Komatsu Crane 150A 150FA service & repair manual

Description Komatsu Crane 150A 150FA service & repair manual

Komatsu Crane 150A, 150FA pdf workshop service & repair manual

Serial numbers:
09695 - 10827
10828 and up

MANUAL CONTENT:
GENERAL
GENERAL ASSEMBLY DRAWING
FUEL, COOLANT, AND LUBRICANTS
ACCORDING TO AMBIENT TEMPERATURE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
ENGINE OIL SPECIFICATIONS
NORMAL OPERATION
ARCTIC OPERATION
TRANSMISSION, TORQUE CONVERTER AND OIL COOLER, AND HYDRAULIC SYSTEM
OIL SPECIFICATIONS
REAR-DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL SPECIFICATIONS
DIESEL FUEL SPECIFICATIONS
COOLANT SPECIFICATIONS
GENERAL
WATER
ANTIFREEZE
SUPPLEMENTAL COOLANT ADDITIVES
MAINTENANCE OF SUPPLEMENTAL COOLANT ADDITIVES
COOLANT TESTING FOR CONDITIONER CONCENTRATION
REPLENISHING COOLANT CONDITIONER
SUPPLEMENTAL COOLANT ADDITIVE MAINTENANCE GUIDE
COOLING SYSTEM TEST KIT

STRUCTURE AND FUNCTION
WIRE ROPE
WIRE ROPE SPECIFICATIONS
MAINTENANCE RECOMMENDATIONS
TRANSMISSION - T20000
SPECIFICATIONS
OPERATION
POWERFLOWS
GEAR AND CLUTCH LAY-OUT
SECTIONAL VIEWS
CONVERTER HOUSING
TRANSMISSION CASE AND REAR COVER
TURBINE SHAFT
DRIVE PLATE
TORQUE CONVERTER
AUXLIARY PUMP DRIVE
PUMP DRIVE
FORWARD SHAFT
REVERSE AND 2ND SHAFT
REVERSE IDLER
LOW SPEED SHAFT
3RD SHAFT
IDLER SHAFT
OUTPUT SHAFT
HI & LOW RANGE SHIFT CONTROL
CHARGING PUMP & FILTER
TRANSMISSION CONTROL VALVE (MANUAL)
TRANSMISSION - HR18000
SPECIFICATIONS
HR18000 CONVERTER
HR18000 LONG DROP CONVERTER AND TRANSMISSION CASE
CONTROL VALVE
6 SPEED CLUTCH AND GEAR
REAR VIEW
POWER FLOW
LOW RANGE
HIGH RANGE
CLUTCH AND GEAR ARRANGEMENT
STEERING CONTROL VALVE
TYPICAL OIL FLOW
OPERATION
DESIGN AND FUNCTION
CONTROL VALVE
METERING SECTION
ROTOR OPERATION IN THE ROTOR SET
POWER STEERING OPERATION
MANUAL STEERING OPERATION
BRAKE VALVE - MASTER
MASTER CYLINDER SECTION
POWER ASSIST SECTION
BRAKE VALVE - EXPLODED VIEW
HYDRAULIC PUMP
DUAL TANDEM
EXPLODED VIEW
DUAL TANDEM PUMP CUTAWAY VIEW
SWING DRIVE MOTOR
EXPLODED VIEW
HOIST/WINCH MOTOR
EXPLODED VIEW
AUXILIARY HOIST MOTOR
EXPLODED VIEW
PARKING BRAKE
SERVICE BRAKE
AXLES
DIFFERENTIAL
PLANETARY AXLE WHEEL ENDS
SENSORS
BACKUP ALARM PRESSURE SWITCH
FUEL LEVEL SENDER
TORQUE CONVERTER OIL TEMPERATURE SENDER
ENGINE WATER TEMPERATURE SENDER
ENGINE OIL PRESSURE SENDER
NEUTRAL START SWITCH
BRAKE LIGHT OIL PRESSURE SWITCH
ENGINE HIGH WATER TEMPERATURE SWITCH (OPTION)
ENGINE LOW OIL PRESSURE SWITCH (OPTION)
REAR STEERING INDICATOR LIGHT SWITCH
TOWING THE CRANE
FRONT DRIVELINE
REAR DRIVELINE

TESTING, ADJUSTING AND TROUBLESHOOTING
TANDEM PUMP
WEAR CONSIDERATIONS IN CS & S PUMPS
TEST PROCEDURE FOR REBUILT PUMP
WINCH MOTOR
INSPECTION & REPLACEMENT
WINCH SPOOLING ADJUSTMENT
PROCEDURE FOR CORRECTING WINCH SPOOLING BY ROTATING AND SHIMMING
ROTATING PROCEDURE
SHIMMING PROCEDURE
HOIST AND SWING BRAKE CHECKS AND ADJUSTMENTS
HOIST BRAKE CHECKS AND ADJUSTMENTS
PRIMARY MANIFOLD
CLEANING AND INSPECTION
SECONDARY MANIFOLD
CLEANING AND INSPECTION
TESTING AND TROUBLESHOOTING
SWING DRIVE BEARING & GEAR ASSEMBLY WEAR TOLERANCE
PERMISSIBLE BEARING CLEARANCES
PROCEDURE FOR CLEARANCE MEASUREMENT
STEERING CONTROL VALVE
INSPECTION AND REPLACEMENT
FILLING AND AIR BLEEDING THE SYSTEM WHEN DRAINED OF OIL
HYDRAULIC FLUID
TIPS FOR MAINTAINING THE HYDROSTATIC STEERING SYSTEM
PRESSURE BLEEDING INSTRUCTIONS
BENCH BLEEDING INSTRUCTIONS
SPRING MOTORS
ADJUSTMENT
HEAD & HOOK BLOCK INSPECTION
HEAD
SHEAVES AND DRUM
HOOK BLOCK INSPECTION
DAILY/10 HOUR INSPECTION
ANNUAL/500 HOUR INSPECTION
WIRE ROPE
RESTING HOOK BLOCK
IMPORTANCE OF LUBRICATION
RECONNECTED LUBRICANTS FOR WIRE ROPE
METHODS OF LUBRICATION
LUBRICATION IN STORAGE
IDLE ROPES
INSPECTION OF WIRE ROPE, SHEAVES AND DRUM
BREAKING IN WIRE ROPE
RESETTABLE CIRCUIT BREAKERS
TROUBLESHOOTING
PRE-DELIVERY PROCEDURES

DISASSEMBLY AND ASSEMBLY
PRECAUTIONS DURING OPERATION
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK
PRECAUTIONS WHEN COMPLETING THE OPERATIONS
OTHER PRECAUTIONS
SKETCHES OF SPECIAL TOOLS
REVERSE IDLER SHAFT NUT SOCKET
HYDRAULIC MOTOR
STEEL SLEEVE
SEAL RETAINER TOOL
CHECK VALVE TOOL
SEAL RETAINER TOOL
DIFFERENTIAL CARRIER
REPAIR STAND
TRANSMISSION T20000 POWERSHIFT 6 SPEED
SERVICING MACHINE AFTER COMPONENTS OVERHAUL
TRANSMISSION TO ENGINE INSTALLATION PROCEDURE
CLEANING AND INSPECTION
CLEANING
LOW (1ST) CLUTCH
REVERSE CLUTCH
2ND CLUTCH
3RD CLUTCH
FORWARD CLUTCH
CONVERTER HOUSING
IDLER SHAFT
OUTPUT SHAFT
CONVERTER DRIVE COUPLING INSTALLATION DETAILS
HYDRAULIC ACTUATED AXLE DISCONNECT
SECTIONAL VIEWS AND PARTS IDENTICATION
OUTPUT SHAFT WITH AXLE DISCONNECT
AXLE DISCONNECT
TOWING OR PUSHING
TRANSMISSION 18000 SERIES 6 SPEED
FREEWHEEL DISASSEMBLY
TRANSMISSION CASE DISASSEMBLY
LOW CLUTCH
DISASSEMBLY
ASSEMBLY
REVERSE AND 2nd CLUTCH
3RD CLUTCH
FORWARD CLUTCH
LOCK NUT TYPE IDLER SHAFT
TURBINE HUB ASSEMBLY WITH BACKING RING AND SPECIAL
SELF LOCKING SCREWS
CONVERTER HOUSING
FREEWHEEL ASSEMBLY
CONVERTER HOUSING
18000 SERIES TRANSMISSION CONVERTER DRIVE PLATE KIT
CLUTCH SHAFT OIL SEALING RING (PISTON RING)
INSTALLATION
TRANSMISSION TO ENGINE INSTALLATION PROCEDURE
SERVICING MACHINE AFTER TRANSMISSION OVERHAUL
TOWING OR PUSH STARTING
PEDESTAL, ROTEK BEARING & SWING DRIVE SYSTEM
DRIVE MOTOR AND BRAKE
SWING DRIVE MOTOR
CLEANING
INSPECTION
START-UP PROCEDURE
WINCH MOTOR
BOOM WINCH
REMOVAL OF WINCH ASSEMBLY FROM CRANE
INSPECTION & CLEANING
INSTALLING WINCH ASSEMBLY ON CRANE
JIB AND GANTRY
JIB EXTENSION PROCEDURE
JIB STOWAGE PROCEDURE
HEAD & HOOK BLOCK
CARE OF WIRE ROPE
WIRE ROPE REPLACEMENT
HOOK & HEAD BLOCK REEVING
METHODS OF LUBRICATION
LUBRICATION IN STORAGE
SPRING MOTORS
UNLOADING RETRACT MECHANISM
SHAFT BEARINGS AND CABLE DRUM
LOADING RETRACT MECHANISM
SETTING SPRING TENSION
LUBRICATION
BRAKE VALVE
MASTER CYLINDER SECTION
REMOVE AND SEPARATE INTO SECTIONS
CONNECTING SECTIONS AND MOUNTING BRAKE VALVE ON VEHICLE
POWER ASSIST SECTION
REMOVE AND SEPARATE INTO SECTIONS
CONNECTING SECTIONS AND MOUNTING BRAKE VALVE ON VEHICLE
STEERING CONTROL VALVE
SERVICING
TANDEM PUMP
PRIMARY MANIFOLD & CONTROLS
OPERATING CABLES
PRIMARY MANIFOLD
SECOND MANIFOLD
REMOVAL OF INDIVIDUAL VALVES
INSTALLATION OF INDIVIDUAL VALVES
HYDRAULIC CYLINDERS
BOOM LIFT CYLINDER
BOOM CROWD CYLINDER ROD SEAL
DUAL CROWD CYLINDER FOUR SECTION POWER BOOM
STEERING CYLINDER
OUTRIGGER CYLINDER
LOWER CROWD CYLINDER
SWING & HOIST BRAKE CYLINDER
PARKING BRAKE
SERVICE BRAKE
WHEEL CYLINDER
AXLES
REMOVE DIFFERENTIAL CARRIER FROM AXLE HOUSING
REMOVE THE DIFFERENTIAL AND RING GEAR FROM THE CARRIER
DISASSEMBLE THE DIFFERENTIAL AND RING GEAR ASSEMBLY
REMOVE THE DRIVE PINION AND BEARING CAGE FROM CARRIER
DISASSEMBLE THE DRIVE PINION AND BEARING CAGE
PREPARING PARTS FOR ASSEMBLY
CLEAN AND INSPECT YOKES
CLEANING GROUND AND POLISHED PARTS
CLEANING ROUGH PARTS
CLEANING AXLE ASSEMBLIES
DRYING PARTS AFTER CLEANING
PREVENTING CORROSION ON CLEANED PARTS
INSPECTING PARTS

OTHERS
HYDRAULIC DIAGRAMS
ELECTRICAL DIAGRAMS