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1. Engine and cooling system
Safety notice
1 (Rev. 2006/09)
Important safety notice
Proper service and repair are 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 k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation
arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions k 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 safety plates stuck to
the machine. For the locations of the
safety plates and detailed explanation of
precautions, see the Operation and Maintenance
Manual.
2) 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, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q Always wear safety glasses when hitting
parts with a hammer.
q Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 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 warning
signs in the operator’s compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift,
service car, etc.
7) If welding repairs are needed, always
have a trained and experienced welder
carry out the work. When carrying out
welding work, always wear welding
gloves, apron, shielding goggles, cap andother clothes suited for welding work. 8) Before starting work, warm up your body thoroughly to start work under good condition.
2. Preparations for work
1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock 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.
Structure, function and maintenance standard
1. Engine and cooling system
1. Pick up for radiator coolant level sensor
2. Upper tank
3. Radiator core
4. Oil cooler (brake, torque converter)
5. Reservoir tank
6. Aftercooler (air to air)
7. Air conditioner condenser
8. Steering hoist oil cooler
A: Coolant inlet port (From engine)
B: Aftercooler inlet port (From turbocharger)
C: Aftercooler outlet port (To engine)
D: Coolant bypass inlet port (For engine)
E: Coolant outlet port (To water pump)
F: Oil inlet port (From rear and front brake)
G: Oil outlet port (To transmission)
Specifications
Radiator
Core type: Al tube
Total radiation surface: 334.8 m2
Torque converter, transmission, brake oil cooler
Core type: PTO-LS
Total radiation surface: 16.26 m2
Steering hoist oil cooler
Core type: CF40-1
Total radiation surface: 5.18 m2
Air conditioner
Gas charge weight (HFC-134a): 1250 ± 50 g
2. Power train system
1. Engine (SAA12V140)
2. Output shaft
3. Front drive shaft
4. Brake cooling pump
(SAR(4)180+180)
5. Torque converter transmission charge pump
and brake cooling brake control pump
(SDR(30)100+100+SAR(1)25)
6. PTO
7. Torque converter
8. Transmission
9. Rear drive shaft
10. Differential gear
11. Drive shaft
12. Brake
13. Tire
14. Final drive
15. Parking brake
16. Steering, hoist and hoist control pump
(SAR(4)180+180+(1)6)
