ParallelToolCarrier
MACHINEMODELSERIALNUMBERS
WA180-3A85001andup
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VARIOUSPRODUCTPARTS&SERVICEPUBLICATIONSAREAVAILABLETOALLKOMATSUCONSTRUCTION EQUIPMENTOWNERS,INCLUDINGOPERATION&MAINTENANCEMANUALS,PARTSBOOKSANDSHOP MANUALS.
SPECIALPUBLICATIONSSUCHASSERVICETOOL,AIRCONDITIONING,ANDTURBOCHARGERSHOP MANUALSAREALSOAVAILABLEASWELLASSELECTEDOPERATION&MAINTENANCEANDSHOPMANUALS INFOREIGNLANGUAGES.
THEPUBLICATIONSLISTEDBELOWAREAVAILABLEFORTHISPARTICULARMACHINE(S).
COMPLETEFORM ANDRETURNTOKomatsuAmericaInternationalCompany
440NorthFairwayDrive
VernonHills,IL60061-8112U.S.A.
Attn:TechnicalPublications FaxNo.(847)970-4186
TelNo.(847)970-5887
COMPANYNAME
SHIPTO
TYPEorPRINT ONLY
ATTN.
STREETADDRESS
CITY,STATE,ZIPCODE COUNTRY
PURCHASEORDERNO.
ORDERDATE
PHONENO.FAXNO.SHIPPINGMETHODDISTR/BRANCHCODE
IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERANDMACHINE SERIALNUMBERMUSTBESHOWN.
QTY.PUBLICATIONFORMNO.P-Paper
MODELNUMBERSERIALNUMBER PARTSBOOK M-Microfiche PUBLICATION DESCRIPTION
SAFETY
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepair techniquesrecommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation. Someoftheseoperationsrequiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.The cautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarises ormaypossiblyarise,firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONS
cleanandmakesurethatthereisnodirtoroilonthe
floor.Smokeonlyintheareasprovidedforsmoking.
Mistakesinoperationareextremelydangerous.ReadtheNeversmokewhileworking. OPERATION&MAINTENANCEMANUALcarefully BEFOREoperatingthemachine.
PREPARATIONSFORWORK
1.Beforecarryingoutanygreasingorrepairs,readall7.Beforeaddingoilormakingrepairs,parkthe theprecautionsgivenonthedecalswhicharefixedtomachineonhard,levelground,andblockthewheels themachine.ortrackstopreventthemachinefrommoving.
2.Whencarryingoutanyoperation,alwayswearsafety8.Beforestartingwork,lowerblade,ripper,bucketor shoesandhelmet.Donotwearlooseworkclothes,anyotherworkequipmenttotheground.Ifthisisnot orclotheswithbuttonsmissing.possible,insertthesafetypinoruseblockstoprevent theworkequipmentfromfalling.Inaddition,besureAlwayswearsafetyglasseswhenhittingpartswith ahammer.
Alwayswearsafetyglasseswhengrindingparts withagrinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.When carryingoutweldingwork,alwayswearwelding gloves,apron,glasses,capandotherclothessuited forweldingwork.
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure beforestarting.Alwaysinformyourfellowworkers beforestartinganystepoftheoperation.Before startingwork,hangUNDERREPAIRsignsonthe controlsintheoperator'scompartment.
5.Keepalltoolsingoodconditionandlearnthecorrect waytousethem.
6.Decideaplaceintherepairworkshoptokeeptools andremovedparts.Alwayskeepthetoolsandparts intheircorrectplaces.Alwayskeeptheworkarea
tolockallthecontrolleversandhangwarningsigns onthem.
9.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbeforestarting work.
10.Removeallmudandoilfromthestepsorother placesusedtogetonandoffthemachine.Always usethehandrails,laddersorstepswhengettingonor offthemachine.Neverjumponoroffthemachine. Ifitisimpossibletousethehandrails,laddersor steps,useastandtoprovidesafefooting.
PRECAUTIONSDURINGWORK
11.Whenremovingtheoilfillercap,drainplugor hydraulicpressuremeasuringplugs,loosenthem slowlytopreventtheoilfromspurtingout.Before disconnectingorremovingcomponentsoftheoil, wateroraircircuits,firstremovethepressure completelyfromthecircuit.
12.Thewaterandoilinthecircuitsarehotwhenthewashingelectricalparts. engineisstopped,sobecarefulnottogetburned. Waitfortheoilandwatertocoolbeforecarryingout19.Besuretoassembleallpartsagainintheiroriginal anyworkontheoilorwatercircuits.places.Replaceanydamagedpartwithnewparts.
13.Beforestartingwork,removetheleadsfromthe battery.ALWAYSremovetheleadfromthenegative (-)terminalfirst.
14.Whenraisingheavycomponents,useahoistor crane.Checkthatthewirerope,chainsandhooks arefreefromdamage.Alwaysuseliftingequipment whichhasamplecapacity.Installthelifting equipmentatthecorrectplaces.Useahoistorcrane andoperateslowlytopreventthecomponentfrom hittinganyotherpart.Donotworkwithanypartstill raisedbythehoistorcrane.
15.Whenremovingcoverswhichareunderinternal pressureorunderpressurefromaspring,always leavetwoboltsinpositiononoppositesides.Slowly releasethepressure,thenslowlyloosentheboltsto remove.
16.Whenremovingcomponents,becarefulnottobreak ordamagethewiring,Damagedwiringmaycause electricalfires.
17.Whenremovingpiping,stopthefueloroilfrom spillingout.Ifanyfueloroildripsontothefloor,wipe itupimmediately.Fueloroilonthefloorcancause youtoslip,orcanevenstartfires.
18.Asageneralrule,donotusegasolinetowashparts. Inparticular,useonlytheminimumofgasolinewhen
Wheninstallinghosesandwires,besurethat theywillnotbedamagedbycontactwithother partswhenthemachineisbeingoperated.
20.Wheninstallinghighpressurehoses,makesurethat theyarenottwisted.Damagedtubesaredangerous, sobeextremelycarefulwheninstallingtubesforhigh pressurecircuits.Alsocheckthatconnectingparts arecorrectlyinstalled.
21.Whenassemblingorinstallingparts,alwaysusethe specifiedtighteningtorques.Wheninstalling protectivepartssuchasguards,orpartswhich vibrateviolentlyorrotateathighspeed,be particularlycarefultocheckthattheyareinstalled correctly.
22.Whenaligningtwoholes,neverinsertyourfingersor hand.Becarefulnottogetyourfingerscaughtina hole.
23.Whenmeasuringhydraulicpressure,checkthatthe measuringtooliscorrectlyassembledbeforetaking anymeasurements.
24.Takecarewhenremovingorinstallingthetracksof track-typemachines.Whenremovingthetrack,the trackseparatessuddenly,soneverletanyonestand ateitherendofthetrack.
FOREWARD
GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesure youunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop. Foreaseofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeach maingroupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel, coolantandlubricantspecificationcharts.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingof thestructure,butalsoservesasreferencematerialfortroubleshooting.
TESTINGANDADJUSTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemade atcompletionofthechecksandrepairs.Troubleshootingchartscorrelating"Problems"to"Causes"arealso includedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeach component,aswellasprecautionstobetakenfortheseoperations.
MAINTENANCESTANDARD
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvance notice.Contactyourdistributorforthelatestinformation.
HOWTOREADTHESHOPMANUAL
VOLUMESREVISEDEDITIONMARK
Shopmanualsareissuedasaguidetocarryingout repairs.Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel
Enginevolume:Issuedforeachengineseries
Electricalvolume:Eachissuedasonetocoverall models
Attachmentvolume:Eachissuedasonetocoverall models
Thesevariousvolumesaredesignedtoavoidduplication ofinformation.Thereforetodealwithallrepairsforany model,itisnecessarythatchassis,engineelectricaland attachmentbeavailable.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbesent toyourdistributors.Getthemostup-to-dateinformation beforeyoustartanywork.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage.File thepagesincorrectorder.
2.Followingexamplesshowhowtoreadthepage number:
Example1(Chassisvolume): 10-3
Itemnumber(10.Structureand Function)
Consecutivepagenumberfor eachitem
Example2(Enginevolume): Refertothepertinentenginemanual.
3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.File asintheexample.
Example: 10-4
10-4-1 10-4-2Addedpages 10-5
Whenamanualisrevised,aneditionmark(....)is recordedonthebottomoutsidecornerofthepages.
REVISIONS
RevisedpagesareshownattheLISTOFREVISED PAGESbetweenthetitlepageandSAFETYpage.
SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwith thefollowingsymbols.
SymbolItemRemarks
Safety Specialsafetyprecautionsare necessarywhenperformingthe work.
Caution
Weight
Tightening torque
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems. Cautionnecessarywhenselecting hoistingwireorwhenworking postureisimportant,etc.
Placesthatrequirespecial attentionfortighteningtorque duringassembly.
CoatPlacestobecoatedwithadhesives andlubricantsetc.
Oil,waterPlaceswhereoil,waterorfuelmustbeadded,andthecapacity.
Drain
Placeswhereoilorwatermustbe drained,andquantitytobe drained.
HOISTINGINSTRUCTIONS
HOISTING
Heavyparts(25kgormore)mustbeliftedwith ahoistetc.IntheDISASSEMBLYANDASSEMBLYsection,everypartweighing25kgormore isindicatedclearlywiththesymbol Ifapartcannotbesmoothlyremovedfromthe machinebyhoisting,thefollowingchecksshouldbe made:
1)Checkforremovalofallboltsfasteningthepart totherelativeparts.
2)Checkforexistenceofanotherpartcausing interfacewiththeparttoberemoved.
WIREROPES
1)Useadequateropesdependingontheweightof partstobehoisted,referringtothetablebelow:
Wireropes (Standard"Z"or"S"twistropeswithoutgalvanizing Ropediameter(mm)Allowableload(tons)
3)Donotslingaheavyloadwithoneropealone,but slingwithtwoormoreropessymmetricallywound ontotheload.
Slingingwithoneropemaycauseturningof theloadduringhoisting,untwistingoftherope, orslippingoftheropefromitsoriginalwinding positionontheload,whichcanresultinadangerous accident.
4)Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.Whenhoistingaload withtwoormoreropes,theforcesubjectedtoeach ropewillincreasewiththehangingangles.The tablebelowshowsthevariationofallowableload (kg)whenhoistingismadewithtworopes,eachof whichisallowedtoslingupto1000kgvertically,at varioushangingangles.Whentworopesslinga loadvertically,upto2000kgoftotalweightcanbe suspended.Thisweightbecomes1000kgwhen tworopesmakea120hangingangle.Onthe otherhand,tworopesaresubjecttoanexcessive forceaslargeas4000kgiftheyslinga2000kg loadataliftingangleof150
Theallowableloadvalueisestimatedtobe1/6or 1/7ofthebreakingstrengthoftheropeused.
2)Slingwireropesfromthemiddleportionofthe hook.Slingingneartheedgeofthehookmay causetheropetoslipoffthehookduringhoisting, andaseriousaccidentcanresult.Hookshave maximumstrengthatthemiddleportion.
COATINGMATERIALS
Therecommendedcoatingmaterialsprescribedintheshopmanualsarelistedbelow.
CategoryCodePartNo.QtyContainerMainapplications,features
LT-1A790-129-9030150gTubeUsedtopreventrubbergaskets,rubbercushionsandcorkplugsfrom comingout
LT-1B790-129-905020g(x2)Usedforplastics(exceptpolyethylene,polypropylene, Plastic container
Usedinplacesrequiringanimmediatelyeffective,strongadhesive. tetrafluoroethylene,andvinylchloride),rubber,metalandnon-metal.
LT-209940-0003050gPlasticFeatures:Resistancetoheat,chemicalscontainerUsedforanti-looseningandsealantpurposesforboltsandplugs.
Adhesive
Gasketsealant
LT-3ofadhesiveandHardagtCanUsedasadhesiveorsealantformetal,glassorplastic.
790-129-9060SetAdh1kg hardeningagent500kg
LT-4790-129-9040250gUsedassealantformachinedholes. Plastic container
Loctite
Features:Resistancetoheat,chemicals 648-50 Usedatjointportionssubjecttohightemperature.
79A-129-911050cc---
LG-1790-129-9010200gTubeUsedasadhesiveorsealantforgasketsandpackingofpowertrain case,etc.
Features:Resistancetoheat Usedassealantforflangesurfacesandboltsathightemperature
LG-3790-129-90701kgCanlocations;usedtopreventseizure.
Usedassealantforheatresistantgasketforathightemperature locationssuchasenginepre-combustionchamber,exhaustpipe.
LG-4790-129-9020200gTubeAlsopossibletouseassealantforflangeswithlargeclearance.
Features:Resistancetowater,oil Usedassealantforflangesurface,thread. Usedassealantformatingsurfacesoffinaldrivecase,transmission case.
LG-5790-129-90801kgPlasticUsedassealantforvariousthreads,pipejoints,flanges.containerUsedassealantfortaperedplugs,elbows,nipplesofhydraulicpiping.
Features:Siliconbased,resistanttoheat,cold.
LG-609940-00011250gTubeUsedassealantforflangesurface,thread.
Usedassealantforoilpan,finaldrivecase,etc.
LG-709920-00150150gTubeUsedassealantforflywheelhousing,intakemanifold,oilpan, Features:Siliconbased,quickhardeningtype. thermostathousing,etc.
Rustpreven-tionlubricant---09940-0005160gCanUsedaslubricantforslidingparts(topreventsqueaking).
Molybdenum disulfidelubricant---09940-00040200gTubeshrinkfitting.
Usedtopreventseizureorscuffingofthethreadwhenpressfittingor Usedaslubricantforlinkage,bearings,etc.
SYG-350Ll
SYG-400Ll
LithiumgreaseG2-L1SYG-400Ll-AVariousVariousGeneralpurposetype
SYG-160Ll
SYGA-160CNLl
SSG2-400CA
SYG2-350CA
CalciumgreaseG2-CASYG2-400CA-AVariousVarious
SYG2-160CA
SYGA-16CNCA
Usedfornormaltemperature,lightloadbearingatplacesincontactwith waterorsteam.
Molybdenum400g disulfidegrease(10/case)---SYG2-400MBellowstypeUsedforplaceswithheavyload.
STANDARDTORQUEREQUIREMENTS
STANDARDTORQUEREQUIREMENTSOFBOLTSANDNUTS
Thefollowingchartsgivethestandardtorquesvaluesofboltsandnuts.Exceptionsaregiveninsectionsof DISASSEMBLYANDASSEMBLY
1kgm=9.806Nm
ThreaddiameterofboltWidthacrossflat
Thistorquetabledoesnotapplytotheboltswithwhichnylonpackingorothernon-ferrousmetalwashersareto beused,orwhichrequiretorquingtootherwisespecifiedvalues.
TORQUEREQUIREMENTSOFSPLITFLANGEBOLTS
Usethesetorquesvaluesforsplitflangebolts.
ThreaddiameterofboltWidthacrossflattorquerequirementvalues
TORQUEREQUIREMENTSFORFLAIREDNUTS
Usethesetorquevaluesforflairedpartofnut.
ThreaddiameterofboltWidthacrossflattorquerequirementvalues
ELECTRICWIRECODE
Inthewiringdiagrams,variouscolorsandsymbolsareemployedtoindicatethethicknessofwires.Thiswirecode tablewillhelpyouunderstandWIRINGDIAGRAMS. Example:05WBindicatesacablehavinganominalnumber05andwhitecoatingwithblackstripe.
CLASSIFICATIONBYTHICKNESS
NominalCableCurrentrating
NumberofDia.OfstrandCrosssecstrands(mm)tion(mm²)
0.85110.320.882.412Starting,lighting,signaletc.
CONVERSIONTABLES
METHODOFUSINGTHECONVERSIONTABLE
TheConversionTableinthissectionisprovidedtoenablesimpleconversionoffigures.Fordetailsofthemethodof usingtheConversionTable,seetheexamplegivenbelow.
EXAMPLE
MethodofusingtheConversionTabletoconvertfrommillimeterstoinches.
1.Convert55mmintoinches.
(1)Locatethenumber50intheverticalcolumnattheleftside,takethisas,thendrawahorizontallinefrom
(2)Locatethenumber5intherowacrossthetop,takethisas,thendrawaperpendicularlinedownfrom.
(3)Takethepointwherethetwolinescrossas.Thispointgivesthevaluewhenconvertingfrommillimeters toinches.Therefore,55millimeters=2.165inches.
2.Convert550mmintoinches.
(1)Thenumber550doesnotappearinthetable,sodivideby10(movethedecimaloneplacetotheleft)to convertitto55mm.
(2)Carryoutthesameprocedureasabovetoconvert55mmto2.165inches.
(3)Theoriginalvalue(550mm)wasdividedby10,somultiply2.165inchesby10(movethedecimaloneplace totheright)toreturntotheoriginalvalue.Thisgives550mm=21.65inches.
MillimeterstoInches
1mm=0.03937in
MillimeterstoInches
1mm=0.03937in mm0123456789
000.0390.0790.1180.1570.1970.2360.2760.3150.354 100.3940.4330.4720.5120.5510.5910.6300.6690.7090.748 200.7870.8270.8660.9060.9450.9841.0241.0631.1021.142 301.1811.2201.2601.2991.3391.3781.4171.4571.4961.536 401.5751.6141.6541.6931.7321.7721.8111.8501.8901.929
501.9692.0082.0472.0872.1262.1652.2052.2442.2832.323 602.3622.4022.4412.4802.5202.5592.5982.6382.6772.717 702.7562.7952.8352.8742.9132.9532.9923.0323.0713.110 803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.7013.7403.7803.8193.8583.898
KilogramtoPound
1kg=2.2046lb kg0123456789
002.204.416.618.8211.0213.2315.4317.6419.84 1022.0524.2526.4628.6630.8633.0735.2737.4839.6841.89 2044.0946.3048.5050.7151.9155.1257.3259.5361.7363.93
50110.23112.44114.64116.85119.05121.25123.46125.66127.87130.07 60132.28134.48136.69138.89141.10143.30145.51147.71149.91152.12 70154.32156.53158.73160.94163.14165.35167.55169.76171.96174.17 80176.37178.57180.78182.98185.19187.39189.60191.80194.01196.21 90198.42200.62202.83205.03207.24209.44211.64213.85216.05218.26