Komatsu D75S-5 Dozer Shovel Operation & Maintenance Manual - PDF DOWNLOAD

Operation & Maintenance Manual

SEAM01 450502

D75S-5

DOZER SHOVEL

SERIAL NUMBERS

D75S-5

:I ijo

and up

KOMAIIU

FOREWORD

FOREWORD This manual describes maintenance,

procedures

checking, and adjustment.

realize peak performance

for operation,

handling,

lubrication,

It will help the operator or anyone

through effective,

economical

and safe machine

operation and maintenance.

0

Please read this manual carefully BEFORE operating the machine.

0

Please continue studying this manual until proper operation is completely reinforced into personal habit.

0

This manual describes operator

the basic techniques.

or anyone get the correct knowledge

Skill is performed

as the

and performance

of the

machine.

0

Operation,

inspection,

and maintenance

should be carefully carried out,

and the safety must be given the first priority. Safety precautions dicated with

A

marks and technical precautions

manual. The safety information to supplement 0

safety

and regulations.

Some photographs chine as technical to up-to-date

0

codes,

contained insurance

local laws, rules

and illustration pictures are different improvement

This operation & maintenance

are in-

marks in this

in this manual is intended only requirements,

is continuously

manual’s content is performed

tional equipment

with *

reflected

from your maon it. Revision

in later editions.

manual may contain attachments

and op-

that are not available in your area. Please consult your

local Komatsu distributor for those items you may require.

Materials and specifications

are subject to change without notice.

-l-

BREAKING

IN YOUR

NEW MACHINE

BREAKING

IN YOUR NEW

MACHINE

Each machine is carefully adjusted and tested before shipment. However, a new machine

requires careful

operation

during the first 100

hours to

break in the various parts.

If a machine is subjected to unreasonably stage, the potential of performance

hard use at the initial operation

will prematurely

deteriorate and the ser-

vice life will be reduced. A new machine must be operated with care, particularly with regard to the following items.

After starting, for

5

engine

let the engine idle

minutes warm-up

to allow

proper

prior to actual

l

At the first 250 hours of operation, the machine should be maintained in the following

operation.

addition

Avoid operation with heavy loads

service:

or at high speeds.

Change

Sudden

starting

unnecessarily

or acceleration,

abrupt braking and

sharp turning should be avoided.

to

usual

manner in

When replacing oil filter elements (cartridges), check their interiors for dirt and dust. If heavily col-

hours

lected, check for possible cause

all oil and oil filter, fuel

before starting operation.

Ir Hours of operation are indicated

filter elements.

For replacement

250

*

by the service meter. procedure

details, see maintenance the maintenance

-2-

and

table in

section.

11-09659

CONTENTS OPERATION MAINTENANCE SAFETY HINTS ...

A ........................

4 PERIODIC MAINTENANCE GENERAL LOCATIONS AND SPECIFICATIONS . . 11 ...............

PRECAUTIONS FOR MAINTENANCE OPERATOR’S COMPARTMENT ................

12 INSTRUMENTS

AND CONTROLS

CHECK BEFORE STARTING OPERATING

.............. ....................

29

..................

33

YOUR MACHINE

67 ...

MAINTENANCE TABLE ...............

EVERY 50 HOURS SERVICE ...........

INITIAL 250 HOURS SERVICE .........

14

68 72 75 76

COLD WEATHER OPERATION

45 50

EVERY 250 HOURS SERVICE ..........

EVERY 500 HOURS SERVICE ..........

76

BUCKET OPERATION

53

EVERY 1000

HOURS SERVICE

........

85

57

EVERY 2000

HOURS SERVICE

........

94

58

EVERY 4000

HOURS SERVICE

........

97

59

WHEN REQUIRED

................. .........................

HOW TO USE INCHING PEDAL .................

TIPS FOR LONGER UNDERCARRIAGE LIFE ......

REPLACEMENT OF BUCKET TEETH ............

ADJUSTMENT OF WORK EQUIPMENT .........

HANDLING OF BATTERY ......................

TRANSPORTATION

...........................

....................

98

ADJUSTMENT

61 64

.........................

TROUBLE SHOOTING GUIDE .............

106

STORAGE

114

MACHINE AND ENGINE SERIAL NUMBERS

116 117

FUEL COOLANT

118

111

..............................

SERVICE METER ........................

D-01687

-3-

83

AND LUBRICANTS

......

SAFETY

HINTS

l

l

l

bl

OPERATION GENERAL Wear well-fitting clothes.

helmet, safety shoes and working

Learn about the safety devices on your own ma-

If the nature of the work requires safety,

chine and about

how to use them.

wear protective goggles or mask, thick gloves, ear plugs or other protection.

thery are position.

Accidents

Such safety devices include: * Guards

or injuries are liable to occur when the

operator is careless or slack. It is most important to

correctly

attached

bear safe operation in mind at all times.

*

Take care of your health. Do not drive when tired, or

Sr Protective Devices

after drinking.

*

Roller-Over Protective Structures

*

Seat Belts, etc.

Learn

the prohibitions,

cautions

and rules about

work procedures in the work site.

When

there

signals and

that

prescribed

Canopies

Read

is a leader, fix standard

Confirm

in the

the

carefully.

Operation Learn how

and

Maintenance

Manual

to use the control

devices,

always follow these signals when operating.

gauges

If there should be an accident

stand the meaning of the caution plates. Remember

such unexpected

or fire or any other

mishap, deal with it quickly, using

beforehand

the

method for engine

oil, fuel, cooling water and hydraulic oil levels. locations

boxes and fire extinguishers It is also important

devices. Be sure you under-

the check points and checking

the nearest apparatus.

Learn

and warning

of the

first

aid

Exhaust gas is dangerous. When running the engine

and how to use them.

to know the emergency

for long periods in a poorly ventilated area, there is

contact

a danger of gas poisoning, so open the windows

system.

or

doors to ensure a good supply of fresh air.

When

operating

the clearances

inside a building always be sure of of the ceiling, entrances,

aisles, etc.

and the load limit of the floor.

Never allow other person than the operator to ride on the machine during operation.

-4

I)-00119

BEFORE STARTING OPERATION Examine the lay of the land and the kind of soil at the

Adjust the operator’s seat until it is in the most com-

work site to determine the dangerous points and the

fortable position for operating. Always sit in the seat

best method of operation.

while operating. Do not operatethe

machine from any

Proceed with the work only after making safety ar-

other position.

rangements about the dangerous points.

Inspect leakages from the fuel, lubricating

Adjust the seat so that the brake pedal can be deand hy-

pressed all the way with the operator’s

back against

the backrest.

draulic systems. Repair any fuel or oil leakage, and wipe off all dirty oil. Check that the shoe bolts are not

Before operating the machine, check and fasten the

loose, and that no other parts are damaged

seat belt.

ing. Machines

having such failures

should

or missnot be

lnspecttheseat

beltandfittings,

replaceanydamaged

or worn parts.

operated.

When getting on or off the machine, use the handrail

To ensure the safety of workers

and step provided. Do not jump up or down from the

always sound the horn to warn them before starting

machine.

Do not leave parts or tools lying around in the vicinity

the engine and moving the machine.

of or on the floor of the operator’s

the machine.

near the machine, Be particularly

careful to check that the rear is clear before backing

comopartment.

Keep everything in its proper place.

Combustible

Wipe off thoroughly

leaves, and pieces of paper may cause fire, so inspect

any grease, oil or mud on the

step, handrail,floororcontrol

the inside of the engine room and remove them.

levers.Failuretodothis

Before starting the engine, confirm that all control

may cause you to slip.

Check the level of the fuel, lubricants water. Extinguish cigarettes

objects such as pieces of wood, dead

levers are in “NEUTRAL”

and cooling

before checking or re-

plenishing. Check that the radiator cap and each oil filler caps or plugs are firmly tightened.

-5-

or “HOLD”.

AFTER STARTING l

Confirm

THE ENGINE

that all gauges

functioning

correctly,

and warning

DURING devices

are

l

and that the gauge readings

OPERATION

Always

concentrate.

It is extremely

allow yourself to be distracted

are within the prescribed range.

dangerous

to

or to think of other

things when operating a machine.

l

Check the play and travel of each lever and pedal.

In dangerous

l

Operate the bucket to confirm that it is functioning

visibility, it is important

normally.

chine and confirm whether it is safe before continu-

l

Move the machine slowly and listen carefully to the any unusual noises.

Operate the gear shift lever to confirm travel speeds for forward

l

and this reduces operator fatigue.

and reverse are function-

l

travel speed.

Choosing a safe place, turn the machine to the left and right to confirm

The machine should always be operated at a speed where it can be correctly controlled. Never do the following: t

that the steering devices are

Speeding

*

Sudden

If these tests reveal anything wrong, however slight

*

turning.

Snaking

it may be, contact the man in charge of the machine

*

Coasting

functioning l

The work area should be made as flat as possible. If the work area is flat, operation is made much easier

that the

ing normally. Also carry out a brake test at each l

and operate

normally.

the machine

there is restricted

to get down from the ma-

ing work.

engine or gears to confirm that they are not making l

places, or where

only after obtaining

his

l

permission.

starting,

sudden

braking,

sudden

Be careful of those around you, and always confirm that

there

is no person

or obstacle

in the way

before traveling or turning the machine. l

Always roads

operate slowly in crowded or in narrow

places,

places. On haul

give way

to loaded

vehicles.

-6-

w006aa

When traveling the machine, keep the bucket 40 to

When

50 cm above the ground.

that

Do not allow unauthorized

before the rain started, so proceed with caution.

persons into the work

continuing conditions

operations will

after rain, remember

have

changed

from

those

area.

Be particularly careful when approaching

Always

der of the road or cliffs, as they may have been

be aware of the operating

capacity

of the

the shoul-

machine. Using the machine to do work beyond its

loosened by the rain.

capacity will not only damage the machine, but may

Check the load limits of bridges before crossing.

even cause unexpected

After

The machine factors.

accidents.

condition

Changes

can be judged

in the gauges,

earthquakes,

confirm

firm; after blasting, confirm that there are no unex-

from many

ploded charges remaining.

sound, vibration,

exhaust gas color or response of the control levers

When

can indicate the occurrence of some disorder. If any

where there are obstacles, points:

disorder occurs, park the machine immediately

in a

operating

on uneven

safe place and take appropriate action. Be especially

o When

careful in the case of a fuel leak as there is danger

low

of fire.

changes in direction.

operating a speed

o Wherever

If the machine breaks down and needs to be towed, first confirm that the brakes are working

that the ground is still

ground

possible

possible,

avoid

and

traveling

obstacles.

remove them, or travel round them.

parking

the

machine

put the gear shift

apply

the

brake

lock,

after

When

discontinuing

the

bucket

sudden

over

large

Either use the working

it is impossible

equipment

to avoid traveling

to

over

them, put the gear shift lever into a low speed,

lever into “NEUTRAL”,

lower

avoid

rocks, fallen trees, tree stumps and other such

properly,

and then tow, using a wire rope or any other suitable

work,

the following

on uneven ground, travel at as as

towing equipment.

When

or in places

remember

to the

reduce speed and mount over the obstacle. Just

ground, and put all safety levers into the “LOCK”

before

position. Never

reduce speed even more to make the shock of

leave the operator’s

seat without

switching the engine off.

I)-00689

the

front

of the

machine

hitting ground as small as possible.

-7

tips

down,

l

o Never mount over an obstacle at an angle; never disengage

0

obstacle. l

When

When operating on slopes, remember

operating

When traveling on a slope, always travel directly up or down it. Never travel horizontally or diago-

at the edge of a cliff or on the

nally across the slope, as this may cause the ma-

shoulder of a road, remember the following points: When operating in a place where there is danger of the machine

the following

points:

one steering clutch to travel over an

chine to roll over or slip sideways.

0

falling over the side, be doubly

When

going down a slope, use the engine as a

brake. If this is not enough to control the speed

careful. Do not approach the edge of the cliff or road shoulder by mistake.

of the machine, use the steering brake as well.

At the instant when the soil is dumped over the’

Never coast down

cliff, or when the machine passes the summit of

lever in “NEUTRAL”.

a slope, the machine

As far as possible, avoid turning the machine on

This is dangerous,

speed suddenly increases.

so press the decelerator

pedal

a slope with the gear shift

a slope. It may cause the machine to roll over or

or use the fuel control lever to reduce the speed,

slip sideways.

and at the same time return the gear shift lever

In forest areas, do not mount fallen trees or logs.

to “NEUTRAL”.

Piles of leaves or branches are also very slippery,

When

working

on river embankments

or other

so proceed with caution.

places made of piled soil, there is the danger that

Before going up or down a slope, select a travel

the weight

speed most suited to the slope. Do not change

or vibration

of the

machine

may

cause the machine to sink into the piled soil, so

gear on the slope.

be extremely

If the engine stalls on a slope, first use the brake

careful

when

operating

in such

places.

to stop the machine,

then return the gear shift

lever to “NEUTRAL”

before starting the engine

again.

-B-

l

l

When operating in water or in muddy areas, rememo When operating

taking

and flow care

not

speed of water, to go beyond

the

l

permitted

the engine

speed,

and forwards.

caution. slopes. Lowering more effective

passing through a narrow space, be careful clearances.

care not to touch any obstacles If necessary,

Take special

on either side or

have someone

at night, remember

the working equipment

During operation, use the seat belt.

l

Do not thrust the bucket speed.

outside the

Be

is a far

way of stopping.

l

especially

into the ground at high

careful

when

working

on

bedrock locations.

machine call out instructions.

When operating points:

side

o Never use the steering brake to stop suddenly on

In such a case, raise the

of the side and overhead

l

the following

In loading operations,

be careful that the bucket and

the machine body does not hit the truck. l

0 Be sure to arrange an adequate lighting system. o At night it is very easy to make mistakes in

WOl567

When operating in snow, or cleaning snow, remem-

slipping, so in such places, operate with extreme

bucket to reduce the load, and drive out slowly.

l

where

o Even slight slopes can cause unexpected

causing

the tracks to spin, or to rock the machine back-

overhead.

or smoke,

ber the following points:

useless to increase

When

mist

and wait for the visibility to improve.

then proceed,

depth.

l

in fog,

When visibility drops below safety level, stop work

and the

o If the machine gets stuck in mud, it is completely

wards

operating

whether operation is safe.

in water or when crossing shal-

lows, first check the bed soil condition depth

When

visibility is bad, be especially careful to confirm first

ber the following points:

When traveling, the bottom of the bucket should be lifted up about 40 to 50 cm. If the position of the

assuming the distance and height of objects and

bucket

land.

unstable.

9-

is high, vision is poor and the machine

is

PARKING l

l

l

When

loaded,

be sure

to

start,

turn

and

stop

l

parking the machine,

park it in a safe place

outside the working area, or in the specified place.

there is a danger of overturning.

The following

You should not perform excavation

work under an

factors

should be considered

when

choosing a parking place: it should be on flat, firm

overhanging cliff because it is dangerous.

ground where there is no danger of rockfalls, land-

You should not let anyone ride on the bucket, carry

slides or floods. If the machine has to be parked on

them or lift them. l

When

smoothly. Especially when the bucket is lifted high,

Take precautions

a slope, it should be parked facing directly up or to avoid electric shocks in work

near power-transmission * *

down the slope, and chocks should be placed under

line.

Use shoes with rubber or leather soles.

Depending even

on the power-transmission

without

touching

them,

some

voltage,

*

the machine

lower the bucket

so that it cuts slightly into the

is facing downhill,

ground to further increase the safety.

lines will

l

spark when you are near them and cause electric shocks. Therefore,

the tracks. When

be sure to work at a safe dis-

When parking the machine, return the gear shift lever to “NEUTRAL”, apply the brake lock, lower the bucket to the ground, and put all safety levers in

tance indicated by a electrical technician.

If by chance you should get a shock, be sure you

the “LOCK”

position.

remove the key.

know measures to be taken.

-lO-

Switch

off the engine and

GENERAL LOCATIONS

GENERAL 1. Bucket

6. Sprocket

2. Tilt lever

7. Track frame

3. Dump cylinder 4. Lift cylinder

8. idler 9. Track shoe

5. Fuel tank

AND

LOCATIONS

AND SPECIFICATIONS

SPECIFICATIONS

OPERATING TRAVEL

WEIGHT

SPEED Max. 9.6 km/h Max. 12.1 km/h

Forward

10. Lift arm

Reverse BUCKET

21130kg

2.2 m3

CAPACITY

ENGINE Komatsu S6D125-1 Model Flywheel horsepower (at 2000 rpm)

NOTE:

D-01668

-11

-

Specifications

diesel engine 200 HP

are subject to change without notice.

OPERATOR’S

COMPARTMENT

COMPARTMENT

OPERATOR’S

1. Inching pedal 2. Steering pedal (Left) 3. Steering pedal (Right) 4. Bucket control lever 5. Horn button 6. Safety lever (for bucket control lever) 7. Brake lock lever 8. Safety lever (for gear shift lever) 9. Fuel control lever 10. Gear shift lever

-

12-

11-09672

OPERATOR’S

20. Fuse box

23. Cab rear lamp switch and pilot

21. Wiper switch

lamp 24. Room lamp switch

22. Cab head lamp switch and pilot lamp

11. Engine water temperature

gauge

12. Torque converter oil temperature

gauge

13. Service meter 14. Charge lamp 15. Engine oil pressure warning lamp 16. Starting switch 17. Heater signal 18. Lamp switch 19. Dust indicator

COMPARTMENT

25. Cigarette lighter

INSTRUMENTS

AND CONTROLS

STARTING

SWITCH

INSTRUMENTS

AND

CONTROLS

ON Charging

and lamp circuits acti-

vate. Keep key at ON after starting.

HEAT Use this position when starting in cold weather.

Release return then,

the

key to allow

automatically without

delay,

to

it to

OFF turn

and it

to

START. t

When starting, be sure to use the starting key.

OFF

START

Key tion.

insertion-withdrawal None

activate.

of

electrical

posi-

At this key position, the starting

circuits

motor will crank the engine. Release key immediately

-

after starting.

14-

INSTRUMENTS

ENGINE OIL PRESSURE WARNING LAMP

ENGINE WATER TEMPERATURE GAUGE

When

indicator

range

during

temperature After

engine

is in the green operation,

0

start-up,

warm

up

moves

into green range.

This lamp indicates a low engine

on, oil pressure

from

green

This

LAMP

lamp

is lower.

Stop

the cause and

take necessary corrective steps.

0

This

lamp

charging off

as

increase.

into red range during operation, indicator

returns

the charge

will

come

on when

starting switch is turned ON. The

run the engine at low idling speed until

indicates

level of alternator.

Oil pressure is normal when lamp is off during operation. If lamp is engine, determine

moves

0

oil pressure.

water

is normal.

the engine until indicator If indicator

0

CHARGE

AND CONTROLS

green

range.

Occasionally check instruments for normal function during operation.

is normal

if lamp goes

engine

revolutions

INSTRUMENTS

AND CONTROLS

TORQUE CONVERTER OIL TEMPERATURE GAUGE

l

l

When

HEATER

indicator is in green range

This

SIGNAL

signal

LAMP

is red-heated

during operation, the oil temperature is normal.

the

If indicator

intake air heater is heated.

moves

from

green

starting

switch

HEAT, thus indicating

range into red range, reduce the work

after

is turned

to

the electrical

SWITCH

With the lamp switch in position 1, the head lamp and illumination lamp for gauges will light.

With the lamp switch in position 2, rear work lamp will also light.

load until the oil tempera-

ture goes down,

-

16-

INSTRUMENTS

FUEL CONTROL

DUST INDICATOR

This device indicates clogging of the air cleaner element.

When

the

AND CONTROLS

LEVER

This lever is used to control the engine speed and output.

red piston appears in the transparent

ENGINE STOP position:

part of this indicator (1). the element

Position

is clogged.

pushed all the way forward with

pulled

ment. After cleaning, push indicator

the

from position Cl).

button

IDLING position.

LOW IDLING position:

Immediately

clean

ele-

(2) to return red piston to

original position.

where

knob

Position pushed (until

raised

where all

the

the

the lever

from

is

LOW

the

lever

way

forward

contacts

stopper at the knob).

-17-

lever

is the

HIGH IDLING position: Position where the all the

way

lever

is

backward

INSTRUMENTS

AND CONTROLS

GEAR SHIFT

INCHING

SAFETY LEVER (For Gear Shift Lever)

LEVER

PEDAL

Free

Three-speed

shift

is

tive

desired

position.

Even

you start the engine without

halfway, the power flow is disconti-

gear shift lever.

nued. Further, depressing

when setting

Q’

When

the

machine

for a while,

chine

gear shift lever to neutral

start

because

safety

fully

is stopped

gear shift lever in NEUTRAL, the mawon’t

If the inching pedal is depressed

This is the locking device of the

obtained

only with lever shifted to a respec-

tion and set the safety

When starting engine, shift gear shift lever in NEUTRAL position.

the position

move the machine

posi-

approaching

lever to

of lock without

the brakes,

the pedal causing

the machine to stop. If you need to

you should set the

switch functions.

actuates

depress

fail.

gradually

when

the object or digging,

the

pedal

intermittingly

with keeping the gear shift lever in its position.

(Refer

to HOW

TO

USE INCHING

PEDAL.) Q

-

18-

1 Do not place

your foot on this

pedal unnecessary.

R-09678

INSTRUMENTS

STEERING

PEDALS

BRAKE

LOCK

LEVER

HORN

AND CONTROLS

BUTTON

Lock

When

pedal on side of desired

This device

is used to lock the

steering pedals when parking. Oper-

To sound the horn, push the button located in front of the R.H.

way, machine will make a slow turn.

ate the lever for locking or unlocking

arm rest.

When the pedal is depressed machine will make pivot turn.

while depressing central both steering pedals.

turning

direction

is depressed

half fully,

When central part of both pedals is depressed, the brake will be activated. your Q T Do not place pedals unnecessary.

ll-ll!l67Y

foot

n!

Whenever lock fail.

machine

steering

pedals

on

-

19-

part

of

is parked, without

INSTRUMENTS

BUCKET

AND CONTROLS

CONTROL

LEVER

04

Lever position 1. RAISE

A. DUMP B. TILT

2. HOLD

C. POSITION

*

The bucket is stopped and holds its position.

the lever is maintained in RAISE or POSITION, the lever is backed to HOLD automatically when the bucket reaches the preset position of kick-out or

When

and the bucket positioner, stopped at that position.

3. LOWER 4. FLOAT

is

The bucket will move freely according to external force.

-

20 -

Ib096RO

INSTRUMENTS

SAFETY LEVER (for Bucket Control

Free,!

: ‘:,:

:I:

,‘!’

This is a locking bucket control lever. n!

When

LIFT ARM

AND CONTROLS

SUPPORT

Lever)

: 7 ‘, ._ -:

device

for

the

parking machine, lower bucket and set safety lever in lock position without fail.

This is a bucket safety device.

Use this device when performing inspection, maintenance: etc. with lift arm in raised state.

Lift arm support is stored below L.H. fender.

There support

-

be be

occasion

when

extracted

beof lift arm bears on support.

In such case, move bucket control lever to RAISE position. Then extract support while raising lift arm. cause

/J !

-21

may cannot

full weight

Be sure to extract before traveling.

support

INSTRUMENTS

FUSE

AND CONTROLS

BOX

Loosen

bolt

(1)

and

Fuse

mark

Terminal

No.

74933

,:apacity

remove

Circuit ~__ ____ Illumination lamp for gauges

cover (2). *

Qf

sure

replacing to turn off

Torque

converter

oil

gauge

temperature

Engine water temperature

Replace a fuse with the same capacity.

Before

Remark

another’of

a the

gauge 20A

L

0

Head lamp

fuse,

Rear lamp

be

Torque converter oil temperature gauge

starting

switch.

Horn H

10A

_

Positioner ~_____._ Engine water

0

F

GD

10A

0

20A

L

temperature -

gauge

__~___~ Spare

L

-

22 -

IbOY

INSTRUMENTS

OPERATOR’S

SEAT

Set seat in the following for comfortable

manner

operation:

SEAT CUSHION

FORWARD-BACKWARD Move lever (1) to left side and set seat in any desired position. Release lever when

seat

position.

has been For

set in

adjustment,

seat can be moved forward or back-

wise or counterclockwise ante

(A) between

and frame

until clear-

tip of chain (3)

becomes

zero. Seat

now adjusted in the most comfortable condition.

ward 160 mm (in 9 steps).

IM!16XR

SEAT FORWARD

ADJUSTMENT

Turn the knob (2) either clock-

ADJUSTMENT

desired

AND CONTROLS

-

23 -

is

TILT

Pulling lever (4). pull back of seat toward forward.

you

and

seat

will

fall

INSTRUMENTS

SEAT

AND CONTROLS

BELT 3. Sit in the seat. Hold buckle

(2)

ii) To lengthen, pull the belt while holding it at a right angle to

and insert (3) into the buckle (2).

buckle or insert.

Check that the belt has locked by pulling it.

4. When removing the *

n !

tip of

the

the buckle

belt,

raise

lever to

release it.

Fasten belt along your body without kinking it. Adjust the lengths

Before

fastening

inspect and

the

the seat belt,

of the belt on both the buckle

securing

brackets

and the insert sides so that the

for

abnormal

buckle is located at the mid-point

belt

Fasten the belt and remove

it in

Adjust the belt length in the fol-

the following manner.

lowing manner.

1. Adjust the seat so that the steer-

i) To shorten

can be depressed

the way with the operator’s

all

back

the belt, pull the

free end of the belt on either the buckle body or insert side.

positioning

*

Inspect

bolts and fittings on the

chassis

for tightness.

Retighten

any loose bolts to 2 to 3 kgm torque. + If the seat belt is scratched

or

frayed or if any of the fittings are

against the backrest.

2. After

use the seat belt.

of your body front.

conditions.

ing pedal

5. When operating a machine equipped with ROPS, be sure to

broken

the seat, install

or deformed

the tether belt (1). With the seat

service,

unoccupied,

immediately.

tense the belt slight-

replace

the

from

long

seat

belt

ly across the seat and install.

Q’

Check

that

there

are no kinks

in the belt.

-

24 -

K-09508 -A

INSTRUMENTS

WIPER

SWITCH

CIGARETTE

ROOM

LIGHTER

LAMP

AND CONTROLS

SWITCH

9

OFF

/’

When

the switch

is put in ON

position, the front or rear wiper actuated.

Turn

the

switch

clockwise

is

Depress automatically

to

the knob and wait

several seconds

for

until it is returned

to its original position.

Then the lighter is ready to use.

spray solvent on the glass.

-

25 -

When

the lamp switch

ON position, lighted.

the

room

is put in lamp

is

INSTRUMENTS

AND CONTROLS

CAB HEAD LAMP

When

SWITCH

the lamp switch

ON position, lighted.

the

head

CAB REAR LAMP

is put in lamps

are

When

the lamp switch

ON position, lighted.

the

PILOT LAMPS FOR HEAD LAMP AND REAR LAMP

SWITCH

rear

is put in

lamps

are

When the head lamps or the rear lamps are lighted, comes on.

-

26 -

each pilot lamp

INSTRUMENTS

FUSE BOX Fuse arrangement

cover (2). jl Replace

a fuse with

another

of

and circuit

Terminal mark

No.

the same capacity.

r

sure

replacing to

turn

off

a the

fuse,

Circuit Front

,‘1, ABefore

Fuse

_ capacity 20A

be

starting

wiper

Rear wiper Head lamp

switch.

Pilot H

U)

10A

lamp for head lamp

Rear lamp Ptlot lamp for rear lamp Room

F

10A -

0

1

-

-

27 -

lamp

Cigarette

lighter _

AND CONTROLS

INSTRUMENTS

LOCKING

AND CONTROLS

CAP

A locking cap is available

as an

optional radiator cap, fuel tank cap or hydraulic tank cap. Open and close locking caps as follows: 1. To open the cap

2. To lock the cap

1) Inset-t the key into the cap * Inset-t the key as far as it will go. If the key is turned before

*

I) Turn the cap into place.

2) Turn the, key clockwise and take the key out.

it is inserted all the way, it may break.

2) Turn the key counterclockwise and bring the rotor groove in line with the aligning

mark on

the cap. Turn the cap slowly until a “clicking� sound is made.

This releases the lock and allows the cap to be opened.

Shoulder

-

28 -

When the cap is locked (against vandalism),

it rotates freely.

CHECK BEFORE STARTING

CHECK BEFORE STARTING Pre-operation

a. Walkaroundthemachineandcheck for any trace of oil or water leak-

checks forestall machine trouble. Never neglect them.

any sign of disconnection

pressure

circuit in the electric wiring.

hydraulic

cylin-

ders, final drive, radiator and float-

also for loose terminals

ing seals with special attention.

any loose parts.

If any leakage

Check the following

is evident,

If diffi-

s

consult your

l

Battery Starting motor

l

Alternator

for the cause and repair. culty is encountered,

check

Komatsu distributor. b. Check tightness of bolts and nuts, and retighten if required. Particular

Remove the radiator cap (I) and

Check for damage of the fuse and

age. Examine connections of high hoses,

d. CHECK AND REFILL COOLANT

c. CHECK ELECTRICAL WIRING or short Check

and tighten

check that the coolant level reaches the vicinity of water filler. If level is low, add water.

Ir If more water than normal level, coolant is considered leaking somewhere.

n!

to be

Immediately

locate the leak and plug it.

A7

If the fuse is damaged

or there is

any sign of shortcircuiting

checks are required for mounting

is re-

quired to fill up to the specified

points carefully.

in the

Do not remove cap (I) while cooling water

is hot. Hot water

may

spout out.

of air cleaner, muffler, as well as

electric wiring, always investigate

When

bucket teeth and track roller sup-

the cause and correct it.

slowly to relieve inner pressure.

ports. *

Please contact your Komatsu distributor for investigation rection of the cause.

-

29 -

and cor-

removing

cap (I),

turn

it

CHECK BEFORE STARTING

f. CHECK OIL LEVEL IN ENGINE

e. CHECK FUEL LEVEL

OIL PAN

After removing cap, pull out fuel

Use dipstick (G) to check the oil

dipstick (G) and check fuel level.

After

each operation,

level. The

fill up the

fuel tank through filler (F). *

Fuel capacity:

*

When

400 II

adding fuel, never let the

fuel overflow. fire.

This may cause a

*

A clogged

cap breather

may stop

the fuel flow

engine.

Check

it from

time and clean.

hole (I) to the time

to

oil level should

*

The type of lubricant

used de-

pends on the ambient

tempera-

ture.

Select

“FUEL, table LUBRICANTS”.

-

30 -

be be-

tween mark L and H. If necessary, add oil at oil filler (F).

according COOLANT

to

the AND

D-01690

CHECK BEFORE STARTING

h. CHECK OIL LEVEL IN

g. CHECK OIL LEVEL IN TRANSMISSION

CASE (INCL.

STEERING CLUTCH CASE

TORQUE CONVERTER CASE)

Use dipstick (G) to check the oil

Use dipstick (G) to check the oil level 5 minutes after stopping the When checking the oil level, park

engine. If necessary, add oil filler (F).

the machine

*

on a level surface,

at oil

level. If necessary, add oil at oil filler (0 The type of lubricant used depends on the ambient

temperature.

Se-

The type of lubricant used depends

lect according to the table “FUEL,

stop the engine and wait for 15

on the ambient

COOLANT AND LUBRICANTS”.

minutes before checking.

lect according to the table “FUEL,

In case the work is carried out on

Do not add oil above the H level mark.

COOLANT AND LUBRICANTS”.

sloped land of more than 25” decli-

*

temperature.

Se-

When checking the oil level, stop

nation, supply oil up to H level.

the engine and wait for 15 minutes

When checking the oil level, stop

before checking.

the engine and wait for 15 minutes before checking.

-31

-

CHECK BEFORE STARTING

i. CHECK DUST INDICATOR When clogged,

air

cleaner

i. CHECK STEERING

element

is

the red piston of dust in-

PEDAL

k. CHECK FOR SEDIMENT WATER IN THE WATER

TRAVEL Normal travel is 127

mm to 19 1

dicator (1) reaches service level and

mm from tip of pedal. If travel ex-

gets locked. In that case, clean element referring to section “WHEN

ceeds

REQUIRED”.

After

cleaning

element,

191

mm,

AND

SEPARATOR The

water

separator

separates

or if pedal gives

water mixed in the fuel. If float (2) is

poor response, adjust by referring to section “ADJUSTMENT”.

at or above red line (1). drain the

push

water.

For the draining

procedure,

see section “WHEN REQUIRED”.

button (2) to return red piston.

*

Even if a water

separator

is in-

stalled, be sure to check the fuel tank to remove

water

and sedi-

ment in the fuel.

,I’

/’ ,’

-

32 -

I)-01692

OPERATlNG

OPERATING

YOUR MACHINE

YOUR MACHINE

HANDLING ENGINE BEFORE STARTING 2. Is brake lock lever (1) in LOCK position?

4. Is bucket lowered on the ground?

And is safety lever (3) for bucket control lever in LOCK position?

1. Carry

out

an initial inspection.

(For details of the inspection see CHECK BEFORE STARTING.)

3. Is gear shift position

lever in NEUTRAL and locked with safety

lever (2)?

i’ :‘.. .q, ._;,t

1 r,

H-OYkY3

,’ ,<“,

-

:’ .-. ._L 1 ;.‘.__. ._,I ‘,,

33 -

;;

.,

OPERATING

STARTING

YOUR MACHINE

ENGINE 2. Turn starting key (2) to START and start engine.

Do not leave key in START for more than 20 seconds.

If engine will not start, repeat the starting procedure after about 2 minutes.

To start engine in cold weather, WEATHER “COLD to refer OPERATION”.

Special

1. Set fuel control lever (1) to LOW IDLING position.

Low adlung

starting

starting after running out of fuel, fill with fuel, then fill the fuel filter cartridge with fuel and bleed the air from the fuel system before When

3. Release key (21, and key return automatically to ON.

will

starting.

Refer to FUEL FILTER in EVERY 500 HOURS SERVICES.

-

34 -

I)-01693

OPERATING YOUR MACHINE

WARM-UP

RUN

CHECKS AFTER STARTING

After starting the cold engine, this warm-up

run should be continued as

the followings.

Pull fuel control lever (2) and run the engine at medium

speed for

about 5 minuteâ&#x20AC;&#x2122;s with no load.

Continue to run the engine at light load until engine water temperaAvoid 1

Run the engine at low idling speed,

abrupt

acceleration

until

turegauge(l)fallswithinthegreen

and check that engine oil pressure

warm-up run is completed.

Do not run the engine at low idling

After warm-up

warning lamp (I) has gone out.

or high idling for more than 20

check gauges, warning

minutes. If it is necessaryto run the

charge lamp for proper operation.

range.

engine at idling, apply a load from

Check for

time to time or raise the engine

exhaust,

speed to a midrange speed.

vibration.

-

35 -

run is completed,

normal

lamp and

coloration

any abnormal

of

sound or

OPERATING

STOPPING

YOUR MACHINE

ENGINE 2. Place

fuel

control

lever

(I)

in

*

ENGINE STOP position with pull-

If engine is stopped abruptly before it cools down, engine life may be greatly shortened.

ing stopper knob (2).

Never Low idling

*

stop

engine

abruptly

except in case of emergency.

Especially when the engine

is

overheated,

allow the engine to

idle without

immediate

so that cooled

the engine down

to

be

stoppage

is gradually ready

for

proper stoppage.

1. Cool the engine by running it at low idling speed for about 5

3. Return starting switch

key (3) to

OFF and remove key.

minutes.

-

36 -

U-09696

OPERATING

OPERATING

YOUR MACHINE

MACHINE

TRAVELING 1. Pull fuel control

lever (1) to in-

3 Put bucket RAISE

crease engine speed.

control lever (2) in position to raise bucket

400 to 500 mm off ground.

;-.. ’

1

:

; ‘.\.. ,.:..

:

:’

2. Unlock

bucket

control

with safety lever (3).

:i : :: :I

:

I

: ‘. .,

.:._.;...‘\. ..__;._.! ,,

H-lJYtiY7

-

37 -

~

lever (2)

OPERATING

4. Depress

YOUR MACHINE

on intersecting

both steering

part of

5. Unlock gear shift safety lever (6).

pedals (4) to free

*

, 6â&#x20AC;&#x2DC;.J

brake lock lever (51, then return pedals to their original positions.

To begin traveling the machine, decrease engine speed so the machine

can

start

off

without

jerking.

Qâ&#x20AC;&#x2122;

id

Lock

When

starting

steep

uphill

grade,

climb

hill

with

engine

at full

speed

and

shift

gear

speed 6. Shift

gear

desired

shift position

machine.

lever

(7)

and

in a start

38 -

of both

pedals.

When

started

at slow

slowly

lever

on a

to

depressing

part

slipping),

-

shift

while

secting

machine

propel

releasing

steering

machine speed

has

(or shoe

machine pedals.

1st

inter-

by

OPERATING YOUR MACHINE

GEAR SHIFTING There is no need to stop machine to shift gears.

FORWARD-REVERSE SHIFTING Forward-reverse shifting should be made after reduction of machine speed for safety

purpose and pre-

venting shock to machine

2. Shift gear shift desired position.

lever

(2)

to

._

ll!b

Gears can be shifted into any position by gear shift lever (1).

1. Reduce

c!fB

RI

fl

R2

fz

It3

h

engine

revolutions

fuel control lever (1).

with

3. Increase

RI

fl

RZ

fz

R3

fa

engine revolutions

fuel control lever (1).

with

OPERATING

YOUR MACHINE

TURNING To turn while traveling, steering

pedal

(1) on the

which you intend to turn.

depress side to l

When

the steering

pedal

is de-

the steering pressed halfway, clutch is desengaged and the machine will turn gently.

When the steering pedal is depressed fully, steering brake works as well as steering clutch is disengaged will turn sharply.

and the machine

OPERATING

TURNING

WHILE

YOUR MACHINE

DESCENDING

A SLOPE *

When enough

descending to

a slope steep

let the

machine

to

coast by its own weight, the machine will sometimes

turn in the

opposite direction to the steering pedal.

If you want to turn gradually on

the steering pedal on the side which you want to turn.

e.g. If you want to turn to the left gradually, depress R.H. steering

turn to the left, depress L.H. steering

pedal “half-way”.

pedal “fully”.

Q T Avoid as much as possible turning the machine on a slope. The machine will tend to slip sideways.

Particular

care should be

taken on soft or clay land.

H-09701

If you need to make pivot turn on such a steep slope, “fully” depress

such a steep slope, depress the opposite side steering pedal “half-way”.

-41

-

e.g. If you want

to make

pivot

OPERATING

YOUR MACHINE

STOPPING

MACHINE 1. Push

full

control

lever

(1)

to

reduce engine speed.

3. Apply ters

brakes of

R.H.

by depressing and

L.H.

cen-

steering

pedals (3).

2. Place

gear

NEUTRAL

shift

position.

lever

(2)

in

4. Lock

brakes

by brake

lock

lever

(4).

Free

-

42 -

1149702

OPERATING

5. Lock

gear

safety

6. Put

shift

lever

(2)

7. Lock bucket control with safety lever (7).

with

lever (5).

bucket

control

lever

(6) in

LOWER position to lower bucket to

while

ground

horizontal.

:

keeping

it

*

For stopping tidn

engine,

HANDLING

(STOPPING

ENGINE).

.m..

:

-

43 -

lever

YOUR MACHINE

(6)

refer to secENGINE

J$,Always stop the machine on ~- flat, stable ground. Avoid parking in a dangerous

place.

OPERATING

YOUR MACHINE

PRECAUTIONS MACHINE When

FOR

OPERATION torque

converter

When oil tem-

l Use this machine

working

in water

or in

muddy areas, observe the following instructions: * Before beginning work, securely

perature gauge indicator exceeds

with

green

range while operating, reduce load and wait for lowering

max. 700°C. and operate alternately for a maximum of 30 mi-

of temperature.

nutes continuous

If the steering clutch one side is

lowed

used frequently

cooling time to prevent the tem-

merged.

perature from rising too high.

that the cooling fan will not come

or if many grad-

ual turns are made with steering

an internal

to handle slag temperature of

by at

least

time. Design the travel road well and steer the machine properly. going downhill,

30

fol-

minutes

tighten each drain plug. *

Do not operate machine in such a depth that carrier rollers are subFurther,

be carefull

in contact with the water.

clutch half-engaged, the steering clutch will wear out in a short

When

operation,

shift gear

shift lever into low speed to run engine at slow speed and travel down slope using the engine as a brake. If there is danger of overrunning the engine, slow the machine by braking.

-

44 -

so

COLD WEATHER OPERATION

COLD WEATHER PREPARATION FOR LOW TEMPERATURE If the temperature

OPERATION Care in using Antifreeze

COOLANT After cleaning inside of the cooling

becomes low, it

Use a Permanent Antifreeze (ethyl-

becomes difficult to start the engine,

system, add antifreeze to the coolant

ene glycol mixed with corrosion

and the coolant may freeze, so do as

to prevent the coolant from freezing

hibitor, antifoam agent, etc.) meeting

follows.

when the machine is not being used.

the standard requirements

FUEL AND LUBRICANTS

*

below. With permanent antifreeze, no

Change to fuel and oil with low viscosity for all components.

For details of the antifreeze ture when changing see WHEN REQUIRED.

mix-

the coolant,

change of coolant

in-

as shown

is required for a

year. If it is doubtful that an available antifreezemeetsthestandardrequire-

For details of the specified viscosity, see the TABLE OF FUEL, COOLANT

ments, ask the supplier of that anti-

AND LUBRICANTS.

freeze for information.

Standard requirementsforpermanent antifreeze l SAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J1034 l

FEDERAL STANDARD ... .. ... .. ... .. ... .. .. ... .. ... .. . O-A-548D

-

45 -

COLD WEATHER OPERATION

Never

use methanol,

ethanol

or

BATTERY drops,

When electrolyte level is low, add distilled water in the morning be-

battery capacity will drop, and elec-

fore work instead of after the dayâ&#x20AC;&#x2122;s

trolyte may sometimes

work. This is to prevent fluid from

propanol based antifreeze.

Where no permanent available,

*

As ambient

antifreeze is

an ethylene glycol anti-

temperature

freeze if bat-

is low. Maintain battery at

freeze without corrosion inhibitor

terycharge

may be used only for the cold sea-

a charge level of approx.

son. In this case, clean the cooling

insulate it against cold temperature

system twice a year (in spring and

so that machine can be readily started the next morning.

autumn).

When refilling the cool-

ing system, add antifreeze

in au-

*

Measure

specific gravity

and obtain rate of charge from the

Absolutely

following

leak preventing agent irrespective ofwhether

it is used independently

I

I

Do not mix one antifreeze with a

Qf Antifreeze

is flammable,

so keep it

100% 90% 80% 75%

1.28 1.26 1.24 1.23

1.29 1.27 1.25 1.24

away from any flame.

-

46 -

1.30 1.28 1.26 1.25

tery.

A

If the electrolyte gets on your skin plenty of clean water.

or mixed with an antifreeze. different brand.

To avoid gas explosions, do not bring fire or sparks near the bat-

or clothes, immediately

conversion table:

Temp. of 1

Q1

of fluid

tumn, but do not add any in spring. avoid using any water

freezing at night.

100% and

1.31 1.29 1.27 1.26

wash with

COLD WEATHER

STARTING WEATHER

OPERATION

IN COLD

For attention

of engine starting,

refer to section “OPERATING

YOUR

MACHINE”.

2. Place

starting

switch

(2) in the

HEAT position to red-hot

heater

heater signal (3) becomes

red, turn key (2) to START

posi-

tion to start the engine.

signal (3).

Necessary

3. When

preheating

times is as

follows:

1. Pull fuel control lever (1) a little toward you from LOW IDLING

- 10°C to - 20°C

30 seconds

the engine starts, turn key

(2) to the ON position.

position.

n-0 I 696

4. After

-

47 -

COLD WEATHER OPERATION

CAUTIONS AFTER COMPLETION OF WORK Ir Do not allow the starting motor to run continuously for more than 20

body

should

moved.

Park the machine

Never

use starting

aid fluids as

re-

2. Drain water collected in fuel systern so that such water

may be

frozen at night.

seconds. If the engine fails to start,

they may cause explosions.

on the machine

be completely

wait about 2 minutes before trying to start it again. !

QL

1. Mud and water

on concrete or

3. As battery capacity drops at low

hard ground. If this is impossible,

ambient

park

battery or remove it from the ma-

the

machine

on

wooden

and undercarriage from freezing to ve-

hicle movement the next morning.

Par-ticularattentionshould

begiven

towaterdropscollectedonthesurface f the hydraulic cylinder piston rods.

Such droplets must be fully wiped off because if water is frozen to the rod when the cylinder is utilized, the cylinder oil seals may be damaged.

-

48 -

cover the

chine to be kept warm at night.

boards.ThiswiIIpreventtheaccessories from freezing or the track the ground threby preventing

temperature,

COLD WEATHER OPERATION

AFTER COLD WEATHER When

weather

becomes

warm,

perform the following without fail: l

Replace lubricating oilsforvarious units with the ones specified for warm-weather

l

use.

If for any reason permanent freezecannot

anti-

be used, and an ethyl

glycol base antifreeze (winter, one season type) is used instead, or if no antifreeze

is used, drain the

cooling system completely,

then

clean out the inside of the cooling system thoroughly, fresh water.

and fill with

- 49 -

BUCKET OPERATION

BUCKET OPERATION Various

types

available

of attachments

to extend

application

the range

beyond

tions described

the

are of

applica-

below.

EXCAVATION l

Scoop

up

the

piled

moving the machine shown

below.

soil

by

forward

as

If the track shoe

2. After

the

penetrated

bucket

has

fully

into the soil, place the

3. When

it is difficult for the bucket

to penetrate

bucket control leve in RAISE posi-

move

raise

tion while

left and right to move the bucket

the

bucket

slightly

to

reduce the load.

forward.

moving

the machine

Move the bucket control

the

into the piled soil,

begins slipping under heavy load,

bucket

control

lever

teeth up and down.

lever to TILT position from time 1 Force the bucket into the pile of soil while

moving

the

machine

to time until the bucket with soil.

is filled

forward.

-

50 -

H-Oâ&#x20AC;&#x2122;J710

BUCKET OPERATION

l In an excavating-loading

opera-

tion on flat ground, move the machine

forward

teeth

facing

with

the

somewhat

ward as shown.

bucket down-

In this case, do

not impose the load on one side only.

1 Direct what

the

bucket

downward horizontal.

teeth from

somethe

2. Scrape the soil gradually by pushing the

bucket

little forward

control

while

lever a

moving

3 Move the machine forward while adjusting the digging depth by

the

means lever.

machine forward. *

When

of

the

digging

bucket

with

control

the bucket,

avoid imposing the digging force onto only one side of the bucket.

-51

-

BUCKET OPERATION

LEVELING

LOADING

To level excavated bucket,

move

earth,

dump

it up and down

small movements,

in

and finally slowly

drag it over the earth in the reverse direction â&#x20AC;&#x153;Floatâ&#x20AC;?

by

placing

position. With

lift

arm

If

dumping

dumping

shorten

TRUCK loading the earth on truck,

BACK FILLING For back filling

cycle

work

work efficiency

time

these steps,

by minimizing turns

and travel distance.

Dozer shovel can transport newly

with

when sub-

jected to excess load. Therefore, always dump with dumping cylinfrom

in foundation

construction

kept horizontally,

first excavated

sites,

with

dump the

soil without dumping

cavated soil to push the previous excavated soil over. Be sure not to approach the edge by mistake.

cylinder fully extended

retracted

bucket

at

it over, and use each succeeding ex-

(up to stroke end), dumping cylin-

der slightly

increase

mixed concrete direct to molds.

is performed

der may be damaged

and

in

earth will be levelled. *

When

fully

extended position.

-

52 -

HOW TO USE INCHING PEDAL

HOW TO USE INCHING High-efficiency fective

excavation

PEDAL

by ef-

use of the inching pedal.

The inching pedal can be used in the following three ways: 1. Positive

stop

of

a

machine

during operation This pedal

2. When

a machine

a target

interlocks

the trans-

Depress

is to approach

inch by inch: the

inching

mission clutch and brake. When

place the transmission

a machine

the half-disengaged

is to

stopped between erations, halfway

power pedal

positively

first depress

op-

the pedal

to its stroke end. Then,

the transmission engage,

be

excavating

clutch will dis-

interrupting from

the

is further

machine

can

the flow

engine.

If the

depressed, be

of the

stopped

completely.

Depress the pedal all the way down.

ly disengaged

inching

pedal

and

clutch in

or complete-

position. Then the

in combination pedal,

in a digging operation

Scooping

machine can approach material little by little. If a steering pedal is used

3. Scooping

with

the

the machine

can

be steered more precisely.

can be done as in a

direct-drive inching the

machine,

pedal.

pedal

all

After the

using the depressing way

down,

release it little by little. As soon as the transmission

clutch is half-

engaged, release the pedal at once. Then, the transmission clutch engages instantly, enabling the bucket to scoop up material.

HOW TO USE INCHING PEDAL

How to Use the Inching Pedal in Actual Material Handling Operations

2. Inching speed

approach

and

bucket

LOADING 1. Approaching correcting

a dump track the

direction

and of

travel

Depress

Approach

the side of the dump

truck and stop the machine

by de-

pressing the inching pedal only.

the

inching

pedal

and

Depress the steering pedal on the same side in which the machine is

bring the transmission

to turn and slowly release the inch-

engaged position to inch toward the

ing pedal

dumD truck.

while

which

was

the machine

fine, delicate

was

directional

kept

down

half-disengaged

clutch

to a

or completely

dis-

at rest. A correction

can be made.

*

When

inching

pedal,

the

with

bucket

the inching can

operate

even at full engine speed without Depress the inching pedal all the

slowing down the bucket speed.

way down.

-

54 -

IH~9714

3. Positive

Slowly stopping

approach position

the

with

pedal kept halfway machine

^. ;. &

’ cc * -__ &IT 9 i<‘l ,, _.m ., *,, ,\.

stopping

HOW TO USE INCHING PEDAL

FILLING

OPERATION

Positive

stopping

desired

positively

9

the inching

by

depressing

il

I.

Leave one eap of soi

down. Stop the c’

,’ *a

the pedal all the way down.

CORNERING Inching steering

1

) r:/

+I

‘1

7

‘I I II

._.

*r

0 ‘j,, ,.. i_ . .

,l3EiEZZh

Slowly Ir If the machine is traveling with a

bring the machine

desired stopping

to the

position, depress-

full bucket, and the inching pedal

ing the inching

is depressed

stop the machine positively, depress

all the way down, it

will act like the emergency

brake,

possibly causing the machine

pedal halfway.

the pedal all the way down.

to

balance.

Consequently, lose slowly depress the inching pedal halfway

after bringing the trans-

mission clutch to the half disengaged

position.

and approaching

When

the

ma-

chine has reached the desired location, depress the pedal all the way down to apply the brake.

-

55 -

To

Depress

the steering

bring the transmission half disengaged

pedal

and

clutch to the

position for micro-

steering or inching up to a building.

HOW TO USE INCHING PEDAL

PRECAUTIONS WHEN APPLYING THE INCHING

EXCAVATION Jerking

PEDAL

Do not keep the inching pedal depressed 10

halfway

sec. with

for more than

the

transmission

clutch in the half-disengaged

po-

sition. This will protect the clutch against excessive wear.

Do

not

rest your

pedal necessary.

After

depressing

the

inching

*

After

depressing

the

inching

pedal all the way down, release the

pedal all the way down,

pedal halfway to bring the transmis-

the pedal fully at once, Then, the

sion clutch position.

to the half disengaged

Then,

release

the

pedal

machine

release

can start off smoothly

as if the gear shift lever were put

fully at once, and the transmission

into the desired speed position. In

clutch will engage instantly, enabling

this case, jerking with the bucket is impracticable.

the bucket to jerk material.

-

56 -

unless

foot on the absolutely

TIPS FOR LONGER UNDERCARRIAGE

TIPS FOR LONGER UNDERCARRIAGE Undercarriage

life greatly varies depending

LIFE

LIFE

on operation method, inspection and main-

tenance. For most efficient operation, keep the following points in mind.

OPERATION l

l

METHOD

Select the track shoe that best suits the type of soil to be en-

Avoid sudden starts, acceleration

countered in service.

speeds or sharp turns.

Do

not

occur

allow

during

shoe

stops,

to

Always

If shoe

straight

slipping

operation.

or

slipping occurs, reduce load until slipping stops.

or

unnecessary

travel

in

a

possible.

When making turns, avoid turning on sloping

terrain

as much

as

possible so that work can be correctly

carried

out

as required.

Make turns with largest possible radius.

-

57 -

Level the work site terrain before actual

work

and other

machine

line whenever

l

high

and clear obstacles

boulders

to prevent

machine from riding over them.

REPLACEMENT

OF BUCKET

TEETH

REFâ&#x20AC;&#x2122;LACEMENT

OF BUCKET TEETH

When bucket has been worn, replace it, taking the following steps: REPLACEMENT

METHOD

1. Raise bucket at a suitable height and apply a block under bucket to prevent it from being lowered. *

Raise

bucket

so

that

bottom becomes horizontal.

2. Remove

bucket

tooth and clean

mounting surface.

3. Install a new tooth on bucket.

*

Clamping torque for bolts:

*

After

its

120 kgm

1

a few

hours of operation,

retighten bolts.

-

58 -

B-09718

ADJUSTMENT

ADJUSTMENT The bucket may be stopped automatically when an optional height of

OF WORK

ADJUSTMENT

OF BOOM

OF WORK EQUIPMENT

EQUIPMENT KICK

rising and digging angle is obtained

OUT Raise the bucket to the optional

When the adjustment is completed, start the engine and operate the

by the kick out device and the posi-

position. Then stop the engine and

bucket control lever for the purpose

tioner device. So, the bucket may be

set the operating

of confirming

adjusted to an optional position ac-

position,

cording to the working conditions.

the following instructions.

and

lever to the RAISE

adjust

according

to

Loosen lock nut (11, screw in bolt (2) till stopper (3) of the lift cylinder is reached. And tighten lock nut (I 1.

that the lever is auto-

matically restored to the HOLD position when the bucket is raised to the optional position. *

Adjust rod (4). if bolt (2) does not touch the stopper (3).

ADJUSTMENT

OF WORK EQUIPMENT

ADJUSTMENT POSITIONER

OF BUCKET

Lower bucket on ground and set at desired

excavating

angle.

Then

stop engine and proceed as follows: Remove

switch

protection

cover

(1) and loosen bolt (4) so that tip (A) of rod (2) will contact (3). Adjust (4).

switch roller

rod (2) and tighten bolt

After adjustment

has been made,

start engine and operate bucket control lever to make sure that lever will automatically

return

to HOLD

position

when bucket assumes desired excavating angle. After this has been confirmed,

reinstall cover

(1).

-

60 -

B-09720

HANDLING OF BATTERY

HANDLING PRECAUTIONS BATTERY 1. Before cable

FOR CHARGING

charging, from

terminal

the of

Otherwise,

disconnect negative the

the t-1

battery.

an unusually high vol-

tage will damage the alternator.

2. While

OF BATTERY

charging

the

battery,

3. If the electrolyte ceeds 45°C.

temperature

ex-

stop charging for a

while.

4. Turn off the charger as soon as the battery is charged.

Overcharging the battery may

6. Do not mix up cables (+I

to negative

(-1

(-1

to positive

(+)I,

7. When

inspecting

battery,

be

sure

and

turn

or servicing to

cause followings:

engine

I) Overheating the battery

switch to (OFF) position.

To avoid gas explosions, do not bring fire or sparks near the

2) Decreasing electrolyte

battery.

3) Damaging the electrode plate

quantity

of

wash with plenty of clean water.

-61

8. When

performing

battery

5. If the electrolyte gets on your skin or clothes, immediately

-

as it will

damage the alternator.

remove all battery plugs for satisfactory ventilation.

the

(positive

or negative

electrolyte specific

besides

the

stop

a

the

starting

any service to checking

the

level or measuring the gravity, disconnect

cables from the battery.

HANDLING

OF BATTERY

REMOVAL

AND INSTALLATION

STARTING

OF BATTERY When

removing

connect

the

battery, cable

first disfrom

the

ground (normally, from the negative (-1 terminal).

If a tool touches

a cable

positive there

terminal is danger

connecting

the

and the chassis, of sparks

being

battry,

the

emitted.

When ground

installing cable should

ed to the ground last step.

ENGINE

BOOSTER

be connect-

terminal

as the

When with

a

WITH

A

2. Connect the booster the following manner.

CABLE starting

up the

engine

booster

cable,

do

I) Connect cable

as

1. Before

connecting

the

1) Size of booster

the

2) Check

cables

positive

cable and clip

should be suitable tery size.

engine which

for the bat-

3) Connect

and

clips

cable

for

3) Make sure cables and clips are

running.

switch

body

in *

of the running 5) The battery engine must be the same capacity

as that

of engine

engine

(+I to be

clip to the to

the

is running. clip

of

booster

negative

(-1

of the engine which

4) Connect

secured.

4) Keep the starting “OFF” position.

one

in

booster

terminal

B to the

terminal

surfaces,

of

positive

the other (+I

etc.

breaks, corroded firmly

of

started.

2) Connect

booster

cable

clip the

terminal

follows:

one

A to

cables

of

the other the

is

clip to the

machine

to

be

started.

Make sure the clips are firmly connected

to battery

teminals.

Then, start the engine.

to

be started.

I

._

Eodv of rhe machine fo bd started

’r .‘r $erz

HANDLING OF BATTERY

A!_ When

connecting

never contact and negative

the

cables,

the positive (-1

(+I

After connected

terminals.

which /&Make

sure

cable

Connect the

that

connections the

body

as

1) Disconnect

cable

to

possible

START

the booster cables

3) Disconnect

4) Disconnect the

the other clip from

negative

(-1

terminal

the clip of booster

cable A from the positive (+I terminal of the running engine.

machine which was started.

2) Disconnect

positive

the other clip from (+I

switch

to

position and start up

the engine.

2) If the engine doesnâ&#x20AC;&#x2122;t

start at

first, try again after 2 minutes or so.

5

;Aâ&#x20AC;&#x2122;

0 14

.I!9 -y

._..27

u-b 0

1

+ Batterv for running engine

Battery

for engine which was started

(@

Bodv of the machine which was started

-

63 -

terminal

of

the engine which was started.

of

the running engine.

3. Starting the engine starting

order in

the clip of booster cable B from the body of the

the the

in the reverse

1. Disconnecting

as

has started, should be dis-

they were connected.

booster

from the battery.

1) Turn

engine cables

are correct.

the

booster far

the

the booster

(11 w

TRANSPORTATION

TRANSPORTATION When

transporting

transportation

the machine,

observe

the various road rules, road

vehicle and vehicle limit ordinances,

etc. It is a good idea to

obtain a special platform for loading and unloading the machine. When it is unavoidably

necessary to use ramps, however, at the least observe the fol-

lowing for safety.

Properly apply the brakes on the

2. Determine

trailer and insert blocks beneath

ramps,

the tires to ensure that

unload the machine.

it does

the then

direction slowly

of the load

or

from

not move. Then fix the ramps in line with the centers of the trailer

3. Load machine at a suitable place on trailer. To prevent machine moving

during transporta-

tion, hold it securely in place by Never

change

travel

direction

applying blocks to front and rear

and the machine.

on the

ramps.

When

changing

of track shoe and by fastening

Make sure the ramps have suffi-

direction,

cient width, length and thickness

ramps

to

grdund.

enable

the

machine

to

Qâ&#x20AC;&#x2122;

be

back

and change

up

off

direction

the on

machine with chain or wire rope.

Secure machine with special care to prevent shifting sideways.

safely loaded and unloaded.

If the ramps sag appreciably, reinforce it with blocks, etc.

-

- -

-

64 -

TRANSPORTATION

4. Lower control

the bucket,

keep various

levers

in the

following

control

lever

in Engine

t

into

places: l

Fuel

Determine porting

the

the

route

for

machine

account

the

trans-

by taking

width,

height

and weight of the machine.

stop position Neutral

Qf

loading

When

l

Gear shift lever

l

Bucket control lever

Hold

park

Brake lock lever Take off the starting key.

Lock

roadbed.

l

tance

the

trailer

the

machine,

on a flat

Keep a fairly

beween

the

der and the machine.

-

65 -

firm

long dis-

road shoul-

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE

operation and Proper lubrication and maintenance assure trouble-free long machine life. Time and money spent for scheduled periodic maintenance will be amply compensated by prolonged machine operation and reduced operating cost.

All hourly figures given in the following descriptions are based on service meter readings. In practice, however, it is recommended to rearrange all of them into units of days, weeks and months to make the maintenance schedule more convenient. Under rough job site or operating conditions, it is necessary

to somewhat

shorten

the maintenance

manual.

K-09198

-

67 -

intervals stated

in this

PRECAUTIONS

FOR MAINTENANCE

PRECAUTIONS

FOR MAINTENANCE

GENERAL l

l

Wear well-fitting clothes. When

l

l

should always be carried out with the

engine stopped.

Fuel or oil are dangerous substances.

the engine running, there must be two men present:

handle

fuel,

oil, grease

or oily clothes

If maintenance

one sitting in the operatorâ&#x20AC;&#x2122;s

in

places where there is any fire of flame.

performing

As preparation in case of fire, always know the loca-

touch any moving part.

tion and directions for use of fire extinguishers

Always

other fire-fighting

l

maintenance

always wear protective goggles.

Never

l

Unless you have special instructions to the contrary,

helmet, safety shoes and working drilling, grinding or hammering,

When

working

and,

the maintenance.

remember

carrying

with others, choose a group leader

In such a case, never

that the hydraulic oil circuit is

out inspection

and work according to his instructions. Do not per-

the pressure first.

form any maintenance

The procedure

beyond the agreed work. equipment

seat and the other one

under pressure. When feeding or draining the oil or

equipment.

Do not handle electrical

is carried out with

is as follows:

while wearing

and maintenance,

release

for releasing the hydraulic pressure lower the bucket to the ground, and

wet gloves, or in wet places, as this can cause elec-

stop the engine; move the control levers to each po-

tric shock.

sition two or three time and then slowly loosen the

During maintenance

oil filler cap.

do not allow any unauthorized

person to stand near the machine.

Always use Komatsu genuine parts for replacement.

Exhaust gas is dangerous. When working inside, be

Always

particularly careful to have good ventilation.

mended by Komatsu. Choose the viscosity specified

use the grades

of grease

and oil recom-

for the ambient temperature.

Always

use pure oil or grease, and be sure to use

clean containers.

When checking or changing the oil, do it in a place free of dust, and prevent any dirt from getting into the oil.

-

68 -

D-00729

PRECAUTIONS

DURING MAINTENANCE Park the machine on firm, fiat ground.

l

Lower the

l

l

and set each control lever to “LOCK”. When maintenance has to be carried out with the bucket raised, it

l

ger that boiling water or oil may spurt out.

After replacing oil, filter element or strainer, bleed the

l

air from the circuit.

When the strainer is located in the oil filler, the strainer

dust into the system.

Hang a caution sign in the operator’s compartment

l

ress”).

must not be removed while’adding oil.

When adding oil or checking the oil level, check that the oil is at the correct level.

When adding oil or fuel, do not let the oil or fuel

This will prevent anyone from starting or moving the

overflow.

in prog-

machine by mistake.

If oil or water are spilled, always wipe it up. Spilled oil

Flames should never be used instead of lamps. Never

or water may cause people to slip; spilled oil may cause fire. If soil is piled on top of a place where fuel

use a naked flame to check leaks orthe level of oil, fuel, remove any oil or grease on the floor of the operator’s compartment, or on the handrail. It is very dangerous if someone slips while on the maImmediately

l

has been spilled, remove the soil.

After greasing up, always wipe off the old grease that was forced out.

l

chine. l

Be particularly careful when removing the radiator cap or the hydraulic oil tank filler cap. If this is done immediately after using the machine, there is a dan-

l

antifreeze or electrolyte. l

of

must be securely supported by blocks.

Thoroughly wash the machine. In particular, be careful to clean the filler caps, grease fittings and the area around the dipsticks. Be careful not to let any dirt or

(for example “Do not start” or “Maintenance

l

Before draining the oil, warm up it to a temperature 30 to 40°C.

bucket to the ground and stop the engine. Return the gear shift lever to “NEUTRAL”, apply the brake lock

l

FOR MAINTENANCE

When changing the oil or filter, check the drained oil and filter for any signs of excessive metal particles or other foreign materials.

check an open gear case there is a risk of dropping things in. Before removing the covers to inspect such cases, empty everything from your

When

pockets. Be particularly careful to remove wrenches and nuts.

- 69 -

PRECAUTIONS

l

When

FOR MAINTENANCE

removing

parts containing

or seals, clean the mounting

O-rings,

surface

l

gaskets

with new sealing parts. l

When the tracks are removed, Special measuring

never put your fing-

l

When

apparatus

is needed for testing

2) Do not continuously apply more than 200 V. 3) Install the ground cable at least 1 m from the range

it is necessary to lift the bucket to perform

maintenance

to be welded.

work, be sure to always use the safety

4) Take

pin so that the lift arm cannot fall.

When

carrying

When welding, be careful of the following:

I) Turn OFF the power (starting switch).

hydraulic pressure. l

out

other

difficult

care

maintenance

l

When working

carrying them out carelessly can cause unex-

electrical

pected

accidents.

corrode.

If you consider the maintenance

always

not to install the

seals between

the

grounded point and the range to be welded.

works,

too difficult,

If it is soaked

with water, it may not operate normally.

ers between the shoes. l

When washing the machine, take care not to splash water over the electrical equipment.

and replace

request the Komatsu

is

distributor

l

to carry out it.

Before

on the sea shore, carefully clean all

equipment working

to ensure

in muddy

that

water,

is does

not

rain or snow,

check that the various plugs, valves, are properly screwed

up. Upon completion

machine,

then check the various parts of the ma-

chine

for

cracking,

of work, wash the

scratching,

nuts and bolts. Also,

loose or missing

oil and grease

the various

parts of the machine. l

When damage

working

on rocky

ground,

to the undercarriage,

be careful

of

loose nuts and bolts,

cracks, wear and other damage.

-

70 -

I)-01577

PRECAUTIONS

l When

working in a dusty location, be careful of the

following:

1) Inspect the dust indicator

to see whether

the air

cleaner is blocked up. Clean the air cleaner as soon as it becomes dirty.

2) Clean the radiator core so that it does not become blocked up.

3) Clean or replace the fuel filter as soon as it becomes dirty.

4) Clean the electrical equipment, ing motor and alternator,

particularly the start-

to prevent accumulation

of dust. l To bleed the air from the hydraulic cylinders or hy-

draulic piping, run the engine at low idling and do as follows.

1) Operate each hydraulic cylinders 4 to 5 times, stopping 100 mm from stroke end.

2) Next, operate each cylinder 3 to 4 times to the stroke end. *

If the engine is run at high speed at first, or if the cylinder is moved to the end of its stroke, the air in the cylinder may damage

the piston packing,

etc.

1kOl578

-71

-

FOR MAINTENANCE

MAINTENANCE

TABLE

MAINTENANCE

TABLE

I

PAGE

SERVICE

ITEM

NO.

CHECK BEFORE STARTING

I

Check

29

Nuts and bolts

Check and retighten

2g

C

Electric wiring

Check and retighten

2g

d

Coolant

Check and supply

29

e

Fuel

Check and supply

30

Check and supply

30

Check and supply

31 -

a

Oil and water

b

leak

-3

/

Lift cylinder

shaft

1

f g

pan

Transmission case fincl. torque converter

case)

I

Lubricate

4 points

75

!

INITIAL

75 75

I

I

I

1 Engineoil

4 points

Drain water and sediment

Fuel tank

b

Lubricate

250 HOURS SERVICE

al

Fuel filter

Replace cartridge

31

b

Transmission case (incl. toraue converter case)

Change oil and clean strainer Change oil and clean strainer

h

Steering clutch case

Check and supply

i

Dust indicator

Check

32

C

Steering clutch case

i

Steering pedal

Check travel

32

d

Final drive case

k

Water separator

Inspect float position

32

e

Hydraulic

tank and filter

76 76 76

Change oil

76

Change oil and replace element

76

EVERY 50 HOURS SERVICE a

Lubricating

75

-

72 -

I)-01699

MAINTENANCE

No.

ITEM

Fmmi”ERY

a

I

SERVICE

I

250 HOURS SERVICE

Lubricating

No.

PAGE

ITEM

PAGE

EVERY 500 HOURS SERVICE

1

I

SERVICE

TABLE

a

76

I

Fuel filter

Replace cartridge

83

Change oil and clean strainer

87

--I-b

Breather

c

Radiator

Steering clutch case

fin

“1

Check oil level

-1

Final drive case

Check and supply

76

-2

Hydraulic

Check and supply

77 78

b

79

c 1 Final drive case

Change oil

88

80

d

Change oil and replace element

89

Check lubricating condition

90

I

oil tank

76

C

Engine oil pan and filter

Change oil and replace cartridge

d

Transmission case and steering clutch case oil filter

Replace element

e

1 Fuel tank bottom

strainer

1 Clean

1

Hydraulic

tank and filter

f

Battery electrolyte

Check

80

e

Undercarriage

g

Track shoe bolt

Check and tighten

81

f

Lubricating

h

Fan belt

Check tension

81

-1

Universal joint

Lubricate

2 points

91

-2

Diagonal brace

Lubricate

2 points

91

g

Turbocharger

clamping joint

Check and retighten

91

h

Turbocharger

rotor

Check play

92

i

Corrosion

Replace cartridge

93

i

1 Fuel

filter

1 ~~~~!ter

and

1 82

-

73 -

components

91

resistor

MAINTENANCE

TABLE

No.

ITEM

No.

PAGE

SERVICE

ITEM

,

I Lubricating

94

t

b

1 Engine

1

( Turbocharger

breather

Alternator

Clean element

1 ELIland

Engine valve clearance

Check and adjust

96

f

Engine vibration

Check

96

a

/

I

EVERY 4000 HOURS SERVICE

Water pump

Check

I

Air cleaner

b

Cooling system

I

/ 1;

clean

e /

1

a

95

and starting motor

damper

PAGE

WHEN REQUIRED

EVERY 2000 HOURS SERVICE

a

SERVICE

I I

97

I

-

74 -

I

I

EVERY

EVERY 50 HOURS grease

b. DRAIN WATER AND SEDIMENT FROM FUEL TANK

fittings

of the tank and drain water and sediment accumulated on bottom with

Loosen valve (I) to grease

:

shown by arrows.

fuel.

1. Bucket pin

(4 points)

3. Lift cylinder shaft

(4 points)

2. Lift arm support shaft

(2 points)

4. Dump cylinder shaft

(4 points)

fi-09734

SERVICE

SERVICE

a. LUBRICATING Apply

50 HOURS

on the bottom

INITIAL

250 HOURS SERVICE

EVERY 250 HOURS SERVICE

INTIAL 250 SERVICE Perform nance

HOURS

the following

after

running

the

EVERY 250 SERVICE

HOURS

should time.

maintemachine

for the first 250 hours.

a. LUBRICATING

1. Tilt lever pin

fittings

TORQUE

CONVERTER CLUTCH

(4 points)

TANK

CASE)

CASE

For

details or

AND

of

the

section on EVERY 500 1000

method

maintaining,

HOURS SERVICE.

see

Remove

plug (G) and check oil

engine oil through oil filler (F).

FILTER replacing

LEVEL

level. If oil level does not reach lower edge of plug hole, fill with

d. FINAL DRIVE CASE e. HYDRAULIC

every 50 hours out at the same

1. Final drive case

CASE (INCL.

c. STEERING

for be carried

b. CHECK AND CORRECT OIL

Apply grease to grease shown by arrows.

a. FUEL FILTER b. TRANSMISSION

or Maintenance

of the

HOURS and 2. Equalizer bar shaft

(I point)

EVERY 250 HOURS SERVICE

Ir The type

of lubricant

pends on the ambient ture. table

Select “FUEL,

LUBRICANTS”.

used detempera-

according COOLANT

to

the AND

2. Hydraulic oil tank Lower

bucket

*

to

ground,

stop

The

type

of lubricant

engine and wait for about 5 mi-

ture.

nutes.

table “FUEL, LUBRICANTS”.

Then

check

oil level

at

sight gauge (G). If level is not be-

used de-

pends on the ambient Select

tempera-

according COOLANT

to

the AND

tween lines at top and bottom of red

circle,

fill

with

engine

oil

through oil filler (F).

Detailed gauge

1b01702

-

77 -

photograph

of

sight

EVERY

250 HOURS

SERVICE

ENGINE OIL PAN AND OIL FILTER After removing

Clean the filter base and fill a new

Refill capacity:

filtercartridgewithengineoiI.Then,

The type of lubricant used depends

drainplug(l)andloosendrainvalve

apply engine oil or a thin coat of

on the ambient

(2).

Tighten the drain valve (2) and plug

grease to the seal.

lect according to the table â&#x20AC;&#x153;FUEL,

After the gasket contacts the seal

COOLANT AND LUBRICANTSâ&#x20AC;?.

(I) after draining oil.

face, tighten it up 314 to 1 of a turn.

Be sure to use a genuine Komatsu

Upon replacement

cartridge.

underside

of

the cover machine,

Using the tool provided,

from

remove

remove

of cartridge, fill

26 R temperature.

cartridge (3) by turning it counter-

with engine oil through oil filler(F).

Change

clockwise.

After supplying oil, run enginefor a

monthsregardlessof

few minutes and then recheck oil

Beforeinstalling

level.

be sure to fill it with engine oil.

-

78 -

the engine

Se-

oil every

6

service hours.

thefiltercartridge,

EVERY 250 HOURS

d. TRANSMISSION *

If the filter cartridge immediately

after

is removed

stopping

the

engine, oil will spill. Wait at least 10

minutes

after

stopping

the

engine before replacing the filter cartridge.

STEERING

CASE AND

CLUTCH

CASE OIL

FILTER Remove cover on left side of side frame and proceed as follows: 1. Remove

cover

bolt (11, extract

(2) by loosening element

(3) and

clean inside of case and removed

replacement of element, 2. After loosen air vent plug (4), start engine and allow oil to flow out

parts. Then install a new element

until air bubbles no longer come

and tighten bolt (1) for cover (2)

out of plug (4). Then tighten plug

after filling with oil. *

(4).

Use a genuine

Komatsu

for oil filter element.

lb01704

SERVICE

- 79 -

product

EVERY

250

HOURS

e. FUEL TANK STRAINER After remove

SERVICE

BOTTOM

tightening

f. BATTERY valve

cap (1) to extract

(2).

strainer,

then wash strainer and strainer case. *

ELECTROLYTE

Add distilled water if battery fluid level is below prescribed level (I 0 to 12 mm above plates). If electrolyte has been reduced by spilling, have a

Since strainer is soldered to cap (11, remove it as an integral part

dilute sulfuric acid of same strength.

of cap assembly.

* Clean air vent of battery cap (1)

battery service shop fill battery with

A i_ To avoid gas explosions, do not bring fire or sparks near the battery.

when checking fluid level.

* Do not use metallic adding fluid.

funnel

for

[/li::,If the.electrolyte skin or clothes, wash water.

-

80 -

with

gets on your immediately

plenty

of

clean

D-01705

EVERY 250 HOURS

g. TRACK

h. FAN BELT

SHOE BOLT

The shoe bolt (1) attaching

the

track shoe to the link will be broken

Push between

if it is used as loosened. So, you are

alternator

required to retighten every time you

the belt slack is about 13 mm, the

V-belt

find a loosened one.

belt

of V-groove

Track shoe bolt tightening torque: 70 + 8 kgm Tightening

sequence

SERVICE

is

the the

belt fan

at the middle pulley and the

pulley (Approx. considered

to

6 kg). If have

the

Check each pulley for damage, and V-grooves and V-belt for wear. Particularly,

correct tension.

Replace

To adjust, loosen bolt (1) and nut (2) to shift alternator (3). * When adjusting the V-belt, do

leaving

not attempt

to push

alternator

(3) directly with a bar or the like, but use a wood

pad to prevent

damage to the core.

-81

-

check whether

is in contact

with bottom

through wear.

belt if it has stretched,

adjustment,

no

allowance

for

or if there is a cut or

crack on belt. When two belts are used, replace same time.

both

belts at the

EVERY 250 HOURS SERVICE

i. DRAIN

WATER

SEDIMENT 1. Remove

AND

FROM FUEL FILTER drain

plug

(1)

on the

4. Tighten

air vent

bottom of the filter to drain water

feed

pump

knob

and sediment accumulated on the bottom. After draining, tight-

and tighten it.

plug (21, push (3) into place,

en plug (1).

2. Loosen air vent plug (2).

3. Loosen feed pump knob (3) and move the pump up and down to draw off fuel until air ceases to come out of plug (2).

-

82 -

H-09741

EVERY

EVERY 500 HOURS

SERVICE

*

500 HOURS

SERVICE

Maintenance for every 50 and 250 hours should be carried out at same time.

FUEL FILTER Close the valve (I) on the fuel tank bottom.

Ir To refit the cartridge, place the gasket face in contact with the seal

Using the tool provided, remove cartridge (2) by turning it counter-

face of the filter stand, then screw

tighten it.

up the cartridge 112 to 314 of a turn (be careful not to tighten it up ex-

Open the valve (1).

After replacing the cartridge, start up the engine and check the filter

clockwise.

Fill the new cartridge with fuel and refit it after applying a dab of oil to the gasket face.

cessively).

4. Afterreplacingthecartridge,

loosen

air vent plug (3).

5. Loosen feed pump knob (4) and move the pump up and down to draw off fuel until air ceases to come out of vent plug (3).

- a3 -

Tighten air vent plug (31, push feed pump knob (4) into place, and

seal face for possible oil leakage.

Be sure to use a genuine Komatsu cartridge.

EVERY 500 HOURS SERVICE

b. BREATHER Remove out dust

the breather and wash remaining inside with diesel fuel oil.

Steering clutch case breather

c. RADIATOR FIN Loosen the eight bolts to open tne radiator grille.

Mud, dust, or leaves blocking the fin shall be blown off by compressed air. Steam or water may also be employed instead of compressed air. * Check the rubber hose on this OCcasion and replace hose that it cracked or fragile. Further, also inspect loosened hose clamps.

Transmission case breather * Since this oil filler cap can also be used as a breather, wash together with the cap.

Final drive case breather

-

84 -

(2 points)

D-01708

EVERY

EVERY 1000

HOURS

SERVICE

*

Maintenance

for every

50,

1000

250

HOURS

SERVICE

and 500

hours

should be carried out at the same time. a. TRANSMISSION TORQUE 1. Removing side

of

CASE (INCL.

CONVERTER cover machine,

CASE)

(1) from remove

2. To

remove

converter,

under-

remove

drain

cover

plugs (2) and (3) from inside and drain oil. After draining, tighten

strainer

be

cover (7).

-

85 -

removed

torque (5) and

together

case,

(8) and unscrew can

for bolt

(4). To remove

transmission

drain plugs (2) and (3).

IbOY

strainer unscrew

strainer remove

with for pipe

bolt (6). Strainer together

with

EVERY

1000

HOURS

SERVICE

3. Clean strainer and inside of case.

After

cleaning,

reinstall

4. After

strainer.

oil filter element

for trans-

mission case has been replaced (see “EVERY 250 HOURS SER-

Replace strainer if damaged.

VICE”),

fill with prescribed quantity of engine oil through oil filler (F).

*

Refill capacity:

47 II

+ The

type of lubricant

pends on the ambient ture.

Select

“FUEL, table LUBRICANTS”.

used detempera-

according COOLANT

to

the AND

I)-01709

EVERY 1000

b. STEERING

CLUTCH

CASE

1. Drain oil by removing (PI from

underside

drain plug

of machine.

After draining, tighten drain plug.

2. Remove cover (I) on left side of side frame.

3. To remove spring 14) and strainer (51, remove cover (3) by loosening bolt (2).

4. Clean

the

assembled

interior

of case, dis-

parts and the strainer.

Then reinstall them. If the strainer is broken, replace one.

II-OY747

-

87 -

it with a new

HOURS

SERVICE

EVERY

1000

HOURS

SERVICE

c. FINAL

DRIVE CASE

First, remove

After oil filter element for steering clutch case has been replaced

oil filling plug (F) from both sides of machine. Then,

(see “EVERY 250 HOURS SERVICE”), fill Prescribed quantity of

drain plug (PI to drain oil. draining, tighten plug (PI and fill prescribed quantity of engine oil through respective oil filling plugs

engine oil through oil filler (F).

Refill capacity: 73 Q The type of lubricant used depends on the ambient temperature. Select according to the “FUEL, COOLANT AND table LUBRICANTS”.

remove

After

(F). k Refill capacity:

23 Pfor each side type ‘of lubricant used depends on the ambient temperature. Select according to the “FUEL, COOLANT AND table

Sr The

.LUBRICANTS”.

EVERY

d. HYDRAULIC FILTER 1. Lower move

TANK

bucket

and forth

to

ground

control

with

and

lever back

engine

stopped.

lower

drain

plug

(1)

from

part of tank and drain oil

from tank. After draining, tighten drain plug (1).

Then slowly turn cap of oil filler (F) and remove, while relieving air pressure.

Ii-OYi4Y

HOURS

SERVICE

AND 2. Remove

bucket

1000

-

89

-

3. Loosening

air

vent

bolt

(3),

remove drain plug (2) and drain oil from filter case.

EVERY 1000

HOURS SERVICE

e. UNDERCARRIAGE COMPONENTS 4. After by

draining, remove cover (5) unscrewing

remove element

bolt

(4)

5. Supply

and

(6). Clean inside

of filter case and removed

parts.

prescribed

quantity

of

Stop

machine

and

through oil filler (F).

track roller, carrier roller and idler.

6. After

changing

consumption

of

oil in

oil, start engine

Install a new element and tighten

with

drain plug (2).

and allow oil to overflow

air vent

check

on level ground

engine oil to tank and filter case

bolt

(3) loosened until air

vent bolt (3) no longer produces air bubbles.

A

When removing the cap, turn it slowly to relieve inner pressure.

* Refill capacity: 63 II * The type of lubricant pends on the ambient ture. table

Select â&#x20AC;&#x153;FUEL,

used detempera-

according COOLANT

to

the AND

LUBRICANTSâ&#x20AC;?.

* Use a genuine Komatsu

part for

filter element.

- 90 -

D-01711

EVERY

f. LUBRICATING Apply Slowly

loosen seal bolt (1) and

grease

to grease

fittings

shown by allows.

9. TURBOCHARGER JOINT 0

see if oil oozes out of screw. If oil oozes

out,

oil is still sufficient.

Tighten bolt immediately.

If oil does not flow

(2 points)

SERVICE

CLAMPING

Back plate mounting bolt (for mounting the back plate on the Tightening torque:

even after 0

oil amount is insufficient. Request distributor

HOURS

center housing).

1. Univesal joint

seal bolt (1) has been removed, Komatsu

1000

1.15 - 1.38 kgm V clamp for compressor housing Tightening torque:

to perform

necessary repairs.

0

1.27 - 1.50 kgm V clamp for turbine housing Tighten

the V-clamp

in the fol-

lowing manner.

1. First, tighten to 1.84 kgm 2. Then, loosen and retighten

to

0.58 kgm.

2. Diagonal brace

(2 points)

3. Finally, 1.27 -

H-09751

-91

-

tighten

to

1.50 kgm.

a torque

of

EVERY

1000

HOURS

SERVICE

h. TURBOCHARGER

ROTOR

Contact your Komatsu distributor Turbocharger

mounting

bolt (for

securing

exhaust

manifold

the

for checking, or proceed as follows: Disconnect

the air intake and ex-

and turbine housing together)

haust system pipes and hoses from

Tightening torque:

the turbocharger 5.5 -

Turbocharger

7.5 kgm

oil feed pipe (inlet

* If the measurements

1. Axial play Move the rotor axially and mea-

line) 3.5 oil

7.5 kgm

feed

pipe

Play: standard

indicate any your contact

abnormality,

Komatsu distributor.

sure the axial play.

Tightening torque: Turbocharger

and make the fol-

lowing checks.

0.08

-

0.25 mm

* If the rotor is excessively

(outlet line)

Measure

leakage

caused

Tightening torque:

rotor holding both ends by hands

trouble

is noted,

in radial direction in parallel.

bocharger

Play: Standard

Komatsu distributor.

3.5 -

7.5 kgm

soiled

with dust or carbon or if any oil

2. Radial play radial

play by moving

0.08 9 Radial clearance J.

-

by turbocharger have the tur-

repaired

by

your

0.18 mm

Move the rotor shaft end on the blower impeller side in the radial direction. That is, push the shaft end in the four radial directions (upward,

downward,

to the left

and to the right).

There must be some play in each direction.

- 92 -

D-01712

EVERY 1000

i. CORROSION 1. After

RESISTOR

screwing

in valves

(2) (2

*

points) on the corrosion resistor, remove the cartridge (1) by turning it counterclockwise

and re-

It

is

recommended

*

Be careful not to screw in more than required.

place it with new one.

2. Turn the cartridge

genuine

Komatsu cartridge are used.

(1) in until its

sealing surface comes into contact with the head. Then, retighten the cartridge l/2 to 314 of a turn.

3. After replacement, open valves (2).

- 93 -

HOURS SERVICE

EVERY

2000

HOURS

SERVICE

EVERY 2000

HOURS SERVICE

*

Maintenance for every 50, 250, 500 and 1000 hours should be carried out at the same time.

a. LUBRICATING Apply shown

grease

to

grease

fittings

by arrows.

1. Steering

pedal shaft

(10 points)

2. Bucket control

lever shaft

3. Gear shift lever shaft

(3 points)

(3 points)

- 94 -

ll-,,w51

EVERY 2000

b. ENGINE 1. Remove

breather

(1)

from

the

breather

in diesel

oil and rinse. Then dry with comhose or pipe,

and if there is any sediment oil

(sludge)

removing

the

breather,

off all the dirt around the

breather.

* Check the O-ring, and if necessary replace it with a new part.

pressed air and install again.

3. Check the breather deteriorated

* Before wipe

2. Put the whole

(2 points)

SERVICE

BREATHER

cylinder block.

4. Fuel control lever shaft

HOURS

for

inside,

replace with a new hose or pipe.

Coat

it with

installing.

engine

oil before

EVERY 2000

HOURS SERVICE

d. ALTERNATOR

c. TURBOCHARGER Excessive carbon or oil sludge adhering to turbocharger peller may deteriorate formance sometimes

blower normal

of turbocharger

imper-

and may

damage it. your

Contact distributor.

Komatsu

the

turbocharger

oil

supply tube and the drain tube. remove

the

connection

area of the intake manifold the blower

housing

and

so that the

2. Using light oil, wash the impeller to eliminate surface.

brushes

oil through

bocharger blower that

oil

impeller

foreign

carbon Do

or the

adhered

not

use

on wire

like to prevent

damage to the impeller surface.

filler.

the

tur-

Turn

the

several turns so

materials

such

as

sludge can be washed away.

4. Using your fingers, turn the im-

AND STARTING

MOTOR As

hours

the

of

indicate

employment

engine that

Komatsu distributor.

* They

should

tion or more. If there is no sigh of

1000

hours,

interfering

frequently operated at night.

with

in somewhere,

or being caught the

impeller

e. ENGINE

the

impeller

seems

contact

distributor

your

to

turn

Komatsu

to ask to repair or re-

place it.

5. If the

impeller

is found

every

if the machine

is

As

VALVE

special

removing

tool

CLEARANCE is required

and adjusting

request shall You distributor for service.

for

the parts, Komatsu

normal

after this check, supply engine oil to the turbocharger.

be repaired

is

normal.

If

the

brushes are already worn out, you repair from a should request

for one revolu-

heavily,

blower impeller can be seen.

the

light

peller vigorously

1. Remove Then,

3. Pour

f. ENGINE Check cracks

VIBRATION the vibration

or

separation

DAMPER damper for on rubber

surface.

If there are cracks or separation, contact

your

Komatsu

distributor

for replacement.

- 96 -

D-01715

EVERY 4000

EVERY 4000

HOURS SERVICE

*

Maintenance 2000

a. WATER

time.

PUMP

Check for loose pulley, grease leakage or water leakage. If any, contact for

your

repair

Komatsu

distributor

or replacement

of

the

water pump.

B-09756

- 97 -

for every

hours should

50, 250,

be carried

HOURS SERVICE

500,

1000

and

out at the same

WHEN REQUIRED

WHEN

REQUIRED

a. AIR CLEANER Checking Whenever indicator

Cleaning or replacing outer element

the red piston in dust

(1) appears,

clean the air

cleanerelement.Stoptheenginewhen cleaning the element.

Replace the outer element

1. Loosen bolt (2), and remove band

edly or used throughout

2. Loosen wing nut and remove the

and the removed cover.

*

Replace seal washer (6) or wing nut

*

When inspecting

(5) if they are broken.

4. Cleanandinspecttheelement.(See the item â&#x20AC;&#x153;cleaning outer elementâ&#x20AC;?.)

or cleaning the

aircleaner,removeevacuatorvaIve

Install the cleaned element.

- 98 -

at the

same time.

3. Clean the air cleaner body interior

return red piston.

a year.

Replace the inner element

outer element.

5. Push button of dust indicator

which

has been cleaned 6 times repeat-

(3) and cover (4).

to

(7) and clean with compressed air.

WHEN REQUIRED

Replacing *

Replace ments

both

inner and outer ele-

when

red piston stalling even

the

dust

appears

soon after in-

the cleaned though

it

indicator

outer element has

not

cleaned 6 times.

Sr Check inner element nuts for looseness

been

Remove

mounting

and, if neces-

The

outer

cleaned number

be

of removed

the cover from

inlet port.

4. Fit a new

of

times been

cover.

by

the

and the remove

inner

element

and

tighten

the outer

element

Push

the

reset button.

seals.

-

99 -

dust

NOTE:

the air to the it

with

and the indicator

Do not attempt

a cleaned n!

3. Clean the air cleaner body interior.

has seen

cover

and then

the inner element.

2. Cover the air inlet port.

nuts.

5. install

number

element can

the outer

the

element,

connector

one seal from

element. the

outer

inner element

remove

Remove

sary, retighten. *

1. First

Do not clean cleaner

to reinstall

inner element. or replace

element engine running.

with

the air the

WHEN REQUIRED

Cleaning

With compressed Direct than

The

outer element

7

air

dry compressed kg/cm21

following

methods

require

spare parts.

With water Dash

air (less

to element

from

city

water

on

element

kg/cm21

(less

than

from

3

inside

Ir If small holes or thinner parts are found on element when it is

inside along its folds, then direct it

along folds, then from outside and

checked

from

outside

along

again from inside. Dry and check it.

after cleaning and drying, replace

again

from

inside,

its folds and

and

With cleaning

*

agent

When wear things safety.

using safety

compressed glasses

required

to

air,

and other maintain

bulb

as carbon etc. attached

on the ele-

ment, the element may be cleaned in lukewarm solution of mild detergent, then rinsed in clean water and

If element

is usable, wrap it and

store it in dry place.

For removing oils and fats as well A!

an electric

the element.

check

element.

with

*

Do not use element whose folds or gasket or seal are damaged.

*

When

cleaning

element,

do not

hit it or beat it against something.

left to drip dry. + Drying

can

blowing

be speeded

dried

(less than

7

inside

the

to

up by

compressed kg/cm21 outside

air

from

the

of

the

element.

Never attempt element. *

Using warm

water

to

heat

the

(about 40°C)

instead of soapy water may also be effective.

-

IOO-

13-09592

WHEN REQUIRED

b. CLEAN INSIDE OF COOLING SYSTEM Clean the inside

of the cooling

*

system, change the coolant, and replace the corrosion resistor, accord-

Be sure to replace the corrosion resistor cartridge.

Sr Use

city water

for the

cooling

l

Add antifreeze in the cooling water When

deciding

the ratio of anti-

freeze to water, check the lowest

ing to the table.

water.

temperature

*

Stop the machine on level ground

If river water, well water or other

cide from the mixing

when

such water supply must be used,

given below.

cleaning

or changing

the

coolant. *

contact your Komatsu distributor.

Use a permanent type of antifreeze.

If, for some reason, it is impossible to use permanent

in the past, and de-

It is actually better to estimate temperature

n!

type antifreeze,

Antifreeze

is flammable,

so keep it

away from any flame.

Kind of coolant

Cleaning inside of cooling system and changing coolant

Permanent type antifreeze (All season type)

Every year (autumn) or every 2000 hours whichever comes first

Replacing corrosion resistor

about

10°C

a

lower

when deciding the mixing rate.

Mixing rate of water and antifreeze

use an antifreeze containing ethylene glycol.

rate table

Min.

1

Amount of antifreeze (Q)

1

Amount of water IQ)

15

( 19.5

/ 23.5

1 26.5

50

45.5

41.5

38.5

* We recommend useof an antifreeze density gauge to control the mixing proportions.

-lOl-

WHEN REQUIRED

1. Stop the engine,

close corrosion

resistor valves (1).

2. Turn radiator cap (2) slowly until it comes off.

A!

Open drain valve (3) at the bottom

When the water reaches the vicin-

of radiator and drain plug (4) at the

ityofthewaterfiller,puttheengine

side of oil cooler and drain off the

at low idling, open the drain valve

cooling water.

(3) and plug (4), then pass water

Close up drain valve (3) and plug

through the cooling system until

(4) and pour in clean water (ex. city

clean water comes out from the

do not remove the cap.

water)uptothevicinityofthewater

drain valve and plug for IO min-

This is because of the possibility of

filler.

utes.

When flushing, adjust the flow so

If the water temperature

is high,

scalding water spurting out. cap

that water is added at the same rate

slowly to allow pressure to be re-

as the water is drained to keep the

lieved.

radiator always full.

When

removing

Corrosion resistor

cap,

turn

Water fillter

Drain valve (bottom of radiator)

-

102-

WHEN REQUIRED

After washing the cooling system,

8. After washing the cooling system,

stop the engine. Open drain valve

drain off all the water, then close

(3) and plug (4) to drain water and close drain valve (3) and plug (4).

in clean water (ex. citywater) slowly

After draining off the cooling water, wash out the cooling system using commercially

available

de-

up drain valve and plug, and pour up to the vicinity of the water filler.

9. When the water reaches the vicin-

tergent. Follow the instructions on

ity of the water filler, put the engine at low idling, open the drain valve

the detergent container.

and plug, then pass water through thecoolingsystemuntilcleanwater comesoutfromthedrainvalveand

pletelyclean,

becomes

com-

stopthe engine and

close the drain valve and plug.

11. Replace the corrosion resistor cartridge and open valve (1). *

For details of replacement corrosion

resistor,

see

of the EVERY

1000 HOURS SERVICE. 12. Supply water until it overflows from water filler.

13. Run the engine 5 minutes at low idling

plug.

* When flushing, adjust the flow so

Drain plug (oil cooler)

10. When the water

and then

minutes

for another

5

at high idling to elimi-

thatwaterisaddedatthesamerate

nate air trapped

as the water is drained to keep the

system

radiator always full.

during the operation).

(leave

in the cooling radiator

cap off

14. Stoptheengineandwaitforabout 3 minutes. Supply cooling water up to the specified level. Tighten the cap.

-

103 -

WHEN REQUIRED

c. TRACK TENSION Inspection

Adjustment

Propel machine forward and let it

To increase tension, force grease

h

When loosening plug (I), do not

come to a stop on level ground with-

into grease fitting under pressure. To

loosen more than one turn. At this

out applying brakes. Put a straight rod

slacken track, unscrew

plug (1) no

time, never attempt to loosen any

rotatingâ&#x20AC;? to

other part (because there is dan-

acrosscarrierrolierandidlerasshown

morethan

in Photograph.

squeeze out grease. Grease may be

ger of any loosened

forced into fitting until dimension

ejected under force of contained

If there is a clearance

of 20 to 30 mm between grouser

rod and

at half way point between

roller and idler, track tension is normal.

â&#x20AC;&#x153;onecomplete

S

part being

reaches 0 mm. If track still remains

high-pressure

slack, pin bushing is excessivelyworn

does not readily come out, move

and must be either reversed

machineslightly;fotwardand

or re-

placed. Refer to Komatsu distributor for necessary repairs.

grease).

If grease back.

WHEN REQUIRED

d. ELECTRICAL INTAKE AIR HEATER Check electrical

intake air heater

(1) once a year before commencing work in the cold season.

e. WATER SEPARATOR When float (2) is at or above red line (I), drain the water according to the following

procedure:

Loosen drain plug (3) and drain the

Remove electrical intake air heater

accumulated

water until the float

(IIfromtheengineintakeconnection,

reaches the bottom.

and check it for possible open-circuits

Tighten drain plug (3).

and dirt.

When

If the air is sucked into fuel line inspecting

and

replacing

when drain the water, be sure to

electrical intake air heater (I), replace

bleed air in the same manner as for the fuel filter.

the gasket with new one.

(See Fuel Filter Cartridge in EVERY 500 HOURS SERVICE section.)

To

fuel filter

fuel tank

-

105 -

ADJUSTMENT

ADJUSTMENT ADJUSTMENT BRAKES When of

OF STEERING

brake lining wears,

steering

pedal

will

travel

increase,

making steering difficult.

To adjust,

Standard travel:

127

-

clearance

lining and drum:

rear removing cover, 1. After remove inspection cover (I).

2. Tighten

proceed as follows: Standard

Adjustment

0.3 mm

191 mm between

clamping that

the

contact

adjustment torque

nut (2) to a

of 9 kgm,

lining come with

drum.

so

into tight (Make

lining is closely contacting

sure drum

by stepping on pedal.)

3. Unscrew

adjustment

nut (2) one

and 516 turn to adjust to standard clearance and travel.

-

106 -

Adjust so that both left and right pedals will have same travel. If there is a difference

in travel be-

tween the pedals, brake on one side only will give effective response to pedal action.

If brakes still give poor response refer to adjustment, after Komatsu distributor for repair.

ADJUSTMENT

ADJUSTMENT CLEARANCE Guide frame

so

OF IDLER

(2)

pinches

that

moved forward

the

the

idler

and backward

external force. Therefore,

track

can

be

by an

when the

Adjustment Move machine about 1 or 2 meters on a flat ground and measure the clearance

A (4 locations;

right,

to wear. Wear

the track frame and the guide. If the

of the guide causes

inside and outside)

left,

idler moves, this guide (2) is subject

between

the idler to roll and tilt, which results

clearance

in failing free of the track. To avoid

bolt (1). remove guide (2) and pull out shim (3) to adjust the clearance

this trouble, the

clearance

make

adjustment

between

the

frame and the guide as follows:

on track

A exceeds 4 mm, loosen

at one side to 0.5 Thickness mm.

mm to 1 .O mm.

of one shim

-

107 -

(3) is 0.6

ADJUSTMENT

ADJUSTMENT OF UNDERCARRIAGE l

Properly

adjust

Tension shown

For rocky slightly tion dures,

mm

terrain,

In clay slacken and

and is usuat this

slightly or

sandy

point.

l

Check as well

idler rollers

for oil leakage

as for

bolts

loose

nuts. If any trouble repair immediately.

tighten

to

and

is detected,

l

Check

idler guide

ance. If clearance may tracks

develop

increases,

part.)

REQUIRED”.)

-

108-

motion

idler and

may come off. (For inspec-

ADJUSTMENT

proce“WHEN

plate for clear-

side

tion and adjustment to refer

areas,

them. (For inspec-

maintenance refer

tension.

at clearance

in photograph

ally 20 to 30 tracks.

track

is measured

procedures, respective

section

for each

ADJUSTMENT

INSPECTION Frequent

AND REPAIR inspection

and prompt

l

Measuring Height of Grouser

repair will reduce repair costs. The

After

following

shoes, measure

items for inspection

will

serve as a guide to maintenance

ser-

vice of each undercarriage

part. Per-

form periodical inspection

and con-

repairable limits and reversing limits.

up slack

in track

height at center

of shoe as shown below. *

tact the Komatsu distributor in your area when machine has approached

taking

*

Standard height (HI: Triple grouser: Semi-double Repair limit

grouser:

36 mm 6 1 mm

Triple grouser:

20 mm

Semi-double

25 mm

-

grouser:

109-

ADJUSTMENT

l

Measuring Outside Diameter of Track Roller 1. Measure height (size C) of link tread as shown. at position machine 2. Stop where link tread, whose size C has been measured completely, contacts roller tread. Then measure size B. 3 Calculate outside diameter tread (size A):

* *

A=(B-C)x2 Standard size (A): Repair limits:

of

222 mm 197mm

H-09767

TROUBLE SHOOTING

GUIDE

TROUBLE SHOOTING GUIDE This guide is not intended to cover every conditions,

however many of the

more common possibilities are listed.

ENGINE This

engine

engine

oil pressure

warning

lamp

speed is raised after completion

remains

alight

The

when

engine

does

not start

when

the

starting

Add the oil to the specified level.

Replace the oil element.

Repair where air is leaking into fuel system.

l

Check oil leakage from the pipe or the joint.

Replace the injection pump or the nozzle.

l

Replace the warning lamp.

Check the valve clearance.

Check engine compression

is emitted

is turned

Add fuel.

l l

Steam

motor

over.

of warm-up.

from the top part of the radiator

pressure.

Refer to the section of electrical system.

(the pressure

valve).

The pointer

of the water

temperature

guage

Exhaust

is in red range on

right hand side of the gauge.

Supply the coolig water and check leakage.

gas is white

or blue.

l

Adjust to specified oil quantity.

l

Replace with specified fuel.

Adjust fan belt tension.

Wash out inside of cooling system.

Exhaust

Clean or repair the radiator fin.

l

Clean or replace the air cleaner element.

Replace the thermostat.

l

Replace the nozzle.

Tighten the radiator cap firmly or replace the gasket of it.

l

Check engine compression

Replace the water temperature

gas occasionaly

of the water

pressure.

gauge.

Combustion

The pointer

turns black.

temperature

gauge

is in white

l

range

noise occasionally

changes

to breathing

Replace the nozzle.

on left hand side of the gauge. l

Replace the thermostat.

l

Replace the water temperature

N-09768

Unusual guage.

-lll-

combustion

noise or mechanical

l

Replace with specified fuel.

l

Check over-heating.

0

Replace the muffler.

0

Adjust valve clearance.

noise.

sound.

TROUBLE SHOOTING

ELECTRICAL Lamp

does

GUIDE

SYSTEM

not glow

brightly

even

when

engine

runs at high

speed.

Lamp flickers

while

engine runs.

l

Check for loose terminals and open-circuit

l

Adjust belt tension.

The starting

Check and repair the wiring.

l

Charge the battery.

lamp does

The heater

not go out even

when

engine

runs at high

speed.

signal does not glow red.

Check and repair wiring.

l

Replace the hedter reliy.

l

Replace the heater signal.

l

Replace the alternator.

l

Inspect and repair wiring.

The oil pressure

l

Replace charge lamp.

stationary

Unusual l

noise is emitted

before the engine starts up.

wiring. l

Charge

motor disengages

e

from the alternator.

warning

(when

lamp does not light up when

the starting

switch

l

Replace the warning lamp.

l

Replace the warning lamp switch.

engine

is

is in ON position.)

Replace the alternator.

Charge

Starting

motor does not turn when

starting

switch

is turned

on.

(When

lamp does not light up when the starting

switch

l

Inspect and repair the wiring.

l

Replace the charge lamp.

l

Charge the batten/.

l

Inspect and repair the wiring.

The pinion of the starting motor keeps going in and out.

Outside

the

l

touched

with the hand.

Charge the battery.

Starting

motor turns the engine sluggishly.

l

Charge the battery.

l

Replace the starting motor.

electrical

the engine

is stationary.

is in ON position.)

intake

air heater

l

Check and repair wiring.

l

Replace the electrical intake air heater.

l

Check and repair the heater switch.

is not

warm

when

TROUBLE SHOOTING

GUIDE

CHASSIS Oil pressure

in torque

converter

When

fails to rise.

Check and repair where air is leaking into oil pipe and pipe joint.

instead

a

Check and replace gear pump.

l

.

Add oil to transmission

l

Clean and replace transmission

l

steering

pedal

Torque converter

overheats.

(Pointer of torque

converter

stops

Adjust steering linkage.

When

filter.

steering

pedal

oil gauge is in red range.1

straight

l

Refer to the above.

l

Adjust brake.

l

Replace fan belt.

l

Refer to the section of engine.

Machine

.

Refer to the item “oil pressure in torque converter fails to rise”

pedals depressed. l

fails to start

machine

speed change.

case. tinues to travel

Machine

on one side is depressed,

of turning or engine

or its speed

fails to increase

when

will

not stop

on one side is depressed, forward

when

instead

middle

machine

of L.H. and R.H. steering

Adjust brake.

gear

shift lever is placed in higher speed.

Track comes off.

l

Add oil to steering clutch case.

Sprocket

.

Refer to the item “oil pressure in torque converter fails to rise”.

l

l

Clean steering clutch case strainer.

-113-

abnormal

wear.

Adjust track tension.

Bucket l

develops

rises for tilts) too slowly

Add oil to hydraulic tank.

con-

of turning.

or does not rise (tilt) at all.

STORAGE

STORAGE BEFORE STORAGE To place the machine for an extended

in storage

period of time, the

Apply metal

a thin coat of grease to surface (hydraulic piston

following measures must be taken to insure that it can be returned to

rods

operation with minimum of service.

As to batteries, remove the termi-

After

every part is washed

dried, housed

the

machine

shall

and be

in a dry building. Never

and

front

idler

adjusting

o When the ambient temperature is anticipated to drop below 0°C. always add antifreeze in the cooling water.

rods). nals and cover them,

or remove

l Set levers and pedals as follows:

Neutral

+ Gear shift lever

Engine stop

them from the machine and store

+ Fuel control lever

separately.

+ Bucket control lever

Hold

*

Free

leave it outdoors.

Brake lock lever

In case it is indispensable to leave it outdoors,

lay wood

plates on

the ground, and park the machine on the wood

b

plates and cover it

rs

4

with canvas etc.

Completely fill fuel tank, lubricate and change oil before storage.

-

114-

11-09771

STORAGE

AFTER STORAGE

DURING STORAGE l

l

machineforashortdistanceoncea

Carry out the following procedure when taking the machine out of long-

month so that new oil film will be

term storage.

coated

l

Wipe off the grease on the hydrau-

l

Completely

Operate the engine and move the

over

movable

parts and

component surfaces.

Before operating the equipment,

wipe off the grease on

fill fuel tank, lubricate

and add oil.

the hydraulic piston rod.

AIf

it is unavoidably

necessary to

carry out rust-preventive

opera-

tion while the machine is indoors, open up doors and windows improve

ventilation

to

and prevent

the gas poisoning.

-

115-

is stored without

carrying out the monthly rust prevention

lic piston rod. working

* If the machine

operation,

request

your

Komatsu distributor for service.

SERVICE METER

SERVICE

METER

How the meter progresses

Consequently,

work hours. So, use itaccording tothe

The service meter progresses by 1

ning, the service meter will advance

following

when the engine

even if the machine does not move.

This meter indicates the integrated instructions.

is operated

for

one hour, regardless of the engine Record the readings

at the start

and the end of work, this is the

speed.

The indicator

work record of the machine.

meter

above

the service

rotates when the engine

This record will indicate when peri-

running to show that the meter is

odical maintenance

running.

It also

indicates

is due. the

integrated

working hourswhen machineproblems are encountered.

The meter is installed on the instrument board.

-

116

-

if the engine is run-

MACHINE AND ENGINE SERIAL NUMBERS

MACHINE AND ENGINE SERIAL NUMBERS When mechanic ment

calling

for

service

of

or when making replace-

parts order,

your Komatsu

be sure to give

distributor

the

ma-

chine and engine serial numbers as well

as the service

beformentioned. are found

meter

These

reading numbers

on the plates shown

in

the photos below. l

II-UY774

Location of the machine number mark

serial

0 Location number

of

engine

serial

mark

... on the left side of the steering

. on the left side of the engine cylin-

clutch case

der block

-

117-

FUEL, COOLANT

AND LUBRICANTS

AND

FUEL, COOLANT PROPER SELECTION

OF FUEL, COOLANT

KIND OF FLUID

RESERVOIR

LUBRICANTS

AND LUBRICANTS AMBIENT

14 -10

TEMPERATURE 50 10

32 0

CAPACITY

32

Engine oil pan

Transmission case (incl. torque converter

case)

Engine oil

Steering clutch case

Hydraulic

Refill capacity

Specified amount

68 20

system

Add antifreeze

I

I

I

(a)

26

52

47

75

73

23

23

135

63

65

I I

-

% ASTM 0975 No. 1

-

118-

I)-01720

FUEL, COOLANT

AND LUBRICANTS

NOTE: (1) When fuel sulphur

content

described

(2) When starting the engine in an atmospheric temperature of lower than Oâ&#x20AC;?C, be sure to use engine oil

is less than 0.5%, change

oil in the oil pan every periodic

maintenance

hours

of SAElOW,

in this manual.

Change oil according to the following sulphur content is above 0.5%.

(3) Fuel sulphur content

ASTM: SAE: API:

l/2 of regular

Above 1.0%

l/4 of regular interval

Petroleum

P-04106

even

goes up to

CD as engine oil and if API

CC, reduce

the engine

oil change

(4) There is no problem if single grade oil is mixed with multigrade oil (SAElOW-30, 15W-401, but be sure to

interval

add single grade oil that matches the temperature in the table on the left.

(5) We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment tions.

Institute

Specified capacity: Total amount of oil including oil for components Refill capacity:

and SAE15W-40,

interval to half.

American Society of Testing and Material Society of Automotive Engineers American

Use API classification classification

Change inte,rvaI of oil in engine oil pan

0.5 to 1.0%

SAElOW-30

though an atmospheric temperature 10°C more or less in the day time.

table if fuel

and oil in piping.

Amount of oil needed to refill system during normal inspection and maintenance.

-

119 -

applica-

FUEL, COOLANT AND LUBRICANTS

UO.

Engine Oil [CD or CEI SAElOW. 30, 40 lOW30, 15w40 (The 15W40 oil is CE.) marked

Supplier

Grease [Lithium-Base] NLGI No. 2

Anti-freeze Coolant [Ethylene Glycol Base] Permanent Type

l

AF-ACL AF-PTL AF-PT (Winter, one season type)

1

KOMATSU

2

AGIP

3

AMOCO

4

ARC0

5

BP

6

CALTEX

7

CASTROL

Turbomax RX super CRD

8

CHEVRON

l

-

l

Arcofleet

S3 plus

Litholine HEP 2 Arco EP moly D Antifreeze

AF engine coolant

l

l

Delo 400

MS3 Spheerol

Ultra-duty

-120-

EPLZ

Anti-freeze_

1

grease 2

P-04110

FUEL, COOLANT AND LUBRICANTS

VO.

Engine Oil [CD or CEI SAElOW. 30, 40 lOW30, 15w40 (The 15W40 oil marked is CE.)

Supplier

Grease [Lithium-Base] NLGI No. 2

Anti-freeze Coolant [Ethylene Glycol Base] Permanent Type

l

9

CONOCO

* Fleet motor oil

10

ELF

Multiperformance Performance 3C

11

Super-sta grease

3C

Tranself EP Tranself EP type 2

Glacelf

EXXON (ESSO)

Essolube D3 Essolube XD-3 Essolube XD-3 Extra * Esso heavy duty Exxon heavy duty l

Beacon EP2

All season coolant

12

GULF

Super duty motor oil * Super duty plus

Gulfcrown EP2 Gulfcrown EP special

Antifreeze and coolant

13

MOBIL

Delvac 1300 Delvac super low-30, 15w-40

Mobilux EP2 Mobilgrease 77 Mobilgrease special

l

l

-121

-

FUEL, COOLANT

\lO.

AND LUBRICANTS

Engine Oil [CD or CEI SAElOW, 30, 40 lOW30, 15w40 (The 15W40 oil marked is CE.)

Supplier

Anti-freeqe Coolant [Ethylene Glycol Base1 Permanent Type

Grease [Lithium-Base] NLGI No. 2

l

14

PENNZOIL

15

PETROFINA

16

SHELL

17

SUN

Multi-purpose white grease 705 707L White Bearing grease

Anti-freeze and summer coolant

FINA kappa TD

FINA marson

FINA tamidor

Rimula

Alvania

EP grease

Sunoco

ultra

l

Supreme duty fleet motor oil

4

X

Sun prestige 18

TEXACO

19

TOTAL

Ursa super plus Ursa premium

Multifak Starplex

Rubia S Rubia X

Multis

EP2

Guardol

Unoba

EP

l

EP2 2

EPLZ

prestige 742

2EP

Sunoco antifreeze and summer coolant Code 2055 startex antifreeze coolant

Antigel/antifreeze

l

20

UNION

l

21

VEEDOL

Turbostar Diesel star MDC l

Antifreeze

l

-

122-

P-04112