S4D95LE-3 DIESEL ENGINE
Contents
1. Liter to U K Gallon 12 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980 10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179 20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6 379 30 6 599 6 819 7 039 7 259 7 479 7 969 7 919 8 139 8 359 8 579 40 8 799 9 019 9 239 9 459 9 679 9 899 10 119 10 339 10 559 10 778 50 10 998 11 281 11 438 11 658 11 878 12 098 12 318 12 528 12 758 12 978 60 13 198 13 418 13 638 13 858 14 078 14 298 14 518 14 738 14 958 15 178 70 15 398 15 618 15 838 16 058 16 278 16 498 16 718 16 938 17 158 17 378 80 17 598 17 818 18 037 18 257 18 477 18 697 18 917 19 137 19 357 19 577 90 19 797 20 017 20 237 20 457 20 677 20 897 21 117 21 337 21 557 21 777 00 18 FOREWORD CONVERSION TABLE kgm to ft Ib 1 kgm 7 233 ft Ib 0 1 2 3 4 5 6 7 8 9 0 0 7 2 14 5 21 7 28 9 36 2 43 4 50 6 57 9 65 1 10 72 3 79 6 86 8 94 0 101 3 108 5 115 7 123 0 130 2 137 4 20 144 7 151 9 159 1 166 4 173 6 180 8 188 1 195 3 202 5 209 8 30 217 0 2242 231 5 238 7 245 9 253 2 260 4 267 6 274 9 282 1 40 289 3 296 6 303 8 311 0 318 3 325 5 332 7 340 0 347 2 354 4 50 361 7 368 9 376 1 383 4 390 62. S is used for high temperature PENGUINE season April October and W for Adhesive SEAL 580 417 926 3910 320 m Polyethylene 2 low temperature season November SUPER S or April as adhesive for glass W Using limit 4 months Sika Japan eA Polyethylene Used as adhesive for glass Sikaflex 256HV 20Y 54 39850 310ml container Using limit 6 months SUNSTAR e Used t I joints of gl rts PENGUINE 417 926 3920 320 m Polyethylene sinc lir mon o r n SEAL No 2505 SEKISUI e Used to seal front window Caulking SILICONE 20Y 54 55130 333 m Polyethylene Using limit 6 months material SEALANT container GE TOSHIBA Used to seal joint of glasses SILICONES 22M 54 27220 333 ml Cartridge Translucent white seal TOSSEAL 381 Using limit 12 months 00 11 FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE WHEN USING TORQUE WRENCH In the case of metric nuts and bolts for which there is no special instruction tighten to the torque given in the table below Tightening torque Thread diameter Width across N ZB N J O0 A J J a z lt CDL00372 Nm kgm mm mm 6 10 11 8 14 7 1 2 1 5 8 13 27 34 2 8 3 5 10 17 59 74 6 7 5 12 19 98 123 10 12 5 14 22 153 190 15 5 19 5 16 24 235 285 23 5 29 5 18 27 320 400 33 41 20 30 455 565 46 5 58 22 32 610 765 62 5 78 24 36 78
3. 397 8 405 1 412 3 419 5 426 8 60 434 0 441 2 448 5 455 7 462 9 470 2 477 4 484 6 491 8 499 1 70 506 3 513 5 520 8 528 0 535 2 542 5 549 7 556 9 564 2 571 4 80 578 6 585 9 593 1 600 3 607 6 614 8 622 0 629 3 636 5 643 7 90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1 100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4 110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 853 5 860 7 120 868 0 875 2 882 4 889 7 896 9 904 1 911 4 918 6 925 8 933 1 130 940 3 947 5 954 8 962 0 969 2 976 5 983 7 990 9 998 2 1005 4 140 1012 6 1019 9 1027 1 1034 3 1041 5 1048 8 1056 0 1063 2 1070 5 1077 7 150 1084 9 1092 2 1099 4 1106 6 1113 9 1121 1 1128 3 1135 6 1142 8 1150 0 160 1157 3 1164 5 1171 7 1179 0 1186 2 1193 4 1200 7 1207 9 1215 1 1222 4 170 1129 6 1236 8 1244 1 1251 3 1258 5 1265 8 1273 0 1280 1 1287 5 1294 7 180 1301 9 1309 2 1316 4 1323 6 1330 9 1338 1 1345 3 1352 6 1359 8 1367 0 190 1374 3 1381 5 1388 7 1396 0 1403 2 1410 4 1417 7 1424 9 1432 1 1439 4 00 19 FOREWORD CONVERSION TABLE kg cm to Ib in 1kg cm 14 2233 Ib in 0 1 2 3 4 5 6 7 8 9 0 0 14 2 28 4 42 7 56 9 71 1 85 3 99 6 113 8 128 0 10 142 2 156 5 170 7 184 9 199
4. Do not wear loose work clothes or clothes with buttons missing e Always wear safety glasses when hitting parts with a hammer e 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 hand shield cap and other clothes suited for welding work 4 When carrying out any operation with two or more workers always agree on the operating 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 work ing PREPARATIONS FOR WORK 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 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 equipmen
5. 34 63 3 5 6 5 44 4 5 14 11 22 54 93 5 5 9 5 74 7 5 ee a 17 5 eS 7 5 76 16UN 24 59 98 6 0 10 0 78 8 0 18 04 27 84 132 8 5 13 5 103 10 5 22 E 16UN 20 6 05 32 128 186 13 0 19 0 157 16 0 24 1 14UNS 25 4 06 36 177 245 18 0 25 0 216 22 0 30 1 E 12UN 30 2 10 41 177 245 18 0 25 0 216 22 0 33 12 46 197 294 20 0 30 0 245 25 0 36 14 55 246 343 25 0 35 0 294 30 0 42 FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams various colors and symbols are employed to indicate the thickness of wires This wire code table will help you understand WIRING DIAGRAMS Example 5WB indicates a cable having a nominal number 5 and white coating with black stripe CLASSIFICATION BY THICKNESS Copper wire Current Morminal Dia of Cross Beran rating Applicable circuit Number of strands section strands 2 2 mm mm 0 85 11 0 32 0 88 2 4 12 Starting lighting signal 2 26 0 32 2 09 3 1 20 Lighting signal etc 5 65 0 32 5 23 4 6 37 Charging and signal 15 84 0 45 13 36 7 0 59 Starting Glow plug 40 85 0 80 42 73 11 4 135 Starting 60 127 0 80 63 84 13 6 178 Starting 100 217 0 80 109 1 17 6 230 Starting CLASSIFICATION BY COLOR AND CODE Circuits kra Classi Charging Ground Starting Light
6. 4 33 9 93 199 4 23 9 11 12 2 4 4 24 75 2 15 0 59 138 2 34 4 94 201 2 23 3 10 14 0 3 9 25 77 0 15 6 0 140 0 35 0 95 203 0 22 8 9 15 8 3 3 26 78 8 16 1 61 141 8 35 6 96 204 8 22 2 8 17 6 2 8 27 80 6 16 7 62 143 6 36 1 97 206 6 21 7 7 19 4 2 2 28 82 4 17 2 63 145 4 36 7 98 208 4 21 1 6 21 2 1 7 29 84 2 17 8 64 147 2 37 2 99 210 2 20 6 5 23 0 1 1 30 86 0 18 3 65 149 0 37 8 100 212 0 20 0 4 24 8 0 6 31 87 8 18 9 66 150 8 40 6 105 221 0 19 4 3 26 6 0 32 89 6 19 4 67 152 6 43 3 110 230 0 18 9 2 28 4 0 6 33 91 4 20 0 68 154 4 46 1 115 239 0 18 3 1 30 2 1 1 34 93 2 20 6 69 156 2 48 9 120 248 0 17 8 0 32 0 1 7 35 95 0 21 1 70 158 0 51 7 125 257 0 17 2 1 33 8 2 2 36 96 8 21 7 71 159 8 54 4 130 266 0 16 7 2 35 6 2 8 37 98 6 22 2 72 161 6 57 2 135 275 0 16 1 3 37 4 3 3 38 100 4 22 8 73 163 4 60 0 140 284 0 15 6 4 39 2 3 9 39 102 2 23 3 74 165 2 62 7 145 293 0 15 0 5 41 0 4 4 40 104 0 23 9 75 167 0 65 6 150 302 0 14 4 6 42 8 5 0 41 105 8 24 4 76 168 8 68 3 155 311 0 13 9 7 44 6 5 6 42 107 6 25 0 77 170 6 71 1 160 320 0 13 3 8 46 4 6 1 43 109 4 25 6 78 172 4 73 9 165 329 0 12 8 9 48 2 6 7 44 111 2 26 1 79 174 2 76 7 170 338 0 12 2 10 50 0 7 2 45 113 0 26 7 80 176 0 79 4 175 347 0 00 21 FOREWORD UNITS UNITS In this manual the measuring units are indicated with Internatinal System of units SI As for reference conventionally used Gr
7. seventh of the breaking strength of the rope used Sling wire ropes from the middle portion of the hook 3 4 Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting and a serious accident can result Hooks have max imum strength at the middle portion 1G d d 100 88 79 71 41 SAD00479 Do not sling a heavy load with one rope alone but sling with two or more ropes symmetrically wound onto 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 Do not sling a heavy load with ropes forming a wide hanging angle from the hook 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 allowable load kN kg when hoisting is made with two ropes each of which is allowed to sling up to 9 8 KN 1000 kg vertically at various hanging angles When two ropes sling a load vertically up to 19 6 KN 2000 kg of total weight can be sus pended This weight becomes 9 8 kN 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 39 2 kN 4000 kg if they sling a 19 6 kN 2000 kg load ata lif
8. to pre vent 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 from a 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 onto 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 00 4 19 Be sure to assemble all parts again in their origi nal places Replace any damaged parts with new parts e 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 install ing 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 violentl
9. torques for bolts and nuts unit mm of Cummins Engine Thread diameter Tightening torque mm Nm kgm 6 10 2 1 02 0 20 8 24 4 2 45 0 41 10 43 6 4 38 0 61 12 77 12 7 85 1 22 2 EYE JOINTS Use these torques for eye joints unit mm of Cummins Engine Thread diameter Tightening torque mm Nm kgm 6 8 2 0 81 0 20 8 10 1 02 0 20 10 12 1 22 0 20 12 24 4 2 45 0 41 14 36 5 3 67 0 51 3 TAPERED SCREWS Use these torques for tapered screws unit inch of Cummins Engine Tightening torque Material In Cast Iron or Steel In Aluminum Thread size inch Nm kgm Nm kgm 1 16 15 2 1 53 0 20 5 1 0 51 0 10 1 8 20 2 2 04 0 20 15 2 1 53 0 20 1 4 25 3 2 55 0 31 20 2 2 04 0 20 3 8 35 4 3 57 0 41 25 3 2 55 0 31 1 2 55 6 5 61 0 61 35 4 3 57 0 41 3 4 75 8 7 65 0 82 45 5 4 59 0 51 TIGHTENING TORQUE TABLE FOR HOSES TAPER SEAL TYPE AND FACE SEAL TYPE Tighten the hoses taper seal type and face seal type to the following torque unless otherwise specified Apply the following torque when the threads are coated wet with engine oil Tightening torque Nm kgm Topal seal Face seal type F ype Nominal size Width across N nminal ti read of hose flats ominal threa Range Target a Ha size Threads per ay A inch Thread series 9 34 54 3 5 5 5 44 4 5 ara 14 3 09 19 4 5 76 18UN
10. 1 213 4 227 6 241 8 256 0 270 2 20 284 5 298 7 312 9 327 1 341 4 355 6 369 8 384 0 398 3 412 5 30 426 7 440 9 455 1 469 4 483 6 497 8 512 0 526 3 540 5 554 7 40 568 9 583 2 597 4 611 6 625 8 640 1 654 3 668 5 682 7 696 9 50 711 2 725 4 739 6 753 8 768 1 782 3 796 5 810 7 825 0 839 2 60 853 4 867 6 881 8 896 1 910 3 924 5 938 7 953 0 967 2 981 4 70 995 6 1010 1024 1038 1053 1067 1081 1095 1109 1124 80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266 90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408 100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550 110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693 120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835 130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977 140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119 150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262 160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404 170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546 180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688 190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830 200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973 210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115 220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257 230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399 240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542 00 20 FOREWORD CONVERSION TABLE Temperature Fahrenheit Centig
11. 3 701 3 740 3 780 3 819 3 858 3 898 00 16 FOREWORD CONVERSION TABLE Millimeters to Inches 1 mm 0 03937 in 0 1 2 3 4 5 6 7 8 9 0 0 0 039 0 079 0 118 0 157 0 197 0 236 0 276 0 315 0 354 10 0 394 0 433 0 472 0 512 0 551 0 591 0 630 0 669 0 709 0 748 20 0 787 0 827 0 866 0 906 0 945 0 984 1 024 1 063 1 102 1 142 30 1 181 1 220 1 260 1 299 1 339 1 378 1 417 1 457 1 496 1 536 40 1 575 1 614 1 654 1 693 1 732 1 772 1 811 1 850 1 890 1 929 50 1 969 2 008 2 047 2 087 2 126 2 165 2 205 2 244 2 283 2 323 60 2 362 2 402 2 441 2 480 2 520 2 559 2 598 2 638 2 677 2 717 70 2 756 2 795 2 835 2 874 2 913 2 953 2 992 3 032 3 071 3 110 80 3 150 3 189 3 228 3 268 3 307 3 346 3 386 3 425 3 465 3 504 90 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898 Kilogram to Pound 1 kg 2 2046 Ib 0 1 2 3 4 5 6 7 8 9 0 0 2 20 4 41 6 61 8 82 11 02 13 23 15 43 17 64 19 84 10 22 05 24 25 26 46 28 66 30 86 33 07 35 27 37 48 39 68 41 89 20 44 09 46 30 48 50 50 71 51 91 55 12 57 32 59 53 61 73 63 93 30 66 14 68 34 70 55 72 75 74 96 77 16 79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 97 00 99 21 101 41 103 62 105 82 108 03 50 110 23 112 44 11
12. 4 64 116 85 119 05 121 25 123 46 125 66 127 87 130 07 60 132 28 134 48 136 69 138 89 141 10 143 30 145 51 147 71 149 91 152 12 70 154 32 156 53 158 73 160 94 163 14 165 35 167 55 169 76 171 96 174 17 80 176 37 178 57 180 78 182 98 185 19 187 39 189 60 191 80 194 01 196 21 90 198 42 200 62 202 83 205 03 207 24 209 44 211 64 213 85 216 05 218 26 00 17 FOREWORD CONVERSION TABLE Liter to U S Gallon 12 0 2642 U S Gal 0 1 2 3 4 5 6 7 8 9 0 0 0 264 0 528 0 793 1 057 1 321 1 585 1 849 2 113 2 378 10 2 642 2 906 3 170 3 434 3 698 3 963 4 227 4 491 4 755 5 019 20 5 283 5 548 5 812 6 076 6 340 6 604 6 869 7 133 7 397 7 661 30 7 925 8 189 8 454 8 718 8 982 9 246 9 510 9 774 10 039 10 303 40 10 567 10 831 11 095 11 359 11 624 11 888 12 152 12 416 12 680 12 944 50 13 209 13 473 13 737 14 001 14 265 14 529 14 795 15 058 15 322 15 586 60 15 850 16 115 16 379 16 643 16 907 17 171 17 435 17 700 17 964 18 228 70 18 492 18 756 19 020 19 285 19 549 19 813 20 077 20 341 20 605 20 870 80 21 134 21 398 21 662 21 926 22 190 22 455 22 719 22 983 23 247 23 511 90 23 775 24 040 24 304 24 568 24 832 25 096 25 361 25 625 25 889 26 153
13. 5 980 80 100 27 41 1150 1440 118 147 30 46 1520 1910 155 195 33 50 1960 2450 200 250 36 55 2450 3040 250 310 39 60 2890 3630 295 370 Tightening torque Thread diameter Width across N of bolt flats CDL00373 mm mm Nm kgm 6 10 5 9 9 8 0 6 1 0 8 12 13 7 23 5 1 4 2 4 10 14 34 3 46 1 3 5 4 7 12 17 74 5 90 2 7 6 9 2 Sealing surface Z YE OCLI OG Ss ZZ Z rd Z2 Z ZTZZZZZZZHZZZZZAZZ TABLE OF TIGHTENING TORQUES FOR FLARED NUTS In the case of flared nuts for which there is no special instruction tighten to the torque given in the table below eannges Thread diameter Width across flat Tightening torque mm mm Nm kgm 14 19 24 5 4 9 2 5 0 5 18 24 49 19 6 542 22 27 78 5 19 6 842 24 32 137 3 29 4 1443 30 36 176 5 29 4 1843 33 41 196 1 49 20 5 36 46 245 2 49 2545 42 55 294 2 49 30 5 00 12 FOREWORD STANDARD TIGHTENING TORQUE TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS In the case of split flange bolts for which there is no special instruction tighten to the torque given in the table below Thread diameter Width across flat Tightening torque mm mm Nm kgm 10 14 59 74 6 7 5 12 17 98 123 10 12 5 16 22 235 285 23 5 29 5 TABLE OF TIGHTENING TORQUES FOR O RING BOSS PIPING JOINTS Unless there are special instructions tighten the O ring boss pi
14. CWP06393 3 Hold in the condition in Steps 1 and 2 and 3 Hold in the condition in Steps 1 and 2 and pull out whole body 2 to disconnect it pull out whole body 2 to disconnect it 2 2 CWP06396 CWP06395 e Hold the mouthpiece of the tightening portion Hold the mouthpiece of the tightening portion and push body 2 in straight until sliding pre and push body 2 in straight until sliding pre vention ring 1 contacts contact surface a of vention ring 1 contacts contact surface a of the hexagonal portion at the male end to con the hexagonal portion at the male end to con nect it nect it S a E fe Oo oe I Ga 2 CWP06392 CWP06391 00 9 FOREWORD COATING MATERIALS COATING MATERIALS The recommended coating materials such as adhesives gasket sealants and greases used for disassembly and assembly are listed below For coating materials not listed below use the equivalent of products shown in this list Category Komatsu code Part No Q ty Container Main applications features Adhesives LT 1A 790 129 9030 150g Tube Used to prevent rubber gaskets rubber cushions and cock plug from coming out LT 1B 790 129 9050 20g 2 pcs Polyethylene container Used in places requiring an immediately effective strong adhesive Used for plastics except polyethylene polyprophylene tetrafluoroethlene and vinyl ch
15. Hold hose adapter 1 or hose 5 and insert it in mating adapter 3 aligning them with each Fig 4 other See Fig 4 4 Do not hold rubber cap portion 4 2 After inserting the hose in the mating adapter perfectly pull it back to check its connecting condition See Fig 5 e When the hose is pulled back the rubber cap portion moves toward the hose about 3 5 mm This does not indicate abnormality 5 5 however N Fig 5 h Bi UB I I Kal 3 5mm CWP10701 00 8 FOREWORD METHOD OF DISASSEMBLING CONNECTING PUSH PULL TYPE COUPLER Type 2 Type 3 1 Hold the mouthpiece of the tightening portion and push body 2 in straight until sliding pre vention ring 1 contacts contact surface a of the hexagonal portion at the male end A l 2 CWP06392 2 Hold in the condition in Step 1 and turn lever 4 to the right clockwise 1 Hold the mouthpiece of the tightening portion and push body 2 in straight until sliding pre vention ring 1 contacts contact surface a of the hexagonal portion at the male end CWP06391 2 Hold in the condition in Step 1 and push until cover 3 contacts contact surface a of the hexagonal portion at the male end gt 2 a me 72 le a da CWP06394 3
16. SM206 4D95LE BE3 SERVICE MANUAL CX50 Forklift Truck EPA Tier 2 Compliant Diesel Export Models FD40ZY 35Y 40Y 45Y 50AY 10 S N 133001 S4D95LE 3 DIESEL ENGINE AA WARNING Read and observe all warnings on this unit before operating it DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place Komatsu Forklift U S A Inc ISSUED MARCH 2009 SAFETY SAFETY NOTICE SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose To prevent injury to workers the symbol A is used to mark safety precautions in this manual The cautions accompanying these symbols should always be followed carefully If any danger ous situation arises or may possibly arise first consider safety and take the necessary actions to deal with the situation GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous Read the Operation and Maintenance Manual care fully 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
17. avitational System of units are indicated in parentheses Example N kg Nm kgm MPa kg cm kPa mmH20 kPa mmHg kW rpm HP rpm g kWh g HPh 00 22
18. eam SYG2 160CA SYGA 160CNCA pat bh SYG2 400M 400 g x 10 Bellows type e Used for heavy load portion Grease sand SYG2 400M A 400 g x 20 Bellows type LM G G2 M SYGA 16CNM 16 kg Can Hyper White SYG2 400T A Seizure resistance and heat resistance Grease G2 T SYG2 16CNT 400 g Bellows type higher than molybdenum disulfide grease GO T SYGO0 400T A 16 k Can Since this grease is white it does not For use in SYGO 16CNT g stand out against machine body cold district e E a on a a a For high SYG2 400BT 16 be C yp on microorganisms animals and plants temperature SYGA 1 aa i g av and large load i SUNSTAR Used as primer for cab side PAINT PRIMER 20 ml Yan Using limit 4 months 580 SUPER Kal aya 417 926 3910 SUNSTAR Glass Used as primer for glass side GLASS PRIMER 20 ml container Using limit 4 months 580 SUPER SUNSTAR Glass Used as primer for painted surface on Primer PAINT PRIMER 22M 54 27230 20 ml G htaiher cab side 435 95 i Using limit 4 months Used as primer for black ceramic SUNSTAR coated surface on glass side and for eae PR MERI eae kere deva can hard polycarbonate coated surface Using limit 4 months SUNSTAR 2 Used as primer for sash Alumite SASH PRIMER 22M 54 27250 20 ml Pere AA r Using limit 4 months GP 402 EK SUNSTAR Ecocart 8 Used as adhesive for glass PENGUINE 22M 54 27210 320 ml Special 5 Using limit 6 months SUPER 560 container g SUNSTAR e
19. ing Instrument Signal Other fication Code Ww B B R Y G L Pri 1 mary Color White Black Black Red Yellow Green Blue Code WR BW RW YR GW LW 2 Color White amp Red White amp Black Red amp White Rellow amp Red Green amp White Blue amp White Code WB BY RB YB GR LR 3 Color White amp Black Black amp Yellow Red amp Black Yellow amp Black Green amp Red Blue amp Yellow Code WL BR RY YG GY LY Auxi liary Yellow amp Green amp Color White amp Blue Black amp Red Red amp Yellow Green Yellow Blue amp Yellow Code WG RG YL GB LB 5 Color White amp Green Red amp Green Yellow amp Blue Green amp Black Blue amp Black Code RL YW GL DII 6 Color Red amp Blue Yellow amp White Green amp Blue 00 15 FOREWORD CONVERSION TABLE CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures For details of the method of using the Conversion Table see the example given below EXAMPLE e Method of using the Conversion Table to convert from millimeters to inches 1 Convert 55 mm into inches 1 Locate the number 50 in the vertical column at the left side take this as A then draw a horizontal line from A 2 Locate the number 5 in the row across the top take this as B then draw a perpendicular line do
20. lectric circuit diagrams and mainte nance standards 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 with Causes are also included in this section DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing installing disassembling and assembling each com ponent as well as precautions for them PERAIR AND REPLACEMENT OF PARTS NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice Use the specifications given in the book with the latest date 00 5 FOREWORD HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL DISTRIBUTION AND UPDATING Any additions amendments or other changes will be sent to KOMATSU distributors Get the most up to date information before you start any work SYMBOLS So that the shop manual can be of ample practical use important safety and quality portions are marked with the following symbols Symbol Item Remarks A Safety Special safety precautions are necessary when per forming the work Caution Special technical precau tions or other precautions for preserving standards are necessary when per forming the work Weight Weight of parts of sys tems Caution necessary when selecting hoisti
21. loride rubber metal and non metal LT 2 09940 00030 50g Polyethylene container Features Resistance to heat and chemicals Used for anti loosening and sealant purpose for bolts and plugs LT 3 790 129 9060 Set of adhesive and hardening agent Adhesive 1kg Hardening agent 500 g Can Used as adhesive or sealant for metal glass and plastic LT 4 790 129 9040 250g Polyethylene container Used as sealant for machined holes Holtz MH 705 790 126 9120 75g Tube Used as heat resisting sealant for repairing engine Three bond 1735 790 129 9140 50g Polyethylene container Quick hardening type adhesive Cure time within 5 sec to 3 min Used mainly for adhesion of metals rubbers plastics and woods Aron alpha 201 790 129 9130 2g Polyethylene container Quick hardening type adhesive Quick cure type max strength after 30 minutes Used mainly for adhesion of rubbers plastics and metals Loctite 648 50 79A 129 9110 50 cc Polyethylene container Resistance to heat chemicals e Used at joint portions subject to high temperatures Gasket sealant LG 1 790 129 9010 200 g Tube Used as adhesive or sealant for gaskets and packing of power train case etc LG 5 790 129 9080 1kg Can Used as sealant for various threads pipe joints flanges Used as sealant for tapered plugs elbows nip
22. ng wire or when working pos ture is important etc torque Places that require special attention for the tightening torque during assembly Coat Places to be coated with adhesives and lubricants etc Oil water Places where oil water or fuel must be added and the capacity c go Tightening Drain Places where oil or water must be drained and quantity to be drained 00 6 FOREWORD HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS HOISTING A Heavy parts 25 kg or more must be lifted with a hoist etc In the DISASSEMBLY AND ASSEMBLY section every part weighing 25 kg or more is indicated clearly with the symbol If a part cannot be smoothly removed from the machine by hoisting the following checks should be made 1 Check for removal of all bolts fastening the part to the relative parts 2 Check for existence of another part causing interference with the part to be removed 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 Rope diameter Allowable load mm kN tons 10 9 8 1 0 11 5 13 7 1 4 12 5 15 7 1 6 14 21 6 2 2 16 27 5 2 8 18 35 3 3 6 20 43 1 4 4 22 4 54 9 5 6 30 98 1 10 0 40 176 5 18 0 50 274 6 28 0 60 392 2 40 0 2 The allowable load value is estimated to be one sixth or one
23. ping joints to the torque below Thread diameter Width across flat Tightening torque Nm kgm Norminal No mm mm Range Target 02 14 35 63 3 5 6 5 44 4 5 03 04 20 Varies depending 84 132 8 5 13 5 103 10 5 05 06 24 on type of 128 186 13 0 19 0 157 16 0 10 12 33 connector 363 480 37 0 49 0 422 43 0 14 42 746 1010 76 0 103 883 90 0 TABLE OF TIGHTENING TORQUES FOR O RING BOSS PLUGS Unless there are special instructions tighten the O ring boss plugs to the torque below Thread diameter Width across flat Tightening torque Nm kgm Norminal No mm mm Range Target 08 08 14 5 88 8 82 0 6 0 9 7 35 0 75 10 10 17 9 8 12 74 1 0 1 3 11 27 1 15 12 12 19 14 7 19 6 1 5 2 0 17 64 1 8 14 14 22 19 6 24 5 2 0 2 5 22 54 2 3 16 16 24 24 5 34 3 2 5 3 5 29 4 3 0 18 18 27 34 3 44 1 3 5 4 5 39 2 4 0 20 20 30 44 1 53 9 4 5 5 5 49 0 5 0 24 24 32 58 8 78 4 6 0 8 0 68 6 7 0 30 30 32 93 1 122 5 9 5 12 5 107 8 11 0 33 33 107 8 147 0 11 0 15 0 124 4 13 0 36 36 36 127 4 176 4 13 0 18 0 151 9 15 5 42 42 181 3 240 1 18 5 24 5 210 7 21 5 52 52 274 4 367 5 28 0 37 5 323 4 33 0 00 13 FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1 BOLT AND NUTS Use these
24. ples of hydraulic piping LG 6 790 129 9020 200 g Tube Features Silicon based resistance to heat cold Used as sealant for flange surface tread Used as sealant for oil pan final drive case etc LG 7 790 129 9070 1kg Tube Features Silicon based quick hardening type Used as sealant for flywheel housing intake manifold oil pan thermostat housing etc Three bond 1211 790 129 9090 100 g Tube Used as heat resisting sealant for repairing engine Three bond 1207B 419 15 18131 100 g Tube Features Silicone type heat resistant vibration resistant and impact resistant sealing material Used as sealing material for transfer case 00 10 FOREWORD COATING MATERIALS Category Komatsu code Part No Q ty Container Main applications features e Used as lubricant for sliding portion to ioden LM G 09940 00051 60 g Can prevent from squeaking disulphide e Used to prevent seizure or scuffling of the lubricant 3 R thread when press fitting or shrink fitting cx LM P 09940 00040 200 g Tube e Used as lubricant for linkage bearings etc SYG2 400LI General purpose type SYG2 350LI G2 LI SYG2 400LI A Various Various SYG2 160LI SYGA 160CNLI SYG2 400CA e Used for normal temperature light load SYG2 350CA bearing at places in contact with water or G2 CA SYG2 400CA A Various Various st
25. rade Conversion a simple way to convert a Fahrenheit temperature reading into a Cen tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col umn of figures These figures refer to the temperature in either Fahrenheit or Centigrade degrees If it is desired to convert from Fahrenheit to Centigrade degrees consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left If it is desired to convert from Centigrade to Fahrenheit degrees consider the center column as a table of Centigrade values and read the corresponding Fahrenheit temperature on the right 1 C 33 8 F 6 F F C oF 2G oF 40 4 40 40 0 11 7 11 51 8 7 8 46 114 8 27 2 81 117 8 37 2 35 31 0 11 1 12 53 6 8 3 47 116 6 27 8 82 179 6 34 4 30 22 0 10 6 13 55 4 8 9 48 118 4 28 3 83 181 4 31 7 25 13 0 10 0 14 57 2 9 4 49 120 2 28 9 84 183 2 28 9 20 4 0 9 4 15 59 0 10 0 50 122 0 29 4 85 185 0 28 3 19 2 2 8 9 16 60 8 10 6 51 123 8 30 0 86 186 8 27 8 18 0 4 8 3 17 62 6 11 1 52 125 6 30 6 87 188 6 27 2 17 1 4 7 8 18 64 4 11 7 53 127 4 31 1 88 190 4 26 7 16 3 2 7 2 19 66 2 12 2 54 129 2 31 7 89 192 2 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58 136
26. t from fall ing In addition be sure to lock all the control levers and hang warning signs on them 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 pro vide safe footing 00 3 SAFETY SAFETY NOTICE 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 not to get burned Wait for the oil and water to cool before carry ing 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 nega tive terminal first 14 When raising heavy components use a hoist or crane 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
27. ting angle of 150 kN A kg Eoen 1400 g8 1000 16 7 1700 mn Load capacity kN kg 9 8 1000 900 30 60 90 120 150 Lifting angle degree 9JS03002 00 7 FOREWORD METHOD OF DISASSEMBLING CONNECTING PUSH PULL TYPE COUPLER METHOD OF DISASSEMBLING CONNECTING PUSH PULL TYPE COUPLER A Before carrying out the following work release Type 1 the residual pressure from the hydraulic tank For details see TESTING AND ADJUSTING Fig 1 Releasing residual pressure from hydraulic 4 tank A Even if the residual pressure is released from the hydraulic tank some hydraulic oil flows out E when the hose is disconnected Accordingly prepare an oil receiving container Disconnection 1 Release the residual pressure from the hydrau lic tank For details see TESTING AND Bie ADJUSTING Releasing residual pressure from 4 hydraulic tank w 2 Hold adapter 1 and push hose joint 2 into mating adapter 3 See Fig 1 The adapter can be pushed in about 3 5 TI mm Do not hold rubber cap portion 4 1 3 After hose joint 2 is pushed into adapter 3 press rubber cap portion 4 against 3 until it clicks See Fig 2 4 Hold hose adapter 1 or hose 5 and pull it out See Fig 3 Since some hydraulic oil flows out prepare an oil receiving container Fig 3 Connection 1
28. wn from B 3 Take the point where the two lines cross as C This point C gives the value when converting from millimeters to inches Therefore 55 mm 2 165 inches 2 Convert 550 mm into inches 1 The number 550 does not appear in the table so divide by 10 move the decimal point one place to the left to convert it to 55 mm 2 Carry out the same procedure as above to convert 55 mm to 2 165 inches 3 The original value 550 mm was divided by 10 so multiply 2 165 inches by 10 move the decimal point one place to the right to return to the original value This gives 550 mm 21 65 inches B Millimeters to inches 1 mm 0 03937 in 0 1 2 3 4 5 6 7 8 9 0 0 0 039 0 079 0 118 0 157 0 197 0 236 0 276 0 315 0 354 10 0 394 0 433 0 472 0 512 0 551 0 591 0 630 0 669 0 709 0 748 20 0 787 0 827 0 866 0 906 0 945 0 984 1 024 1 063 1 102 1 142 30 1 181 1 220 1 260 1 299 1 339 1 378 1 417 1 457 1 496 1 536 40 1 575 1 614 1 654 1 693 1 732 1 772 1 811 1 850 1 890 1 929 a 80 1 969 2 008 2 047 2 087 2 126 2 165 2 205 2 244 2 283 2 323 60 2 362 2 402 2 441 2 480 2 520 2 559 2 598 2 638 2 677 2 717 70 2 756 2 795 2 835 2 874 2 913 2 953 2 992 3 032 3 071 3 110 80 3 150 3 189 3 228 3 268 3 307 3 346 3 386 3 425 3 465 3 504 90 3 543 3 583 3 622 3 661
29. y or rotate at high speed be par ticularly careful to check that they are installed correctly 22 When aligning two holes never insert your fin gers 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 GENERAL FOREWORD GENERAL 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 judge ments 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 the following chapters these chapters are fur ther divided into the each main group of components STRUCTURE FUNCTION AND MAINTENANCE STANDARD This section explains the structure and function of each component It serves not only to give an under standing of the structure but also serves as reference material for troubleshooting In addition this section may contain hydraulic circuit diagrams e
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