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File under Dump trucks

HD465-5
(Serial No. 4001 and up)

STANDARD MAN-HOUR TABLE FOR MAINTENANCE OPERATION .................................. 2


TABLE ............................................................................... 4
1. PERIODICMAINTENANCE.. ........................................................ 4
2. TESTING AND ADJUSTING ......................................................... 4
3. ENGINE (SA6D170-1). ............................................................. 5
4. POWERTRAIN ................................................................... 6
5. TRAVEL AND STEERING SYSTEM .................................................... 7
6. AIR SYSTEM.. .................................................................. 7
7. HYDRAULICSYSTEM ............................................................. 8
8. WORK EQUIPMENT, OUTER COMPONENT AND OTHERS ................................... 9

Note: Please refer to standard man-hour guide of ENGINE SERlESwhen you repair engine.

-l-
FORM SEKQ3223
STANDARD MAN-HOUR TABLE FOR MAINTENANCE OPERATION

1. Purpose
The standard man-hour table has been prepared to satisfy the following requirements:
(1) To make basis of calculation of indicated and claimed man-hours for maintenance and repair in factory and field work to
be performed by KOMATSU distributors.
(2) To give KOMATSU distributors a guide for improvement of their technical serviceability and facilities to advance work

2.
efficiency.

Constitution of standard man-hours


_-_-
- Actual working
hours
1. Direct working
---r Actual full
working hours
(Principal work,

transporting work
hours

2. Indirect working
Float I
hours
Working hours (Control
(Arranging
(Portal-to-portal - allowance, Personal
surroundings,
hours) allowance)
cleaning, service, -_-_
checking and
maintaining
- Waiting time
facilities, training,
(Time spent waiting tools, parts
morning meetings,
and instructions etc. in excess of
etc.
the allowable limit of float.

- Rest period
- Loss time
(Noon recess, etc.)
(Time spent redoing work which
was not done right the first time)

[Supplementary explanation of words]


(1) Actual full working hours:
Include time required for maintenance working hours of disassembly/assembly, inspection/test, cleaning and maintaining
parts, preparing, clearing up, transporting parts and service facilities, etc.
Note:
(i) Suitable man-hours are added to some Component in this table of machine model for maintenance, because
machine model requires more man-hours of cleaning, inspection, maintaining, etc. compared with a new machine.
However:
(a) Exclude time necessary for removing mud, cleaning, acceptance inspection, completion inspection, painting, and
preparing/arranging service facilities and parts before/after field work and turnaround, waiting in field, making
report.
(b) Exclude field work under special conditions (bad conditions such as nighttime, storm, snow, etc.).
(c) Exclude time spent for rebuilding and repairing (machining, welding sheet metal, repairing bolt crimp).
(ii) Maintaining parts means cleaning component/removing rust.
(iii) Maintaining means repairing parts (for instance, simple filing, hammer work for straightening), stripping gasket, and
removing tight bolt.
(2) Float:
Control allowance means instructions and meeting in work, writing out a chit, preparing parts, waiting crane (within 5
minutes) etc. Constant man-hour increase is added to each item of man-hours table.
Personal allowance means fatigue allowance for recovery of fatigue and physiological allowance for drinking water, going
to the toilet, smoking etc.
Generally, man-hour increase is added to this table. Moreover, suitable personal allowance is added to this table by expert,
according to environment difference in field work.

-2-
3. Basic conditions of this man-hour table

Generally, field work includes only removal/installation and replacing unit (replacing parts only for some component).
In principle, bring units to shop and overhaul units, rebuild and repair for.readjustment in shop according to basic conditions
of standard man-hours table.
But working hours for repair is determined separately if necessary.
(1) Service facilities:
Service facilities such as special tools etc. are to be prepared as prescribed in Komatsus shop manuals.
(2) Worker:
In principle, worker must be a certified mechanic having at least 4 or 5 years of experience.
Some work needs assistants* who do not require above level.
However, worker and assistants must satisfy specified rules in the region.
(3) Working procedures:
Working procedures should conform to disassembly and assembly instructions given in Komatsus shop manuals.
(Excluding work under special conditions in field.)
(4) Machines:
Machines should be standard models.
(5) Working environment:
Field for maintenance work should be level ground, on which service cars and truck with crane should be workable.
Moreover, prepare power source and pneumatic source for using pneumatic tools and electric tools.
(6) Others:
Refer to corresponding items about special conditions for inspection, adjustment/oil & water related and replacement
of single part which occurs often in field.
Man-hours for specialist of crane operation are not involved in this man-hours table.

4. How to read the man-hour table

(1) Code
(a) X ..... means removal and installation work or replacement. This work comprises removal of the faulty part, replace-
ment of gasket, oil seal, O-ring and any other wear parts as necessary, installation of the same or a new part,
and necessary adjustments.
(b) OV.... means an overhaul operation. The work comprises disassembly of the faulty unit, inspection of all component
parts, replacement of defective parts, reassembly, and necessary adjustments.
(c) T . . . . . . means test to be performed on a special test apparatus such as a bench test.
(e) * . . . . . . Mark * in remarks means removal or installation work which requires more than 2 workers for safety work
etc.
In this case, man-hours show the total man-hours.
(2) Reading
(a) As shown in example below, each list contains the name of individual units (under the heading Components?
preceded by index numbers; the kind of work for each assembly or part (under the heading Operation); and the
unit of work (under the heading Operation) which indicates that the corresponding man-hours are based on each
machine, on each side of a machine or on each part.
In the Man-hours coloumn, the total value including the man-hours for necessary attedant work (preparation) is
indicated as a rule.
(b) All numerals of time are in units of hours calculated down to tenths of an hour.
Namely, 0.1 H (man-hours) indicates 6 minutes.
(c) Supplementary explanation and related matters are written in remarks.
(Reference) :
This man-hour table is subject to change without notice.

Example:

No. Component Operation Unit Man-hour Remark

3-01 A*BC assembly X Each machine 24.5 * 2 Workers

Only man-hours for separating/


-0i B assembly X Each machine 1.5
connection of item 3-01.

I -03 B assembly
I
ov Each machine 18.0
I

I -04I
I
B assembly
I
T Each machine
I
6.0 Bench test

Man-hours for removal and

I -05 C assembly X Each machine 0.9


installation of item 3-01.

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TABLE
1. PERIODIC MAINTENANCE
*This table shows man-hour for individual work.

-Premise condition:
1. Park the machine in workable state on level ground.
2. Prepare all jigs and tools necessary for work in working area.
3. See working procedure of Operation & Maintenance Manual.
4. Judge oil drain when oil stops flowing in filamentous state to begin dropping.
5. Grease by oil pump for more than 502, and grease by jug for less than 5012.

2. TESTING AND ADJUSTING


This table shows man-hour for individual work.

I No. I Operation I Unit 1 Man-hour 1 Remark

1 2-01 1 Adjusting valve clearance Each machine 5.1 I


-02 Adjusting fan belt tension Each machine 0.2

-03 Adjusting alternator belt tension Each machine 0.2

-04 Measuring blow-by Each machine 0.4

-05 Measuring compression pressure Each machine 7.9

-06 Adjusting fuel injection timing Each machine 1.3

-4-
No. Operation Unit Man-hour Remark
!

& s
Measuring injection pressure
2-07 Each machine 5.x 6 pcs./one machine
(Nozzle holder)

I I -08 Exhaust gas color

I -09 I Measuring engine oil pressure Each machine 0.4 I

I I -10
Measuring torque converter inlet oil
pressure
Each machine / 0.4 1

Measuring torque converter main relief


-11 Each machine 0.4
oil pressure

Measuring torque converter lock-up oil


Each machine 0.4
pressure I

-13 Measuring transmission clutch oil pressure Each machine 2.3

-14 Measuring brake oil pressure Each machine 0.4

-15 Measuring steering circuit oil pressure Each machine 0.4

-16 Measuring hoist circuit oil pressure Each machine 0.4

-17 Adjusting body positioner Each machine 0.3 I


-18 Receiving - Delivery inspection Each machine 1.2
I

-Premise condition:
7 , 1. Park the machine in workable state on level ground.
/ 2. Prepared%aIIjigs and tools necessary for work in working area.
3. See working procedure of Shop Manual and Operation & Maintenance Manual.
4. Exclude working time necessary for setting oil temperature and warm-up rum.

3. ENGINE

I No. I Component 1 Operation 1 Unit 1 Man-hour 1 Remark

3-01 Starting motor assembly X Each machine 1.8

-02 Alternator assembly X Each machine 0.6

-03 Engine oil cooler assembly X Each machine 1.5

-04 Fuel injection pump assembly X Each machine 3.3

1 -05 1 Air compressor assembly X 1 Each machine ) 1.5 1


I I I I I 1

I -06 1 Water pump assembly I x 1 Each machine I 2.9 I

1-07cAfter-cooEcore assembly 1 X 1 Each machine 1 5.1 1

4.5 Upper
-08 Turbocharger assembly X Each machine
4 5 Lower

-09 Nozzle holder assembly X Each machine 5.0 6 pcs./one machine

-10 Cylinder head assembly X Each machine 33.0 6 pcs./one machine

I -11
I Engine assmebly Each machine

-5-
I No. I Component 1 Operation 1 Unit 1 Man-hour I Remark I
3-12 Radiator assembly X Each machine 8.8

-13 Fuel tank assembly X Each machine 12.0 ?


-14 Battery assembly X Each machine 1.0

-15 Replacing starting switch Each machine 2.0


I 1
-16 Replacing lamp switch Each machine 0.3

-17 Replacing back-up lamp Each machine 0.2

-18 Replacing battery relay switch - Each machine 0.2

Note: This man-hour shows total man-hour, so half of this man-hour is man-hour when 2 workers are working.

4. POWER TRAIN

No. Component Operation Unit Man-hour Remark

4-01 Output shaft assembly X Each machine 5.4 * 2 Workers

-02 Output shaft assembly ov Each machine 6.4

Torque converter -
-03 X Each machine 11.6 * 2 Workers
Transmission assembly

Separating torque converter


-04 Each machine 2.2
and transmission assembly I

Torque converter *
-05 ov Each machine 12.2
PTO assembly

-06 Transmission assembly ov Each machine 32.0 * 2 Workers

Torque converter control


-07 X Each machine 1.2
valve assembly

Torque converter control


-08 ov Each machine 1.8
valve assembly

-09 Transmission ECMV assembly X Each machine 4.2 7 pcs./onemachine

-10 Transmission pump assembly X Each machine 3.0

-11 Differential assembly X Each machine 18.9 Including X6.7H of item S-01

-12 Differential assembly ov Each machine 6.0

-13 Carrier assembly X Each side 6.0

-14 Carrier assembly ov Each side 2.0

-15 Final drive assembly ov Each side 10.0

-16 Rear drive shaft assembly X Each machine 1.5 Transmission-differential

Note: This man-hour shows total man-hour, so half of this man-hour is man-hour when 2 workers are working.

_6-
5. TRAVEL AND STEERING SYSTEM

No. Component Operation Unit Man-hour Remark


I I I
* 2 Workers
5-01 Rear wheel brake assembly I X Each side I 25.0 Including lO.OH of item 4-15
3
-02 Rear wheel brake assembly ov Each side 2.9
I
-03 Parking brake caliper assembly X Each machine 2.1

-04 Parking brake caliper assembly OV Each machine 0.4


,
-05 Parking brake pad X Each machine 1.7

-06 Front brake caliper assembly X Each side 5.0


I I 4
-07 Front brake caliper assembly ov Each side 1.2
I I 1
-08 Front brake pad X Each side 5.6
I I
-09 Steering valve assembly X Each machine 3.0
I I I
-10 Steering valve assembly ov Each machine 4.0
, I I
-11 Front wheel assembly X Each side 3.0 * 2 Workers
I I I I
-12 ! Rear wheel assembly ) X Each side 5.4
I I I 1
-13 Front wheel hub assembly ov Each side 11.0 including X3.OH of item 5-11
I I I I
Front suspension cylinder
-14 X Each side 16.0 Including 11 .OH of item 5-13
assembly

Front suspension cylinder


ov One cylinder 2.0
-\ -15
assembly

Variable damping force


-16 X Each side 2.8
selector valve assembly

Variable damping force


-17 ov One valve 0.9
selector valve assembly
I
Rear suspension cylinder
-18 X Each side 4.0
assembly

Rear suspension cylinder


-19 ov One cylinder 2.0
assembly

Note: This man-hour shows total man-hour, so half of this man-hour is man-hour when 2 workers are working.

6. AIR SYSTEM

No. Component Operation Unit Man-hour Remark

Parking brake spring


6-01 X Each side 0.8
cylinder assembly

Parking brake spring


-02 ov One cylinder 2.0
cylinder assembly

-03 Brake valve assembly X Each machine 2.4

-04 Brake valve assembly ov Each machine 1.5

-7-
3

No. Component Operation Unit Man-hour Remark

6-05 Front brake chamber assembly X Each side 2.2

-06 Front brake chamber assembly OV One chamber 2.0 ?


-07 Rear brake chamber assembly X Each side 2.4

mbn%echamber assembly 1 OV ( One chamber 1~ 2.4 ~ IPm ~ I


1-09 governor assembly ( X I Each machine ( 0.4 I

-10 Air governor assembly ov Each machine 0.5


I
Note: This man-hour shows total man-hour, so half of this man-hour is man-hour when 2 workers are working.

7. HYDRAULIC SYSTEM

No. Component Operation Unit Man-hour Remark

7-01 Slack adjuster assembly X Each machine 0.8

-02 Slack adjuster assembly ov Each machine 1.6

I -03
IHydraulic pump assembly
(brake cooling) I x I
Each machine

Hydraulic pump assembly


-04 X Each machine 2.4
(steering and hoist)

-05 Brake oil cooler assembly X Each machine 7.5

-06 Demand valve assembly X Each machine 2.5

-07 Demand valve assembly ov Each machine 2.0

I -08
IEmergency steering motor
pump assembly I x I
Each machine
I 3*o If

-09 Steering cylinder assembly X Each side 4.0

-10 Steering cylinder assembly ov One cylinder 3.8

-11 Hoist valve assembly X Each machine 4.0

-12 Hoist valve assembly ov Each machine 1.8

-13 Hoist cylinder assembly X Each side 3.6

I -14 1 Hoist cylinder assembly I ov 1 One cylinder ( 4.0 I

Note: This man-hour shows total man-hour, so half of this man-hour is man-hour when 2 workers are working.

-8-
8. WORK EQUIPMENT * OUTER COMPONENTS * OTHERS

No. Component Operation Unit Man-hour Remark

8-01 Dump body X Each machine 6.7 * 2 Workers


\
Transmission controller
-02 X Each machine 0.6
assembly

Suspension controller
-03 X Each machine 0.6
assembly

Note: This man-hour shows total man-hour, so half of this man-hour is man-hour when 2 workers are working.

-9-
No. Component Unit Man-hour 1 Remark
/
- Removing crooked bolt One pc.
0.3
o3
When removing with welded nut.
JO@ When drilling and retapping.
/
0.2 When removing with welded nut.
124 One pc.
0.4 When drilling and retapping.

0.2 When removing with welded nut.


One pc. o 5
When drilling and retapping.

0.2 When removing with welded nut.


16@ One pc. o 5
When drilling and retapping.

1 0.3 When removing with welded nut.


One PC. / ()6 When drilling and retapping.

0.3 When removing with welded nut.


20@ One pc. o7
When drilling and retapping.

0.3 When removing with welded nut.


246 One pc. o8
When drilling and retapping.

0.4 When removing with welded nut.


27~ One pc. o9
When drilling and retapping.

Removal by gas-cutting One pc.


bolt and nut
One pc.

33$ One pc. 0.14

Printed in Japan
FORM SE KQ3223 II-90(23)02601