HD465-5
(Serial No. 4001 and up)
Note: Please refer to standard man-hour guide of ENGINE SERlESwhen you repair engine.
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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.
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)
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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.
(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:
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
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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.
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No. Operation Unit Man-hour Remark
!
& s
Measuring injection pressure
2-07 Each machine 5.x 6 pcs./one machine
(Nozzle holder)
I I -10
Measuring torque converter inlet oil
pressure
Each machine / 0.4 1
-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
4.5 Upper
-08 Turbocharger assembly X Each machine
4 5 Lower
I -11
I Engine assmebly Each machine
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I No. I Component 1 Operation 1 Unit 1 Man-hour I Remark I
3-12 Radiator assembly X Each machine 8.8
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
Torque converter -
-03 X Each machine 11.6 * 2 Workers
Transmission assembly
Torque converter *
-05 ov Each machine 12.2
PTO assembly
-11 Differential assembly X Each machine 18.9 Including X6.7H of item S-01
Note: This man-hour shows total man-hour, so half of this man-hour is man-hour when 2 workers are working.
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5. TRAVEL AND STEERING SYSTEM
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
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3
7. HYDRAULIC SYSTEM
I -03
IHydraulic pump assembly
(brake cooling) I x I
Each machine
I -08
IEmergency steering motor
pump assembly I x I
Each machine
I 3*o If
Note: This man-hour shows total man-hour, so half of this man-hour is man-hour when 2 workers are working.
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8. WORK EQUIPMENT * OUTER COMPONENTS * OTHERS
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.
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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.
Printed in Japan
FORM SE KQ3223 II-90(23)02601