MachineModelSerialnumber
SK820-5E0F60003andup
00Indexandforeword
50Disassemblyandassembly
Hydraulicdiagram(float-roadhomologation).........................................................................................5
Hydraulicdiagram(float-roadhomologation-SlowSpeedcontrol).......................................................7
Hydraulicdiagram(High-flow)..................................................................................................................9
Hydraulicdiagram(High-flow-roadhomologation)...............................................................................11
Hydraulicdiagram(High-flow-roadhomologation-SlowSpeedcontrol)............................................13
Electricalcircuitdiagrams.........................................................................................................................15
Electricalcircuitdiagram(1/2)................................................................................................................15
Electricalcircuitdiagram(2/2)................................................................................................................17
(Rev.2010/03)
Importantsafetynotice
Appropriateservicingandrepairareextremelyimportanttoensuresafeoperationofthemachine. TheshopmanualsdescribetheeffectiveandsafeservicingandrepairmethodsrecommendedbyKomatsu.SomeoftheservicingandrepairmethodsrequireuseofspecialtoolsdesignedbyKomatsu forspecialpurposes.
Thesymbolmark"k"isindicatedforsuchmattersthatrequirespecialprecautions.Theworkindicatedwiththewarningmarkshouldbeperformedaccordingtotheinstructionswithspecialattention totheprecautions.Shouldahazardoussituationoccurorbeanticipatedduringsuchwork,besure tokeepsafefirstandtakeeverynecessarymeasure.
1.Generalprecautions
kInappropriatehandlingcreatesanextremedanger.Readandunderstandwhat isdescribedintheOperationandMaintenanceManualbeforeoperatingthemachine.Readandunderstandwhatis describedinthismanualbeforestarting work.
1)Beforeperforminganygreasingorrepairs, readallthesafetylabelsstucktothe machine.Forthelocationsofthesafety labelsanddetailedexplanationofprecautions,seetheOperationandMaintenance Manual.
2)Locateaplaceintherepairworkshoptokeep toolsandremovedparts.Alwayskeepthe toolsandpartsintheircorrectplaces.Always keeptheworkareacleanandmakesurethat thereisnodirt,water,oroilonthefloor. Smokeonlyintheareasprovidedfor smoking.Neversmokewhileworking.
3)Whenperforminganyoperation,always wearsafetyshoesandhelmet.Donotwear looseworkclothes,orclotheswithbuttons missing.
qAlwayswearthesafetyglasseswhenhittingpartswithahammer.
qAlwayswearthesafetyglasseswhen grindingpartswithagrinder,etc.
4)Whenperforminganyoperationwithtwoor moreworkers,alwaysagreeontheoperating procedurebeforestarting.Alwaysinform yourfellowworkersbeforestartinganystep oftheoperation.Beforestartingwork,hang UNDERREPAIRwarningtagintheoperator'scompartment.
5)Onlyqualifiedworkersmustperformthework andoperationwhichrequirelicenseorqualification.
6)Keepalltoolsingoodcondition,learnthe correctwaytousethem,andusetheproper ones.Beforestartingwork,thoroughlycheck thetools,machine,forklifttruck,servicecar, etc.
7)Ifweldingrepairsareneeded,alwayshavea trainedandexperiencedwelderperformthe work.Whenperformingweldingwork,always wearweldinggloves,apron,shielding goggles,capandotherclothessuitedfor weldingwork.
8)Beforestartingwork,warmupyourbody thoroughlytostartworkundergoodcondition.
9)Avoidcontinuingworkforlonghoursand takerestsatproperintervalstokeepyour bodyingoodconditionandattheprovided place.
Safetypoints
1Goodarrangement
2Correctworkclothes
3Followingworkstandard
4Makingandcheckingsignals
5Prohibitionofoperationandhandlingbyunlicensedworkers
6Safetycheckbeforestartingwork
7Wearingprotectivegoggles(forcleaningorgrindingwork)
8Wearingshieldinggogglesandprotectors(for weldingwork)
9Goodphysicalconditionandpreparation
10Precautionsagainstworkwhichyouarenotused tooryouareusedtotoomuch
2.Preparationwork
1)Beforeaddingoilormakinganyrepairs,park themachineonahardandlevelground,and applytheparkingbrakeandchockthe wheelsortrackstopreventthemachinefrom moving.
2)Beforestartingwork,lowertheworkequipment(blade,ripper,bucket,etc.)tothe ground.Ifthisisnotpossible,insertthelock pinoruseblockstopreventtheworkequipmentfromfalling.Inaddition,besuretolock allthecontrolleversandhangwarningtagon them.
3)Whendisassemblingorassembling,support themachinewithblocks,jacks,orstands beforestartingthework.
4)Removeallmudandoilfromthestepsor otherplacesusedtogetonandoffthe machine.Alwaysusethehandrails,ladders orstepswhengettingonoroffthemachine. Neverjumponoroffthemachine.Ifitis impossibletousethehandrails,laddersor steps,useastandtoprovidesafefooting.
3.Precautionsduringwork
1)Beforedisconnectingorremovingcomponentsfortheoil,water,oraircircuits,first releasethepressurecompletelyfromthe circuit.Whenremovingtheoilfillercap,a drainplug,oranoilpressurepickupplug, loosenitslowlytopreventtheoilfrom spurtingout.
2)Thecoolantandoilinthecircuitsarehot whentheengineisshutdown,sobecareful nottogetscalded.Waitfortheoilandcoolant tocoolbeforeperforminganyworkontheoil orwatercircuits.
3)Beforestartingwork,shutdowntheengine. Whenworkingonoraroundarotatingpart,in particular,shutdowntheengine.When checkingthemachinewithoutshuttingdown theengine(measuringoilpressure,revolving speed,temperature,etc.),takeextremecare nottogetcaughtinrotatingpartsormoving parts.
4)Beforestartingwork,removethecablesfrom thebattery.Alwaysremovethecablefrom thenegative(–)terminalfirst.
5)Whenraisingaheavycomponent(heavier than25kg),useahoistorcrane.Before startingwork,checkthattheslings(wire ropes,chains,andhooks)arefreefrom damage.Alwaysuseslingswhichhave amplecapacityandinstallthemtoproper places.Operatethehoistorcraneslowlyto preventthecomponentfromhittinganyother part.Donotworkwithanypartstillraisedby thehoistorcrane.
6)Whenremovingacoverwhichisunder internalpressureorunderpressurebya spring,alwaysleavetwoboltsindiagonal positions.Loosenthoseboltsgraduallyand alternatelytoreleasethepressure,andthen removethecover.
7)Whenremovingcomponents,becarefulnot tobreakordamagetheelectricalwiring. Damagedwiringmaycauseelectricalfires.
8)Whenremovingpiping,stopthefueloroil fromspillingout.Ifanyfueloroildripsonto thefloor,wipeitoffimmediately.Fueloroil onthefloorcancauseyoutoslipandcan evencausefires.
9)Asageneralrule,donotusegasolineto washparts.Donotuseittocleanelectrical parts,inparticular.
10)Besuretoassembleallpartsagainintheir originalplaces.Replaceanydamagedparts andpartswhichmustnotbereusedwithnew parts.Wheninstallinghosesandwires,be surethattheywillnotbedamagedbycontact withotherpartswhenthemachineisoperated.
11)Wheninstallinghighpressurehosesand tubes,makesurethattheyarenottwisted. Damagedhosesandtubesaredangerous, sobeextremelycarefulwheninstalling hosesandtubesforhighpressurecircuits.In addition,checkthatconnectionsofthemare correct.
12)Whenassemblingorinstallingparts,always tightenthemtothespecifiedtorques.When installingprotectivepartssuchasguards,or partswhichvibrateviolentlyorrotateathigh speeds,beparticularlycarefultocheckthat theyareinstalledcorrectly.
13)Whenaligningtwoholes,neverinsertyour fingersorhand.Becarefulnottogetyour fingerscaughtinahole.
14)Whenmeasuringhydraulicpressure,check thatthemeasuringtoolsarecorrectly installed.
15)Takecarewhenremovingorinstallingthe wheels.
16)Iftheengineisoperatedforalongtimeina placewhichisnotventilatedwell,youmay sufferfromgaspoisoning.Accordingly,open thewindowsanddoorstoventilatewell.
4.Precautionsforslingingworkandmakingsignals
1)Onlyoneappointedworkermustmake signalsandco-workersmustcommunicate witheachotherfrequently.Theappointed signallermustmakespecifiedsignalsclearly ataplacewhereheiswellseenfromthe operator'sseatandwherehecanseethe workingconditioneasily.Thesignallermust alwaysstandinfrontoftheloadandguide theoperatorsafely.
qDonotstandundertheload.
qDonotstepontheload.
2)Checktheslingsbeforestartingslingwork.
3)Keepputtingonglovesduringslingwork. (Putonleathergloves,ifavailable.)
4)Measuretheweightoftheloadbytheeye andcheckitscentreofgravity.
5)Useproperslingaccordingtotheweightof theloadandmethodofslinging.Iftoothick wireropesareusedtoslingalightload,the loadmayslipandfall.
6)Donotslingaloadwithonewireropealone. Ifitisslungso,Itmayrotateandmayslipout oftherope.Installtwoormorewireropes symmetrically.
kSlingingwithoneropemaycause turningoftheloadduringhoisting,untwistingoftherope,orslippingofthe ropefromitsoriginalwindingposition ontheload,whichcanresultinadangerousaccident.
7)Limitthehangingangleto60degree,asa rule.
Donotslingaheavyload(25kgormore) withropesformingawidehangingangle fromthehook.
Whenhoistingaloadwithtwoormoreropes, theforcesubjectedtoeachropewillincrease withthehangingangle.Thetablebelow showsthevariationofallowableloadinkN {kg}whenhoistingismadewithtworopes, eachofwhichisallowedtoslingupto9.8kN {1000kg}vertically,atvarioushanging angles.Whenthetworopesslingaloadvertically,upto19.6kN{2000kg}oftotalweight canbesuspended.Thisweightisreducedto 9.8kN{1000kg}whenthetworopesmake ahangingangleof120degree.Ifthetwo ropesslinga19.6kN{2000kg}loadata liftingangleof150degree,eachofthemis subjectedtoaforceaslargeas39.2kN {4000kg}.
8)Wheninstallingwireropestoanangular load,applypadstoprotectthewireropes.If theloadisslippery,applypropermaterialto preventthewireropefromslipping.
9)Usethespecifiedeyeboltsandfixwireropes, chains,etc.tothemwithshackles,etc.
10)Applywireropestothemiddleportionofthe hook.
qSlingingnearthetipofthehookmay causetheropetoslipoffthehookduring hoisting.Thehookhasthemaximum strengthatthemiddleportion.
11)Donotusetwistedorkinkedwireropes.
12)Whenliftingupaload,observethefollowing.
qWindinthecraneslowlyuntilwireropes arestretched.Whensettlingthewire ropeswiththehand,donotgraspthem butpressthemfromabove.Ifyougrasp them,yourfingersmaybecaught.
qAfterthewireropesarestretched,stop thecraneandchecktheconditionofthe slungload,wireropes,andpads.
qIftheloadisunstableorthewireropeor chainsaretwisted,lowertheloadandlift itupagain.
qDonotliftuptheloadatanangle.
13)Whenloweringaload,observethefollowing.
qWhenliftingdownaload,stopittemporarilyat30cmabovethefloor,andthen loweritslowly.
qCheckthattheloadisstable,andthenremovethesling.
qRemovekinksanddirtfromthewire ropesandchainsusedfortheslingwork, andputtheminthespecifiedplace.
5.Precautionsforusingmobilecrane aReadtheOperationandMaintenanceManualofthecranecarefullyinadvanceandoperatethecranesafely.
6.Precautionsforusingoverheadtraveling crane kAhoistcraneorsimilardevicemustbe usedforliftingaheavyload(25kgor more).Theweightofapartthatis25kgor moreisindicatedwiththesymbol"4"in "Disassemblyandassembly".
1)Beforestartingwork,inspectthewireropes, brake,clutch,controller,rails,overwindstop device,groundfaultcircuitinterrupter,crane collisionpreventiondevice,andpowerapplicationwarninglamp,andchecksafety.
2)Observethesignalsforslingwork.
3)Operatethehoistatasafeplace.
4)Checkthedirectionindicatorplates(east, west,south,andnorth)andthedirectionsof thecontrolbuttonswithoutfail.
5)Donotslingaloadatanangle.Donotmove thecranewhiletheslungloadisswinging.
6)Donotraiseorloweraloadwhilethecrane ismovinglongitudinallyorlaterally.
7)Donotdragasling.
8)Whenliftingupaload,stopitjustafterit leavesthegroundandchecksafety,and thenliftitup.
9)Considerthetravelrouteinadvanceandlift upaloadtoasafeheight.
10)Placethecontrolswitchinapositionwhereit willnotbeanobstacletoworkandpassage.
11)Afteroperatingthehoist,donotswingthe controlswitch.
12)Rememberthepositionofthemainswitchso thatyoucanturnoffthepowerimmediatelyin anemergency.
13)Ifthehoiststopsbecauseofapowerfailure, turnthepowerswitchOFF.Whenturningon aswitchwhichwasturnedOFFbythe groundfaultcircuitinterrupter,checkthatthe devicesrelatedtothatswitcharenotinoperatingcondition.
14)Ifyoufindanobstaclearoundthehoist,stop theoperation.
15)Afterfinishingthework,stopthehoistatthe specifiedpositionandraisethehooktoat least2mabovethefloor.Donotleavethe slinginstalledtothehook.
7.Selectingwireropes
1)Selectadequateropesdependingonthe weightofpartstobehoisted,referringtothe tablebelow
Wireropes
(Standard"Z"twistropeswithoutgalvanizing) (JISG3525,No.6,Type6X37-A)
Nominaldiameter ofrope Allowableload mmkNton 108.80.9 1212.71.3 1417.31.7 1622.62.3 1828.62.9 2035.33.6 2555.35.6 3079.68.1 40141.614.4 50221.622.6 60318.332.4
aTheallowableloadisone-sixthofthe breakingstrengthoftheropetobeused (Safetycoefficient:6).
8.Precautionsfordisconnectingand connectinghosesandtubesinanairconditionercircuit
1)Disconnection
kAlthoughtherefrigerant(refrigerant gas:R134a)usedonthemachine'sair conditionerislessdestructivetothe ozonelayerforenvironmentallyfriendliness,itisnotallowedtobereleased intotheatmosphereasis.Whenever disconnectingtheairconditionergas circuit,besuretorecovertherefrigerantgastoreuseit.
aAskaqualifiedpersonforcollectionand chargeoftherefrigerant(R134a).
aNeverreleasetherefrigerant(R134a)to theatmosphere.
kIftherefrigerantgasgetsinyoureyes orcontactsyourskin,youmaylose yoursightoryourskinmaybefrozen. Wheneverrecoveringoraddingrefrigerantgas,youmustputonsafety glasses,safetyglovesandlong sleevedclothes. Therefrigerantgasmustberecovered andaddedbyaqualifiedperson.
2)Connection
1]Wheninstallingtheairconditionercircuit hosesandtubes,takecarethatdirt,dust, water,etc.willnotenterthem.
2]Whenconnectingtheairconditioner hosesandtubes,checkthatO-rings(1) arefittedtotheirjoints.
3]CheckthatO-ring(1)isfreefromflawand deterioration.
4]Whenconnectingtherefrigerantpiping, applycompressoroilforrefrigerant (R134a)(DENSO:ND-OIL8,VALEO THERMALSYSTEMS:ZXL100PG (equivalenttoPAG46))toitsO-rings. aExampleofO-ring(Fittedtoevery jointofhosesandtubes)
aFortighteningtorque,seetheprecautionsforinstallationineachsectionof "Disassemblyandassembly".