KOMATSU D75S-5 DOZER SHOVEL OPERATION & MAINTENANCE MANUAL (SN:16538 & UP) KOMATSU D75S-5 – PDF

EMISSION CONTROL WARRANTY EMISSION CONTROL WARRANTY

1.

STATEMENT

(APPLIES TO CANADA ONLY)

Products Warranted Komatsu America International Company. Komatsu Mining Systems Inc. and Komatsu Utility Corporation (collecttvely “Komatsu”) produce and/or market products under brand names of Komatsu. Dresser. Dressta. Haulpak and Galion. This emissions warranty applies to new engines bearing the Komatsu name installed in these products and used in Canada in machines designed for industrial off-highway use. This warranty applies only to these engines produced on or after January I. 2000. This warranty will be administered by Komatsu distribution in Canada.

2.

Coverage Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform. at the time of sale by Komatsu. with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations within five years or 3.000 hours of operation, whichever occurs tirst. as measured from the date ofdelIvery of the engine to the ultimate purchaser.

3.

Limitations Komatsu is not responsible for Failures, other than those resulting from defects in materials or workmanship, are not covered by this warranty. failures or damage resulting from what Komatsu determines to be abuse or neglect, includin,,(7 but not limited to: operation without adequate coolant or lubricants; over fueling; over speed& lack of maintenance of lubricating, cooling or intake systems; improper storage, starting. warn-up. run-in or shutdown practices; unauthorized modifications of the engine. Komatsu is also not responsible for failures caused by incorrect fuel or by water, dirt or other contaminants in the fuel. Komatsu is not responsible for non-engine repairs. “downtnne” expense. related damage, tines. all business costs or other losses resulting from a warrantable failure.

KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL

DAMAGES.

This warranty, together with the express commercial warranties, are the sole warranties of Komatsu. THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICUALR PURPOSE.

GARANTIE SUR LE CONTR~LE ~NONCG DE GARANTIE SUR LE CONTR~LE

DES EMISSIONS

DES OMISSIONS (APPLICABLE

AU CANADA SEULEMENT):

Produits garantis: Komatsu America International Company, Komatsu Mining Systems Inc. et Komatsu Utility Corporation (collectivement Komatsu) produisent et/au font la mise en marche de prod&s portant les noms de marque Komatsu, Dresser. Dressta. Haulpak et Galion. Cette garantie sur les emissions s’applique a tous les nouveaux moteurs pottant le nom Komatsu, install& dans ces prodmts et utilises au Canada dans des machines concues pour utihsation industrielle nonrout&e. Cette garantie s’applique seulement sur les moteurs produits a partir du ler Janvier 2000. Cette garantie sera administree par la distribution de Komatsu au Canada.

Couverture: Komatsu garantit a I’acheteur ultime et chaque acheteur subsequent que le moteur est concu, construit et Cquipt en toute confonnite. au moment de la vente par Komatsu. avec tomes les Reglementations fed&ales americaines sur les emissions applicables au moment de la fabrication et qu’il est exempt de defauts de construction ou de materiaux qui auraient pour effet de contrevenir a ces reglementations en dedans de 5 ans ou 3000 heures d’operation, mesure a partir de la date de livraison du moteur au client ultime.

Limitations: Les bris, autres que ceux resultant de defauts de materiaux ou de construction, ne sont pas couverts par cette Garantie. Komatsu n’est pas responsable pour bris ou dommages resultant de ce que Komatsu determine comme etant de I’abus ou negligence, incluant mais ne se limitant pas a: I’operation sans lubrifiants ou agent refroidissants adequats; la suralimentation d’essence; la survitesse; le manque d’entretien des systemes de lubritication, de refroidissement ou d’entree; de pratiques non-propices d’entreposage, demise en marche, de rtchauffement. de conditionnement ou d’arret: les modifications non-autorisees du moteur. De plus, Komatsu n’est pas responsable de bris causes par de I’essence inadequate ou de I’eau, des saletes ou autres contaminants dans I’essence. Komatsu n’est pas responsable des reparations non-reliees au moteur, des dtpenses encoumes suite aux temps d’arrets, des dommages relatifs, amendes. et de tout autre codt d’affaires ou autres pertes resultant d’un bris couvert par la garantie.

KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSkQUENTS. Cette garantie, ainsi que les garanties expresses commerciales, sont les seules garanties de Komatsu. IL N’Y A AUCUNE AUTRE GARANTIE, EXPRESSE OU SOUS-ENTENDUE, MARCHANDABLE OU PROPICE A UNE UTILISATION PARTICULIkRE.

CEHQ000700

- Komatsu America International Company 12199

\

INFORMATION IMPORTANTE SUR LE MOTEUR CE MOTEUR EST CONFORME AUX NORMES AMERICAINES DB’EPA (ANNCE DU MODCLE) ET DE LA CALIFORNIE POUR LES MOTEURS LARGES NON-ROUTIERS A IGNITION PAR COMPRESSION. CE MOTEUR EST CERTIFIt POUR OPERATION A ESSENCE DIhEL.

DES BLESSURES PEUVENT RisULTER ET LA GARANTIE S’ANNULER SI LES RPM DU TAUX D’ESSENCE OU CALTITUDE EXCkDENT LES VALEURS MAXIMALES PUBLIEES POUR CE (_ MODE.,&,:,TlON: ;

\ IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMSTO YYYY MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIA REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTIFIED TO OPERATE ON DIESEL FUEL. WARNING INJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL R4TE RPM OR ALTITUDES EXCEED ’ PUBLISHED MAXIMUM VALUES FOR THIS MODEL AND APPLICATION. . ENGINE MODEL

SERIAL NO. -

. ENGINE FAMILY

DISPLACEMENT

EXHAUST EMISSION CONTROL SYSTEM DE SORTIE ADV.

Kw

+ VALVE LASH COLD (mm)

LITERS -

FIRING ORDER

ADV. LOAD OUTPUT (CHARGE

DBPLACEMENT

IN.

(

l-5-3-6-2-4 .

RPM

HP)

EX. FUEL RATE AT ADV.

mm3/STROKE\bTAUX

IDLE SPEED INITIAL INJECTION TIMING RkGLAGE DE UALLUMAGE INJECTION INITIALE

-

D’ESSENCE

AADV. )

RPM FAMILY EMISSION LIMIT DEG. BTDC DATE OF MANUFACTURE

LA FAMILLE

KOMATSU LTD. MADE IN JAPAN

ENGINE DATAPLATE - ENGLISH / FRENCH

1. FOREWORD

This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.

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

Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.

This manual may contain attachments and optional equipment that are not available in your area.

Consult Komatsu or your Komatsu distributor for those items you may require.

A

WARNING

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

Operators and maintenance personnel should read this manual thoroughly before beginning operation or maintenance.

Keep this manual in a readily available place near the machine (on machines with cab, there is a door pocket to hold the manual), and have all personnel involved in working on the machine read the manual periodically.

Where to keep this manual. -I See “11.8 MANUAL POCKET�.

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

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

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

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

The description of safety is given in SAFETY INFORMATION l-l.

on page O-2 and in SAFETY from page

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects,

and other

reproductive

harm.

O-l

2. SAFETY INFORMATION

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

To identify safety messages in this manual and on machine labels, the following signal words are used.

A DANGER

-

This word is used on safety messages and safety labels where there is a high probability of serious injury or death if the hazard is not avoided. These safety messages or labels usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the machine.

A WARNING

-

This word is used on safety messages and safety labels where there is a potentially dangerous situation which could result in serious injury or death if the hazard is not avoided. These safety messages or labels usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the machine.

A CAUTION

-

This word is used on safety messages and safety labels for hazards which could result in minor or moderate injury if the hazard is not avoided. This word might also be word for hazards where the only result could be damage to the machine.

-

This word is used for precautions that could shorten the life of the machine.

NOTICE

must

be taken

to avoid

actions

which

Safety precautions are described in SAFETY from page l-l.

Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact your Komatsu distributor.

o-2

3. INTRODUCTION

3.1 INTENDED USE This Komatsu DOZER SHOVEL is designed to be used mainly for the following work: l Excavation 0 Leveling l Back filling l Loading See the section “12.10 WORK POSSIBLE USING DOZER SHOVEL� for further details.

3.2 FEATURES l

l l

l l l

Since the Komatsu S6D125E-2 low fuel-consumption-type engine is mounted, and high production for fuel (m3/e)results, use of this machine is economical.

Since the dumping clearance is large, this machine can load 20-ton dumptrucks easily.

Large production is secured by the bucket whose capacity is equal to 2.2m3, powerful engine and large digging force.

The rigid and large undercarriage produces high power.

With the inching pedal, this machine can scoop the ground as easily as a direct drive machine.

The decelerator pedal is installed as standard.

3.3 BREAKING IN THE MACHINE Your Komatsu machine has been thoroughly adjusted and tested before shipment.

However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break in the machine for the initial 100 hours (as indicated by the service meter.)

During breaking in: l Idle the engine for 5 minutes after starting it up. l Avoid operation with heavy loads or at high speeds. l Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of emergency.

The precautions given in this manual for operating, maintenance, and safety procedures are only those that apply when this product is used for the specified purpose. If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of safety in such operations is the responsibility of the user.

Operations that are prohibited in this manual must never be carried out under any circumstances.

o-3

4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

4.1 MACHINE SERIAL NO. PLATE POSITION The machine serial No. plate is attached to the left side of the operator’s seat.

4.2 ENGINE SERIAL NO. PLATE POSITION The engine serial Nd. plate is attached to the left side of the cylinder block of the engine.

4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No.: Engine serial No.: Distributor name:

Address:

Service personnel for your machine:

REMARKS

o-4

Phone:

5. CONTENTS

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

1.

Foreword

2.

Safety information

3.

Introduction

4.

Location of plates, table to enter serial No. and distributor

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

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

0- 1 o- 2 0- 3 0- 4

SAFETY .......... ....... .. ... ........ ... ....... ..... ..... .. ...... ..... ............. ...... ... ... ............. .......... ......... ..

I- 2

6.

General precautions

7.

Precautions during operation ..........................................................................................................

Before starting engine .............................................................................................................

7.1 After starting engine ................................................................................................................

7.2 Transportation ..........................................................................................................................

7.3 Battery .......................................................................................................................................

7.4 Towing ......................................................................................................................................

7.5

I- 7 I- 7 I-IO 1-15 1-16 1-18

6.

Precautions for maintenance ...........................................................................................................

Before carrying out maintenance ..........................................................................................

8.1 During maintenance ................................................................................................................

8.2

1-19 I-19

l-23

Position for attaching safety labels ................................................................................................

Position for attaching safety labels .......................................................................................

9.1

l-28 l-28

9.

OPERATION 10. General view

10.1 10.2

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

General view of machine ........................................................................................................

General view of controls and gauges ...................................................................................

11. Explanation of components .............................................................................................................

11.1 Meters and lamps ....................................................................................................................

11.2 Switches ....................................................................................................................................

11.3 Control levers, pedals.. ............................................................................................................

11.4 Fuse box ...................................................................................................................................

11.5 Dust indicator ...........................................................................................................................

11.6 Power pickup connectors ........................................................................................................

11.7 Lift arm stay .............................................................................................................................

11.8 Manual pocket ..........................................................................................................................

2- 2 2- 2 2- 3 2- 4 2- 4 2- 6 2- 8 2-12 2-13 2-13 2-14 2-14

o-5

12. Operation . ... ...... ... ... ...... .... .. ........... ............. ...... ...... ...... ...... ...... .......... ......... ... ..... ... ........ ....................

12.1 Check before starting engine .................................................................................................

12.2 Starting engine.. .......................................................................................................................

12.3 Operations and checks after starting engine.. ......................................................................

12.4 Moving machine ......................................................................................................................

12.5 Shifting gear .............................................................................................................................

12.6 Shifting between forward and reverse.. ................................................................................

12.7 Steering machine .....................................................................................................................

12.8 Stopping machine.. ..................................................................................................................

12.9 Precautions for operation .......................................................................................................

12.10 Work possible using dozer shovel .........................................................................................

12.11 How to use inching pedal.. .....................................................................................................

12.12 Parking machine ......................................................................................................................

12.13 Check after finishing work ......................................................................................................

12.14 Stopping engine.. .....................................................................................................................

12.15 Check after stopping engine.. ..................................................................................................

12.16 Tips for longer undercarriage life ..........................................................................................

2-l 5 2-15 2-28 2-31 2-33 2-34 2-35 2-36 2-38 2-40 2-41 2-43 2-47 2-48 2-49 2-50 2-51

13. TransDortation .. .. ...... ...... ...... ..... ....... .... .. ...... ... ... ...... ............ ............. ......... .. ...... ............ ...................

13.1 Loading, unloading work ........................................................................................................

13.2 Precautions for loading, and securing the machine.. ..........................................................

13.3 Lifting the machine ..................................................................................................................

13.4 Precautions for transportation ................................................................................................

2-54 2-54 2-55 2-56 2-59

14.

14.1 14.2 14.3

weather operation ....................................................................................................................

Precautions for low temperature ...........................................................................................

After completion of work.. ......................................................................................................

After cold weather ...................................................................................................................

2-60 2-60 2-61 2-62

15. Long-term storage .............................................................................................................................

15.1 Before storage ..........................................................................................................................

15.2 During storage .........................................................................................................................

15.3 After storage.. ...........................................................................................................................

2-63 2-63 2-63 2-63

16. Troubleshooting .................................................................................................................................

16.1 After running out of fuel.. .......................................................................................................

16.2 If battery is discharged ...........................................................................................................

16.3 Other trouble ............................................................................................................................

2-64 2-64 2-64 2-67

O-6

5. CONTENTS

MAINTENANCE 17. Guides to maintenance

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

3- 2

18. Outlines of service ............................................................................................................................

18.1 Outline of oil, fuel, coolant .....................................................................................................

18.2 Relating to electric system .....................................................................................................

3- 4 3- 4 3- 6

19. Wear parts list ...................................................................................................................................

3- 7

20. Use of fuel, coolant and lubricants according to ambient temperature

3- 8

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

21. Standard tightening torques for bolts and nuts ...........................................................................

21 .I Introduction of necessary tools.. ............................................................................................

21.2 Torque list.. ............................................................................................................................... of safety critical parts ..... ........... ...... ...... ...... ... .. ....... ............ ............. ..........

3-14

schedule chart ... ............. ....... .. ... ... ... ......... ... ...... .. .. ........ ..... .. ... .. ....... .... ......... .. ..........

3-15

22. Periodic replacement 23. Maintenance

3-12 3-12 3-13

24. Service Procedure ..............................................................................................................................

24.1 Initial 250 hours service ..........................................................................................................

24.2 When required .........................................................................................................................

24.3 Check before starting ..............................................................................................................

24.4 Every 50 hours service.. ..........................................................................................................

24.5 Every 250 hours service ..........................................................................................................

24.6 Every 500 hours service.. ........................................................................................................

24.7 Every 1000 hours service ........................................................................................................

24.8 Every 2000 hours service ........................................................................................................

24.9 Every 4000 hours service ........................................................................................................

3-18 3-18 3-19 3-29 3-36 3-38 3-45 3-48 3-55 3-58

SPECIFICATIONS 25. Specifications

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

4- 2

OPTIONS, ATTACHMENTS 26. Installation

of fire extinguisher

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

5- 2

27. Handling with cabin installed ...........................................................................................................

27.1 How to read lamps and use switches.. .................................................................................

27.2 Fuse box ...................................................................................................................................

27.3 Door lock.. .................................................................................................................................

27.4 When required .........................................................................................................................

27.5 Precautions for work ...............................................................................................................

555555-

3 3 5 6 6 7

28. Operation of airconditioner.. .............................................................................................................

28.1 Name of each part of control panel ......................................................................................

28.2 Operation method ....................................................................................................................

28.3 Precautions for use of airconditioner ....................................................................................

28.4 Inspection and maintenance ...................................................................................................

5- 8 5- 8 5- 9 5-12 5-13

29. General precautions ...........................................................................................................................

29.1 Safety precautions ...................................................................................................................

5-15 5-15

o-7

O-8

SAFETY

result in serious injury or death.

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

l-l

a

6. GENERAL PRECAUTIONS

WARNING: For reasons of safety, always follow these safety precautions.

SAFETY RULES l l

l

l

l

4

Only trained and authorized personnel can operate and maintain the machine.

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

Do not operate the machine if you are not feeling well, or if you are taking medicine which will make you sleepy, or if you have been drinking. Operating in such a condition will adversely affect your judgement and may lead to an accident.

When working with another operator or with a person on worksite traffic duty, be sure that all personnel understand all hand signals that are to be used.

Always follow all rules related to safety.

SAFETY FEATURES

1

l

Be sure that all guards if damaged.

and covers are in their proper

l

Use safety features such as safety Never remove any safety features.

position.

Have guards

and covers

Proper position of all guards and covers + See “12.1.1 WALK-AROUND l

repaired

CHECK”.

lock levers and the seat belt properly.

Always keep them in good operating condition.

Safety lock lever + See “12.12 PARKING MACHINE”.

Seat belt + See “12.1.4 USING SEAT BELT”. l

1 l

l l

l

Improper use of safety features injury or death.

could

result in serious

CLOTHING AND PERSONAL PROTECTIVE ITEMS

bodily

1

Avoid loose clothing, jewelry, and loose long hair. They can catch on controls and cause serious injury or death.

Also, do not wear oily clothes, because they are flammable.

Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating machine. Always wear safety goggles, hard hat and heavy gloves if your job metal chips or minute materials particularly when driving pins with a hammer the air cleaner element with compressed air. Check also that there is no one Check that all protective equipment functions properly before using.

Cleaning element

or in moving

parts

or maintaining the involves scattering and when cleaning near the machine.

--) See “24.2 WHEN REQUIRED”.

AE305770

--j

UNAUTHORIZED

MODIFICATION

1

Any modification made without authorization from Komatsu can create hazards. modification, consult your Komatsu distributor.

Komatsu will not be responsible damage caused by any unauthorized modification.

l-2

Before making a for any injury or

g WARNING: Failure to follow these safety precautions may lead to a serious accident.

6. GENERAL PRECAUTIONS

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT To prevent an accident caused by touching an unlocked control lever, perform the following before leaving the operator’s seat. l Set the gear shift lever to the neutral position, then set the safety lock lever of the gear shift lever (on the left side of the operator’s seat) to the lock position. l Press the center of the right-hand and left-hand steering pedals to apply the brake, then set the safety lock lever of the steering pedals to the lock position. l Lower the work equipment to the ground, then set the safety lock lever of the work equipment control lever ton the right side of the operator’s seat) to the lock position.

If the machine starts moving suddenly or moves differently from the operator’s will, it can cause serious injury or death.

Never jump on or off the machine. Never get on or off a moving machine.

When getting on or off the machine, always face the machine and use the handrails and steps.

Never hold any control levers or lock levers when getting on or off the machine.

To ensure safety, always maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps to ensure that you support yourself.

If there is any oil, grease, or mud on the handrails or steps, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts.

When getting on or off the machine, or when moving along the top of the track, if you hold the handrail inside the door when moving on- top of the track shoe, and the door lock is not locked securely, the door may move and cause you to fall.

Always lock the door securely.

5010

5020

AL187320

l-3

6. GENERAL PRECAUTIONS

FIRE PREVENTION

A E;JJ:c1,Gs’, f%;ereasons of safety, always ty precautrons.

FOR FUEL AND OIL

Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly flammable and can be hazardous.

Always observe the following: l Keep any flame or lighted cigarette away from flammable fluids. l Stop the engine and do not smoke when refueling. l Tighten all fuel and oil caps securely. l Use well-ventilated areas for adding or storing oil and fuel. l Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.

A0055020

A0055030

A0055040

Immediately after operations are stopped, the engine oil and hydraulic oil are at high temperature and are still under pressure. Attempting to remove the cap, drain the oil or water, or replace the filters may lead to serious burns. Always wait for the temperature to go down, and follow the specified procedures when carrying out these operations.

To prevent hot water from spurting out, stop the engine, wait for the water to cool, then loosen the cap slowly to relieve the pressure before removing the cap.

(When checking if the water temperature has gone down, put your hand near the front face of the radiator and check the air temperature. Be careful not to touch the radiator.)

To prevent hot oil from spurting out, stop the engine, wait for the oil to cool, then loosen the cap slowly to relieve the pressure before removing the cap.

(When checking if the oil temperature has gone down, put your hand near the front face of the hydraulic tank and check the air temperature. Be careful not to touch the hydraulic tank.)

1-4

A WARNING: Failure to follow these safety precautions may lead to a serious accident.

Asbestos Komatsu

dust can be hazardous does not use asbestos

6. GENERAL PRECAUTIONS

to your health if it is inhaled. in its products, but if you handle materials containing

asbestos fibers, follow the guidelines given below: Never use compressed air for cleaning.

Use water to keep down the dust when cleaning.

If there is danger that there may be asbestos dust in the air, operate the machine from an upwind position whenever possible.

Use an approved respirator if necessary.

1

CRUSHING

OR CUTTING PREVENTION

1

Do not enter, or put your hand or arm or any other part of your body between movable parts such as the work equipment and cylinders, or between the machine and work equipment.

If the work equipment is operated, the clearance will change and this may lead to serious damage or personal injury.

If it is necessary to go between movable parts, always lock the levers and be sure that the work equipment cannot move. For details, see “PRECAUTIONS DURING MAINTENANCE”.

FIRE EXTINGUISHER

AND FIRST AID KIT

Always follow the precautions below to prepare for action if any injury or fire should occur.

Be sure that fire extinguishers have been provided and read the labels to ensure that you know how to use them.

Provide a first aid kit at the storage point. Carry out periodic checks and add to the contents if necessary.

Know what to do in the event of a fire or injury.

Decide the phone numbers of persons (doctor, ambulance, fire station, etc.) to contact in case of an emergency. Post these contact numbers in specified places and make sure that all personnel know the numbers and correct contact procedures.

Location of fire extinguisher, first aid box + See “26. INSTALLATION OF FIRE EXTINGUISHER”.

6. GENERAL PRECAUTIONS

A WARNING: For reasons of safety, always follow these safety precautions.

ROPS If ROPS is installed, do not operate the machine with the ROPS removed.

ROPS is installed to protect the operator if the machine should roll over. It supports the load when the machine rolls over and also absorbs impact energy. The Komatsu ROPS fulfills all worldwide regulations and standards, but it is damaged by falling objects or by rolling over, its strength will be reduced and it will not be able to provide its original capacity.

In such a case, please contact your Komatsu distributor for advice on the method of repair. Even if ROPS is installed, it can only protect you properly if you wear the seat belt.

Always fasten the seat belt when operating the machine.

Seat belt + See “12.1.4. USING SEAT BELT”.

PRECAUTIONS

FOR AlTACHMENTS

l

When installing and using an optional attachment, read the instruction manual for the attachment and the information related to attachments in this manual.

l

Do not use optional parts or attachments that are not authorized by Komatsu or your Komatsu distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine.

l

Any injury, accidents, product failures resulting from the use of unauthorized be the responsibility of Komatsu.

PRECAUTIONS

attachments will not

WITH SEAT BELT

l

To ensure safety during operations, always wear the seat belt.

l

Before fastening the seat belt, check that there is no abnormality in the belt or belt mount bracket.

If these are worn or damaged, replace the seat belt.

l

Be sure that the seat belt is not twisted when fastening it.

Seat belt + See “12.1.4 USING SEAT BELT”.

VENTILATION

FOR E

Exhaust fumes from the engine can kill.

If it is necessary to start the engine within an enclosed area, or you handle fuel, flushing oil, or paint, open the doors and windows to ensure that you provide adequate ventilation to prevent gas poisoning.

l

l

I

l-6

If opening the doors and windows still does not provide adequate ventilation,

set up fans.

A0055060

7. PRECAUTIONS DURING

OPERATION

A WARNING:

Failure to follow these safety precautions may lead to a serious accident.

7.1 BEFORE STARTING ENGINE Before starting operations, thoroughly dangerous.

check the area for any unusual conditions that could be

Check the terrain and condition of the ground at the worksite, and determine the best and safest method of operation.

Make the ground surface as hard and horizontal as possible before carrying out operations.

If the jobsite is dusty, spray water before starting operations.

If you need to operate on a road, protect pedestrians and cars by designating a person for worksite traffic duty or by installing fences and putting up No Entry signs around the worksite.

If water lines, gas lines, or high-voltage electrical lines may be buried under the worksite, contact each utility and identify their locations. Be careful not to sever or damage any of these lines.

Check the ground condition and the depth and flow of water before operating in water or crossing a river. NEVER be in water which is in excess of the permissible water depth.

Permissible water depth -I See “12.9 PRECAUTIONS FOR OPERATION”.

AE205030

CHECKS BEFORE STARTING

ENGINE

Carry out the following checks before starting the engine at the beginning of the days work.

Failure to carry out these checks may lead to serious injury or damage.

Completely remove all flammable materials accumulated around the engine and battery, return all fuel containers to their proper place, remove all parts and tools from the operator’s compartment, and remove any dirt from the mirrors, handrails, and steps.

Walk-around checks + See “12.1.1 WALK-AROUND CHECK”.

Check the coolant level, fuel level, and oil level in the hydraulic tank, check for clogging of the air cleaner, and check the electric wiring.

Checks before starting + See “12.1.2 CHECK BEFORE STARTING”.

Adjust the operator’s seat to a position where it is easy to carry out operations, and check for wear or damage to the seat belt and seat belt mounting equipment.

Adjusting operator’s seat + See “12.1.3 ADJUST OPERATOR’S SEAT”.

Check that the gauges work properly, and check that the control levers are all at the NEUTRAL position.

Method of checking operation of gauges + See “12.1.5 OPERATIONS AND CHECKS BEFORE STARTING ENGINE”. the above inspections show any abnormality, carry out repairs immediately.

A0055020

l-7

7. PRECAUTIONS DURING OPERATION

l

l

l

-

A WARNING: For reasons of safety, always follow these safety precautions.

Do not place parts or tools around the operator’s seat. They could break lever or a switch or can cause an accident. Place them in the tool box in the engine room (on the right side).

If mud, oil, snow, etc. stick to the floor, levers, handrails, steps, etc., you may slip on them. Wipe them off well.

Before fastening the seal belt, confirm that it and its fittings are free from damage and wear.

PRECAUTIONS FOR LOCKING WINDOW POSITION (MACHINES WITH CAB)

GLASS AT MAINTENANCE

The window glass can be locked at an intermediate position to prevent it from chattering.

Even if it is locked, it may move them the machine is started or stopped sharply.

Do not put your head, hands, or body outside the window when the machine is working or moving.

l-8

g ~A$4~G;

Faz;zo

follow these safety precautions may lead

7. PRECAUTIONS DURING OPERATION

WHEN OPERATING THE ENGINE INDOORS, VENTILATE THE WORKING

PLACE WELL

The exhaust gas from the engine is dangerous. l When starting the engine in a room or confined space, open the windows and doors for ventilation.

A0055060

PRECAUTIONS FOR USE OF MIRRORS (OPTIONAL), WINDOW (MACHINE WITH CAB) AND LIGHTS l l

l

GLASS

Clean the window glass and lights to keep visibility high.

Adjust the position of the rear view mirrors so that you can see them most easily from the operator’s seat, and clean their surfaces.

If any of them is broken, replace it.

Confirm that headlamps and rear lamps suitable for the work are installed, and that they can be turned on and off normally.

INSPECTION

OF MACHINE

Before starting the engine, adjust the operator’s seat so that you can operate in a easy position.

If the operator’s seat is not adjusted correctly, you may make a mistake in operation or be fatigued, and that can cause accidents.

Adjust the operator’s seat so that you can operate the control levers and pedals fully with your back fitted to the seat back.

Adjustment of operator’s seat + See “12.1.3 ADJUSTMENT OF OPERATORS SEAT”.

Before starting the engine, confirm that the safety lock lever is at the LOCK position.

Before starting the engine, be sure to perform a “Walk-around check”, “Check before starting” and “Operation and check before starting engine” Walk-around check + See “13.1.1 WALK-AROUND CHECK”.

Check before starting + See “12.1.2 CHECK BEFORE STARTING”.

Operation and check before starting engine + See “12.1.4 OPERATION AND CHECK BEFORE STARTING”.

Confirm by the above checks that the machine is free from trouble.

If trouble is found and it cannot be repaired, be sure to but a warning tag on the work equipment lever.

Lock

Free

A0142136

l-9

& :;I;;/& 7. PRECAUTIONS DURING OPERATION

Fooeeasons of safety, always y precautions.

7.2 AFTER STARTING ENGINE WHEN STARTING

ENGINE

Walk around your machine again just before mounting it, and check for people and objects that might be in the way.

Never start the engine if a warning tag has been attached to the’blade control lever.

When starting the engine, sound the horn as an alert.

Start and operate the machine only while seated.

An additional worker may ride in the machine only when sitting in the passenger seat. Do not allow anyone to ride on the machine body.

If the backup alarm is installed, confirm that the alarm operates normally.

DO NOT operate When this plate is not being used keep it in the storage compartment.

09963-03000 d

CHECKS AFTER STARTING

ENGINE

Failure to carry out the checks properly after starting the engine will lead to delays in discovery of abnormalities, and this may lead to serious injury or damage to the machine.

When carrying out the checks, use a wide area where there are no obstructions. Do not allow anyone near the machine. l Check the operation of the gauges and equipment, and check the operation of the blade, ripper, brakes, travel system, and steering system. l Checks for any abnormality in the sound of the machine, vibration, heat, smell, or gauges; check also that there is no leakage of air, oil, or fuel. l If any abnormality is found, carry out repairs immediately.

If the machine is used when it is not improper condition, it may lead to serious injury or damage to the machine.

PRECAUTIONS

WHEN STARTING

OFF

Before starting off, check again that there is no one in the surrounding area and that there is no obstacles.

When starting off, sound the horn as an alert.

Always operate the machine only when seated.

An additional worker may ride in the machine only when sitting in the passenger seat. Do not allow anyone to ride on the machine body.

Check that the backup alarm works properly.

Always close the door of the operator’s compartment and check that the door is securely locked.

AE305600

I-IO

1

g

g;;F.l;If;

E;zzc

follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATION

4

CHECK WHEN CHANGING

DIRECTION

1

To prevent serious injury or death, always do the following before moving the machine or doing the leveling work.

Before changing between forward and reverse, reduce speed and stop the machine.

Before operating the machine, sound the horn to warn people in the area.

Check that there is no one near the machine. Be particularly careful to check behind the machine.

When operating in areas that may be hazardous or have poor visibility, designate a person to direct worksite traffic.

Ensure that no unauthorized person can come within the direction of turning or direction of travel.

Always be sure to carry out the above precautions even when the machine is equipped with a backup alarm and mirrors.

Appoint a ground guide, when necessary, particularly when driving in reverse.

* A0055080

PRECAUTIONS

WHEN TRAVELING

It is dangerous

to look around

It is dangerous

to drive too fast, or to start suddenly,

you when

operating.

Always

concentrate

stop suddenly,

on your work.

turn sharply,

or zigzag.

If you find any abnormality in the machine during operation (noise, vibration, smell, incorrect gauges, air leakage, oil leakage, etc.), move the machine immediately to a safe place and look for the cause.

Do not operate the steering suddenly. The work equipment may hit the ground surface and cause the machine to lose its balance, or may damage the machine or structures in the area.

When

traveling

on rough

ground,

travel

at low speed,

and avoid

sudden

changes

in direction.

Avoid traveling over obstacles as far as possible. If the machine has to travel over an obstacle, keep the work equipment as close to the ground as possible and travel at low speed. Never travel over obstacles which make the machine tilt strongly (IO� or more).

When traveling or carrying structures to avoid coming

out operations, always into contact with them.

keep your

distance

from

other

machines

or

I-II

a ;;zJ;l& 7. PRECAUTIONS DURING OPERATION

TRAVELING

Po;ereasons of safety, always ty precautrons.

ON SLOPES

Traveling on slopes could result in the machine tipping over or slipping to the side.

When traveling on slopes, keep the blade approximately 20 to 30 cm above the ground. In case of emergency, quickly lower the blade to the ground to help the machine to stop.

Do not turn on slopes or travel across slopes. Always go down to a flat place to perform these operations.

Do not travel on grass, fallen leaves, or wet steel plates. Even slight slopes may cause the machine to slip to the side, so travel at low speed and make sure that the machine is always traveling directly up or down the slope.

When traveling downhill, use the braking force of the engine and travel slowly.

Be careful when allowing the machine to travel downhill under its own weight. It may steer in the opposite direction.

Reverse steering when traveling downhill * See “12.72 TURNING WHILE DESCENDING A SLOPE”.

ADO51 690

-j’ SECURING ENOUGH VISIBILITY l

l

1

When working in a dark place, turn on the head lamp and rear lamp of the machine, and use additional lighting equipment, if necessary.

If visibility is lowered by fog, snow, rain, etc., stop working and wait until sufficient visibility for the work is restored.

OPERATE CAREFULLY ON SNOW When working on snow or icy roads, even a slight slope may cause the machine to slip to the side, so always travel at low speed and avoid sudden starting, stopping, or turning. There is danger of slipping particularly on uphill or downhill slopes.

With frozen road surfaces, the ground becomes soft when the temperature rises, so the travel conditions become unstable. In such cases be extremely careful when traveling.

When there has been heavy snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be seen, so always carry out operations carefully.

When traveling on snow-covered slopes, never apply the brakes suddenly. Reduce the speed and use the engine as a brake while applying the foot brake intermittently (depress the brake intermittently several times). If necessary, lower the blade to the ground to stop the machine.

The load varies greatly according to the characteristics of the snow, so adjust the load accordingly and be careful not to let the machine slip.

1-12

g ;V;;;;Gs

Fai;ai~~

follow these safety precautions may lead

7. PRECAUTIONS DURING OPERATION

I Do not operate the machine on soft ground. It is difficult to get the machine out again.

Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these areas collapse under the mass or vibration of your machine, it could fall or tip over and this could result in serious injury or death. Remember that the soil after heavy rain, blasting, or earthquakes is weakened in these areas.

Earth laid on the ground and the soil near ditches is loose. It can collapse under the mass or vibration of your machine and cause your machine to tip over.

Install the head guard (FOPS) when working in areas where

there is danger of falling stones.

Install the ROPS and wear the seat belt when working in areas where there is danger of falling rocks or of the machine turning over.

PARKING MACHINE Park the machine on level ground where there is no danger of -falling rocks or landslides, or of flooding if the land is low, and lower the work equipment to the ground.

If it is necessary to park the machine on a slope, set blocks under the tracks to prevent the machine from moving, then dig the work equipment into the ground.

After stopping the engine, operate the blade control lever several times to the RAISE and LOWER positions to release the remaining pressure in the hydraulic circuit.

When parking on public roads, provide fences, signs, flags, or lights, and put up any other necessary signs to ensure that passing traffic can see the machine clearly, and park the machine so that the machine, flags, and fences do not obstruct traffic.

Parking

procedure

+

See “12.12

PARKING

MACHINE”.

When leaving the machine, lower the work equipment completely to the ground, place the joystick to the neutral position, and the blade and ripper control levers to the HOLD position. Then set the safety lock lever and parking brake lever to the LOCK position, stop the engine, and use the key to lock all the equipment. Always remove the key and take it with you.

Work

equipment

posture

+

See “12.12

PARKING

MACHINE”.

Always close the door of the operator’s compartment.

Lock

Free

AD142136

1-13

7. PRECAUTIONS DURING OPERATION

4

PRECAUTIONS

IN COLD AREAS

1

After completing operations, remove all water, snow, or mud stuck to the wiring harness, connector 0, switches, or sensors, and cover these parts.

If the water freezes, it will cause malfunctions of the machine when it is next used, which may lead to unexpected accidents.

Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.

Operate the control levers to relieve the hydraulic pressure (raise to above the set pressure for the hydraulic circuit and release the oil to the hydraulic tank) to warm up the oil in the hydraulic circuit. This ensures good response from the machine and prevents malfunctions.

If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is danger that this will ignite the battery.

When charging or starting the engine with a different power source, melt the battery electrolyte and check for leakage of battery electrolyte before starting.

Battery charge rate + See “14. COLD WEATHER OPERATION�.

/

1-14

AE305820

A WARNING: Failure to follow these safety precautions may lead to a serious accident.

7.3

7. PRECAUTIONS DURING OPERATION

TRANSPORTATION LOADING AND UNLOADING Loading

and

unloading

the machine .always involves

potential

hazards. EXTREME

CAUTION

SHOULD BE USED. When loading or unloading the machine, run the engine at low idling and travel at low speed.

Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of a road.

ALWAYS use ramps of adequate strength. Be sure that the ramps are wide, long, and thick enough to provide a safe loading slope. Place blocks under both ramps to support them before loading and unloading.

When unloading on to an embankment strength, and grade.

or temporan/ structure, make sure that it has ample width,

To prevent the machine from slipping, be sure that the ramp surface is clean and free of grease, oil, ice and loose materials. Remove mud from the machine tracks.

NEVER correct your steering on the ramps. If necessary, drive away from the ramps and climb again.

After loading, block the machine tracks and secure the machine with tie-downs.

Loading and unloading * See “13. TRANSPORTATION”.

Tie-downs + See “13. TRANSPORTATION”.

Ra

Distance between ramps

AE50648B

When shipping the machine on a hauling vehicle, obey all state and local laws governing weight, width, and length of a load. Also obey all applicable traffic regulations.

the

Take into account the width, height and weight of the load when determining the shipping route.

Height, width, load of machine -I See “13.4 PRECAUTIONS FOR TRANSPORTATION”.

When passing over bridges or structures on private land, check first that the structure is strong enough to support the mass of the machine. When traveling on public roads, check first with the relevant authorities and follow their instructions.

On machines equipped with a cab, always lock the door securely.

1-15

A ;f!/;;ze 7. PRECAUTIONS DURING OPERATION

Fcxeasons of safety, always y precautrons.

7.4 BATTERY BAlTERY

HAZARD PREVENTION

Battery electrolyte contains sulphuric acid, and batteries generate hydrogen gas, handling can lead to serious injury or fire. For this reason, always observe the following Never bring any lighted cigarette or flame near the battery.

When

working

with

batteries,

If you spill acid on your clothes

ALWAYS

Before working

safety glasses

or skin, immediately

Battery acid could cause blindness immediately with large quantities If you accidentally oil. Call a doctor

wear

and rubber

so mistaken precautions.

gloves.

flush the area with large amounts

of water.

if splashed into the eyes. If acid gets into your eyes, flush them of water and see a doctor at once.

drink electrolyte, drink a large quantity of water or milk, beaten egg or vegetable or poison prevention center immediately. with

batteries,

stop the engine

and turn the starting

switch

to the OFF position.

Avoid short-circuiting the battery terminals (between the positive @ terminal terminal) through accidental contact with metal objects, such as tools.

When installing the battery, connect the positive @terminal disconnect the negative @ terminal (ground side) first.

first, and when

and negative

removing

0

the battery,

When removing or installing, check which is the positive @ terminal and negative 0 terminal, and tighten the nuts securely.

If the battery electrolyte is near the LOWER LEVEL, add distilled water. Do not add distilled water above the UPPER LEVEL. When cleaning the top surface of the battery, wipe it with thinner, or any other organic solvent or cleaning agent.

Tighten

the battery

a damp

cloth.

Never

use gasoline,

caps securely.

If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is danger that this will ignite the battery.

When charging or starting the engine with a different power source, melt the battery electrolyte and check for leakage of battery electrolyte before starting.

Always

remove

the battery

from the chassis

before

charging

it.

A0055110

1-16

A ~~~f$Gi;

E$rrr$

follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATION

STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause a fire, so always do as follows.

Carry out the starting operation with two workers (with one worker sitting in the operator’s seat).

When starting from another machine, do not allow the two machines to touch.

When connecting the booster cables, turn the starting switch OFF for both the normal machine and problem machine.

Be sure to connect the positive @ cable first when installing the booster cables. Disconnect the ground or negative @ cable first when removing them.

The final ground connection is the connection of the ground to the engine block of the problem machine. However, this will cause sparks, so be sure to connect it as far as possible from the battery.

Starting procedure when using booster cables + See “16.2 IF BATTERY IS DISCHARGED”.

When removing the booster cables, be careful not to let the booster cable clips touch each other or to let the clips touch the machine.

INCORRECT

w

A0067320

If the battery is handled incorrectly when it is being charged, there is danger that the battery may explode, so follow the instructions in HANDLING BATTERY and in the instruction manual for the charger, and always observe the following precautions.

Carry out the charging in a well-ventilated place, and remove the battery caps. This disperses the hydrogen gas and prevents explosion.

Set the voltage on the charger to match the voltage on the battery to be charged. If the voltage setting is wrong, it will cause the charger to overheat and catch fire, and this may lead to an explosion.

Connect the positive @ charging clip of the charger to the positive @terminal of the battery, then connect the negative 0 charging clip to the negative 0 terminal of the battery. Be sure to tighten both terminals securely.

If the battery charge is less than l/IO of the rated charge, and high speed charging is carried out, set to a value below the rated capacity of the battery.

If there is an excessive flow of charging current, it may cause leakage or evaporation of the electrolyte, which may catch fire and explode.

INCORRECT

A0055110

1-17

a WARNING: For reasons of safety, always follow these safety precautions.

7. PRECAUTIONS DURING OPERATION

7.5 TOWING -I

WHEN TOWING

1

Injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection of the wire rope, so always do as follows.

Do not tow in a different way from the method given in the section METHOD OF TOWING. Always wear leather gloves when handling wire rope.

When carrying out the preparation starting the operation.

for towing with another worker, agree on signals before

If the engine on the problem machine will not start or there is a failure in the brake system, please contact your Komatsu distributor for repairs.

It is dangerous to tow a machine on a slope, so choose a place where there is a gradual slope.

If there is no place with a gradual slope, carry out work to make the slope as small as possible.

If a problem machine is towed by another machine, ALWAYS towing capacity for the weight of the problem machine.

use a wire rope with a sufficient

Do not use a wire rope which has cut strands @, kinks @, or reduced diameter 0.

1-18

8. PRECAUTIONS FOR MAINTENANCE

a

WARNING: Failure to follow these safety precautions may lead to a serious accident.

8.1 BEFORE CARRYING OUT MAINTENANCE NOTIFICATION

OF FAILURE

Carrying out maintenance not described in the Komatsu operation and maintenance lead to unexpected failures.

Please contact your Komatsu distributor for repairs.

WARNING

manual may

TAG

ALWAYS attach the “DO NOT OPERATE” warning tag to the blade control lever in the operator’s cab to alert others that you are working on the machine. Attach additional warning tags around the machine if necessary.

If others start the engine, or touch or operate the blade control lever while you are performing service or maintenance, you could suffer serious injury or death.

Warning tag Part No. 09963-03000

DO NOT operate When this plate is not being used keep it in the storage compartment.

09963.03000

CLEAN BEFORE INSPECTION AND MAINTENANCE

1

Clean the machine before carrying out inspection and maintenance. This will ensure that dirt does not get into the machine and will also ensure that maintenance can be carried out safely.

If inspection and maintenance are carried out with the machine still dirty, it will be difficult to find the location of problems, and there is also the danger that you will get dirty or mud in your eyes, and that you will slip and injure yourself.

When washing the machine, always do as follows.

Wear non-slip shoes to prevent yourself from slipping on the wet surface.

When using high-pressure steam to wash the machine, always wear protective clothing.

This will protect you from being hit by high-pressure water, and cutting your skin or getting mud or dust into your eyes.

Do not spray water directly on to the electrical system (sensors, connectors) 0. If water gets into the electrical system, there is danger that it will cause defective operation and malfunction.

A0055150

AE305620

8. PRECAUTIONS FOR MAINTENANCE

KEEP WORK PLACE CLEAN AND TIDY Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances that will cause you to slip. Always keep the work place clean the tidy to enable you to carry out operations safely.

If the work place is not kept clean and tidy, there is danger that you will trip, slip, or fall over and injure yourself.

-I

APPOINT

LEADER

WHEN

WORKING

WITH

OTHERS

1

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his instructions during the operation.

When working with others, misunderstandings between workers can lead to serious accidents.

RADIATOR WATER LEVEL When inspecting the radiator water level, stop the engine, and wait for the engine and radiator to cool down. Check the water level in the sub-tank. Under normal conditions, do not open the radiator cap.

If there is no sub-tank, or the radiator cap must be removed, always do as follows.

Wait for the radiator water temperature to go down before checking the water level.

(When checking if the water temperature has gone down, put your hand near the engine or radiator and check the air temperature.

Be careful not to touch the radiator or engine.)

Release the internal pressure before removing the radiator cap, and remove the radiator cap slowly.

A0055050

STOP

ENGINE

BEFORE CARRYING

OUT INSPECTION AND

MAINTENANCE When carrying out inspection and maintenance, park the machine on level ground where there is no danger of falling rocks or land slides, or of flooding if the land is low, then lower the work equipment to the ground and stop the engine.

Operate blade control lever @ several times to the RAISE and LOWER positions to release the remaining pressure in the hydraulic circuit, then set safety lock lever @ to the LOCK position.

Put blocks under the track to prevent

the machine

The worker carrying out the maintenance in the moving parts.

should

HEAT

from

moving.

be extremely

careful

not to touch or get caught

OFF

\

L Free Lock

AE214979

I-20

AE214439

g 8. PRECAUTIONS FOR MAINTENANCE

WARNING: For reasons of safety, always follow these safety precautions.

USE OF LIGHTING l

When checking tions.

If such lighting

fuel, oil, or battery equipment

electrolyte,

is not used, there

always

use lighting

is danger

installing

If work is carried out in dark places without install proper lighting.

l

Even if it is dark, do not use a lighter or flame instead of lighting. fire, and if the battery gas ignites, it may cause an explosion.

l

When using the machine as the power Operation and Maintenance Manual.

lighting,

there is danger

for the lighting,

There

follow

Use non-flammable materials as the flushing oil for cleaning gasoline. There is danger that they will catch fire.

When tions.

out inspection

checking fuel, oil, or battery electrolyte, always Never use lighters or matches as lighting.

When carrying out grinding materials to a safe place.

Be sure that a fire extinguisher

1-22

or maintenance.

or welding

is present

operations

parts.

Always

use lighting

on the

at the inspection

of injury, so always

is danger

of starting

the instructions

There is danger of the fuel and battery gas catching fire during maintenance, precautions below when cartvinn out maintenance.

Store fuel, oil, grease, and-other flammable materials away from flame.

Never smoke when carrying

specifica-

of explosion.

l

supply

with anti-explosion

so always

smoke in the prescribed with anti-explosion

chassis,

remove

and maintenance

any

point.

in this

follow

Do not use diesel

a

the

oil or

place.

specifica-

flammable

A EAa;;;;G;

F;;;e$c

follow these safety precautions may lead 8. PRECAUTIONS FOR MAINTENANCE

8.2 DURING MAINTENANCE PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized into the area. If necessary, employ an observer.

Extra precaution should be used when grinding, welding, and using a sledge-hammer.

personnel

AlTACHMENTS Appoint a leader before starting removal or installation

operations for attachments.

Do not allow anyone other than the workers close to the machine or attachment.

Place attachments that have been removed from the machine in a safe place so that they do not fall. Put a fence around the attachments, and set up No Entry signs to prevent unauthorized persons from coming close.

WORK UNDER THE MACHINE Stop the machine on firm, level ground, and always lower all work equipment to the ground before performing service or repairs under the machine.

0

Always block the track shoes securely.

0

It is extremely dangerous to work under the machine if the track shoes are off the ground and the machine is supported only by the work equipment. Never work under the machine if the machine is poorly supported.

A0055140

WORK ON TOP OF MACHINE When carrying out maintenance on top of the machine, make sure that the footholds are clean and free of obstructions, and follow the precautions below to prevent yourself from falling.

Do not spill oil or grease.

Do not leave tools lying around.

Mind your step when you are walking. l

l

l

Never jump down from the machine. When getting on or off the machine, always use the steps and handrails, and maintain three-point contact (both feet and one hand or both hands and one foot) at all times.

Use protective equipment

if necessary.

1-23

A

$Y~;;;ize

8. PRECAUTIONS FOR MAINTENANCE

Fo%eeasons qf safety, y precautions.

always

When carrying out maintenance with the inspection cover open, lock it securely with a lock bar.

If maintenance is carried out with the inspection cover open and not locked in position, it may close suddenly if knocked or blown by the wind, and may cause injury to the operator.

MAINTENANCE

WITH ENGINE RUNNING

To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows.

One worker must always sit in the operator’s seat and be ready to stop the engine at any time.

All workers must maintain contact with the other workers.

When carrying out operations near rotating parts, there is danger of being caught in the parts, so be extremely careful.

When cleaning inside the radiator, set safety lock lever @ to the LOCK position to prevent the work equipment from moving.

Do not touch any control levers. If any control lever must be operated, always give a signal to the other workers to warn them to move to a safe place.

Never touch the fan blade or fan belt with any tool or any part of your body. There is danger of serious injury.

Lock

Free

A0055210

AD142138

d

DO NOT DROP TOOLS OR PARTS INSIDE MACHINE

1

l

When opening the inspection window or tank oil filler to carry out inspection, be careful not to drop any nuts, bolts, or tools inside the machine.

If such parts are dropped into the machine, it will cause breakage of the machine, mistaken operation, and other failures. If you drop any part into the machine, always be sure to remove it from the machine.

l

When carrying out inspection,

PRECAUTIONS

1 I

do not carry any unnecessary tools or parts in your pocket.

WHEN USING HAMMER

1 I

When using a hammer, always wear safety glasses, safety helmet, and other protective clothing, and put a brass bar between the hammer and the part being hammered.

If hard metal parts such as pins, edges, teeth, or bearings are hit with a hammer, there is danger that broken pieces might fly into your eyes and cause injury.

l-24

AE305880

g

WARNING: Failure to follow to a serious accident.

these safety precautions

may lead 8. PRECAUTIONS FOR MAINTENANCE

Welding operations must always be carried out by a qualified welder and in a place equipped with a proper equipment. Gas is generated, and there is danger of fire or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.

The qualified welder must follow the precautions given below.

Disconnect the battery terminals to prevent explosion of the battery.

Remove the paint from the place being welded to prevent gas from being generated.

If hydraulic equipment or piping, or places close to these are heated, flammable vapor or spray will be generated, and there is danger of this catching fire, so avoid applying heat to such places.

If heat is applied directly to rubber hoses or piping under pressure, they may suddenly burst, so cover them with fireproof sheeting.

Always wear protective clothing.

Ensure that there is good ventilation.

Clear up any flammable materials, and make sure that there is a fire extinguisher at the workplace.

-j

PRECAUTIONS

WITH BATTERY

1

When repairing the electrical system or when carrying out electrical welding, (4 terminal of the battery to stop the flow of current.

Handling

-I

battery

WHEN ABNORMALITY

+

See “16.2

IS LOCATED

IF BAlTERY

remove the negative

IS DISCHARGED�.

1

l

If any abnormality is found during inspection, always carry out repairs. In particular, if the machine is used when there is any abnormality in the brakes or work equipment systems, it may lead to serious accident.

l

Depending

on the type of failure, please contact your Komatsu distributor for repairs.

RULES TO FOLLOW WHEN ADDING

FUEL OR OIL

If any flame is brought close to fuel or oil, there is danger that it will catch fire, so always follow the precautions below. l Stop the engine when adding fuel or oil. l Do not smoke. l Spilled fuel and oil may cause you to slip, so always wipe it up immediately. l Always tighten the cap of the fuel and oil fillers securely. l Always add fuel and oil in a well-ventilated place.

A0055020

A0055030

A0055040

l-25

A ~~VJ~~~;e f%;ereasons of safety, always ty precautions.

8. PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS WHEN USING HIGH-PRESSURE ADJUST TRACK TENSION

GREASE TO

Grease is pumped into the track tension adjustment system under high pressure.

If the specified procedure for maintenance is not followed when making adjustment, valve @ may fly out and cause damage or personal injury.

When loosening grease drain valve 0,

never loosen it more than one turn.

Never put your face, hands, feet, or any other part of your body directly in front of any grease drain valve.

Adjusting track tension -) See “24.2 WHEN REQUIRED�.

AM143090

HANDLING

HIGH-PRESSURE

A0055200

HOSES

If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to personal injury or damage. If any damaged hoses or loose bolts are found, stop work and contact your Komatsu distributor for repairs.

Replacing high-pressure hoses requires a high level of skill, and the torque is determined according to the type of hose and size, so please do not carry out replacement yourself. Ask your Komatsu distributor to carry out replacement.

-I

I

PRECAUTIONS

WITH HIGH-PRESSURE

OIL

1 I

When inspecting or replacing high-pressure piping or hoses, always check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to serious injury or damage, so always do as follows.

For details of the method of releasing the pressure, see 8.1 BEFORE MAINTENANCE, STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE. Never carry out inspection or replacement before releasing the pressure completely.

Wear safety glasses and leather gloves.

If there is any leakage from the piping or hoses, the piping, hoses, and the surrounding area will be wet, so check for cracks in the piping and hoses and for swelling in the hoses.

If it is difficult to locate the leakage, always please contact your Komatsu distributor for repairs.

If you are hit by a jet of high-pressure

oil, consult a doctor immediately CORREC;_

lNCORREgp

A0055180

l-26

for medical attention.

A0055190

1

A ;/P$J;;C;

Faaililzo

follow these safety precautions may lead 8. PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS WHEN HIGH TEMPERATURE

CARRYING

OUT

MAINTENANCE

AT

Immediately after stopping operations, the engine coolant, oil at all parts, the exhaust manifold, and the muffler are at high temperature.

In this condition, if the cap is removed, or the oil is drained, or the filters are replaced, this may result in burns or other injury. Wait for the temperature to go down, then carry out the inspection and maintenance in accordance with the procedures given in this manual.

Cleaning inside of cooling system + See “24.2 WHEN REQUIRED”.

Checking coolant level, oil level in hydraulic tank + see “24.3 CHECK BEFORE STARTING”.

Checking lubricating oil level, adding oil + see “24.3 CHECK BEFORE STARTING”.

Changing oil, replacing filters + see “24.4 PERIODIC MAINTENANCE”.

A0055050

1

CHECKS

AFTER

INSPECTION

AND

MAINTENANCE

1

Failure to carry out inspection and maintenance fully, or failure to check the function of various maintenance locations may cause unexpected problems and may even lead to personal injury or damage, so always do as follows.

Checks when engine is stopped Have all the inspection and maintenance locations been checked?

Have all the inspection and maintenance items been carried out correctly?

Have any tools or parts dropped inside the machine? It is particularly dangerous if they get caught in the lever linkage.

Has water and oil leakage been repaired? Have bolts been tightened? l

l

l

l

Checks when engine is running For details of checks when the engine is running, see “8.2 DURING MAINTENANCE, NANCE WITH ENGINE RUNNING”, and be extremely careful to ensure safety.

Do the inspection

I I

0

Is there

and maintenance

any oil leakage

when

locations

the engine

work

speed

MAINTE-

normally?

is raised

and load is applied

to the hydraulic

system?

To prevent pollution, particularly in places where people procedures given below.

Never dump waste oil in a sewer system, rivers, etc.

or animals

are living,

always

follow

the

INCORRECT Always put oil drained from your machine drain oil directly onto the ground.

in containers.

Never

Obey appropriate laws and regulations harmful objects such as oil, fuel, coolant, batteries.

when disposing of solvent, filters, and

1-27

9. POSITION FOR ATTACHING SAFETY LABELS

Always keep these labels clean. If they are lost or attaching them again or replace them with a new label.

There are other labels in addition to the safety labels follows, so handle them in the same way.

Safety labels may be available in languages other than To find out what labels are available, contact your distributor.

9.1 POSITION FOR AlTACHING

damage, listed as English.

Komatsu

SAFETY LABELS

AD216850

\

AE216670

l-28

AD21 6660

9. POSITION FOR ATTACHING SAFETY LABELS

1.

Cautions for checking engine room

5.

(09667-03000)

Warnings for leaving operator’s seat (09654-03000)

WHILE ENGINE IS RUNNING:

OBSERVE THE FOLLOWING CAUTIONS WHEN STARTING THE MACHINE OR WHEN YOU LEAVE OPERATOR’S SEAT AFTER PARKING THE MACHINE: 1. SET THE GEARbHlti LEVER INTO NEUTRAL POSITION AND LOCK IT WITH TH5 SAFETY LEVER WHEN APPLICABLE. 2. LOCK THE BRAKES. 3. LOWER THE WORKING EQUIPMENT TO THE GROUND AND LOCK THE LEVER.

1. DO NOT OPEN COVER. 2. KEEP AWAY FAN-BELT.

FROM FAN AND 09667-03000

2.

-

Warnings for opening radiator cap (09668-03000)

09654-03000

6.

Cautions before operating machine (09651-03000)

DO NOT LOOSEN CAP WHEN WATER TEMPERATURE IS HIGH. IF LOOSENED, BOILING WATER MAY GUSH OUT BECAUSE OF HIGH INTERNAL PRESSURE. 09668-03000

3.

BEFORE OPERATING MACHINE, READ OPERATION MMANUAL CAREFULLY.

-

Cautions for inspection and maintenance (09173-03000)

-.

7.

Cuations for opening hydraulic tank cap (09653-03000)

WHEN CARRYING OUT MAINTENANCE. 1. PARK THE MACHINE ON LEVEL GROUND. 2. LOWER WORK EQUIPMENTTOTHE GROUND, AND LOCK THE LEVER. 3. DO NOT GO UNDER MACHINE WHEN IT IS RAISED BY THE WORK EQUIPMENT. 09173-03000

4.

-

ALWAYS STOP ENGINE WHEN REMOVING CAP. DO NOT LOOSEN CAP i’/HiN OIL TEMPERATURE IS HIGH. IF LOOSENED, OIL MAY GUSH OUT. SLOWLY OPEN HYDRULIC OIL TANK CAP AND RELEASE INTERNAL PRESSURE COMPLETELY. DO NOT OPEN DRAIN PLUG WHEN OIL TEMPERATURE IS HIGH.

-

Warnings for adjusting track tension (09657-03010)

,

09653-03000 -

1. TO INCREASE TRACK TENSION. PUMP IN GREASE THROUGH LUBRICATOR. 2. TO SLACKEN IT. RELEASE GREASE BY ROTATING LUBRICATION ONE TURN. (FOR TRACK ADJUSTMENT PROCEDURE, READ AND OPERATION MAINTENANCE MANUAL.) 3. DO NOT LOOSEN LUBRICATOR MORE THAN ONE FULL TURN, ALSO BE CAREFUL NOT TO LOOSEN ANY PARTS OTHER THAN LUBRICATOR. SINCE THE GREASE IS UNDER HIGH PRESSURE EXCESS LOOSENING IS HIGHLY DANGEROUS. 4. RETIGHTEN LUBRICATOR SECURELY AFTER ADJUSTMENT.

09657-03010

-

l-29

9. POSITION FOR AlTACHING

SAFETY LABELS

Precautions for use of safety devices of lift arm (09658-30082)

8.

WHEN USING A STAY; DO NOT CAUSE DAMAGE T 1.

PISTON ROD WITH THE STAY. DO NOT POSITION THE 2.

BUCKET CONTROL LEVER A “LOWER”.

09658-30082

9.

I-30

Precautions for maintenance (125-98-31131)

of engine

0 2

10. GENERAL VIEW

10.1 GENERAL VIEW OF MACHINE If directions are indicated in this section, they diaaram below.

refer to the directions shown by the arrows in the

Bucket

da

Dump

cylinder

I ift

CYI

inder

ocket

0

Truck’shoe

Idler

Truck

Left

frame

AD141956

2-2

IO. GENERALVIEW

10.2 GENERAL VIEW OF CONTROLS AND GAUGES

Fu el

control

Gear

Safe (for

tv

lever

Steering

Pedal

Pedal

shift

lock gear

Inching

lever shift

lever)

/ Brake

lock

lever

Safety (for

Front Engine warning

oil

pressure IamD

lock bucket

lever)

wiper

sw’tch\ Rear switch

lever control

Front lamp

wiper \

work 7;;; \

ADZlSOOB

Front Pilot work

work IamP /

I amp

work lamp

lamp

/

I/

\\\ button

Ena i n e water t emne rature gauge

\Startina

I

Dust

indicator

/

Lamp

I Torque converter oil temperature gauge

switch switch

./ Cigarette I iahter AD141978

Room switch

I

lamp

\

Rear Pilot

ADl419BB

2-3

1.1. .-EXPLANATION OF COMPONENTS

The following is an explanation of the devices needed for operating the machine.

To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the equipment and the meanings of the displays.

11.1 METERS AND LAMPS

AM141990

1.

ENGINE WATER TEMPERATURE GAUGE This gauge indicates the cooling water temperature.

When the indicator is in the green range during operation, the water temperature is normal.

If the indicator moves from the green range into the red range during operation, stop the machine and run the engine with no load at medium speed until the water temperature goes down.

After starting the engine, warm up it until the indicator moves into the green range.

TORQUE CONVERTER OIL TEMPERATURE GAUGE This gauge indicates the torque converter oil temperature.

When the indicator is in the green range during operation, the oil temperature is normal.

If the indicator moves from the green range into the red range during operation, stop the machine and run the engine with no load at medium speed until the oil temperature goes down.

AC1214380

2.

2-4

AM086070

11. EXPLANATION OF COMPONENTS

3.

SERVICE METER This meter shows the total operation hours of the machine.

The service meter advances while the engine is running - even if the machine is not traveling.

Set the periodic maintenance intervals using this display.

While the engine is running, operation display @ at the top inside of the meter will rotate to show that the meter is advancing.

Meter @ will advance by 1 for each hour of operation regardless of the engine speed.

4.

CHARGE LAMP This lamp indicates malfunction of the alternator.

When the starting switch is turned ON, it will light up, but it should go out when the engine speed rises.

If the lamp lights up during operation, stop the engine and check the V-belt tension. If any abnormality is found, see “16.3 OTHER TROUBLE”.

A0120660

5.

ENGINE OIL PRESSURE WARNING LAMP This lamp warns that the engine lubricating oil pressure has dropped. When the starting switch is turned ON, it will light up.

When the lamp goes off after the engine is started, the oil pressure is normal.

When the lamp lights up during operation, the oil pressure is lower.

Immediately stop the engine and look for the cause. For details, see “16.3 OTHER TROUBLE”.

GLOW SIGNAL This indicates the glow plug is red-heated.

When holding the starting switch key at the HEAT position, this signal glows red after 20 - 30 seconds.

When releasing the key, the key will return to the OFF position and the signal will go off.

A0120700

6.

l @

2-5

11. EXPLANATION

OF COMPONENTS

11.2 SWITCHES

I

1.

STARTING SWITCH This switch is, used to start or stop the engine.

OFF ( 0 I position At this position, the starting switch key can be inserted or removed. When the switch is turned to this position, the electrical circuits are switched off and the engine stops.

ON 1 I I position In this position, electric current flows in the charging and lamp circuits. .Keep the starting switch key at the ON position while the engine is running.

START @I position This is the position to start the engine. Hold the key at this position while cranking. Release the key immediately after the engine has been started. The key will return to ON position when released.

HEAT (@I position Turn the starting switch key to the HEAT position when starting in cold weather.

The glow plug is operated while the key is held in the HEAT position.

When the glow signal is red hot, release the key.

When the key is released, it will return to OFF, so turn it immediately to the START position to start the engine.

2-6

AM142020

11. EXPLANATION

OF COMPONENTS

., LAMP SWITCH This lights up the head lamps, the rear working lamp and the panel lamp.

Position OFF: Lamps go off.

Head lamps and panel lamp light up.

Position 1: Rear working lamp lights up in addition to the lamps Position 2: in position 1.

2.

I

^

2 1

OFF

ADl4203B

3.

HORN BUTTON To sound the horn, push the button located in front of the R.H. arm rest.

I

AM142040

2-7

11. EXPLANATION

OF COMPONENTS

11.3 CONTROL LEVERS, PEDALS

1.

GEAR SHIFT LEVER This lever is used to change the gear speed.

The transmission has three forward gears and three reverse gears, and any of them can be selected by shifting this lever to the corresponding position.

REMARK If the gear shift lever is not at N (Neutral) position, the engine does not start.

AM142060

2.

FUEL CONTROL LEVER This lever is used to adjust the speed and output of the engine. @ Engine stop: Pull the knob from the low idling position, then push in forward end. @ Low idling: Push in the lever to forward (to the knob stopper). @ Full speed: Pull the knob from position @I to the end.

AM142070

2-8

11. EXPLANATION

3.

INCHING

PEDAL

OF COMPONENTS

I

A

WARNING

Do not place your foot on this pedal unnecessarily.

This pedal is used to disconnect and connect the engine power for operating the machine at a little movement. If it is pressed halfway, the power is disconnected. If it is further pressed, the brake ! is applied to stop the machine.

Use this pedal when’ approaching an object or moving the machine body little by little during digging work.

4.

I

AM142080

STEERING PEDAL

A

WARNING

Do not place your foot on this pedal unnecessarily.

If the steering pedal in the turning direction is pressed, the steering clutch is disengaged and the machine turns slowly. If it is pressed further, the steering brake is turned on the machine performs a pivot turn.

If the center between both pedals is pressed, the steering clutch is engaged and the brake is applied.

BUCKET CONTROL LEVER This lever is used to control the bucket.

RAISE : (X HOLD : l-1 Bucket is stopped and held in this position.

LOWER : (4, FLOAT : (F) Bucket wili%&e freely according to external force.

When released from FLOAT position, this lever will not return to HOLD position, so it must be moved back by hand. @ TILT @I DUMP @ POSITION

AM142090

AM142100

: ($1 : (@-I

REMARK If the lever is set to “RAISE” or “POSITION” position, it is automatically returned to “HOLD” position and the bucket stops when the bucket returns to the adjustment position of the kick-out or positioner.

2-9

1I.. EXPLANATION OF COMPONENTS

6.

DECELERATlON PEDAL

A WARNING When the machine climbs to the top of a slope or it dumps soil from a cliff, the load reduces and the travel speed rises suddenly, and that is dangerous. T.o prevent, this, press the decelerator pedal to lower the travel speed.

.s

This pedal is used to lower the engine speed from the level set with the fuel control lever to the low,idling level.

If this pedal is pressed, the engine speed lowers. I.

7.

SAFEN

LOCK LEVER (For bucket control lever)

A WARNING When leaving the operator’s compartment, set the safety lock lever securely to the LOCK position. If the control lever is not locked, and it is touched by mistake, this may lead to a serious accident.

If the safety lock lever is not placed .securely in the LOCK position, the control lever may not be properly locked.

When parking or servicing the machine,, be sure to lower the bucket and set the safety lock in the LOCK position.

This is the locking device of bucket control lever.

LOCK position: FREE position:

2-10

Raising, lowering, dumping, and tilting operations are locked.

Raising, lowering, dumping, and tilting operations can be performed.

I

AM142120

‘_

11. EXPLANATION

8.

OF COMPONENTS

BRAKE LOCK LEVER

Whenever

g WARNING machine is parked, lock brake pedal without

fail.

This is the locking device of the brake pedal when parking.

When locking the brake, pull the lock lever towards you (place in the LOCK position), then depress the center of steering, pedal strongly to apply the lock securely.

When releasing the brake, keep the center of steering pedal depressed, and push the lock lever.

9.

SAFETY LOCK LEVER (For gear shift lever)

When leaving the operator s seat, set the safety lock lever to the lock Dosition securelv. *WARN,,7 If the safety lock lever is not in the lock position and someone touches the gear shift lever by mistake, a serious accident may occur.

If the safety lock lever is not set the lock position securely, the gear shift lever may not be locked.

When parking the machine, be sure to set the gear shift lever to N (Neutral) position, and lock it.

Free a

This lever is used to lock the gear shift lever.

2-11

Il.

EXPLANATION

OF COMPONENTS

11.4 FUSE BOX NOTICE Before replacing a fuse, be sure to turn off the starting switch.

The fuses protect the electrical equipment and wiring from burning out.

If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.

Replace a fuse with another of the same capacity.

11.4.1 REPLACEMENT OF FUSES 1.

Remove

bolt @ and cover 0,

then

// replace

worn-out

\\

fuses.

Fuse capacity and circuit name No

Fuse capacity

Terminal symbol

20A

L

0

Circuit name

Remarks

Lamp in instruments Head lamp Rear lamp Torque converter oil temperature gauge

-

@

/

H

/

loA

1 Ki:ioner

/

-

o

/

F

I

loA

Engine water temperature gauge I I Backup alarm

-

@

1

0

1

20A

1 Spare circuit

-

2-12

I

ci

AE215010

11. EXPLANATION OF COMPONENTS

11.5

DUST INDICATOR

This indicator indicates that the air cleaner element is clogged.

If the cleaner element is clogged, the red piston keeps projecting into transparent part @_ In this case, clean the cleaner element.

After cleaning the cleaner element, press button @ of the indicator to return the red piston to the original position.

I

I

0 II

\\

Al4142270

\ Q

a’

ADO52091

11.6 POWER PICKUP CONNECTOR NOTICE l Do not use this connector as a power source for a 12 V device.

If it is used, the connected device will be broken. l Do not connect a device which consumes more power than 480W (24 V x 20 A) [I20 W (12 V x 10 A) in case of a cigarette lighter] to this connector.

Open battery cover @ on the left side of the machine body.

Locked connector CN4 @ can be used as a power source.

Remove the male side of the connector and connect a device to be used. The capacity of the connector is 480 W (24 V x 20 A). l

Machines equipped with cab It is possible to remove the cigarette lighter and use the socket as a power supply.

Capacity of cigarette lighter: 120 W (24 V x IO A).

2-13

11. EXPLANATION

11.7

OF COMPONENTS

LIFT ARM STAY

l

When inspecting

or maintaining

with the lift arm raised, be

l

When driving the machine forward or backward, be sure to

The lift arm stay is a safety device of the bucket. Use it when working the lift arm raised.

Store the lift arm stay to underside the left-hand fender.

If the lift arm stay cannot be pulled out because of the weight of the lift arm, set the bucket control lever in RAISE position to raise the lift arm, then pull out the stay.

11.8 MANUAL POCKET The operator’s seat has a manual pocket in the back of backrest.

This manual should be kept in it for reference and periodical reviewing.

.2-l 4

12. OPERATION

12.1 CHECK BEFORE STARTING ENGINE 12.1.1 WALK-AROUND

CHECK a

l

l

WARNING

If someone touches the control lever by mistake, the machine may start moving. When leaving the operator’s seat, set the safety lock to the lock position.

Combustible materials, fuel or oil around the hot parts of the engine such as the engine muffler, turbocharger, etc. or the battery can catch fire. Check around those parts carefully. If any trouble is found, repair or call our distributors.

Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, or leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.

Check also for loose wiring, play, and collection of dust at places which reach high temperatures.

2-35

1.

Check for damage, wear, play in work equipment, cylinders, linkage, hoses Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses. If any abnormality is found, repair it.

2.

Remove dirt and dust from around engine, battery radiator Check if there is any dirt or dust accumulated around the engine or radiator. Check also if there is any flammable material (dead leaves, twigs, grass, etc.) accumulated around the battery or high temperature engine parts, such as the engine muffler or turbocharger, Remove all such dirt or flammable material.

3.

Check for leakage of water or oil around engine Check that there is no leakage of oil from the engine or leakage of water from the cooling system. If any abnormality is found, repair it.

4.

Check for loose air cleaner mounting bolt and muffler mounting bolts If the air cleaner or muffler is damaged, repair it, and retighten the mounting bolts.

5.

Check for oil leakage of oil from power train case, final drive case, hydraulic tank, hose, joints Check that there is no oil leakage. If any abnormality is found, repair the place where the oil is leaking.

Check for leakage of oil from the undercover. Check the ground for traces of oil leakage.

6.

Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from rollers If any damage, wear, or oil leakage is found, repair the problem and tighten the bolts.

7.

Check for damage to handrail, loose bolts Repair any damage and tighten any loose.

8.

Check for damage to gauges, lamps on instrument panel, loose bolts Check that there is no damage to the panel, gauges and lamps.

If any abnormality is found, replace the parts. Clean off any dirt on the surface.

9.

Check for damage to seat belt and mounting clamps (option) Check that there is no abnormality in the seat belt or mounting clamps. If there is any damage, replace with new parts.

2-16

12. OPERATION

10. Inspection

of electric

wiring a

WARNING

If the fuses are broken frequently or there is a trace of short circuit on the electric wiring, be sure to find out the cause and repair it.

Check the fuses for damage and the electric wiring for a trace of short circuit. Check the terminals for looseness and retighten loosened ones.

Check the following items, in particular. l Battery 0 Starting motor l Alternator Ask one of our distributors trouble and repairing it.

4L

for finding

out the cause

of the

WARNING

o If dead leaves, twigs, grasses, etc. accumulate around the battery, they may catch fire. Be sure to remove them. l Keep the top of the battery clean. Check the vents of the battery caps for clogging, and wash clogged battery caps in water.

Remove any combustible materials from around the during the walk-around check and check before starting.

battery

2-17

12.1.2 CHECK BEFORE STARTING CHECK AND

REFILL COOLANT

7

a

WARNING

Do not remove cap @ while cooling water is hot. Hot water may spout out.

When removing cap 0, wait until the water temperature goes down and release radiator pressure little by little by loosening caps slowly, then remove the cap.

1.

Open the top cover at the front part of the machine body.

2.

Remove radiator cap @ and confirm that the coolant is filled up to the neck of water filler. Refill new coolant, if necessary.

NOTICE If more somewhere.

coolant than usual is required, it may be leaking Check for leakage in this case.

from

CHECK FUEL LEVEL g

WARNING

When adding fuel, never let the fuel overflow. This may cause a fire. If spilling fuel, thoroughly clean up any spillage.

1.

Check the fuel level using fuel gauge 0.

2.

After completing work, fill the fuel tank through oil filler port 0.

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

3.

After adding fuel, tighten the cap securely.

Fuel capacity: 400 !J

NOTlCE A clogged cap breather engine. Check it from time

hole 0 to time

may stop the fuel flow and clean.

to the

AD054210

2-18

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the upper cover at the front of the machine.

2.

Remove dipstick @ and wipe the oil off with a cloth.

3.

Insert dipstick @ fully in the oil filler pipe, then take it out again.

4.

The oil level should be between the H and L marks on dipstick 0.

If the oil level is below the L mark, take out the dispstick and add engine oil through oil filler 0.

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE�.

5.

6.

If the oil is above the H mark, drain the excess engine oil from drain plug, and check the oil level again.

ADO52340

If the oil level is correct, tighten the oil filler cap securely, insert oil level gauge @ fully into the dipstick guide, then close the upper cover.

REMARK l When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking. l If the machine is at an angle, make it horizontal before checking. l When adding oil, remove the oil level gauge from the gauge guide so that the air in the crank case will be released.

2-19

12. OPERATION

CHECK OIL LEVEL IN TRANSMISSION CASE (INCLUDING TORQUE CONVERTER CASE), ADD OIL 1. Open the cover, remove dipstick 0, and wipe the oil off with a cloth.

2.

Insert dipstick @Jfully in the oil filler pipe, then take it out again.

3.

The oil level should be between the H and L marks on dipstick 0.

If the oil level is below the L mark, add engine oil through oil filler 0.

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

4.

5.

If the oil is above the H mark, drain the excess engine oil from drain plug @, and check the oil level again.

If the oil level is correct, tighten the oil filler cap securely and close the cover.

REMARK l When stopping the engine, check the oil level. l When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking.

If the machine is at an angle, make it horizontal before checking.

2-20

AD052340

CHECK OIL LEVEL IN STEERING

1. Remove dipstick 0,

CLUTCH

CASE, ADD

OIL

and wipe the oil off with a cloth.

2.

Insert dipstick @ fully in the oil filler pipe, then take it out again.

3.

The oil level should be between the H and L marks on dipstick

_

0.

If the oil level is below the L mark, add engine oil through oil filler 0.

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

4.

If the oil level is above the H mark, drai the excess engine oil from drain plug 8, and check the oil level again.

5.

If the oil level is correct, tighten the oil filler cap securely.

1

REMARK When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking.

If the machine is at an angle, make it horizontal before checking.

2-21

12. OPERATION

CHECK DUST INDICATOR 1. Check that the red piston has not appeared in the transparent portion of dust indicator 0.

2.

If the red piston has appeared, clean or replace the element immediately.

For details of the method of cleaning the element, see “24.2 WHEN REQUIRED�.

3.

After checking, cleaning, and replacing, press the knob of dust indicator 0 to return the red piston to its original position.

I

ADO52091

CHECK STEERING PEDAL TRAVEL 1. Depress the brake pedal all the way until it stops.

2.

The distance of travel at the center of the pedal (position in the diagram on the right) should be 127 - 191 mm (5.0 - 7.6 in).

3.

When this value exceeds 192 mm (7.7 in), or the brake fails to work, please contact your Komatsu distributor for adjustment.

2-22

&

127-191 mm (5. O-7. 6 in) AD,,226B

12. OPERATION

CHECK THAT LAMPS LIGHT UP

1.

Insert the key into starting switch @ and turn the key to the ON position.

HEA?

OFF

START

2.

Confirm that the lamps light up by operating lamp switch 0.

OFF position: Lamps are turned off.

Headlight and instrument lights are turned on.

Position 1: Headlight, instrument light, and rear working lamps Position 2: are turned on.

If any of the lamps does not light up, ask our distributor inspect the machine.

to AD142039

CHECK HORN SOUND

1.

Insert the key into starting switch @ and turn the key to the ON position.

2.

Push the horn switch @ and check that the horn sounds.

AM142040

2-23

CHECK BACKUP ALARM SOUND (OPTION)

1. Insert the key into starting switch @) and turn the key to the ON

position.

AE214499

2.

Set gear shift lever @ to the rear position.

The buzzer must sound immediately. It keeps sounding until the gear shift lever is set to “NEUTRAL” or “FORWARD” position.

Rl

I CHECK SEAT BELT FOR WEAR OR DAMAGE (OPTION) Check the belt and mounting clamps, and if they are worn or damaged, replace the seat belt.

2-24

AD205110

12. .OPERATION

12.1.3 ADJUST

OPERATOR’S

SEAT

l

Adjust the seat position

at the beginning

of each shift or

l

Adjust the seat so that the brake pedal can be depressed all the way with the operator’s back against the backrest.

Fore-aft adjustment of seat Move lever 0 to the left set the seat to a position where it is easy to operate, then release the lever.

Fore-aft adjustment: 160 mm (6.3 in) (9 stages) Adjustment of cushion Turn knob @ to eliminate gap (A) between the end of chain @ and the frame. At this point, the seat is set under the best condition.

Tilting the seat forward Pull lever @ and pull the seat back, and the seat is tilted forward.

AN142280

2-25

12.1.4 USING

SEAT BELT (OPTION)

When operating a machine equipped with ROPS, be sure to use the seat belt.

I

A WARNING Before fastening the seat belt, inspect the securing brackets and belt for abnormal conditions.

Replace any worn or damaged seat belt or the securing brakets.

Adjust and fasten the seat belt before operating the machine.

Always use the seat belt when operating the machine.

Do not use seat belt with either half of the belt kinked.

FASTEN THE BELT AND REMOVE IT IN THE FOLLOWING MANNER 1 1. Adjust the seat so that the brake pedal can be depressed all the way with the operator’s back against the backrest.

2.

After positioning the seat, adjust the tether belt 0. With the seat unoccupied, tense the belt slightly across the seat and install.

3.

Sit in the seat. Hold buckle @ with your left hand and tonque @ with your right hand, put the tonque into the buckle. Check that the belt has locked by pulling it.

4.

When removing the belt, raise the tip of the buckle lever to release it.

Fasten belt along your body without kinking it. Adjust the lengths of the belt on both the buckle and the tonque sides so that the buckle is located at the mid-point of your body front.

ADJUST THE BELT LENGTH IN THE FOLLOWING

A

MANNER

TO SHORTEN THE BELT Pull the free end of the belt on either the buckle body or tonque side.

AM088710

TO LENGTHEN THE BELT Pull the belt while holding it at a right angle to buckle or tonque.

Inspect bolts and fittings on the chassis for tightness. Retighten any loose bolts to 24.5 f 4.9 Nm (2.5 f 0.5 kgfm, 18 +. 3.6 Ibft) torque.

If the seat is scratched or frayed or if any of the fittings are broken or deformed from long service, replace the seat belt immediately.

2-26

AM088720

12.1.5 OPERATIONS ENGINE

AND CHECKS BEFORE STARTING

If the control levers are touched by accident, the work equipment or the machine may move suddenly. When leaving the operator’s compartment, always set the safety lock lever sei’ curely to the LOCK position. WARN’NG 1. Confirm that the steering pedals are locked with brake lock lever

0.

2.

Confirm that the gear shift lever is at N (NEUTRAL) position and locked with safety lock lever 0. ee

a ADl4231B

3.

Check that the bucket is lowered on the ground and the bucket control lever is locked with safety lock lever 0.

Lock

0

Free

a

AD142328

2-27

12.2 STARTING ENGINE 12.2.1 NORMAL STARTING Ah WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.

NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.

If the engine will not start, wait for at least 2 minutes before trying to start the engine again.

1.

Pull fuel control lever @ to a position a little past the LOW IDLING position toward the HIGH IDLING position.

Low idline naine

2.

Turn the key of starting switch @ to the START position. The engine will start.

3.

When the engine starts, release the key in starting switch 0. The key will return automatically to the ON position.

stop

START AE21451B

2-28

12.2.2 STARTING

IN COLD WEATHER

When starting in low temperatures,

A

do as follows.

WARNING

Never use starting aid fluids as they may cause explosions.

NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.

If the engine fails to start, repeat steps 2 and 3 after waiting for about 2 minutes.

1.

2.

Pull fuel control lever @ to a position a little past the LOW IDLING position toward the HIGH IDLING position.

Turn the key of starting switch @to the HEAT position and hold it until glow signal @ glows red.

I idling

HEAT NF

The preheating times are as shown below.

AE21452.3

If the preheating time is too long or too short, the engine will not start easily. Observe the correct preheating time.

3.

When glow signal @ becomes red, turn the key of starting switch @ to the START position and start the engine.

START AE21453B

2-29

1.

When the engine starts, release the key in starting switch 0. The key will return automatically to the ON position.

HEA:

START AE21451B

2-30

12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE After starting the engine, do not immediately start operations.

First, carry out the following operations and checks.

NOTICE Avoid abrupt acceleration until warm-up run is completed.

Do not run the engine at low idling or high idling for more than 20 minutes. If it is necessary to run the engine at idling, apply a load or run at a medium speed from time to time.

1.

Pull fuel control lever @ to the center position between LOW IDLING and HIGH IDLING and run the engine at medium speed for about 5 minutes with no load.

2.

After warm-up run is completed, check gauges, warning lamps and charge lamp for proper operation. If any abnormality is found, repair it.

Continue to run the engine at light load until engine water temperature gauge indicator @ falls within the white range.

3.

Check that there is no abnormal exhaust gas color, noise, or vibration. If any abnormality is found, repair it.

Mid

idling

Low

idling

CHECK BACKUP ALARM SOUND (OPTION)

1.

Press decelerator pedal @ to lower the engine speed.

AM142500

2-31

12. OPERATION

2.

Press the center between both steering pedals @ to apply the brake. Lock the brake with brake lock lever 0.

Lock

0 t aa

AD14260B

3.

Set safety lock lever @ of the gear shift lever to FREE position.

4.

Set gear shift lever @ to position RI and confirm that the backup alarm sounds.

N

Rl

AD205110

2-32

12.4

MOVING

MACHINE

OFF

A WARNING When starting the machine, check for the safety around, and sound the horn.

Do not let any one approach the machine.

When moving the machine in reverse, be careful of the rear of the machine which cannot be seen from the operator’s seat.

When starting the machine on a slope, be sure to keep pressing the center between steering pedals @ even after setting brake lock lever @ free.

When starting the machine on a steep uphill slope, raise the engine speed to the full level and set gear shift lever @) to 1st Gear with the center of steering pedals @ pressed. After the machine starts (or the shoe slips) slowly, release the steering pedals slowly to start the machine.

If the machine is equipped with the backup alarm (option), set gear shift lever 0 in the reverse position and confirm that the alarm operates normally.

1.

Pull fuel control lever @ to increase engine speed.

AD142428

2.

Set safety lock lever @ for bucket control lever @ to the FREE @ position.

Lock 0 Free

a

AD14243B

3.

Pull bucket control lever @ in the RAISE position to raise the blade 40 - 50 cm (16 - 20 in) off the ground.

2-33

4.

Press the center between both steering pedals @ and push brake lock lever @ to set it free, then return the pedal.

Keep pressing steering pedals 0.

Lack 0 4 aa

AD142456

5.

Set safety lock lever @ of the gear shift lever free.

Free a

AD142466

I Set gear shift lever @ to the desired position.

6.

Rl

Fl

R2

F2

R3

F3 AM142470

Release the center between both steering pedals 0, and start the machine.

7.

12.5

SHIFTING

GEAR

There is no need to stop machine to shift gears.

Set gear shift lever 0 in the desired position to shift gear.

RI

Fl

R2

F2

R3

F3 AM142470

2-34

12.6

;;lFz;NV

BETWEEN

FORWARD

AND

&h WARNING Forward-reverse shifting should be made after reduction of machine speed for safety purpose and preventing shock to machine.

AM142490

1.

Press decelerator pedal @ to lower the engine speed.

I 2.

AM142500

1

Change gear shift lever @ to the desired position.

Rl

Fl

R2

F2 F3

R3 J

AM142470

3.

Return decelerator pedal @I and raise the engine speed.

I 4.

AMl49610 1

If the machine is equipped with backup alarm, confirm that the alarm sounds when gear shift lever @ is placed in the reverse position.

If the alarm does not sound, ask your Komatsu distributor for repairs.

2-35

12.7 STEERING MACHINE l

Avoid as much as possible turning the machine on a slope.

l

Never make a pivot turn at high speed.

12.7.1 NORMAL TURNING If either steering pedal @ is pressed during travel, the machine turns toward the direction of the pressed pedal.

I

AM142520

When turning to the left slowly Press the left-hand steering pedal halfway, and the steering clutch is disengaged and the machine turns to the left slowly. l

REMARK When turning to the right slowly, operate the right-hand steering pedal similarly to the above.

AN142530

When performing a pivot turn to the left Press the left-hand steering pedal to the end, the steering clutch is disengaged and the steering brake is applied, and the machine performs a pivot turn to the left.

l

REMARK When performing a pivot turn to the right, operate the right-hand steering pedal the same as described above.

.

AN142540

2-36

1

12. OPERATION

12.7.2 TURNING

WHILE DESCENDING

A WARNING

A SLOPE

p

When descending such a sharp slope that the machine will go down of its own weight or when going down a slope with a scraper or the like, you should exercise great care. The machine will turn to the opposite side to the direction of the moved lever.

When turning to the left slowly Press the right-hand steering pedal halfway, and the machine turns to the left slowly (Counter steering). l

REMARK When turning to the right slowly, operate the left-hand steering pedal similarly to the above (Counter steering).

AN142550

When performing a pivot turn to the left Press the left-hand steering pedal to the end, and the machine performs a pivot turn to the left (Normal steering).

l

REMARK When performing a pivot turn to the right, operate the right-hand steering pedal similarly to the above (Normal steering).

AN142560

2-37

12.8 STOPPING MACHINE

A

WARNING

Avoid stopping suddenly. Give yourself ample room when stopping.

When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert blocks underneath the track shoes. As an additional safety measure, thrust the bucket into the ground.

If the control lever is touched by accident, the work equipment or the machine may move suddenly, and this may lead to a serious accident. Before leaving the operator’s compartment, always apply the lock securely.

l

l

l

1.

Lower the engine speed with the fuel control lever 0.

I 2.

Set the gear shift lever @ to N (Neutral) position.

iIff I

ADl4258B

N

F

1

1

2

2

3

3

An142590

3.

Press the center between both steering pedals @I_Lock the brake with brake lock lever 0.

ADl4260B

4.

Lock gear shift lever @ with safety lock lever 0.

Free

a

ADl4231B

2-38

12. OPERATION

5.

Lower bucket control lever @to lower the bucket to the ground.

w 0

Lower

t

7-n-%90 6.

Lock bucket control lever @ with the safety lock lever 0.

Lock Free

AD142328

2-39

12. OPERATION

12.9 PRECAUTIONS FOR OPERATION 12.9.1 METHOD

OF USING STEERING

CLUTCH

If the steering clutch one side is used frequently or if many gradual turns are made with steering clutch half-engaged, the steering clutch will wear out in a short time. Design the travel road well and steer the machine properly.

12.9.2 PERMISSIBLE

WATER DEPTH

When operating in water, always keep the bottom of the carrier roller above the surface of the water.

Also, be careful that the engine cooling fan will not come in contact with water. The fan can be damaged.

12.9.3 PRECAUTIONS WHEN TRAVELING OR DOWN HILLS

UP

Use engine as a brake When going downhill, shift gear shift lever into low speed to run engine at slow speed and travel down slope using the engine as a brake.

Never coast down slope with the gear shift lever in the N (neutral) position or with the inching pedal depressed.

Braking when traveling downhill While descending a slope using the engine as a brake, also apply the brakes.

Failure to brake may result in overrunning, causing engine trouble.

12.9.4 PRECAUTIONS

ON SLOPES

Be careful of fuel level If the fuel level in the fuel tank becomes low when working on slopes, the engine may suck in air because of the angle of the machine or the swaying of the machine. If this makes the engine stop, so be careful not to let the fuel level in the fuel tank become too low.

Precautions when engine stops on slopes If the engine stops while working or traveling on a hill, immediately depress the brake pedal, lower the bucket to the ground to stop the machine, then lock the brake pedal with the brake lock lever.

Thereafter, move the gear shift lever to the N (neutral) position, lock the lever, then restart the engine.

2-40

12.

OPERATION

12.10 WORK POSSIBLE USING DOZER SHOVEL In addition to the following, it is possible to further increase the range of applications by using various attachments.

12.10.1 0

1.

2.

EXCAVATION

Scoop up the piled soil by moving the machine forward as shown. If the track shoe begins slipping under heavy load, raise the bucket slightly to reduce the load.

Force the bucket into the pile of soil while moving the machine forward.

After the bucket has fully penetrated into the soil, place the bucket control lever in RAISE position while moving the machine forward. Move the bucket control lever to TILT position from time to time until the bucket is filled with soil.

L

3,

When it is difficult for the bucket to penetrate into the piled soil, move the bucket control lever left and right to move the bucket teeth up and down.

I 0

1.

AN142660

operation on flat ground, move the In an excavating-loading machine forward with the bucket teeth facing somewhat downward as shown. In this case, do not impose the load on one side only.

Direct the bucket teeth somewhat downward from the horizontal.

AN142670

y

AN142660

2.

Scrape the soil gradually by pushing the bucket control lever a little forward while moving the machine forward.

AN142690

2-41

3.

Move the machine forward while adjusting the digging depth by means of the bucket control lever.

REMARK When digging with the bucket, avoid imposing the digging force onto only one side of the bucket.

12.10.2 LOADING When loading the earth on truck, shorten cycle time and increase work efficiency by minimizing turns and travel distance.

Dozer shovel can transport newly mixed concrete direct to molds.

12.10.3 LEVELING 1. Scoop up the soil into the bucket, drive the machine in reverse, and dump the bucket a little at a time to dump the soil.

2. With the bucket at the dump position, lower the bucket until the bucket edge is in contact with the ground, then drive in reverse with the bucket dragging along the ground to level the soil.

3. Fill the bucket with soil, set the bucket in a horizontal position, place the boom at FLOAT, then drive in reverse to finish the surface.

NOTICE If dumping is performed with dumping cylinder fully extended (up to stroke end), dumping cylinder may be damaged when subjected to excess load. Therefore, always dump with dumping cylinder slightly retracted from fully extended position.

12.10.4 BACK FILLING For back filling in foundation work at construction sites, with bucket kept horizontally, dump the first excavated soil without dumping it over, and use each succeeding excavated soil to push the previous excavated soil over. Be sure not to approach the edge by mistake.

-.r /

-

AE205140

AE205150

2-42

12.11

HOW TO USE INCHING

PEDAL

High-efficiency excavation by effective use of the inching pedal.

12.11.1

OPERATION

OF INCHING

PEDAL

The inching pedal can be used in the following

three ways:

POSITIVE STOP OF A MACHINE DURING OPERATION When a machine is to be positively stopped between excavating operations, first depress the inching pedal. Then, the transmission clutch will disengage, interrupting the flow of power from the engine. If the brake pedal is depressed, the machine can be stopped completely.

AH142750

WHEN A MACHINE IS TO APPROACH A TARGET INCH BY INCH Depress the inching pedal and place the transmission clutch in the half-disengaged or completely disengaged position. Then the machine can approach material little by little.

AM142760

SCOOPING IN A DIGGING OPERATION Scooping can be done as in a direct-drive machine, using the inching pedal. After depressing the pedal all the 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.

AM142710

2-43

12. OPERATION

12.11.2

HOW TO USE INCHING PEDAL IN ACTUAL MATERIAL HANDLING OPERATIONS

LOADING l Approaching

a dump truck and correcting

the direction

of travel

Approach the side of the dump truck and stop the machine by depressing the inching pedal and brake pedal.

AN142780

Depress the inching pedal all the way down, then depress the brake pedal.

%OOO AM142750

When adjusting the turning direction finely, press the steering pedal in the turning direction, then slowly release the inching pedal that has been pressed during stoppage.

I l

Inching

approach

and bucket

speed

AM142800

I

I

Depress the inching pedal and bring the transmission clutch to a half-disengaged or completely disengaged position to inch toward the dump truck.

I

AN142810

I

AH142760

REMARK

When inching with the inching pedal, the bucket can operate even at full engine speed without slowing down the bucket speed.

2-44

1

12. OPERATION

0

Positive stopping Slowly approach the desired stopping position with the inching pedal kept halfway down. Stop the machine positively by depressing the brake pedal all the way down.

REMARK If the machine is traveling with a full bucket, and the brake pedal is depressed all the way down, it will act like the emergency brake, possibly causing the machine to lose balance. Consequently, slowly depress the inching pedal’after bringing the transmission clutch to the half disengaged position. When the machine has reached the desired location, depress the brake pedal all the way down to apply the brake.

c

*.

AE205160

b,oO AM142750

FILLING OPERATION 0 Positive stopping Slowly bring the machine to the desired stopping position, depressing the inching pedal halfway. To stop the machine positively, depress the brake pedal all the way down.

_ ._-

AE205170

cs,oo

AM142750

CORNERING l Inching steering and approaching Operate the steering and directional lever and depress the inching pedal to bring the transmission clutch to the half disengaged position for microsteering or inching up to a building.

2-45

EXCAVATION Jerking After depressing the inching pedal all the way down, release the pedal halfway to bring the transmission clutch to the half disengaged position. Then, release the pedal fully at once, and the transmission clutch will engage instantly, enabling the bucket to jerk material. l

REMARK After depressing the inching pedal all the way down, release the pedal fully at once. Then, the machine can start off smoothly as if the gear shift lever were put into the desired speed position. In this case, jerking with the bucket is impracticable.

AM142770

12.11.3

PRECAUTIONS WHEN APPLYING THE INCHING PEDAL

l

Do not keep the inching pedal depressed halfway for more than 10 sec. with the transmission clutch in the half-disengaged position. This will protect the clutch against excessive wear.

l

Do not rest your foot on the pedal unless absolutely necessary.

2-46

12.12

PARKING

MACHINE

A

WARNING

Avoid stopping suddenly. Give yourself ample room when stopping.

When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert blocks underneath the track shoes. As an additional safety measure, thrust the bucket into the ground.

If the control lever is touched by accident, the work equipment or the machine may move suddenly, and this may lead to a serious accident. Before leaving the operator’s compartment, always apply the lock securely.

1.

Lower engine speed by operating fuel control lever @I_ Low idling

2.

Place gear shift lever @ in NEUTRAL position.

m N

I

a

F

1

1

2

2

3

3

J

I

AM142590

Press the center between both steering pedals 0. Lock the brake with brake lock lever 0.

Lock

0 t a&

AD142600

4.

Lock gear shift lever @ with safety lock lever 0. ee

d

2-47

12. OPERATION

5.

Put bucket control lever @ in the LOWER position to lower the bucket to the ground while keeping it horizontal.

AD142628

6.

Lock bucket control lever @ with safety lock lever 0.

Lock

Free

AD142328

12.13 CHECK AFTER FINISHING WORK 1. Check the gauges and lamps for engine water temperature, engine oil pressure, fuel level and air cleaner clogged.

2-46

12.14

STOPPING ENGINE

NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency.

In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop it.

1.

Run the engine at low idling speed for about 5 minutes to allow it to gradually cool down.

2.

Pull the knob and set fuel control lever @ to ENGINE STOP position to stop the engine.

I

Low

AM162470

idline naine

stop

nob

3.

Turn the key in starting switch @ to the OFF position and stop the engine.

4.

Remove the key from starting switch 0.

2-49

12.15

CHECK AFTER STOPPING

ENGINE

1. Walk around the machine and check the work equipment,

paintwork, and undercarriage, and check also for leakage of oil or water. If any abnormalities are found, repair them.

2.

Fill the fuel tank.

3.

Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.

4.

Remove any mud stuck to the undercarriage.

2-50

12.16

TIPS FOR LONGER UNDERCARRIAGE LIFE

Undercarriage life greatly varies depending on operation method, inspection and maintenance. For most efficient operation, keep the following point in mind.

12.16.1

OPERATION

METHOD

Select the track shoe that best suits the type of soil to be encountered in service.

Please consult your Komatsu distributor when selecting track shoes.

Do not allow shoe slipping to occur during operation. If shoe slipping occurs, reduce load to the bucket until slipping stops.

Avoid sudden starts, acceleration or stops, unnecessarily speeds and sharp turns.

high

Always operate machine in a straight line whenever possible.

When making turns, be careful not to allow the machine to stay to one side, so operation in both turning directions can be done properly. Make turns with the largest possible radius.

Prior to operation, clear boulders and obstacles to prevent machine from riding over them while operating.

On a slope, operate the machine parallel to the inclination of the slope. Do not operate across the slope. Also when stopping the machine on a slope, the machine should face toward the top of the slope.

When ground inclines to left or right during digging operation, do not continue to dig with machine inclined. Move machine back to level ground and start to dig again.

When idlers or sprockets are lifted due to obstacles during dozing, do not attempt to force the machine to perform. Because work at this time exceeds machine working capability.

2-51

12.

OPERATION

12.16.2

INSPECTION

AND ADJUSTMENT

l

Properly adjust track tension.

Tension should be measured at clearance @ shown in the diagram - usually 20 to 30 mm (0.8 to 1.2 in) at this point. For rocky terrain, tighten tracks slightly. In clay or sandy areas, slightly loosen them. (For inspection and adjustment proce- dures, refer to “24.2 WHEN REQUIRED”).

l

Check idler rollers for oil leakage as well as for loose bolts and nuts. If any trouble is detected, repair immediately.

l

Check the clearance between the idler guide plate and the track frame. If clearance @ increases, idler may develop side motion and tracks may come off. (For inspection and adjustment procedures, refer to “24.2 WHEN REQUIRED”.)

12.16.3

INSPECTION

Clearance

A

AE14294B

AND REPAIR

Frequent inspection and prompt repair will reduce repair costs.

The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Perform periodical inspection and contact the Komatsu distributor in your area when machine has approached repairable limits and reversing limits.

MEASURING LINK PITCH 1. Insert a wooden block between track shoe and sprocket to take up the slack in track shoes.

2.

Measure pitch length of 4 links in stretched portion at more than 2 links away from master pin. Of length obtained, l/4 is the link pitch.

AN142960

Standard link pitch (PI: 216.25 mm (8.65 in) Reversing limit link pitch: 219.25 mm (8.77 in) (At heavy-duty work) 221.25 mm (8.85 in) (At light-duty work) REMARK A center hole is not provided on both ends of master pin.

(1/4L)

t-7 ON

AD142978

2-52

i2. OPERATION

MEASURING HEIGHT OF GROUSER After taking up slack in track shoes, measure height at center of shoe as shown.

Standard height (h): 36.0 mm (1.44 in) Repair limits: 20.0 mm (0.8 in)

AD205190

MEASURING OUTSIDE DIAMETER OF TRACK ROLLER 1. Measure height (size C) of link tread as shown.

2. Stop machine at position where link tread, whose size C has been measured completely, contacts roller tread. Then measure size B. 3. Calculate outside diameter of tread (size A): A=(B-0x2 Standard size (A): 222 mm (8.88 in) Repair limits: 197 mm (7.88 in)

AD205200

2-53

13. TRANSPORTATION

When transporting the machine, observe all related laws and regulations, and be careful to assure safety.

13.1

LOADING, UNLOADING WORK 4b

WARNING

Make sure the ramp has sufficient width, length and thickness to enable the machine to be safely loaded and unloaded.

If the ramp sags appreciably, reinforce it with blocks, etc.

When loading and unloading the machine, park the trailer on a flat firm roadbed. Keep a fairly long distance between the road shoulder and the machine.

Remove the mud from the undercarriage to prevent the machine from slipping to the side on slopes.

Be sure the ramp surface is clean and free of grease, oil, ice and loose materials.

Never change the direction of travel when on the ramps. If it is necessary to change direction, drive off the ramps and correct the direction, then drive on to the ramps again.

l

l

l

l

When loading or unloading, always use ramps or a platform and carry out the operations as follows.

1. Properly apply the brakes on the trailer and insert blocks beneath

the tires to ensure that it does not move. Then fix the ramps in line with the centers of the trailer and the machine. Be sure that the two sides are at the same level as one another.

2.

Determine the direction of the ramps, then slowly load or unload the machine.

3.

Load the machine trailer.

Ra

Distance between ramps

2-54

correctly

in the specified

position

on the

13. TRANSPORTATION

13.2

PRECAUTIONS FOR LOADING, AND SECURING THE MACHINE

After loading to the specified position, secure the machine as follows.

1.

Lower the work equipment

2.

Lock all the control levers securely with the safety lock lever.

3.

Set the parking lever to the LOCK position.

4.

Set the fuel control lever to the ENGINE STOP position to stop the engine, then turn the starting switch to the OFF position and remove the key.

5.

slowly.

For avoiding slip of the machine, secure it tightly as follows.

Put blocks @ in front and behind the track shoes of both sides. l Set up chain or wire, following @ or @I. @: Set up chain or wire around the track shoes. @I: Set up chain or wire through the holes of track links. l Protect the wire from contacting directly with angular parts of the machine, by inserting pads.

l

6.

Confirm the way of trees) tation.

Refer to

that the height of the load clears various limitations on (width and height of tunnels, size of guards, branches and meets all laws and regulations governing transpor“13.4 PRECAUTIONS

FOR TRANSPORTATION�.

2-55

13. TRANSPORTATION

13.3 I

LIFTING

THE MACHINE a

DANGER

While lifting the machine, if wire or rope is not fitted correctly the machine may fall and cause serious injury or even death.

Raise the machine 100 - 200 mm (4 - 8 in) from the ground, check that the machine is horizontal and that there is no slack in the wire rope, then continue to lift the machine.

Before lifting the machine, always stop the engine and lock the parking brake.

IA

1

WARNING Lifting operations using a crane must be carried out by a qualified operator.

Never raise the machine with any worker on it.

Always make sure that the wire rope used for lifting the machine is of ample strength for the weight of the machine.

Never try to lift the machine at any position or in any procedure other than the posture given in the procedure below. There is danger that the machine may lose its balance.

NOTICE l For details of the weight, see “25. SPECIFICATIONS�. l The values given for the specifications are for the standard machine, so the method of lifting may differ according to the options and attachments actually installed. In such cases please contact your Komatsu distributor for advice.

2-56

13. TRANSPORTATION

13.3.1POSITION

FOR AlTACHlNG

LIFUNG

POSITION

0

MARKS

Lifting (I 45-98-5

image

mark

1880)

145-98-51880AE21509B

FOR DETAILS OF THE WEIGHT, SEE “25. SPECIFICATIONS”.

2-57

13.3.2 LIFTING

Ti It bucket an d apply IO ck

Pass

at

behind

PROCEDURE

A

back safety

the

Install

l

Detail of installation of ropes to inside of track and frame of work equipment

l

Detail of installation of ropes to diagonal brace

to al

idler

!

I=\

Pass under

inside track, undercover

then AD215106

Diagonal brace

Wind onto

rope brace

ADD I Y protector AE2146lB

Tilt

diagonal

bucket

brat l

Pass under

behind

the

I nsta’l ripper

idler Pass under

2-58

inside track. undercover

I

Detail of installation to ripper beam

of ropes

to beam AE214630

then AD215116

13. TRANSPORTATION

Before starting the lifting operation, horizontal place and do as follows.

stop the machine

in a

1.

Stop the engine, depress the brake pedal fully, then pull the brake lock lever to lock the brakes.

2.

As shown in the diagram in previous page, use wire rope, slings or other lifting equipment according to the weight, pass the wire rope around the lifting position, then fit it to a crane.

NOTICE Fit protectors at may cut into the and prevent the Choose a sledder the chassis.

sharp corners or places where the wire rope contact point in order to protect the machine wire rope from being cut. and bar of ample width which will not contact

When the machine leaves the ground, stop for a moment at a point 100 - 200 mm (4 - 8 in) from the ground, check that there is no slack in the wire rope and that the machine is horizontal, then continue the lifting operation slowly.

13.4

PRECAUTIONS FOR TRANSPORTATION a

WARNING

Determine the route for transporting the machine by taking into account the width, height and weight of the machine.

Obey all state and local laws governing the weight, width and length of a load. Observe all regulations governing wide loads.

2-59

14. COLD WEATHER OPERATION

14.1

PRECAUTIONS

FOR LOW TEMPERATURE

If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows.

14.1.1 FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components.

For details of the specified viscosity, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

14.1.2 COOLANT

Keep antifreeze fluid away from an open flame.

NOTICE Never use methanol,

Never smoke

ethanol or propanol based antifreeze.

Where no permanent antifreeze is available, an ethylene glycol antifreeze without corrosion inhibitor may be used only for the cold season. In this case, clean the cooling system twice a year (in spring and autumn). When refilling the cooling system, add antifreeze in autumn, but do not add any in spring.

Absolutely avoid using any water leak preventing agent irrespective of whether it is used independently or mixed with an antifreeze.

Do not mix one antifreeze with a different brand.

For details of the antifreeze mixture when changing the coolant, see “24.1 WHEN REQUIRED”.

Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the standard requirements as shown below. With permanent antifreeze, no change of coolant is required for a year. If it is doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for information.

Standard requirements for permanent antifreeze. l SAE ..... .... ........ ..... ............. ............. ............. .............. ............. . J1034 l FEDERAL STANDARD ...... .............. .............. ............ .... O-A-548D

2-60

14. COLD WEATHER OPERATION

14.1.3 BATTERY

A l

l

WARNING

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

Battery electrolyte is dangerous.

If it gets in your eyes or on

your skin, wash it off with consult a doctor.

large amounts

of water,

and

When the ambient tem’perature drops, the capacity of the battery will also drop. If the battery charge ratio is low, the battery electrolyte may freeze. Maintain the battery charge as close as possible to lOO%, and insulate it against cold temperature so that the machine can be started easily the next morning.

Measure the specific gravity and calculate the rate of charge from the following conversion table.

100% 90% 80% 75%

20°C

0°C

-10°C

-20°C

1.28 1.26 1.24 1.23

1.29 1.27 1.25 1.24

1.30 1.28 1.26 1.25

1.31 1.29 1.27 1.26

14.2 AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, alwavs observe the following precautions.

Mud and water on the machine body should be completely removed. This is to prevent damage to the seal caused by mud or dirt getting inside the seal with frozen drops of water.

Park the machine on concrete or hard ground. If this is impossible, park the machine on wooden boards. The boards help protect the tracks from being freezed in soil and the machine can start next morning.

Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.

As the battery capacity drops markedly in low temperatures, cover the battery or remove it from the machine, keep it in a warm place, and install it again the next morning.

If electrolyte level is found low, add distilled water in the morning before beginning work. do not add the water after the day’s work so as to prevent fluid in the battery from freezing in the night.

2-61

14. COLD WEATHER OPERATION

14.3 AFTER COLD WEATHER When season changes and the weather becomes warmer, do as follows. l Replace the fuel and oil for all parts with oil of the viscosity specified.

For details, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. l If for any reason permanent antifreeze cannot 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, and fill with fresh water.

2-62

15. LONG-TERM

15.1

STORAGE

BEFORE STORAGE

When putting the machine in storage for more than one month, do as follows.

0 After every part is washed and dried, the machine shall be housed in a dry building. Never leave it outdoors.

In case it is indispensable to leave it outdoors, park the machine on the flat ground and cover it with canvas etc.

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

Apply a thin coat of grease to metal surface of the hydraulic piston rods and the idler adjusting rods.

Disconnect the negative terminals of the battery and cover it, or remove it from the machine and store it separately.

If the ambient temperature is expected to drop below O�C, always add antifreeze to the cooling water.

Lock each control lever with the safety lock and place the fuel control lever in the low idling position. Do not lock the brake pedal; use blocks to stop the machine from moving.

15.2

DURING

If it is unavoidably windows

STORAGE necessary to carry out the rustpreventive

to improve ventilation

and prevent gas poisoning.

l

Operate the engine and move the machine for a short distance once a month so that a new film of oil will be coated over movable parts and component surfaces. At the same time, also charge the battery.

l

Before operating the work equipment, wipe off the grease on the hydraulic piston rod.

15.3 AFTER STORAGE NOTICE If the machine is stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service.

Carry out the following of long-term storage. l l

procedure when taking the machine out

Wipe off the grease from the hydraulic cylinder rods.

Add oil and grease to all places.

2-63

16. TROUBLESHOOTING

16.1 AFTER RUNNING OUT OF FUEL When starting after running out of fuel, fill with fuel, then fill the fuel filter cartridge with clean fuel and bleed the air from the fuel system before starting.

For details of bleeding the air, see “24.6 EVERY 500 HOURS SERVICE�

16.2

IF BATTERY IS DISCHARGED

A

WARNING

When checking or handling the battery, stop the engine and turn the starting key to the OFF position before starting.

The battery generates hydrogen gas, so there is danger of explosion. Do not bring lighted cigarettes near the battery, or do anything that will cause sparks.

Battery electrolyte is dilute sulphuric acid, and it will attack your clothes and skin. If it gets on your clothes or on your skin, wash it immediately off with large amounts of water. If it gets in your eyes, wash it out with fresh water, and consult a doctor.

When handling battery, always wear-protective goggles and rubber gloves.

When removing the battery, first disconnect the cable from the ground (normally, from the negative 0 terminal). When installing, install the positive @terminal first. If a tool touches the cable connecting the positive terminal and the chassis, there is danger that it will cause sparks.

If the terminals are loose, there is danger that the defective contact may generate sparks that will cause an explosion.

When installing the terminals, install them tightly.

16.2.1 STARTING

ENGINE WITH BOOSTER CABLE

When starting the engine with a booster cable, do as follows:

2-64

When installing, connect the cable to the positive @ terminal first.

/

w

AM087770

REMOVAL,

INSTALLATION

OF BATTERY

1. Open battery cover 0.

2.

Disconnect the grounding cable (from the 0 (negative) terminal, usually) first. If a tool, etc. touches the @ (positive) terminal and sparks will be produced. the machine body simujtaneously, Loosen the terminal nut and disconnect the cable from the battery.

3.

When connecting, connect the grounding cable at last. Inset-t the terminal hole to the battery, then tighten the nut.

Tightening torque: 5.88 - 9.81 N-m IO.6 - 1.O kgf.m, 1.2 - 2.0 Ibft)

4.

Close battery cover 0.

When removing, disconnecf the

minal first.

WHEN PRECAUTIONS BOOSTER CABLE

CONNECTING

a

AND

DISCONNECTING

AM087770

WARNING

When starting the engine from another machine, connect the batteries in parallel. the cables, never contact the positive @ When connecting and negative @ terminals.

When starting the engine with a booster cable, always wear safety glasses.

Be careful not to let the normal machine and problem machine contact each other. This prevents sparks from generatgas ing near the battery which could ignite the hydrogen given off by the battery. If hydrogen gas explodes. It could cause serious injury. in the booster cable Make sure that there is no mistake connections. The final connection is to the engine block of the when this is problem machine, but sparks will be generated done, so connect to a place as far as possible from the battery.

Use care when removing the cables from the machine has been started. Do not allow the cable ends to contact other or the machine, to avoid hydrogen explosion.

NOTICE The size of the booster battery size.

l

cable and clip should

be suitable

that each

for the

l

The battery of the normal machine must be the same capacity as that of the engine to be started.

l

Check the cables

l

Make

and clips for damage

sure that the cables

AM087790

or corrosion.

and clips are firmly

connected.

2-65

16.

TROUBLESHOOTING

CONNECTING THE BOOSTER CABLES Keep the starting switch at the OFF position.

Connect the booster cable as follows, in the order of the numbers marked in the diagram.

1. Make sure that the starting switches of the normal machine and problem machine are both at the OFF position.

2. Connect one clip of booster cable @ to the positive @ terminal of the problem machine.

3. Connect the other clip of booster cable @ to the positive @ terminal of the normal machine.

4. Connect one clip of booster cable @I to the negative @ terminal of the normal machine.

5. Connect the other clip of booster cable @ to the engine block of the problem machine.

roblem machine

ADO52980

STARTING THE ENGINE 1. Make sure the clips are firmly connected to the battery terminals.

2.

Start the engine of the normal machine and keep it to run at high idling speed.

3.

Turn the starting switch to start the engine. If the engine does not start, wait for at least 2 minutes, then try again.

DISCONNECTING THE BOOSTER CABLES After the engine has started, disconnect the booster cables in the reverse of the order in which they were connected.

1.

I

Remove one clip of booster cable @I from the engine block of the problem machine.

1

2.

Remove the other clip of booster cable @ from the negative 0 terminal of the normal machine.

3.

Remove one clip of booster cable @ from the positive terminal of the normal machine.

4.

Remove the other clip of booster cable @ from the positive @ terminal of the problem machine.

2-66

@

Battery of the normal machine

I

fi

W’

Battery of the oroblem machine

===a Engine block of the problem machine

Aw52e8,

16. TROUBLESHOOTING

16.3.2 CHASSIS Main causes

Problem

Transmission

oil pressure does not rise

0 l

0

Wear or scuff of gear pump Insufficient oil in transmission case (including torque converter case) Clogging of strainer of transmission case

Remedy

10 Check, replace) Referring to check before starting, supply oil to specified level l Referring to EVERY 1000 HOURS SERVICE, clean

l

Traction force is low (Travel speed does not rise)

0

Insufficient engine power

0

When gear shift lever is set, machine does not start

l

Insufficient oil in steering clutch case Low transmission oil pressure

Referring to check before starting, supply oil to specified level l See above problem of “Transmission oil pressure does not rise” (o Check, replace)

0

Torque converter overheats (Indicator is in red range)

l

Slip of steering clutch 0 Wear or scuff of gear pump

0

Insufficient oil in transmission case (including torque converter case) Low transmission oil pressure

0

See section of engine

l

Referring to check before starting, supply oil to specified level l See above problem of “Transmission oil pressure does not rise” (o Check, replace) l

l

Slip of steering clutch 0 Wear or scuff of gear pump Excessive working load

When either steering pedal is pressed, machine does not turn but travels straight

l

Inoperable pressed brake

(o Adjust)

When either steering pedal is pressed, machine does not turn but stops or engine speed changes

l

Improper adjustment of steering mechanism

(o Adjust)

When brake pedal is pressed, machine does not stop.

l

Wrong adjustment of brake or improper oil pressure

(o Adjust, check, repair)

Track comes off

l

Looseness of track

l

Referring to WHEN REQUIRED, adjust track tension

Sprocket is worn abnormally

l

Looseness of tightness of track

Bucket does not rise (or tilt) quickly or at all

l

Insufficiency of hydraulic oil

l

Referring to EVERY 250 HOURS SERVICE, add hydraulic oil to specified level.

l

2-68

l

Use gear speed lower by one rank or reduce load to heighten working speed.

16. TROUBLESHOOTING

16.3.3 ENGINE Main

Problem

Engine oil pressure warning lamp remains alight when engine speed is raised after completion of warm-up

l

l

l

l

causes

Engine oil pan oil level is low (sucking in air) Clogged oil filter cartridge Defective and pipe damaged Defective

tightening of oil pipe joint, oil leakage from part warning lamp

Remedy

Add oil to specified level, see CHECK BEFORE STARTING l Replace cartridge, see EVERY 250 HOURS SERVICE (o Check, repair)

l

(o Replace lamp)

Cooling water level low, water leakage Loose fan belt

Steam is emitted from top part of radiator (pressure valve)

Add cooling water, repair, see CHECK BEFORE STARTING Adjust fan belt tension, see EVERY 250 HOURS SERVICE Change cooling water, clean inside of cooling system, see WHEN REQUIRED Clean or repair, see WHEN REQUIRED

Dirt or scale accumulated in cooling system Clogged radiator fin or damaged fin Defective thermostat Loose radiator filler cap (high altitude operation) Defective water temperature

Indicator of water temperature gauge is in red range on right side of gauge

Replace thermostat) Tighten cap or replace packing Replace water temperature

gauge)

Replace thermostat Replace water temperature

gauge

gauge Indicator of water temperature gauge is in white range on left side of gauge

l l

Defective thermostat Defective water temperature gauge Lack of fuel

Engine does not start when starting motor is turned

Air in fuel system Defective fuel injection pump or nozzle Starting motor cranks engine sluggishly Glow signal does not glow red Defective compression o Defective valve clearance Exhaust gas is white or blue

Exhaust gas occasionally turns black

Combustion noise occasionally makes breathing sound Abnormal noise generated (combustion or mechanical)

l l

Add fuel, see CHECK BEFORE STARTING l Repair place where air is sucked in (e Replace pump or nozzle) l

I-

See ELECTRICAL SYSTEM

(0 Adjust valve clearance) Add oil to specified level, see CHECK BEFORE STARTING Change to specified fuel

l

Too much oil in oil pan

l

l

Improper fuel

l

l

l

l

Clogged air cleaner element Defective nozzle Defective compression

l

Defective nozzle

(o Replace nozzle)

l

Low grade fuel being used Overheating

l

l

l

l l

Damage inside muffler Excessive valve clearance

Clean or replace, see WHEN REQUIRED (o Replace nozzle) (o Adjust valve clearance)

Change to specified fuel See item “Indicator of water temperature gauge is in red range on right side of gauge�. (o Replace muffler) (o Adjust valve clearance) l

2-69

2-70

2 I m 2

3 b

17. GUIDES TO MAINTENANCE

Do not carry out any inspection and maintenance Perform maintenance

operation that is not given in this manual.

work on hard, flat ground.

Check service meter Check the service meter reading every day to see if the time has come for any necessary maintenance to be carried ‘out.

Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the parts list as replacement

parts.

Komatsu genuine oils: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities ambient temperature.

specified for

Clean oil and grease: Use clean oil and grease. Also, keep containers of the oil and grease clean. Keep foreign materials away from oil and grease.

Keeping the machine clean: Always keep the machine clean. This makes is easier to find parts causing problems. Keep in particular grease fittings, breathers and oil level gauges clean and avoid foreign matters from getting in them.

Be careful of hot water and oil: Draining hot oils and coolants and removing their filters immediately after the engine stops are hazardous. Allow the engine to cool.

If the oil has to be drained when it is cold, warm up the oil to a suitable temperature (approx. 20 - 40°C) before draining it.

Check drained oil and filter: When replacing the oil or the filter, check it for metal chips, foreign matter, etc.

Fuel strainer: If your machine is equipped with a fuel strainer, do not remove it while fueling.

Oil change: Check or change oils in the places where dust is scarce to keep foreign materials away from oils.

Warning tag: Attach the warning tag to the starting switch or other appropriate control lever to avoid someone who is not aware of the circumstances from starting the engine.

3-2

17.

Obey precautions: During the operation, always obey the precautions

GUIDES TO MAINTENANCE

on the safety label stuck to the machine.

Welding instructions: l Turn off the engine starting switch. l Do not apply more than 200 V continuously. l Connect grounding the cable within 1 m from the area to be welded. l Avoid seals or bearings from being between the area to be welded and the position of grounding point.

Fire prevention: Use nonflammable oil.

cleaner or light oil for cleaning parts. Keep flame or cigerette light away from light

Clamp faces: When O-rings or gaskets are removed, clean the clamp faces and replace the O-rings and gaskets with new ones. Be sure to fit O-rings and gaskets when assembling.

Objects in your pockets: Keep your pockets free of loose objects which can fall out and drop into the machinery; especially when you work on the machinety while bending over it.

Checking undercarriage: When working in rocky areas, check for damage to the undercarriage and for looseness, flaws, wear and damage in bolts and nuts. Loosen the track tension a little when working in such areas.

Cleaning machine: l Do not direct a high-pressure jet directly at the radiator. l Do not splash water over the electrical equipment.

Pre-and post-work checks: Before starting work in mud rain, snow or at seashore, check plugs and valves for tightness.

Wash the machine immediately after the work to protect components from rusting.

Lubricate components more frequently than usual. Be sure to lubricate work equipment pins daily if they are submerged in water.

Dusty worksites: When working at dusty worksites, do as follows: 0 Check the air cleaner for clogging more frequently. Clean the air cleaner at shorter intervals than specified. l Clean the radiator core frequently to avoid clogging. l Clean and replace the fuel filter frequently.

0 Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.

Avoid mixing oils: Never mix oils of different brands. If you have only oil which is a different brand from the one that is used in the machine, do not add it but replace all the oil.

3-3

18. OUTLINES OF SERVICE

l

Use Komatsu genuine parts for replacement.

l

When changing or adding oil, do not use a different type of oil.

l

Unless otherwise specified, the oil and coolant used at the time of shipment from the factory are as shown in the table below.

Item

I

Kind of fluid

Engine oil pan

SAE 15W-40 API classification CD

Power train case (including torque converter case) Steering clutch case Final drive case

SAE 30 API classification CD

Hydraulic tank

SAE 1OW API classification CD

Fuel tank

ASTM D975 No. 2 (However, ASTM D975 No. 1 is used for the winter season (October to March))

Radiator

Komatsu Super Coolant (AF-ACL) 41% added to water

18.1 OUTLINE OF OIL, FUEL, COOLANT 18.1.1 OIL Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pressure), and it deteriorates with use.

Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual. Even if the oil is not dirty, always replace the oil after the specified interval.

Oil corresponds to blood in the human body, so always be careful when handling it to prevent any impurities (water, metal particles, dirt, etc.) from getting in.

The majority of problems with machine are caused by the entry of such impurities.

Take particular care not to let any impurities get in when storing or adding oil.

Never mix oils of different grades or brands.

Always add the specified amount of oil.

Having too much oil or too little oil are both causes of problems.

If the oil in the work equipment is not clear, there is probably water or air getting into the circuit.

In such cases, please contact your Komatsu distributor.

When changing the oil, always replace the related filters at the same time.

We recommend you to have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor.

3-4

18. OUTLINES OF SERVICE

18.1.2 FUEL l

l l

l

l

l

The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.

Be extremely careful not to let impurities get in when storing or adding fuel.

Always use the fuel specified in the Operation and Maintenance Manual.

Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -lS”C), so it is necessary to change to a fuel that matches the temperature.

To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank after completing the day’s work.

Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from the fuel tank.

If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.

18.1.3 COOLANT River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the engine and radiator, and this will cause defective heat exchange and overheating.

Do not use water that is not suitable for drinking.

When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.

Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped.

This anti-freeze is effective in preventing corrosion of the cooling system.

The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as it is even in hot areas.

Anti-freeze is inflammable, so be extremely careful not to expose it to flame or fire.

The proportion of anti-freeze to water differs according to the ambient temperature.

For details of the mixing proportions, see “24.1.1 CLEAN INSIDE OF COOLING SYSTEM”.

If the engine overheats, wait for the engine to cool before adding coolant.

If the coolant level is low, it will cause overheating and will also cause problems with corrosion from the air in the coolant.

18.1.4 GREASE l l

l

Grease is used to prevent twisting and noise at the joints.

The nipples not included in the maintenance section are nipples for overhaul, so they do not need grease.

If any part becomes stiff after being used for a long time, add grease.

Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts.

3-5

18. OUTLINES OF SERVICE

18.1.5 STORING l l

l

OIL AND FUEL

Keep indoors to prevent any water, dirt, or other impurities from getting in.

When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at the side. (To prevent moisture from being sucked in) If drum cans have to be stored outside, cover them with a waterproof sheet or take other measures to protect them.

To prevent any change in quality during long-term storage, be sure to use in the order of first in first out (use the oldest oil or fuel first).

18.1.6 FILTERS l

l l

l l

Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering important equipment and causing problems.

Replace all filters periodically.

For details, see the Operation and Maintenance Manual.

However, when working in severe conditions, it is necessary to consider replacing the filters at shorter intervals according to the oil and fuel (sulfur content) being used.

Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.

When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found, please contact your Komatsu distributor.

Do not open packs of spare filters until just before they are to be used.

Always use Komatsu genuine filters.

18.2 RELATING TO ELECTRIC SYSTEM l

If the wiring gets wet or the insulation is damaged, in hazardous malfunction of the machine.

l

Services relating to the electric system are (I) check of fan belt tension, in the fan belt and (3) check of battery fluid level.

l

Never

remove

l

Never

install any electric

l

Be careful

l

When

working

on the seashore,

l

Never

connect

any optional

3-6

or disassemble

any electric

components

to keep the electric

system

components

other than these free of water

carefully

power

the electric

system

leaks and this could

(2) check of damage

installed

in the machine.

specified

by Komatsu.

when

clean the electric

washing system

source to the fuse, starting

the machine to prevent

switch,

battery

or when corrosion. relay, etc.

result

or wear

it rains.

19. WEAR PARTS LIST

Wear parts such as the filter element, cutting edge, etc. are to be replaced at the time of periodic maintenance or before their abrasion limits.

The wear parts should be changed correctly in order to use the machine economically.

For part change, Komatsu genuine parts of excellent quality should be used.

The parts in parentheses are to be replaced at the same time.

Item

Part No:

Engine oil filter

600-211-1231

Cartridge

1

Power train/

175-49- 11580

Element

2

steering

(07000-02115)

(O-ring)

(2)

600-3 11-8293

Cartridge

141-60-18270 (07000-15145)

Cartridge (O-ring)

oil filter

Fuel filter

Hydraulic

oil filter

Replacement frequency

Q’tv

Part Name

Every 250 hours service

Every 500 hours service 1 Every 1000 hours

(1)

service Corrosion

resistor

600-41 l-l 151

I

600-8 I-7032

Cartridge Element

I

’

ass’y

I

1 -

Air cleaner

Bucket tooth

Electrical

intake air heater

600-181-4300

Outer element

145-70-44180 (145-70-44120) (I 45-70-44130)

Tooth (Bolt)

6150-11-4820

NOTICE When handling parts that weight the necessary care.

(Nut) I

Gasket

more than 20 kg, remember

ass’y

1 9

(27) (27) 12.1

that they are heavy objects,

-

and take

3-7

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

RESERVOIR

KIND OF FLUID

AMBIENT 22 -4 30 -20

14 -10

TEMPERATURE 32 0

50 10

68 20

r

86 104’F 30 4O’C

CAPACITY Specified

Refill

Engine oil pan

32 Q 8.3 US gal 7.0 UK gal

26 Q 6.7 US gal 5.7 UK gal

Power train case (Frl.e:;)rque con-

52 Q 13.5 US gal 11.4 UK gal

47 Q 12.2 US gal 10.3 UK gal

75 Q 19.5 US gal 16.5 UK gal

73 Q 18.9 US gal 16.0 UK gal

23 Q 5.9 US gal 5.0 UK gal

23 Q 5.9 US gal 5.0 UK gal

135 Q 35.1 US gal 29.7 UK gal

63 Q 16.4 US gal 13.9 UK gal

Engine oil Steering cluth case

Final drive case (each)

Hydraulic tank

Fuel tank

Cooling system (incl. sub-tank)

400 Q 104 US gal 88 UK gal

Diesel fuel

Water

65 Q 16.9 US gal 14.3 UK gal

Add antifreeze J % ASTM

3-8

D975

No. 1

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

REMARK When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual.

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

Above 1.0%

l/4 of regular interval

When starting the engine in an atmospheric temperature of lower than O’C, be sure to use engine oil of SAEIOW, SAEIOW-30 and SAE15W-40, even though an atmospheric temperature goes up to 10°C more or less in the day time.

Use API classification interval to half.

CD as engine oil and if API classification

CC, reduce the engine oil change

There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-30, sure to add single grade oil that matches the temperature in the table.

We recommend Komatsu genuine oil which has been specifically formulated in engine and hydraulic work equipment applications.

ISW-401, but be

and approved for use

Specified capacity: Total amount of oil including oil for components and oil in piping.

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

ASTM: SAE: API:

American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute

3-9

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

No.

1

2

Supplier

KOMATSU

AGIP

Engine Oil [CD or CEI SAEIOW, 30, 40 1ow30, 15w40 (The 15W40 oil marked * is CE.) EOI O-CD EOBO-CD EOIO-30CD EOI 5-40CD Diesel sigma S Super dieselmultigrade *Sigma

turbo 300

Gear Oil [GL-4 or GL-51 SAEBO, 90, 140

Grease [Lithium-Base] NLGI No. 2

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

GO90 GO140

G2-LI G2-LI-S

Rotra MP

GR MU/EP

Multi-purpose

gear oil

RYKON prenium grease

3

AMOCO

*Amoco

4

ARC0

*Arcofleet

5

BP

Vanellus

6

CALTEX

*RPM delo 400 RPM delo 450

7

CASTROL

*Turbomax *RX super CRD

8

CHEVRON

*Del0 400

Universal gear

Ultra-duty grease 2

9

CONOCO

*Fleet motor oil

Universal gear lubricant

Super-sta grease

10

ELF

Multiperformance Performance 3C

”

EXXON (ESSO)

Essolube D3 “Essolube XD-3 *EssoIube XD-3 Extra *Esso heavy duty Exxon heavy duty

12

GULF

Super duty motor *Super duty plus

13

MOBIL

Delvac 1300 *Delvac super 1ow-30, 15w-40

3-10

S3 plus

C3

Arco HD gear oil

Litholine HEP 2 Arco EP moly D

Gear oil EP Hypogear EP

Energrease

LS-EP2

Universal thuban Marfak all purpose 2 Universal thuban EP Ultra-duty grease 2 EP EPX

MS3 Spheerol

HYP~Y HYP~Y B HYP~Y C

EPL2

-

Antifreeze

AF engine

coolant

Anti-freeze

-

Tranself EP Tranself EP type 2

Glacelf

Gear oil GP Gear oil GX

Beacon EP2

All season coolant

Multi-purpose gear lubricant

Gulfcrown Gulfcrown

Antifreeze

Mobilube Mobilube

Mobilux EP2 Mobilgrease 77 Mobilgrease special

3C

oil

Anti-freeze Coolant [Ethylene Glycol Base1 Permanent Type

-

GX HD

EP2 EP special

and coolant

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATU RE

rl0.

Supplier

14

PENNZOIL

15 / PETROFINAI

16 1 SHELL

Engine Oil [CD or CEI SAE 1OW, 30, 40 1ow30, 15w40 (The 15W40 oil marked * is CE.)

Gear Oil [GL-4 or GL-51 SAE80, 90, 140

*Supreme duty fleet motor oil

Multi-purpose Multi-purpose

FINA kappa TD

/ ~~~~ $~~~~

4092 4140

/E

Spirax EP Spirax heavy duty

j Rimula X

-

17

SUN

18

TEXACO

*Ursa super plus Ursa premium

19

TOTAL

Rubia S *Rubia X

Grease [Lithium-Base1 NLGI No. 2

Multi-purpose white grease 705 707L White - bearing grease

/ FINA marson EPL2

Alvania

Anti-freeze Coolant [Ethylene Glycol Base1 Permanent Type

Anti-freeze and summer coolant

/ FINA tamidor

EP grease

Sunoco

Sunoco GL5 gear oil

ultra prestige 2EP Sun prestige 742

Sunoco antifreeze and summer coolant

Multigear

Multifak Starplex

Code 2055 startex antifreeze coolant

Total EP Total transmission

Multis

EP2 2

EP2

TM

20

UNION

*Guard01

MP gear lube LS

21

VEEDOL

*Turbostar *Diesel star MDC

Multigear Multigear Multigear

B C

Antigel/antifreeze

Unoba EP

-

Antifreeze

3-11

21. iTl&tDARD

21.1

INTRODUCTION

The following No. 1

TIGHTENING TORQUES FOR BOLTS AND

OF NECESSARY TOOLS

tools are needed when

Name of tool

Wrench set

carrying

out maintenance.

Part No. 09000-30006

Remarks Applicable width across flats (S1 - S2) 8 mm - 10 mm, 12 mm - 14 mm 13 mm - 17 mm, 19 mm - 22 mm 24 mm - 27 mm, 30 mm - 32 mm

2

Screwdriver

09033-00190

Interchangeable

3

Socket wrench set

09020-10285

Applicable width across flats

s2

flat-head and cross-head type

10 mm, 13 mm 14 mm, 17 mm 19 mm, 22 mm, 24 mm, Extension, Handle 4

Filter wrench

090 1g-08035

5

Socket

09084-00915

6

Grease pump

07952-80002

For greasing work

7

Grease cartridge

07950-90403

(Lithium base grease, 400 g)

For filter cartridges

If any of the above tools are broken, please order them from your Komatsu distributor. not using the tools, always put them in the tool box on the inside of the battery inspection cover on the left side of the machine.

When

3-12

21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

21.2

TORQUE LIST

Unless the torque

otherwise specified, shown in the table.

tighten

the metric

bolts and nuts to

The tightening torque is determined by the width across the flats @ of the nut and bolt.

If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

Nm (newton meter): INm e 0.1 kgm + 0.74 Ibft Thread diameter of bolt (mm)

Width across flat (mm)

(a)

(b)

I

AD054300

Nm

lbft

km

6 8 10 12 14

10 13 17 19 22

13.2 31.4 65.7 112 177

16 18 20 22 24

24 27 30 32 36

279 383 549 745 927

* 2 + 2 t

29 39 58 78 98

28.5 2 3 t 39 f 3 56 2 6 76 2 8 94.5 * IO

27 30 33 36 39

41 46 50 55 60

1320 1720 2210 2750 3280

r r 2 r k

140 190 240 290 340

135 175 225 280 335

2 1.4 -c 2.9 2 6.8 + 9.8 * 19

1.35 f 0.15 3.2 ‘c 0.3 6.7 2 0.7 11.5 r 1.0 18.0 k 2.0

+ 15 2 20 2 25 3 30 rc_35

b

9.73 � 1.03 23.2 2 2.1 48.5 f 5.0 82.6 + 7.2 131 f 14

t

206 282 405 549 684

2 it + 2 2

21 29 43 58 72

973 f 100 1270 2 140 1630 2 180 2030 r 210 2420 r 250

NOTICE When tightening panels or other parts having tightening fixtures made of plastic, be careful not to use excessive tightening torque: doing so will damage the plastic parts.

3-13

22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out periodic maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of the parts given in the table. These parts are particularly closely connected to safety and fire prevention.

With these parts, the material changes as time passed, or they easily wear or deteriorate. However, it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function completely.

However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced immediately.

If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same as the hoses.

When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.

Ask your Komatsu distributor to replace the critical parts.

No.

Safety critical parts for periodic replacement

1

Fuel hose (Between fuel filter and injection pump)

2

2

Fuel hose (Between strainer and injection pump)

1

3

Fuel hose (Between injection pump and connector)

1

Fuel hose (Between connector and fuel tank) I 5 1 Spill hose (Betw een nozzle and connector)

I II

1

6

Spill hose (Between connector and fuel tank)

1

7

Turbocharger

1

8

Hose between torque converter relief valve and transmission control valve

I/

9

Hose between transmission transmission filter

pump and I

Hose between transmission transmission control valve

filter and

1o

hose

between torque converter relief valve and toraue converter 12

13

3-14

interval

1

4

lubricating

Replacement

O’ty

I

Every 2 years or 4000 hours, whichever comes sooner

1 1 1

I I

I I 1

Hose between steering oil filter and steering relief valve

I

Seat belt

I 1

2

I I

Replace every 3 years

23. MAINTENANCE

23.1

MAINTENANCE

SCHEDULE CHART

SCHEDULE

CHART

SERVICE ITEM

PAGE

INITIAL 250 HOURS SERVICE (only after the first 250 hours) Replacement of fuel filter cartridge

3-18

Replacement of transmikssion case oil (including torque converter case oil) and cleaninu of strainer

3-18

Replacement

3-18

of steering clutch case oil

Replacement of final drive case oil

3-18

Replacement

3-18

of hydraulic oil and hydraulic oil filter cartridge

Replacement of oil in engine oil pan and engine oil filter cartridge

3-18

Check of engine valve clearance

3-18 WHEN REQUIRED

Clean inside of cooling system

3-19

Check, clean and replace air cleaner element

3-22

Check track tension

3-24

Check electrical intake air heater

3-25

Adjustment

of steering brake

3-26

Adjustment

of clearance of idler

3-27

Adjustment

of work equipment

3-27

of bucket tooth

3-28

Replacement

CHECK BEFORE STARTING Check and refill of coolant

3-29

Check fuel level

3-29

Check oil level in engine oil pan, add oil

3-30

Check oil level in transmission

3-31

case (including torque converter case), add oil

Check oil level in steering clutch case, add oil

3-32

Check dust indicator

3-33

Check steering pedal travel

3-33

Check that lamps light up

3-34

Check horn sound

3-34

Check backup alarm sound (option)

3-35

Check seat belt for wear or damage (option)

3-35

3-15

23. MAINTENANCE

SCHEDULE CHART

SERVICE ITEM

PAGE

EVERY 50 HOURS SERVICE Supply of grease to bucket pin (4 places)

3-36

Supply of grease to dump cylinder shaft (4 places)

3-36

Supply of grease to lift arm support shaft (2 places)

3-36

Supply of grease to lift cylinder shaft (4 places)

3-36

Draining water and sediment from fuel tank

3-37

EVERY 250 HOURS SERVICE Supply of grease to tilt lever pin (4 places)

3-38

Supply of grease to equalizer bar shaft (I place)

3-38

Check oil level in final drive case, add oil

3-39

Check and supply of hydraulic tank oil

3-39

Replace oil in engine oil pan and engine oil filter cartridge

3-40

Replace transmission

3-41

and steering oil filter

Clean strainer at bottom of fuel tank

3-42

Check battery fluid level

3-42

Check and adjust fan belt tension

3-43

Check and retighten track shoe bolts

3-44

EVERY 500 HOURS SERVICE Replace fuel filter cartridge

3-45

Cleaning of steering clutch case breather

3-47

Cleaning of transmission

3-47

case breather

Cleaning of final drive case breather Clean and check radiator fin

3-47 EVERY 1000 HOURS SERVICE

Replace corrosion resistor cartridge

3-48

Supply of grease to diagonal brace (2 places)

3-48

Supply of grease to universal joint (2 places)

3-48

Replace oil in transmission

3-49

case (including torque converter case) and clean strainer

Replace oil in steering clutch case and clean strainer

3-51

Replace oil in final drive case

3-52

Replace oil in hydraulic tank and hydraulic oil filter element Check oil for undercarriage

3-16

3-54

23. MAINTENANCE

SERVICE ITEM

SCHEDULE CHART

PAGE

EVERY 1000 HOURS SERVICE (continued) Check clamping parts of turbocharger

3-54

Check turbocharger

3-54

rotor for play EVERY 2000 HOURS SERVICE

Supply of grease to steering pedal shaft (IO places)

3-55

Supply of grease to gear shift lever shaft (3 places)

3-55

Supply of grease to fuel control lever shaft (2 places)

3-56

Supply of grease to decelerator pedal shaft (3 places)

3-56

Supply of grease to bucket control lever shaft (3 places)

3-56

Clean engine breather element

3-57

Check alternator and starting motor

3-57

Check and adjust engine valve clearance

3-57

Clean and check turbocharger

3-57

Check vibration

3-57

damper EVERY 4000 HOURS SERVICE

Check water pump

3-58

3-17

24. SERVICE PROCEDURE

24.1 INITIAL

250 HOURS

Carry out the following hours. l l

l l l

l

l

SERVICE

maintenance

only after the first 250

REPLACEMENT OF FUEL FILTER CARTRIDGE CASE OIL (INCLUDING REPLACEMENT OF TRANSMISSION TORQUE CONVERTER CASE OIL) AND CLEANING OF STRAINER REPLACEMENT OF STEERING CLUTCH CASE OIL REPLACEMENT OF FINAL DRIVE CASE OIL REPLACEMENT OF HYDRAULIC OIL AND HYDRAULIC OIL FILTER CARTRIDGE REPLACEMENT OF OIL IN ENGINE OIL PAN AND HYDRAULIC OIL FILTER CARTRIDGE CHECK OF ENGINE VALVE CLEARANCE

For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS and 2000 HOURS SERVICE.

3-18

24. SERVICE PROCEDURE

24.2

WHEN

REQUIRED

24.2.1 CLEAN INSIDE OF COOLING

SYSTEM

a WARNING Soon after the engine has been stopped, the coolant is hot and can cause personal injury. Allow the engine to cool before draining water.

Never be under the machine with the engine running. To avoid serious injury, .always stop the engine before being under the machine to open the drain valve.

Never remove the radiator cap when the engine is at operating temperature.

At operating temperature, the coolant is under pressure. Steam blowing up from the radiator could cause personal injury. Allow the engine to cool until the radiator filler cap is cool enough to touch with your hand.

Remove the filler cap slowly to relieve pressure.

When removing drain plug, avoid pouring coolant on yourself.

Antifreeze is flammable, so keep it away from any flame. l

Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the table below.

Kind of coolant

Cleaning inside of cooling system and changing coolant

Replacing corrosion resistor

Permanent type antifreeze (All season type)

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

Non permanent type antifreeze containing ethylene glycol (Winter, one season type)

Every 6 months (spring, Every 1000 hours and when cleaning the inside autumn) (Drain antifreeze in spring, of the cooling system and add antifreeze in autumn) when changing coolant

When not using antifreeze

Every 6 months or every 1000 hours whichever comes first

I

3-19

24. SERVICE PROCEDURE

0

Use a permanent type of antifreeze.

If, for some reason, it is impossible to use permanent antifreeze, use an antifreeze containing ethylene glycol.

type

l

Stop the machine on level ground when cleaning or changing the coolant.

l

When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing rate table given below.

It is actually better to estimate a temperature about 10°C (50°F) lower when deciding the mixing rate.

Mixing rate of water and antifreeze

l

We recommend use of an antifreeze density gauge to control the mixing proportions.

l

Use city water for the cooling water.

If river water, well water or other such water supply must be used, contact your Komatsu distributor.

1.

Stop the engine and close corrosion resistor levers @ (2 places).

AE20521B

3-20

24. SERVICE

2.

Slowly turn radiator cap @ to remove it.

3.

Prepare a container to receive the coolant mixture, then open drain valve @ on the underside of the radiator and drain plug @ on the oil cooler to drain the coolant.

4.

After draining the coolant, close drain valve @ and drain plug 0, then supply city water to the radiator.

5.

If the radiator becomes full of water, open drain valve @ and drain plug 0, then start and run the engine idle at a low speed.

While the engine is running idle at a low speed, keep supplying water for 10 minutes.

Adjust the supply rate and draining rate so that the radiator is kept full of water, and take care that the water supply hose will not come off the water filler of the radiator while cleaning the radiator.

6.

After cleaning the radiator, stop the engine and open drain valve @ and drain plug @ to drain the water, then close them.

7.

After draining the water, wash the inside of the radiator with detergent. Follow the washing instructions of the detergent.

8.

After washing the radiator, open drain valve @ and drain plug @to drain the water. Close the valve and plug and supply water up to near the water filler.

9.

If the water is filled up to near the water filter, open drain valve @ and drain plug @ and start and run the engine idle at a low speed until clear water flows up.

I lo

PROCEDURE

\ AM143020

AM143030

Adjust the supply rate and draining rate so that the radiator is kept full of water.

IO. If clean water flows out, stop the engine and close drain valve

@ and drain plug 0.

11. Replace the corrosion

resistor and open levers @ (2 places).

For the replacement procedure of the corrosion resistor, see “24.7.1 REPLACE CORROSION RESISTOR CARTRIDGE�.

12. Supply city water until it spills out of the water filler.

13. Run the engine idle at a low speed for five minutes to bleed air mixed in the cooling water, then run idle it at a high speed for 5 minutes. (Keep the water filler cap removed during this period.)

14. Stop the engine and wait for about 3 minutes. Supply city water up to near the oil filler, then close the cap.

3-21

24. SERVICE

PROCEDURE

24.2.2 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT

Never clean or replace the air cleaner element l

with the engine

When using pressure air to clean the element glasses or goggles to protect the eyes.

wear

safety

CHECKING

Whenever the red piston in dust indicator @ appears, clean the air cleaner element.

CLEANING AND REPLACEMENT OF OUTER CYLINDER ELEMENT 1. Remove bolt @ to remove clamp 0. Remove cover 0, then

remove the wing nut in it, and remove the outer cylinder element.

2.

Clean the inside of the body and cover.

3.

Blow dry compressed air (68.6 MPa (7 kg/cm*) maximum) against the inside of the element along the pleats. Then, blow against outside along the pleats, then against inside again.

1) Remove one seal each time the element is cleaned.

2) Replace the outer cylinder element after cleaning it 6 times

3)

4) 5) 6)

or after one year. When replacing it, replace the inner cylinder element, too.

Even if the outer cylinder element has not been cleaned 6 times yet, if the dust indicator indicates red just after cleaning it, replace both outer and inner cylinder elements.

Check the inner cylinder element clamping nut for looseness, and retighten it if necessary.

If seal washer @ is damaged or the threads of wing nut @ are damaged, replace them.

Remove evacuator valve @) and clean it with compressed air.

Then, install it again.

ADO53020

24. SERVICE PROCEDURE

NOTICE If small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning and drying, replace the element.

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

When cleaning the element, do not hit it or beat it against something.

4.

AD053040

Install the cleaned element, then install cover 0.

REPLACEMENT OF INNER CYLINDER ELEMENT 1.

Remove the cover and outer cylinder element, then remove the inner cylinder element.

2.

Cover the air connector opening (outlet side) with clean cloth or cloth tape.

3.

Clean the inside of the body, them remove the cover fitted in Step 2 above.

4.

Install a new inner cylinder element to the cylinder and tighten the nut.

Do not clean and reuse the inner cylinder element.

5.

Install outer element.

6.

After replacing the element, indicator.

return the red piston of the dust

3-23

24. SERVICE PROCEDURE

24.2.3 CHECK TRACK TENSION The wear of pins and bushings on the undercarriage will vary with the working conditions and soil properties. It is thus necessary to continually inspect the track tension so as to maintain the standard tension.

Carry out the check and adjustment under the same conditions as when operating (on jobsites where the track becomes clogged with mud, measure with the track clogged with mud).

INSPECTION Stop the machine on level ground (stop with the transmission in FORWARD without applying the brake). Then place a straight bar on the track shoes between the carrier roller and the idler as shown in the figure, and measure the clearance between the bar and the grouser at the midpoint. If the clearance is 20 - 30 mm (0.8 - 1.2 in), the tension is standard.

If the track tension is not at the standard value, adjust it in the following manner.

AN143080

ADJUSTMENT WARNING

-a

Grease inside the adjusting mechanism is under high pressure.

Grease coming from lubricator @ under pressure can penetrate the body causing injury or death. For this reason, do not loosen lubricator @ more than one turn. Do not loosen any part other than lubricator 0. Furthermore, do not bring your face in front of the grease fitting.

If the track tension is not relieved by this procedure, please contact your Komatsu distributor.

0

1.

When increasing tension Pump in grease through

the grease fitting 0

N

2-

AM143090

with a grease

pump.

2.

To check that the correct tension has been achieved, move the machine backwards and forwards.

3.

Check the track tension again, and if the tension is not correct, adjust it again.

4.

Continue to pump in grease until S becomes 0 mm. If the tension is still loose, the pin and bushing are excessively worn, so they must be either turned or replaced. Please contact your Komatsu distributor.

‘s’-

3-24

AM143100

24. SERVICE PROCEDURE

l

When loosening tension a WARNING It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor.

1. Loosen lubricator @ gradually to release the grease.

2.

Turn lubricator 0 a maximum

3.

If the grease does not come out smoothly, backwards and forwards a short distance.

4.

Tighten lubricator 0.

5.

To check that the correct tension has been achieved, move the machine backwards and forwards.

6.

Check the track tension again, and if the tension is not correct, adjust it again.

24.2.4

of one turn. move the machine

CHECK ELECTRICAL INTAKE AIR HEATER

Before the cold season (once a year), ask one of our distributors for check of electrical intake air heater. Remove electrical intake air heater @ from the engine intake manifold and check it for wire breakage, dust, etc.

When installing the electrical heater after checking it, replace its gasket with new one.

3-25

24. SERVICE PROCEDURE

24.2.5 ADJUSTMENT

OF STEERING

BRAKE

When the stroke of the steering pedals is too long, the brake lining may be worn. Adjust in this case according to the following procedure.

INSPECTION The standard stroke of each steering pedal is 127 - 191 mm (5.0 - 7.6 in). If the stroke is 192 mm (7.7 in) or longer, adjust it according to the following procedure.

The standard clearance between the lining and drum is 0.3 mm (0.012 in). &

127-191 mm (5. O-7. 6 in) AD,42268

ADJUSTING 1.

Remove

the rear cover, then remove

brake inspection

cover 0.

AN143130

2.

Tighten adjustment nut @ (Tightening torque: 88.3 N-m (9 kgf.m, 19.8 Ibft)) to fit the lining to the drum (Confirm by pressing the pedal).

3.

Return adjustment nut @ about 1 and 5/6 turns, and confirm the standard stroke is obtained.

that

If the brake does not work normally after the above adjustment, please contact your Komatsu distributor.

3-26

24.

24.2.6 ADJUSTMENT

OF CLEARANCE

SERVICE

PROCEDURE

OF IDLER

The idler is moved by external forces, and the guide plate is worn at this time.

If the guide plate is worn, the idler shakes or slants sideways or the tracks come off or are worn unevenly. Accordingly, adjust the clearance of the idler according to the following procedure.

ADJUSTMENT METHOD 1. Run the machine by 1 - 2 m (3.28’ - 6.56’) on a flat place, then measure clearance A between the track frame and guide plate (4 places on both sides, inside and outside).

2.

If clearance A is larger than 4 mm (0.16 in), loosen bolt @ and remove one or more shims to adjust the clearance on each side to 0.5 - 1 mm (0.02 - 0.04 in). The thickness of one shim is 0.6 mm (0.024 in).

Track

24.2.7 ADJUSTMENT

frame

AE,~3,5B

OF WORK EQUIPMENT

The bucket can be stopped automatically at a desired height and angle for each work with the boom kick-out device and bucket positioner.

ADJUSTMENT OF KICK-OUT 1. Raise the bucket to the desired level, then stop the engine and set the bucket control lever to RAISE position, then adjust the kick-out as follows.

2.

Loosen lock nut 0 and tighten bolt @ to stopper @ of the lift cylinder, then tighten lock nut 0.

3.

After adjusting the kick-out, start the engine and operate the bucket control lever and confirm that the lever returns to HOLD position automatically when the bucket rises to the desired level.

r

I

If bolt @ does not touch the stopper 0,

adjust rod 0.

3-27

24. SERVICE PROCEDURE

ADJUSTMENT OF POSITIONER 1. Lower the bucket to the ground digging follows.

angle, then stop the engine

switch

and adjust it to the desired and adjust the positioner as

2.

Remove

cover 0.

3.

Loosen bolt @ and adjust rod @I so that projection will touch roller 0, then tighten bolt 0.

4.

After adjusting the positioner, start the engine and operate the bucket control lever and confirm that the lever returns to HOLD position automatically when the bucket is set to the desired digging angle. After confirmation, install the cover.

@ of rod @

ANI

24.2.8 REPLACEMENT

OF BUCKET TOOTH

A

WARNING

It is dangerous for the work equipment to move by itself while replacing the bucket tooth. Accordingly, set the work equipment down and stop the engine, then apply the safety lock lever.

If the bucket tooth is worn, procedure.

replace

1. Raise the bucket to a proper that it will not lower.

Level the bucket

it according

level and support

Remove bolt @ and nut 0, then remove clean the fitting surface of the bucket.

3.

Install a new tooth to the bucket. torque

it with a block so

bottom.

2.

Tightening

to the following

of mounting

bucket

bolt: 1180 N-m {I20

tooth

@ and

But

kgf.m, 264.6

Ibft} After mounting

3-28

operating bolts.

the

machine

for several

hours,

retighten

the

I

Cl43218

24. SERVICE

24.3

PROCEDURE

CHECK BEFORE STARTING

24.3.1 CHECK AND REFILL COOLANT

A

WARNING

Do not remove cap @while cooling water is hot. Hot water may spout out.

When removing cap (ij, wait until the water temperature goes down and release radiator pressure little by little by loosening caps slowly, then remove the cap.

1.

Open the top cover at the front part of the machine body.

2.

Remove radiator cap @I and confirm that the coolant is filled up to the neck of water filler. Refill new coolant, if necessary.

NOTICE lf more coolant than usual is required, it may be leaking from somewhere. Check for leakage in this case.

AM142210

24.3.2 CHECK FUEL LEVEL

A

WARNING

When adding fuel, never let the fuel overflow. This may cause a fire. If spilling fuel, thoroughly clean up any spillage.

1.

Check the fuel level using fuel gauge 0.

2.

After completing work, fill the fuel tank through oil filler port 0.

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

3.

After adding fuel, tighten the cap securely.

Fuel capacity: 400 e (104 US gal, 88 UK gal)

NOTlCE A clogged cap breather hole @ may stop the fuel flow to the engine. Check it from time to time and clean.

AD054210

3-29

24.3.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the upper cover at the front of the machine.

2.

Remove dipstick @ and wipe the oil off with a cloth.

3.

4.

Insert dipstick @fully in the oil filler pipe, then take it out again.

The oil level should be between the H and L marks on dipstick 0.

If the oil level is below the L mark, take out the dispstick and add engine oil through oil filler 0.

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

5.

If the oil is above the H mark, drain the excess engine oil from drain plug, and check the oil level again.

6.

If the oil level is correct, tighten the oil filler cap securely, insert oil level gauge @ fully into the dipstick guide, then close the upper cover.

REMARK l When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking. l If the machine is at an angle, make it horizontal before checking. l When adding oil, remove the oil level gauge from the gauge guide so that the air in the crank case will be released.

3-30

I

1

/I

’

AD352340

24. SERVICE PROCEDURE

24.3.4 CHECK OIL LEVEL IN TRANSMISSION CASE (INCLUDING TORQUE CONVERTER CASE), ADD OIL 1.

Open the cover, cloth.

2.

insert dipstick @fully

3.

The oil level should

remove

dipstick

0,

and wipe the oil off with a

in the oil filler pipe, then take it out again. be between

the H and L marks on dipstick

0.

If the oil level is below the L mark, add engine oil through

oil filler

0.

AND 4.

5.

For details of the oil to use, see “20. USE OF FUEL, COOLANT LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

If the oil is above the H mark, drain the excess engine drain plug 8, and check the oil level again.

If the oil level is correct, close the cover.

tighten

the oil filler

oil from

cap securely

AD052340

and

REMARK When stopping the engine, check the oil level. l When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking.

If the machine is at an angle, make it horizontal before checking.

l

3-31

24.

SERVICE

PROCEDURE

24.3.5 CHECK OIL LEVEL IN STEERING ADD OIL

CLUTCH CASE,

When working on a slope of 25” or steeper, add engine oil up to the H mark.

1. Remove dipstick 0,

and wipe the oil off with a cloth.

2.

insert dipstick @fully

in the oil filler pipe, then take it out again.

3.

The oil level should be between the H and L marks on dipstick 0.

If the oil level is below the L mark, and engine oil through oil filler 0.

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

4.

If the oil level is above the H mark, drai the excess engine oil from drain plug 8, and check the oil level again.

5.

If the oil level is correct, tighten the oil filler cap securely.

REMARK When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking.

If the machine is at an angle, make it horizontal before checking.

3-32

24. SERVICE PROCEDURE

24.3.6 CHECK DUST INDICATOR 1. Check that the red piston has not appeared

in the transparent

portion of dust indicator 0.

2.

3.

If the red piston has appeared, clean or replace the element immediately.

For details of the method of cleaning the element, see “24.2 WHEN REQUIRED”.

0 II

\\

AM142270

After checking, cleaning, and replacing, press the knob of dust indicator @ to return the red piston to its original position.

ADO52091

24.3.7 CHECK STEERING

PEDAL TRAVEL

1.

Depress the brake pedal all the way until it stops.

2.

The distance of travel at the center of the pedal (position in the diagram on the right) should be 127 - 191 mm (5.0 - 7.6 in).

3.

When this value exceeds 192 mm (7.7 in), or the brake fails to work, please contact your Komatsu distributor for adjustment.

L’!kc 127-191 mm (5. O-7. 6 in) AD,4226B

3-33

24. SERVICE PROCEDURE

24.3.8 CHECK THAT LAMPS LIGHT UP

1. Insert the key into starting switch @ and turn the key to the ON

position.

HEA,T

OFF

AE214499

2.

Confirm that OFF position: Position 1: Position 2:

the lamps light up by operating lamp switch 0.

Lamps are turned off.

Headlight and instrument lights are turned on.

Headlight, instrument light, and rearworking lamps are turned on.

If any of the lamps does not light up, ask our distributor inspect the machine.

2 1

OFF

to AD14203B

24.3.9 CHECK HORN SOUND

1.

Insert the key into starting switch Q) and turn the key to the ON position.

2.

Push the horn switch @ and check that the horn sounds.

AH142040

3-34

24.

24.3.10

1.

CHECK BACKUP ALARM

SOUND

(OPTION)

SERVICE

PROCEDURE

\QL2

Insert the key into starting switch @ and turn the key to the ON position.

AE21449B

2.

Set gear shift lever @ to the rear position.

The buzzer must sound immediately. It keeps sounding until the gear shift lever is set to “NEUTRAL” or “FORWARD” position.

N

Rl

I 24.3.11

-

AD205110

CHECK SEAT BELT FOR WEAR OR DAMAGE (OPTION)

Check the belt and mounting damaged, replace the seat belt.

clamps, and if they are worn or

3-35

24. SERVICE PROCEDURE

24.4

EVERY 50 HOURS

SERVICE

24.4.1 SUPPLY OF GREASE 1.

Lower the bucket to the ground engine.

2.

Supply grease to the grease fittings indicated by the arrows with a grease pump.

1.

horizontally,

then stop the

Bucket pin (4 places)

-AN143220

2.

Dump cylinder shaft (4 places)

230

3.

3.

Lift arm support shaft (2 places)

4.

Lift cylinder shaft (4 places)

After supplying grease.

3-36

new grease, wipe off the used and projected

24. SERVICE PROCEDURE

24.4.2 DRAIN WATER AND SEDIMENT

FROM FUEL TANK

1

1

1. Drain water and sediment from the fuel tank before starting the

machine.

2.

Prepare a container to receive water and sediment.

3.

Open valve @) on the underside of the tank to drain the sediment and water together with fuel. Take care not get soaked with fuel at this time.

4.

When only clear fuel flows out, close drain valve 0.

3-37

24. SERVICE PROCEDURE

24.5

EVERY 250 HOURS

Maintenance the same time.

SERVICE

for every 50 hours service should be carried out at

24.5.1 SUPPLY GREASE 1.

When supplying grease to the tilt lever pin, lower the bucket to the ground horizontally, then stop the engine.

2.

When supplying grease to the equalizer bar, raise the lift arm and apply the lift arm stay, then stop the engine.

3.

Supply grease to the grease fittings indicated by the arrows with a grease pump.

4.

1.

Tilt lever pin (4 places)

2.

Equalizer bar shaft (I place)

After supplying grease.

3-38

new grease, wipe off the used and projected

24.5.2 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL -------A

WARNING v

The oil temperature is high just after the engine is stopped. Wait until the oil temperature lowers before starting the following work.

1. Remove both plugs 0.

If the oil is filled up to near the bottom of each plug hole, the oil is sufficient.

2.

AN143290

If the oil level is low, add engine oil through oil filler (E).

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

24.5.3 CHECK AND SUPPLY OF HYDRAULIC I

TANK OIL

A WARNING When removing the oil filler cap, release internal pressure little by little by loosening it slowly, then remove it, otherwise the oil may spout out.

If oil is supplied more than the H mark, stop the engine and wait until the hydraulic oil is cooled, then discharge excessive oil through the drain plug.

NOTlCE Do not refill oil more than the H mark. If it is over-supplied, hydraulic circuit may be damaged or it may spurt out.

the

1.

Lower the bucket to the ground horizontally, then stop the engine and wait for about five minutes. The oil level should be between the top and bottom of the red circle in sight gauge 0.

2.

If the oil level is below the bottom of the red circle, add engine oil through oil filler 0.

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

3-39

24.5.4 REPLACE OIL IN ENGINE OIL FILTER CARTRIDGE

part is still hot. Wait

0

0 0

OIL PAN AND ENGINE

the engine, until the oil is cooled.

26 !Z (6.7 US gal, minimum Replacement oil: 26 e (6.7 US gal, 5.7 UK gal) Prepare socket wrench and filter wrench.

Container

to receive

used oil:

since each

5.7

UK gal)

1.

Remove the undercover of the machine body and place a container to receive used oil just under the drain plug.

2.

Remove drain plug @ slowly, taking care not to get soaked with oil, and loosen valve @ to drain oil.

3.

Check the drained oil. If it contains matter, please contact your Komatsu

4.

Install drain

5.

Turn filter cartridge @to the left with the filter wrench to remove it. If the engine has been operated, wait about 10 minutes, since much oil flows out.

metal chips distributor.

and foreign

plug 8.

6.

Clean the filter stand and fill the new cartridge with engine oil.

Apply engine oil (or grease) to the packing of the new filter cartridge and install it.

7.

After the packing surface touches cartridge further by 3/4 - 1 turn.

8.

After replacing the filter cartridge, supply engine oil through oil filler @ up to between H and L marks of the oil level gauge.

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

When supplying oil, take care not to splash it over the alternator.

9.

Run the engine idle at a low speed for a while, then stop it.

Referring to “24.3 CHECK BEFORE STARTING”, confirm that the oil level is between the H and L marks of the oil level gauge.

the

filter

stand,

turn

\

the

Even if the machine has not been operated for 500 hours, the oil and filter cartridge must be replaced when the machine has been operated for 6 months.

In the same way, even if the machine has not been operated for 6 months, the oil and filter cartridge must be replaced when the machine has been operated for 500 hours.

3-40

\

AM143350

24. SERVICE PROCEDURE

24.5.5 REPLACE TRANSMISSION FILTER ELEMENT

AND STEERING

OIL

1.

Raise the lift arm and apply the lift arm stay, then stop the engine.

2.

Set the safety lever of the bucket control lever to LOCK position.

3.

Remove bolts @) of the filter case in the left-hand side frame, then remove covers 0.

L

4.

Take out filter elements @ and clean the inside of the case and the parts taken out. Install a new filter element and fill it with oil, then install covers 0.

5.

Start the engine and loosen air bleed plug @to let oil flow until bubbles do not come out any more, then tighten the plug 0.

6.

Start the engine and set the safety lever of the bucket control lever to the FREE position, then raise the lift arm a little.

Remove the lift arm stay and lower the bucket to the ground horizontally.

iL\\m\\

\\

\ \\\

-AM143360

3-41

24. SERVICE

PROCEDURE

24.5.6 CLEAN STRAINER 1.

AT BOlTOM

OF FUEL TANK

Close valve @ on underside of the fuel tank and remove cap 0, then clean strainer and strainer case.

REMARK Since the strainer is fixed to cap @ by brazing, take out them together.

24.5.7 CHECK BAlTERY

FLUID LEVEL

Check the battery fluid level before operating the machine.

WARNING l

Since the battery produces combustible

gas, do not bring fire

l

Battery fluid is dangerous!. Take special care that it does not get in the eyes or on the skin. If it does, wash it away with much water, and immediately call doctor.

1.

Open the cover on the left side of the operator’s seat.

2.

Remove cap @ and check the fluid level. If the fluid level is lower than the UPPER LEVEL line, add distilled water. Do not add distilled water more than the UPPER LEVEL. If so much is added, leakage or fire may occur. If the battery fluid has spilt, add dilute sulfuric acid.

3.

Clean the vent of each battery cap, then tighten it securely. Keep the battery top clean and wipe it with wet cloth.

REMARK In the cold season, add distilled water before starting the work on the next day, to prevent it from freezing.

3-42

24. SERVICE PROCEDURE

24.5.8 CHECK AND ADJUST

FAN BELT TENSION

CHECK Push the intermediate point between the alternator and fan pulley with the thumb (About 58.8 N (6 kgf, 13.2 Ibft)). It should be deflected by 13 mm (0.52 in).

ApDrox

13mm (0.52in) _c

/

Fan PUI IY

Alternator PUIIY

Crankshaft

?I

PUIIY

AD143428

ADJUSTMENT 1. Insert a claw bar between alternator @ and cylinder block, and fix it to alternator 0. When fixing the claw bar, insert a wood liner between it and alternator @ so that the latter will not be damaged.

2.

Loosen bolt and nut 0 and 0.

3.

Move alternator @ with the claw bar so that the belt will be deflected about 13 mm (0.52 in) (About 58.8 N (6 kgf, 13.2 Ibft)).

4.

Tighten bolt and nut 0 and @ to secure alternator 0.

5.

Check each pulley for damage and V-grooves and V-belt for wear. Particularly, check to see if the V-belt touches the bottom of any V-groove.

6.

If the belt is lengthened eliminate the adjustment it has any cut or crack, replace it.

7.

If the belt is replaced, adjust its tension again after one-hour operation.

allowance or

3-43

24. SERVICE PROCEDURE

24.5.9 CHECK AND RETIGHTEN

TRACK SHOE BOLTS

If the machine is operated with track shoe bolts @ loosened, the latter will be broken. Accordingly, if any track shoe bolt is loosened, retighten it to 785 + 78.5 N-m (80 + 8 kgf.m).

Tightening Tighten

3-44

order the track shoe bolts in the order shown

at right.

24. SERVICE PROCEDURE

24.6

EVERY 500 HOURS

SERVICE

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

be

24.6.1 REPLACE FUEL FILTER CARTRIDGE a l

l

WARNING

Do not replace the filter just after stopping the engine, since each part is still hot. ‘Wait until each part is cooled.

Do not bring fire near the machine.

Prepare the filter wrench and a oil receiving container

1. Raise the lift arm and apply the lift arm stay, then stop the

engine.

2.

Set the safety lever of the bucket control lever to LOCK position.

3.

Close fuel feed valve @ on under side of the fuel tank.

4.

Place a container cartridge.

5.

Turn filter cartridge @ counterclockwise remove it.

6.

Clean the filter stand and fill the new cartridge with fuel. Apply engine oil to the packing of the new filter cartridge and install it to the filter stand.

7.

After the packing surface touches the sealing surface of the filter stand, turn the cartridge further by 2/3 turns.

to receive

used fuel just under the filter

with the filter wrench to

If the filter cartridge is tightened too strongly, the packing will be damaged and fuel will leak. If it is too loose, however, fuel will leak through the gap of the packing. Accordingly, be sure to observe the tightening angle.

8.

After replacing filter cartridge 0,

loosen air bleed plug 0.

3-45

24. SERVICE PROCEDURE

9.

Loosen the knob of feed pump @ and move it up and down to let fuel flows out through air bleed plug @ until bubbles do not come out any more.

10. Tighten air bleed plug @ and push in and tighten the knob of the feed pump @.

11. Wipe off all spilt fuel with a cloth.

12. After replacing the filter cartridge, start the engine and check the filter seal for fuel leakage. If any fuel leaks, check and adjust the tightening condition of the filter cartridge. If fuel still leaks, remove the filter cartridge by performing the procedures 4 and 5, and check the packing for damage and foreign matters. If the packing is damaged or any foreign matter is caught in it, replace the cartridge and repeat procedures 6 through 10.

13. Set the safety lever of the bucket control lever to the FREE position, then raise the lift arm a little.

Remove the lift arm stay and lower the bucket to the ground horizontally.

3-46

24. SERVICE PROCEDURE

24.6.2 CLEAN BREATHER 1.

Remove the breather and wash it in clean light oil.

Steering clutch case breather (I place)

2.

Transmission case breather (I place) Since the breather is a part of the oil filler cap, wash them together.

3.

Final drive case breather (2 places)

24.6.3 CLEAN AND CHECK RADIATOR

FINS

&h WARNING Compressed air, steam and water can cause injury. Be sure to put on protective goggles, mask, safety shoes, etc.

1. Remove the bolts, then open the radiator grill.

2.

Blow off sticking mud, dust, leaves, etc. from the radiator fins.

Steam or water may be used instead of compressed air.

3.

Check the rubber hoses for cracking and brittleness, and replace them if necessary. Check the hose clamps for looseness.

3-47

24.7

EVERY 1000 HOURS SERVICE

Maintenance for every 50,250 out at the same time.

and 500 hours should be carried

24.7.1 REPLACE CORROSION

RESISTOR CARTRIDGE

a

WARNING

If you replace the corrosion resistor cartridge just after stopping the engine, since the cooling water is hot. Wait until the engine is cooled.

1.

Close levers @ (2 places) above the corrosion resistor.

2.

Turn filter cartridge @to the left with the filter wrench to remove it.

3.

Clean the filter stand and apply engine oil to the sealing surface of the filter stand, then install a new filter cartridge.

4.

After the gasket touches the sealing surface of the filter stand, turn the cartridge about 2/3 turns further.

5.

Open levers @ (2 places).

24.7.2 SUPPLY GREASE 1.

When supplying grease to the universal joint, raise the lift arm and apply the lift arm stay, then stop the engine.

2.

Supply grease to the grease fittings indicated by the arrows with a grease pump.

1.

Diagonal brace (2 places)

2.

Universal joint (2 places)

3-48

\

A

n

24. SERVICE PROCEDURE

25.7.3 REPLACE OIL IN TRANSMISSION CASE (INCLUDING TORQUE CONVERTER CASE) AND CLEAN STRAINER

still hot. Wait until the oil is cooled.

0

0 0

Container to receive used oil:

47 e (12.2 US gal, 10.3 UK gal) minimum Replacement oil: 47 !Z (12.2 US gal, 10.3 UK gal) minimum Prepare socket wrenches.

1.

Remove undercover @ of the machine body and place a container to receive used oil just under the drain plugs @ and 0.

2.

Remove drain plugs @ and @ slowly, taking care not to get soaked with oil, to drain the oil. After draining the oil, tighten the plugs.

3.

Remove bolts @ to remove the strainer of the torque converter case together with cover 0.

4.

Remove pipe @ and bolts 8, then remove the strainer of the transmission case together with cover 0.

5.

If the strainer is broken, replace it with new one.

6.

Remove dust from the strainer and wash in light oil. Wash the inside of the case and plug, etc.

AN143550

3-49

24. SERVICE

7.

AND

8.

3-50

PROCEDURE

After installing the strainer, up to the specified level.

supply engine

oil through

oil filler @

For details of the oil to use, see “20. USE OF FUEL, COOLANT LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

After supplying the oil, confirm CHECK BEFORE STARTING”.

its level

according

to

“24.3

24. SERVICE PROCEDURE

24.7.4 REPLACE OIL IN STEERING CLEAN STRAINER

CLUTCH CASE AND

Do not replace the oil still hot. Wait until the oil is cooled.

0

0 0

Container to receive used oil: 73 a (18.9 US gal, 16.0 UK gal) minimum Replacement oil: 73 e (18.9 US gal, 16.0 UK gal) Prepare socket wrenches.

1.

Raise the lift arm and apply the lift arm stay, then stop the engine.

2.

Set the safety lever of the bucket control lever to LOCK position.

3.

Place a container to receive used oil just under drain plug @ on the underside of the machine body.

4.

Remove drain plug @ slowly, taking care not to get soaked with oil, to drain the oil. After draining the oil, tighten plug @.

5.

Remove cover @ from the left side of the side frame.

6.

Remove bolts @to remove cover 0, then take out spring @ and strainer 0.

7.

If the strainer is broken, replace it with a new one.

8.

Remove dust from the strainer and wash in light oil. Wash the inside of the case, spring, and cover, too.

9.

After installing the strainer, supply engine oil through oil filler @ up to the specified level.

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

10. After

supplying the oil, confirm CHECK BEFORE STARTING”.

its level according

to “24.3

11. Set the safety lever of the bucket control lever to FREE position,

then raise the lift arm a little.

Remove the lift arm stay and lower the bucket to the ground horizontally.

3-51

24. SERVICE

PROCEDURE

24.7.5 REPLACE OIL IN FINAL DRIVE CASE a

WARNING

Do not replace the oil just after stopping the engine, since it is still hot. Wait until the oil is cooled.

0

Container to receive used oil: 23 e (5.9 US gal, 5.0 UK gal) minimum Replacement oil: 23 e (5.9 US gal, 5.0 UK gal) Prepare socket wrenches.

1.

Place a container to receive used oil just under drain plug 8.

2.

Remove drain plug @ to drain the oil. After draining the oil, tighten plug 8.

3.

Supply engine oil through oil filler @ up to the specified level.

0

0

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

4.

After supplying the oil, confirm EVERY 250 HOURS SERVICE”.

3-52

its level according

to “24.5

1

24. SERVICE PROCEDURE

24.7.6 REPLACE OIL IN HYDRAULIC TANK AND HYDRAULIC OIL FILTER ELEMENT

Do not replace the oil just after stopping the engine, since it is Loosen the oil filler cap slowly to release the internal pressure,

0

0 0

1.

Container to receive used oil: 63 .f (16.4 US gal, 13.9 UK gal) minimum Replacement oil: 63 e (16.4 US gal, 13.9 UK gal) Prepare socket wrenches and box wrenches.

Lower the bucket to the ground horizontally, and stop the engine. Move the bucket control lever forward and backward (to the right and left), then loosen the cap of oil filler @ to release the internal pressure, then remove it.

2.

Place a container under drain plug 0 to receive oil.

3.

Remove drain plug @to drain oil. After draining oil, tighten plug

r

0.

When removing drain plug 0, take care not to get soaked with oil.

L

4.

Loosen air breather bolt @ of the hydraulic oil filter, then loosen drain plug 0.

5.

Remove bolt @ to remove cover 0, then remove filter element 0.

6.

Wash the removed parts in clean light oil. Wash the inside of the filter case, too.

7.

Install a new filter element and tighten drain plug 0.

8.

Supply engine oil through oil filler 0

9.

After supplying the oil, confirm EVERY 250 HOURS SERVICE�.

up to the specified level.

its level according

to “24.5

10. After supplying the oil, loosen air bleeder bolt @ and start the engine. Let the oil flows out until bubbles do not come out any more, then tighten air bleeder bolt 0.

11. Wipe off all spilt oil with cloth.

3-53

24. SERVICE PROCEDURE

24.7.7 CHECK OIL FOR UNDERCARRIAGE Check the oil for the track rollers, carrier rollers, and idler for consumption according to the following procedure.

1.

Park the machine on fiat place.

2.

Loosen the seal bolt slowly. If any oil oozes through the threads, the oil is not consumed yet. Tighten the bolt immediately in this case.

3.

If oil does not flow out when the seal bolt is removed, oil is not sufficient. Ask your Komatsu distributor for repairs in this case.

24.7.8 CHECK CLAMPING

PARTS OF TURBOCHARGER

Ask your Komatsu distributor for check of clamping parts of the turbocharger.

24.7.9 CHECK TURBOCHARGER

ROTOR FOR PLAY

Ask your Komatsu distributor for check of the turbocharger for play.

3-54

rotor

AN143710

24. SERVICE PROCEDURE

24.8

EVERY 2000 HOURS

SERVICE

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

24.8.1 SUPPLY GREASE 1. Lower the bucket to the ground

horizontally,

and stop the

engine.

2.

Supply grease to the grease fittings indicated by the arrows with a grease pump.

I.

Steering pedal shaft (IO places)

AN143720

2.

Gear shift lever shaft (3 places)

AN143730

3-55

24. SERVICE PROCEDURE

3.

Fuel control lever shaft (2 places)

4.

Decelerator pedal shaft (3 places)

AN143750

5.

Bucket control lever shaft (3 places)

AN143760

3-56

24. SERVICE PROCEDURE

24.82

CLEAN ENGINE BREATHER ELEMENT

1.

Remove breather 0.

2.

Wash the breather unit in light oil, then dry it by blowing compressed air against it.

3.

Check the inside of the breather hose or pipe for sludge. If any sludge is sticking, replace the hose or pipe.

4.

Replace the O-ring of the breather and apply engine oil to it, then fit it.

24.8.3 CHECK ALTERNATOR

AND STARTING

MOTOR

Since the brushes of the alternator and starting motor may be worn and grease in their bearings may have been used up, ask your Komatsu distributor for check and repair.

If the engine is started frequently, have them checked every 1000 hours.

24.8.4 CHECK AND ADJUST

ENGINE VALVE CLEARANCE

Since special tools are required for check and adjustment of the engine valve clearance, ask your Komatsu distributor.

25.8.5 CLEAN AND CHECK TURBOCHARGER Ask your Komatsu distributor to wash and check the turbocharger.

25.8.6 CHECK VIBRATION

DAMPER

Check the outside of rubber 0 for cracks. If any crack is found, ask your Komatsu distributor for replacement of the vibration damper.

3-57

24. SERVICE PROCEDURE

24.9

EVERY 4000 HOURS SERVICE

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

and 2000 hours service

24.9.1 CHECK WATER PUMP Check the water pump pulley for play. Check water leakage from the pump and clogging drain hole. If any defect is found, ask your Komatsu distributor for overhaul or replacement of the water pump.

3-58

SPECIFICATIONS

4-l

25. SPECIFICATIONS

D75S-5 WEIGHT l

Operating weight (Excluding operator)

21130 (46592 lb)

(kg)

PERFORMANCE l

Bucket capacity

(m3)

1

2.2

l

Maximum

(kg)

1

4,400 (9702 lb)

l

Travel speed

I

0 - 3.3

load capacity

l

Maximum

l

Ground pressure

Forward

1st gear

Forward

2nd gear

(km/h)

1

0 - 5.8

Forward

3rd gear

(km/h)

1

0 - 9.6

Reverse

1st gear

(km/h)

1

0 - 4.3

Reverse

2nd gear

(km/h)

1

0 - 7.5

Reverse

3rd gear

(km/h)

1

0 - 12.1

(N IkgfI)

1

250360 (25530)

traction force

82.37 (0.84)

ENGINE Komatsu S6D125E-2 diesel engine

l

Model

l

Rated output

151.51 kW 1206 PSI/2000 rpm

l

Maximum

922 N.m I94 kgf.m1/1500 rpm

torque

24 V

0 Starting motor l

Alternator

l

Battery

4-2

24 V 12 V

7.5 kW 35 A

170 Ah x 2 pieces

D75S-5

,’

/’

/”

---_-

AD21 5288

4-3

25. SPECIFICATIONS

D75-5

(with cab (option))

(,9

,o I)

OOZE

II-’ (,L

‘L) E6 1

I

(,E ,EI) 9SOP (,Z

’ (,Z ‘4 I) 08c

,81)9P95

AD21 5278

4-4

OPTIONS, ATTACHMENTS

5-1

26. INSTALLATION OF FIRE EXTINGUISHER

A fire extinguisher

can be installed to the oosition shown below.

AD215130

l

5-2

For the parts necessary for installation

of a fire extinguisher,

ask your Komatsu distributor.

27. HANDLING WITH CABIN INSTALLED

27.1

HOW TO READ LAMPS

AND USE SWITCHES

AM143790

Ktwn wlrtn avwibn Used to operate the rear windshield wiper.

ON Position: The windshield wiper starts.

Turning to right: The window washer switch is turned on to spout washing fluid.

1.

AD14380B

2.

FRONT WIPER SWITCH Used to operate the front windshield wiper.

ON Position: The windshield wiper starts.

Turning to right: The window washer switch is turned on to spout washing fluid.

hD14380B

3.

FRONT WORKING LAMP SWITCH Used to turn on and off the working cabin.

ON position: The lamp is turned on.

lamp at the front of the

I

AD143828

5-3

27. HANDLING WITH CABIN INSTALLED

REAR WORKING LAMP SWITCH Used to turn on and off the working lamp at the rear of the cabin.

ON position: The lamp is turned on.

4.

ON OFF

AD143828

5.

PILOT LAMP OF FRONT WORKING LAMP Lights up when the front working lamp is turned on.

AM143840

6.

PILOT LAMP OF REAR WORKING LAMP Lights up when the rear working lamp is turned on.

An143840

7.

ROOM LAMP SWITCH Used to turn on and off the room lamp ON position: The lamp is turned on.

ON OFF

8.

CIGARETTE LIGHTER Used to light cigarettes.

If this lighter is pushed in, it returns in several seconds. Pull it out to light a cigarette.

0 9 AM143870

5-4

27. HANDLING WITH CABIN INSTALLED

27.2

FUSE BOX

NOTICE Before replacing a fuse, be sure to turn off the starting switch.

The fuses protect the electrical equipment and wiring from burning out.

If the fuse becomes corroded or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.

Replace a fuse with another of the same capacity.

Remove bolt 0, and remove cover 0.

L

I3

An143880

Fuse capacity and circuit Iname No.

Terminal symbol L

0 0

1 Fuse

20A

H

IOA

F

10A

0

Circuit name

capacity

3emarks El

Front windshield wiper Rear windshield wiper

I

Front working lamp Pilot lamp of front working lamp Rear working lamp Pilot lamp of rear working lamp Room lamp

Cigarette

0

AM143890

lighter

5-5

27. HANDLING WITH CABIN INSTALLED

27.3

I

DOOR LOCK

Used to lock the door open.

1.

Push lever @ above catcher 0 of the upper door, and the catcher is released and the upper and lower parts of the door can be separated.

2.

If the upper door is pressed against catcher 0,

3.

If lever @I under the catcher is pressed, the catcher is released and the door can be opened.

it is fixed.

When fixing the door, fix it to the catcher securely.

27.4

WHEN REQUIRED

Check the fluid level in washer fluid tank 0. If it is not sufficient, add window washing fluid for automobiles.

NOTICE When adding the washing enter the eyes.

5-6

fluid, take care that dust will not

27. HANDLING WITH CABIN INSTALLED

27.5

PRECAUTIONS FOR WORK

27.5.1 INHIBITION OF KEEPING DOOR OPEN DURING OPERATION (MACHINE WITH CAB) When driving and operating the machine, keep the doors closed.

If the doors are not closed, they may be broken by strong vibration and obstacles.

27.5.2 INHIBITION OF MODIFICATION OF CAB GLASSES TO WORSEN VISIBILITY (MACHINE WITH CAB) o Installation of anything which can worsen the visibility to the cab glasses is inhibited

by the law.

o

Do not anything which can worsen the visibility to the glasses.

o

Keep the glasses clean and always work safely.

27.5.3 PRECAUTIONS PILLARS

ON BLIND SPOTS BEHIND CAB

Some blind spots are made by the cab pillars cles or workers around the machine.

5-7

28. OPERATION OF AIRCONDITIONER

28.1 NAME

OF EACH PART OF CONTROL

PANEL ZONTROL PANEL

1.

AIR OUTLET CHANGEOVER Knob position FACE Intermediate position between FACE and FOOT FOOT DEF

KNOB

Air outlet

I

Overhead

Uses outlet

Cooling,

Foot area outlet Defroster outlet

ventilation

cooling (Air flow rate frin eacg iytket cab be adjusted for each knob position

Foot area outlet Overhead outlet Defroster outlet

Heating,

Heating, drying/heating i

2.

FRESH/RECIRC CHANGEOVER KNOB Used to change the air intake openings for cooling and heating.

0

Recirc air .... .... ....... Air in the cab is taken in (Usually used for cooling).

Recirc + Fresh ...... Fresh air is taken in, as well as air in the cab (Usually used for heating, ventilation and pressurizing).

0

3.

HEATER TEMPERATURE CHANGEOVER KNOB Used to control the temperature in the heating mode.

0

As the knob is moved toward “HIGH HEAT”, the air temperature at the air outlet is heightened.

If the knob is set to “OFF” position, the water valve is closed and the heating function is turned off.

0

COOLER TEMPERATURE CHANGEOVER KNOB Used to control the temperature in the cooling mode. Used as the cooler switch, too.

4.

0

0

As the knob is moved toward “HIGH COOL”, the air temperature at the air outlet is lowered.

If the knob is set to “OFF” position, the cooler switch is turned off and the heating function is turned off.

BLOWER SWITCH Used to adjust the air flow rate in the cooling and heating modes, and used as the main switch.

5.

l

l

5-8

The air flow rate can be set to three levels of “LOW”, “MED” and “HIGH”.

If this switch is turned “OFF”, the power is turned off and the airconditioning function is turned off.

UR

OUTLET

28. OPERATION OF AIRCONDITIONER

28.2 OPERATION METHOD COOLING MODE If the control knobs are set as shown in the figure, comfortable cool air blows from the overhead air outlet. l l

Set knobs @ - @ as shown in the figure.

Set knobs @ and @ as shown below, according to your preference. @ Cooling temperature

o Blower switch

~

VENTILATION COOLING MODE If the air in the cab becomes dirty, set the control knobs as follows to ventilate and cool the cab. l l

l

Set knobs @) - @ as shown in the figure.

Set knobs @ and @ as shown below, according to your preference, similarly to the ordinary cooling mode.

If the ventilation cooling is continued for a long time, the cooling effect may become insufficient. After ventilation is finished, return Fresh/Recirc changeover knob @ to the “Fresh position

5-9

28. OPERATION OF AIRCONDITIONER

HEATING MODE If the control knobs of the control panel and that at the right of the ceiling of the cab are set as shown below, hot air blows from the foot area air outlet and defroster outlet. l l

Set knobs 0, @ and @ as shown in the figure.

Set knobs @I and @ as shown below, according ence.

@ ~~~~r~, tintrrat”re

to your prefer-

@ Blower

switch

Quick heating

HIGH HEAT

HIGH

Ordinary

MED HEAT

MED - LOW

LOW HEAT

LOW

heating

Low heating

RECIRCULATION

HEATING MODE

If the outside air is dirty with dust, smells bad, etc., set the control knobs as shown in the figure to recirculate the air. l l

l

Set knobs CTJ,@ and @ as shown in the figure.

Set knobs @ and @ as shown below, according ence, similarly to the ordinary heating mode.

If the recirculation heating is continued for a long time, the air in the cab becomes dirty. Accordingly, return Fresh/Recirc changeover operation

5-10

to your prefer-

knob @ to the “Fresh in the normal

environment.

+ Recir position

(&I”

for

28. OPERATION OF AIRCONDITIONER

DRYING HEATING MODE If the control knobs of the control panel are set as shown in the figure,

hot dry air blows from the foot area air outlet and defroster

outlet. l l

Set knobs 0, @ and @ as shown in the figure.

Set knobs @ and @ as shown below, according to your preference. @ Heater temperature control knob

@ Blower switch

Drying heating in winter

HIGH HEAT

HIGH

Drying heating in spring and autumn

MED HEAT

MED - LOW

l

If this mode is used when the air in the cab in spring, autumn or on a rainy day, the cab is heated comfortably without fogging the window glasses.

l

If the outside temperature is 2 - 6.5% or below, the compressor is automatically turned off and drying heating mode cannot be used.

VENTILATION MODE If the control knobs are set as shown in the figure, fresh air flow out of the overhead outlet to ventilate the cab. l

Set knobs @ - @ as shown in the figure.

l

Set blower switch @to “LOW”, “MED” or “HIGH” according to your preference.

5-11

28. OPERATION OF AIRCONDITIONER

WHEN AIRCONDITIONER IS NOT USED While the airconditioner is not used, set the control knobs as shown in the figure.

d

I

28.3

PRECAUTIONS FOR USE OF AIRCONDITIONER

After parking the machine in a place where it receives the direct sunlight If the machine is parked in a place where it receives direct sunlight for a long hours, the temperature in the cab become very high. In this case, open the windows fully to let the hot air out, then operate the airconditioner.

After the cab is cooled, close the windows and set the temperature to a desired level. l

When eyes feel drying If you smoke in an cooled cab, your eyes may feel dry. In this case, open the windows to let the smoke out. l

0

Proper cooling operation The airconditioner makes a comfortable air by lowering temperature and humidity. It is good for health to set the temperature to the degree you feel a little cool when you rides in the machine (when temperature difference between the outside and inside is 5 6°C). If the cab is too cool, your health may be affected. Take care in adjusting the temperature.

When the window glasses become foggy The glasses become foggy easily and the visibility is lowered on a rainy day. In this case, operate the cooler, and the glasses are cleared up. l

5-12

d

b

AD215266

28. OPERATION

OF AIRCONDITIONER

28.4 INSPECTION AND MAINTENANCE CHECK OF COMPRESSOR BELT TENSION If the belt is loosened, it slips and the cooling effect is lowered.

Check the belt tension occasionally by pressing its center between the drive pulley and compressor pulley, and adjust the tension so that the belt will be deflected by about IO mm (0.4 in) when it is pressed with the force of about 58.8 N 16 kgf, 13.2 Ibft}.

If the belt is new, it is lengthened remarkably. Accordingly, be sure to adjust its tension in two - three days.

CHECK OF QUANTITY

Approx

1Omm (0. 4in)

AEl62378

OF REFRIGERANT

refrigerant gets in the eyes or on the hands, you may be blinded or receive frostbite, Never loosen the refrigerant parts!

If the refrigerant is insufficient, the cooling effect is lowered.

While the engine and the airconditioner are running at the full speed, check the flowing condition of the refrigerant in the sight glass (inspection window) of the receiver.

l l

l

No bubbles are contained in the flow ...... ............. ........... Proper Some bubbles are contained (and pass continuously) in the flow .... ...... ............. ... Insufficient Colorless and transparent .......... ............ ...... ...... ... No refrigerant

b

REMARK If bubbles are seen, the refrigerant is insufficient. In this case, have a distributor add the refrigerant. If the airconditioner is operated with insufficient refrigerant, the compressor may be broken. If leakage of refrigerant is left, the inside of the airconditioner will be rusted.

CHECK OUT OF SEASONS Operate the airconditioner even out of the season for 3 - 5 minutes once in a month to keep the compressor parts lubricated.

5-13

28. OPERATION OF AlRCONDlTlONER

INSPECTION

AND MAINTENANCE

Inspection and maintenance item

LIST OF AIRCONDITIONER

Contents of inspection and maintenance

Maintenance

period

Refrigerant

Charged quantity

In spring and autumn (Twice a vear)

Condenser

Clogging of fins

WHEN REQUIRED 4000 HOURS SERVICE

Comoressor -----r----

Ooeratina condition

V-belt

Damage and tension

250 HOURS SERVICE

Blower motor

Operating condition

WHEN REQUIRED

Control mechanism

Ooeratina condition

WHEN REQUIRED

Piping

Mounting condition, looseness of clamps and joints, gas leakage, damage

WHEN REQUIRED

Receiver, drier

Replacement

2 - 4-season maintenance

5-14

29. GENERAL PRECAUTIONS

29.1 SAFETY

PRECAUTIONS

If an attachment, option, etc. other than the ones approved by Komatsu is installed, the life of the machine is shortened and safety may be lowered.

When installing an attachment not described in this manual, consult your Komatsu distributor. If we are not notified, we can not take any responsibility.

A

WARNING

Precautions for removal and installation When removing

or installing

When removing

an attachment,

or installing

observe the following

an attachment,

When two or more workers work together, to those signs.

precautions

and work safely.

work on a flat and level place. signs must be made and they must work according

When carrying a heavy item (25 kg or heavier), use a crane.

When removing a heavy item, be sure to prepare a support in advance. When hanging it with a crane, take care of the location of the center of gravity.

It is dangerous to work on an item hung with a crane. be sure to support on a stand and confirm safety.

When leaving a removed attachment

or installing it, place it stably so that it will not fall down.

Do not stand under an items hung with a crane. Keep aside so that you will be safe even if that item falls.

NOTICE A qualification the crane.

or license is required to operate a crane. A person not qualified must not operate

For details of removal and installation

of the attachments,

consult your Komatsu distributor.

5-15