SAFETY SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforsafemachineoperation.Theserviceand repairtechniquesrecommendedbyKomatsuanddescribedinthismanualarebotheffective andsafe.SomeofthesetechniquesrequiretheuseoftoolsspeciallydesignedbyKomatsufor thespecificpurpose.
Topreventinjurytoworkers,thesymbolkisusedtomarksafetyprecautionsinthismanual. Thecautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise,firstconsidersafety,andtakethenecessaryactions todealwiththesituation.
GENERALPRECAUTIONS
Mistakesinoperationareextremelydangerous. ReadtheOperationandMaintenanceManualcarefullyBEFOREoperatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,read alltheprecautionsgivenonthedecalswhichare fixedtothemachine.
2.Whencarryingoutanyoperation,always wearsafetyshoesandhelmet.Donotwear looseworkclothes,orclotheswithbuttons missing.
Alwayswearsafetyglasseswhenhitting partswithahammer.
Alwayswearsafetyglasseswhengrinding partswithagrinder,etc.
3.Ifweldingrepairsareneeded,alwayshavea trained,experiencedweldercarryoutthework. Whencarryingoutweldingwork,alwayswear weldinggloves,apron,handshield,capand otherclothessuitedforweldingwork.
4.Whencarryingoutanyoperationwithtwoor moreworkers,alwaysagreeontheoperating procedurebeforestarting.Alwaysinformyour fellowworkersbeforestartinganystepofthe operation.Beforestartingwork,hangUNDER REPAIRsignsonthecontrolsintheoperator's compartment.
5.Keepalltoolsingoodconditionandlearnthe correctwaytousethem.
6.Decideaplaceintherepairworkshoptokeep toolsandremovedparts.Alwayskeepthetools andpartsintheircorrectplaces.Alwayskeep theworkareacleanandmakesurethatthereis nodirtoroilonthefloor.Smokeonlyintheareas providedforsmoking.Neversmokewhileworking.
PREPARATIONSFORWORK
7.Beforeaddingoilormakinganyrepairs,parkthe machineonhard,levelground,andblockthe wheelsortrackstopreventthemachinefrom moving.
8.Beforestartingwork,lowerblade,ripper,bucket oranyotherworkequipmenttotheground.If thisisnotpossible,insertthesafetypinoruse blockstopreventtheworkequipmentfromfalling.Inaddition,besuretolockallthecontrol leversandhangwarningsignsonthem.
9.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbefore startingwork.
10.Removeallmudandoilfromthestepsorother placesusedtogetonandoffthemachine. Alwaysusethehandrails,laddersorstepswhen gettingonoroffthemachine.Neverjumponor offthemachine.Ifitisimpossibletousethe handrails,laddersorsteps,useastandtoprovidesafefooting.
PRECAUTIONSDURINGWORK
11.Whenremovingtheoilfillercap,drainplugor hydraulicpressuremeasuringplugs,loosen themslowlytopreventtheoilfromspurtingout. Beforedisconnectingorremovingcomponents oftheoil,wateroraircircuits,firstremovethe pressurecompletelyfromthecircuit.
12.Thewaterandoilinthecircuitsarehotwhenthe engineisstopped,sobecarefulnottoget burned.
Waitfortheoilandwatertocoolbeforecarryingoutanyworkontheoilorwatercircuits.
13.Beforestartingwork,removetheleadsfromthe battery.Alwaysremovetheleadfromthenegative()terminalfirst.
14.Whenraisingheavycomponents,useahoistor crane.
Checkthatthewirerope,chainsandhooksare freefromdamage. Alwaysuseliftingequipmentwhichhasample capacity.
Installtheliftingequipmentatthecorrectplaces. Useahoistorcraneandoperateslowlytopreventthecomponentfromhittinganyotherpart. Donotworkwithanypartstillraisedbythehoist orcrane.
15.Whenremovingcoverswhichareunderinternal pressureorunderpressurefromaspring, alwaysleavetwoboltsinpositiononopposite sides.Slowlyreleasethepressure,thenslowly loosentheboltstoremove.
16.Whenremovingcomponents,becarefulnotto breakordamagethewiring.Damagedwiring maycauseelectricalfires.
17.Whenremovingpiping,stopthefueloroilfrom spillingout.Ifanyfueloroildripsontothefloor, wipeitupimmediately.Fueloroilonthefloor cancauseyoutoslip,orcanevenstartfires.
18.Asageneralrule,donotusegasolinetowash parts.Inparticular,useonlytheminimumof gasolinewhenwashingelectricalparts.
19.Besuretoassembleallpartsagainintheiroriginalplaces.
Replaceanydamagedpartswithnewparts. Wheninstallinghosesandwires,besure thattheywillnotbedamagedbycontact withotherpartswhenthemachineisbeing operated.
20.Wheninstallinghighpressurehoses,makesure thattheyarenottwisted.Damagedtubesare dangerous,sobeextremelycarefulwheninstallingtubesforhighpressurecircuits.Also,check thatconnectingpartsarecorrectlyinstalled.
21.Whenassemblingorinstallingparts,alwaysuse thespecifiedtighteningtorques.Wheninstalling protectivepartssuchasguards,orpartswhich vibrateviolentlyorrotateathighspeed,beparticularlycarefultocheckthattheyareinstalled correctly.
22.Whenaligningtwoholes,neverinsertyourfingersorhand.Becarefulnottogetyourfingers caughtinahole.
23.Whenmeasuringhydraulicpressure,checkthat themeasuringtooliscorrectlyassembledbefore takinganymeasurements.
24.Takecarewhenremovingorinstallingthetracks oftrack-typemachines. Whenremovingthetrack,thetrackseparates suddenly,soneverletanyonestandateither endofthetrack.
FOREWORD
GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemanan accurateunderstandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesureyouunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaservice workshop.Foreaseofunderstanding,themanualisdividedintothefollowingchapters;thesechaptersarefurtherdividedintotheeachmaingroupofcomponents.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingofthestructure,butalsoservesasreferencematerialfortroubleshooting.
Inaddition,thissectionmaycontainhydrauliccircuitdiagrams,electriccircuitdiagrams,andmaintenancestandards.
TESTINGANDADJUSTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentsto bemadeatcompletionofthechecksandrepairs.
Troubleshootingchartscorrelating"Problems"with"Causes"arealsoincludedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheproceduresforremoving,installing,disassemblingandassemblingeachcomponent,aswellasprecautionsforthem.
MAINTENANCESTANDARD
Thissectiongivesthejudgmentstandardsforinspectionofdisassembledparts. ThecontentsofthissectionmaybedescribedinSTRUCTUREANDFUNCTION.
OTHERS
Thissectionmainlygiveshydrauliccircuitdiagramsandelectriccircuitdiagrams. Inaddition,thissectionmaygivethespecificationsofattachmentsandoptionstogether.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutany advancenotice.Usethespecificationsgiveninthebookwiththelatestdate.
HOWTOREADTHESHOPMANUAL
VOLUMES
Shopmanualsareissuedasaguidetocarryingout repairs.Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel Enginevolume:Issuedforeachengineseries
Electricalvolume: Attachmentsvolume:
REVISEDEDITIONMARK
Whenamanualisrevised,aneditionmark ((1)(2)(3)....)isrecordedonthebottomofthepages.
REVISIONS
RevisedpagesareshownintheLISTOFREVISED PAGESnexttotheCONTENTSpage.
SYMBOLS
DISTRIBUTIONANDUPDATING
Thesevariousvolumesaredesignedtoavoidduplicatingthesameinformation.Therefore,todealwith allrepairsforanymodel,itisnecessarythatchassis,engine,electricalandattachmentvolumesbe available.
Anyadditions,amendmentsorotherchangeswillbe senttoKOMATSUdistributors.Getthemostup-todateinformationbeforeyoustartanywork.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage. Filethepagesincorrectorder.
2.Followingexamplesshowhowtoreadthepage number.
Example1(Chassisvolume): 10-3
Itemnumber(10.Structureand Function)
Consecutivepagenumberforeach item.
Example2(Enginevolume): 12-5
Unitnumber(1.Engine)
Itemnumber(2.TestingandAdjusting)
Consecutivepagenumberforeach item.
3.Additionalpages:Additionalpagesareindicated byahyphen(-)andnumberafterthepage number.Fileasintheexample.
Example:
10-4
10-4-1
10-4-2
10-5
Eachissuedasone volumetocoverall models 12-203 12-203-1 12-203-2 12-204 Addedpages
Sothattheshopmanualcanbeofamplepractical use,importantsafetyandqualityportionsare markedwiththefollowingsymbols.
SymbolItemRemarks
Specialsafetyprecautions arenecessarywhenperformingthework. a Caution
Safety
4Weight
3Tightening torque
2Coat
5Oil,water
6Drain
Specialtechnicalprecautionsorotherprecautions forpreservingstandards arenecessarywhenperformingthework.
Weightofpartsofsystems.Cautionnecessary whenselectinghoisting wire,orwhenworkingpostureisimportant,etc.
Placesthatrequirespecial attentionforthetightening torqueduringassembly.
Placestobecoatedwith adhesivesandlubricants, etc.
Placeswhereoil,wateror fuelmustbeadded,and thecapacity.
Placeswhereoilorwater mustbedrained,and quantitytobedrained.
HOISTINGINSTRUCTIONS
HOISTING
kHeavyparts(25kgormore)mustbelifted withahoist,etc.IntheDISASSEMBLY ANDASSEMBLYsection,everypart weighing25kgormoreisindicatedclearly withthesymbol
Ifapartcannotbesmoothlyremovedfromthe machinebyhoisting,thefollowingchecks shouldbemade:
1)Checkforremovalofallboltsfasteningthe parttotherelativeparts.
2)Checkforexistenceofanotherpartcausing interferencewiththeparttoberemoved.
WIREROPES
1)Useadequateropesdependingonthe weightofpartstobehoisted,referringto thetablebelow:
Wireropes (Standard"Z"or"S"twistropes withoutgalvanizing)
RopediameterAllowableload
Slingingneartheedgeofthehookmaycause theropetoslipoffthehookduringhoisting,and aseriousaccidentcanresult.Hookshavemaximumstrengthatthemiddleportion.
Theallowableloadvalueisestimatedtobeonesixthorone-seventhofthebreakingstrengthof theropeused.
2)Slingwireropesfromthemiddleportionofthe hook.
3)Donotslingaheavyloadwithoneropealone, butslingwithtwoormoreropessymmetrically woundontotheload.
kSlingingwithoneropemaycauseturning oftheloadduringhoisting,untwistingof therope,orslippingoftheropefromits originalwindingpositionontheload,which canresultinadangerousaccident.
4)Donotslingaheavyloadwithropesforminga widehanginganglefromthehook. Whenhoistingaloadwithtwoormoreropes, theforcesubjectedtoeachropewillincrease withthehangingangles.Thetablebelow showsthevariationofallowableloadkN{kg} whenhoistingismadewithtworopes,eachof whichisallowedtoslingupto9.8kN{1000kg} vertically,atvarioushangingangles. Whentworopesslingaloadvertically,upto 19.6kN{2000kg}oftotalweightcanbesuspended.Thisweightbecomes9.8kN{1000kg} whentworopesmakea120°hangingangle. Ontheotherhand,tworopesaresubjectedto anexcessiveforceaslargeas39.2kN{4000 kg}iftheyslinga19.6kN{2000kg}loadata liftingangleof150°.
METHODOFDISASSEMBLING,CONNECTINGPUSH-PULLTYPECOUPLER
kBeforecarryingoutthefollowingwork,release theresidualpressurefromthehydraulictank. Fordetails,seeTESTINGANDADJUSTING, Releasingresidualpressurefromhydraulic tank.
k
Eveniftheresidualpressureisreleasedfrom thehydraulictank,somehydraulicoilflowsout whenthehoseisdisconnected.Accordingly, prepareanoilreceivingcontainer.
Disconnection
1)Releasetheresidualpressurefromthehydraulictank.Fordetails,seeTESTINGAND ADJUSTING,Releasingresidualpressurefrom hydraulictank.
2)Holdadapter(1)andpushhosejoint(2)into matingadapter(3).(SeeFig.1)
Theadaptercanbepushedinabout3.5 mm.
Donotholdrubbercapportion(4).
3)Afterhosejoint(2)ispushedintoadapter(3), pressrubbercapportion(4)against(3)untilit clicks.(SeeFig.2)
4)Holdhoseadapter(1)orhose(5)andpullitout. (SeeFig.3)
Sincesomehydraulicoilflowsout,prepare anoilreceivingcontainer.
Connection
1)Holdhoseadapter(1)orhose(5)andinsertitin matingadapter(3),aligningthemwitheach other.(SeeFig.4)
Donotholdrubbercapportion(4).
2)Afterinsertingthehoseinthematingadapter perfectly,pullitbacktocheckitsconnecting condition.(SeeFig.5)
Whenthehoseispulledback,therubber capportionmovestowardthehoseabout 3.5mm.Thisdoesnotindicateabnormality, however.
Type1
Disassembly
Type2Type3
1)Holdthemouthpieceofthetighteningportion andpushbody(2)instraightuntilslidingpreventionring(1)contactscontactsurfaceaof thehexagonalportionatthemaleend.
1)Holdthemouthpieceofthetighteningportion andpushbody(2)instraightuntilslidingpreventionring(1)contactscontactsurfaceaof thehexagonalportionatthemaleend.
2)HoldintheconditioninStep1),andturn lever(4)totheright(clockwise).
2)HoldintheconditioninStep1),andpush untilcover(3)contactscontactsurfaceaof thehexagonalportionatthemaleend.
3)HoldintheconditioninSteps1)and2),and pulloutwholebody(2)todisconnectit.
3)HoldintheconditioninSteps1)and2),and pulloutwholebody(2)todisconnectit.
Holdthemouthpieceofthetighteningportion andpushbody(2)instraightuntilslidingpreventionring(1)contactscontactsurfaceaof thehexagonalportionatthemaleendtoconnectit.
Holdthemouthpieceofthetighteningportion andpushbody(2)instraightuntilslidingpreventionring(1)contactscontactsurfaceaof thehexagonalportionatthemaleendtoconnectit.
COATINGMATERIALS
Therecommendedcoatingmaterialssuchasadhesives,gasketsealantsandgreasesusedfordisassembly andassemblyarelistedbelow.
Forcoatingmaterialsnotlistedbelow,usetheequivalentofproductsshowninthislist.
CategoryKomatsucodePartNo.Q'tyContainerMainapplications,featuresr
LT-1A790-129-9030150gTube
LT-1B790-129-905020g(2pcs.) Polyethylene container
LT-209940-0003050gPolyethylene container
LT-3 790-129-9060 (Setofadhesive andhardening agent)
Adhesives
Adhesive: 1kg Hardening agent: 500g Can
LT-4790-129-9040250gPolyethylene container
Usedtopreventrubbergaskets,rubbercushions,andcockplugfrom comingout.
Usedinplacesrequiringanimmediatelyeffective,strongadhesive. Usedforplastics(exceptpolyethylene,polyprophylene,tetrafluoroethleneandvinylchloride),rubber, metalandnon-metal.
Features:Resistancetoheatand chemicals
Usedforanti-looseningandsealant purposeforboltsandplugs.
Usedasadhesiveorsealantformetal,glassandplastic.
Usedassealantformachinedholes.
Holtz MH705790-126-912075gTubeUsedasheat-resistingsealantforrepairingengine.
Threebond1735790-129-914050gPolyethylene container
Aron-alpha201790-129-91302gPolyethylene container
Loctite 648-5079A-129-911050ccPolyethylene container
LG-1790-129-9010200gTube
LG-5790-129-90801kgCan
LG-6790-129-9020200gTube
Quickhardeningtypeadhesive
Curetime:within5sec.to3min.
Usedmainlyforadhesionofmetals, rubbers,plasticsandwoods.
Quickhardeningtypeadhesive Quickcuretype(max.strengthafter 30minutes) Usedmainlyforadhesionofrubbers, plasticsandmetals.
Resistancetoheat,chemicals
Usedatjointportionssubjecttohigh temperatures.
Usedasadhesiveorsealantforgasketsandpackingofpowertraincase, etc.
Usedassealantforvariousthreads, pipejoints,flanges.
Usedassealantfortaperedplugs, elbows,nipplesofhydraulicpiping.
Features:Siliconbased,resistance toheat,cold Usedassealantforflangesurface, tread.
Usedassealantforoilpan,final drivecase,etc.
Features:Siliconbased,quickhardeningtype
LG-7790-129-90701gTube
Usedassealantforflywheelhousing,intakemanifold,oilan,thermostathousing,etc.
Threebond1211790-129-9090100gTubeUsedasheat-resistingsealantforrepairingengine.
Threebond1207B419-15-18131100gTube
Features:Siliconetype,heatresistant,vibrationresistant,andimpact resistantsealingmaterial
Usedassealingmaterialfortransfer case
Gasket sealant
CategoryKomatsucodePartNo.Q'tyContainerMainapplications,featuresr
LM-G09940-0005160gCanUsedaslubricantforslidingportion (topreventfromsqueaking).
Molybdenum disulphide lubricant
Grease
LM-P09940-00040200gTube
SYG2-400LI
SYG2-350LI
G2-LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
SYG2-400CA
SYG2-350CA
G2-CA
Molybdenum disulphide grease
LM-G(G2-M)
HyperWhite GreaseG2-T G0-T(*)
*:Foruseincold district
BiogreaseG2B G2-BT(*) *:Forhigh temperature andlargeload
SUNSTAR PAINTPRIMER 580SUPER
Primer
SUNSTAR GLASSPRIMER 580SUPER
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
SYG2-400M
SYG2-400M-A
SYGA-16CNM
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A(*)
SYG0-16CNT(*)
SYG2-400B
SYGA-16CNB
SYG2-400BT(*)
SYGA-16CNBT(*)
VariousVarious
VariousVarious
400g×10 400g×20 16kg Bellowstype Bellowstype Can
400g 16kg
Bellowstype Can
400g 16kg
Bellowstype Can
20mlGlasscontainer
Usedtopreventseizureorscuffling ofthethreadwhenpressfittingor shrinkfitting.
Usedaslubricantforlinkage,bearings,etc.
Generalpurposetype
Usedfornormaltemperature,light loadbearingatplacesincontact withwaterorsteam.
Usedforheavyloadportion
Seizureresistanceandheatresistancehigherthanmolybdenumdisulfidegrease
Sincethisgreaseiswhite,itdoes notstandoutagainstmachine body.
Sincethisgreaseisdecomposed bybacteriainshortperiod,ithas lesseffectsonmicroorganisms, animals,andplants.
Usedasprimerforcabside (Usinglimit:4months)
20mlGlasscontainerUsedasprimerforglassside (Usinglimit:4months)
417-926-3910
Adhesive
SUNSTAR PENGUINE SEAL580 SUPER"S"or "W"
320mlPolyethylene container
SikaJapan, Sikaflex256HV20Y-54-39850310mlPolyethylene container
SUNSTAR PENGUINE SEALNo.2505 417-926-3920320mlPolyethylene container
Adhesive for cab glass
"S"isusedforhigh-temperatureseason(April-October) and"W"forlow-temperature season(November-April)as adhesiveforglass. (Usinglimit:4months)
Usedasadhesiveforglass. (Usinglimit:6months)
Usedtosealjointsofglass parts. (Usinglimit:4months)
Caulking material
SEKISUI SILICONE SEALANT 20Y-54-55130333mlPolyethylene container
Usedtosealfrontwindow. (Usinglimit:6months)
