REVISEDPAGES
Theaffectedpagesareindicatedbytheuseofthefollowingmarks.Itisrequestedthatnecessaryactionsbe takentothesepagesaccordingtotablebelow.
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kIMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine. TheserviceandrepairtechniquesrecommendedbyKomatsuUtilityanddescribeinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperationsrequiretheuseoftoolsspeciallydesigned byKomatsuUtilityforthepurpose.
Topreventinjurytoworkers,thesymbolkisusedtomarksafetyprecautionsinthismanual.Thecautions accompanyingthesesymbolsshouldalwaysbecarefullyfollowed.Ifanydangerarisesormaypossiblyarise, firstconsidersafety,andtakenecessarystepstoface.
kSAFETY
GENERALPRECAUTIONS
Mistakesinoperationextremelydangerous. ReadalltheOperationandMaintenanceManualcarefully BEFOREoperatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,readall theprecautionswrittenonthedecalswhicharesuck onthemachine.
2.Whencarryingoutanyoperation,alwayswearsafety shoesandhelmet.Donotwearlooseworkclothes,or clotheswithbuttonsmissing.
Alwayswearsafetyglasseswhenhittingparts withahammer.
Alwayswearsafetyglasseswhengrindingparts withagrinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.Whencarrying outweldingwork,alwayswearweldinggloves,apron, glasses,capandotherclothessuitedforwelding work.
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedurebeforestarting.Alwaysinformyourfellowworkersbeforestartinganystepoftheoperation.Beforestarting work,hangUNDERREPAIRsignsonthecontrolsin theoperatorscompartment.
5.Keepalltoolsingoodconditionandlearnthecorrect waytousethem.
6.Decideaplaceintherepairworkshoptokeeptools andremovedparts.Alwayskeepthetoolsandpartsin theircorrectplaces.Alwayskeeptheworkareaclean andmakesurethatthereisnodirtoroilonthefloor. Smokeonlyintheareasprovidedforsmoking.Never smokewhileworking.
PREPARATIONSFORWORK
7.Beforeaddingormakinganyrepairs,parkthemachineonhard,levelground,andblockthewheelsto preventthemachinefrommoving.
8.Beforestartingwork,loweroutrigger,bucketorany otherworkequipmenttotheground.Ifthisisnotpossible,useblockstopreventtheworkequipmentfrom fallingdown.Inaddition,besuretolockallthecontrol leversandhangwarningsignonthem.
9.Whendisassemblingorassembling,supportthemachinewithblocks,jacksorstandsbeforestarting work.
10.Removeallmudandoilfromthestepsorotherplaces usedtogetonandoffthemachine.Alwaysusethe handrails,laddersorstepswhengettingonoroffthe machine.
Neverjumponoroffthemachine. Ifitisimpossibletousethehandrails,laddersorsteps, useastandtoprovidesafefooting.
PRECAUTIONSDURINGWORK
11.Whenremovingtheoilfillercap,drainplugorhydraulicpressuremeasuringplugs,loosenthemslowlyto preventtheoilfromspurtingout. Beforedisconnectingorremovingcomponentsofthe hydrauliccircuitandenginecoolingcircuit,firstremovethepressurecompletelyfromthecircuit.
12.Thewaterandoilinthecircuitsarenothotwhenthe engineinstopped,sobecarefulnottogetburned. Waitfortheoilwatertocoolbeforecarryingoutany workonthecoolingwatercircuits.
13.Beforestartingwork,removetheleadsfromthebattery.Alwaysremovetheleadfromthenegative() terminalfirst.
14.Whenraisingheavycomponents,useahoistor crane.Checkthatthewirerope,chainsandhooks arefreefromdamage. Alwaysuseliftingequipmentwhichhasamplecapacity.Installtheliftingequipmentatthecorrect places.
Useahoistorcraneandoperateslowlytoprevent thecomponentfromhittinganyotherpart. Donotworkwithanypartstillraisedbythehoistor crane.
15.Whenremovingcoverswhichareunderinternal pressureorunderpressurefromaspring,always leavetwoboltsinpositiononoppositesides.Slowly releasethepressure,thenslowlyloosentheboltsto remove.
16.Whenremovingcomponents,becarefulnotto breakordamagethewiring. Damagewiringmaycauseelectricalfires.
17.Whenremovingpiping,stopthefueloroilfromspillingout.Ifanyfueloroildripsontothefloor,wipeitup immediately.
Fueloroilonthefloorcancauseyoutoslip,orcan evenstartfires.
18.Asageneralrule,donotusegasolinetowashparts. Inparticular,useonlytheminimumofgasolinewhen washingelectricalparts.
19.Besuretoassembleallpartsagainintheiroriginal places.Replaceanydamagepartswithnewparts. Wheninstallinghosesandwires,besurethatthey willnotbedamagedbycontactwithotherparts whenthemachineisbeingoperated.
20.Wheninstallinghighpressurehoses,makesure thattheyarenottwisted.Damagedtubesaredangerous,sobeextremelycarefulwheninstalling tubesforhighpressurecircuits.Also,checkthat connectingpartsarecorrectlytightened.
21.Whenassemblingorinstallingparts,alwaysuse specifiedtighteningtorques. Wheninstallingthepartswhichvibrateviolentlyor rotateathighspeed,beparticularycarefultocheck thattheyarecorrectlyinstalled.
22.Whenaligningtwoholes,neverinsertyourfingersor hand.
23.Whenmeasuringhydraulicpressure,checkthatthe measuringtooliscorrectlyassembledbeforetaking anymeasurement.
24.Takesurewhenremovingorinstallingwheels.
FOREWORD
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheoperatoranaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesure youunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.
Themanualisdividedintochaptersoneachmaingroupofcomponents;thesechaptersarefurtherdividedintothe followingsections.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstanding ofthestructure,butalsoservesasreferencematerialfortroubleshooting.
TESTINGANDADJUSTING
Thissectionsexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobe madeatcompletionofthechecksandrepairs.
Troubleshootingchartscorrelating«Problems»to«Causes»arealsoincludedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeach component,aswellasprecautionstobetakenfortheseoperations.
NOTE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanynotice.
ContactyourKomatsuUtilitydistributorforthelatestinformation.
VOLUMES
HOWTOREADTHESHOPMANUAL
Shopmanualareissuedasaguidetocarryoutrepairs. Thesevariousvolumesaredesignedtoavoidduplicatingthesameinformation.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbe senttoKomatsuUtilitydistributors. Getthemostup-to-dateinformationbeforeyoustartany work.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage. Filethepagesincorrectorder.
2.Followingexamplesshowyouhowtoreadthepage number. Example:
3.Additionalpages:additionalpagesareindicatedby ahyphen()andnumberafterthepagenumber. Fleasintheexample. Example:
REVISEDEDITIONMARK
Whenamanualisrevised,aneditionmarkisrecorded onthebottomoutsidecornerofthepages.
REVISIONS
RevisedpagesareshownontheLISTOFREVISED PAGESbetweenthetitlepageandSAFETYpage. SYMBOLS
4Weight
3Tightening torque
Specialsafetyprecautions arenecessarywhen performingthework.
Extraspecialsafetyprecautions arenecessarywhenperforming theworkbecauseitisunderinternalpressure.
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems. Cautionnecessarywhenselectinghoistingwire,orwhenworkingpostureisimportant,etc.
Partsthatrequirespecialattentionforthetighteningtorqueduringassembly.
2CoatPartstobecoatedwithadhesivesandlubricantsetc.
5Oil,water
Placeswhereoil,waterorfuel mustbeadded,andtheirquantity.
6Drain
Placeswhereoilorwatermust bedrained,andquantitytobe drained.
HOISTINGINSTRUCTIONS
kHeavyparts(25kgormore)mustbeliftedwitha hoistetc.IntheDisassemblyandAssemblysection, everypartweighing25kgormoreisclearlyindicated withthesymbol4
1.Ifapartcannotbesmoothlyremovedfromthemachinebyhoisting,thefollowingchecksshouldbe made:
Checkforremovalofallboltsfasteningthepartto therelativeparts.
Checkforanypartcausinginterferencewiththe parttoberemoved.
2.Wireropes
1)Useadequateropesdependingontheweightof partstobehoisted,referringtothetablebelow:
WIREROPES
(Standard«S»or«Z»twistropes withoutgalvanizing)
Ropediameter(mm)Allowableload(tons)
Theallowableloadvalueisestimatedtobeonesixthorone-seventhofthebreakingstrengthofthe ropeused.
2)Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausethe ropetoslipoffthehookduringhoisting,andaseriousaccidentcanresult.
Hookshavemaximumstrengthatthemiddleportion.
3)Donotslingaheavyloadwithoneropealone,but slingwithtwoormoreropessymmetricallywound ontotheload.
kSlingingwithoneropemaycauseturningoftheload duringhoisting,untwistingoftherope,orslippingof theropefromitsoriginalwindingpositiononthe load,whichcancausedangerousaccidents.
4)Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.
Whenhoistingaloadwithtwoormoreropes,the forcesubjectedtoeachropewillincreasewiththe hangingangles.
Thetablebelowshowsthevariationofallowable load(kg)whenhoistingismadewithtworopes, eachofwhichisallowedtoslingupto1000kgvertically,atvarioushandingangles.
Whentworopesslingaloadvertically,upto2000kg oftotalweightcanbesuspended.
Thisweightbecomes1000kgwhentworopes makea120°hangingangle.
Ontheotherhand,tworopesaresubjectedtoanexcessiveforceaslargeas4000kgiftheyslinga2000 kgloadataliftingangleof150°.
STANDARDTIGHTENINGTORQUE
Thefollowingchartsgivethestandardtighteningtorquesofboltsandnuts. Exceptionsaregiveninsectionof«DisassemblyandAssembly».
1.STANDARDTIGHTENINGTORQUEOFBOLTSANDNUT
Thistorquetabledoesnotapplytoboltsornutswhichhavetofastennylonorotherpartsnon-ferrousmetalwasher. aNm(newtonmeter):1Nm=0.102kgm
2.TIGHTENINGTORQUEFORNUTSOFFLARED
Usethesetorquesfornutpartofflared.
Threaddiameter ofnutpart (mm)
1/2-20
9/16-18
3/4-16
7/8-14
1.1/16-12
1.5/16-12
Widthacrossflats ofnutpart (mm)
Sealingsurface
Threaddiameter ofnutpart (mm)
9/16-18
11/16-16
13/16-16
1-14
1.3/16-12
1.7/16-12
1.11/16-12
2-12
Widthacrossflats ofnutpart (mm)
COATINGMATERIALS
TherecommendedcoatingmaterialsprescribedinKomatsuUtilityShopManualsarelistedbelow:
NomenclatureCodeApplications
ASL800010Usedtoapplyrubberpads,rubbergasketsandcorkplugs.
ASL800020Usedtoapplyresin,rubber,metallicandnon-metallicpartswhenafast,strong sealisneeded.
Loctite222Usedforlowresistancelockingofscrews,checknutsandadjustmentnuts.
Loctite242
Adhesives
Gasketsealant
Antifrictioncompound (Lubricantincluding Molybdenumdisulfide)
Topreventthelooseningofbolts,nutsandplugsandtheleakageofoil.Usedfor mediumresistancelockingofscrewsandnutsofeverytype,andforlocking keysandbearings.
Loctite262Usedforhighresistantofthreadedpartsthatcanberemovedwithnormaltools.
Loctite270Usedforhighresistantlockingandforsealingthreadedparts,boltsandstud bolts.
Loctite542Usedforsealingtheunionthreadsforhydraulictubes.
Loctite573Usedforsealingratherexactplanesurfaceswhentheoptionofpossiblefuture dismantlingisrequired.
Loctite601Usedforhighresistantlockingofmechanicalcomponentsthatcanberemoved onlyafterheating
Loctite675Usedtolockcylindricalcouplingsandforthepermanentlockingofthreaded parts,andalsotolockshaftstobearings,gears,pulleys,pins,bushings,etc.
ASL800060Usedbyitselftosealgreasefittings,taperedscrewfittingsandtaperedscrew fittingsinhydrauliccircuitsoflessthan50mmindiameter.
Loctite510Usedbyitselfonmountingflatsurface
(Clearancebetweensurfaceswithin0.2mm)
Loctite518Usedbyitselfonmountingflatsurface(Clearancebetweensurfaceswithin0.5mm
ASL800040Appliedtobearingsandtapershafttofacilitatepress-fittingandtoprevent sticking,burningorrusting.
Grease (Lithiumgrease)ASL800050Appliedtobearings,slidingpartsandoilsealsforlubrication,rustprevention andfacilitationofassemblingwork.
Vaseline
Usedforprotectingbatteryelectrodeterminalsfromcorrosion
Inthewiringdiagramsvariouscolourandsymbolsareemployedtoindicatethethicknessofwires. ThiswirecodetablewillhelpyouunderstandWIRINGDIAGRAMS.
Example:RN1.5indicatesacablehavinganominalnumber1.5andredcoatingwithblackstripe.
CLASSIFICATIONBYTHICKNESS
Nominal number Copperwire
(mm) Currentrating (A) Number strands Øofstrands (mm) Crosssection (mm) 0.5160.200.351.553.5 1140.300.992.8011 1.5210.301.483.3514 2.5350.302.473.8020 4560.303.954.6028 6840.305.935.2037 10840.4010.557.1053 503990.4050.1114160
CLASSIFICATIONBYCOLOURANDCODE
PrimaryAuxiliary
CodeAABA/BAGANA/NARA/RAVA/V ColourLightBlueLightBlueWhiteLightBlueYellowLightBlueBlackLightBlueRedLightBlueGreen CodeBBGBNB/NBRB/RB/V ColourWhiteWhiteYellowWhiteBlackWhiteRedWhiteGreen CodeCCBC/BCLCN ColourOrangeOrangeWhiteOrangeBlueOrangeBlack CodeGGNG/NGRGV ColourYellowYellowBlackYellowRedYellowGreen CodeHHLHNH/N ColourGreyGreyBlueGreyBlack CodeLLBL/BLGL/N ColourBlueBlueWhiteBlueYellowBlueBlack CodeMMBMNM/NMV ColourBrownBrownWhiteBrownBlackBrownGreen CodeN ColourBlack CodeRRGRNR/NRV ColourRedRedYellowRedBlackRedGreen CodeSSGSN ColourPinkPinkYellowPinkBlack CodeVVBVNV/N ColourGreenGreenWhiteGreenBlack CodeZZBZ/BZNZ/N ColourVioletVioletWhiteVioletBlack
COMPOSITIONOFTHECOLOURS
Thecolorationoftwo-colourwiresisindicatedbythecompositionofthesymbollisted. Example:GV=Yellow-Greenwithlongitudinalcolouring G/V=Yellow-Greenwithtransversalcolouring