ShopManual
Thisshopmanualmaycontainattachmentsandoptionalequipmentthatarenotavailableinyourarea. PleaseconsultyourlocalKOMATSUdistributorforthoseitemsyoumayrequire.Materialsandspecifications aresubjecttochangewithoutnotice.
WA500-3HmounttheSA6D140E-3engine. Fordetailsofthisengine,seethe140-3SeriesEngineShopManual
Itisourpolicytoimproveourproductswheneveritispossibleandpracticaltodoso.Wereservetherighttomakechangesor addimprovementsatanytimewithoutincurringanyobligationtoinstallsuchchangesonproductssoldpreviously.
Duetothiscontinuousprogramofresearchanddevelopment,periodicrevisionsmaybemadetothispublication.Itisrecommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision.
01GENERAL.
10STRUCTUREANDFUNCTION.
20TESTING,ADJUSTINGANDTROUBLESHOOTING.
30DISASSEMBLYANDASSEMBLY.
40MAINTENANCESTANDARD
90OTHER.
00SAFETY
00SAFETYNOTICE
00IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.Thecautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise,firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
00GENERALPRECAUTIONS
Mistakesinoperationareextremelydangerous.ReadtheOPERATION&MAINTENANCEMANUALcarefullyBEFORE operatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,readalltheprecautionsgivenonthedecalswhicharefixedtothemachine.
2.Whencarryingoutanyoperation,alwayswearsafetyshoesandhelmet.Donotwearlooseworkclothes,orclotheswith buttonsmissing.
Alwayswearsafetyglasseswhenhittingpartswithahammer.
Alwayswearsafetyglasseswhengrindingpartswithagrinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained,experiencedweldercarryoutthework.Whencarryingoutwelding work,alwayswearweldinggloves,apron,glasses,capandotherclothessuitedforweldingwork.
4.Whencarryingoutanyoperationwithtwoormoreworkers,alwaysagreeontheoperatingprocedurebeforestarting. Alwaysinformyourfellowworkersbeforestartinganystepoftheoperation.Beforestartingwork,hangUNDER REPAIRsignsonthecontrolsintheoperator'scompartment.
5.Keepalltoolsingoodconditionandlearnthecorrectwaytousethem.
6.Decideaplaceintherepairworkshoptokeeptoolsandremovedparts.Alwayskeepthetoolsandpartsintheircorrect places.Alwayskeeptheworkareacleanandmakesurethatthereisnodirtoroilonthefloor.Smokeonlyintheareas providedforsmoking.Neversmokewhileworking.
PREPARATIONSFORWORK
1.Beforeaddingoilormakingrepairs,parkthemachineonhard,levelground,andblockthewheelsortrackstopreventthe machinefrommoving.
2.Beforestartingwork,lowerblade,ripper,bucketoranyotherworkequipmenttotheground.Ifthisisnotpossible,insert thesafetypinoruseblockstopreventtheworkequipmentfromfalling.Inaddition,besuretolockallthecontrollevers andhangwarningsignsonthem.
3.Whendisassemblingorassembling,supportthemachinewithblocks,jacksorstandsbeforestartingwork.
4.Removeallmudandoilfromthestepsorotherplacesusedtogetonandoffthemachine.Alwaysusethehandrails,laddersorstepswhengettingonoroffthemachine.Neverjumponoroffthemachine.Ifitisimpossibletousethehandrails, laddersorsteps,useastandtoprovidesafefooting.
PRECAUTIONSDURINGWORK
1.Whenremovingtheoilfillercap,drainplugorhydraulicpressuremeasuringplugs,loosenthemslowlytopreventtheoil fromspurtingout.Beforedisconnectingorremovingcomponentsoftheoil,wateroraircircuits,firstremovethepressure completelyfromthecircuit.
2.Thewaterandoilinthecircuitsarehotwhentheengineisstopped,sobecarefulnottogetburned.Waitfortheoiland watertocoolbeforecarryingoutanyworkontheoilorwatercircuits.
3.Beforestartingwork,removetheleadsfromthebattery.ALWAYSremovetheleadfromthenegative(-)terminalfirst.
12 4.Whenraisingheavycomponents,useahoistorcrane. Checkthatthewirerope,chainsandhooksarefreefrom damage.Alwaysuseliftingequipmentwhichhasample capacity.Installtheliftingequipmentatthecorrect places.Useahoistorcraneandoperateslowlytopreventthecomponentfromhittinganyotherpart.Donot workwithanypartstillraisedbythehoistorcrane.
5.Whenremovingcoverswhichareunderinternalpressureorunderpressurefromaspring,alwaysleavetwo boltsinpositiononoppositesides.Slowlyreleasethe pressure,thenslowlyloosentheboltstoremove.
6.Whenremovingcomponents,becarefulnottobreakor damagethewiring,Damagedwiringmaycauseelectricalfires.
7.Whenremovingpiping,stopthefueloroilfromspilling out.Ifanyfueloroildripsontothefloor,wipeitup immediately.Fueloroilonthefloorcancauseyouto slip,orcanevenstartfires.
8.Asageneralrule,donotusegasolinetowashparts.In particular,useonlytheminimumofgasolinewhen washingelectricalparts.
9.Besuretoassembleallpartsagainintheiroriginal places.Replaceanydamagedpartwithnewparts.
Wheninstallinghosesandwires,besurethattheywill notbedamagedbycontactwithotherpartswhenthe machineisbeingoperated.
10.Wheninstallinghighpressurehoses,makesurethat theyarenottwisted.Damagedtubesaredangerous,so beextremelycarefulwheninstallingtubesforhighpressurecircuits.Alsocheckthatconnectingpartsarecorrectlyinstalled.
11.Whenassemblingorinstallingparts,alwaysusethe specifiedtighteningtorques.Wheninstallingprotective partssuchasguards,orpartswhichvibrateviolentlyor rotateathighspeed,beparticularlycarefultocheckthat theyareinstalledcorrectly.
12.Whenaligningtwoholes,neverinsertyourfingersor hand.Becarefulnottogetyourfingerscaughtinahole.
13.Whenmeasuringhydraulicpressure,checkthatthe measuringtooliscorrectlyassembledbeforetakingany measurements.
14.Takecarewhenremovingorinstallingthetracksof track-typemachines.Whenremovingthetrack,the trackseparatessuddenly,soneverletanyonestandat eitherendofthetrack.
00GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethe qualityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrect waytoperformrepairsandmakejudgements.Makesure youunderstandthecontentsofthismanualanduseittofull effectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnical informationforoperationsperformedinaserviceworkshop. Foreaseofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeach maingroupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel, coolantandlubricantspecificationcharts.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeach component.Itservesnotonlytogiveanunderstanding ofthestructure,butalsoservesasreferencematerialfor troubleshooting.
TESTING,ADJUSTINGANDTROUBLESHOOTING
Thissectionexplainscheckstobemadebeforeandafter performingrepairs,aswellasadjustmentstobemadeat completionofthechecksandrepairs.Troubleshooting
NOTICE
chartscorrelatingProblemstoCausesarealso includedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhen removing,installing,disassemblingorassemblingeach component,aswellasprecautionstobetakenforthese operations.
MAINTENANCESTANDARD
Thissectiongivesthejudgementstandardswhen inspectingdisassembledparts.
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvancenotice.Contact yourdistributorforthelatestinformation.
12
00HOWTOREADTHESHOPMANUAL
VOLUMES
00
Shopmanualsareissuedasaguidetocarryingoutrepairs.Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel
Enginevolume:Issuedforeachengineseries
Electricalvolume:Eachissuedasonetocoverallmodels
Attachmentvolume:Eachissuedasonetocoverallmodels
Thesevariousvolumesaredesignedtoavoidduplicationofinformation.Thereforetodealwithallrepairsforanymodel,itis necessarythatchassis,engine,electricalandattachmentbeavailable.
DISTRIBUTIONANDUPDATING
00
Anyadditions,amendmentsorotherchangeswillbesenttoyourdistributors.Getthemostup-to-dateinformationbeforeyou startanywork.
FILINGMETHOD
00
1.Seethepagenumberonthebottomofthepage.Filethepagesincorrectorder.
2.Followingexamplesshowhowtoreadthepagenumber: Example: 10-3
Itemnumber(10.StructureandFunction)
Consecutivepagenumberforeachitem
3.Additionalpages:Additionalpagesareindicatedbyahyphen(-)andnumberedafterthepagenumber.Fileasinthe example. Example:
REVISEDEDITIONMARK
Whenamanualisrevised,aneditionmark( )isrecordedonthebottomoutsidecornerofthepages.
REVISIONS
RevisedpagesareshownattheLISTOFREVISEDPAGESbetweenthetitlepageandSAFETYpage.
Sothattheshopmanualcanbeofamplepracticaluse,importantplacesforsafetyandqualityaremarkedwiththefollowing symbols.
SymbolItemRemarks
Safety
Caution
Weight
Tightening torque
Specialsafetyprecautionsare necessarywhenperformingthe work.
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems.Cautionnecessarywhenselecting hoistingwireorwhenworking postureisimportant,etc.
Placesthatrequirespecialattentionfortighteningtorqueduring assembly.
CoatPlacestobecoatedwithadhesivesandlubricantsetc.
Oil,waterPlaceswhereoil,waterorfuel mustbeadded,andthecapacity.
Drain
Placeswhereoilorwatermust bedrained,andquantitytobe drained.
00HOISTINGINSTRUCTIONS
00HOISTING
WARNING!Heavyparts(25kgormore) mustbeliftedwithahoistetc.In theDISASSEMBLYAND ASSEMBLYsection,everypart weighing25kgormoreisindicatedclearlywiththesymbol
Ifapartcannotbesmoothlyremovedfromthemachinebyhoisting,thefollowingchecksshouldbemade:
1.Checkforremovalofallboltsfasteningtheparttotherelativeparts.
2.Checkforexistenceofanotherpartcausinginterfacewiththeparttoberemoved.
WIREROPES
1.Useadequateropesdependingontheweightofpartstobehoisted,referringtothetablebelow:
Wireropes (StandardZorStwistropeswithoutgalvanizing)
RopediameterAllowableload
Theallowableloadvalueisestimatedtobe1/6or1/7ofthebreakingstrengthoftheropeused.
2.Slingwireropesfromthemiddleportionofthehook.Slingingneartheedgeofthehookmaycausetheropetoslipoffthe hookduringhoisting,andaseriousaccidentcanresult.Hookshavemaximumstrengthatthemiddleportion.
3.Donotslingaheavyloadwithoneropealone,butslingwithtwoormoreropessymmetricallywoundontotheload.
WARNING!Slingingwithoneropemay causeturningoftheloadduring hoisting,untwistingoftherope, orslippingoftheropefromits originalwindingpositiononthe load,whichcanresultinadangerousaccident
4.Donotslingaheavyloadwithropesformingawidehanginganglefromthehook.Whenhoistingaloadwithtwoormore ropes,theforcesubjectedtoeachropewillincreasewiththehangingangles.Thetablebelowshowsthevariationof allowableload(kg)whenhoistingismadewithtworopes,eachofwhichisallowedtoslingupto1000kgvertically,at varioushangingangles.Whentworopesslingaloadvertically,upto2000kgoftotalweightcanbesuspended.This weightbecomes1000kgwhentworopesmakea120°hangingangle.Ontheotherhand,tworopesaresubjecttoan excessiveforceaslargeas4000kgiftheyslinga2000kgloadataliftingangleof150°
