ASAFETY
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the Operation and 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. 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 theerating 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 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 any 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.
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, 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 notto 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 hoist or crane. a
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 froma 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.
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 parts 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.
-FOREWORD
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 chapters for each main group of components; these chapters are further divided into the following sections.
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 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. or
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information.
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK ( 2 3....)
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
Attachments volume : volume to cover all models
These various volumes are designed to avoid duplicating the same information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will besentto KOMATSU distributers. Get themost upto-date information before you start any work.
FILING METHOD
1. See thepage number on the bottom of the page. File the pages in co File the pages in correct order.
2. Following examples show how to read the page number.
Example 1 (Chassis volume):
21-3
When a manual is revised, an edition mark is recorded on thebottomoutside corner ofthepages
REVISIONS
Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page.
SYMBOLS
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol
Remarks
Special safety precautions are necessary when performing the work.
Unit number (2. Power train)
Item number (1. Structure and Eunctid Function)
.Consecutive page number for Caution each item.
Example 2 (Engine volume):
12 410 TT
Unit number (1. Engine) kg
Extra special safety precautions LAla special saley recau are necessary when pertorming the wark hocauseitis undar the work because it is under internal pressure. interpal pressure
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight of parts or systems. Caution necessary when Caution necessary when selecting hoisting wire, or when working posture posture is important,
Item number (2. Testing and Adjusting) etc.
Group No. (4. Fuel system)
Consecutive page No. (Page 10 kgm Tightenof Group 4)
3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page nhor Fila number. File as inthe example. ing torque
Example: 21-4
21-4-1 12-203 -12-203-1
21-4-2 21-5 12-204
Added pages12-203-2
Placesthatrequire special attention for the tightening torque during assembly.
Places to be coated with A Coat adhesives and lubricants etc.
Oil, water Drain
Places where oil, water or fuel must be added, and the capacity.
Places where oil or water must be drained, and quantity to be drained.
HOISTING INSTRUCTIONS
Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and As- witr a noist et assemory and sembly section, every part weighing 25 kg or more is indicated clearly with the symbolkg
1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made:
Check for removal of all bolts fastening the part to the relative parts.
Check for existence of another part causing interference with the part to be removed.
2. 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) Allowable load (tons)
The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength oftherope 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, he topetosudon and a serious accident can result. Hooks have maximum strength at the middle portion.
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetricaliy 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 fromthehook.
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 allowableload (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 2000kg of totalweight can besuspended.This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angleof 150°.
STANDARD TIGHTENING TORQUE
2kgm STANDARD TIGHTENING TORQUE
1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give thestandard tightening torques of bolts and nuts. Exceptions are given insections of "Disassembly and Assembly".
This torque table does not apply tothebolts with which nylon packings or other non-ferrous metal washers are to be used, or which require tightening to otherwise specified torque.
* Nm (newton meter): 1Nm= 0.1 kgm
2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
Sealing surface
3. TIGHTENING TORQUE FOR NUTS OF FLARED
Use these torques for nut part of flared.
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.
Nomenclature Komatsu code Applications
LT-1A Used to apply rubber pads, rubber gaskets, and cork plugs.
LT-1B Used to apply resin, rubber, metallic and tallic parts when a fast, strong seal is needed.
Adhesives
LT-2* Preventing bolts, nuts and plugs from loosening and leaking oil.
LT-3 Provides an airtight, electrically insulating seal. Usedfor aluminum surfaces.
LG-1 Used with gaskets and packings to increase sealing effect.
LG-3 Heat-resistant gasket for precombustion chambers and exhaust piping. Liquid gasket
LG-4 Used by itself on mounting surfaces on the final drive and transmission cases. (Thickness after tightening: 0.07 - 0.08 mm)
LG-5 Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings in hydraulic circuits of less than50 mm in diameter.
Antifriction Antiinietioncompound compound (Lubricant including LM-P Applied edded to bearings and taper shafts to facilitate press-fitting and to molybdenum disulfide) prevent sticking,burning or rusting.
Grease esparG
G2-LI (Lithium grease)
Vaseline
Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and facilitation of assembling work.
Used for protectingbattery electrode terminals from corrosion.
*LT-2 is also called LOCTITE in the shop manuals.
