CONTENTS
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20
TESTING AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40
MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
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The affected pages are indicated by using the following marks. It is requested that necessary actions be taken to these pages according to the table below.
Mark
(
)
Indication
Action
New page to be added
Add
Page to be replaced
Replace
Page to be deleted
Discard
Pages without marks were previous additions or revised pages. LIST OF ORIGINAL, NEW AND REVISED PAGES MARK
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30-158 FOLD-OUTS 10-120 10-121
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PRODUCT PUBLICATIONS INFORMATION
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS. SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS IN FOREIGN LANGUAGES. THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S). DESCRIPTION
FORM NUMBER
PARTS BOOK - PAPER: Engine and Chassis
BEPB002100
PARTS BOOK - MICROFICHE: Engine and Chassis
BEPM002100
OPERATION & MAINTENANCE MANUAL: Engine and Chassis
CEAM001300
SHOP MANUAL: Chassis Engine:
SAFETY MANUAL
CEBM001101 SEBM010002
WLT70-1
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS, USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INFORMATION PROCESSING SYSTEM (PIPS). IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91D IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.
00-3
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM AND RETURN TO Komatsu America International Company 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887
COMPANY NAME
PURCHASE ORDER NO.
SHIP TO ATTN.
ORDER DATE
STREET ADDRESS
TYPE or PRINT ONLY
CITY, STATE, ZIP CODE COUNTRY
PHONE NO.
FAX NO.
SHIPPING METHOD
DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. PARTS BOOK QTY.
KDC91D 081696
00-4
PUBLICATION FORM NO.
P-Paper M-Microfiche
PUBLICATION DESCRIPTION
MODEL NUMBER
CURRENT PRICES WILL BE CHARGED
SERIAL NUMBER
SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE
IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7.
Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8.
Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9.
When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
10.
Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area
PRECAUTIONS DURING WORK 11.
When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil,
00-5
SAFETY water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
00-6
SAFETY NOTICE 18.
As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
19.
Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.
20.
When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
21.
When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.
22.
When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
23.
When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.
24.
Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
FOREWARD
GENERAL
FOREWARD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" to "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
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FOREWARD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL VOLUMES
REVISED EDITION MARK
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models
When a manual is revised, an edition mark ( ....) is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page. SYMBOLS
These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine electrical and attachment be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number: Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item Example 2 (Engine volume): Refer to the pertinent engine manual. 3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example: 10-4 10-4-1 Added pages 10-4-2 10-5
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So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol
Item
Remarks
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.
Tightening torque
Places that require special attention for tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water must be drained, and quantity to be drained.
FOREWARD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING Heavy parts (25 kg or more) must be lifted with a hoist etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interface with the part to be removed. WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing Rope diameter (mm) 10.0 11.2 12.5 14.0 16.0 18.0 20.0 22.4 30.0 40.0 50.0 60.0
Allowable load (tons) 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120 hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150 .
The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
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FOREWARD
COATING MATERIALS
COATING MATERIALS The recommended coating materials prescribed in the shop manuals are listed below. Category
Code
Part No.
Qty
Container
Main applications,features
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions and cork plugs from coming out
LT-1B
790-129-9050
20 g (x2)
Plastic container
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal and non-metal.
LT-2
09940-00030
50 g
Plastic container
Features: Resistance to heat, chemicals Used for anti-loosening and sealant purposes for bolts and plugs.
LT-3
790-129-9060 Set of adhesive and hardening agent
Adh 1 kg Hard agt 500 kg
Can
LT-4
790-129-9040
250 g
Plastic container
Loctite 648-50
79A-129-9110
50 cc
---
Features: Resistance to heat, chemicals Used at joint portions subject to high temperature.
LG-1
790-129-9010
200 g
Tube
Used as adhesive or sealant for gaskets and packing of power train case, etc.
Can
Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations; used to prevent seizure. Used as sealant for heat resistant gasket for at high temperature locations such as engine pre-combustion chamber, exhaust pipe.
Adhesive
LG-3
790-129-9070
1 kg
Used as adhesive or sealant for metal, glass or plastic. Used as sealant for machined holes.
LG-4
790-129-9020
200 g
Tube
Features: Resistance towater, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case.
LG-5
790-129-9080
1 kg
Plastic container
Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
LG-6
09940-00011
250 g
Tube
Features: Silicon based, resistant to heat, cold. Used as sealant for flange surface, thread. Used as sealant for oil pan, final drive case, etc.
LG-7
09920-00150
150 g
Tube
Features: Silicon based, quick hardening type. Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Rust preven-tion lubricant
---
09940-00051
60 g
Can
Used as lubricant for sliding parts (to prevent squeaking).
Molybdenum disulfide lubricant
---
09940-00040
200 g
Tube
Used to prevent seizure or scuffing of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
G2-L1
SYG-350Ll SYG-400Ll SYG-400Ll-A SYG-160Ll SYGA-160CNLl
Various
Various
General purpose type
Calcium grease
G2-CA
SSG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-16CNCA
Various
Various
Used for normal temperature, light load bearing at places in contact with water or steam.
Molybdenum disulfide grease
---
SYG2-400M
400 g (10/case)
Bellows type
Gasket sealant
Lithium grease
00-10
Used for places with heavy load.
FOREWARD
STANDARD TORQUE REQUIREMENTS
STANDARD TORQUE REQUIREMENTS STANDARD TORQUE REQUIREMENTS OF BOLTS AND NUTS The following charts give the standard torques values of bolts and nuts. Exceptions are given in sections of DISASSEMBLY AND ASSEMBLY. 1 kgm = 9.806 Nm Thread diameter of bolt
Width across flat
mm
mm
kgm
Nm
6
10
1.35 ±0.15
13.2 ±1.4
8
13
3.20 ±0.3
31.4 ±2.9
10
17
6.70 ±0.7
65.7 ±6.8
12
19
11.5 ±1.0
112 ±9.8
14
22
18 ±2.0
177 ±19
16
24
28.5 ±3
279 ±29
18
27
39 ±4
383 ±39
20
30
56 ±6
549 ±58
22
32
76 ±8
745 ±78
24
36
94.5 ±10
927 ±98
27
41
135 ±15
1320 ±140
30
46
175 ±20
1720 ±190
33
50
225 ±25
2210 ±240
36
55
280 ±30
2750 ±290
39
60
335 ±35
3280 ±340
This torque table does not apply to the bolts with which nylon packing or other non-ferrous metal washers are to be used, or which require torquing to otherwise specified values.
00-11
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