause gas poisoning. Open the windows and doors to ventilate the place well.
G0000877
Precautions for Slinging Work and When You Make Signals •
Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaler must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely. k Never stand under the load.
k Do not move a load over a person. k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they
are not caught between the load and materials or equipment on the ground or hit by the load even if the crane starts abruptly. •
Check the slings before starting sling work.
•
Keep putting on gloves during sling work. (Put on leather gloves, if available.)
•
Measure the weight of the load by the eye and check its center of gravity.
•
Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.
•
Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or
slipping of the rope from its original slinging position on the load, which can result in a dangerous accident. •
Hanging angle must be 60° or smaller as a rule.
00-12
SK715-8E0
00 Index and Foreword
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Safety Notice for Operation
When slinging a heavy load ( 25 kg or heavier), the hanging angle of the rope must be narrower than that of the hook. REMARK When slinging a load with 2 or more ropes, the force subjected to each rope increases with the hanging angle. The figure below shows the variation of allowable load in kN {kg} when slinging is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1000 kgf} vertically, at various hanging angles. When the 2 ropes sling a load vertically, they can sling up to 2000 kg of total weight. This weight is reduced to 1000 kg when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 2000 kg load at a hanging angle of 150°, each rope is subjected to a force as large as 39.2 kN {4000kgf} .
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When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping.
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Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
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Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch sys-
tem.
k Slinging
near the tip of the hook may cause the rope to slip off the hook during hoisting.
REMARK The strength of the hook is maximum at its central part.
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Never use a wire rope which has breaks in strands (A), reduced diameter (B), or kinks (C). There is a danger that the rope may break during the towing operation.
Precautions for slinging up •
Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught.
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After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
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If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
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Do not lift up the load at an angle.
Precautions for slinging down •
When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
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Check that the load is stable, and then remove the sling.
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Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
Precautions When You Use Mobile Crane REMARK Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
SK715-8E0
00-13