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LISTOFORIGINAL,NEWANDREVISEDPAGES
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VARIOUSPRODUCTPARTS&SERVICEPUBLICATIONSAREAVAILABLETOALLKOMATSUCONSTRUCTION EQUIPMENTOWNERS,INCLUDINGOPERATION&MAINTENANCEMANUALS,PARTSBOOKSANDSHOP MANUALS.
SPECIALPUBLICATIONSSUCHASSERVICETOOL,AIRCONDITIONING,ANDTURBOCHARGERSHOP MANUALSAREALSOAVAILABLEASWELLASSELECTEDOPERATION&MAINTENANCEANDSHOPMANUALS INFOREIGNLANGUAGES.
THEPUBLICATIONSLISTEDBELOWAREAVAILABLEFORTHISPARTICULARMACHINE(S). DESCRIPTION
PARTSBOOK-PAPER:
PARTSBOOK-MICROFICHE:
OPERATION&MAINTENANCEMANUAL:
SHOPMANUAL:
PARTSANDSERVICEPUBLICATIONSCANONLYBEACQUIREDBYAUTHORIZEDKOMATSUDISTRIBUTORS, USINGTHEKOMATSUAMERICAINTERNATIONALCOMPANYPARTSINFORMATIONPROCESSINGSYSTEM (PIPS).
IFTHEPIPSSYSTEMISNOTAVAILABLEATTHEDISTRIBUTORLOCATION,THENTHEFOLLOWING REQUISITIONFORTECHNICALSERVICEPUBLICATIONSANDSERVICEFORMSCANBEUSED.FORMKDC91D ISSHOWNONTHEREVERSESIDEOFTHISPAGE.
COMPLETEFORM ANDRETURNTOKomatsuAmericaInternationalCompany
440NorthFairwayDrive
VernonHills,IL60061-8112U.S.A.
Attn:TechnicalPublications FaxNo.(847)970-4186 TelNo.(847)970-5887
COMPANYNAME
ATTN.
STREETADDRESS
CITY,STATE,ZIPCODE COUNTRY
PURCHASEORDERNO.
ORDERDATE
PHONENO.FAXNO.SHIPPINGMETHODDISTR/BRANCHCODE
IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERANDMACHINE SERIALNUMBERMUSTBESHOWN.
QTY.PUBLICATIONFORMNO.P-Paper
MODELNUMBERSERIALNUMBER
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,andblockthe themachine.wheelsortrackstopreventthemachinefrom
2.Whencarryingoutanyoperation,alwayswearsafety shoesandhelmet.Donotwearlooseworkclothes,8.Beforestartingwork,lowerblade,ripper,bucketor orclotheswithbuttonsmissing.anyotherworkequipmenttotheground.Ifthisis notpossible,insertthesafetypinoruseblockstoAlwayswearsafetyglasseswhenhittingparts withahammer.
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
moving. preventtheworkequipmentfromfalling.In addition,besuretolockallthecontrolleversand hangwarningsignsonthem.
9.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbefore startingwork.
10.Removeallmudandoilfromthestepsorother placesusedtogetonandoffthemachine.Always usethehandrails,laddersorstepswhengettingon oroffthemachine.Neverjumponoroffthe machine.Ifitisimpossibletousethehandrails, laddersorsteps,useastandtoprovidesafe footing.
PRECAUTIONSDURINGWORK
11.Whenremovingtheoilfillercap,drainplugor hydraulicpressuremeasuringplugs,loosenthem slowlytopreventtheoilfromspurtingout.Before disconnectingorremovingcomponentsoftheoil,
wateroraircircuits,firstremovethepressurecompletely18.Asageneralrule,donotusegasolinetowash fromthecircuit.parts.Inparticular,useonlytheminimumof
gasolinewhenwashingelectricalparts.
12.Thewaterandoilinthecircuitsarehotwhenthe engineisstopped,sobecarefulnottogetburned.19.Besuretoassembleallpartsagainintheiroriginal Waitfortheoilandwatertocoolbeforecarryingoutplaces.Replaceanydamagedpartwithnewparts. anyworkontheoilorwatercircuits.
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.
Wheninstallinghosesandwires,besurethat theywillnotbedamagedbycontactwithother partswhenthemachineisbeingoperated.
20.Wheninstallinghighpressurehoses,makesure thattheyarenottwisted.Damagedtubesare dangerous,sobeextremelycarefulwheninstalling tubesforhighpressurecircuits.Alsocheckthat connectingpartsarecorrectlyinstalled.
21.Whenassemblingorinstallingparts,alwaysuse thespecifiedtighteningtorques.Wheninstalling protectivepartssuchasguards,orpartswhich vibrateviolentlyorrotateathighspeed,be particularlycarefultocheckthattheyareinstalled correctly.
22.Whenaligningtwoholes,neverinsertyourfingers orhand.Becarefulnottogetyourfingerscaught inahole.
23.Whenmeasuringhydraulicpressure,checkthat themeasuringtooliscorrectlyassembledbefore takinganymeasurements.
24.Takecarewhenremovingorinstallingthetracksof track-typemachines.Whenremovingthetrack,the trackseparatessuddenly,soneverletanyone standateitherendofthetrack.
FOREWARD
GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesure youunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop. Foreaseofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeach maingroupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel, coolantandlubricantspecificationcharts.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstanding ofthestructure,butalsoservesasreferencematerialfortroubleshooting.
TESTINGANDADJUSTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobe madeatcompletionofthechecksandrepairs.Troubleshootingchartscorrelating"Problems"to"Causes"are alsoincludedinthissection.
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: 10-410-4-1 10-4-2Addedpages
10-5
Whenamanualisrevised,aneditionmark(....)is recordedonthebottomoutsidecornerofthepages.
REVISIONS
RevisedpagesareshownattheLISTOFREVISED PAGESbetweenthetitlepageandSAFETYpage.
SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwith thefollowingsymbols.
SymbolItemRemarks
Safety
Caution
Weight
Tightening torque
Specialsafetyprecautionsare necessarywhenperformingthe work.
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems. Cautionnecessarywhenselecting hoistingwireorwhenworking postureisimportant,etc.
Placesthatrequirespecial attentionfortighteningtorque duringassembly.
CoatPlacestobecoatedwithadhesives andlubricantsetc.
Oil,waterPlaceswhereoil,waterorfuelmustbeadded,andthecapacity.
Drain
Placeswhereoilorwatermustbe drained,andquantitytobe drained.
HOISTINGINSTRUCTIONS
HOISTING
Heavyparts(25kgormore)mustbeliftedwith ahoistetc.IntheDISASSEMBLYAND ASSEMBLYsection,everypartweighing25kgor moreisindicatedclearlywiththesymbol Ifapartcannotbesmoothlyremovedfromthe machinebyhoisting,thefollowingchecksshouldbe made:
1)Checkforremovalofallboltsfasteningthe parttotherelativeparts.
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 causetheropetoslipoffthehookduring hoisting,andaseriousaccidentcanresult. Hookshavemaximumstrengthatthemiddle portion.
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 648-5079A-129-911050Usedatjointportionssubjecttohightemperature. cc---
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.