Komatsu CK35-1 Compact Track Loader Operation and Maintenance Manual - PDF DOWNLOAD

CEAM017300

Operation and Maintenance Manual

CK35-1 COMPACT TRACK LOADER

SERIAL NUMBERS

CK35-1

A40001

and UP

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.

June 2006

Copyright 2006 Komatsu Published in USA Komatsu America Corp.

0INTRODUCTION

CK35-1

0-1

INTRODUCTION

FOREWORD This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel achieve peak performance through effective, economical and safe machine operation and maintenance.

Keep this manual handy and have all personnel read it periodically. If this manual is lost, damaged or becomes dirty and cannot be read, request a replacement manual from your local distributor.

If you sell the machine, be sure to give this manual to the new owner.

The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. Continuing improvements in the design of this machine can lead to changes, which may not be reflected in this manual. Consult your local distributor or for the latest available information on your machine or for questions regarding information in this manual.

This manual may contain attachments and optional equipment that are not available in your area. Consult your local distributor or for those items that you may require.

Punctual periodic notes regarding the maintenance operations that have been carried out are important to have a clear prospect of the situation and to know exactly what has been done and what has to be done after the next maintenance interval. Therefore, it is advisable to consult either the hour meter and/or the maintenance schedule frequently.

Over the years Komatsu distributors have gathered considerable experience in customer service. If more information is needed, do not hesitate to contact your Komatsu distributor. He always knows how to get the best performance from the machine, he can suggest the use of the equipment that is most suitable for specific needs and can provide the technical assistance necessary for any change that may be required to conform the machine to the safety standards and traffic rules. Furthermore, Komatsu distributors also ensure their assistance for the supply of genuine Komatsu spare parts, which alone guarantee safety and interchangeability.

The table included in this manual must be filled in with the machine data, which are the data that must always be indicated to the distributor when requesting assistance and ordering spare parts.

Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death.

Operators and maintenance personnel must read this manual thoroughly before operating or maintaining this machine. This manual should be kept near or with the machine for reference and periodically reviewed by all personnel who operate it.

Some actions involved in operation and maintenance can cause a serious accident, if they are not performed in the manner described in this manual.

The procedures and precautions given in this manual apply only to the intended uses of this machine.

If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual.

KOMATSU delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety features and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult your local distributor or KOMATSU before operating the machine.

The safety description is given in SAFETY INFORMATION and in the SAFETY section 1.

0-2

CK35-1

INTRODUCTION

SAFETY INFORMATION Most accidents are caused by failure to follow fundamental safety rules for the operation and maintenance of the machine. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before performing maintenance and machine operations.

To identify safety messages in this manual and on machine product graphics, the following signal words are used: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

Other signal words In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is are useful to know.

Remark This word is used for precautions that must be taken to avoid actions, which could shorten the life or damage the machine.

The safety precautions are described in SAFETY section 1.

KOMATSU cannot predict every circumstance that might involve a potential hazard in operation and maintenance.

Therefore the safety message in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine or causing injury. If you are unsure about the safety of some procedures, contact your local distributor.

Before starting any maintenance operation, position the machine on a firm and level surface, lower the equipment to the ground, engage the safety locks of the equipment and of the controls and stop the engine.

To make the information clearer, some illustrations in this manual represent the machine without safety guards. Do not use the machine without guards and do not start the engine when the engine hood is open, unless this is expressly prescribed for some specific maintenance operations.

CK35-1

0-3

INTRODUCTION

It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu cannot be held liable for any damage to people, property, or the machine, if this has been tampered with by modifying the standard setting of the hydraulic system.

Before carrying out any electrical welding, disconnect the battery and the alternator (see See “ELECTRICAL PRECAUTIONS” on page 1-32).

Install only authorized additional equipment (See “CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION WITH HIGH FLOW AND SUPER-FLOW HYDRAULIC SYSTEM” on page 5-5).

Travel on roads is allowed only if the machine is provided with appropriate lighting, signalling and safety devices and properly authorized by the relevant permits.

Before travelling on roads, make sure that the equipment installed on the machine is approved and the safety locks are correctly engaged.

It is absolutely forbidden to operate the machine while standing on the ground.

Every single maneuver must be carried out by the operator, correctly seated in the driving position.

0-4

CK35-1

INTRODUCTION

APPROVED AND NON APPROVED USES APPROVED The Komatsu MACHINES described in this manual have been designed and constructed to be used by duly trained personnel mainly for EXCAVATION and EARTH-MOVING OPERATIONS. If provided with suitable safety devices, they can be used with authorized optional equipment having the characteristics illustrated at point, See “AUTHORIZED OPTIONAL EQUIPMENT” on page 5-2.

NON APPROVED •

The instructions regarding the authorized optional equipment are given in the relevant operation and maintenance manuals; if the equipment is supplied by Komatsu, these publications are attached to this manual.

•

The instructions regarding the assembly of the authorized equipment, the controls requiring special arrangements on the machine and the hydraulic couplings necessary for the operation of the equipment are shown in the final section of this manual.

Komatsu MACHINES are constructed exclusively for the handling, excavation and treatment of inert materials; therefore, the following uses are absolutely forbidden: •

USE OF THE MACHINE BY MINORS OR INEXPERIENCED PEOPLE.

•

USE OF THE MACHINE FOR LIFTING PEOPLE OR OBJECTS.

•

TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.

•

USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.

•

USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.

CK35-1

0-5

INTRODUCTION

PRODUCT INFORMATION Listed are features and machine identification locations. Komatsu skid steer loader and main components are identified by serial numbers stamped on identification plates or decals attached to the machine or component.

MAIN FEATURES ★ Simple and easy operation. ★ Hydrostatic transmission obtained through a double variable displacement pump and axial piston motors operating epicyclic reduction gears. ★ Two driving tracks always engaged through oil-immersed roller chains. ★ Main equipment and travel control through servo levers ensuring combination movements that can be modulated proportionally and continually. ★ Foot control for the optional equipment (if installed). ★ Foot accelerator. ★ Lever accelerator. ★ Parking brake control. ★ Complete series of instruments visible from the operating position. ★ Easy maintenance with simplified intervals. ★ Road travel (on request).

BREAK IN PERIOD Every new machine is properly adjusted and tested before delivery. A new machine must be operated carefully for the first 100 hours to ensure proper run-in time for the various components. It the machine is subjected to excessive or severe work loads at the beginning of it’s operation, it’s functions will be greatly reduced or damaged. Every new machine must be used carefully, paying special attention to the following indications: ★ After start up, let the engine idle at a low RPM for 5 minutes, to warm up the machine gradually before beginning actual operation. ★ Operate the machine with limited loads. Avoid abrupt starts, accelerations, sudden decelerations, abrupt reversals or sudden stops. ★ After the first 50 hours, perform the following maintenance, in addition to normal maintenance performed at 50 hours: A. Check the drive chain tension.

B. Check the rubber track tension. ★ After the first 250 hours, perform the following maintenance, in addition to normal maintenance performed at 250 hours perform: C. Change the hydraulic system filter.

SYNTHETIC BIODEGRADABLE OIL TYPES On machines in which synthetic biodegradable oil type HEES is used, the following operations are to be performed, besides the standard maintenance operations: ★ After the first 50 hours of operation, change the hydraulic system filter. ★ After the first 500 hours of operation, change the hydraulic system oil and filter.

0-6

CK35-1

INTRODUCTION

PRODUCT IDENTIFICATION The serial numbers and model numbers on the components are the only numbers that your distributor will need when requiring assistance or ordering replacement parts. It is a good idea to record this information in this manual on page 0-9 (Serial Number and distributor information). All views indicated below are viewed from the operators position.

MACHINE SERIAL NUMBER The machine serial number is stamped on the inner wall of the right rear pillar.

MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) The PIN plate is located on the inner wall of the right rear pillar.

CK35-1

0-7

INTRODUCTION ENGINE SERIAL NUMBER AND EMISSION PLATE The plate (1) indicating the engine serial number and the exhaust gas emission plate (2) are positioned on the top of the valve cover.

TRAVEL REDUCTION GEAR SERIAL NUMBER The serial number of the travel reduction gear is stamped on the plate positioned on the hydraulic motor cover.

CAB SERIAL NUMBER The cab serial number is stamped on the plate positioned on the right side of the base cross member.

0-8

CK35-1

INTRODUCTION

SERIAL NUMBERS AND DISTRIBUTOR INFORMATION MODEL: CK35-1 Machine # Product identification # (PIN) Engine # Travel reduction gear # Cab # Excavator # (if installed) Distributor:

Address:

Phone # Contacts: NOTES:

CK35-1

0-9

INTRODUCTION

CONTENTS INTRODUCTION FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 APPROVED AND NON APPROVED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 NON APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 PRODUCT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 MAIN FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 BREAK IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 SYNTHETIC BIODEGRADABLE OIL TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7 MACHINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) 0-7 ENGINE SERIAL NUMBER AND EMISSION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 TRAVEL REDUCTION GEAR SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 CAB SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 SERIAL NUMBERS AND DISTRIBUTOR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9 MODEL: CK35-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9 CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10 SAFETY SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 LOCATION OF THE SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 SAFETY PLATES FOR MACHINES WITH EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 DECALS DEFINED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 LEAVING THE OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 MOUNTING AND DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 CHECKING THE REAR-VIEW MIRRORS (IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 FIRE PREVENTION FOR FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 PREVENTING BURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 DUST HAZARD PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 PREVENTING ACCIDENTS CAUSED BY IMPROPER OPERATION OF THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 FIRE EXTINGUISHER AND FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 PRECAUTIONS CONCERNING THE CAB STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 PRECAUTIONS CONCERNING THE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 PRECAUTIONS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 SAFETY ON THE WORK SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . 1-17 0-10

CK35-1

INTRODUCTION ROOM VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS (IF INSTALLED) . . . . . . . . . . . . . . . . . 1-18 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 PRECAUTIONS TO BE TAKEN WHEN WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 RULES FOR TRAVELING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 MOVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 WORKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 PREVENTING ELECTROCUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 VISIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 WORKING ON ICY OR SNOW-COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 PREVENTING ACCIDENTS CAUSED BY THE IMPROPER OPERATION OF THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 WORKING ON LOOSE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 LOADING AND UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 THE ROUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 SAFETY PRECAUTIONS FOR WORK ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 STARTING WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 PRECAUTIONS FOR EMERGENCY RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 PRECAUTIONS DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 WARNING TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 EQUIPMENT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 ENGINE OPERATION DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 RULES FOR REFUELING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31 COOLING SYSTEM PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31 USING LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31 ELECTRICAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 PRECAUTIONS CONCERNING THE STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 PRECAUTIONS CONCERNING HIGH PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 PRECAUTIONS FOR WORKING ON HIGH PRESSURE SYSTEMS . . . . . . . . . . . . . . . . . . . 1-33 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 ROTATING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE RUBBER TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 CK35-1

0-11

INTRODUCTION HYDRAULIC ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 DISPOSAL OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 HYDRAULIC ENVIRONMENTAL ESTER SYNTHETIC (HEES) OIL . . . . . . . . . . . . . . . . . . 1-35 OPERATION SAFETY LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 LOADER ARM SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 EXCAVATOR LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 COLD PLANER LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 GENERAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 FRONT VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 REAR VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 INSIDE VIEW OF CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 HOUR METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 ENGINE COOLANT TEMPERATURE INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 FUEL LEVEL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 ALTERNATOR WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 PREHEATING WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 ENGINE OIL PRESSURE WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 AIR CLEANER CLOGGING WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 HYDRAULIC OIL FILTER CLOGGING WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . 2-14 PARKING BRAKE WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 SPEED INCREASE INDICATOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 FLOAT SWITCH INDICATOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 DIRECTION INDICATOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 WORKING LIGHT INDICATOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 SAFETY DEVICE FUNCTIONALITY CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 SWITCHES AND PUSH BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 PARKING BRAKE PUSH BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 ROTATING BEACON LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 LEFT STABILIZER BUTTON (IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 RIGHT STABILIZER BUTTON (IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 WORKING LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 EMERGENCY (HAZARD) SWITCH (IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 PARKING LIGHT AND LOW BEAM SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 DIRECTION INDICATOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 FRONT EQUIPMENT HIGH FLOW HYDRAULIC SYSTEM MOMENTARY SWITCH (3 LINES)(IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 FRONT EQUIPMENT SUPER FLOW HYDRAULIC SYSTEM CONTINUOUS SWITCH (5 LINES)(IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 SPEED INCREASE BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 FLOATING DEVICE SWITCH (IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 SEAT OVERRIDE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 0-12

CK35-1

INTRODUCTION AVAILABLE FOR OTHER FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 ELECTRICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 AUDIBLE ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 ELECTRIC OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 MASTER ELECTRICAL DISCONNECT SWITCH (IF INSTALLED) . . . . . . . . . . . . . . . . 2-25 MACHINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 SAFETY BARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 ISO PATTERN CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 LEFT PPC CONTROL JOYSTICK (TRAVEL AND STEERING) . . . . . . . . . . . . . . . . . . . . 2-29 RIGHT PPC CONTROL JOYSTICK (LOADER ARM AND BUCKET) . . . . . . . . . . . . . . . . . . 2-31 OPTIONAL PATTERN CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 LEFT PPC CONTROL JOYSTICK (LEFT TRACK TRAVEL, STEERING, AND LOADER ARM CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 RIGHT PPC CONTROL JOYSTICK (RIGHT TRACK TRAVEL, STEERING, AND BUCKET CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 AUXILIARY HYDRAULIC KIT CONTROL PEDAL (IF INSTALLED) . . . . . . . . . . . . . . . . . 2-37 FOOT ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 HAND ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 STANDARD FLOW HYDRAULIC SYSTEM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 (2 OR 3 LINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 SUPER FLOW HYDRAULIC SYSTEM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 SPEED INCREASE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 FLOATING POSITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 PATTERN SHIFTING CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 RIGHT STABILIZER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 LEFT STABILIZER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 OPTIONAL ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 MACHINE FUNCTION FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 STANDARD VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 VERSION WITH OPTIONAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 MAIN FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 GUARDS AND OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 REAR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 TILTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 STANDARD SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 TECHNICAL DOCUMENTATION CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 CHECKS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 VISUAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 CK35-1

0-13

INTRODUCTION DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 STARTING A WARM ENGINE OR IN TEMPERATE CLIMATES . . . . . . . . . . . . . . . . . . 2-61 STARTING A COLD ENGINE OR IN COLD CLIMATES . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 WARMING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 HEATING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 MOVING THE MACHINE (ISO PATTERN CONTROL SYSTEM) . . . . . . . . . . . . . . . . . . . . . 2-64 STEERING (CHANGING DIRECTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM) . . . . . . . . 2-68 STEERING (CHANGING DIRECTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 HAND AND FOOT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 MACHINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 TRAVEL AND STEERING CONTROL JOYSTICKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 WORK EQUIPMENT CONTROL PEDALS (LOADER ARM AND BUCKET) . . . . . . . . 2-75 AUXILIARY HYDRAULIC CONTROL JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM) . . . . . . . . . . . 2-81 STEERING (CHANGING DIRECTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83 MOVING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85 MAXIMUM IMMERSION DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87 PARKING ON LEVEL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87 PARKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90 LOADING AND UNLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90 TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91 HOW TO LIFT THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 COLD WEATHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93 FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94 OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94 PRECAUTIONS TO BE TAKEN AT THE END OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94 WARM WEATHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95 OPERATING THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96 LOWERING THE EQUIPMENT IN CASE OF MACHINE FAILURE . . . . . . . . . . . . . . . . . . . 2-96 ORGANIZING THE WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97 LOADING HEAPED AND LEVEL MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98 LOADING OPERATIONS ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99 DIGGING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100 CHANGING THE BUCKET OR ATTACHMENT WITH STANDARD QUICK COUPLER 2-101 REMOVING THE BUCKET OR ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102 INSTALLING THE BUCKET OR ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103 CHECKING THE POSITION OF THE LOCKING PINS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104 ADJUSTING THE LOCKING PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105 USING THE RUBBER TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106 OPTIMAL USE OF THE RUBBER TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106 RUBBER TRACK WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106 0-14

CK35-1

INTRODUCTION PRECAUTIONS TO BE TAKEN WHEN USING THE RUBBER TRACKS . . . . . . . . . . 2-106 PRECAUTIONS FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107 LONG PERIODS OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 BEFORE THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 DURING THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110 AFTER THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111 HOW TO MOVE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111 IF THE FUEL HAS BEEN COMPLETELY DEPLETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111 BATTERY IS EXHAUSTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112 STARTING WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113 OTHER TROUBLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114 ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116 HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117 MAINTENANCE GUIDE TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 MAINTENANCE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 NOTES REGARDING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 NOTES REGARDING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 NOTES REGARDING THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 NOTES REGARDING LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING . . . . . . . . . . . . . . 3-5 FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 SELECTION ACCORDING TO THE AMBIENT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . 3-6 GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES . . . . . . . . . . . . . . . 3-10 LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 CRITICAL PARTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 FUEL SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 STANDARD FLOW HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 SUPER FLOW HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 OPERATOR’S SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 STANDARD TORQUE FOR BOLTS AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 SPECIFIC TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 AFTER THE FIRST 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 EVERY 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 CK35-1

0-15

INTRODUCTION MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . .

EVERY 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AFTER THE FIRST 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 1000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 2000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR CLEANER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRAINING THE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RELEASING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE BATTERY CHARGE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE RUBBER TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING AND ADJUSTING THE RUBBER TRACK TENSION . . . . . . . . . . . . . . . . .

CHANGING THE RUBBER TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VARIOUS CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC SYSTEM OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRAINING WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE WIRING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . .

MAINTENANCE EVERY 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE RUBBER TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE COOLANT LEVEL IN THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE OIL LEVEL IN THE TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . .

FIRST 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING THE OUTSIDE OF THE RADIATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATING THE JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHANGING THE ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE TORQUE OF THE BOLTS AND NUTS THAT FASTEN THE CARRIAGES TO THE MACHINE FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . .

MAINTENANCE EVERY 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHANGING THE FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHANGING THE HYDRAULIC OIL DRAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHANGING THE OIL IN THE TRAVEL MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING THE WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRAINING CONDENSATE FROM THE HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . .

MAINTENANCE EVERY 1000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE . . . . . . . . . . . . . .

MAINTENANCE EVERY 2000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0-16

3-22 3-22 3-22 3-22 3-23 3-23 3-24 3-24 3-25 3-26 3-27 3-28 3-30 3-33 3-35 3-35 3-35 3-36 3-37 3-38 3-39 3-39 3-40 3-40 3-40 3-41 3-41 3-42 3-42 3-42 3-43 3-44 3-45 3-46 3-47 3-48 3-49 3-49 3-50 3-51 3-52 3-53 3-55 3-55 3-57 3-58 3-58

CK35-1

INTRODUCTION CHANGING THE SUCTION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 CHECKING THE ALTERNATOR AND THE STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 SPECIFICATIONS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STANDARD MACHINE OVERALL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . .

TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2 4-2 4-3 4-4

OPTIONS, ATTACHMENTS AUTHORIZED OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 BASIC PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT . . . . . . . . . . . . . . . . 5-3 CHARACTERISTICS OF THE STANDARD MACHINE OPTIONAL EQUIPMENT . . . . . . . . 5-4 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION WITH HIGH FLOW AND SUPER-FLOW HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . 5-5 CHANGING THE AUTHORIZED EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 CONNECTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 CONNECTING THE HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 CONNECTING THE RETURN CIRCUIT WITH DIRECT DRAINAGE INTO THE TANK . . 5-11 PREPARING THE MACHINE FOR USE WITH THE EXCAVATOR . . . . . . . . . . . . . . . . . . . 5-12 USING THE MACHINE WITH THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 PALLET FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

CK35-1

0-17

INTRODUCTION

0-18

CK35-1

1SAFETY WARNING! Read and follow all safety precautions. Failure to do so may result in serious injury or death.

This safety section also contains precautions for optional equipment and attachments made by Komatsu.

CK35-1

SAFETY

SAFETY AND WARNING DECALS LOCATION OF THE SAFETY DECALS ★ The safety decals must always be legible and in good condition. If they are dirty with dust, oil, or grease, clean them with a solution of water and detergent. Do not use fuel, petroleum based products, or solvents. ★ If the decals are damaged they must be replaced before operating the machine. ★ When a component provided with a safety decal is replaced, make sure the decal is also applied to the replacement component. ★ The machine may be provided with other decals, in addition to those shown below, which must be followed for safe operation.

1-2

CK35-1

SAFETY

CK35-1

1-3

SAFETY SAFETY PLATES FOR MACHINES WITH EXCAVATOR

1-4

CK35-1

SAFETY

CK35-1

1-5

SAFETY DECALS DEFINED The warning and danger decals applied to the machine are accompanied or represented by pictograms. The personnel charged with the operation and maintenance of the machine must know the symbols contained in the pictograms perfectly; the following descriptions illustrate what they look like and their respective meanings.

DANGER IN THE WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . .

(Only for machines with the excavator) Do not approach or stand near the work equipment operating radius when the boom and the bucket of the excavator are raised.

MOVING PARTS IN ENGINE COMPARTMENT . . . . . . . . . . . . .

Keep clear of moving parts inside engine compartment.

CONSULT THE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carefully read the contents of the manual before using the machine or performing maintenance operations.

1-6

CK35-1

SAFETY DO NOT LOOSEN THE BOLTS Do not loosen or remove the fastening bolts of the rear damping supports of the cab.

DANGER! TRACK TENSIONER ADJUSTMENT Carefully read the contents of this manual before adjusting the track tensioner unit.

DANGER! LOADER ARM RAISED Always engage the safety lock before carrying out maintenance operations, checks, or adjustments with loader arm raised.

Carefully read the instructions contained in this manual.

OPENING AND CLOSING THE ENGINE HOOD Always engage the safety lock before carrying out any maintenance operation with the hood open.

Carefully read the instructions contained in this manual.

OPENING THE REAR PANEL For correct use of the rear panel safety lock, follow the instructions contained in this manual.

CK35-1

1-7

SAFETY HYDRAULIC OIL FILL CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FILL THE SYSTEM WITH HEES TYPE OIL . . . . . . . . . . . . . . . .

HEES is a synthetic, biodegradeable type oil that is used only in the hydraulic oil tank.

ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL TANK FILLER TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE AIR FILTER CLOGGING WARNING . . . . . . . . . . . . . .

ENGINE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE COOLANT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFTING POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-8

CK35-1

SAFETY FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ANCHOR POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CK35-1

1-9

SAFETY

SAFETY RULES AND PRECAUTIONS GENERAL SAFETY RULES Only trained and authorized personnel are allowed to operate and service this machine.

Before operating this machine it is important to study the operator’s manual thoroughly and become familiar with all controls and safety decals. Keep this manual with your machine at all times for easy reference.

Safety must always be the operator’s most important concern.

Never operate a machine that is unsafe or in poor operating condition. Always perform a pre-operational check on your machine before operating it.

If the machine is equipped with a seat belt and rollover protective structure, OSHA law requires the operator remain within the confines of the rollover protective structure, with the seat belt fastened snugly around their waist before operating the machine.

OSHA law states if your equipment is designed for operation by one person, it is for one person only, never allow other personnel to ride on your machine.

Never leave your machine running and unattended. Always park the machine in a level area, lower any work equipment to the ground, set the parking brake, lock the controls and turn the engine off before exiting the operator’s compartment.

Be sure that all personnel are at least 12 m (13 yd) away from any point on the machine before moving or operating the machine. Never allow anyone to stand near the machine while it’s operating. Remember, the larger the machine the more restricted your visibility will be.

If pedestrians are in the area proceed slowly and sound your horn. Keep in mind, pedestrians have the right of way, and a loaded or smaller machine has the right of way over an unloaded machine.

Never use your machine for tasks it was not designed for, damage to the machine or injury to the operator may result.

Follow all safety rules, precautions, and instructions when operating or performing maintenance on the machine.

It is the owner and/or operator’s responsibility to replace any safety or warning decals if they are defaced or removed from the machine.

Think before you act, study the job carefully. Careful operator and service personnel are the best insurance against accidents.

The operator of this machine must be alert, physically fit, and free from the influences of alcohol, drugs, or medications that might affect his/her eyesight, hearing, or reactions.

1-10

CK35-1

SAFETY When working with another person on a work site, or during traffic control, be sure all personnel involved understand all hand signals that are to be used. When leaving a job site for long periods of time always lower all work equipment to the ground, neutralize work equipment controls and lock and secure your machine properly to avoid tampering by other personnel.

Never drive up to anyone standing in your path of travel. Always be sure all personnel are standing to the side when you approach them and acknowledge your approach. Follow all rules relating to safety as outlined in this manual and by your company, never get involved in horseplay.

SAFETY FEATURES Be sure all guards and covers are in place, especially after servicing the machine. Have guards or covers repaired immediately if they are damaged. See “PRECAUTIONS BEFORE STARTING THE ENGINE” on page 1-17.

Use safety equipment such as safety locks and seat belt properly.

Never remove any safety features, always keep them in good operating condition.

Always secure the machine in a safe position: See “PARKING THE MACHINE” on page 1-23.

Seat belt: See “SEAT BELT” on page 2-57. Improper use of safety features could result in serious bodily injury or death. Be sure the machine has the correct equipment required by local rules and regulations.

PERSONAL PROTECTIVE EQUIPMENT If your machine is equipped with safety equipment, OSHA law requires this equipment to be used when operating your machine.

Avoid loose fitting clothing, jewelry and loose long hair. These can catch on controls or in moving parts and cause serious injury.

Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the machine.

Always wear safety goggles, hard hat and heavy gloves, if your job involves driving pins with a hammer or cleaning the air cleaner element with compressed air.

Check to be sure no one is near your work area. Check to be sure all personal protective equipment are in good condition before using.

When working for 8 hours with a noise level exceeding 85 dBA, it is necessary to use headphones or ear plugs and to be particularly careful, especially towards the end of the work shift. Always check current local government noise regulations for compliance.

CK35-1

1-11

SAFETY UNAUTHORIZED MODIFICATIONS Any modification made without authorization can create a hazard. Before making any modifications, consult your local distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modifications to the machine.

LEAVING THE OPERATOR’S SEAT •

When leaving the operator’s seat, even if temporarily, make sure that the machine is in a safe position.

•

Before leaving the operator’s seat, carry out the following operations in the sequence indicated below: 1. Rest the equipment on the ground.

2. Apply the parking brake. See “PARKING BRAKE PUSH BUTTON” on page 2-19

3. Engage the safety device of the optional equipment control pedal (if installed).

4. Lock the equipment and travel control by shifting the safety bars to the lock position. See “SAFETY BARS” on page 2-28 5. Stop the engine (See “STOPPING THE ENGINE” on page 2-89) 6. If you have to go so far away that you will not be able to see the machine, remove the ignition key.

1-12

CK35-1

SAFETY MOUNTING AND DISMOUNTING •

Do not jump on or off the machine, either when it is at rest or when it is moving.

•

When getting on or off the machine, always use the appropriate handles and footrests; get on and off the machine very carefully.

•

Never hold or rest on the control levers.

•

Either when getting on or when getting off the machine, always maintain three points of contact (holding or resting points), to avoid losing your balance and falling down.

•

Clean the handles and footboards if they are dirty with oil or grease. Carefully clean the cab floor if it is dirty with oil, grease, mud or rubble.

CHECKING THE REAR-VIEW MIRRORS (IF INSTALLED) •

Make sure that the rear-view mirrors are clean and correctly aimed; the operator must be able to check the area behind the machine with no need to twist his trunk with respect to his normal operating position.

•

If the rear-view mirrors should move or break during operations, stop the machine immediately and fix or change them.

•

Working without checking the area behind the machine involves the risk of running over people who have carelessly approached the machine or colliding with fixed obstacles or maneuvering vehicles.

CK35-1

1-13

SAFETY FIRE PREVENTION FOR FUEL AND OIL Fuel, oil, and some types of antifreeze are flammable. Fuel is particularly flammable and can be hazardous. Always observe the following: • Keep any open flames away from flammable fluids.

• Stop the engine and do not smoke when refueling.

• Refueling or adding oil should be done in well ventilated areas and only after stopping the engine.

• Keep oil and fuel in its proper place.

• When refuelling, hold the fuel nozzle firmly and keep it constantly in contact with the filler until you have finished, to avoid sparks due to static electricity.

• Do not fill the tank completely, to leave room for the fuel to expand.

• After refueling, tighten the fuel and oil filler caps securely.

• In case some fuel is spilled, wipe it up immediately.

PREVENTING BURNS Wear gloves and safety goggles when checking any fluid levels: engine oil, hydraulic oil, engine coolant, transmission fluid.

Before checking the engine coolant, engine oil, or hydraulic oil, stop the engine and let the fluids cool down. If you don’t, the hot fluids may spurt out and cause burns. If the coolant level, in the radiator, needs to be checked due to overheating, slowly loosen the radiator cap to release the internal pressure or the hot coolant may spurt out and cause burns.

1-14

CK35-1

SAFETY DUST HAZARD PRECAUTIONS Dust can be hazardous to your health, if it is inhaled. Komatsu does not use asbestos in its products, but if you handle materials containing asbestos fibers or other dust materials during demolition operations, always do as follows: • Never use compressed air for cleaning. Only use an aspirator and make sure the room in which you are working in is well ventilated.

• Use water to keep down the dust when cleaning.

• If there is a danger there may be asbestos dust in the air, operate the machine with the wind to your back whenever possible. Use an approved respirator.

• Do not allow any other person into the area during operation.

• There may be a danger that non genuine Komatsu parts may contain asbestos, use only genuine Komatsu parts.

• Always observe rules and regulations related to the job site and working environment.

PREVENTING ACCIDENTS CAUSED BY IMPROPER OPERATION OF THE WORK EQUIPMENT Never stand under or place any part of your body between the movable components such as the work equipment and cylinders or between the machine and work equipment.

Keep in mind, when the work equipment is operated, the clearance will change, this may lead to serious personal injury or death. Never drive up to anyone standing in front of a solid object or your path of travel, the brakes could fail or the machine could slide on a slippery surface causing injury or even death.

FIRE EXTINGUISHER AND FIRST AID KIT As a precaution, if a fire or an injury should occur, always keep a fire extinguisher and first aid kit on your machine and do as follows: • Make sure that fire extinguishers have been provided and note their position.

• Be sure that the fire extinguisher is in good condition and read the label on it to ensure you know how to use it.

• Keep a first aid kit in the storage area. Check the kit periodically and replace any bandages, disinfectants, etc. as necessary.

• Keep a list of emergency phone numbers in case of an accident.

CK35-1

1-15

SAFETY PRECAUTIONS CONCERNING THE CAB STRUCTURE •

If the cab is inadvertently hit or the machine overturns during work, the cab may be damaged with consequent reduction of its stiffness and of the safety that must be guaranteed to the operator. Consult your Komatsu distributor to have the cab structure and strength checked in case of impact or damage.

PRECAUTIONS CONCERNING THE EQUIPMENT •

When installing and using optional equipment, carefully read the relevant instruction manual and operate the machine accordingly.

•

Do not use optional or special equipment without the authorization of your Komatsu distributor. The installation and use of unauthorized equipment may create safety problems and adversely affect the efficiency and life of the machine.

•

Komatsu cannot be held liable for any damage, accident, or product failure resulting from the installation and use of unauthorized equipment.

1-16

CK35-1

SAFETY

PRECAUTIONS BEFORE STARTING THE ENGINE Before starting your work operations, it is important to perform several procedures to be sure your equipment is in a safe operating condition. It is also important to be aware of the hazards involved when operating your machine.

SAFETY ON THE WORK SITE Before starting your machine and proceeding with any work operations it is important to be sure your machine is safe to operate.

• Before starting the engine, thoroughly check the area for any unusual ground conditions that may cause the work to be dangerous.

• Check the conditions of the work site and, before starting the engine, define the work plan and the best and safest operating procedure.

• Make the ground surface as level as possible before carrying out any operation.

• In case of work on the road, protect pedestrians and cars by designating a person for work site traffic duty and install fences around the work site.

• If water lines, gas lines, and telephone or high-voltage electrical lines are located under the work site, contact the relevant utility company to find out their exact locations or to make them inoperative until the end of the operations. Be careful not to sever or damage any of these lines.

• Check the depth and flow of water before operating in water or on river banks.

FIRE PREVENTION • Completely remove all wood chips, rubbish, paper and other flammable materials that may have accumulated inside the engine compartment, since they can cause fires.

• Check the fuel and hydraulic system tubes/hoses for leaks and, if necessary, repair them. Wipe up any excess oil, fuel or other flammable fluids.

• Make sure that fire extinguishers are available in the work area.

PRECAUTIONS TO BE TAKEN FOR THE OPERATOR’S CAB • Do not keep objects or tools in the operator’s cab. They may hinder the operation of the controls and cause serious accidents.

• Keep the cab floor and the controls (pedals and levers) clean, by removing any trace of oil and grease and, as far as the floor is concerned, remove any excess dirt (dirt, stones, etc.).

• Check the safety belt and change it if it is broken or damaged. Replace any component only with approved parts supplied by your distributor.

CK35-1

1-17

SAFETY ROOM VENTILATION Exhaust gases are deadly. If starting the machine inside a building, connect a suction duct to the exhaust pipe to vent fumes outside.

PRECAUTIONS TO BE TAKEN FOR THE LIGHTS (IF INSTALLED) • Remove any trace of dirt from the lights, to ensure perfect visibility of the work area.

• Make sure that all the bulbs and the working lights are functioning properly. If necessary, replace any faulty bulbs with new ones, making sure that their ratings are correct.

CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES • Remove any trace of dirt from the cab windows and clean the rear-view mirrors, to ensure unobstructed visibility in the work area.

• Adjust the rear-view mirrors that may have moved, so that the operator seated in the driving position can clearly see the area behind the machine. If any glass is damaged, replace it with new.

• Check the condition of the windshield wiper blades; the scraping edge must be smooth, with no indentations and attached to the rubber back of the blade.

In case of doubts about the efficiency of the edge, change the blade.

1-18

CK35-1

SAFETY

PRECAUTIONS TO BE TAKEN WHEN WORKING STARTING THE ENGINE • Before operating the machine, walk around it and check for people or objects that might be in the way.

• Do not start the engine if warning tags have been attached to the steering wheel or control levers.

• Sound your horn to warn others in the area before starting the engine or moving the machine.

• Start the engine only when seated and with the seat belt fastened snugly around your waist.

• Do not allow anyone in the cab or on the machine during operations.

RULES FOR TRAVELING IN REVERSE • When operating in areas that may be hazardous or where visibility is poor, designate a person to direct the movements of the machine and the traffic on the work site.

• Make sure that no unauthorized person is standing within the machine operating radius or in its travel direction. If necessary, put up appropriate fences.

• Before moving the machine, sound the horn to warn people near the work area.

• There are blind spots behind the machine, which cannot be seen by the operator and where someone may be standing.

Therefore, it is necessary to make sure that there is no one behind the machine before traveling in reverse.

MOVING THE MACHINE

The use of the speed increase button is allowed only for the high speed transfers of the machine.

• When moving the machine, lower the arm and roll the bucket back completely; this position makes it possible to evaluate the space required for movement more precisely and at the same time ensures the stability of the machine.

• If the equipment control levers must be used during travel, avoid moving them abruptly; sudden maneuvers change the attitude of the machine and make driving difficult.

• When traveling on rough ground, keep the speed low and avoid sudden movements of the bucket arm.

• If possible, avoid moving onto obstacles. If the machine has to travel over an obstacle, keep the equipment as close to the ground as possible and travel at low speed. Never move onto obstacles that may drastically incline the machine (over 10°).

• If one of the rubber tracks goes over an obstacle or gets into a hole in the ground, the machine may overturn. In these cases, reduce the speed to a minimum and be very careful of the balance of the machine.

CK35-1

1-19

SAFETY WORKING ON SLOPES • Operations on slopes and on river or lake banks with damp ground may result in the tipping over or sliding of the machine.

• Do not operate the bucket while the machine is on a slope.

• On hills, banks or slopes, keep the arm lowered and the bucket rolled back, and in case of an emergency, quickly lower it to the ground to help the machine stop.

• Do not change direction and, if possible, avoid traveling sideways when working on slopes. It is advisable to go down or up to a flat surface before performing these maneuvers.

• Travel up or down slopes with the heaviest part of the loader facing the top of the slope.

• Do not travel on wet grass or thick layers of leaves: if the machine moves sideways under these conditions, it may slide.

• Before carrying out any operation on a slope, always check the functionality of the parking brake.

• Do not go down slopes at high speed; you may lose control of the machine and cause serious damage and even death.

• Do not move on slopes with an inclination exceeding 15°, since the machine may overturn.

• When the fuel level indicator reaches the red reserve area during work on a slope, immediately provide for refueling; due to the inclination of the machine, the engine may suck in air and suddenly stop, which represents a grave risk for the safety of the operator and of people in front of the machine.

• If the engine should stop suddenly, immediately lower the bucket to the ground and apply the parking brake.

1-20

CK35-1

SAFETY .

PREVENTING ELECTROCUTION • Digging operations near overhead electric lines are extremely dangerous and may also cause death due to electrocution; for this reason, when working near overhead electrical lines, always respect the minimum safety distances prescribed by competent authorities and by the accident-prevention rules in force.

• As far as underground long-distance lines are concerned, the minimum distance depends on the material of the pipes in which the cables are laid.

• 1 - Wear shoes with thick rubber or leather soles.

• 2 - Request the aid of another person who can warn you if the machine gets too close to the electric wires.

Voltage

Min. Safe Distance

• 3 - Operate at low speed.

6.6kV

3m

10 ft.

• 4 - Learn what is to be done first in case of electrocution.

66.0kV

5m

16 ft.

• 5 - Keep the phone number of the electricity company and of the nearest first aid station at hand.

275kV

10 m

33 ft.

• If the work equipment accidentally gets entangled in the cables, the operator must remain still and must not leave the cab until the electricity company has shut off the power.

• When carrying out this kind of operation, warn everyone standing in the work area to keep at the minimum distance prescribed from the machine and the work equipment.

• Ask the electricity company in advance what are the voltage of the cables and the minimum safety distance are.

CK35-1

1-21

SAFETY VISIBILITY • Switch on the working lights as soon as visibility starts decreasing. If visibility decreases due to mist, smoke or heavy rain, stop the machine in a safe position and wait for the weather to improve until visibility becomes acceptable.

WORKING ON ICY OR SNOW-COVERED SURFACES • If the ground is icy or covered with snow, even a slight slope may cause the machine to slip sideways, therefore it is advisable to move at low speed and to avoid abrupt starts, stops or turns.

• When it has snowed heavily, the road shoulders and any obstacles are buried in snow and are not visible, therefore proceed with care when clearing snow.

PREVENTING ACCIDENTS CAUSED BY THE IMPROPER OPERATION OF THE WORK EQUIPMENT • When working in tunnels, galleries, under electric cables or other ducts (air, telephone lines) and wherever the height is limited, proceed with the greatest care to prevent the bucket or the arms from causing any damage.

WORKING ON LOOSE GROUND • Avoid operating the machine too close to the edge of cliffs, overhangs and deep ditches. These areas may collapse, making the machine fall down or tip over and this could result in serious injuries or even death. Remember that after heavy rain or earthquakes these dangerous conditions usually get worse.

• The earth laid near ditches is loose and can easily collapse due to the weight or vibrations of the machine. Be extremely careful and remember to fasten your safety belt.

1-22

CK35-1

SAFETY PARKING THE MACHINE • Park the machine on firm and level ground. If this is not possible and it is necessary to park on a slope, position the machine with the bucket facing downwards and carry out the following operations: • 1 - Rotate the bucket forward and rest it on the ground.

• 2 - Apply the parking brake.

• 3 - Stop the engine.

• 4 - Put wedges or safety blocks in front of the rubber tracks.

• Always rest the work equipment on the ground; if it is necessary to park with the arms raised, make sure that the safety locks are engaged (See “SAFETY LOCKS” on page 2-2).

• Always lock the equipment and travel control by shifting the safety bars to the lock position (See “MACHINE CONTROLS” on page 2-26).

• When leaving the machine, always apply the parking brake and remove the ignition key.

• If it is necessary to park on public roads, provide for signalling the presence of the machine according to the local regulations in force (signalling fires, fences, road work ahead, alternate directions and direction signs, etc.).

CK35-1

1-23

SAFETY

TRANSPORTING THE MACHINE LOADING AND UNLOADING THE MACHINE • Loading and unloading the machine on/from another vehicle always involves potential hazards. Proceed with extreme care.

• Perform loading and unloading on firm, level ground. Maintain a safe distance from the edges of ditches or road sides.

• If the vehicles used have not been appropriately equipped, put support blocks under the ramps, to avoid any bending.

• Always lock the wheels of the transporting vehicle with chocks.

• Always use ramps that are sufficiently wide and can support the weight of the machine. The longitudinal axes of the ramps must be parallel to each other and perpendicular to the loading board and their distance from each other must be sufficient to accommodate the tread of the machine.

• Make sure the ramps are securely positioned and anchored to the loading board and are the same length.

• Position the ramps with a maximum angle of 15°.

• Make sure that the ramp surface is clean and there is no trace of grease, oil, soil or ice; remove any dirt from the tracks of the machine before starting to load it on the vehicle. If the bucket is empty or no optional accessories are fitted to the machine, this end must face the rear.

• Do not reposition the machine while on the ramps. If necessary, go down the ramps and start the operation again.

• After loading the machine, block the tracks with wedges and secure it with tie-downs or chains that prevent any shifting (See “TRANSPORTING THE MACHINE” on page 2-90).

THE ROUTE • Define the route to be followed, taking into account the width, height and weight of the transporting vehicle plus the machine.

Make sure that the overall dimensions of the vehicle and its load are compatible with the roads and any tunnel, underpass, bridge, power and telephone lines, etc. along the route.

• Adhere to the regulations in force regarding the permissible width, height, weight and speed of heavy vehicles.

1-24

CK35-1

SAFETY

BATTERY SAFETY PRECAUTIONS FOR WORK ON BATTERIES • Electrolytic batteries contain sulfuric acid which can cause burns. It can also corrode clothing and make holes in it. If you inadvertently splash battery acid on yourself or on someone else, immediately wash the affected part with plenty of water.

• Battery acid may cause blindness if it comes into contact with the eyes. If acid accidentally gets into your eyes, wash them immediately with plenty of water and consult a doctor right away.

• If you accidentally swallow battery acid, drink a large quantity of water or milk, beaten egg white, or vegetable oil and in any case antacid substances like magnesia, bicarbonate, etc.. Call a doctor or a poison treatment center immediately.

• Always wear safety goggles when working on batteries.

• Batteries produce hydrogen gas, which is highly explosive and can be easily ignited with small sparks or exposed flames.

• Before working with batteries, stop the engine and remove the ignition key.

• Avoid short-circuiting the battery terminals through accidental contact with metal objects or tools or through the reversing of the cables.

• Tighten the battery cable clamps securely. Loose terminals may generate sparks and even cause the explosion of the battery

STARTING WITH BOOSTER CABLES • When starting the machine with booster cables, always wear safety goggles.

• When starting the engine by means of another machine, avoid any contact between the two machines.

• Be sure to connect the positive cable (+) first and then the negative or ground cable (-) when connecting the booster cables.

After the start, first disconnect the negative or ground (-) cable and then the positive cable (+).

• Connect the batteries in parallel: positive to positive and negative to negative.

• When connecting the ground cable to the frame of the machine to be started, select a point as far as possible from the battery.

(See “BATTERY IS EXHAUSTED” on page 2-112).

CK35-1

1-25

SAFETY PRECAUTIONS FOR EMERGENCY RECOVERY • The removal hooks are to be used exclusively for emergency recovery and not for towing vehicles.

• Before moving the machine, make sure that all the controls are in neutral.

• Release the parking brake of the travel hydraulic motors (See “RELEASING THE PARKING BRAKE” on page 3-26).

• Incorrect maneuvers may result in serious injuries or even death.

• To move the machine, use proper strength steel cables; do not use worn cables or cables with broken strands (A), twisted cables (B), or deformed cables (C).

• During the recovery operation, no one is allowed to approach the machines or the cables.

• Move the machine just far enough to permit the required repairs.

• Do not move the machine in any way other than that indicated in paragraph See “HOW TO MOVE THE MACHINE” on page 2-111.

1-26

CK35-1

SAFETY

Never stand next to the tow lines when towing the machine.

The cable or chain could break causing injury. Always stay clear of the towing equipment.

• The maximum pulling force for the emergency recovery is the following: F = 3,870 kg. (8,333 lb.)

• Use cables of the same length and pull continuously, without jerks.

• Arrange and connect the machine to be moved by positioning it on the same axis as the towing vehicle; the force must be parallel to the axis of movement.

CK35-1

1-27

SAFETY

PRECAUTIONS DURING MAINTENANCE All maintenance performed on this machine must only be performed by trained and authorized personnel. When performing maintenance it is important to follow the outlined maintenance procedures and safety information outlined in this manual and in the Shop Manual for this machine.

WARNING TAGS Before performing any maintenance operations on this machine, position the machine on a level and firm surface.

Lock the equipment controls, remove the ignition key and tag the control levers.

Alert all personnel in your area that the machine is down for maintenance. If necessary, tag the machine at specific points to warn others that this machine is down for maintenance.

If the machine will be down for maintenance for a long period of time, be sure to check and see if the warning tags are still in place before you start your repair procedures the next day.

TOOLS • Use only the tools provided with the machine and high-quality tools suitable for the tasks to be performed.

• Do not use worn, damaged, low-quality tools or tools that are not suitable for the tasks to be performed, to avoid any personal injury.

• After use, always put the tools in the appropriate compartment (1) behind the driver’s seat.

1-28

CK35-1

SAFETY PERSONNEL Only authorized and duly trained personnel can service and repair the machine; additional precautions must be taken when grinding, welding and using a sledge hammer or heavy hammers.

When assembling the equipment or cylinder connection pins, use wooden, plastic or in any case softer tools to check the centering of the holes.

Do not use your fingers, since you run the risk of cutting them.

EQUIPMENT STORAGE The normal or special equipment that must be installed on the machine or that have been removed must be stored in safe places, preventing them from falling down. If they fall on someone, they can cause serious bodily harm.

When assembling or removing any equipment, make sure that the ropes and the lifting hook are in good condition and properly sized for the load to be lifted.

WORKING UNDER THE MACHINE Always use approved jack stands to support the machine when performing maintenance under the chassis. Never rely on hydraulic jacks or the machines work equipment to support the machine when working under or on the machine.

Always lower the work equipment to the ground or in any case to their lowest position before performing service or repairs under the machine. Always lock the machine tracks securely. Do not work under the machine if it is not sufficiently supported.

KEEPING THE MACHINE CLEAN Never use flammable liquids to clean your machine. Use only approved non flammable cleaning solvents to clean parts of the machine itself.

Avoid using high pressure steam cleaners or caustic soaps to wash the machine, if possible. Steam cleaning or using caustic soaps may damage paint, wiring or sensitive electrical components.

Never use high pressure water or flood the inside of the operator’s cab. Doing so may damage sensitive electrical components.

When pressure washing, keep the jet a minimum of 60 cm (24 in.) from any surface.

Always grease the machine after cleaning to push any water out of the pivot point connections.

CK35-1

1-29

SAFETY ENGINE OPERATION DURING MAINTENANCE If during maintenance the engine must be running, be sure all work equipment is locked.

Have someone remain in the operator’s seat while the engine is running to stop the engine quickly, if required.

During maintenance operations with the engine running, never disengage the safety locks of the controls from the LOCK position.

Service personnel must not move any control lever.

CRITICAL PARTS Periodically some parts must be replaced for safety purposes.

Even if these parts seem to be in good condition and operating properly they may fail at some point causing possible injury to the operator or a pedestrian. Listed are some of the systems containing these components that may fail under extended use: • Fuel supply and delivery hoses.

• Hydraulic system: main delivery hoses and tubing.

• Hydraulic hoses: all the hoses that feed and return the hydraulic fluid to and from the work equipment.

For additional information: See “CRITICAL PARTS FOR SAFETY” on page 3-14.

STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION • Stop the machine only on firm and level ground and stop the engine before carrying out any maintenance operation or inspection.

• If the engine must be running during a maintenance operation, shift the safety bars to the LOCK position and carry out the maintenance operation with the help of another person; one operator must remain on the machine and the words and signs to be used must be agreed upon in advance.

• The person who carries out the maintenance operations must be very careful not to touch any moving part of the engine.

1-30

CK35-1

SAFETY RULES FOR REFUELING THE MACHINE Keep away from exposed flames while refueling or adding oil.

Spilled fuel or oil makes the ground slippery and may cause accidents; clean any dirty area immediately and carefully.

Always tighten the fuel tank and the hydraulic circuit oil safety caps securely.

Do not use fuel to clean any part of the machine that is dirty with oil or dust.

Always top off the fuel and oil tanks in properly ventilated areas and refrain from smoking.

When refueling, hold the fuel nozzle firmly and keep it constantly in contact with the filler tube until you have finished, to avoid sparks due to static electricity.

Do not fill the tank completely, to leave room for the fuel to expand.

COOLING SYSTEM PRECAUTIONS Never add coolant to a hot or warm engine. Always allow the engine time to cool down completely before opening the radiator cap.

If it is necessary to remove the cap with the engine still hot, wear suitable clothes and protection before loosening the cap. Loosen the cap slowly to relieve pressure gradually.

Never dump used coolant on the ground, in a lake, stream or in a sewer system. EPA law requires these fluids to be captured and recycled properly. Failure to do so is in violation of the law.

USING LAMPS When checking the fuel, oil, coolant or battery electrolyte levels, always use approved explosion proof lights.

If such lighting equipment is not used, there is a danger of fire and/or explosion.

CK35-1

1-31

SAFETY ELECTRICAL PRECAUTIONS When repairing the electrical system, disconnect the battery to stop the flow of electricity.

When working on the electrical system, disconnect the negative (-) battery cable b first, then the positive (+) battery cable c last.

Upon completion of work, reconnect the positive (+) cable c first, then the negative (-) cable b last.

If electrical welding operations are to be performed on the machine, it is necessary to disconnect the battery and also the alternator.

Be aware that the fuel injector harness contains high voltage and high amperage.

PRECAUTIONS CONCERNING THE STARTER Do not start the engine by tampering with the terminals of the starter, since the machine may move.

Sudden or accidental movements of the machine may cause serious injuries or even death.

1-32

CK35-1

SAFETY PRECAUTIONS CONCERNING HIGH PRESSURE HOSES Do not use bent, cut or cracked tubing or hoses which have been previously rejected because of leaks or other defects. Faulty hoses can burst during operation causing injury or fire.

Repair or replace any loose or faulty fuel or hydraulic lines immediately. Do not operate the machine with damaged or leaking hoses or lines.

PRECAUTIONS FOR WORKING ON HIGH PRESSURE SYSTEMS Remember that working hydraulic systems are always under pressure. If you have to add or drain hydraulic fluid, service or inspect the hydraulic system, lower the equipment to the ground and release system pressure and residual tank pressure before starting any work.

Leaks from pressurized hydraulic lines are extremely dangerous since the spray from them can penetrate your skin and enter the bloodstream, or the eyes.

Always wear thick gloves and protective goggles when working on the hydraulic system. Use a sheet of cardboard or plywood to search for leaks.

If you are struck by a jet of hydraulic fluid under pressure, or if you are injured even slightly, consult a doctor immediately for appropriate treatment

PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES When you stop the machine at the end of a job, remember the engine coolant, oil, all engine parts, exhaust stack and the hydraulic system are still hot and under pressure. If you attempt to drain engine coolant, hydraulic fluid, or engine oil under these conditions, you expose yourself to various dangers, including the risk of serious burns.

Carry out maintenance procedures described in this manual only when the machine has had time to cool down.

ROTATING PARTS Take particular care near rotating parts. Keep your body at a safe distance.

If hands, clothing, or tools become entangled in the fan blades or fan belt, severe injury may result. Keep well away from all rotating parts.

CK35-1

1-33

SAFETY PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE RUBBER TRACK TENSION The grease contained in the rubber track tension adjustment device is pressurized. If the adjustment isn't carried out according to the instructions given in the maintenance section, the grease valve (1) may be ejected due to the high pressure and may be dangerous for the operator.

When reducing the tension of the rubber tracks, do not loosen the valve (1) more than five turns.

Keep face, hands and other body parts away from the valve (1).

DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT The shock absorber unit is provided with a shock absorbing spring with high preload, which absorbs impacts on the front idler roller.

Do not attempt to remove the spring, since this may lead to serious accidents and even death.

For any work to be carried out on the shock absorber unit, contact your Komatsu distributor.

HYDRAULIC ACCUMULATOR The hydraulic accumulator contains pressurized nitrogen.

When performing any work on the accumulator, proceed carefully, since this may cause an explosion and consequent serious injury and even death. For this reason, follow these instructions: •

Do not remove the accumulator;

•

Do not bring the accumulator near sparks or open flames;

•

Do not make holes in the accumulator, do not weld or use oxyhydrogen flames;

•

Do not hit or press the accumulator;

•

When disposing of the accumulator, take care when releasing the gas it contains.

Have this work done only by a Komatsu distributor.

1-34

CK35-1

SAFETY DISPOSAL OF WASTE MATERIALS Never dump waste fluids in a sewer system, on the ground, in rivers, etc. Always drain fluids from your machine into the appropriate containers. Never drain fluids directly onto the ground.

Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, filters, batteries, coolant, brake fluid and hydraulic oil.

HYDRAULIC ENVIRONMENTAL ESTER SYNTHETIC (HEES) OIL HEES is a synthetic, biodegradeable oil intended for use in the hydraulic system only.

• Never use HEES in the: engine, transmission, axle, braking system or mix HEES with organic hydraulic oil. Doing so could clog the hydraulic oil filter.

When switching to HEES for the hydraulic system: 1. Drain the organic oil from the tank completely. Disconnect the hydraulic lines and drain the oil from the lines and the cylinders.

2. Replace the hydraulic oil filter with a new one. Reconnect the hydraulic oil lines.

3. Fill the hydraulic oil tank with HEES type oil.

4. Start the engine and let it idle until the hydraulic oil reaches 40°C(104°F). Operate all the work equipment to fill the hydraulic circuits.

5. Stop the engine and check the hydraulic oil level. Add oil as needed.

CK35-1

1-35

SAFETY

1-36

CK35-1

2OPERATION

CK35-1

2-1

OPERATION

SAFETY LOCKS

If it is necessary to stop the machine with the loader arm raised, always engage the mechanical loader arm support on the loader arm and lock the equipment and travel control by lifting the safety bars (See “SAFETY BARS� on page 2-28).

When traveling on roads with a machine approved for this purpose and equipped with a backhoe, roll the bucket back completely, apply the lock between boom and arm, the anti rotation lock between boom and sliding plate and the center lock of the sliding plate.

Raise the stabilizer supports completely, assemble the relevant safety chains and finally lock the equipment controls by shifting the safety device lever to the lock position. If the machine is also equipped with rear stabilizers, raise the supports and lock them with the relevant safety chains.

When traveling on roads with a machine approved for this purpose and equipped with the cold planer, apply the lock on the lifting jack to keep the equipment at a given distance from the ground, lower the loader arm completely, and finally lock the equipment controls by shifting the safety device lever to the lock position.

Non-compliance with these rules may lead to serious accidents.

LOADER ARM SUPPORT The loader arm is provided with a loader arm support (1) to be used to keep the arm raised when the machine is serviced or routine operations are carried out.

The engagement of the loader arm support must be carried out by two people, one seated in the driving position to check the movements of the machine and the other standing on the ground to engage the support correctly.

It is important to remember that under operating conditions the loader arm support (1) must be positioned against the arm and kept in this position by means of the safety pin (2).

The loader arm support must always rest against the hydraulic cylinder rod.

The loader arm support must be brought to its final position by moving the contact surfaces slowly and continuously, in such a way as not to damage the cylinder head surface.

2-2

CK35-1

OPERATION

After engaging the loader arm support (1), hold it in position with the safety pin (2).

Do not perform any work under the raised loader arm if the loader arm support (1) is not in the locked position.

The safety bars (3) located in front of the operator seated in the driving position make it possible to lock the equipment and travel controls.

For the operation of the safety bars (See “SAFETY BARS� on page 228).

The safety guard (4) locks the optional equipment control pedal in the neutral position.

CK35-1

2-3

OPERATION

EXCAVATOR LOCKS

When traveling on roads, always position the backhoe following the longitudinal axis of the vehicle, apply the safety locks and lock the equipment controls by shifting the safety device lever to the lock position.

The backhoe safety locks must be used for traveling on roads and applied by proceeding as follows: • The safety locks of the excavator are necessary for movement on roads and they must be applied by proceeding as follows:

2-4

CK35-1

OPERATION Insert the spacers (1) to prevent the completely lowered loader arm from touching the ground.

Fold the bucket completely and engage the retainer (2) between boom and arm.

Lift the boom and apply the lock (3) for connection with the revolving support.

Position the sliding plate to the center and engage the lock (4) to secure it in this position on the frame of the excavator.

CK35-1

2-5

OPERATION Raise the stabilizers completely and secure them in this position with the safety chains (5).

If the machine is equipped with rear stabilizers, raise them completely and secure them in this position with the safety chains (6).

COLD PLANER LOCK

When traveling on roads, always position the cold planer following the longitudinal axis of the vehicle, apply the safety locks and lock the equipment controls by shifting the safety device lever to the locked position.

If the machine is equipped with a cold planer, it is also necessary to install the spacers (1) to prevent the completely lowered loader arm from touching the ground.

2-6

CK35-1

OPERATION

GENERAL VIEWS FRONT VIEW OF MACHINE

123456-

CK35-1

Bucket Bucket Cylinder Front idler roller Rubber track Track roller Left carriage frame

7 - Rear idler roller 8 - Travel reduction gear 9 - Lift cylinder 10- Frame 11- Loader arm 12- Cab

2-7

OPERATION

REAR VIEW OF MACHINE

1 - Rear Panel 2 - Engine Hood

2-8

3 - Muffler 4 - Right carriage frame

CK35-1

OPERATION

INSIDE VIEW OF CAB

1 - Safety bars 2 - Left PPC control joystick ISO PATTERN SYSTEM - Travel and steering OPTIONAL PATTERN SYSTEM - Left track travel and loader arm control 3 - Right PPC control joystick ISO PATTERN SYSTEM - Loader arm and bucket control OPTIONAL PATTERN SYSTEM - Right track travel and bucket control 4 - Auxiliary hydraulic control pedal (if installed) 5 - Foot accelerator 6 - Hand accelerator 7 - Parking brake 8 - Dashboard

CK35-1

2-9

OPERATION 10 - Left console switches 11 - Right console switches

2-10

CK35-1

OPERATION

INSTRUMENTS AND CONTROLS INSTRUMENTS

1 - Hour Meter 2 - Engine Coolant Temperature Indicator 3 - Fuel Level Indicator

HOUR METER This instrument indicates the total number of operating hours on the engine. The count is continuous and the number is increased by 1 when the engine has run for one hour, independently of its speed. When the engine is running, the LED (A) positioned under the instrument flashes and counts for every second. The hour meter keeps functioning even if the machine is not travelling or working. The reading of the hour meter is to be considered valid for the calculation of the maintenance intervals.

CK35-1

2-11

OPERATION ENGINE COOLANT TEMPERATURE INDICATOR This instrument indicates the temperature of the engine coolant, which, under normal conditions, should be 80-85°C(176-185°F). After starting the engine and before starting work, let it warm up until the temperature indicator reaches the green range. If the indicator exceeds the limit values while the engine is running and indicates overheating, the red range, let the engine idle until the indicator returns to the normal temperature, the green range.

When the indicator suggests overheating, the red range, the audible alarm also sounds.

If this problem occurs repeatedly, find out the cause (See “TROUBLESHOOTING” on page 2-111).

FUEL LEVEL INDICATOR This instrument indicates the fuel level in the tank; this information is available only with the ignition key in position <<I>> (See “IGNITION SWITCH” on page 2-21).

The green range indicates the normal fuel level, while the red range indicates a low fuel level (reserve).

If the indicator reaches the reserve, red range, while the machine is working, stop and add fuel to the correct level.

2-12

CK35-1

OPERATION

INDICATOR LIGHTS

123456-

Alternator Warning Light Preheating Indicator Light Engine Oil Pressure Warning Light Air Cleaner Clogging Warning Light Hydraulic Oil Filter Clogging Warning Light Parking Brake Warning Light

7891011-

Speed Increase Indicator Light Floating Device Indicator Light Direction Indicator Light Working Light Indicator Light Safety Device Functionality Control Unit

ALTERNATOR WARNING LIGHT This warning light lights when the starting circuit is energized and goes out when the engine exceeds idle speed; if this warning light remains on even when the engine is running at the normal operating speed, it means that the alternator is not charging and the battery is not charged correctly.

If the warning light remains off when the ignition key is turned to position "I", it means that the alternator is faulty or broken.

CK35-1

2-13

OPERATION PREHEATING WARNING LIGHT This warning light lights when the ignition key is turned to position << >> to start the engine at low temperatures and goes out automatically after approximately 13 seconds (See “STARTING THE ENGINE” on page 2-61).

ENGINE OIL PRESSURE WARNING LIGHT This warning light lights and activates the audible alarm with the engine stopped when the starting circuit is energized and goes out as soon as the engine lubrication circuit is pressurized. If this warning light remains on or lights with the engine running, stop the machine immediately and try to locate the trouble.

AIR CLEANER CLOGGING WARNING LIGHT This warning light lights when the engine air filter needs cleaning or replacing.

HYDRAULIC OIL FILTER CLOGGING WARNING LIGHT This warning light lights when the hydraulic circuit filter needs replacing.

2-14

CK35-1

OPERATION PARKING BRAKE WARNING LIGHT This warning light lights when the park brake circuit is not functioning properly. If this light lights during normal operation, stop the machine and try to locate the trouble.

SPEED INCREASE INDICATOR LIGHT This light lights when the high speed button on the left joystick is pressed (See “SPEED INCREASE BUTTON” on page 2-22).

FLOAT SWITCH INDICATOR LIGHT This light lights when the float switch is selected (See “FLOATING DEVICE SWITCH (IF INSTALLED)” on page 2-22).

DIRECTION INDICATOR LIGHT This warning light lights intermittently when the lever on the left console is operated (See “DIRECTION INDICATOR SWITCH” on page 2-21) or when the emergency switch is operated (See “EMERGENCY (HAZARD) SWITCH (IF INSTALLED)” on page 2-20).

CK35-1

2-15

OPERATION WORKING LIGHT INDICATOR LIGHT This light lights when the working lights are turned on with the switch on the right console (See â&#x20AC;&#x153;WORKING LIGHT SWITCHâ&#x20AC;? on page 220)

SAFETY DEVICE FUNCTIONALITY CONTROL UNIT This control unit is positioned on the dashboard and checks the condition of the safety devices installed on the machine.

The signals are shown on the display by the lighting and extinguishing of the warning lights.

The functions are as follows:

0A - RED WARNING LIGHT LED off - This indicates that all the safety devices are on and therefore all the machine functions are normal (the solenoid valve ensures the lifting of the work equipment and the machine travel).

LED on - This indicates that at least one safety function is lacking; in this case the solenoid valve is closed and does not permit the lifting and therefore the use of the work equipment and the machine travel.

0B - GREEN INDICATOR LIGHT LED on - This indicates that the operator is correctly seated in the driving position and that the operator seat switch sensor is on.

LED off - (With the red warning light coming on at the same time) This indicates that the operator is standing or that he is not inside the cab.

The operator presence signal (seat) starts the emergency procedure after a delay of 1.5 seconds, all hydraulic functions are locked out and the parking brake is applied. To resume operation, the operator must sit in the driving position, lower the safety bars and press the park brake push button on the left console.

The delay allows the machine to be operated on uneven ground without signalling repeated emergencies.

2-16

CK35-1

OPERATION

0C - GREEN INDICATOR LIGHT LED on - This indicates that the safety bars are down and the work equipment and the travel functions can be operated.

LED off - (With the red warning light coming on at the same time) This indicates that the safety bars are not completely down and therefore the work equipment and the travel functions cannot be used.

The sounding of the audible alarm (buzzer) signals that the PPC valve coil is not functioning properly.

This alarm sounds even with the engine stopped and the ignition key removed from the ignition switch.

Take notice of the following conditions: A) Engine stops and the audible alarm sounds.

Safety bars raised and temporary binding of the PPC solenoid valve.

Lower the work equipment to the ground (See "MACHINE CONTROLS" on page 2-25), get off the machine and try to locate the trouble.

B) Audible alarm sounds with the engine off.

PPC solenoid valve binding.

Lower the work equipment to the ground (See "MACHINE CONTROLS" on page 2-25), get off the machine and try to locate the trouble.

When troubleshooting for extended periods of time, disconnect the negative cable (-) at the battery, to avoid discharging it completely.

The green LED’s (seat and safety bar) light only if the operator has engaged all the safety locks and released the parking brake (red LED on). The LED’s go out whenever the safety bar is lifted (PPC controls off); to reactivate the PPC controls, sit in the driving position, lower the safety bar and press the parking brake push button (green and red LED’s on).

CK35-1

2-17

OPERATION

SWITCHES AND PUSH BUTTONS 1 - Parking brake push button 2 - Rotating beacon light switch 3 - Left stabilizer button (if installed) 4 - Right stabilizer button (if installed) 5 - Working light switch 6 - Emergency (HAZARD) light switch 7 - Parking light and low beam switch 8 - Direction indicator switch 9 - Ignition switch 10 - Horn 11 - High Flow hydraulic system switch (3 lines) for front equipment (if installed)

2-18

CK35-1

OPERATION 12 - Super Flow (momentary reverse) hydraulic push button for optional attachments (if installed) 13 - Speed increase button 14 - Floating device button (if installed) 15 - Operates electro-hydraulic functions of optional attachments (if installed) 16 - Seat Override switch

PARKING BRAKE PUSH BUTTON If pressed, this switch engages the parking brake.

If pressed again, it disengages the brake, thus releasing the machine.

The parking brake is automatically engaged whenever the engine stops; this is due to the lack of pressure in the hydraulic circuit.

The push button releases the brake only when the engine is running and all the safety devices are engaged (warning lights off).

ROTATING BEACON LIGHT SWITCH This switch turns on the rotating beacon and must be operated when necessary to travel on roads.

CK35-1

2-19

OPERATION LEFT STABILIZER BUTTON (IF INSTALLED) This is a button with three positions: forward, center and back.

Press the button forward or backward to lower or raise the stabilizer.

The center position turns the left stabilizer off.

For use, See “LEFT STABILIZER BUTTON (IF INSTALLED)” on page 2-20.

RIGHT STABILIZER BUTTON (IF INSTALLED) This is a button with three positions: forward, center and back.

Press the button forward or backward to lower or raise the stabilizer.

The center position turns the left stabilizer off.

For use,See “RIGHT STABILIZER BUTTON (IF INSTALLED)” on page 2-20.

WORKING LIGHT SWITCH Turns on the working lights.

EMERGENCY (HAZARD) SWITCH (IF INSTALLED) Operates all the direction lights at the same time and must be used whenever the machine is temporarily parked on the roadside or in an abnormal position while traveling on roads.

2-20

CK35-1

OPERATION PARKING LIGHT AND LOW BEAM SWITCH This is a two-position switch: The 1st click turns on the instrument lights and the parking lights.

The 2nd click turns on the low beam or working lights, according to the position of the switch (2).

DIRECTION INDICATOR SWITCH This is a lever switch with three positions. The neutral position is in the center.

Shift the switch lever to the right or to the left to indicate the turn direction.

IGNITION SWITCH This is a rotary key switch with four positions marked by the following symbols « » - }(OFF) - I - « »(START).

For further details on the use of this switch, See “STARTING THE ENGINE” on page 2-61.

HORN This push button is located on the left joystick grip and serves to warn people in the vicinity of the machine, at the beginning of work, and in case of danger, after being pushed by the operator.

CK35-1

2-21

OPERATION FRONT EQUIPMENT HIGH FLOW HYDRAULIC SYSTEM MOMENTARY SWITCH (3 LINES)(IF INSTALLED) This is a momentary switch and allows increased oil delivery from the hydraulic pump to flow in reverse only when it is pressed.

For use, See “STANDARD FLOW HYDRAULIC SYSTEM CONTROL” on page 2-40.

FRONT EQUIPMENT SUPER FLOW HYDRAULIC SYSTEM CONTINUOUS SWITCH (5 LINES)(IF INSTALLED) This is a double-function switch and allows the oil delivery from the hydraulic pump to constantly flow forward.

For use, See “SUPER FLOW HYDRAULIC SYSTEM CONTROL” on page 2-41.

SPEED INCREASE BUTTON This button is positioned on the underside of the left joystick grip and serves to increase the machine speed when pressed.

For use, See “SPEED INCREASE CONTROL” on page 2-43.

FLOATING DEVICE SWITCH (IF INSTALLED) This switch is positioned on the underside of the right joystick grip and, when pressed, enables the electrohydraulic circuit of the floating device.

For use, See “FLOATING POSITION CONTROL” on page 2-43

2-22

CK35-1

OPERATION SEAT OVERRIDE SWITCH The operator must press this switch when using any attachment that requires him/her to be out of the normal seated driving position when operating that attachment.

AVAILABLE FOR OTHER FUNCTIONS The operator has the opportunity to use 3 push-button controls for electrohydraulic equipment with more than one function. For use, See “OPTIONAL ELECTRICAL CONNECTIONS” on page 2-46.

CK35-1

2-23

OPERATION

ELECTRICAL ACCESSORIES 1 - Audible alarm 2 - Electric outlet 3 - Optional Master Electrical Disconnect Switch (if installed)

AUDIBLE ALARM This audible alarm sounds when the circuits are energized with the ignition key (rotation to position «I») and is automatically disengaged when the engine is started.

The sounding of the alarm during operation signals: • insufficient engine oil pressure; • overheating of the engine cooling circuit; • malfunction of the PPC control solenoid valve coil

2-24

CK35-1

OPERATION ELECTRIC OUTLET An electric outlet is positioned on the right rear of the cab inner wall for the connection of a lighting device for routine and maintenance operations.

It is a two-pole outlet and is in compliance with the ISO 4165-1979 standard.

Power supply 12 V.

MASTER ELECTRICAL DISCONNECT SWITCH (IF INSTALLED) This is a removable lever-type switch positioned near the battery. To reach it, it is necessary to open the engine hood (See “ENGINE HOOD” on page 2-51).

The current transmitted by the battery to the electric system of the machine can be stopped by rotating the switch clockwise (position B).

Always rotate the switch to “position B” if it is necessary to work on the battery or the electrical system, or if electric welding must be carried out on the machine.

The electrical connection can be restored by rotating the switch counterclockwise (position A).

CK35-1

2-25

OPERATION

MACHINE CONTROLS

1 - Safety bars 2 - Left PPC control joystick Travel and steering - ISO PATTERN SYSTEM Left wheel travel and loader arm control - OPTIONAL PATTERN SYSTEM 3 - Right PPC control joystick Loader arm and bucket control - ISO PATTERN SYSTEM Right wheel travel and bucket control - OPTIONAL PATTERN SYSTEM Auxiliary hydraulic kit control pedal 5 - Foot accelerator 6 - Hand accelerator 7 - Parking brake 8 - Super Flow hydraulic system control (continuous forward) (if installed) 9 - Super Flow hydraulic system control (momentary reverse) (if installed) 10 - Speed increase control

2-26

CK35-1

OPERATION 11 - Float position control 12 - Pattern shifting control 13 - Right stabilizer control (if installed) 14 - Left stabilizer control (if installed) 15 - Optional Attachment Electrical Connection control

CK35-1

2-27

OPERATION SAFETY BARS

Before leaving the operator seat, lower the equipment to the ground and rotate the safety bars to the vertical (unlocked) position.

The safety devices on this machine are composed of electrical components. Before modifying or replacing any wiring or electrical components, which may result in malfunctions of the devices, contact your Komatsu distributor.

The locking of the PPC control safety device is performed by lifting the safety bars (1) to a vertical position.

The safety device can be released by lowering the safety bars to the horizontal position and pressing the parking brake push button (warning light off).

Equipment movement and machine travel cannot be performed with the safety bars (1) in the locked, or vertical position.

2-28

CK35-1

OPERATION

ISO PATTERN CONTROL SYSTEM LEFT PPC CONTROL JOYSTICK (TRAVEL AND STEERING)

Before performing any maneuver with this joystick, the operator must be seated in the work position with the seat belt fastened; before any maneuver the operator must take all the precautions indicated in â&#x20AC;&#x153;3.6.5 HOW TO MOVE THE MACHINEâ&#x20AC;?.

Before moving, make sure that the safety bars are in the horizontal (unlocked) position and the parking brake is disengaged.

When traveling on roads, make sure that all the safety devices have been engaged.

Failure to comply with these rules may lead to serious accidents.

The left PPC control joystick (2) controls the forward/reverse movements and the steering of the machine as indicated in the diagram below.

N - Neutral A - Forward gear B - Counter rotation to the right C - Reverse gear D - Counter rotation to the left

CK35-1

2-29

OPERATION If the joystick is operated in directions that are inclined with respect to the machine axis, simultaneous steering movements proportional to the angle of inclination are obtained, since the two hydraulic pumps corresponding to each single function are engaged at the same time.

N - Neutral A - Forward left steering B - Forward right steering C - Reverse left steering D - Reverse right steering

Always travel at moderate speed to obtain maximum accuracy and efficiency while working.

While working, the movement of the joystick must be proportional to the required effort to maintain constant engine speed.

Maneuver the joystick smoothly, without abrupt movements, and avoid counter rotations as much as possible, since these maneuvers result in rapid track wear.

The joystick grip is provided with the horn, which must be used to warn people in the vicinity of the machine at the beginning of work and in case of danger.

All movement is cancelled by rotating the safety bars to the locked (vertical) position (See â&#x20AC;&#x153;SAFETY BARSâ&#x20AC;? on page 228).

2-30

CK35-1

OPERATION

RIGHT PPC CONTROL JOYSTICK (LOADER ARM AND BUCKET)

Before performing any maneuver with this joystick, the operator must be seated in the work position with the seat belt fastened and the safety bars in the unlocked (horizontal) position; before any maneuver perform the operations described in “3.13 USING THE WORK EQUIPMENT”.

Before leaving the operating position, lower the equipment to the ground and rotate the safety bars to the locked (vertical) position, then stop the engine.

Failure to comply with these instructions may lead to serious accidents.

The loader self-leveling system is operated automatically only when the loader arm is lifted with a loaded bucket.

When the loader arm is in the lowering phase the system cannot be operated.

At maximum height, the self-leveling system keeps the bucket partially rolled back to prevent material from falling out of the bucket.

The right PPC control joystick (3) controls the loader arm and bucket functions of the machine as indicated in the diagram below.

The bucket should never be rolled back more than 45° with the arm in the dump position.

The following diagrams show the basic maneuvers and the possible combined maneuvers.

BASIC MANEUVERS N - Neutral A - Arm lowering B - Bucket dumping C - Arm lifting D - Bucket roll back

CK35-1

2-31

OPERATION If the joystick is operated in directions that are inclined with respect to the machine axes, simultaneous movements proportional to the angle of inclination are obtained, since the two hydraulic valves corresponding to each single function are engaged at the same time.

N - Neutral A - Arm Lower - Bucket Roll Back B - Arm Lower - Bucket Dump C - Arm Raise - Bucket Dump D - Arm Raise - Bucket Roll Back

All movements are cancelled by shifting the safety bars to the locked (vertical) position.

2-32

CK35-1

OPERATION

OPTIONAL PATTERN CONTROL SYSTEM LEFT PPC CONTROL JOYSTICK (LEFT TRACK TRAVEL, STEERING, AND LOADER ARM CONTROL)

Before performing any maneuver with this joystick, the operator must be seated in the work position with the seat belt fastened and the safety bars in the unlocked (horizontal) position; before any maneuver the operator must take all the precautions indicated, See “MOVING THE MACHINE (ISO PATTERN CONTROL SYSTEM)” on page 2-64 or See “HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM)” on page 2-68.

Before moving, make sure the safety bars are in the horizontal (unlocked) position and the parking brake is disengaged.

When traveling on roads, make sure that all the safety devices have been engaged.

Before leaving the work position, lower the equipment to the ground and rotate the safety bars to the locked (vertical) position, then stop the engine.

Failure to comply with these instructions may lead to serious accidents.

The self-leveling system is operated automatically only when the loader arm is lifted with a loaded bucket. When the loader arm is in the lowering phase the system cannot be operated.

At maximum height the self-leveling system keeps the bucket partially rolled back to prevent the material from spilling out of the bucket.

The left PPC control joystick (2) serves to control the forward and reverse movements, the steering of the machine to the right, and the loader arm raising and lowering functions according to the movements indicated in the diagram below.

To move the machine forward or backward, move the control joysticks (2) and (3) at the same time and in the same direction.

CK35-1

2-33

OPERATION N - Neutral A - Forward right steering B - Arm lowering C - Reverse right steering D - Arm lifting

Always travel at moderate speed to obtain maximum accuracy and efficiency while working.

While working, the movement of the joystick must be proportional to the required effort to maintain constant engine speed.

Move the joystick smoothly, without abrupt movements and avoid counter rotations as much as possible, since these maneuvers result in rapid track wear.

The joystick grip is provided with the horn, which must be used to warn people in the vicinity of the machine at the beginning of work and in case of danger.

All movements are cancelled by rotating the safety bars to the locked (vertical) position (See â&#x20AC;&#x153;SAFETY BARSâ&#x20AC;? on page 2-28).

2-34

CK35-1

OPERATION

RIGHT PPC CONTROL JOYSTICK (RIGHT TRACK TRAVEL, STEERING, AND BUCKET CONTROL)

Before performing any maneuver with this joystick, the operator must be seated in the work position with the seat belt fastened; before every maneuver the operator must take all the precautions indicated See “MOVING THE MACHINE (ISO PATTERN CONTROL SYSTEM)” on page 2-64 or See “HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM)” on page 2-68 and See “OPERATING THE WORK EQUIPMENT” on page 2-96.

Before moving, make sure that the safety bars are in the horizontal (unlocked) position and the parking brake is disengaged.

When traveling on roads, make sure that all the safety devices have been engaged.

Before leaving the work position, lower the equipment to the ground and lock the safety bars (vertical position), then stop the engine.

Failure to comply with these rules may lead to serious accidents.

The right PPC control joystick (3) serves to control the forward and reverse movements, the steering of the machine to the left, the bucket roll back and dumping function, according to the movements indicated in the diagram below..

To move the machine forward or backward, shift the control joysticks (2) and (3) at the same time and in the same direction.

N - Neutral A - Forward left steering B - Bucket dumping C - Reverse left steering D - Bucket roll back

CK35-1

2-35

OPERATION

Always travel at moderate speed, to obtain maximum accuracy and maximum efficiency during work.

During work, the use of the joystick must be proportional to the required effort to maintain constant engine speed.

Move the joystick smoothly, without abrupt movements, and avoid counter rotations as much as possible, since these maneuvers result in rapid track wear.

All movements are cancelled by rotating the safety bars to the locked (vertical) position (See â&#x20AC;&#x153;SAFETY BARSâ&#x20AC;? on page 2-28).

2-36

CK35-1

OPERATION

AUXILIARY HYDRAULIC KIT CONTROL PEDAL (IF INSTALLED)

Always engage the safety guard (2) when use of the control is not required, during travel, and when parking the machine.

When connecting a hydraulic attachment, make sure the control pedal (1) is always in the neutral or horizontal position and covered with the safety guard.

Never set the control pedal to the maximum flow position unless the machine is stopped, the safety bar is in the lowered position, and the operator is seated with the seat belt fastened.

The pedal (1) controls the starting and stopping of the oil flow to the attachment and has three fixed positions ( applied, neutral, and applied).

To apply the pedal (1), lift the safety guard (2).

1 - Neutral or horizontal position (HYDRAULIC CIRCUIT CLOSED).

No flow provided to the attachment.

CK35-1

2-37

OPERATION 2-

applied position (HYDRAULIC CIRCUIT OPEN).

In the applied position, oil flow is supplied to the attachment (excavator, demolition hammer, asphalt cutter, etc.) and is obtained by pressing the pedal with the left part of the foot pedal. To provide continuous oil flow, lock foot pedal in position with lever (3).

To release pedal (1) to the neutral, or horizontal position, push locking lever (3) forward to agree with illustration .

3 - Two direction variable flow position.

The pedal is also used to control the oil flow to attachments with two hydraulic circuits (multipurpose buckets, drills, asphalt cutters, etc.). Shift locking lever (3) to the unlocked (forward) position and press pedal (1) to position or to control the flow of oil to the attachment. The amount of flow in each direction is proportional to the distance the pedal is moved.

2-38

CK35-1

OPERATION FOOT ACCELERATOR The accelerator pedal (1) is positioned on the operator’s right and serves to control the engine speed and power.

Use the accelerator pedal with care, especially when the machine is under load or is working under difficult conditions.

Avoid useless acceleration, to reduce fuel consumption and extend the life of both the engine and the machine.

HAND ACCELERATOR

The use of the hand accelerator is allowed only under the indicated conditions; its use in other conditions may lead to accidents.

The hand accelerator must be used during the warming up of the engine and successively when operations with the optional equipment are to be carried out; it can also be used for some maintenance operations.

•

Idle position : Lever pushed completely forward.

•

Maximum speed position : Lever pulled completely backward.

CK35-1

2-39

OPERATION PARKING BRAKE

The parking brake must be applied whenever the operator leaves the driving position, even if for a short time.

The machine must be positioned with the tracks resting firmly on the ground. If one of the tracks is unstable or is resting on a small obstacle, the machine may move.

Periodically check the functionality of the parking brake.

Failure to comply with these instructions may lead to serious accidents or even death.

In case of failure of the hydraulic system, before moving the machine, release the negative brake installed on the travel hydraulic motors (See “RELEASING THE PARKING BRAKE” on page 3-26).

The braking action is obtained by pressing the switch (1) (LED ON); the release is obtained by pressing the switch again (LED OFF).

The parking brake is automatically engaged whenever the engine stops; this is due to the lack of pressure in the hydraulic system.

Every time the engine is started or restarted, it is necessary to release the parking brake before moving the machine.

STANDARD FLOW HYDRAULIC SYSTEM CONTROL (2 OR 3 LINES)

Never connect an attachment to the hydraulic lines before the attachment is mechanically installed and locked to the machine front coupler.

Controls must be in neutral and deactivated prior to connecting hydraulic lines to an attachment.

Connect hydraulic lines only with the engine off and the parking brake engaged.

Do not risk serious injury. Always operate the attachment from the operator’s seat. Do not allow other people close to the machine or attachment.

Read and understand the attachment Operator’s Manual regarding attachment control functions and operation.

The oil flow, which is bidirectional, to the attachment is controlled by the pedal (See “AUXILIARY HYDRAULIC KIT CONTROL PEDAL (IF INSTALLED)” on page 2-37) and is proportional to the distance the pedal is moved in either direction. The hydraulic lines are located on the left arm.

2-40

CK35-1

OPERATION SUPER FLOW HYDRAULIC SYSTEM CONTROL (5 LINES)

Never connect an attachment to the hydraulic lines before the attachment is mechanically installed and locked to the machine front coupler.

Controls must be in neutral and deactivated prior to connecting hydraulic lines to an attachment.

Connect hydraulic lines only with the engine off and the parking brake engaged.

Do not risk serious injury. Always operate the attachment from the operator’s seat. Do not allow other people close to the machine or attachment.

Read and understand the attachment Operator’s Manual regarding attachment control functions and operation.

If the Super Flow button, (1) or (2), is pressed ON, be aware that the hydraulic flow will operate the attachment if the button is pressed.

The Super Flow hydraulic controls can be used when the operator needs increased oil delivery in the attachments hydraulic system. With the “Super Flow” hydraulic system it is possible to use equipment that requires a high-flow hydraulic line (left) and, at the same time, a standard-flow hydraulic line (right) with limited oil flow for secondary functions (auxiliary hydraulic kit control pedal).

CK35-1

2-41

OPERATION With the Super Flow hydraulic controls, the operator can utilize two independent hydraulic circuits (located on the right and left arms). With the Super Flow system, the standard flow lines are moved to the right arm. The amount of oil flow in the right hydraulic lines and the flow reversal are managed by means of the pedal (See â&#x20AC;&#x153;AUXILIARY HYDRAULIC KIT CONTROL PEDAL (IF INSTALLED)â&#x20AC;? on page 237).

Left side hydraulic lines are used only for the equipment requiring Super Flow rates and controlled by push button (1) and push button (2) on the left joystick.

To provide oil flow to the attachment, press and release push button (2) (red LED above the button on); press the button again to completely stop the oil flow (red LED off) thru the hydraulic lines.

To provide the oil flow and at the same time reverse it, press and hold push button (1). Release push button (1) to restore normal operation.

2-42

CK35-1

OPERATION SPEED INCREASE CONTROL The button (1) that allows the machine travel speed to be increased is positioned on the underside of the left joystick grip.

When the button is pressed, the speed increases; push the button again to return to normal speed.

The speed increase function should be used only for the high speed repositioning of the machine; in any other case, it is advisable to use the normal speed.

Do not use the speed increase control when performing steering or counter rotation maneuvers.

FLOATING POSITION CONTROL The right joystick grip is provided with a switch (1) that, when pressed, (INDICATING LIGHT ON) (See “FLOAT SWITCH INDICATOR LIGHT” on page 2-15) frees the loader arm (floating position), that is, allows it to automatically follow the undulations of the ground.

Press the switch again to restore the standard operating conditions (INDICATING LIGHT OFF) (See “FLOAT SWITCH INDICATOR LIGHT” on page 2-15).

CK35-1

2-43

OPERATION PATTERN SHIFTING CONTROL

Before using the pattern shifting control, lower the equipment to the ground, engage the safety devices and stop the engine.

Failure to comply with these instructions may lead to serious injuries or even death.

The pattern shifting control is located in the engine compartment on the rear wall of the cab and can be reached after opening the engine hood (See “ENGINE HOOD” on page 2-51).

The lever (1) of the pattern shifting control has two positions: • ISO CONTROL SYSTEM Lever in position A • OPTIONAL CONTROL SYSTEM Lever in position B

2-44

CK35-1

OPERATION The control system selection lever (1) is held in the correct position by means of a safety screw (2).

When it is necessary to modify the control system, loosen the safety screw (2) until lever (1) can be moved. Use a 13 mm wrench or the factory supplied ring.

Select the desired control system and lock the lever in place by tightening the safety screw (2).

Before moving the machine, the operator must make sure that the selected control system is the one that is required.

The control panels (3) located on the sides of the central dashboard are lit from behind. The backlighting of the panels is helpful to the operator in identifying the type of control system selected (ISO PATTERN control or OPTION control).

CK35-1

2-45

OPERATION RIGHT STABILIZER CONTROL

Before moving the machine in any way, make sure that the stabilizer feet are completely raised.

Before traveling on roads, make sure that the safety locks of the stabilizer feet have been applied.

The right stabilizer is operated by means of the button (1) installed on the left console and according to the indicated positions.

1. Press the button forward to lower the stabilizer foot.

2. Press the button backward to raise the stabilizer foot.

LEFT STABILIZER CONTROL

Before moving the machine in any way, make sure that the stabilizer feet are completely raised.

Before traveling on roads, make sure that the safety locks of the stabilizer feet have been applied.

The left stabilizer is operated by means of the button (1) installed on the left console and according to the indicated positions.

1 - Press the button forward to lower the stabilizer foot.

2 - Press the button backward to raise the stabilizer foot.

OPTIONAL ELECTRICAL CONNECTIONS The right three-button joystick is used when the operator needs to connect electro-hydraulic equipment with several functions.

Each push button corresponds to an electric line activated by a pulse control: press the push button to activate the electric contact; release the push button to deactivate the contact.

This feature is only available with the Super Flow Auxiliary Hydraulics.

2-46

CK35-1

OPERATION

FUSES AND RELAYS

When changing a fuse, make sure that the ignition switch is in the OFF position. If the fuses are oxidized, corroded, or do not fit perfectly in their seat, replace them only with new fuses having the same capacity.

If the engine does not turn when the ignition switch is turned to START, check the engine start fuse and if necessary change it.

MACHINE FUNCTION FUSES The fuses relevant to the machine functions are grouped on a single base positioned on the dashboard behind the seat.

STANDARD VERSION COLOR

CAPACITY A

1

Violet

3

Left parking lights

2

Violet

3

Control panel lights, right parking lights

3

Light Blue

15

Horn, low beam, or front working lights

4

Brown

7.5

Switch lights

5

Light blue

15

Rear working lights

6

Red

10

Power supply for joystick switches, floating device, pattern shifting

7

Red

10

12V electrical outlet, revolving beacon light

8

Red

10

Power supply for control panel, safety unit, solenoid valve stop, control bar sensor, seat sensor, brake switch

9

Brown

7.5

Back-up alarm

10

Brown

7.5

Fuel pump, safety relay (against repeated starting), alternator

11

Green

30

Solenoid pull relay, servo control safety pressure switch

POSITION

CK35-1

CIRCUIT

2-47

OPERATION VERSION WITH OPTIONAL CONNECTIONS POSITION

COLOR

CAPACITY A

CIRCUIT

1

Violet

3

Left parking light, number plate light

2

Violet

3

Control panel lights, right parking lights

3

Light blue

15

Horn, low beam, or front working lights

4

Red

10

Switch lights, direction indicator lights

5

Light blue

15

Rear working lights, stop lights

6

Red

10

Power supply for joystick switches, floating device, pattern shifting

7

Red

10

12V electrical outlet, revolving beacon light, emergency lights (HAZARD)

8

Red

10

Power supply for control panel, safety unit, solenoid valve stop, control bar sensor, seat sensor, brake switch

9

Brown

7.5

Back-up alarm, power supply for Super-flow 3-way equipment hydraulic system, stabilizers, safety valves

10

Brown

7.5

Fuel pump, safety relay (against repeated starting), alternator

11

Green

30

Solenoid pull relay, servo control safety pressure switch

MAIN FUSE The main fuse (1) is positioned near the battery and can be reached by tilting the cab (See “TILTING THE CAB” on page 2-54).

POSITION

COLOR

CAPACITY (A)

1

RED

50

2-48

CIRCUIT SYSTEM GENERAL CIRCUIT

CK35-1

OPERATION RELAYS The relays are positioned inside the engine compartment and can be reached by tilting the cab (See â&#x20AC;&#x153;TILTING THE CABâ&#x20AC;? on page 2-54).

Some relays are grouped inside the box attached to the right side of the machine frame and can be reached by removing the cover (A).

POSITION

DESCRIPTION

1

Engine stop relay

2

Safety relay (against repeated cranking)

Other relays are contained inside the base installed on panel (B) behind the seat and can be reached by removing panel (B).

CK35-1

2-49

OPERATION POSITION 3

POSITION 4

POSITION

2-50

DESCRIPTION Safety Unit

DESCRIPTION Relay board: A - Stop lights B - 1 way C - 3 way D - Momentary high-low E - 2 way F - Blinking G - Detent high-flow

DESCRIPTION

5

Stoplight relay

6

Floating device control relay

7

Parking brake relay

CK35-1

OPERATION

GUARDS AND OPERATORâ&#x20AC;&#x2122;S SEAT ENGINE HOOD

Do not open the engine hood when the engine is running. Do not use the machine without the engine hood and do not start the engine when the hood is open, unless this is expressly prescribed for certain maintenance operations.

Failure to follow these rules may result in serious accidents.

OPENING THE HOOD After releasing the lock, press the push button (1) and raise the engine hood (2).

The maximum opening position is maintained by the lifting piston (3), which is locked in position by the safety retainer (4).

CLOSING THE HOOD Press the safety retainer (4) of the lifting piston (3) and at the same time lower the hood.

Push it downwards until the lock engages.

Lock the hood.

Make sure that the safety retainer (4) is engaged every time you open the hood.

CK35-1

2-51

OPERATION

REAR PANEL

Do not open the rear panel when the engine is running.

Do not use the machine without the rear panel and do not start the engine with the panel open, if this is not expressly prescribed for certain maintenance operations.

Failure to follow these rules may lead to serious accidents.

The rear panel can be opened only after opening the engine hood.

When inspecting or carrying out a maintenance operation inside the rear panel, always engage the panel in the safety retainer to keep it open.

To reach the release lever (2) for the rear panel (1), raise the engine hood (See â&#x20AC;&#x153;ENGINE HOODâ&#x20AC;? on page 2-51).

To open the rear cover (1), lift the lever (2) positioned on the inner left side of the machine, at the same time rotate the cover to the maximum opening position and hold it open with retainer (3), by proceeding as follows: 1. Lift retainer (3) and rotate it clockwise until it rests against the rear cover (1).

2. Release retainer (3) and make sure that it has been engaged correctly.

To close the rear cover (1), release retainer (3) by rotating it counter clockwise and resting it against the rear cover (1).

2-52

CK35-1

OPERATION

CAB

The cab is a combined ROPS-FOPS; if it is subjected to an impact for any reason, or if the machine overturns, contact your distributor, who will make sure the operator’s safety is ensured.

For maintenance or routine operations, the cab must be tilted; carry out this operation according to the procedure described in section (See “TILTING THE CAB” on page 2-54) and adhere to all safety precautions indicated therein.

The cab is of the semi-closed type.

The windows are positioned on the rear and upper part and the rear window can be removed.

In a special version of the machine, available on request, the cab can be completely closed through the addition of side windows and front door.

CK35-1

2-53

OPERATION TILTING THE CAB

Tilt the cab only with the machine parked on a firm and level surface and with the loader arm lowered to the ground complete with bucket or any other optional equipment.

Make sure that the surface on which the machine is parked is not slippery.

Before tilting the cab, make sure that the engine hood is open (see ENGINE HOOD on page 2-51.).

When lifting the cab, avoid removing the fastening screws (A) of the rear dampening supports of the cab itself.

The cab must be raised or lowered by two people, one per side and it is important to make sure that the handles and hold points are not dirty with oil or grease.

After tilting the cab, always engage the safety split pin of the cab overturning protection lock.

Do not carry out any operation on the machine if the hitch pin clip of the cab overturning protection lock is not engaged.

Always tighten the cab fastening screws to the torque indicated in (See “SPECIFIC TORQUES” on page 3-20).

To carry out some maintenance or routine operations, it is necessary to tilt the cab, an operation that must be carried out by two people according to the following procedure: 1. Stop the machine on firm and level ground.

2. Lower the equipment to the ground.

3. Apply the parking brake and lock the controls by rotating the safety bars to the lock (vertical) position.

4. Stop the engine as indicated in (See “STOPPING THE ENGINE” on page 2-89).

5. Open the engine hood (See “ENGINE HOOD” on page 2-51) and remove the rear screws (1) that fasten the cab to the frame.

Use a 19 mm hexagon wrench.

6. With the help of another person, raise the rear part of the cab using the appropriate handles and pull it forward until it stops.

7. Engage the hitch pin clip (2) of the cab overturning protection lock (3).

2-54

CK35-1

OPERATION

When lowering the cab, be careful of the hold points and carry out the operation with the help of another person.

1.

2.

3.

Remove the hitch pin clip (2) of the cab overturning protection lock (3) and put it in the appropriate seat (4).

Lower the rear of the cab until it touches the support surface.

Reassemble the fastening screws (1) and tighten them to the torque indicated in paragraph (See “SPECIFIC TORQUES” on page 3-20) and close the engine hood (See “ENGINE HOOD” on page 2-51).

CK35-1

2-55

OPERATION STANDARD SEAT The seat can be adjusted longitudinally and the operator can choose the driving position that is most suitable for his physique.

The longitudinal adjustment of the seat is obtained by operating the lever (1) and making the seat slide on the guides; once the desired position has been found, release the lever and move forward and backward to make sure that the lock pin is engaged in its seat.

SUSPENSION SEAT This seat is extremely comfortable, offering four adjustment options: a - longitudinal adjustment; b - back inclination adjustment; c - adjustment of the suspension, aimed at dampening the inevitable vibrations and jerks as much as possible; d - seat cushion inclination adjustment.

The operator can choose the driving position that is most suitable for his physique.

The longitudinal adjustment of the seat is obtained by operating the lever (1) and making the seat slide on the guides; once the desired position has been found, release the lever and move forward and backward, to make sure that the lock pin is engaged in its seat.

The back adjustment is achieved by operating the lever (2); move the lever and find the position that is most suitable for the operator’s physical structure. Three different degrees of inclination are possible.

The adjustment of the suspension is carried out with the lever (3), according to the operator’s weight. The suspension can be stiffened or lightened according to the operator’s needs; adjust the seat suspension by positioning the lever (3) in one of the five positions available. Shift the lever to the left to stiffen the suspension or to the right to soften it.

The inclination of the seat cushion is obtained by operating the lever (4) and positioning the front part of the cushion at the same time; it is possible to select 2 different positions.

2-56

CK35-1

OPERATION SEAT BELT

Before starting the engine, fasten the seat belt.

The seat belt must be changed when it is frayed, damaged or worn and in any case every 4 years.

The seat belt (1) is of the type with two coupling points and adjustable length (2); it must be well tightened and hold the operatorâ&#x20AC;&#x2122;s hips, while leaving the upper part of his body completely free.

EMERGENCY EXIT The machine is provided with an emergency exit located in the rear window (1).

In case of emergency, pull the plate (2) positioned on the upper side of the window and remove the weather strip completely.

Push the window toward the outside.

CK35-1

2-57

OPERATION TECHNICAL DOCUMENTATION CASE

The Operation and Maintenance Manual and the Parts Book are integral parts of the machine and must accompany it even in case of resale.

The Operation and Maintenance Manual must be handled with care and kept aboard the machine, so it can be easily consulted at any time. Put the manual in the technical documentation case located inside the cab on the left side, where the ownership documents and the logbook are usually kept.

FIRE EXTINGUISHER

The machineâ&#x20AC;&#x2122;s owner must provide for installing and mounting the fire extinguisher where prescribed.

Periodically make sure that the fire extinguisher is full.

The fire extinguisher (1) must be installed by the owner of the machine and positioned inside the cab on the left side behind the left console.

FIRST AID KIT

Periodically make sure that the first aid kit contains the necessary disinfectants, bandages, medicine, etc. and check their condition and expiration dates. Replace as necessary.

The first aid kit must be installed by the owner of the machine and positioned inside the cab on the right side behind the right console.

2-58

CK35-1

OPERATION

OPERATING THE MACHINE CHECKS BEFORE STARTING THE ENGINE VISUAL CHECKS

Dirt, oil, and fuel in the engine compartment near its hot parts may damage the machine and even cause fires.

Check frequently and eliminate any leakage; if leakages occur repeatedly, contact your distributor.

Before starting the engine, check around and under the machine to verify: 1. If there are loose bolts or nuts.

2. If there are oil, fuel, or coolant leaks.

3. The wear of the work equipment.

4. The fastening of the electrical connections.

5. The fastening of the engine exhaust pipe and manifold.

6. The conditions and the wear of the rubber tracks.

7. If the safety and warning plates are sufficiently clean.

8. If the ladders and the handles for access to the operatorâ&#x20AC;&#x2122;s seat are clean.

Any leak or abnormality must immediately be repaired and any trace of oil or grease must be removed.

Further visual checks concern: 9. The correct torque of the rear fastening bolts of the cab.

10. The condition of the seat belt.

11. The efficiency of the instruments and of the dashboard.

12. The condition of the cab windows and the efficiency of the lights, working lights and direction indicators.

DAILY CHECKS

Do not smoke during fuel and oil topping off and do not use open flames or non-approved lighting to check the fuel and oil levels, to not cause fires. If fuel, oil, or lubricants are spilled while filling the tanks, clean the dirty areas immediately.

Before starting any operation, check the engine coolant, engine oil, and hydraulic circuit oil levels. At the end of work, refuel to avoid the formation of condensation, always checking the fuel level on the indicator provided on the dashboard.

CK35-1

2-59

OPERATION

Avoid filling the tank completely, to leave room for the fuel to expand. After filling the tank, put back the filler cap, making sure that the bleed hole is completely open. Check the engine oil level with the machine level and the hydraulic circuit oil level with the front bucket resting on the ground.

OPERATIONAL CHECKS

All the checks must be carried out by the operator while seated, with the seat belt fastened. When the machine is at rest after use or maintenance, some safety locks may not be engaged; when the operator gets into the cab, he must make sure that all the mechanical safety locks are engaged and that the equipment cannot move suddenly and create dangerous situations.

The checks concern: 1. The locking of the safety bars.

2. The hand accelerator idle position.

3. The neutral position of the controls.

4. The application of the parking brake.

The following check is carried out by turning the ignition key to position <<I>> to apply voltage to the control panel and check the functionality of the audible alarm, the fuel level indicator, and the engine oil pressure, alternator, and preheating warning lights.

2-60

CK35-1

OPERATION

STARTING THE ENGINE

Before starting the engine, carefully read the instructions and information regarding safety given in this manual and make sure that you know the controls.

From the moment in which the engine is started, the operator is directly responsible for any damage that may be caused by wrong maneuvers and non compliance with the safety regulations and the rules of the road.

Before starting the engine, make sure that there is no one within the operating radius of the machine and sound the horn.

STARTING A WARM ENGINE OR IN TEMPERATE CLIMATES 1.

2.

Turn the ignition key directly to position « » (START).

As soon as the engine starts, release the ignition key, which will automatically return to position «I».

If the engine does not start within 15 seconds, release the key, which will automatically return to position I and wait for 30 seconds before trying again.

CK35-1

2-61

OPERATION STARTING A COLD ENGINE OR IN COLD CLIMATES

Do not use any starting fluids or ether to assist in starting an an engine in cold weather. These products may cause an explosion, damaging the engine or causing injury.

1.

2.

3.

Pull the accelerator lever until reaching half of its stroke and turn the ignition key to the preheating position « » for a maximum of 13 seconds in the coldest weather.

Preheating is indicated by the warning light located on the dashboard.

Turn the ignition key to position « » (START) until the engine starts or for a maximum of 15 seconds.

As soon as the engine starts, release the ignition key, which will automatically return to position «I» and reduce the engine speed to idle.

If the engine does not start on the first attempt, repeat steps 1 and 2 after waiting for at least 1 minute, to not overload the battery.

2-62

CK35-1

OPERATION

WARMING THE ENGINE 1.

2.

After starting the engine, let it warm up before starting work.

The ideal warming up of the engine is achieved with a constant speed obtained with the hand accelerator

Do not use full throttle or accelerate abruptly until the coolant temperature has reached at least 60°C (140°F).

3.

4.

To reduce the time necessary to warm up the engine, move the hand accelerator lever now and then to the midpoint of its travel.

During the warming up of the engine, check the color of the exhaust gases and verify if abnormal noises or vibrations can be noticed; any problem must be verified and its cause must be eliminated.

HEATING THE HYDRAULIC OIL When warming up the engine, especially in cold weather, it is advisable to also heat the hydraulic system oil. For this reason, when the coolant temperature has reached approximately 60°C (140°F), proceed as follows: 1. Release the safety device of the controls by rotating the safety bars down and releasing the park brake. (See “SAFETY BARS” on page 2-28 and See “PARKING BRAKE” on page 2-40).

2. Slowly extend and retract the lift and bucket cylinders completely several times.

3. Lower the bucket to the ground and lock the safety device again by rotating the safety bars up(See “SAFETY BARS” on page 2-28).

CK35-1

2-63

OPERATION

MOVING THE MACHINE (ISO PATTERN CONTROL SYSTEM)

Before moving the machine, make sure that you are completely familiar with all control functions and all relevant safety regulations.

The operator must be seated in the driving position with seat belt fastened.

Before moving the machine, check the position of the rearview mirrors and make sure that there is no one within the operating radius of the machine and that there are no obstacles in the surrounding area.

Be extremely careful when engaging reverse and make sure there are no people, working means, or obstacles in the way.

Avoid maneuvers or changes of direction when travelling at full speed, since the maneuvers carried out under these conditions cause abrupt machine movements.

Do not use the speed increase function when changing direction or carrying out a counter-rotation.

The use of the speed increase function is allowed only for fast transfers of the machine.

Before moving the machine, check the instruments, warm up the engine and the hydraulic system oil, make sure that the safety device for the controls is released (safety bars down) and the bucket is rolled back; the equipment control joystick must be in neutral position.

Release the parking brake.

2-64

CK35-1

OPERATION 1.

Pull the hand accelerator lever to set the engine to the desired macnine travel speed.

2.

Operate the joystick (1), shifting it forward to make the machine advance or backward to make it move in reverse.

CK35-1

2-65

OPERATION STEERING (CHANGING DIRECTION)

If possible, avoid any abrupt change of direction. Counter rotations should be carried out with the machine running at moderate speed.

When traveling on roads, avoid carrying out counter rotations, since they may create dangerous situations; carry out counter rotations only during work cycles.

CHANGING DIRECTION WHEN THE MACHINE IS NOT MOVING To turn to the LEFT, operate the travel joystick as indicated in the diagram. To move FORWARD, push the joystick to the left with 45째 inclination. To move BACKWARD, pull the joystick to the right with 45째 inclination.

To turn to the RIGHT, operate the travel joystick as indicated in the diagram. To move FORWARD, push the joystick to the right with 45째 inclination. To move BACKWARD, pull the joystick to the left with 45째 inclination.

2-66

CK35-1

OPERATION CHANGING DIRECTION WHEN THE MACHINE IS MOVING To turn to the LEFT, rotate the travel joystick counterclockwise by approximately 45째.

To turn to the RIGHT, rotate the travel joystick clockwise by approximately 45째.

HOW TO CARRY OUT A COUNTER ROTATION (with the machine not moving) To turn to the LEFT, shift the travel joystick to the left with an angle of 90째 with respect to the longitudinal axis.

To turn to the RIGHT, shift the travel joystick to the right with an angle of 90째 with respect to the longitudinal axis.

CK35-1

2-67

OPERATION

HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM)

Before moving the machine, make sure that you know the control functions and all the relevant safety regulations perfectly.

The operator must be seated in the driving position with seat belt fastened and the safety bars lowered.

Before moving the machine, check the position of the rearview mirrors and make sure that there is no one within the operating radius of the machine and that there are no obstacles in the surrounding area.

Be extremely careful when engaging reverse and make sure that there are no people, working means, or obstacles in the way.

Avoid maneuvers or changes of direction when travelling at full speed, since the maneuvers carried out under these conditions cause abrupt machine movements.

Do not use the speed increase function when changing direction or carrying out a counter-rotation.

The use of the speed increase function is allowed only for fast transfers of the machine.

Before moving the machine, check the instruments, warm up the engine and the hydraulic system oil, make sure that the safety device for the controls is released (safety bars down) and the bucket is rolled back; the equipment control joysticks must be in neutral position.

Release the parking brake.

1.

Pull the hand accelerator lever and set the engine at the desired travel speed.

2-68

CK35-1

OPERATION 2.

Operate the joysticks (1) and (2) at the same time, shifting them forward or backward to move the machine.

CK35-1

2-69

OPERATION STEERING (CHANGING DIRECTION)

If possible, avoid any abrupt change of direction. Counter rotations should be carried out with the machine running at moderate speed.

When traveling on roads, avoid carrying out counter rotations, since they may create dangerous situations; carry out counter rotations only during work cycles.

CHANGING DIRECTION WHEN THE MACHINE IS NOT MOVING To turn to the LEFT, operate the right joystick by proceeding as follows: to move FORWARD, push the joystick; to move BACKWARD, pull the joystick.

To turn to the RIGHT, operate the left joystick by proceeding as follows: to move FORWARD, push the joystick; to move BACKWARD, pull the joystick.

2-70

CK35-1

OPERATION CHANGING DIRECTION WHEN THE MACHINE IS MOVING (THE TWO JOYSTICKS ARE IN THE SAME POSITION) To turn to the LEFT, shift the left joystick to the NEUTRAL position (N): the machine will turn to the LEFT.

To turn to the RIGHT, shift the right joystick to the NEUTRAL position (N): the machine will turn to the RIGHT.

HOW TO CARRY OUT A COUNTER ROTATION (WITH THE MACHINE NOT MOVING) To turn to the LEFT, pull the left joystick backward and push the right joystick forward.

To turn to the RIGHT, pull the right joystick backward and push the left joystick forward.

CK35-1

2-71

OPERATION

HAND AND FOOT CONTROL SYSTEM MACHINE CONTROLS

The controls represented in the figures and not described in this section remain unchanged and are the same present on the standard version. For details on how to use them, See “MACHINE CONTROLS” on page 2-26

1.

2.

3.

4.

Left PPC control joystick HAND & FOOT CONTROL SYSTEM (Left wheel travel) Right PPC control joystick HAND & FOOT CONTROL SYSTEM (Right wheel travel and auxiliary hydraulic control) Left foot operated hydraulic control HAND & FOOT CONTROL SYSTEM (Loader arm raising and lowering control) Right foot operated hydraulic control HAND & FOOT CONTROL SYSTEM (Bucket dumping and roll back control)

2-72

CK35-1

OPERATION

TRAVEL AND STEERING CONTROL JOYSTICKS

Before carrying out any machine movements with these joysticks, the operator must be seated in the work position with seat belt fastened and the safety bars in the unlocked (horizontal) position; before any machine movement the operator must take all the precautions indicated in "1.2 HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM)".

Before moving, make sure the safety bars are in the horizontal (unlocked) position and the parking brake is disengaged.

When traveling on roads, always make sure all safety devices have been engaged.

Before leaving the work position, lower the equipment to the ground and rotate the safety bars to the locked (vertical) position, then stop the engine.

Failure to follow these rules may lead to serious accidents.

The travel control joysticks (1) and (2) are positioned on the operator's left and right side, respectively, and control the forward and reverse travel of the machine according to the movements shown in the diagram.

To move the machine forward or in reverse, shift the joysticks (1) and (2) at the same time and in the same direction.

For further details on the use of the joysticks, see "pos. 1.2 HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM)".

CK35-1

2-73

OPERATION N - Neutral A - Forward B - Reverse

The right PPC control joystick (2) is used to control the right track and also to control the auxiliary hydraulic circuit according to the movements indicated in the following diagram: NABC-

Neutral Right track forward travel Right track reverse travel Oil delivery from the male coupling of the auxiliary hydraulic circuit D - Oil delivery from the female coupling of the auxiliary hydraulic circuit For details on the use of the auxiliary hydraulic control, see "1.1.3 AUXILIARY HYDRAULIC CONTROL JOYSTICK"

Always travel with the engine running at moderate speed to obtain maximum accuracy and productivity while working.

While working, use of the joysticks must be proportional to the effort required to maintain a constant engine speed.

Operate the joysticks smoothly, without abrupt movements and avoid counter-rotations as much as possible, since this type of machine movement causes rapid track wear.

NOTE The horn (3) is positioned on the grip of the left joystick (1) and must be used to warn all the people in the vicinity before starting work and in case of danger.

All movements can be stopped by rotating the safety bars to the vertical (locked) position. (See "SAFETY BARS").

2-74

CK35-1

OPERATION WORK EQUIPMENT CONTROL PEDALS (LOADER ARM AND BUCKET)

Before carrying out any machine movement with these pedals, the operator must be seated in the work position with seat belt fastened and the safety bars in the unlocked (horizontal) position; before any machine movement the operator must take all the precautions indicated in "1.2 HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM)".

Before leaving the work position, lower the equipment to the ground and rotate the safety bars to the lock (vertical) position, then stop the engine.

Failure to follow these rules may lead to serious accidents.

The self-leveling system is automatically operated only when the loader arm is lifted with a full bucket.

When the arm is being lowered, the self-leveling system does not engage.

At maximum height, the self-leveling system keeps the bucket partially rolled back to prevent material from being spilled.

The control pedals (1) and (2) are positioned on the floorboard in front of the operator seat and control the movements of the loader arm and the bucket.

CK35-1

2-75

OPERATION The pedal (1), positioned on the operator's left, controls the raising and lowering of the loader arm, as indicated in the following diagram:

N - Neutral A - Loader arm raise B - Loader arm lower

On machines provided with a floating device, press the pedal to position B (lower loader arm) and press the switch positioned under the right joystick (see "MACHINE CONTROLS").

2-76

CK35-1

OPERATION The pedal (2), positioned on the operator's right, controls the roll back and dumping of the bucket, as indicated in the following diagram:

N - Neutral A - Bucket roll back B - Bucket dumping

CK35-1

2-77

OPERATION AUXILIARY HYDRAULIC CONTROL JOYSTICK

Before carrying out any machine movements with this joystick, the operator must be seated in the work position with seat belt fastened and the safety bars in the unlocked (horizontal) position.

The control joystick (1) is positioned on the operator's right and controls the movement of the right track and the auxiliary hydraulic circuit, according to the movements indicated on the plate (2) and in the following diagram:

N - Neutral A - Right wheel forward travel B - Right wheel reverse travel C - Oil delivery from the male coupling (3) of the auxiliary hydraulic circuit D - Oil delivery from the female coupling (4) of the auxiliary hydraulic circuit

2-78

CK35-1

OPERATION The auxiliary hydraulic control starts and stops the oil flow to any optional equipment and has four positions (neutral, left, right and detent position).

1.

Neutral position (N) (CLOSED HYDRAULIC CIRCUIT) No oil flow to the optional equipment.

2.

Positions (C) and (D) (OPEN HYDRAULIC CIRCUIT).

These positions are used to control optional equipment with bidirectional oil flow (multi-purpose bucket, drill, asphalt cutter, etc.).

Move the joystick (1) to position (C) to deliver oil from the male coupling (3) positioned on the left side of the loader arm, or to position (D) to deliver oil from the female coupling (4).

CK35-1

2-79

OPERATION 3.

Detent position (E) (OPEN HYDRAULIC CIRCUIT).

This position is used to obtain a continuous unidirectional oil flow for the operation of equipment such as excavator, demolition hammer, sweeper, etc. To hold the joystick (1) in the detent position (E), move the joystick further to the left.

The joystick (1) remains in detent position (E) only with a pressurized hydraulic system.

When the joystick (1) is in position (E), pressurized oil is delivered from the male coupling (3), with return thru the female coupling (4).

2-80

CK35-1

OPERATION HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM)

Before moving the machine, make sure that you are completely familiar with the control functions and all relevant safety regulations.

The operator must be seated in the work position with seat belt fastened and the safety bars in the unlocked (horizontal) position.

Before moving the machine, check the position of the rearview mirrors (if installed) and make sure there is no one within the operating radius of the machine and that there are no obstacles in the surrounding area.

Be extremely careful when shifting into reverse and make sure that there are no people, other equipment, or obstacles in the way.

Avoid any travel maneuver or change of direction with the accelerator at maximum speed, since maneuvers carried out under these conditions may cause dangerous machine movements.

Do not use the speed increase function when changing direction or carrying out a counter-rotation. The speed increase function must be used only for traveling at high speed.

Check the instruments and warm up the engine and the hydraulic system oil before moving the machine. Make sure that the safety bars are lowered to the horizontal (unlocked) position and that the bucket is rolled back; the equipment control pedals must be in neutral position. At this point, release the parking brake.

1.

Set the manual accelerator lever to the desired travel speed.

CK35-1

2-81

OPERATION 2.

Move the joysticks (1) and (2) forward or backward at the same time to move the machine.

2-82

CK35-1

OPERATION STEERING (CHANGING DIRECTION)

Avoid abrupt changes of direction as much as possible. Carry out counter-rotations at moderate speed.

Avoid carrying out counter-rotations when traveling on roads, since these maneuvers may cause dangerous situations; make counter-rotations only during work.

Do not use the speed increase function when changing direction or carrying out a counter-rotation.

CHANGING DIRECTION WITH MACHINE AT REST To turn to the LEFT, use the right joystick as follows: to move FORWARD, push the joystick. To move BACKWARD, pull the joystick.

To turn to the RIGHT, use the left joystick as follows: to move FORWARD, push the joystick. To move BACKWARD, pull the joystick.

CK35-1

2-83

OPERATION CHANGING DIRECTION WITH MACHINE IN MOTION (THE TWO JOYSTICKS ARE SHIFTED TO THE SAME POSITION) To turn to the LEFT, shift the left joystick to the NEUTRAL position (N) and the machine will turn to the LEFT.

To turn to the RIGHT, shift the right joystick to the NEUTRAL position (N) and the machine will turn to the RIGHT

.

HOW TO PERFORM A COUNTER-ROTATION (with machine at rest) To perform a counter-rotation to the LEFT, pull the left joystick backward and push the right joystick forward.

To perform a counter-rotation to the RIGHT, pull the right joystick backward and push the left joystick forward.

2-84

CK35-1

OPERATION MOVING ON SLOPES

Before working on slopes, always check the functionality of the parking brake.

Always go up or down slopes at moderate speed and with the heavier end of the loader always directed towards the top of the slope.

When going up or down slopes, keep the equipment lowered; movements with the arm raised may cause the machine to overturn.

Do not use the speed increase function when the machine travels on slopes.

When working on slopes the following precautions should be taken to avoid risks for the operator and anyone in the vicinity; the checks and operations to be carried out are the following: 1. Always check the work area for snow, landslides, gravel, loose ground and anything that may suddenly modify the work conditions and the stability of the machine.

2. When it is necessary to travel downhill, the front bucket must always be directed downward, in transport position.

3. When loading or traveling uphill, the front bucket must always be directed upward.

4. When moving the machine during work cycles, always lower the bucket.

5. Carry out any lateral movement on a flat surface at the beginning or at the end of the slope; if this is not possible, move at an angle, keeping the machine axis as parallel to the slope direction as possible. Do not move at too great an angle or, even worse, with the machine axis rotated by 90° with respect to the slope direction.

CK35-1

2-85

OPERATION MAXIMUM IMMERSION DEPTH

If it is necessary to work with the machine immersed in water on river banks or sea shores, always check the water depth and the current flow. Make sure that the surface on which you are working is sufficiently firm.

If it is necessary to work with the machine immersed in water, make sure that the maximum depth does not exceed 24 cm and in any case that the engine cooling fan does not touch the water, since it may get damaged or even break.

When working in water or on muddy ground, lubricate the articulated joints more frequently than usual. After work, remove any dirt or mud and lubricate the articulated joints.

2-86

CK35-1

OPERATION

PARKING THE MACHINE PARKING ON LEVEL GROUND

Park the machine on firm and flat ground, in a sufficiently wide space, so that the checks, daily lubrication, and refueling can be carried out without problems. Lower the work equipment to the ground. Engage all safety locks and apply parking brake. Keep to all the safety rules, to avoid any movement of the machine when the operator is absent.

When leaving the machine, remove the ignition key.

1.

2.

3.

4.

5.

6.

7.

8.

9.

Park the machine on firm and flat ground, in a sufficiently wide space.

Lower the bucket to the ground.

Lock the equipment and travel hydraulic control by shifting the safety bars to the lock position (vertical) (See “SAFETY BARS” on page 2-28).

Engage the safety guard to lock the optional equipment control pedal.

Apply the parking brake.

Stop the engine following the procedure indicated in paragraph (See “STOPPING THE ENGINE” on page 2-89).

Remove the ignition key.

Leave the cab using the handles and the footboards.

Refuel taking the necessary precautions.

CK35-1

2-87

OPERATION

PARKING ON SLOPES

The movement of the machine when the operator is not on board may cause serious accidents or even death; to prevent this, carry out the operations described below. Park on slopes only when it is absolutely necessary. Park only with the front bucket directed downwards.

1.

2.

3.

4.

5.

6.

7.

8.

9.

Park the machine with the bucket directed downwards and resting against an obstacle. If this is not possible due to the absence of natural obstacles, rotate the bucket to the dump position and thrust the teeth into the ground.

Lock the equipment and travel hydraulic controls by rotating the safety bars to the lock (vertical) position (See “SAFETY BARS” on page 2-28).

Engage the safety guard to lock the optional equipment control pedal.

Apply the parking brake.

Stop the engine following the procedure indicated, (See “STOPPING THE ENGINE” on page 2-89).

Remove the ignition key.

Leave the cab using the handles and footboards.

Put wedges under the tracks.

Refuel taking the necessary precautions.

2-88

CK35-1

OPERATION

STOPPING THE ENGINE

The sudden stop of the engine while it is running shortens its life. Do not stop it suddenly, except in case of emergency.

It is likewise recommended not to stop the engine suddenly if it has been running for a long period and is still hot; in this case, let the engine idle at a min. speed of 1200 rpm for about 5 minutes, to allow it to cool down gradually before stopping.

Before stopping the engine, proceed as follows: 1. Rest the work equipment on the ground.

2. Shift the joysticks to the neutral position and engage the safety devices.

3. Move the hand accelerator lever to the idle position.

Stop the engine by turning the ignition key to position ÂŤOÂť (OFF).

CK35-1

2-89

OPERATION

TRANSPORTING THE MACHINE LOADING AND UNLOADING

The loading and unloading of the machine on-off the means of transport must be carried out on a flat surface and at a safe distance from the edges of ditches or from the road side. Block the means of transport by positioning wedges in front of and behind each track. Make sure that the ramps are sufficiently strong; if necessary, reinforce them with blocks to prevent any dangerous bending. Make sure the ramps are the same length, firmly anchored to the motor vehicle, parallel to each other and perpendicular to the loading board; the distance between the ramps must be suitable for the machine gauge. Position the ramps with a maximum inclination of 15°. Remove any trace of oil, grease or ice from the ramps and the loading board. Do not change direction when the machine is already on the ramps; if necessary, go down and find the correct direction.

1.

2.

3.

4.

5.

6.

7.

The machine, with empty bucket or without optional accessories, must move on the ramps with the bucket (1) at the back and raised above the ground.

Once the machine has been loaded, lower the work equipment to the bed and rotate the safety bars to the lock (vertical) position.

Apply the parking brake.

Stop the engine and remove the ignition key.

Keep the machine in position also by putting wedges (2) in front of and behind each track.

Attach the machine with tie downs or chains (3) in the tie down hooks(5) and (6).

Cover the end of the exhaust pipe (4).

2-90

CK35-1

OPERATION

TRANSPORT 1.

2.

Check the overall dimensions; the height, width and weight of the means of transport - machine included. It must be compatible with the road and any tunnel, subway, bridge, electric or telephone line that may be found on the way.

Observe all regulations regarding signals, speed limits, road traffic, permits, etc.

CK35-1

2-91

OPERATION

HOW TO LIFT THE MACHINE

To lift the machine use cables of adequate strength; do not use worn cables or cables with broken strands.

Do not lift the machine with the operator on board and make sure that no one is approaching the machine before lifting it.

Before lifting the machine, make sure the eye bolts are correctly attached to the cab roof.

The owner of the machine is responsible for installing the eyebolts correctly on the cab roof.

Torque to 80 Nm (59 lbf-ft) Use only eyebolts approved by Komatsu for this specific type of machine.

Approved eyebolts must be requested from your Komatsu Distributor, specifying the machine model and serial number.

To lift the machine, proceed as follows: 1. Lower the loader arm to the ground and roll the bucket completely back.

2. Rotate the safety bars to the lock (vertical) position and stop the engine.

3. Insert chains or nylon ropes in the two front eye bolts on the cab roof and attach with the appropriate retainers or safety pins.

4. Assemble the chains or nylon ropes in the two couplings on the rear shoulders of the frame, near the arm fulcrum.

5. Connect the ropes or chains to the spreader bar as indicated in the figure.

Always use the four attaching points provided for the lifting of the machine.

6.

Lift slowly until the ropes or chains are tensioned and make sure that the machine is hooked correctly before lifting it off the ground.

During the lift, avoid jerks and abrupt changes of direction.

When lifting the machine, make sure that it is correctly balanced and that it can be lifted level.

Do not lift the machine with optional equipment installed on it.

2-92

CK35-1

OPERATION

COLD WEATHER PRECAUTIONS During cold weather or in areas where the temperature is particularly low, especially during the night, it is necessary to take some countermeasures meant to limit the damage resulting from low temperatures.

FUEL AND LUBRICANTS 1.

2.

Change the fuel and use winter fuel ASTM D975N.1 when the ambient temperature is below -10°C. Change the engine oil for an oil of suitable viscosity. For the relevant specifications, See “FUEL, COOLANT AND LUBRICANTS” on page 3-6.

COOLANT

The coolant containing antifreeze is flammable; do not smoke and do not use open flames when checking and preparing the mixture. Do not use methanol-, ethanol- or propanol-based antifreezes.

1.

2.

3.

4.

5.

6.

Use only permanent, ethylene glycol-based antifreeze, with corrosion inhibitors and antifoam products.

The antifreeze to water ratio must be 1:1 (50% antifreeze and 50% water).

Do not use plugging additives, either alone or added to the antifreeze, to eliminate leakage.

Do not mix antifreezes of different brands.

The use of permanent antifreeze requires only the checking of the level and the periodic changing of the fluid. It is not necessary to wash the coolant system.

The required standards for the permanent antifreeze are SAE-J1034 and FEDERAL STANDARD O-A-548D. In case of doubt regarding the compliance of the antifreeze used with the standards, contact the manufacturer and ask for precise information.

CK35-1

2-93

OPERATION

BATTERY

To avoid explosions due to the presence of gas, do not provoke sparks and do not use open flames near the battery.

The battery electrolyte is dangerous. If it comes in contact with the eyes or skin, immediately rinse with plenty of water and consult a doctor without delay.

1.

2.

When the ambient temperature decreases, the battery capacity decreases accordingly and, if the battery charge is low, the electrolyte may freeze. Keep the battery completely charged and insulate it to protect it from low temperatures, so the machine can be started without problems the following day.

Measure the specific gravity of the fluid and check the battery charge percentage in comparison to the following table:

CHARGE%

3.

FLUID TEMPERATURE 20°C (68°F)

0°C(32°F)

-10°C(14°F) -20°C(-4°F)

100%

1.28

1.29

1.30

1.31

90%

1.26

1.27

1.28

1.29

80%

1.24

1.25

1.26

1.27

75%

1.23

1.24

1.25

1.26

To prevent the fluid from freezing, add distilled water in the morning, before starting work.

OTHER PRECAUTIONS 1.

Before using the machine in normal operating conditions, carry out some slow movements either forward or in reverse, and operate all the work equipment cylinders slowly more than once. These operations serve to warm up and decrease the viscosity of the oil in the hydraulic circuit and the transmission.

PRECAUTIONS TO BE TAKEN AT THE END OF WORK 1.

2.

3.

4.

Completely remove mud and water from the machine body. Park the machine on firm ground; if the machine must be parked near banks or ditches, park it on wooden boards to distribute the weight of the machine over a larger area.

Be careful of water drops forming on the hydraulic cylinder rods: these drops must be completely removed, since if they freeze the cylinder seals may be damaged. After removing the water drops, protect the rods with oil.

Drain any condensate that may have formed in the fuel tank, to prevent the water from freezing overnight.

Since the battery capacity may decrease considerably at low temperatures, after work cover the battery or remove it and store it at a suitable temperature.

2-94

CK35-1

OPERATION

WARM WEATHER PRECAUTIONS 1.

At the end of the cold weather, change the lubricants, the coolant, and the fuel.

The engine coolant must be changed only if it is not permanent, See “FUEL, COOLANT AND LUBRICANTS” on page 36.

2.

3.

4.

Make sure the cooling fan belt is in good condition.

Make sure that the fins of the radiator and of the heat exchanger are clean.

Check the radiator cap gasket and spring; in case of doubt regarding tightness and setting, change the cap.

CK35-1

2-95

OPERATION

OPERATING THE WORK EQUIPMENT

Always fasten the seat belt. Before moving the equipment, make sure that there is no one standing in the work area.

Carry out all the possible movements and make sure that the control joysticks operate correctly. If visibility is insufficient or there are ducts of any kind, proceed at low speed and ask the assistance of another person. Always warn the people present in the work site, even if they are authorized, by means of the horn. The basic illustrations shown are those necessary for the proper use and utilization of the machine; the operator must get to know the controls, the prescribed operating method, and learn how to organize work in an open area, while seated in the driving position.

LOWERING THE EQUIPMENT IN CASE OF MACHINE FAILURE

Carry out the operations while seated in the work position with the seat belt fastened.

After lowering the equipment to the ground, move the control joysticks more than once to release any residual pressure.

If the machine should suddenly stop with the work equipment raised due to a mechanical or hydraulic failure, the operator must lower the equipment to the ground before leaving the machine to locate the trouble. Make sure that the safety bars are lowered (open hydraulic circuit), turn the ignition key to position ÂŤIÂť and lower the bucket to the ground by shifting the equipment control joystick; only limited movements are possible.

2-96

CK35-1

OPERATION

ORGANIZING THE WORK AREA If, after a first inspection, the area appears to be uneven, encumbered with big obstacles or characterized by considerable height differences, it is advisable to level the ground as much as possible, before starting work, for the benefit of the loader and the vehicles to be loaded.

This preliminary operation will make work quicker, ensure better results, and at the same time reduce the operatorâ&#x20AC;&#x2122;s stress and the straining of the machine components; furthermore, this will considerably reduce the time necessary to load the trucks destined for the transport of the material.

To obtain the best performance from the machine it is necessary to synchronize the movements of the equipment with the traveling movements, by operating the joysticks smoothly and without jerks. The changes of direction must be carried out correctly with ample steering radii. Short steering radii or counter rotations involve useless efforts of the machine and rapid track wear.

CK35-1

2-97

OPERATION

LOADING HEAPED AND LEVEL MATERIAL The efficiency of the bucket depends on how the operator starts loading; proceed as follows: 1. Start moving with the arm completely lowered and direct the bucket towards the base of the pile.

2. While the upper material falls down filling the bucket, raise the arms gradually and at the same time roll the bucket to the end of its stroke.

3.

Reverse the motion of the machine and dump the bucket into the truck.

Start loading the truck from the cab side and, if the material is sufficiently mixed, dump from the maximum height to increase the compaction of the material and its distribution on the loading platform.

4.

After removing the pile completely, incline the bucket forward, lower the arm until the rubber tracks are slightly raised and, moving in reverse, level the ground distributing the material uniformly.

Repeat the operation reducing the inclination of the bucket for the finishing work.

2-98

CK35-1

OPERATION

LOADING OPERATIONS ON SLOPES

Travel uphill with the bucket directed forward; the same rule must be followed when loading. Travel downhill in reverse with the loader directed forward and bucket lowered. Move, changing direction very slowly, with the bucket as low as possible. Avoid any transverse position with respect to the slope direction. Sudden movements of the bucket and dangerous positions may cause the machine to overturn and lead to serious accidents or even death

CK35-1

2-99

OPERATION

DIGGING METHOD 1.

2.

3.

4.

5.

6.

At the beginning of work, keep the bucket at the correct penetration angle.

Once the desired digging depth has been reached, position the bucket with its back parallel to bottom of the excavation and then start filling.

During the collection phase, move the bucket and arm simultaneously. Combined movements facilitate the filling of the bucket and therefore increase productivity.

The removal depth must be correct and suitable for the type of ground; an excessive digging depth may cause the locking of the movements due to the overloading of the engine and pump, and therefore slow down the digging operations.

To dump material from piles, unload the bucket as soon as it gets near the dumping area; the inertia resulting from the movement will ensure the compaction of the material with no need to use the bucket for this purpose, which avoids impacts and vibrations that facilitate the wear of pins and bushings.

The correct method is illustrated in pictures ①, ✍, and ③.

CORRECT The bucket starts digging with a slight penetration angle.

INCORRECT If the penetration angle is too wide, the bucket is thrust downwards, slowing the digging work.

2-100

CK35-1

OPERATION

CHANGING THE BUCKET OR ATTACHMENT WITH STANDARD QUICK COUPLER

• Stop the machine on a firm and level surface and lower the bucket or attachment to the ground.

• Before leaving the machine, stop the engine, release the residual hydraulic pressures by operating the equipment control joystick more than once in all directions and raise the safety bars to the locked position.

• Clean the upper and lower mounting areas of the bucket or attachment of all dirt and debris before mounting or releasing it to or from the quick coupler.

• Before starting work, make sure the quick coupler locking pins are completely engaged in, and protruding from, the retaining tabs (slots) provided on the bucket or attachment and that the coupler levers are pushed down to a horizontal (locking) position.

• After locking the equipment and before starting work, make sure that the locking pins are correctly engaged and the length of the protruding portion of the pins is in compliance with the prescribed safety values (See “CHECKING THE POSITION OF THE LOCKING PINS” on page 2-104).

Keep the levers lubricated and free of dirt and debris. Lubricate the coupling pins and keep the area around the pins free of dirt and debris.

Do not use your fingers to align the holes, since your fingers may be injured or cut in the event of the loader bucket or attachment suddenly moving.

The loader is designed in such a way as to permit the installation of various types of buckets or attachments.

To ensure their quick and comfortable change, a special, universal coupler is provided with the machine, which permits the release or installation of the bucket or attachment via a spring loaded over-center lever and pin latching system that secures the machine coupler to an attachment or bucket.

LOCKING THE BUCKET OR ATTACHMENT Rotate the levers (1) down to a horizontal position facing the center of the bucket or attachment (2).

UNLOCKING THE BUCKET OR ATTACHMENT Rotate the levers (1) completely upward to a vertical position.

For Non-Komatsu attachments, read the manufacturer’s instruction manual before installing any attachment.

Refer to the Komatsu Skid Steer Attachment Directory for a single source of work site application choices of attachments.

CK35-1

2-101

OPERATION REMOVING THE BUCKET OR ATTACHMENT

AVOID INJURY. Perform all operations with the bucket or attachment at ground level.

1.

2.

3.

4.

5.

Lower the arm completely and rest the bucket on the ground in a horizontal position.

Stop the engine, release any residual hydraulic pressures, raise the safety bars to the locked position and leave the operatorâ&#x20AC;&#x2122;s seat.

Pull both lock levers (1) completely upward to a vertical position to disengage coupling pins (2).

Return to the operatorâ&#x20AC;&#x2122;s seat, fasten the seat belt, lower the safety bar, start the engine and release the brake.

Rotate the coupler (3) forward allowing the bucket or attachment retaining lip (4) to slide off the top edge of the coupler.

2-102

CK35-1

OPERATION INSTALLING THE BUCKET OR ATTACHMENT

Do not use your fingers to align the holes, since they may become stuck or even cut in case of sudden or uncontrolled movements.

1.

2.

3.

4.

5.

6.

7.

8.

Make sure that levers (1) are in a vertical position and that coupling pins (2) are completely retracted.

Incline the top of coupler (3) forward and slowly approach the bucket (4) or attachment until the top edge of the coupler is completely under the top flange of the bucket (4) or attachment. Make sure you center the coupler with the bucket or attachment.

Tilt the coupler backward until the cutting edge of the bucket or attachment is slightly off the ground.

Roll back the bucket or attachment completely.

Stop the engine, release the residual hydraulic pressures, raise the safety bars to the locked position and leave the operatorâ&#x20AC;&#x2122;s seat.

Lock the bucket or attachment to the coupler by rotating levers (1) toward the center of the bucket or attachment to a horizontal position.

Before moving the machine, make sure that the locking pins (2) are completely engaged in the tabs provided on the bucket or attachment.

To confirm engagement, tilt the bucket or attachment down and apply downward pressure. Back up the machine to make sure there is no movement between the bucket or attachment and the coupler.

CK35-1

2-103

OPERATION CHECKING THE POSITION OF THE LOCKING PINS The position of the coupler locking pins (1) must be checked with the levers in the locked or horizontal position. The length of the protruding part of the pins must be in compliance with the specified values, as indicated in the figure.

To check the locking pin protrusion: 1. Slowly raise the arm.

2. Roll the bucket or attachment forward until the pin protrusion can be seen from the operator’s seat.

3.

If the length (1) does not appear within the specified range, adjust it by proceeding as indicated in See “ADJUSTING THE LOCKING PINS” on page 2-105.

Coupler locking pins must extend through the holes in the bucket or attachment. Levers must be fully down and locked.

Failure to secure the locking pins can allow the bucket or attachment to come off and may cause serious injury or death.

2-104

CK35-1

OPERATION ADJUSTING THE LOCKING PINS The pin adjustment must be carried out with the bucket flat on the ground and the levers (1) of the quick coupler in a horizontal or locked position and proceeding as indicated below: 1. Check the protrusion of the locking pins per See “CHECKING THE POSITION OF THE LOCKING PINS” on page 2-104.

2. Loosen lock nut (3).

3. Adjust nut (2) until the specified dimension is reached.

4. Tighten lock nut (3) against adjusting nut (2) to maintain the specified dimension.

CK35-1

2-105

OPERATION

USING THE RUBBER TRACKS OPTIMAL USE OF THE RUBBER TRACKS The materials used for the construction of the rubber tracks offer many advantages that improve the performance of the machine, but at the same time have some problems regarding resistance. For this reason, it is important to know the characteristics of the rubber tracks, to take the precautions suggested, and to avoid performing operations that are not allowed. In this way, the rubber tracks will last longer and it will be possible to take full advantage of their pluses. Before using the rubber tracks, read paragraph "3.13.7.4 PRECAUTIONS FOR USE".

RUBBER TRACK WARRANTY It is important to carry out checks and routine maintenance to ensure that the tension of the rubber tracks is always correct. These must not be used on work sites where they may be cut due to the presence of steel plates, U-shaped grooves, pointed stones or rocks, steel rods or iron scraps. Komatsu takes no responsibility for any damage to the rubber tracks due to incorrect use by operators who carry out unauthorized operations or fail to take the precautions indicated.

This type of damage is not covered by the warranty.

PRECAUTIONS TO BE TAKEN WHEN USING THE RUBBER TRACKS UNAUTHORIZED USES For correct use of the rubber tracks, bear in mind the following: 1. Rotations or other operations on hard rocky surfaces, rocky surfaces with protrusions, steel bars or scraps, or near the edges of steel plates may damage the rubber tracks.

2. In places where there are many small and large stones, like river beds, the stones may get stuck in the rubber tracks, which may come off or be damaged. Using the machine to carry out leveling operations when the tracks slide on the ground may damage the tracks and reduce their service life.

3. Do not dirty the rubber tracks with oil, fuel or chemical solvents. If one of these substances gets on the tracks, clean them immediately.

Do not use the machine on roads where there are traces of oil.

4. When the machine is going to remain unused for a long period (3 months or more), keep it indoors, away from direct sunlight and protected from the rain.

5. Avoid using the machine in areas where the temperature is particularly high, for example near burning wood, hot steel plates or roads being asphalted.

2-106

CK35-1

OPERATION PRECAUTIONS FOR USE During work, always adhere to the following rules and take the precautions indicated: 1. Avoid abrupt steering or counter rotations on concrete surfaces.

2. Do not carry out abrupt changes of direction that may damage or cause the untimely wear of the rubber tracks.

3. Do not move or steer on surfaces distinguished by considerable differences in height. When there is a difference in height, move perpendicularly. This will prevent the track from coming off.

4. If the machine has been raised from the ground by means of the work equipment, lower it slowly.

5. Avoid using the machine to handle materials or substances that once crushed produce oil (like soy, maize or other vegetables from which oil is derived), or wash the machine soon after use.

6. Avoid using the machine in the presence of materials that may affect the adhesion of the steel core, like salt, ammonium sulfate, potassium chloride, potassium sulfate or calcium super phosphate, or wash the machine after use.

7. Since salt affects the adhesion of the steel core, avoid using the machine in coastal areas.

8. When handling salt, sugar, flour or soy seeds, the presence of deep cuts in the tracks may cause the infiltration of these products into the tracks or the dispersion of rubber pieces into the products.

Therefore, it is advisable to repair the tracks before use.

9. Avoid using the machine when the rubber tracks may rub against concrete walls.

10. Rubber tracks slip very easily on snow or ice. Be careful not to slip when travelling or working on slopes.

11. If the machine works in very low temperatures, the properties of the rubber tracks may change and their service life may be reduced.

12. Considering the particular properties of rubber, it is advisable to use tracks made with the same material at temperatures between -25°C and +55°C. 13. Make sure that the track tension is always correct, to prevent the tracks from coming off. If the tracks are slack, they may come off in the situations indicated on the following page. When carrying out the maneuvers on the following page, proceed with the utmost care even if the track tension is correct.

CK35-1

2-107

OPERATION 1.

Do not change direction when travelling on curbs, rocks or surfaces with great differences in height. If this cannot be avoided, always proceed perpendicularly to the obstacles.

2.

When travelling up slopes in reverse, avoid steering at the beginning of the slope. If it is necessary to steer on the slope, carry out this maneuver gradually.

3.

Do not proceed along the edge of a slope or on uneven ground keeping one track in horizontal position and the other inclined or partially raised. To avoid damaging the rubber tracks, always proceed with both tracks resting on the same horizontal plane.

4.

In the situations described in points from 1 to 3, avoid changing direction when the rubber track does not conform exactly to the ground, as shown in the figure.

2-108

CK35-1

OPERATION

LONG PERIODS OF INACTIVITY BEFORE THE PERIOD OF INACTIVITY

When draining the fuel, do not smoke or bring exposed flames near the machine. Place a container under the machine to gather the fuel and prevent it from spreading around. If some fuel is spilled, clean the dirty surface immediately. To protect the cylinder rods when the machine is not used, position the work equipment as shown. This serves to prevent the cylinder rods from rusting.

If the machine must be stored for a long period of inactivity, it is advisable to put it in a sheltered place and to take the following precautions, to keep all its components sound and efficient: 1. Clean the machine thoroughly, repainting it where necessary to prevent oxidation.

2. Drain and replace all the hydraulic circuit fluids and the lubricants, axles, reduction gears, converter and engine, keeping to the rules indicated in the section regarding maintenance.

3. Change all the filtering elements, air cleaner, engine oil filter, hydraulic circuit filters, diesel oil filter.

4. Change the coolant to permanent type coolant.

5. Drain the normal fuel and fill the tank with at least 5 l of special cleaning and preservation fuel.

6. Let the engine run for about 10 minutes, to eliminate the remaining regular fuel from the filters, the injection pump and the entire fuel supply system. This operation avoids the freezing of the injection pump and the injectors. Stop the engine and refuel with normal diesel oil.

7. Remove the battery, check the electrolyte level and make sure that the battery charge is sufficient. Store the battery in a room with suitable temperature and periodically recharge it.

8. Grease the hydraulic cylinder rods and the equipment joints.

9. Seal the end of the exhaust pipe.

10. Move the machine controls to the neutral position and engage all the safety locks.

11. Hang a warning notice on the controls to indicate the condition of the machine.

12. Lock the engine hood.

CK35-1

2-109

OPERATION DURING THE PERIOD OF INACTIVITY

If it is necessary to carry out a rust prevention treatment while the machine is kept indoors, open doors and windows to increase ventilation and avoid poisoning by gas.

Start the engine and move the machine for a short distance once a month, so a new oil film covers all the moving parts and the surfaces of the components. Provide also for charging the battery.

AFTER THE PERIOD OF INACTIVITY

If the machine is stored without carrying out the monthly rust-prevention treatment, have maintenance performed by your distributor.

When using the machine after a long period of inactivity, proceed as follows: 1. Remove the seals from the exhaust pipe and the fuel tank.

2. Check all the fluid levels: engine oil, coolant, fuel, hydraulic circuit oil.

3. Make sure that the battery charge is sufficient and install the battery.

4. Disconnect the engine stop solenoid.

5. Turn the ignition key directly to the start position and crank the engine until the engine oil pressure warning light goes out. This operation serves to start the circulation of the lubricating oil and to carry out a first lubrication cycle.

6. Reconnect the stop solenoid valve and start the engine.

7. Run the engine at idle for about 20 minutes.

8. While the engine is warming up, remove the protection grease from the hydraulic cylinder rods.

9. Before moving the machine, make sure that the instruments, the warning lights, and working lights work properly.

10. Warm up the hydraulic cylinders, by slowly moving all the work equipment as soon as possible.

2-110

CK35-1

OPERATION

TROUBLESHOOTING HOW TO MOVE THE MACHINE

When moving the machine, use a wire rope suitable for the weight of the machine to be removed.

If the machine gets stuck in mud and cannot get out using only its motive power, or in case of breakdown, use a wire rope as shown in the figure at right.

In case of failure of the hydraulic circuit, before moving the machine release the negative brake installed on the rear axle (See “RELEASING THE PARKING BRAKE” on page 3-26).

IF THE FUEL HAS BEEN COMPLETELY DEPLETED Before starting the engine, when the fuel has run out and therefore air has entered the fuel supply circuit, it is necessary to bleed the fuel supply circuit. For the necessary operations, See “EVERY 500 HOURS OF OPERATION” on page 3-22.

CK35-1

2-111

OPERATION

BATTERY IS EXHAUSTED

When checking or carrying out any operation on the battery, stop the engine and make sure that the ignition switch is in OFF position. The battery produces hydrogen, which may explode. Do not use open flames and do not smoke near the battery, and avoid creating sparks. The battery electrolyte is made of diluted sulfuric acid that may corrode clothes and even skin; in case of contact with this fluid, immediately rinse the involved area with plenty of water. If the acid gets into the eyes, immediately rinse with plenty of water and consult a doctor without delay. When working on the battery, always wear goggles and gloves.

When removing the battery, first disconnect the ground cable (-); when installing the battery, first connect the positive cable (+). If a tool comes into contact with the positive terminal and the machine structure at the same time, this may generate sparks with consequent risk of explosion.

Carefully tighten the connection terminals, since false contacts may generate sparks with consequent risk of explosion. When starting the engine with the aid of another machine, connect the batteries in parallel. When connecting the cables, avoid any contact between the positive cable (+) and the negative cable (-).

When starting the engine with booster cables, always wear safety goggles. Take care to avoid any contact between the machine to be started and the machine used as starting aid, to avoid sparks and therefore the explosion of the hydrogen produced by the batteries. The explosion of a battery may cause serious damage and injuries. Take care not to reverse the cables and connect the ground cable (-) last, as far from the battery as possible. Remove the cables with great care; prevent the cables disconnected from the battery from touching other parts of the machine, to avoid the explosion of the hydrogen. The cables and pliers must be suitable for the current load that must be transferred. The battery to be used for the starting must have greater capacity or at least the same capacity as the battery of the machine to be started. Make sure that the cables and pliers are neither corroded, nor damaged. Make sure that the pliers hold the terminals firmly.

2-112

CK35-1

OPERATION STARTING WITH BOOSTER CABLES CONNECTING THE CABLES AND STARTING THE ENGINE 1.

2.

3.

4.

5.

Make sure that the ignition key is in OFF position.

Connect the positive poles (+) of the two batteries with each other A. Connect the cable of the negative terminal (-) of the charged battery to the engine block of the machine to be started B. Start the engine of the machine that supplies current and increase its speed.

Start the engine of the machine that does not work, See â&#x20AC;&#x153;STARTING THE ENGINEâ&#x20AC;? on page 2-61.

REMOVING THE CABLES When the engine has started, remove the cables in reverse order of the connection process.

1. Disconnect the negative cable (-) from the engine block of the engine that has been started and then from the battery B. 2. Disconnect the positive cable (+) first from the battery used for the starting and then from the depleted battery A.

CK35-1

2-113

OPERATION

OTHER TROUBLES ✩ Always contact your distributor when you have to carry out this operation. ★ If the problem or its cause are not included in the failures indicated below, contact your distributor for the necessary repair.

ELECTRICAL CIRCUIT TROUBLE

CAUSE

REMEDY ★ Check and repair any loose termi-

Lights do not work satisfactorily even with engine running at high speed

• Faulty cables

Lights come on intermittently with engine running

• Faulty fan belt tension

✩ Adjust fan tension, see EVERY 250 HOURS.

Alternator charge warning light does not go out with engine running and increasing speed

• Faulty alternator • Faulty cables

★ Change ★ Check and repair

Alternator emits an abnormal noise

• Faulty alternator

★ Change

Starter does not turn with key in START position

• Faulty cables • Battery charge insufficient • Faulty main fuse

★ Check and repair

Starter pinion engages and then disengages

• Battery charge insufficient

✩ Charge battery

Starter makes engine crank slowly

• Battery charge insufficient • Faulty starter

★ Change

nal and connection

✩ Charge battery ✩ Change

✩ Charge battery

Starter disengages before engine has started

• Faulty cables • Battery charge insufficient

★ Check and repair

Engine oil pressure warning light does not come on when engine is stopped, ignition key in <<I>> position

• Faulty bulb • Faulty pressure sensor

★ Change ★ Change

Alternator charge warning light does not come on when engine is stopped, ignition key in <<I>> position

• Faulty bulb • Faulty cables

★ Change ★ Check and repair

2-114

✩ Charge battery

CK35-1

OPERATION HYDRAULIC SYSTEM TROUBLE

CAUSE

REMEDY

Pump emits an abnormal noise

• No oil in the tank • Faulty pump • Hydraulic oil unsuitable for the temperature

✩ Top off ★ Repair or change ✩ Change oil

Equipment moves only at low speed

• Faulty pump • Max. pressure valve setting incorrect or not closed due to impurities • Dirty drain filter

★ Repair or change ★ Calibrate or change

CK35-1

✩ Change

2-115

OPERATION ENGINE TROUBLE

CAUSE

REMEDY

Oil pressure warning light remains on even with engine at high speed

• Oil level in oil pan too low.

• Oil filter clogged.

• Oil unsuitable for the season.

✩ Top off. ✩ Change filter. ✩ Change.

Steam comes out of radiator breather pipe

• Fluid level low, fluid leakage.

• Fan belt slackened.

• Mud or limestone accumulated in cooling system.

• Radiator fins damaged or closed.

• Faulty thermostat.

• Radiator cap loose or broken.

(Working at considerable altitude)

✩ Top off, repair. ✩ Check and adjust belt tension. ✩ Change fluid and clean cooling system. ✩ Repair or clean. ★ Change. ✩ Tighten or change cap.

Temperature indicator always on the right end of the scale

• Faulty temperature indicator.

★ Change.

Temperature indicator pointer always on the left end of the scale

• Faulty thermostat.

• Faulty indicator.

★ Change. ★ Change.

Engine does not start with starter cranking

• No fuel.

• Air in fuel system.

• Compression defect, valves with wrong clearance.

✩ Refuel. ✩ Bleed system. ★ Adjust valve clearance.

Exhaust gases white or light blue

• Too much oil in oil pan.

• Unsuitable fuel.

✩ Correct oil level. ✩ Change with suitable fuel.

Exhaust gases occasionally tend to be black

• Air cleaner clogged.

• Faulty injectors.

• Faulty compression.

★ Change. ★ Adjust valve clearance.

Combustion noise occasionally makes a breathing sound

• Faulty injectors.

★ Change.

Abnormal noises, during combustion or in mechanical parts

• Fuel with low cetane rating.

✩ Change to fuel compliant with standards. ✩ See defects of temperature indicator. ★ Change. ★ Adjust valve clearance.

Engine coolant temperature indicator reaches overheating (red) range:

• Overheating.

• Muffler insides damaged.

• Excessive valve clearance.

2-116

✩ Clean or change.

CK35-1

OPERATION HYDROSTATIC TRANSMISSION TROUBLE

CAUSE

REMEDY

Machine moves neither forward, nor backward:

• • • • • •

Oil level insufficient.

Suction filter clogged.

Faulty flexible coupling.

Max. pressure valves faulty or dirty.

Positioning hydraulic connection interrupted.

Travel motor faulty.

✩ Top off. ✩ Change. ★ Change coupling. ★ Clean or change valves. ★ Restore connection. ★ Repair or change.

Machine moves with delay Abnormal noise

• • • • • •

Oil level too low.

Presence of foam.

Suction pipe tightness.

Suction filter clogged.

Fuel supply max. pressure valve faulty.

Travel motor faulty.

✩ Top off. ✩ Use the recommended oil. ★ Check and eliminate leakage. ✩ Change. ★ Disassemble, clean, or change. ★ Repair or change.

Traction force in the two travel directions is insufficient

• Engine does not reach max. speed.

★ Change diesel oil filter and

• Auxiliary fuel pump (gear pump) faulty.

• Max. pressure valve setting incorrect.

• Connection to servo control faulty lever angle incorrect.

• Pressure relief valve setting incorrect.

• Excessive oil temperature.

★ Repair or change. ★ Set. ★ Restore connection shift lever

check injection pump.

• Travel motor faulty.

Traction force is insufficient in one direction only

• Engine strongly overloaded.

• Incorrect setting of the max. pressure valve relevant to that direction.

Oil overheating

• Oil level too low • Exchanger clogged or dirty.

to correct position.

★ Set. ✩ Check oil level and clean exchanger. ★ Repair or change. ✩ Reduce loads due to lifting.

★ Set valve. ✩ Top off.

★ Check and change if necessary.

CK35-1

• Unsuitable oil.

• Suction pipe tightness.

• Setting and operation of the max. pressure valves.

★ Use the recommended oil. ★ Check and eliminate leakage. ★ Check setting - repair or

• Travel pump faulty.

• Pressure relief valve with high setting.

• Travel motor faulty.

★ Repair or change. ★ Set valve. ★ Repair or change.

change.

2-117

OPERATION

TROUBLE

CAUSE Suction filter clogged.

Engine does not reach max. speed Auxiliary pump (gear pump) faulty.

Pilot pressure insufficient.

Pressure relief valve setting incorrect.

REMEDY ✩ Change ★ Change diesel oil filter and check injection pump. ★ Check delivery, repair or change. ★ Set. ★ Set to rated value.

Machine does not reach max. speed selected

• • • • •

Machine decelerates intermittently

• Mechanical connection with servo control lever too hard.

★ Check if rotation is smooth.

Machine accelerates slowly.

• Engine power drop.

★ Check clogging of diesel oil filter,

• Pressure relief valve setting incorrect.

★ Set to rated value.

• Sealing rings faulty.

• Counterpressure in pump casing.

• By-pass valve setting too high.

★ Change. ★ Drain pipes clogged or damaged. ★ Check and restore.

injection pump and valves.

Oil leakage from engine propeller shaft and/or pump.

2-118

CK35-1

3MAINTENANCE

CK35-1

3-1

MAINTENANCE

GUIDE TO MAINTENANCE ★ Before opening the engine hood, engage safety locks and stop the engine. If it is necessary to check the hydraulic oil level in the reservoir, lower the arm and rest the bucket on the ground, See “SAFETY LOCKS” on page 2-2. ★ Carry out any operation on firm and level ground, after applying the parking brake. ★ Raise the cab taking all the precautions indicated in See “TILTING THE CAB” on page 2-54. ★ Use genuine Komatsu oils and greases; choose oils suitable for the ambient temperature. Use clean oils and greases. Keep the oil and grease containers clean. Keep any foreign matter away from oils and greases. ★ Always keep the machine clean. This makes it easier to locate any parts causing problems. Keep the grease fittings, the breathers, and the areas near the openings for the fluid level checks clean and prevent any impurities from getting into/on them. ★ Draining hot oil or coolant immediately after stopping the engine is hazardous. Wait for the engine to cool down to at least 40 to 50°C (104-122°F) before draining hot liquids. After changing the oil or the filters, check if metal particles are present. If you find large quantities of metal particles, contact your distributor. Check and change the oil in clean locations and prevent any impurities from getting into the tank/container. ★ Before carrying out any maintenance operation, hang the warning plates on the ignition switch and control levers to prevent anyone from starting the engine by mistake. When performing maintenance operations, always take the precautions indicated on safety decals applied to the machine. ★ Instructions for arc welding.

1. Turn ignition key to the OFF position.

2. Disconnect the battery (first, negative - pole and then positive + pole). Disconnect the alternator.

3. Do not apply more than 200V continuously.

4. Connect the ground cable within 1 mm of the point on which welding will take place.

5. Avoid placing gaskets and bearings between the welding area and ground cable. ★ Do not use flammable fluids to clean machine parts. Keep exposed flames and lit cigarettes away from these fluids. When o-rings and gaskets are removed, thoroughly clean sealing surfaces and replace all o-rings and gaskets with new ones. Fit the o-rings and gaskets correctly when reassembling. ★ Avoid keeping loose objects or tools in your pockets: they may fall out and drop into the machine, especially when you open covers and work on the machine while bending over it. When washing the machine, do not direct high pressure water jet onto the radiator and heat exchanger. When washing the machine, protect electric system connectors and avoid getting the ignition switch wet. ★ Before starting work in mud, in rain, on seashores, or river banks perform general lubrication. Wash the machine immediately after work to protect components from rust. Lubricate equipment joints more frequently than usual. ★ When working at dusty work sites, proceed as follows: 1. Check the air cleaner for any clogging and clean it more frequently than usual.

2. Clean the radiator and the heat exchanger frequently, to avoid any clogging of the fins.

3. Change the diesel oil filter more frequently than usual.

4. Clean the electrical components, especially the starter and alternator, to avoid any accumulation of dust. ★ Never mix oils of different brands. Do not top off with any oil different from oil used in the machine. If necessary, drain all the oil and fill tank with new, different brand oil.

Oils, filters, coolant, and the batteries are considered special waste and must be collected and disposed of according to the regulations in force. Combustible material of some components may become extremely dangerous if it burns. For this reason, avoid any contact of burnt material with your skin or eyes and do not inhale fumes.

3-2

CK35-1

MAINTENANCE

MAINTENANCE NOTES ★ Use only genuine Komatsu replacement parts. Do not mix different types of oil. Unless specified otherwise, oils and coolant used by Komatsu before delivery of the machine are as follows:

ITEM

SPECIFICATIONS

• Engine oil

SAE 10W-30 API classification CD

• Hydraulic system oil

SAE 10W API classification CD

• Biodegradable hydraulic system oil. Only for machines in which the synthetic biodegradable oil type HEES (not of plant origin) is used.

SHELL NATURELLE HFX-32

• Chain case oil

SAE 10W-30 API classification CD Ambient temperature above -10° C(14°F): ASTM D975 no. 2 diesel oil

• Fuel Ambient temperature below -10° C(14°F): ASTM D975 no. 1 diesel oil • Radiator coolant

Permanent, ethylene glycol-based antifreeze, with corrosion inhibitor for protection up to -36°C (-33°F).

NOTES REGARDING THE ENGINE ENGINE OIL ★ Engine oil must be selected very carefully, since it lubricates the engine, which is the machine’s heart; the main maintenance operations required for engine oil are as follows: 1. Daily check of the oil level.

2. Check condition of the oil with periodic analysis.

3. Periodic oil changes.

CK35-1

3-3

MAINTENANCE COOLANT ★ Engine coolant serves to keep the engine at the correct temperature and therefore to ensure optimal operating conditions; check coolant level in the expansion tank daily and top off if necessary. The quantity of antifreeze to be added to the coolant depends on the minimum temperature in the place where the machine is working. ★ Use only permanent ethylene glycol-based antifreeze with the addition of anticorrosion and anti foam products. The antifreeze-water ratio must be 50% (50% antifreeze and 50% water). ★ The use of permanent antifreeze requires only the routine change. It is not necessary to wash the cooling circuit. ★ Use drinkable water and in any case soft water. ★ Do not use corrosion inhibitors containing soluble oil, since they damage the rubber hoses. ★ The required standards for permanent antifreeze are the following: SAE-J1034 and FEDERAL STANDARD O-A-548D. In case of doubt regarding the compliance of the antifreeze used with the standards, contact your Komatsu Utility distributor and ask for precise information.

FUEL ★ Always use fuel suitable for the engine. Other fuels with different specifications may damage the engine or reduce its power. ★ Always refuel at the end of the work day. ★ When refueling, make sure that there is no water on the fuel drum cover and take care not to draw condensation from the drum bottom. ★ If fuel runs out, or if the fuel filter has been replaced, it is necessary to bleed the circuit.

NOTES REGARDING THE HYDRAULIC SYSTEM ★ Be extremely careful when performing maintenance on the hydraulic system, since the oil is very hot. The system is pressurized not only during work, but also at the end of work. ★ The maintenance operations required for the hydraulic system are the following: 1. Daily check the oil level in the tank.

2. Periodically change the oil filter.

3. Periodically change the oil and clean the suction filter. ★ Always bleed the system after changing the oil filter and the oil. When a component is removed from the circuit, check the gaskets and o-rings and change them if they are damaged. When a cylinder or a component of the hydraulic system is removed, after reassembly bleed the system by proceeding as follows: 1. Start the engine and let it idle.

2. Make all the cylinders perform 4 to 5 movements, stopping them at about 100 mm from the end of their stroke.

3. Slowly make all the cylinders reach the end of their stroke for 3 to 4 times.

NOTES REGARDING THE ELECTRICAL SYSTEM ★ If the cables are wet or their insulating material is damaged, the electrical system may short, and may result in machine malfunctions. The maintenance operations required for the electrical system are the following: 1. Check the alternator belt tension.

2. Check the alternator belt for damage or breakage.

3. Check the battery electrolyte level. ★ Do not remove or eliminate any electrical component installed on the machine and do not install any electrical component with characteristics different from those specified and approved by Komatsu. ★ Be careful to keep the electric system dry. When working on seashores or river or lake banks, protect the jack plugs from corrosion. Do not connect any optional device to the fuses, ignition switch, battery, relays, etc. For the installation of any optional equipment, contact your distributor. If any electric welding needs to be done, disconnect the battery and the alternator.

3-4

CK35-1

MAINTENANCE

NOTES REGARDING LUBRICATION ★ Lubrication makes the operations carried out with the machine and work equipment smoother, while preventing wear and the noise that may be produced if the joints are dry. ★ Lubrication is to be carried out with grease or oil. The maintenance operations required for the components that need lubricating are the following: 1. Check the fluid and lubricant levels.

2. Change oil at recommended intervals.

3. Inject grease through the grease fittings. ★ Use only the specified lubricants, according to the ambient temperature. Always clean the grease fittings before injecting grease and remove any excess grease after lubrication; this cleaning operation must be performed with extreme care on the revolving parts. Keep the lubricants at the correct levels; excessive or insufficient quantities are to be avoided.

PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING ★ The parts subject to wear such as filters, bucket teeth, etc. must be replaced according to the periodic maintenance intervals prescribed or when they reach their wear limit. The timely change of these parts ensures economical use of the machine. Use only genuine Komatsu parts, which alone can guarantee excellent quality and interchangeability.

ITEM

DESCRIPTION

QTY

CHANGE INTERVAL

Hydraulic oil filter

Cartridge (drain)

1

500 hours

Engine oil filter

Cartridge

1

250 hours

Fuel filter

Cartridge

1

500 hours

Air cleaner

Main cartridge Safety cartridge

1 1

When required When required

Front bucket

Tooth Screw Nut

6 12 12

– – –

CK35-1

3-5

MAINTENANCE

FUEL, COOLANT AND LUBRICANTS SELECTION ACCORDING TO THE AMBIENT TEMPERATURE

Ambient Temperature Reservoir

Kind of fluid

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

Capacity 30 86

40 104

50°C1 22°F

Specified

Refill

10 l (2.64 gal)

10 l (2.64 ga)

50 l (13.2 gal)

32 l (8.4 gal)

50 l (13.2 gal)

32 l (8.4 gal)

1.17 l (.31 gal)

1.17 l (.31 gal)

72l (19.0 gal)

-

15 l (3.9 gal)

-

SAE 5W-30 SAE 10W Engine oil pan Oil API CD

SAE 30 SAE 40 SAE 10W-30

Hydraulic system and hydrostatic transmission

SAE 5W-30 SAE 10W

Hydraulic system with biodegradable oil

See page 312

Travel reduction gears (ea.)

Oil API CD

Fuel tank

Diesel fuel

SAE 10W-30 ASTM D975 No. 1 ASTM D975 No. 2

Engine cooling system

Permanent antifreeze★

★ Special red permanent antifreeze compatible with aluminum radiators. If pure, dilute with (50%) water.

GREASE LUBRICATION POINTS

CONSISTENCY

TYPE

Joints, grease fittings

NLGI 2

(See note 1)

Track tensioner unit

NLGI 2

LITHIO EP +MoS2

Note 1: The recommended lubricating grease is No.2 multi purpose lithium grease with 3% molybdenum disulfide (Lithio EP + MoS2).

3-6

CK35-1

MAINTENANCE Remark When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%.

Fuel sulphur content

Change interval of oil in engine oil pan

0.5 to 1.0%

1/2 of regular interval

Above 1.0%

1/4 of regular interval

★ When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAE10W, SAE5W-30 or SAE10W-30, even though atmospheric temperature goes up 10°C more during the day time. ★ Use engine oil with CD classifications; if oil with CC classification is used, reduce the engine oil change interval by one half. ★ Use genuine Komatsu oil which has been specifically formulated and approved for use in the engine, hydraulic work equipment, in the reduction gears, and in the transmission.

First filling quantity: total quantity of oil, including the oil for the components and pipes.

Oil change quantity: quantity of oil necessary to fill the system or unit during the normal inspection and maintenance operations.

ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute NLGI: National Lubricant Grease Institute

CK35-1

3-7

MAINTENANCE

No.

Supplier

Engine Oil API CD, CE or CF-4

Transmission Oil GM Dexron® II C4 Allison C4

Grease LI, EP, MoS2

Antifreeze Coolant [Ethylene Glycol Base] Permanent Type

KOMATSU Premium multi grade Engine Oils PM701 SAE 10W/30 SAE 15W/40

Komatsu PM704 (1902) Dexron® III

Komatsu Super Grease NLGI 2 PM706 ASTM D128

2

AMOCO

Amoco 300 SAE 15W/40

Dexron II ATF

Molylith grease 2

Ready Antifreeze

3

ARCO

Arcofleet S3 plus SAE 15W/40 Hy-Vis HD extra S3 plus SAE 15W/40

ATF Dexron II

Litholine HEP 2 Arco EP moly D

Sincol-Blu (-40°C)

4

BP

Vanellus C3 SAE 15W/40 Vanellus C3 Extra SAE 15W/40

Autran MBX

Grease LTX2-M

Sigil Fluid (-40°C)

5

CALTEX

RPM Delo 500 RPM Delo 600 RPM Delo SPH

ATF-HD

Molytex EP2

AF engine coolant CX engine coolant

6

CASTROL Turbomax RX super

TQ - Dexron II

Spheerol LMM

Antifreeze (pure)

7

CHEVRON Delo 400 Delo 500

Supreme Automatic Transmission Fluid

Moly grease

Flurant

8

CITGO

9

CONOCO

10

11

1

12

D-21571

–

*Fleet motor oil SAE 15W/40

D21718 D21570

–

EXXON (ESSO)

Essolube TD SAE 15W/40 Heavy Truck Diesel Motor Oil SAE 15W/ 40

ATF Dexron II D D-21849 (East Canada) D-21848 (West Canada)

GULF

Super duty SAE 15W/40 Super duty plus SAE 15W/40

MOBIL

–

Delvac 1300 Super SAE 15W/40 Delvac 1200 Super SAE 15W/40 Delvac 1300 Super SAE 10W/30

– ATF 220

–

– Fleet Heavy Duty

MP Grease Moly

All-season coolant

Gulfcrown EP2 Gulfcrown EP special

Antifeeze and coolant

Mobilgrease sp.I ó –

13

PENNZOIL Supreme duty fleet SAE 14W/40

Pennzoil ATF

Multi-purpose white grease 705 707L White-bearing grease

Antifreeze and summer coolant

14

SHELL

Donag TG (Dexron II)

Alvania EP grease MP MOS (Can.) Retinax AM (Corea)

Shellzone all season antifreeze

15

SUN

Sunoco ultra prestige 2EP Sun prestige 742

Sunoco antifreeze and summer coolant

3-8

Rimula Super SAE 15W/40 Myrina X SAE 15W/40 Rotella T SAE 10W/30 -

-

CK35-1

MAINTENANCE No. 16

17

Supplier TEXACO

UNION

CK35-1

Engine Oil API CD, CE or CF-4

Transmission Oil GM Dexron® II C4 Allison C4

Grease LI, EP, MoS2

Ursa Super TD SAE 15W/40 Ursa Super LA SAE 15W/40

Havoline ATF Dexron II Texamatic 7045 (9226)

Molytex EP2 ó

Guardol

D21460

Unoba EP

Antifreeze Coolant [Ethylene Glycol Base] Permanent Type – –

3-9

MAINTENANCE

APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin, therefore use of oils indicated in the following table is authorized and recommended: SUPPLIER KOMATSU

HEES SYNTHETIC BIODEGRADABLE OIL BO 46 G4 (KES 07.872)

AGIP

–

ARAL

–

AVIA

–

BP

–

CONDAT

CONDAT D 46 K

ELF

–

ESSO

–

FINA

BIOHYDRAN SE 46

FUCHS

–

KENDALL

–

KUWAIT PETROLEUM K8

–

MOBIL

EAL SYNDRAULIC

MOBIL (USA)

–

PAKELO

–

PANOLIN

HLP SYNTH 46

SHELL

NATURELLE HFE-46

TAMOIL

–

TEXACO

–

TOTAL VAVOLINE

3-10

HYDROBIO 46 –

CK35-1

MAINTENANCE

It Is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils, since when the temperature increases insoluble compounds are generated, which are deposited on the filters and clog them (the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil). The synthetic biodegradable oil can be used only in the hydraulic system; it cannot be used in the engine, the transmission, the braking system, etc. Before introducing the synthetic biodegradable oil in the hydraulic system, empty the system completely, disconnecting the cylinders and all the parts that may contain ordinary oil, and replace the drain filter with a new one. Start the engine and let it idle without using the work equipment, wait until the oil reaches a temperature of at least 40°C(104°F), then start moving the equipment, so all the parts of the system are filled with oil. Stop the engine and check the oil level, (See “ENGINE OIL LEVEL” on page 3-37).

For the lubrication procedures for the single points, See “MAINTENANCE PLAN” on page 3-21.

The type of lubricant to be used is indicated in the lubricant table (See “FUEL, COOLANT AND LUBRICANTS” on page 36).

CK35-1

3-11

MAINTENANCE

LUBRICATION DIAGRAMS GENERAL

3-12

CK35-1

MAINTENANCE

PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY To ensure safety at all times while driving and using the machine, the operator must carry out all periodic maintenance operations prescribed. Furthermore, the operator must periodically replace the components indicated in the table on the following pages, which are especially related to safety and fire prevention rules. These components are subject to wear and since it is particularly difficult to evaluate their conditions through simple periodic maintenance, after a certain period it is advisable to change them regardless of their condition, to keep them efficient over time. Repair or replace these components immediately in case of failures or abnormalities, even if the time interval prescribed for their change has not yet elapsed. If the hose clamps show signs of deterioration, like deformations or cracks, replace them at the same time as the hoses.

In addition to periodic replacement of the components listed on the following pages, the inspections described below are to be performed on the hydraulic hoses. In case of abnormalities, perform the necessary adjustments and replacements, or institute any other required measure.

TYPE OF CHECK

CHECK ITEM

Check before starting

Leakage from joints, grease fittings, hydraulic hoses, or fuel lines.

Periodic check (monthly check)

Leakage from joints, fittings, hydraulic hoses, or fuel lines.

Damaged hydraulic or fuel lines, cracks, wear and tear.

Periodic check (annual check)

Leakage from joints, fittings, hydraulic hoses fuel lines.

Deteriorated, twisted, damaged hydraulic hoses fuel lines, cracks, wear and tear, or in contact with other parts of the machine.

CK35-1

3-13

MAINTENANCE

CRITICAL PARTS FOR SAFETY FUEL SUPPLY SYSTEM NO

COMPONENTS RELATED TO SAFETY THAT REQUIRE REPLACING

QTY

1

Fuel line (Fuel tank - precleaner)

1

2

Fuel line (Precleaner - fuel pump)

1

3

Fuel line (Fuel pump - fuel filter)

1

4

Fuel line (Fuel filter - injection pump)

1

5

Fuel line (Fuel filter - fuel tank)

1

6

Fuel recovery line (Injection pump - fuel filter)

1

7

Fuel recovery line (Between the injectors - injection pump)

3

REPLACEMENT INTERVAL

Every 2 years or 4000 hours, whichever occurs first

★ For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual section regarding the components connected with safety and components that must be periodically replaced. ★ When replacing hoses, always change o-rings, gaskets, and associated components.

3-14

CK35-1

MAINTENANCE STANDARD FLOW HYDRAULIC SYSTEM NO COMPONENTS RELATED TO SAFETY THAT REQUIRE REPLACING

QTY

REPLACEMENT INTERVAL Every 2 years or 4000 hours, whichever occurs first

1

Hydraulic hose (Travel pump supply)

4

2

Hydraulic hose (Machine function pump supply)

1

★ For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual section regarding the components connected with safety and components that must be periodically replaced. ★ When replacing hoses, always change o-rings, gaskets, and associated components.

CK35-1

3-15

MAINTENANCE

NO

COMPONENTS RELATED TO SAFETY THAT REQUIRE REPLACING

QTY

3

Hydraulic hoses (Lift cylinders)

6

4

Hydraulic hoses (Bucket cylinders)

6

5

Hydraulic hoses (Auxiliary hydraulic kit - 2 line)

2

3-16

REPLACEMENT INTERVAL

Every 2 years or 4000 hours, whichever occurs first

CK35-1

MAINTENANCE

SUPER FLOW HYDRAULIC SYSTEM

NO COMPONENTS RELATED TO SAFETY THAT REQUIRE REPLACING

QTY

1

Hydraulic hose (Travel pump supply)

4

2

Hydraulic hose (Machine function pump supply)

1

3

Hydraulic hose (Flow rate increase pump supply)

1

REPLACEMENT INTERVAL

Every 2 years or 4000 hours, whichever occurs first

★ For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual section regarding the components connected with safety and components that must be periodically replaced. ★ When replacing hoses, always change o-rings, gaskets, and associated components.

CK35-1

3-17

MAINTENANCE

NO COMPONENTS RELATED TO SAFETY THAT REQUIRE REPLACING

QTY

4

Hydraulic hoses (Lift cylinder)

6

5

Hydraulic hose (Bucket cylinder)

6

6

Hydraulic hose (Auxiliary hydraulic kit - 3 line)

2

3-18

REPLACEMENT INTERVAL

Every 2 years or 4000 hours, whichever occurs first

CK35-1

MAINTENANCE OPERATORâ&#x20AC;&#x2122;S SAFETY No 1

Components needing replacement Safety belt

CK35-1

Qty

Interval

1

Every 4 years

3-19

MAINTENANCE

TIGHTENING TORQUE STANDARD TORQUE FOR BOLTS AND NUTS

Thread diameter (mm)

Pitch (mm)

6 8 10 12 14

1 1.25 1.5 1.75 2

16 18 20 22 24 27 30

Property class designation

Wrench size (mm)

8.8

10.9

N•m

N•m

10 13 17 19 22

9.5 ± 1 23 ± 2 45 ± 4.9 77 ± 8 122 ± 13

13.5 ± 1.5 32.2 ± 3.5 63 ± 6.5 108 ± 11 172 ± 18

2 2.5 2.5 2.5 3

24 27 30 32 36

191 ± 21 262 ± 28 372 ± 40 511 ± 57 644 ± 70

268 ± 29 366 ± 36 524 ± 57 719 ± 80 905 ± 98

3 3.5

41 46

945 ± 100 1287 ± 140

1329 ± 140 1810 ± 190

SPECIFIC TORQUES

This torque table is not valid for bolts or nuts that contain nylon parts or spring washers.

Item

Description

N•m

Cab

Rear fastening bolts

98 ± 7.3

Wheels

Front Rear

186± 9.8 186± 9.8

Engine

Front support bolt Rear support bolt

186 ± 9.8 186 ± 9.8

3-20

CK35-1

MAINTENANCE

MAINTENANCE PLAN WHEN REQUIRED ITEM

DESCRIPTION

OPERATION

PAGE

a.

Engine air cleaner

Check, clean or change

24

b.

Parking brake

Release

26

c.

Fuel tank

Drain condensate

25

d.

Rubber tracks

Checking for wear

28

e.

Battery

Check charge level

27

f.

Rubber track tension

Check and adjust

30

g.

Rubber track

Changing

33

CHECKS BEFORE STARTING ITEM

DESCRIPTION

OPERATION

PAGE

a.

Various checks

Check

35

b.

Fuel tank

Check and top off

36

c.

Coolant

Check and top off

41

d.

Engine oil

Check and top off

41

e.

Hydraulic oil tank

Check and top off

38

f.

Water separator

Drain water

39

g.

Electrical system

Check

39

AFTER THE FIRST 50 HOURS OF OPERATION ITEM

DESCRIPTION

OPERATION

PAGE

a.

Front and rear carriage fasteners

Check torque

47

b.

Hydraulic oil drain filter (only for machines filled with biodegradable oil)

Change cartridge

50

EVERY 50 HOURS OF OPERATION ITEM

DESCRIPTION

OPERATION

PAGE

a.

Rubber tracks

Check tension

40

b.

Radiator

Check level

41

c.

Reduction gears

Checking oil level

41

CK35-1

3-21

MAINTENANCE

MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION ★ Perform these operations together with those to be initiated every 250 HOURS .

ITEM a.

DESCRIPTION Hydraulic oil drain filter

OPERATION Change

PAGE 50

EVERY 250 HOURS OF OPERATION ITEM

DESCRIPTION

OPERATION

PAGE

a.

Fan belt

Check condition and tension

42

b.

Radiator

Clean outside

43

c.

Pivot points

Lubricate

44

d.

Engine oil

Change

45

e.

Engine oil filter

Change

46

f.

Front and rear carriage fasteners

Check torque

47

AFTER THE FIRST 500 HOURS OF OPERATION ★ Only for machines in which synthetic biodegradable oil, type HEES is used. Perform these operations together with those to be initiated every 500 HOURS. ITEM a.

DESCRIPTION Hydraulic oil and suction filter (only for machines filled with biodegradable oil)

OPERATION Change oil and clean filter

PAGE 55

EVERY 500 HOURS OF OPERATION ITEM

DESCRIPTION

OPERATION

PAGE

a.

Fuel filter

Change cartridge

49

b.

Hydraulic oil drain filter

Change cartridge

50

c.

Water separator

Clean

52

d.

Hydraulic oil tank (only for machines filled with biodegradable oil)

Drain condensate

e.

Reduction gears

Change oil

3-22

53

51

CK35-1

MAINTENANCE

EVERY 1000 HOURS OF OPERATION ITEM

DESCRIPTION

OPERATION

PAGE

a.

Hydraulic oil and suction filter

Change oil and filter

55

b.

Engine valves

Check clearance, adjust

57

EVERY 2000 HOURS OF OPERATION ITEM

DESCRIPTION

OPERATION

a.

Coolant

Change

58

b.

Suction filter

Change

60

c.

Alternator and starter

Check

61

CK35-1

PAGE

3-23

MAINTENANCE

WHEN REQUIRED AIR CLEANER CARTRIDGE

Remove the air cleaner only after stopping engine, and do not start engine after the air cleaner is removed. Always wear safety goggles during cleaning operations. â&#x2DC;&#x2026; The air filter system consists of a primary filter element with considerable capacity and of a secondary cartridge that ensures additional safety protection. The primary element can be cleaned with compressed air, while the cartridge must be replaced. The filter must be cleaned when the clogging warning light A positioned on the instrument panel comes on or flashes.

The air cleaner can be reached after raising the engine hood and opening the rear panel. To clean the primary element, proceed as follows: 1. Release safety locks b, moving them toward the outside and remove the filter cover c.

2. Remove the main filtering element d.

3. Lightly tap the filter element d on the palm of your hand, in a manner to remove the dust, and blow compressed air on the inner surface, keeping the air jet at a distance of approximately 15 cm (5.9 in.) and taking care to prevent pressure from exceeding 4 to 5 kg/ cm² (58-73 psi).

4. Carefully clean the inside of the filter case e, taking care to prevent foreign debris from getting into the suction duct and reassemble the unit making sure that the ejector is positioned vertically and at the bottom.

If the clogging warning light comes on after starting the engine, it is necessary to replace the primary filter element and safety cartridge.

Replace the primary filter element after 5 cleaning operations or after one year. Every time the primary filter element is replaced, the safety cartridge must also be replaced.

3-24

CK35-1

MAINTENANCE To change the safety cartridge, after removing the primary element, then proceed as follows: 5. Remove the safety cartridge f and replace it with a new one.

6. Once the safety cartridge f has been installed inside the filter case e, make sure that it is perfectly seated in its housing.

7. Reassemble the unit as described above, making sure that all filter components are perfectly locked.

8. Push the safety locks b toward the housing.

DRAINING THE FUEL TANK

When draining the fuel tank, avoid spilling fuel, since this may cause fires.

If some fuel is accidentally spilled, clean the dirty area immediately, to prevent it from getting slippery and to avoid fires.

This operation serves to let all the impurities and the condensate flow out of the tank.

Proceed as follows: 1. Raise the engine hood (See “ENGINE HOOD” on page 2-51).

2. Open the valve (1), using the lever (2) supplied with the machine.

3. Turn the extension (2) counterclockwise, until clean fuel flows out.

4. Turn the extension (2) clockwise to stop the fuel flow.

5. Close the engine hood (See “ENGINE HOOD” on page 2-51) and put the extension (2) in the technical documentation case (See “TECHNICAL DOCUMENTATION CASE” on page 2-58).

The tank must be drained before starting the engine, with temperatures exceeding 0ºC (32°F); when the temperature is below 0ºC (32°F), the tank must be drained at the end of work or in any case with the machine at operating temperature, to prevent the condensate from freezing.

The condensate and the impurities that may have accumulated inside the tank must be eliminated before refueling.

CK35-1

3-25

MAINTENANCE RELEASING THE PARKING BRAKE

In case of failure of the hydraulic system and before moving the machine, release the negative brake installed on the travel motors.

The release of the parking brake is obtained by acting on the negative brake installed on the travel motors, according to the following procedure.

1. Raise the cab (See “TILTING THE CAB” on page 2-54).

2. Disconnect the pipe (1) that supplies pressure to the travel motors.

3. Connect a grease nipple (3) to the union (2).

4. Using a grease pump, inject grease until reaching the minimum pressure required to release the brake.

5. After releasing the brake, carry out the necessary maintenance operations.

6. To restore the braking circuit to the standard configuration, remove the grease nipple (3) from the coupling (2) and put back the pipe (1).

7. Lower the cab (See “TILTING THE CAB” on page 2-54).

After restoring the circuit to the standard configuration, it is not necessary to make any adjustments.

3-26

CK35-1

MAINTENANCE CHECKING THE BATTERY CHARGE LEVEL

Check the battery charge level only with the engine stopped.

To prevent gas explosions, do not use open flames, do not smoke, and avoid producing sparks due to short circuits.

The battery electrolyte is dangerous: in case of contact with the eyes or the skin, wash with plenty of running water and consult a doctor. The battery is maintenance-free.

Make sure that the connection terminals are not oxidized; if necessary, clean them and cover them with anti-oxidation grease.

The battery (1) can be reached after opening the engine hood (See “ENGINE HOOD” on page 2-51).

The change of color of the indicator shows the battery charge level, according to the table positioned beside the indicator itself: - Green: the charge is correct - Grey: the battery needs recharging - White: the battery must be changed

If a dry battery is installed, check the electrolyte level, which must be approximately 6 mm above the edge of the plate ; if necessary, top off using distilled water only.

If, on the contrary, the level is low because some electrolyte has been spilt, add sulphuric acid, dilute as much as necessary to reach the concentration suitable for the ambient temperature (See “FUEL, COOLANT AND LUBRICANTS” on page 3-6).

It is advisable to add distilled water before starting work, to prevent it from freezing.

Before putting back the cell plugs, make sure that the breather holes are not clogged.

CK35-1

3-27

MAINTENANCE CHECKING THE RUBBER TRACKS Change the rubber tracks upon reaching the indicated wear limits.

1. When the height "A" of the rubber claw is less than 5 mm (3/16â&#x20AC;?) the track may slip and its traction force reduced.

1 - Roller 2 - Rubber track

2.

When the steel core (3) is visible in two or more points of the track.

3.

When more than half of the steel core cords at the center of the track are cut.

4.

When one or more steel cores (4) have come off the track or are pushed out due to excessive tension.

3-28

CK35-1

MAINTENANCE 5.

If the rubber track cannot be tensioned correctly through the injection of grease, check the track tensioner seals and if necessary change them or the track.

(See "4.8.1.f CHECKING AND ADJUSTING THE RUBBER TRACK TENSION").

Do not exceed the tension indicated in the figure.

6.

If the broken area between the rubber track support claws reaches a length (1) of approximately 60 mm (2-3/8 in), the track must be repaired.

It must also be immediately repaired when the steel cores are visible, even if the broken area is very small.

If the length of the broken area (2) is less then 30 mm or its depth is less than 10 mm (.39 in), it is not necessary to repair the track.

For any repair or replacement, contact your Komatsu Distributor.

CK35-1

3-29

MAINTENANCE *

CHECKING AND ADJUSTING THE RUBBER TRACK TENSION

This operation must be carried out by two people. One operator must be seated in the cab and maneuver the machine following the signals of the other operator who performs the check and adjustment.

The track tension must be checked with the frame raised from the ground; be careful not to shift any control lever while the operator is carrying out the check.

The wear of the rubber tracks may vary according to the operating conditions and to the type of ground on which the machine works, therefore it is necessary to check the wear and tension of the tracks frequently. To carry out the check and the corresponding maintenance operation, stop the machine on firm and level ground.

In particular, on new machines or after the installation of new tracks, it is advisable to carry out a first check after 30 hours of operation. Adjusting the track tension frequently until the initial slackening doesn't occur repeatedly will prevent the track from coming off due to insufficient tension.

If the machine works with slackened rubber tracks, they may come off and cause the untimely wear of the steel cores.

CHECK PROCEDURE 1.

2.

3.

4.

5.

Stop the machine on a firm and level surface and lower the bucket to the ground.

Raise the front part of the machine, pushing the bucket blade against the ground until the front idler roller reaches a height of approximately 75 mm (2.95 in) from the ground.

Move the machine slowly forward to create any slack.

Stop the engine.

Measure the slack between the contact surfaces of the central track rollers and the track rolling guide. The standard slack must be between 15 and 20 mm (9/16 and 13/16 in).

If the slack is not within the standard values, adjust it accordingly.

NOTE Check both tracks.

Adjust the support "A" at a minimum distance of 5 mm (.2 in) from the track surface, with the machine resting on the ground.

When using the machine on SANDY GROUND, mainly on level surfaces, it is advisable to reduce the tension to a maximum of 40 mm (1.57 in), to prolong the life of the components.

If the machine works on slopes exceeding 10°, it is advisable to adjust the tension to the usual values of 15-20 mm (9/1613/16 in).

3-30

CK35-1

MAINTENANCE *

ADJUSTMENT

The grease contained in the hydraulic cylinder is pressurized.

For this reason, do not give the grease valve (1) more than 5 turns when loosening it; in fact, if the valve is loosened excessively it may be pushed out due to the grease pressure and this is very dangerous for the operator. Do not loosen any component apart from the valve (1). If the rubber track tension doesn't decrease after this operation, contact your Komatsu distributor.

If the resistance met when injecting the grease is excessive, move the track slowly covering a short distance.

To adjust the rubber tracks, position the machine by proceeding as described below: 1. Stop the machine on a firm and level surface and lower the bucket to the ground.

2. Raise the front part of the machine, pushing the bucket blade against the ground until the front idler roller reaches a height of approximately 75 mm (2.95 in) from the ground. Position two stands or safety blocks under the frame.

3. With the aid of a crane or a lift truck, raise the rear part of the machine until the rear idler roller reaches a height of approximately 75 mm (2.95 in) from the ground. Position two stands or safety blocks under the frame.

4. Slowly lower the machine onto the stands or safety blocks, making sure that it is in a stable and safe position.

To increase the tension 1.

2.

Loosen the screws and remove the cover over the adjusting device (2). Use a 5 mm Allen wrench.

Carefully clean the grease valve (1) and inject grease through the grease nipple until the tension reaches the correct value. If the injection of grease doesn't proceed smoothly, move the track slowly over a short distance.

CK35-1

3-31

MAINTENANCE To decrease the tension

It is extremely dangerous to let the grease out without following the one indicated below.

If the rubber track tension doesn't decrease after this operation, contact your Komatsu Distributor.

1.

2.

3.

4.

5.

After removing the cover over the adjusting device (2), gradually loosen the grease valve (1) to let the grease out; do not give the valve more than five turns.

Use a 5 mm Allen wrench and a 22 mm hexagon wrench.

If the grease doesn't come out smoothly, move the track slowly over a short distance.

Tighten the valve (1) and remove any trace of grease.

Move the track forward and backward and, after stopping it, check that the tension is correct.

If the rubber track cannot be tensioned enough by injecting grease, it is necessary to change the track or the track tensioner seals.

For any repair or replacement, contact your Komatsu Distributor.

The wear of the rubber tracks may vary according to the operating conditions and the type of ground on which the machine works (see "3.13.7 USING THE RUBBER TRACKS").

Therefore it is necessary to check the track tension frequently and to adjust it when necessary.

After the installation of new tracks, it is advisable to carry out a first check after 50 hours of operation.

3-32

CK35-1

MAINTENANCE CHANGING THE RUBBER TRACKS

This operation must be carried out by two people. One operator must be seated in the cab and maneuver the machine following the signals of the other operator who carries out the change and the adjustment.

The track tension must be checked with the frame raised from the ground; be careful not to shift any control lever while the operator is carrying out the check.

During the change do not remove any component other than the track.

If the rubber track tension doesn't decrease after this operation, contact your Komatsu distributor for the necessary repairs.

REMOVING THE TRACK

The grease contained in the hydraulic cylinder is pressurized.

For this reason, do not give the grease valve (1) more than 5 turns when loosening it; in fact, if the valve is loosened excessively it may be pushed out due to the grease pressure and this is very dangerous for the operator.

Do not loosen any component other than the valve (1). If the rubber track tension doesn't decrease after this operation, contact your Komatsu distributor.

When installing or removing the tracks, make sure that the grease contained in the cylinder has been removed before turning the sprocket.

Secure the machine in the correct position by placing support blocks under the front and rear part of the frame.

Stop the machine on a firm and level surface and lower the equipment to the ground.

Raise the machine approximately 75 mm (2.95 in) from the ground and secure it in this position by placing safety blocks under the frame.

Follow the same procedure indicated for the adjustment of the track tension.

1. Loosen the screws and remove the cover over the adjusting device (2).

Use a 5 mm Allen wrench.

2. Gradually loosen the grease valve (1) to let the grease out; do not give the valve more than five turns. Use a 22 mm hexagon wrench.

Remove any trace of grease.

3. If the grease doesn't come out smoothly, move the track slowly over a short distance.

4. Introduce steel tubes (3) in the track, turn the sprocket in reverse (4), so that the steel tubes move with the track and become engaged with the front idler roller; slide the track sideways (5), and remove it.

CK35-1

3-33

MAINTENANCE INSTALLING THE TRACK 1.

2.

3.

4.

5.

6.

7.

Before installing the track, make sure the grease contained in the track tensioner cylinder has been removed.

Install the rubber track on the sprocket, fitting the drive blocks, insert the guides in the seat of the rear idler roller and guide the track until it is in the correct position on the front idler roller.

Slowly turn the sprocket in reverse (1) while pushing the track towards the machine frame.

Using a steel tube (2), position the track guides correctly in the seat of the front idler roller and turn the sprocket again in reverse (1).

Make sure that the track is correctly positioned on the sprocket, track rollers and idler rollers.

Adjust the track tension following the procedure and keeping to the values indicated in "4.8.1.f CHECKING AND ADJUSTING THE RUBBER TRACK TENSION".

Lower the machine until the tracks rest on the ground.

3-34

CK35-1

MAINTENANCE

CHECKS BEFORE STARTING VARIOUS CHECKS

Dirt, oil, and fuel spread in the engine compartment near hot areas may cause fires and damage the machine. Check to see if there are frequent leaks, and perform any necessary repairs immediately. If this occurs repeatedly, contact your distributor.

Before starting the engine, check the following: 1. Check for loose screws or nuts.

2. Check for oil, fuel or coolant leakage.

3. Check for worn equipment.

4. Check condition of wheel rims, and condition and wear of the tires.

5. Check condition and efficiency of instruments and warning lights on the dashboard, working lights and direction indicators.

The other general checks concern safety, and functionality: 1. Soundness of the safety belt.

2. Clearness and legibility of the warning decals.

3. Cleanliness of the ladders and hand rails used to reach the drivers seat, cleanliness inside the operator’s compartment.

CHECKING THE COOLANT LEVEL

Carry out this check with the machine parked on a level surface and the equipment resting on the ground.

Do not remove the radiator cap; the coolant level must be checked in the coolant reservoir with the engine cold.

The coolant reservoir (1) can be reached by raising the engine hood (See “ENGINE HOOD” on page 2-51) and opening the rear panel (See “REAR PANEL” on page 2-52). The coolant level must fall between the MIN. and MAX. marks.

If necessary, add coolant and, if a constant and considerable decrease in the fluid level is noticed, check the tightness of the radiator-engine unit and of the radiator.

CK35-1

3-35

MAINTENANCE CHECKING THE FUEL LEVEL

When refueling, avoid spilling fuel to prevent any risk of fire.

If some fuel should inadvertently be spilled, clean the dirty area immediately.

Fuel is flammable; neither use open flames, nor smoke while refueling.

Place the fuel nozzle into the filler neck when refueling.

To check the fuel level, use the indicator (1) positioned on the dashboard, after turning the ignition key to position «I».

To refuel, if necessary, open the engine hood (See “ENGINE HOOD” on page 2-51).

Do not fill the tank completely, in order to leave room for the fuel to expand.

It is advisable to refuel after work, in order to avoid the formation of water condensate.

After refueling, tighten the filler cap (2) thoroughly, lower the engine hood, and lock it.

3-36

CK35-1

MAINTENANCE ENGINE OIL LEVEL

After the machine is stopped, the engine is very hot. Let the engine cool down before performing any check. Hot engines may cause burns. If it is necessary to check the oil level during or soon after work, stop the engine and wait for 15 minutes before checking.

The dipstick b can be reached after opening the engine hood. The check must be performed with a cold engine and the machine located on level ground.

The oil level can be checked on the graduated dipstick b and must be between MIN. and MAX. marks. If the level is near the MIN. mark, top off with oil, through filler tube c, of the same brand, suitable for the ambient temperature, as prescribed in the lubricant chart (See â&#x20AC;&#x153;FUEL, COOLANT AND LUBRICANTSâ&#x20AC;? on page 3-6).

CK35-1

3-37

MAINTENANCE HYDRAULIC SYSTEM OIL LEVEL

The oil level in the hydraulic system must be checked with cold oil and the machine positioned on a level surface and the bucket resting on the ground. If it is necessary to top off, stop the engine and then eliminate the residual pressures present in the work equipment by moving the controls more than once and in the tank by slowly loosening the filler cap.

When adding oil, do not exceed the MAX level. This would damage the hydraulic system and cause oil to overflow. If a constant or abnormal decrease of the oil level is observed, thoroughly check the hydraulic system, the pistons, and the pump for leaks. After topping off, tighten the hydraulic tank cap completely.

To check the oil level in the hydraulic circuit, open the rear panel (See “REAR PANEL” on page 2-52). The oil level must be visible through the gauge (1) positioned on the tank and must be between the MIN. and MAX. marks. If the level is near the MIN. mark, top off through the filler opening (2) with suitable hydraulic oil (See “FUEL, COOLANT AND LUBRICANTS” on page 3-6), after removing the cap. Reinstall and tighten the cap after topping off.

3-38

CK35-1

MAINTENANCE DRAINING WATER SEPARATOR

Fuel is flammable; do not use open flames and do not smoke while draining the water separator. If some fuel is spilled, wipe it up immediately.

The water separator can be reached after opening the engine hood (See “ENGINE HOOD” on page 2-51). The check must be carried out by means of the red ring (1) installed in the filter.When the red ring floats on the surface of the water contained in the water separator, it is necessary to drain it. Provide a suitable container to catch the drained liquid.

Proceed as follows: 1. Turn the valve (2) to close the fuel flow.

2. Loosen the wing nut (3) and drain the condensate until clear diesel fuel flows out. Close the wing nut (3).

3. Open the valve (2).

4. Drain the fuel tank as described in paragraph See “DRAINING THE FUEL TANK” on page 3-25.

5. Bleed the fuel supply circuit as described in paragraph See “CHANGING THE FUEL FILTER” on page 3-49.

6. Properly dispose of the drained liquid.

If the filtering element is considerably clogged or damaged, change it.

CHECKING THE WIRING SYSTEM

If the fuses are corroded, oxidized or they are not perfectly held in their seat, replace them only with fuses having the same capacity; before changing a fuse, make sure that the ignition key is in position «O».

If there are signs of short circuits on the cables, find the cause and repair them; always contact your Komatsu distributor for troubleshooting.

Before checking the wiring, take all the necessary precautions to ensure safety.

Make sure that there are no disconnected cables or signs of short circuits in the electrical system. Make sure that all the cables are well tightened in the corresponding terminals; tighten any loose cables.

CK35-1

3-39

MAINTENANCE

MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION These maintenance operations must be carried out after the first 50 hours of operation, together with those to be carried out “EVERY 50 HOURS”. ★ CHECK THE TIGHTNESS OF THE CARRIAGE TO FRAME BOLT TIGHTNESS ★ CHANGE THE HYDRAULIC OIL DRAIN FILTER (only for machines filled with biodegradable (HEES) oil) For details on the various maintenance operations, see sections See “EVERY 250 HOURS OF OPERATION” on page 3-22 and See “EVERY 500 HOURS OF OPERATION” on page 3-22.

MAINTENANCE EVERY 50 HOURS OF OPERATION CHECKING THE RUBBER TRACK TENSION

This operation must be carried out by two people. One operator must be seated in the cab and maneuver the machine following the signals of the other operator who carries out the check and adjustment.

The track tension must be checked with the frame raised off the ground; be careful not to shift any control lever while the operator is carrying out the check.

The wear of the rubber tracks may vary according to the operating conditions and the type of ground on which the machine works, therefore it is necessary to check the tension of the tracks regularly.

To carry out the check, stop the machine on firm and level ground.

In particular, on new machines or after the installation of new tracks, it is advisable to carry out a first check after 30 hours of operation. Regular checks will prevent the tracks from coming off and the steel cores from wearing out due to insufficient tension.

CHECK 1.

2.

3.

4.

5.

Stop the machine on a firm and level surface and lower the bucket to the ground.

Raise the front part of the machine, pushing the bucket blade against the ground until the front idler roller reaches a height of approximately 75 mm (2.95 in) from the ground.

Move the machine slowly forward to create any slack.

Stop the engine.

Measure the slack between the contact surfaces of the central track rollers and the track rolling guide. The standard slack must be between 15 and 20 mm (9/16 and 13/16 in).

If the slack is not within the standard values, adjust it accordingly.

(See "4.8.1.f CHECKING AND ADJUSTING THE RUBBER TRACK TENSION").

3-40

CK35-1

MAINTENANCE CHECKING THE COOLANT LEVEL IN THE RADIATOR

Carry out this check with the machine parked on a level surface and the equipment resting on the ground. Do not remove the radiator cap when the fluid is hot, since it may be sprayed out violently and cause burns. Loosen the cap slowly in order to release the pressure before removing it.

The radiator cap can be reached after raising the engine hood (See “ENGINE HOOD” on page 2-51). Remove the cap (1) and make sure that the fluid level reaches the filling hole.

If the fluid level in the radiator is low and the expansion tank is full of coolant, check the tightness of the radiator cap and make sure that there is no air leakage from the radiator to expansion tank hose. If this cap looseness occurs repeatedly, contact your distributor.

CHECKING THE OIL LEVEL IN THE TRAVEL MOTOR

Carry out the check with the machine parked on a firm and level surface and the bucket resting on the ground.

Right after the machine is stopped the oil is very hot; allow it to cool down to 40-45°C (104-113°F) before performing the check.

This check must be carried out on each travel motor positioned with the plug (1) at a distance of 20 mm (.79 in) from the horizontal axis, as shown in the figure. If necessary, move the machine slightly until reaching the specified position, which is necessary for an accurate check.

Remove plug (1), check for the oil level to be at the bottom of the hole; if necessary, remove the plug (2) and top off using the prescribed oil (see "4.3 FUEL, COOLANT AND LUBRICANTS").

Put back plugs (1) and (2).

Use an 8 mm Allen wrench.

CK35-1

3-41

MAINTENANCE

FIRST 250 HOURS OF OPERATION Perform the following maintenance after the first 250 hours, together with those to be initiated EVERY 250 HOURS. ★ HYDRAULIC OIL DRAIN FILTER For details on the various maintenance operations, ★ See “EVERY 500 HOURS OF OPERATION” on page 3-22.

EVERY 250 HOURS OF OPERATION These operations must be carried out together with those to be carried out See “EVERY 50 HOURS OF OPERATION” on page 3-21.

FAN BELT TENSION The fan belt can be reached after opening the engine hood, See “ENGINE HOOD” on page 2-51 The test is manual: press the belt b with your thumb on the indicated point with a force equal to about 10 kg (22 lb.) N; the resulting deflection must be about 10 to 15 mm (0.4-0.6 in). If the deflection exceeds this value, loosen the bolt c that fastens the alternator d and, with a lever inserted between the engine block and casing, move the alternator.

Lock the bolt and check again. Use a 12 mm wrench.

A Fan pulley B

Driving shaft puller

C

Alternator pulley

If the belt is worn, replace it and check the tension again after a few hours of operation.

3-42

CK35-1

MAINTENANCE CLEANING THE OUTSIDE OF THE RADIATORS

If compressed air, steam or water are directed against a person, they may cause injuries. Always wear an eye shield and safety shoes.

The radiator/hydraulic oil cooler can be cleaned after opening the rear panel (See â&#x20AC;&#x153;REAR PANELâ&#x20AC;? on page 2-52), using a compressed air jet and, if necessary, carrying out a washing cycle with low pressure water or steam; the specific detergents available on the market can be used, provided that the instructions given on the package are followed and that at the end of the operations the washed parts are rinsed and dried.

Do not use products containing petroleum products, even if in slight quantities, since these promote the sticking of dust, which reduces the heat exchange process. Clean the outside of the radiators whenever the radiator and the hydraulic oil cooler are dirty, even if accidentally, with oil, diesel oil, greasy or oily substances. If the machine is used in dusty places, clean the radiator/hydraulic oil cooler more frequently, to avoid the clogging of the fins.

CK35-1

3-43

MAINTENANCE LUBRICATING THE JOINTS

Clean the grease nipples before applying the grease pump. After lubrication, remove any excess grease.

If the machine is used in difficult conditions, perform these maintenance operations more frequently.

These maintenance operations must be carried out with the arm completely lowered and the bucket resting on the ground. For the lubrication, use a grease pump and the recommended grease. (See â&#x20AC;&#x153;FUEL, COOLANT AND LUBRICANTSâ&#x20AC;? on page 36).

As a general rule, consider that each cylinder is provided with two grease nipples positioned on the couplings and that each pin serving as fulcrum for a movement is provided with at least one grease nipple.

EQUIPMENT LUBRICATION POINTS

3-44

1 - Bucket coupling pin

(2 points)

2 - Tool-holder plate fulcrum pin

(2 points)

3 - Bucket cylinder head pin

(2 points)

4 - Bucket cylinder base pin

(2 points)

5 - Lifting cylinder head pin

(2 points)

6 - Arm fulcrum pin

(2 points)

7 - Lifting cylinder base pin

(2 points)

CK35-1

MAINTENANCE CHANGING THE ENGINE OIL

Immediately after the engine has been shut off the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40-45°C (104-113°F) before draining the oil.

The oil that may be spilled during the change makes the ground slippery, therefore, use anti-slip shoes and immediately remove any trace of oil from the floor.

Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force.

Drain the oil after positioning the drain hose outside the engine compartment.

Change the engine oil at the same time as the engine oil filter (See “CHANGING THE ENGINE OIL FILTER” on page 3-46). This operation must be carried out with the machine parked on firm and level ground and performing the following steps: 1. Detach the lower cover (1) after removing the fastening screws (2).

Use a 17 mm wrench.

2. Extract the oil drain flexible hose (3) from the lower opening.

3. Raise the engine hood (See “ENGINE HOOD” on page 2-51).

4. Remove the drain plug (4) from the drain hose (3), gathering the used oil that flows out into a container with suitable capacity. Use a 27 mm wrench. While the oil flows out, remove the filler cap (5), so that the oil can flow freely.

5. After the oil has completely drained from the pan, screw the drain plug (4) back into the drain hose, tuck the drain hose away. Pour the specified quantity of new oil into the pan, using the dipstick (6) to make sure that the oil reaches the MAX. level.

6. Replace the filler cap (5), start the engine, let it run for 5 minutes and then stop it. Check the level again and top off, if necessary.

7. Assemble the lower cover (1).

8. Close the engine hood.

Use oil suitable for the ambient temperature (See “FUEL, COOLANT AND LUBRICANTS” on page 3-6).

After the oil change and after removing any trace of oil, put the drain hose back inside the engine compartment.

CK35-1

3-45

MAINTENANCE Some versions of the machine come with special safety drain plugs. To change the oil proceed as follows: Remove the plug (7), apply the special union provided and turn manually until the oil drains. Carry out the change procedures described for the standard version. At the end of the operation, remove the special union and put it in the appropriate tool container.

Reassemble the plug (7).

CHANGING THE ENGINE OIL FILTER

Immediately after the engine has stopped, the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40-45°C (104-113°F) before draining the oil. The oil that may spill during the change makes the ground slippery, therefore, use anti-slip shoes and immediately remove any trace of oil from the floor. Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force.

This operation must be carried out during every oil change.

Proceed as follows: 1. Raise the engine hood (See “ENGINE HOOD” on page 2-51).

2. Drain the engine oil (See “CHANGING THE ENGINE OIL” on page 3-45) into a suitable container.

3. Position a container below the filter to catch any oil. Unscrew the used filter (1) with the special wrench provided and dispose of it properly.

4. Clean the contact surface between the seal and the filter base (2).

5. Lubricate the seal of the new filter and screw on until the filter contacts the base.

6. Give the filter a further half turn by hand.

7. Fill the engine with new oil and complete the operations as described in, See “CHANGING THE ENGINE OIL” on page 3-45.

Start the engine, make sure that there is no leakage and that the oil pressure warning light goes out.

Close the engine hood.

Do not use the wrench to tighten the filter, since this may cause damage and result in oil leaks.

3-46

CK35-1

MAINTENANCE CHECKING THE TORQUE OF THE BOLTS AND NUTS THAT FASTEN THE CARRIAGES TO THE MACHINE FRAME

On new machines, check the torque after the first 50 hours of operation and successively every 250 hours of operation.

This operation must be carried out on both sides, with the machine parked on firm and level ground.

Before carrying out the check, raise the loader arm and secure it with the safety lock (see "3.1.1 LOADER LOCKS").

The check must be carried out using a torque wrench calibrated according to the value indicated in paragraph "4.4.2 SPECIFIC DRIVING TORQUES FOR SCREWS AND NUTS" and serves to restore the driving torque of the nuts (1) and screws (2) that fasten the carriage to the machine frame. Use 22 and 24 mm wrenches.

NOTE Do not lubricate the threads when the torque must be checked.

The check must be carried out on both the front and rear carriages on each side.

If the entire carriage has been removed, before reassembling it contact your Komatsu distributor and ask for precise instructions regarding the correct procedure for fastening bolts and nuts.

CK35-1

3-47

MAINTENANCE

MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION ★ (Only for machines filled with synthetic biodegradable oil type HEES) ★ The following maintenance operation must be carried out after the first 500 hours of operation, together with those to be carried out EVERY 500 HOURSî.

• HYDRAULIC OIL CHANGE AND CLEANING OF THE SUCTION FILTER For details on the various maintenance operations, See “EVERY 1000 HOURS OF OPERATION” on page 3-23î.

3-48

CK35-1

MAINTENANCE

MAINTENANCE EVERY 500 HOURS OF OPERATION These operations must be carried out together with those to be carried out EVERY 50 and 250 HOURS.

CHANGING THE FUEL FILTER

Change the filter element after work and after the engine has cooled down to 40-45°C (104-113°F). When this operation is performed, fuel may spill; clean the spill immediately, to prevent any risk of slipping or fire. Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force.

The fuel filter and the fuel pump can be reached by opening the engine hood (See “ENGINE HOOD” on page 2-51).

FUEL FILTER 1.

2.

3.

4.

5.

Clean the outside of the filter and then unscrew the used filter (1) with the special wrench provided and dispose of the filter properly.

Clean the inside of the head (2).

Lubricate the new filter seal and screw on until the seal contacts the base.

Give the filter a further half turn by hand.

Bleed the fuel supply circuit.

BLEEDING THE CIRCUIT After filling the tank, turn the ignition key to position «I» and wait for approximately 15-20 seconds, to bleed the fuel supply circuit.

After bleeding the circuit, turn the ignition key to position « » for a few seconds and wait at least 2 minutes before starting the engine. If the engine starts without problems and then stops or runs irregularly, check if there is air in the circuit; if so, check the tightness of the fuel filter and of the fuel pump prefilter.

If the machine has run out fuel, bleed the circuit by proceeding as described above and repeat the operation at least 2-3 times after filling the tank.

CK35-1

3-49

MAINTENANCE CHANGING THE HYDRAULIC OIL DRAIN FILTER

Immediately after the engine has stopped the hydraulic oil is very hot; let it cool down until it reaches a temperature of 4045°C (104-113°F) before changing the filter. The hydraulic system is pressurized; loosen the filling cap slowly to release the residual pressure. Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force.

On new machines, change the hydraulic oil filter cartridge after the first 250 hours of operation and successively every 500 hours. On machines filled with synthetic biodegradable oil type HEES, the first change must be carried out after the first 50 hours of operation and the successive changes every 500 hours.

The filter is positioned on the hydraulic system drain outlet and blocks the metal particles that come off the various components due to their wear. The filter can be reached after opening the rear panel (See “REAR PANEL” on page 2-52).

To change it, proceed as follows: 1. Slowly loosen the filler cap (1) to release the residual pressure from the tank and then remove the cap.

2. Unscrew the used filter (2) and discard it.

3. Clean the contact surface between the seal and the filter base (3), lubricate the seal of the new filter and screw on until the seal contacts the base.

4. Give the filter a further half turn by hand.

5. Close the rear panel.

6. Check for oil leaks after running the engine.

Do not use the wrench to tighten the filter, since this may cause damage and result in oil leakage. If the machine contains synthetic biodegradable oil type HEES, the filter must be changed after the first 50 hours of operation.

3-50

CK35-1

MAINTENANCE CHANGING THE OIL IN THE TRAVEL MOTORS

Soon after the machine has been stopped the oil is very hot; allow it to cool down to 40-45째C (104-113째F) before carrying out the check. Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of according to the regulations in force.

This operation must be carried out on each travel motor with the machine parked on level ground and at a temperature of 40- 45째C (104113째F), so that the oil becomes fluid and can be easily drained, which facilitates the elimination of any suspended solid particles.

1. Move the machine until the drain and level plug (1) is in its lowest position and vertically aligned with the filling plug (2).

2. Remove the drain plug (1) and let the used oil flow out completely, gathering it into a container with suitable capacity. While the oil flows out, remove the filling plug (2).

Use a 8 mm Allen wrench.

3. Once the oil has been drained, move the machine gradually until the drain and level hole (1) is positioned at a distance of 20 mm (.79 in) from the horizontal axis.

4. Fill through the filling hole (2), using oil of the prescribed type, until reaching the lower edge of the hole (1).

5. Put back the plugs (1) and (2).

Move the machine forward and backward a few times, stop the machine and check the levels again. Always use oil of the prescribed type, (see "4.3 FUEL, COOLANT AND LUBRICANTS").

CK35-1

3-51

MAINTENANCE CLEANING THE WATER SEPARATOR

Change the precleaner at the end of work and after the engine has cooled down to 40-45°C (104-113°F). When these operations are performed, fuel may spill; clean the dirty areas immediately, to prevent any risk of slipping or fire.

The water separator can be reached after opening the engine hood (See “ENGINE HOOD” on page 2-51).

CLEANING THE WATER SEPARATOR. 1. Close the valve (1).

2. Loosen the metal ring (2) and remove the cup (3) and the filtering element, collect the fluid in a container of suitable capacity.

3. Clean the inside of the cup and the filter with diesel oil or oil.

4. Replace the filter and the cup (3), tighten the metal ring (2) and open the valve (1).

When disassembling the water separator, be careful not to lose the red ring contained in the cup. If the filtering element is clogged or damaged, change it.

BLEEDING THE CIRCUIT After filling the tank, turn the ignition key to position «I» and wait for approximately 15-20 seconds, to bleed the fuel supply circuit.

After bleeding the circuit, turn the ignition key to position « » for a few seconds and wait at least 2 minutes before starting the engine. If the engine starts without problems and then stops or runs irregularly, check if there is air in the circuit; if so, check the tightness of the fuel filter and of the fuel pump prefilter.

If the machine has run out fuel, bleed the circuit by proceeding as described above and repeat the operation at least 2-3 times after filling the tank.

3-52

CK35-1

MAINTENANCE DRAINING CONDENSATE FROM THE HYDRAULIC OIL TANK (Only for machines filled with synthetic biodegradable oil type HEES)

Lower the loader arm completely, rest the bucket on the ground and, after stopping the engine, eliminate the residual pressures that may be present in the equipment (by operating the controls more than once) and lock the safety bars (See “SAFETY BARS” on page 2-28). Let the oil cool down until it reaches 40-45°C (104-113°F) before performing any maintenance operation. Immediately clean any area dirty with oil.

Stop the machine on a firm and level surface, lower the equipment to the ground, stop the engine and release the residual pressures that may be present in the equipment by operating the controls more than once.

Raise the engine hood (See “ENGINE HOOD” on page 2-51) and open the rear panel (See “REAR PANEL” on page 2-52).

1. Slowly loosen the filler cap (1) to release the residual pressure from the tank and remove the cap.

2. Position a container of suitable capacity under the drain plug.

CK35-1

3-53

MAINTENANCE 3.

4.

Loosen the lower plug (2) until the condensate has completely drained. Use a 12 mm hexagon wrench.

Retighten the lower plug (2), check the oil level and top off if necessary. Install the filler cap (1) and close the rear panel and the engine hood.

Be careful to only loosen the lower plug enough to allow the condensate to drain and not lose too much hydraulic oil.

The draining of the tank must be carried out at temperatures exceeding 0째C (32째F), before starting the engine; when the temperature is below 0째C (32째F), the hydraulic oil tank must be drained at the end of work, or in any case when the temperature of the machine is high enough to prevent the condensate from freezing and to allow it to flow out of the tank without problems.

3-54

CK35-1

MAINTENANCE

MAINTENANCE EVERY 1000 HOURS OF OPERATION These operations must be carried out together with those to be carried out EVERY 50, 250, 500 HOURS.

CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER

On machines filled with synthetic biodegradable hydraulic oil type HEES the oil must be changed after the first 500 hours of operation and successively every 1000 hours, and in any case at least once a year.

Lower the loader arm completely, lower the bucket to the ground, stop the engine, release the residual pressures from the work equipment circuits (by operating the controls more than once) and lock the safety bars (See “SAFETY BARS” on page 2-28). Let the oil cool down until it reaches 40-45°C (104-113°F) before carrying out any maintenance operation.

Immediately clean any area dirty with oil. Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force.

Stop the machine on a firm and level surface, lower the equipment to the ground, stop the engine and release the residual pressures from the work equipment circuits by operating the controls more than once.

Raise the engine hood (See “ENGINE HOOD” on page 2-51) and open the rear panel (See “REAR PANEL” on page 2-52).

1. Slowly loosen the filler cap (1) to release the residual pressure from the tank and then remove the cap.

CK35-1

3-55

MAINTENANCE 2.

3.

4.

5.

Remove the lower plug (2) and let the used oil flow out completely, gathering it in a container with suitable capacity. Use a 12 mm hexagon spanner.

Once the oil has been drained, disconnect the suction pipe (3) and remove the flange (4) after removing the screws (5). Use a 17 mm hexagon spanner.

Clean the filtering element (6).

Put back the flange (4), the filter (6), the gasket (7) and the lower plug (2).

3-56

CK35-1

MAINTENANCE 6.

Fill the tank with the specified oil until reaching the correct level (8). Use only the prescribed type of oil (See “FUEL, COOLANT AND LUBRICANTS” on page 3-6).

7. Raise the cab (See “TILTING THE CAB” on page 2-54) and make sure that the oil in the hydraulic pump reaches the maximum level.

To do this, remove the upper plug (9) and make sure that the hole is completely filled with oil. Use a 1/2” square drive wrench.

8. If the oil does not reach the maximum level, top off with the specified oil (See “FUEL, COOLANT AND LUBRICANTS” on page 3-6).

9. After the check, lower the cab, install the filler cap (1), close the rear panel and the engine hood and deaerate the system.

10. Make sure that all the control levers are in neutral position and let the engine idle for 2-3 minutes before operating the work equipment. Move each piston more than once to deaerate the system; check level again and top off if necessary.

Never start the engine with an empty tank, since this would certainly damage the pump.

CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE Since the check and adjustment of the engine valve clearance require the use of special tools, have these operations carried out by your distributor.

CK35-1

3-57

MAINTENANCE

MAINTENANCE EVERY 2000 HOURS OF OPERATION Carry out these operations together with those to be performed EVERY 50, 250, 500 and 1000 HOURS.

CHANGING THE COOLANT

The coolant must be replaced every 2000 hours of operation or every 2 years, whichever occurs first.

Immediately after the engine has stopped the coolant is very hot and under pressure and it may cause serious burns; let the engine cool down until it reaches approximately 40-45°C (104-113°F) before changing the coolant.

Slowly loosen the radiator cap, to release the residual pressure.

Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force.

Changing permanent type coolant does not require descaling the system.

1.

2.

3.

4.

Raise the engine hood (See “ENGINE HOOD” on page 2-51) and open the rear panel (See “REAR PANEL” on page 2-52).

Loosen and remove the filler cap (1) of the radiator.

Open the drain cock (2) of the radiator, remove the drain plug (3) positioned on the engine block and let the fluid flow into a suitable size container. Use a 17 mm hexagon wrench. While the fluid flows out, drain the coolant tank (4).

Close the drain cock (2) and install the plug (3) on the engine block. Fill the radiator with new coolant (See “FUEL, COOLANT AND LUBRICANTS” on page 3-6).

3-58

CK35-1

MAINTENANCE 5.

6.

7.

Start the engine and let it idle for a few minutes; check the level again and if necessary top off before putting back the radiator cap (1).

Fill the tank (4) until the coolant reaches the maximum level.

Close the rear panel and the engine hood.

CK35-1

3-59

MAINTENANCE CHANGING THE SUCTION FILTER

Lower the loader arm completely, rest the bucket on to the ground, stop the engine, eliminate the residual pressures that may be present in the equipment (by operating the controls more than once) and lock the safety bars (See “SAFETY BARS” on page 2-28).

Before carrying out any maintenance operation, let the oil cool down until it reaches 40-45°C (104-113°F).

Immediately clean any area dirty with oil.

Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force.

Stop the machine on a firm and level surface, lower the equipment to the ground, stop the engine and release the residual pressures from the equipment by operating the controls more than once.

Raise the engine hood (See “ENGINE HOOD” on page 2-51) and open the rear panel (See “REAR PANEL” on page 2-52).

The suction filter must be changed every two hydraulic oil changes.

1. Slowly loosen the filler cap (1) in order to release the residual pressure from the tank and then remove it.

3-60

CK35-1

MAINTENANCE 2.

3.

4.

5.

6.

Drain the hydraulic oil (See “CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER” on page 3-55).

Once the oil has been drained, disconnect the suction pipe (3) and remove the flange (4) after removing the screws (5). Use a 17 mm hexagon spanner.

Change the filtering element (6).

Put back the flange (4), the filter (6), the gasket (7) and the lower plug (2).

Complete the tank filling operations by proceeding as described in See “CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER” on page 3-55

Never start the engine with an empty tank, since this would certainly damage the pump.

CHECKING THE ALTERNATOR AND THE STARTER For any inspection and/or repair, contact your distributor.

If the engine is started frequently, the alternator and the starter should be inspected every 1000 hours of operation.

CK35-1

3-61

MAINTENANCE

3-62

CK35-1

4SPECIFICATIONS

CK35-1

4-1

SPECIFICATIONS

SPECIFICATIONS STANDARD MACHINE OVERALL DIMENSIONS

The weight of the machine increases by 120 kg (264 lb.) when it is equipped with additional rear counterweights.

If the bucket is provided with teeth, the machine length increases by 100 mm (3.9 in).

With the extended bucket the machine length increases by 130mm.

OVERALL DIMENSIONS WITH STANDARD BUCKET L 2030 mm (6’8”) AND 450 mm (1’6”) RUBBER TRACKS

Unit: mm OVERALL DIMENSIONS WITH STANDARD BUCKET L 1880 MM (6’2”) AND 320 MM (1’1”) RUBBER TRACK

Unit: mm

4-2

CK35-1

SPECIFICATIONS

MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT

The weight of the machine increases by 120 kg (264 lb.) when it is equipped with additional rear counterweights.

OVERALL DIMENSIONS WITH EXCAVATOR (E35-2)

Unit: mm OVERALL DIMENSIONS WITH ASPHALT CUTTER

Unit: mm

CK35-1

4-3

SPECIFICATIONS

TECHNICAL SPECIFICATIONS TOTAL WEIGHT Max. with L 2030 standard bucket and 450 mm(1’6”) track

4320 kg (9504 lb)

Max. with L 1880 standard bucket and 320 mm(1’1”) track

4300 kg (9460 lb)

Max. total mass with E35-2 excavator and 450 mm(1’6”) track

5160 kg (11,352 lb)

Max. total mass with asphalt cutter and 450 mm(1’6”) track

5150 kg (11,330 lb)

BUCKET CAPACITY Standard bucket L 20300 (SAE)

0.448 cu.m. (0.586 cu.yd.)

Narrow bucket L 1880 (SAE)

0.415 cu.m. (0.543 cu.yd.)

ENGINE Komatsu diesel engine model

S4D98E-2NFE

Rated power (2500 rpm EEC 80/1269)

64 kW (85.8 HP)

Maximum torque (1600 rpm EEC 80/1269)

286 Nm (211 lb.ft)

ELECTRICAL SYSTEM Alternator

12 V

Electrical output

40 A

Ground

Negative

Battery

100 Ah-12 V

Starter

3.0 kW (4.02 HP)

SPEED FORWARD GEARS

REVERSE

1

2

1

2

km/h

5.88

9.89

5.88

9.89

MPH

3.65

6.145

3.65

6.145

RUBBER TRACKS SIZE

MAKE

STANDARD TRACK WIDTH

450 MM (1’6”)

OPTIONAL TRACK WIDTH

320 MM (1’1”)

4-4

CK35-1

OPTIONS, ATTACHMENTS

5

Komatsu does not assume any responsibility for the performance of any attachments used on the machine that have not been designed, tested, or manufactured by Komatsu. The attachment manufacturer is solely responsile for any defects or failures, personal injury, or property damage caused by the equipment or its use.

CK35-1

5-1

OPTIONS, ATTACHMENTS

AUTHORIZED OPTIONAL EQUIPMENT Komatsu machines can be supplied with optional equipment in addition to the standard equipment. If optional equipment is installed and used on your machine, read and study all operations and safety information instructions relating to the optional equipment you will be using. Failure to do so may result in damage to the equipment or injury to the operator.

Komatsu cannot be held liable for damage, accident or reduction of machinery performance due to the application and use of unauthorized equipment. Always use authorized equipment on your machine.

BASIC PRECAUTIONS The installation of optional accessories or equipment other than those authorized by Komatsu shortens the life of the machine and may also cause problems concerning safety. It is advisable to contact a Komatsu distributor before installing any accessory not indicated in this operation and maintenance manual. In case of failure to comply with this recommendation, Komatsu declines any responsibility for accidents or damage.

Install or remove optional equipment on a firm level surface.

Be sure the equipment you are installing is in good operating condition.

When operations are performed using two or more personnel, agree to a set communication signals in advance and stick to them.

Always use an overhead crane when lifting equipment weighing more than 25 kg (55 lb.).

Always support any heavy part before removing it. When heavy parts are lifted, be always careful to the position of the center of gravity of the object being handled.

It is very dangerous to carry out any operation with a suspended load; therefore, always position the load on a support and make sure that it is in a safe position.

When installing or removing any equipment, make sure that it is stable and cannot fall down.

Never stand under loads being lifted by a crane. Take care to choose a safe position, where you do not run any risk in case the load should fall down.

Cranes must be operated by specialized personnel. Do not allow non-specialized personnel to use cranes.

For further details regarding installation and removal operations, contact your distributor.

5-2

CK35-1

OPTIONS, ATTACHMENTS

PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT

The use of lengthened work equipment reduces the stability of the machine.

If it is necessary to go up or down a slope, be particularly careful, since the machine may lose its balance and overturn.

When installing work equipment with dimensions exceeding those of the standard equipment, be aware of the space necessary for the movements of the equipment and of the machine.

CK35-1

5-3

OPTIONS, ATTACHMENTS CHARACTERISTICS OF THE STANDARD MACHINE OPTIONAL EQUIPMENT ★ Specific weight of the handled material = 1.8 tons/m³

EQUIPMENT

MAX. WEIGHT

MAX. DIMENSIONS

MAX. SAE CAPACITY

MAX. OPERATING PRESSURE

(cu m)

(bar)

MAX. FLOW RATE (l/min.)

(kg)

Width (mm)

Height (mm)

215

2030

520

0.415

—

—

—

2030

550

—

206

80

1100

● –

S 3200

Excavator —

206

80

Excavator bucket

73

800

—

—

—

—

Hydraulic hammer

150

—

—

—

206

80

Drill

190

¹ 600

—

—

206

80

Pallet fork

160

1500

710

206

—

Manure fork

120

1800

—

—

206

—

Grapple fork

190

1800

—

—

206

80

Front bucket Multi-purpose front bucket Excavator

●

S ¹

5-4

1000

Max. outreach Max. digging depth The value is the drill diameter Max. tooth length

CK35-1

OPTIONS, ATTACHMENTS CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION WITH HIGH FLOW AND SUPER-FLOW HYDRAULIC SYSTEM ★ Specific weight of the handled material = 1.8 tons/m³

EQUIPMENT

MAX. WEIGHT

MAX. DIMENSIONS

MAX. SAE CAPACITY

MAX. OPERATING PRESSURE

(cu m)

(bar)

MAX. FLOW RATE (l/min.)

(kg)

Width (mm)

Height (mm)

215

2030

520

0.415

—

—

—

2030

550

—

206

80

Asphalt cutter

900

1000

—

206

130

Excavator

1100

Front bucket Multi-purpose front bucket

●

S

—

3200

Excavator —

206

80

Excavator bucket

73

800

—

—

—

—

Hydraulic hammer

150

—

—

—

206

80

Drill

190

¹ 600

—

—

206

80

Pallet fork

160

1500

710

1000

206

—

Manure fork

120

1800

—

—

206

—

190

1800

—

—

206

80

Grapple fork ● Max. outreach S Max. digging depth

¹

The value is the drill diameter Max. tooth length Cutting depth

CK35-1

5-5

OPTIONS, ATTACHMENTS

5-6

CK35-1

OPTIONS, ATTACHMENTS

CHANGING THE AUTHORIZED EQUIPMENT to

Stop the machine on a firm and level surface and lower the equipment to the ground.

Before getting off the machine, stop the engine, release the residual pressures by moving the equipment control levers more than once in all directions and lock the safety bars (“SAFETY BARS” on page 2-28).

Before starting work, make sure the quick coupler locking pins are completely engaged in, and protruding from, the retaining tabs (slots) provided on the bucket or attachment and that the coupler levers are pushed down to a horizontal (locking) position.

Do not use your fingers to center the pins, since they may be injured or even cut due to sudden or uncontrolled movements.

The machine is provided with a special tool-holder, called a universal quick coupler, which is used for the installation of buckets or optional equipment. Change the optional equipment using the same procedure adopted to change the bucket. “CHANGING THE BUCKET OR ATTACHMENT WITH STANDARD QUICK COUPLER” on page 2101.

Besides the assembly on the tool-holder, the hydraulic excavator also requires fastening to the machine by means of two connecting tie-rods and the hydraulic connection for the independent control of the equipment. When changing equipment with independent hydraulic circuits, stop the oil flow to the equipment with the auxiliary kit pedal and disconnect the quick disconnects before releasing the equipment from the tool-holder. “CONNECTING THE HYDRAULIC CIRCUIT” on page 5-9.

CK35-1

5-7

OPTIONS, ATTACHMENTS CONNECTING THE EXCAVATOR Couple the excavator to the PAN-TACH with the same procedure adopted for the standard equipment and apply the connection tie-rods.

1.

Asemble the tie-rods (1) to the excavator and secure them with the safety pins (2).

2.

Engage the tie-rods with the couplings (3) and connect the hydraulic circuit. See “CONNECTING THE HYDRAULIC CIRCUIT” on page 5-9.

To disconnect the excavator from the PAN-TACH device, proceed as follows: 1.

Remove the safety pins (2), release the tie rods (1) from the plates (3), and disconnect the hydraulic circuit of the excavator.

2.

Raise the tie rods (1) and secure them with the safety locks (4).

5-8

CK35-1

OPTIONS, ATTACHMENTS CONNECTING THE HYDRAULIC CIRCUIT

Before performing any operation on the hydraulic circuit, stop the engine and eliminate the residual pressures from the equipment circuits by operating the controls more than once, then lock the safety bars (see â&#x20AC;&#x153;SAFETY BARSâ&#x20AC;? on page 2-28).

Before and after any operation on the hydraulic circuit, clean up any oil.

After the mechanical connection of equipment with the independent hydraulic circuit, make sure that the auxiliary kit control pedal is in position A - flow interrupted - and assemble the flexible hoses of the equipment to quick disconnects (1) and (2). See B,C and D. The quick disconnect couplings must be in compliance with the ISO 8434-3 standard.

Remark In case there are questions regarding the connection of the hydraulic circuit to the equipment, contact your Komatsu distributor.

CK35-1

5-9

OPTIONS, ATTACHMENTS

5-10

CK35-1

OPTIONS, ATTACHMENTS CONNECTING THE RETURN CIRCUIT WITH DIRECT DRAINAGE INTO THE TANK

Before performing any operation on the hydraulic circuit, stop the engine and eliminate the residual pressures from the equipment circuits by operating the controls more than once, then lock the safety bars (see "3.3.5 pos. 1 - SAFETY BARS").

Before and after any operation on the hydraulic circuit, clean up any oil.

The machine may be fitted for the application of equipment with separate return circuits directed into the tank.

The return system is positioned on the left side of the loader arm and the equipment drain pipe must be connected to quick disconnect (1).

Remark In case there are questions regarding the connection of the hydraulic circuit to the equipment, contact your Komatsu distributor.

CK35-1

5-11

OPTIONS, ATTACHMENTS PREPARING THE MACHINE FOR USE WITH THE EXCAVATOR After the installation of the excavator, make sure that the mechanical and hydraulic connections have been carried out correctly and proceed as follows: 1.

Press the auxiliary kit control pedal to the left with your toe and pull the lever to the rear to lock the pedal in position (B); this position ensures the flow of oil to the equipment.

2.

For the use of the excavator, see the specific instruction manual.

3.

Before leaving the seat, press the SEAT OVERRIDE SYSTEM button on the left console.

4.

If the machine is equipped with rear stabilizers, lower them until the rubber tracks are partially raised; this maneuver stabilizes the machine and avoids any overload on the tracks (see "3.3.5 pos. 13 RIGHT STABILIZER CONTROL (IF INSTALLED)" e pos. 14 LEFT STABILIZER CONTROL (IF INSTALLED)").

USING THE MACHINE WITH THE EXCAVATOR

Before using the excavator, read the relevant operation and maintenance manual carefully and follow the instructions contained therein.

If the machine is equipped with rear stabilizers, always lower them before using the excavator.

After the digging operation and before moving the machine, bring the stabilizers back to their original position.

If it is necessary to travel on roads, engage all the safety locks provided. See "3.1 SAFETY LOCKS".

5-12

CK35-1

OPTIONS, ATTACHMENTS

PALLET FORKS

Before using the forks for any operation, the operator must get acquainted with the increased dimensions of the machine and must also practice the use of the swinging movements.

After grasping the material with the forks and before lifting the load, swing the equipment in such a way as to lift the tips of the forks and prevent the load from slipping.

Use the lifting, swing and travel controls slowly and smoothly, to avoid jerks that may cause the load to move.

Use the maximum fork width possible.

The forks must always be resting on the plate and be secured in their position with the safety pins.

The pallet forks make it possible to use the machine like a normal lift truck and the controls for lifting and swinging the loads are the same used to control the standard bucket. â&#x20AC;&#x153;MACHINE CONTROLSâ&#x20AC;? on page 2-26.

The pallet forks may require being set to different widths (distance from each other) according to the load to be handled: adjustment is made by sliding them on the upper coupling bar; once the desired position has been found, carry out slight movements to make sure that the upper lock pin is engaged in its seat.

CK35-1

5-13

OPTIONS, ATTACHMENTS

5-14

CK35-1

Komatsu America Corp.

DataKom Publications & Training 100Komatsu Drive Cartersville, Ga. 30121 U.S.A. Attn: Service Publications Fax No. (678) 721-3430

PROPOSER

DATE: NAME OF COMPANY:

PROPOSAL FOR MANUAL OR CSS REVISION

FOR INTERNAL USE ONLY -- No.PMR CITY: STATE OR PROVINCE:

DEPARTMENT:

COUNTRY:

NAME:

FAX:

MANUAL DESCRIPTION:

CSS PROGRAM - e.g: Lookup, Parts or Service

MANUAL OR CSS CD NO:

CSS PROGRAM RELEASE VERSION:

MANUAL OR CSS CD ISSUE DATE:

CSS BOOK PUBLISHER:

BOOK DESCRIPTION MACHINE MODEL & S/N: MANUAL SECTION/PAGE NUMBERS OR CSS REFERENCE & PAGE NUMBERS PROBLEM:

Attach photos or sketches.

If more space is needed, use another sheet.

FOR INTERNAL USE ONLY CORRECTIVE ACTION:

PROPFREV.FM 041206