SKIDSTEERLOADER
ThismaterialisproprietarytoKomatsuAmericaCorp.andisnottobereproduced,used,ordisclosedexceptin accordancewithwrittenauthorizationfromKomatsuAmericaCorp.
Itisourpolicytoimproveourproductswheneveritispossibleandpracticaltodoso.Wereservetherightto makechangesorimprovementsatanytimewithoutincurringanyobligationtoinstallsuchchangesonproducts soldpreviously.
Duetothiscontinuousprogramofresearchanddevelopment,revisionsmaybemadetothispublication.Itis recommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision.
Copyright2010Komatsu PrintedinU.S.A. KomatsuAmericaCorp.
January2010
00FORWARD.
01GENERAL
10STRUCTURE,FUNCTIONANDMAINTENANCESTANDARD
20STANDARDVALUETABLES
30TESTINGANDADJUSTING.
40TROUBLESHOOTING.
50DISASSEMBLYANDASSEMBLY.
90DIAGRAMSANDSCHEMATICS.
FOREWORD
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SafetyNotice
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.Thecautions accompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise, firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GeneralPrecautions
Mistakesinoperationareextremelydangerous.Readthe OPERATION&MAINTENANCEMANUALcarefully BEFOREoperatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,readallthe precautionsgivenonthedecalswhicharefixedtothe machine.
2.Whencarryingoutanyoperation,alwayswearsafety shoesandhelmet.Donotwearlooseworkclothes,or clotheswithbuttonsmissing.
•Alwayswearsafetyglasseswhenhittingpartswitha hammer.
•Alwayswearsafetyglasseswhengrindingpartswitha grinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.Whencarrying outweldingwork,alwayswearweldinggloves,apron, glasses,capandotherclothessuitedforweldingwork.
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure beforestarting.Alwaysinformyourfellowworkers beforestartinganystepoftheoperation.Beforestarting work,hang"UNDERREPAIR"signsonthecontrolsin 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.
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12 4.Whenraisingheavycomponents,useahoistorcrane.Checkthatthewirerope,chainsandhooksarefreefromdamage. Alwaysuseliftingequipmentwhichhasamplecapacity.Installtheliftingequipmentatthecorrectplaces.Useahoistor craneandoperateslowlytopreventthecomponentfromhittinganyotherpart.Donotworkwithanypartstillraisedby thehoistorcraneandalwaysstandclearfromwhatyouareraising.
5.Whenremovingcoverswhichareunderinternalpressureorunderpressurefromaspring,alwaysleavetwoboltsin positiononoppositesides.Slowlyreleasethepressure,thenslowlyloosentheboltstoremove.
6.Whenremovingcomponents,becarefulnottobreakordamagethewiring,Damagedwiringmaycauseelectricalfires.
7.Whenremovingpiping,stopthefueloroilfromspillingout.Ifanyfueloroildripsontothefloor,wipeitup immediately.Fueloroilonthefloorcancauseyoutoslip,orcanevenstartfires.
8.Neveruseflammableliquidstocleanparts,alwaysuseapprovednon-flammablesolventstocleanparts.
9.Besuretoassembleallpartsintheiroriginallocations.Replaceanydamagedpartwithnewparts.
•Wheninstallinghosesandwires,besurethattheywillnotbedamagedbycontactwithotherpartswhenthemachine isbeingoperated.
10.Wheninstallinghighpressurehoses,besurethattheyarenottwisted.Damagedtubbingdangerous,beextremelycareful wheninstallingtubesforhighpressurecircuits.Alsomakesurepartsarecorrectlyinstalled.
11.Whenassemblingorinstallingparts,alwaysusethespecifiedtighteningtorquesandsequences.Wheninstalling protectivepartssuchasguards,orpartsthatmayvibrateorrotateathighspeeds,beparticularlycarefultochecktheir installationcarefully.
12.Whenaligningtwoholes,neverinsertyourfingersorhand.Useappropriatetoolstoalignparts.
13.Whenmeasuringhydraulicpressure,besurethemeasuringtooliscorrectlyassembledbeforetakinganymeasurements.
14.Takecarewhenremovingorinstallingthetracksontrack-typemachines.Whenremovingthetrack,thetrackseparates suddenly,neverletanyonestandateitherendofthetrack.
15.Whenmakingrepairsoradjustmentsonelectronicallycontrolledengines,avoidanyphysicalcontactwiththeinjection systemswiringharnesswhiletheengineisrunning.Duetothehighvoltageandamperageinthissystem,seriousinjury mayoccur.
16.Whenremovingthetrack,thetrackseparatessuddenly,soneverletanyonestandateitherendofthetrack.
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesureyou understandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.For easeofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeachmain groupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel,coolantand lubricantspecificationcharts.
STRUCTURE,FUNCTIONANDMAINTENENCESTANDARD
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingofthe structure,butalsogivesthejudgementstandardswheninspecting,dissembledpartsandservesasreferencematerialfor troubleshooting.
TESTINGANDADJUSTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemadeat completionofthechecksandrepairs.
TROUBLESHOOTING
Troubleshootingchartscorrelating“Problems”to“Causes”arealsoincludedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeachcomponent, aswellasprecautionstobetakenfortheseoperations.
DIAGRAMSANDDRAWINGS
Thissectionhasthehydraulicandelectricalschematics.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvancenotice.Contact yourdistributorforthelatestinformation.
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: 10-3
Itemnumber(10.StructureandFunction)
Consecutivepagenumberforeachitem
3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.Fileas intheexample. Example:
Revisions
RevisedpagesareshownattheLISTOFREVISEDPAGES betweenthetitlepageandSAFETYpage.
Symbols
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwiththe followingsymbols.
SymbolItemRemarks
Safety
Caution
Weight
Tightening torque
Specialsafetyprecautionsare necessarywhenperformingthe work.
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems. Cautionnecessarywhen selectinghoistingwireorwhen workingpostureisimportant, etc.
Placesthatrequirespecial attentionfortighteningtorque duringassembly.
CoatPlacestobecoatedwithadhesivesandlubricantsetc.
Oil,waterPlaceswhereoil,waterorfuel mustbeadded,andthecapacity.
Drain
Placeswhereoilorwatermust bedrained,andquantitytobe drained.
RevisedEditionMark
Whenamanualisrevised,aneditionmark(…)is recordedonthebottomoutsidecornerofthepages.
12 HOISTINGINSTRUCTIONS
Hoisting
WARNING!Heavyparts(25kgormore) mustbeliftedwithahoistetc. IntheDISASSEMBLYAND ASSEMBLYsection,every partweighing25kgormoreis indicatedclearlywiththe symbol
•Ifapartcannotbesmoothlyremovedfromthemachine byhoisting,thefollowingchecksshouldbemade:
1.Checkforremovalofallboltsfasteningtheparttothe relativeparts.
2.Checkforexistenceofanotherpartcausinginterface withtheparttoberemoved.
WireRopes
1.Useadequateropesdependingontheweightofpartsto behoisted,referringtothetablebelow:
Wireropes
(Standard“Z”or“S”twistropeswithoutgalvanizing)
3.Donotslingaheavyloadwithoneropealone,butsling withtwoormoreropessymmetricallywoundontothe load.
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Theallowableloadvalueisestimatedtobe1/6or 1/7ofthebreakingstrengthoftheropeused.
2.Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausetheropeto slipoffthehookduringhoisting,andaseriousaccident canresult.Hookshavemaximumstrengthatthemiddle portion.
WARNING!Slingingwithoneropemay causeturningoftheload duringhoisting,untwistingof therope,orslippingofthe ropefromitsoriginalwinding positionontheload,which canresultinadangerous accident.
4.Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.Whenhoistingaloadwith twoormoreropes,theforcesubjectedtoeachropewill increasewiththehangingangles.Thetablebelow showsthevariationofallowableload(kg)when hoistingismadewithtworopes,eachofwhichis allowedtoslingupto1000kgvertically,atvarious hangingangles.Whentworopesslingaloadvertically, upto2000kgoftotalweightcanbesuspended.This weightbecomes1000kgwhentworopesmakea120° hangingangle.Ontheotherhand,tworopesaresubject toanexcessiveforceaslargeas4000kgiftheyslinga 2000kgloadataliftingangleof150°.
12 COATINGMATERIALS
Therecommendedcoatingmaterialsprescribedintheshopmanualsarelistedbelow.
CategoryCodePartNo.QuantityContainerMainapplications,features
LT-1A790-129-9030150gTube•Usedtopreventrubbergaskets,rubber cushionsandcorkplugsfromcomingout
•Usedinplacesrequiringanimmediately effective,strongadhesive.
Gasket sealant
LT-1B790-129-905020g(2pieces)
Polyethylene container
LT-209940-0003050gPolyethylene container
•Usedforplastics(exceptpolyethylene, polypropylene,tetrafluoroethylene,and vinylchloride),rubber,metaland non-metal.
•Features:Resistancetoheat,chemicals
•Usedforanti-looseningandsealant purposesforboltsandplugs.
LT-3
790-129-9060 (Setofadhesive andhardening agent)
Adhesive: 1kg Hardening agent: 500g
Can•Usedasadhesiveorsealantformetal,glass orplastic.
LT-4790-129-9040250gPolyethylenecontainer•Usedassealantformachinedholes.
Holtz MH705790-126-912075gTube•Usedasheat-resistingsealantforrepairing engine.
Threebond 1735179-129-91402gPolyethylene container
Aron-alpha 201790-129-913050gPolyethylene container
Loctite 648-5079A-129-911050ccPolyethylene container
•Quickhardeningtypeadhesive.
•Curetime:within5sec.to3min.
•Usedmainlyforadhesionofmetals, rubbers,plasticsandwoods.
•Quickhardeningtypeadhesive.
•Quickcuretype(max.strengthafter 30minutes).
•Usedmainlyforadhesionofrubbers, plasticsandmetals.
•Features:Resistancetoheat,chemicals
•Usedatjointportionssubjecttohigh temperature.
LG-1790-129-9010200gTube•Usedasadhesiveorsealantforgasketsand packingofpowertraincase,etc.
•Features:Resistancetoheat
LG-3790-129-90701kgCan
•Usedassealantforflangesurfacesandbolts athightemperaturelocations;usedto preventseizure.
•Usedassealantforheatresistantgasketfor athightemperaturelocationssuchasengine pre-combustionchamber,exhaustpipe.
CategoryCodePartNo.QuantityContainerMainapplications,features
•Features:Resistancetowater,oil
•Usedassealantforflangesurface,thread.
LG-4790-129-9020200gTube
LG-5790-129-90801kgPolyethylene container
•Alsopossibletouseassealantforflanges withlargeclearance.
•Usedassealantformatingsurfacesoffinal drivecase,transmissioncase.
•Usedassealantforvariousthreads,pipe joints,flanges.
•Usedassealantfortaperedplugs,elbows, nipplesofhydraulicpiping.
Gasket sealant
LG-609940-00011250gTube
LG-709920-00150150gTube
•Features:Siliconbased,resistanttoheat, cold.
•Usedassealantforflangesurface,thread.
•Usedassealantforoilpan,finaldrivecase, etc.
•Features:Siliconbased,quickhardening type.
•Usedassealantforflywheelhousing,intake manifold,oilpan,thermostathousing,etc.
Threebond 1211790-129-9090100gTube•Usedasheat-resistingsealantforrepairing engines.
MolybdenumdisulphidelubricantLM-G09940-0005160gCan•Usedaslubricantforslidingparts (topreventsqueaking).
LM-P09940-00040200gTube
SYG2-400LI
SYG2-350LI
G2-LI
SYG2-400LI-A
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
G2-CA
Grease
SYG2-160CA
SYG2160CNCA
•Usedtopreventseizureorscuffingofthe threadwhenpressfittingorshrinkfitting.
•Usedaslubricantforlinkage,bearings,etc.
VariousVarious•Generalpurposetype
VariousVarious
•Usedfornormaltemperature,lightload bearingatplacesincontactwithwateror steam.
MolybdenumdisulphidelubricantSYG2-400M400g(10percase)Belowstype•Usedforplaceswithheavyload.
