Issuu

MachinemodelSerialnumber

•WA320-5mountstheSAA6D102E-2-Aengine. Fordetailsoftheengine,seethe102SeriesEngineShopManual. WA320-5and

•Thisshopmanualmaycontainattachmentsandoptionalequipmentthatarenotavailablein yourarea.PleaseconsultyourlocalKomatsudistributorforthoseitemsyoumayrequire. Materialsandspecificationsaresubjecttochangewithoutnotice.

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.

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

Type2Type3

1)Holdthemouthpieceofthetighteningportion andpushbody(2)instraightuntilslidingpreventionring(1)contactscontactsurfaceaof thehexagonalportionatthemaleend.

2)HoldintheconditioninStep1),andturn lever(4)totheright(clockwise).

Disassembly

3)HoldintheconditioninSteps1)and2),and pulloutwholebody(2)todisconnectit.

2)HoldintheconditioninStep1),andpush untilcover(3)contactscontactsurfaceaof thehexagonalportionatthemaleend.

•Holdthemouthpieceofthetighteningportion andpushbody(2)instraightuntilslidingpreventionring(1)contactscontactsurfaceaof thehexagonalportionatthemaleendtoconnectit.

3)HoldintheconditioninSteps1)and2),and pulloutwholebody(2)todisconnectit. Connection

COATINGMATERIALS

Therecommendedcoatingmaterialssuchasadhesives,gasketsealantsandgreasesusedfordisassembly andassemblyarelistedbelow.

Forcoatingmaterialsnotlistedbelow,usetheequivalentofproductsshowninthislist.

CategoryKomatsucodePartNo.Q’tyContainerMainapplications,features

LT-1A790-129-9030150gTube•Usedtopreventrubbergaskets,rubber cushions,andcockplugfromcomingout.

LT-1B790-129-905020g(2pcs.) Polyethylene container

•Usedinplacesrequiringanimmediately effective,strongadhesive. Usedforplastics(exceptpolyethylene, polyprophylene,tetrafluoroethleneand vinylchloride),rubber,metalandnonmetal.

LT-209940-0003050gPolyethylene container

790-129-9060

LT-3

Adhesives

(Setofadhesive andhardening agent)

Adhesive: 1kg Hardening agent: 500g Can

LT-4790-129-9040250gPolyethylene container

•Features: Resistancetoheatandchemicals

•Usedforanti-looseningandsealant purposeforboltsandplugs.

•Usedasadhesiveorsealantformetal, glassandplastic.

•Usedassealantformachinedholes.

Holtz MH705790-126-912075gTube•Usedasheat-resistingsealantfor repairingengine.

Threebond1735790-129-914050gPolyethylene container

•Quickhardeningtypeadhesive

•Curetime:within5sec.to3min.

•Usedmainlyforadhesionofmetals, rubbers,plasticsandwoods.

•Quickhardeningtypeadhesive

Aron-alpha201790-129-91302gPolyethylene container

•Quickcuretype (max.strengthafter30minutes)

•Usedmainlyforadhesionofrubbers, plasticsandmetals.

•Resistancetoheat,chemicals

Loctite

648-5079A-129-911050ccPolyethylene container

•Usedatjointportionssubjecttohigh temperatures.

LG-1790-129-9010200gTube•Usedasadhesiveorsealantforgaskets andpackingofpowertraincase,etc.

LG-5790-129-90801kgCan

LG-6790-129-9020200gTube

LG-7790-129-90701kgTube

•Usedassealantforvariousthreads,pipe joints,flanges.

•Usedassealantfortaperedplugs, elbows,nipplesofhydraulicpiping.

•Features:Siliconbased,resistanceto heat,cold

•Usedassealantforflangesurface,tread.

•Usedassealantforoilpan,finaldrive case,etc.

•Features:Siliconbased,quickhardening type

•Usedassealantforflywheelhousing, intakemanifold,oilpan,thermostat housing,etc.

Threebond1211790-129-9090100gTube•Usedasheat-resistingsealantfor repairingengine.

Threebond1207B419-15-18131100gTube

•Features:Siliconetype,heatresistant, vibrationresistant,andimpactresistant sealingmaterial

•Usedassealingmaterialfortransfercase

CategoryKomatsucodePartNo.Q’tyContainerMainapplications,features

Molybdenum disulphide lubricant

Grease

LM-G09940-0005160gCan•Usedaslubricantforslidingportion(to preventfromsqueaking).

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(*) *:Forusein colddistrict

BiogreaseG2B G2-BT(*) *:Forhigh temperature andlargeload

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(*)

SUNSTAR PAINTPRIMER 580SUPER 417-926-3910

VariousVarious

400g×10 400g×20 16kg Bellowstype Bellowstype Can

400g 16kg Bellowstype Can

•Usedtopreventseizureorscufflingofthe threadwhenpressfittingorshrinkfitting.

•Usedaslubricantforlinkage,bearings, etc.

•Generalpurposetype

Primer

Adhesive

400g 16kg Bellowstype Can

20mlGlasscontainer

•Usedfornormaltemperature,lightload bearingatplacesincontactwithwateror steam.

•Usedforheavyloadportion

•Seizureresistanceandheatresistance higherthanmolybdenumdisulfidegrease •Sincethisgreaseiswhite,itdoesnot standoutagainstmachinebody.

•Sincethisgreaseisdecomposedby bacteriainshortperiod,ithaslesseffects onmicroorganisms,animals,andplants.

•Usedasprimerforcabside (Usinglimit:4months)

SUNSTAR GLASSPRIMER 580SUPER 20mlGlasscontainer•Usedasprimerforglassside (Usinglimit:4months)

SUNSTAR PAINTPRIMER 435-95

SUNSTAR GLASSPRIMER 435-41

SUNSTAR SASHPRIMER GP-402

SUNSTAR PENGUINE SUPER560

SUNSTAR PENGUINE SEAL580 SUPER“S”or “W”

22M-54-2723020mlGlasscontainer•Usedasprimerforpaintedsurfaceon cabside (Usinglimit:4months)

22M-54-27240150mlCan

•Usedasprimerforblackceramiccoatedsurfaceonglasssideandfor hardpolycarbonate-coatedsurface (Usinglimit:4months)

22M-54-2725020mlGlasscontainer•Usedasprimerforsash(Alumite). (Usinglimit:4months)

22M-54-27210320ml Ecocart (Special container)

417-926-3910320mlPolyethylene container

SikaJapan, Sikaflex256HV20Y-54-39850310mlPolyethylene container

SUNSTAR PENGUINE SEALNo.2505

417-926-3920320mlPolyethylene container

•Usedasadhesiveforglass. (Usinglimit:6months)

•“S”isusedforhigh-temperature season(April-October)and“W”for low-temperatureseason(NovemberApril)asadhesiveforglass. (Usinglimit:4months)