Komatsu Dump Truck HD465-5 Operator & Maintenance Manual - PDF DOWNLOAD

Operation & Maintenance Manual

SEAM056g0500

HD465-s

DUMP TRUCK

SERIAL NUMBERS

HD4@j

:4()01

and up

FOREWORD

FOREWORD This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment.

It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.

Please read this manual carefully BEFORE operating the machine.

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

This manual describes the basic techniques.

Skill .is performed as the operator or anyone get the correct knowledge and performance of the machine.

Operation, inspection, and maintenance should be carefully carried out, and the safety must be given the first priority.

Safety precautions are indicated with A marks and technical precautions with * marks in this manual. The safety information contained in this manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations.

Some illustration pictures are different from your machine as technical improvement is continuously reflected on it. Revision to up-to-date manual’s content is performed in later editions.

This operation & maintenance manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require.

Materials and specifications are subject to change without notice.

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BREAKING IN YOUR NEW MACHINE

BREAKING IN YOUR NEW MACHINE Each machine is carefully adjusted and tested before shipment.

However, a new machine requires careful operation during the first 100 hours to break in the various parts.

If a machine is subjected to unreasonably hard use at the initial operation stage, the potential of performance will prematurely deteriorate and the service life will be reduced. A new machine must be operated with care, particular?v’. with regard to the following items.

After starting, let the engine idle for 5 minutes to allow proper engine warmup prior to actual operation.

Avoid operation with heavy loads or at high speeds.

Sudden starting or acceleration, unnecessarily abrupt braking and sharp turning should be avoided.

If the machine is delivered without any cooling water. in the radiator, flush the cooling system with ample clean water to clean the system, then fill the radiator with cooling water.

When replacing oil filter elements (cartridges), check their interiors for dirt and dust. If heavily collected, check for possible cause before starting operation.

Hours of operation are indicated by the service meter.

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CONTENTS

I

FOREWORD

BREAKING IN YOUR NEW MACHINE / /

I I

OPERATION

o-1

o-2 l-l 2-l

MAINTENANCE

OPERATING INSTRUMENTS

3-l

OPTIONAL PARTS, ATTACHMENT

4-l

TROUBLE SHOOTING GUIDE

/ SERVICE METER, SERIAL NUMBERS, LUBRICANTS

6-l

OPERATION AND MAINTENANCE (EQUIPPED WITH A MACHINE MONITOR)

7-l

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o-3 -

’

OPERATION SAFETY HINTS ... A ........................................................

GENERAL LOCATIONS AND SPECIFICATIONS ................................

INSTRUMENTS AND CONTROLS .............................................

OPERATING YOUR MACHINE ................................................

I- 2 l-l 3 l-l 4 l-42

CHECKS BEFORE OPERATING THE MACHINE .............................

BEFORE STARTING THE ENGINE ..........................................

TO START THE ENGINE ...................................................

AFTER STARTING ........................................................

TO MOVE THE MACHINE OFF .............................................

CHANGING GEAR SPPED .................................................

TRAVEL ..................................................................

REVERSING ..............................................................

OPERATING DUMP BODY .................................................

TO STOP THE MACHINE ..................................................

TO STOP THE ENGINE ....................................................

BRAKE PERFORMANCE GRAPH ..............................................

PRECAUTIONS REGARDING TYPE OF LOAD ..................................

PRECAUTIONS FOR MACHINE OPERATION ........... : .......................

l-42 l-46 l-47 1-51 l-52 l-54 1-55 l-58 l-59 1-61 l-63 l-64 1-71 l-72

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SAFETY HINTS..

.A

GENERAL Wear well-fitting hard hat, safety shoes and working clothes. Never wear loose or unbuttoned clothes as they may catch on protruding parts of machine.

Never wear clothes covered in oil.

If the nature of the work so requires, wear protective goggles or mask, ear plugs or other protection.

Accidents or injuries are liable to occur when the operator is careless or inattentive.

It is most important to bear safe operation in mind at all times.

Learn the prohibitions, precautions and rules about work procedures in the job site. Make every effort to prevent accidents by always following these and always bearing safety in mind.

Do not overwork or drive after drinking. Take care of your health. Driving while unfit can lead to mistakes in judgement in emergencies.

Never allow more than the permitted number of persons to ride on the machine.

If there should be an accident or fire or any other such unexpected mishap, deal with it quickly, using the nearest apparatus.

In addition, it is necessary to prevent any secondary mishaps.

It is also important to know the emergency contact system.

Learn beforehand the locations and method of use of emergency equipment such as first aid boxes, fire extinguishers or other firefighting equipment.

Fuel, oil and anti-freeze are dangerous.

Never smoke or light matches when handling fuel, oil, grease or anti-freeze.

Do not handle these substances near any fire or flame.

When selecting a place for storing them, take care to choose a place away from where fire is used.

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1-2-

When operating inside a building always be sure of the clearances of the ceiling, entrances, aisles, etc. and the load limit of the floor.

Exhaust gas is dangerous.

When running the engine for long periods in a poorly ventilated area, there is a danger of gas poisoning, so open the windows or doors to ensure a good supply of fresh air.

Learn how to use the control devices, gauges and warning devices.

Be sure you understand the meaning of the caution plates and other signs. Remember the check points and checking method for engine oil, fuel, cooling water and hydraulic oil levels. Always know the demensions and capacity of your machine.

BEFORE STARTING OPERATION Examine the lay of the land and the kind of soil at the site to determine the dangerous points and the best method of operation.

Proceed with the work only after, making safety arrangements about the dangerous points. Avoid operating near cliffs or deep gullies. Be particularly careful of the edge of cliffs, falling rocks or landslides.

Always carry out inspection and maintenance correctly.

Check for leakage of fuel, lubricant or hydraulic oil, and for loose, broken or missing parts.

If there are any such problems always correct them. Never use the machine without correcting all problems.

Use repaired machines only after receiving permission from the serviceman in charge of the repair.

Adjust the operator’s seat until it is in the most comfortable position for operating.

Use seat belts if it is equipped to the seat, before you start to drive.

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When getting on or off the machine, use the handrail and step provided.

Do not jump up or down from the machine.

Learn about the safety devices on your own machine and about how to use them. Confirm that they are correctly attached in the prescribed position.

Before starting the engine, confirm that all control levers are in “NEUTRAL” or “HOLD”.

To ensure the safety of workers near the machine, always signal or sound the horn to warn them before starting the engine, moving the machine or turning.

Be particularly careful to check that the rear is clear before backing the machine.

Do not leave parts or tools lying around in the vicinity of or on the floor of the operator’s compartment.

Keep everything in its proper place, to avoid any hindrance while driving.

Wipe off thoroughly any grease, ‘oil or mud on the step, handrail, floor or control levers.

Failure to do this may cause you to slip.

Check the level of the fuel, lubricants and cooling water. Do not smoke or use naked flames when checking.

Extinguish cigarettes before checking or refilling.

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

When there is a leader, fix standard signals and always follow these signals when operating. Learn the signs and rules used in the job site and always follow them.

OPERATION DURING OPERATION Proceed with the operation steadily tep by step. Always aim at unhurried and harmonious safe operation.

Dazzling high speed operation may look efficient, but it does not continue for long. It causes breakdowns, in addition to being dangerous, and in the long run is not effective.

When stopping at crossing, to avoid collisions with other vehicles, keep your distance and confirm who has priority.

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1-4-

If there is no one giving instructions during operations, there is danger of being hit by dump trucks. In such places, all persons not concerned with the operation should be kept out of the operating area.

When driving, sit in the operator’s seat correctly so that the truck can be operated properly.

During while not sitting in the’ operator’s seat, or driving while standing are dangerous.

Always concentrate. It is extremely dangerous to allow yourself to be distracted or to think of other things when operating a machine. Always pay attention to your driving, and to your surroundings.

In dangerous places, or where there is restricted visibility, it is important to get down from the machine and confirm whether it is safe before continuing work.

0 Never drive off the road, or in place which you consider dangerous or outside the range of your skill.

The machine should always be operated at a speed where it can be correctly controlled.

The following are dangerous: * Speeding * Snaking * Coasting l

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1-5-

As far as possible sudden stopping or sudden starting should be avoided except in emergencies.

Be careful to avoid repeated stamping on the brakes.

Before entering curves, slow down. Increase speed when coming out of the curve. If you enter the curve without slowing down, or while braking, the rear wheels may go over the shoulder or the truck may skid. This is very dangerous.

When there is a danger of going over the edge on road shoulders, on slopes or when passing other vehicles, use a leader and follow his signals.

If you attempt to control the speed of your truck by pressing lightly on the brake pedal, this may cause breakdowns coming from overheating of the brakes (fading or separation of the lining). This can be the cause of unexpected accidents, so do not use the brakes in this way.

Where visibility is bad, such as at corners, or when entering or leaving a narrow road, slow down and sound the horn.

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1-6-

TRAVELING DOWNHILL Never overrun the engine. Before starting to descend downhill slopes, stop and check that the brakes are working.

It is dangerous to use only the brake pedal to control speed on a long downhill slope. In such a case see the Operation & Maintenance Manual for instructions on how to use the retarder. Then, descend the hill using the engine and retarder to brake the machine.

Take care not to overload the dump body.

Overloading not only shortens the service life of the truck, but also overheats the tires, causing them to burst.

When the dump truck is loaded with soil, its center of gravity is higher than when unloaded. It therefore is easily affected by the road surface. Failure to remember this can be the cause of overturning or other accidents.

When driving through puddles, water may get into the wheel brakes. Pay careful attention to this point as it drastically lowers the efficiency of the brakes.

In such a case, before driving on, apply the brakes to heat up the brake lining to some extent and this will dry them out.

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1-7-

0 Before crossing bridges, confirm that the bridge is strong enough to take the weight of the dump truck.

LOADING Be sure to load the dump truck evenly. If the weight is greater on one side, there is danger of losing control of the steering wheel or overturning.

If the load is too far forward, the steering becomes heavy. If it is too far back, the front wheels tend to leave the ground when going uphill.

0 When backing to dump a load, be careful not to back too far. Place blocks or build a small ridge to stop the wheels at the dumping point.

l

Never drive with the dump body Always lower the body before moving.

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raised.

When continuing operations after rain, remember that conditions may have changed from those before the rain, so proceed with caution.

Be particularly careful when approaching the shoulder of the road or cliffs, as they may have been loosened by the rain.

Always consider when driving on muddy or soft the tires slipping

the weight of the machine roads in snow or rain, or on terrain. Be careful to avoid or sinking into the ground.

When towing a broken-down machine, first check that the brakes are working properly, then connect the machine with a suitable tow-rope or cable. When towing on roads, always follow traffic regulations and attach a correct warning sign.

After earthquakes, confirm that the ground is still firm; after blasting, confirm that there are no unexploded charge remaining.

Follow signals or the leader’s instructions.

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(

is poor, keep a greater dis0 When visibility in front and drive at machine the tance from drops below a lower speed. When visibility safety level, stop work and wait for the visibility to improve. relation

This table shows the and traveling speed.

Safe speed (km/h)

between

visibility

+

Use a sprinkler when necessary to keep dust down and maintain good visibility.

the

Always use lights when driving at night or in dip your lights when etc. Always tunnels, vehicle. on-coming an meeting At night it is very easy to make mistakes in the distance and height of objects estimating and land. in fog, mist or smoke, where When driving the is poor, drive safely, following visibility traffic in given instructions and precautions regulations.

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I-IO -

0 The machine condition can be judged from many factors. Changes in the gauges, sound, vibration, exhaust gas color or response of the control levers can indicate the occurrence of some disorder. If any disorder occurs, park the machine immediately in a safe place action. Be especially and take appropriate careful in the case of fuel leaks as there is danger of fire.

AFTER OPERATION Stopping the machine 0 Apply the brake lock.

0 Return the gear shift lever to NEUTRAL. 0 Never fail to lower the dump body.

Stopping the engine 0 Run the engine at low idling to cool the engine slowly. Then stop the engine.

0 Remove the key from the starting switch.

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I-II

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When parking the machine, park it in a safe place outside the working area, or in the specified place.

The following factors should be considered when choosing a parking place: it should be on flat, firm grouns where there is no danger of rockfalls, landslides or floods. If the machine has to be parked on the road, always follow traffic regulations.

When the machine has to be parked on a slope, chocks must always be placed under the wheels.

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1-12 -

GENERAL LOCATIONS AND SPECIFICATIONS

GENERAL LOCATIONS AND SPECIFICATIONS 1. Dump body 2. Rear wheel 3. Front wheel

4. Turn signal lamp 5. Head lamp

WEIGHT 0 Gross weight (empty-truck weight + maximum 85955 [87155]kg payload + 1 operator): 39900 [41100] kg 0 Empty-truck weight: PERFORMANCE 0 Traveling speed 66 [70] km/h Forward: 11 [I 21 km/h Reverse: 46000 kg 0 Maximum payload: 34.2 m3 0 Dump body capacity: 11.5 seconds 0 Dumping speed (at 2100 rpm): ENGINE Komatsu SA6D170 diesel engine 0 Model: 715 HP 0 Flywheel horsepower (at 2100 rpm): NOTE: Specifications

are subject to change without notice.

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1-13 -

[

I: With large size tires

‘INSTRUMENTS AND CONTROLS

INSTRUMENTS

AND CONTROLS

The role, action, and operation of devices needed for operation are as follows.

METERS AND LAMPS, MACHINE WARNING DEVICE, SWITCHES, LEVERS AND PEDALS, MECHATRONICS EQUIPMENT CONTROLLER, SAFETY PIN, DUST INDICATOR, OPERATOR’S SEAT, SEAT BELT, FUSES Knowledge of these devices is necessary for safe and pleasant operation.

Make sure that you understand them thoroughly.

For details of the order of operation when starting the machine, see OPERATING YOUR MACHINE. Note: Details of the machine monitor mounted on the machine are given separately at the end of this manual.

METERS AND LAMPS 1. TORQUE CONVERTER OIL TEMPERATURE GAUGE When the pointer of the temperature gauge shows the green range, the oil temperature is normal.

When the pointer enters the red range, stop the machine immediately, and run the engine at 2000 rpm with the gear shift lever in neutral until the oil temperature drops to the normal

INSTRUMENTS

2. AIR PRESSURE GAUGE During operation this should normally register in the green range.

If the green range is not reached, the central warning lamp will light red and a buzzer will sound. When this happens, stop the machine and keep the engine speed raised until the pointer enters the green range. t When the air pressure gets lower (less than 5.2 kg/cm*), the parking brake automatically works.

When the air pressure gets lower (less than 2.2 kg/cm2), the emergency brake automatically works.

Raise the ,air pressure so that the parking brake is released.

Do not travel before the parking brake valve lever is released.

3. RETARDER OIL TEMPERATURE GAUGE The indicator should be in the green range during normal operation. If it goes above the green range and enters the red range, stop the machine, return the transmission shift lever to neutral, and run the engine at 2000 rpm until the oil temperature drops.

4. ENGINE WATER TEMPERATURE GAUGE is normal if the pointer Water temperature stays in the green range during running of the engine. up the warm starting the engine, After engine sufficiently until the pointer comes into green range.

If the pointer deflects beyond the green range to red range during traveling of the machine, reduce the engine speed to low-idling this until the pointer and maintain speed returns to green range.

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AND CONTROLS

.

’ INSTRUMENTS AND CONTROLS

5. SPEEDOMETER The speedometer indicates the machine running speed in kilometer per hour. An odometer is built in the speedometer.

6. TACHOMETER The tachometer indicates the engine speed in revolutions per minute. When the pointer enters the red range, it indicates that the engine is over running. Either shift the lever to the proper speed stage or decelerate so that the pointer leaves the red range.

When the engine speed reaches 2500 rpm, the retarder brake works automatically to reduce engine speed and slow down to reduce engine speed and slow down the machine. Do not use this function unless absolutely necessary.

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1-16 -

INSTRUMENTS AND CONTROLS

7. SHIFT INDICATOR Indicates what gear the transmission is in.

When the lock-up clutch is applied, the lock-up indicator lamp (green) in the meter lights up to show direct drive travel.

8. SERVICE METER Indicates the total machine operation hours.

When the engine is running, a current flows to advance the meter reading even if the machine is not moving.

So, use it according to the following instructions.

Record the readings at the start and the end of a work, which will be a work record of the machine.

The time for periodical maintenance is informed.

It indicates the integrated working hours which must be informed at trouble information.

When the engine is running, the meter indicator turns to show that the meter is operating.

9. TURN SIGNAL PILOT LAMP (GREEN) This indicator lamp flashes when the signal switch is operated.

turn

10. HIGH BEAM PILOT LAMP (BLUE) This indicator lamp comes on when the head lamp is on high beam.

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1-17 -

INSTRUMENTS AND CONTROLS

MACHINE WARNING DEVICE 1. CENTRAL WARNING LAMP (RED) In case, the following abnormality occurs, this warning lamp and pilot lamp light, also, warning buzzer sounds.

Then, immediately stop the machine and check causes.

0 Rear brake oil temperature exceeds the allowable limit.

0 Torque converter is overheating.

0 Engine oil pressure is less than specified value (0.5 + 0.2 kg/cm2).

0 Engine is overheating.

0 Cooling water capacity is less than specified level.

0 Air pressure is less than the specified value (5.2 f 0.5 kg/cm2).

0 Gear shift lever is placed in any speed range other than the NEUTRAL position, during parking brake valve lever is applied.

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1-18 -

INSTRUMENTS AND CONTROLS

2. AIR PRESSURE CAUTION LAMP If the air tank pressure drops below 5.2 f 0.5 kg/cm*, the central warning lamp and caution lamp come on and at the same time, a buzzer sounds.

3. REAR BRAKE OIL TEMPERATURE CAUTION LAMP If the rear brake oil temperature exceeds 120’ f 4X, the central warning lamp and caution lamp come on and at the same time, a buzzer sounds.

4. TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP If the torque converter oil temperature exceeds 120” f 4’C, the central warning lamp and caution lamp come on and at the same time, a buzzer sounds.

5. COOLANT TEMPERATURE CAUTION LAMP If the engine cooling water temperature exceeds 102’ f 4X, the central warning lamp and caution lamp come on and at the same time, a buzzer sounds.

6. RADIATOR COOLANT LEVEL CAUTION LAMP If the water level in the radiator sub-tank drops below the specified level, the central warning lamp and caution lamp come on and at the same time, a buzzer sounds.

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1-19 -

,’

INSTRUMENTS AND CONTROLS

7. ENGINE OIL PRESSURE CAUTION

LAMP If the engine oil pressure drops below 0.5 f 0.2 kg/cm*, the central warning lamp and caution lamp come on and at the same time, a buzzer sounds.

8. EXHAUST BRAKE PILOT LAMP This pilot lamp lights up when brake is actuated.

the exhaust

9. REAR BRAKE PILOT LAMP This lamp lights up when the service brake is depressed or the retarder control lever is pulled to actuate the rear brake.

10. TRANSMISSION OIL FILTER CAUTON LAMP The caution lamp lights up to warn that the transmission oil filter is clogged.

INSTRUMENTS AND CONTROLS

11. CHARGE WARNING LAMP The lamp lights up if there is any abnormality in the charging system when the engine is running.

12. PARKING BRAKE PILOT LAMP This lamp lights up when the parking brake is applied.

In addition, if any attempt is made to drive the machine with the parking brake applied, the central warning lamp will light up and the buzzer will sound.

13. BODY FLOAT CAUTION LAMP When the dump body control lever is set to any position other than FLOAT, this lamp lights up. When traveling, always set the lever to the FLOAT position.

Check for blown bulbs in caution lamps and pilot lamps Before starting the engine, turn the starting switch to ON and press bulb check switch (14) to check if any caution lamp or pilot lamp bulb is broken. * If any lamp does not light up, the bulb is probably broken, so replace the bulb.

If it still does not light up even when the bulb is changed, there is probably some failure or disconnection, so contact your Komatsu distributor.

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INSTRUMENTS AND CONTROLS

SWITCHES 1. STARTING SWITCH This switch is used engine.

to

start

or

stop

OFF Key insertion-withdrawal position. None electrical circuits activate.

To stop the engine, turn the switch to OFF.

the

of

ON Charging and lamp circuits activate.

START At this key position, the starting motor will crank the engine. Release the key immediately after starting, and the key will return automatically to ON.

0F;F

INSTRUMENTS

AND CONTROLS

2. LAMP SWITCH This switch turns on the head lamps, clearnace lamps, tail lamps, internal lighting for the instrument panel, and the rear lamps.

0 OFF 0; 041 position: Clearance lamps, tail lamps, rear lamps, and internal lighting of vehicle monitor light up. @I 3Da position: The head lamps light up in addition to the lamps at position 0. * The lamp switch can be operated regardless of the position of the lever.

2. TURN SIGNAL LEVER This lever operates the turn signal lamps.

0 RIGHT TURN: Push lever FORWARD. @ LEFT TURN: Pull lever BACK. * When the lever is operated, the turn signal pilot lamp will also flash. t When the steering wheel is turned to the neutral position, the turn signal lever will return automatically to OFF. If not, return the lever to OFF manually.

2. DIMMER SWITCH This switches the beam and low beam. @ Low beam Q High beam

head

lamp

between

high

3. ROOM LAMP SWITCH This switch turns the room lamp on and off. @I OFF 0 ON

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l-23 -

I

If

%=%.

INSTRUMENTS AND CONTROLS

4. CAUTION, PILOT LAMP BULB CHECK SWITCH Turn the starting switch to ON and press this switch to check if any bulbs are broken.

5. FOG LAMP SWITCH This turns on the fog lamp.

1 position: OFF position: ON

6. EXHAUST BRAKE SWITCH 1 position (the lamp OFF): If the service brake is depressed or the retarder control lever is operated when the torque converter is locked up, the exhaust brake is actuated.

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l-24 -

INSTRUMENTS AND CONTROLS

-

position (the lamp ON): If the accelerator pedal is released and the torque converter is locked up, the exhaust brake is actuated.

The pilot lamp inside the switch lights up.

7. FRONT BRAKE OFF SWITCH This switch is used to change the braking method according to the road conditions.

1 position (the lamp OFF): When the brake pedal is depressed, the brakes are applied to the front and rear wheels.

- position (the lamp ON): Even when the brake pedal is depressed, the brakes are not applied to the front wheels; the brakes are only applied to the rear wheels.

On icy road A faces where

surfaces, on snow, or on surthe machine is likely to slip, control of the steering is needed, so set the front brake switch to the 1 (ON) position and travel slowly at a safe speed.

8. PANEL DIMMER SWITCH This switch is used to adjust the brightness of the lighting inside the monitor panel and pilot lamp.

Adjust as follows: To INCREASE brightness, turn CLOCKWISE To DECREASE brightness, turn COUNTERCLOCKWISE 9. QUICK START SWITCH This is used when starting in cold areas.

When the switch is pressed and then released, ether is sprayed into the intake manifold. * For details of the method of operation, see “Starting the engine in cold weather�.

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INSTRUMENTS AND CONTROLS

10. EMERGENCY STEERING SWITCH This switch is used to actuate the emergency steering pump. Push the switch, and the emergency pump is actuated, so the steering can be operated. t When the switch is ON, the pilot lamp (red) inside the switch lights up. pump can be used steering * The emergency for a period of up to 90 seconds. steering, drive at * When using the emergency km/h.

5 a speed of less than it steering is actuated, * When the emergency is possible to raise the body with the dump lever.

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INSTRUMENTS AND CONTROLS

11. SHIFT LIMITER SWITCH This switch is used to limit the highest speed range when the gear shift lever is in D or L ranges.

1 position: D range -F2 to F7 L range - Fl to F2 -position: D range - F2 to F6 L range - Fl 12. EMERGENCY BRAKE LEVER This lever actuates the emergency brake.

Applied: Emergency brake is actuated Travel: Emergency brake is released + If the air pressure inside the air tank drops below 2.2 kg/cm2, the emergency brake is automatically applied. * If the emergency brake is actuated because of a failure in the air circuit, the central warning lamp will flash and the buzzer will sound.

For details of the method of releasing the brake when this happens, see “Method of releasing parking brake and emergency brake i when actuated in a emergency�.

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INSTRUMENTS AND CONTROLS

13. PARKING BRAKE VALVE LEVER This is used to applied the parking brake.

Parking: Parking brake is actuated Travel: Parking brake is released * If the lever is palced in the PARKING posibrake pilot lamp will light tion, the parking up. * When the lever is placed in the PARKING position, and the gear shift lever is in any position other than neutral, the central warning buzzer will lamp will flash and the alarm sound. * When the air pressure drops below 2.2 kg/ brake and parking brake cm*, the emergency applied. are automatically the of releasing For details of the method brake is actuated brake when the parking in the air circuit, see because of a failure and brake parking of releasing “Method brake when actuated in a emergemergency i ency�. parking the A When the parking brake.

machine,

always

apply

loading operations, do not apply the A During parking brake. Pull the retarder control lever to apply the brakes.

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INSTRUMENTS AND CONTROLS ../

14. CIGARETTE LIGHTER This is used to light cigarettes. To use, push the lighter in. After the few seconds it will spring back. At that time, remove the lighter and light your cigarette.

15. HORN BUTTON When the button in the center of the steering wheel is pressed, the horn will sound.

16. WIPER SWITCH This operates the wipers.

INT: Operates intermittently OFF: OFF LOW: Operates at low speed HI: Operates at high speed _ Press this switch to spray washer liquid.

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INSTRUMENTS AND CONTROLS

LEVERS AND PEDALS 1. BRAKE PEDAL This pedal is used to apply the wheel brakes.

2. ACCELERATOR PEDAL This pedal is used to adjust the engine speed.

It can operate the engine speed freely from low idling to full throttle.

I

INSTRUMENTS AND CONTROLS

3. GEAR SHIFT LEVER Select the gear shift range to match the travel conditions.

Position D This is used for normal travel.

If the lever is placed in this position, the transmission is automatically shifted between 2nd torque drive and 7th according to the travel speed. t The maximum speed at this position is 66 km/h (70 km/h with large diameter tires).

Position R This is used when traveling in reverse.

Torque converter drive is used in this position. sr If the dump lever is in any position except FLOAT, the machine cannot travel in reverse.

Place the dump lever at FLOAT first, then operate the gear shift lever to the R position.

Positions 5 - L These ranges are used on high speed travel is difficult, or on soft ground, or when startig loaded, or when going downhill is used as a brake.

0 The speed ranges for each follows.

Position 5

(

jobsites where when traveling on slopes when and the engine position

Max. speed

Speed ranges 1st torque converter 5th direct

1: Speeds for machines large-diameter tires

are

37.5 (39) km/h

fitted with

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as

INSTRUMENTS AND CONTROLS

When operating the gear shift lever, put it securely into each position.

If the lever is not set securely in position, the shift position display on the panel may go out, and the transmission warning monitor may light up.

When shifting between FORWARD and REVERSE, always stop the machine completely before operating the lever.

When starting the engine, check that the gear shift lever is at N (neutral). If it is in any other position, the engine will not start.

If the starting switch is turned ON with the gear shift lever at any position other than N, the central warning lamp will flash and the alarm buzzer will sound.

If the gear shift lever is moved to any position other then N when the parking brake is applied, the central warning lamp will flash and the alarm buzzer will sound.

If the gear shift lever is moved to any position other than N when the dump lever is at a position other than FLOAT, the central warning lamp will light up and the alarm buzzer will sound.

When traveling, never shift the gear shift lever back to the N position.

When moving the gear shift lever from N to the FORWARD or REVERSE positions, always release the accelerator pedal.

When moving the gear shift lever from N to R, or from D to 5, press the lock button on the gear shift lever before moving the gear shift lever.

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i

INSTRUMENTS AND CONTROLS

4. SAFETY LOCK

This device

locks the dump lever.

carrying A When machine with the

on the inspection out dump body raised, always lock the dump lever in the HOLD position, and then install the safety pin.

5. DUMP LEVER This lever operates the dump body.

0 RAISE 0 HOLD: This holds the dump body in the same position. @ FLOAT: This allows the dump body to move freely in response to external force. @ LOWER * When traveling, tion. *

always

For details, see “Operating

use the

FLOAT posi-

dump body”.

0

,. ;.

INSTRUMENTS

AND CONTROLS

6. RETARDER CONTROL LEVER retarder that This lever operates together with the rear brake when downhill.

The harder the lever is pulled, the the braking force becomes. is operated, the retarder * When brake pilot lamp lights up. t For details, see “DOWNHILL TRAVEL”.

A The

retarder brake.

is used traveling stronger the

rear

must not be used as a parking

* When leaving the operator’s apply the parking brake.

compartment,

7. STEERING TILT LEVER This lever is used when tilting the steering wheel forward or back, or moving it up or down.

Lift up the lever and set the steering wheel at the desired position, then push the lever down to lock the steering wheel securely in position. t Amount of adjustment Fore-aft: 5 Up: 30 mm Down: 20 mm

INSTRUMENTS AND CONTROLS

A Always

stop the machine before the tilt of the steering wheel.

adjusting

8. DIFFERENTIAL LOCK PEDAL This operates the differential lock control.

When the pedal is depressed, the differential lock is actuated; when the pedal is released, the differential lock is canceled.

-

l-35 -

WiSTRUEMNTS AND CONTROLS

MECHATRONICS CONTROLLER

EQUIPMENT

This informs the location of any abnormality in the mechatronics equipment system.

1. SHIFT CONTROLLER 2-digit failure code is displayed inside the inspection window, so that it is possible to know the location of the abnormality.

The normal display is ‘fi. &‘, or r &‘. ;I J .

2. SUSPENSION CONTROLLER There are green and red LEDs (Light Emitting Diodes) inside the inspection window, and these light up, flash, or go out.

The combination of these conditions shows the location of the abnormality.

Normally, the green LED lights up. * For details of the display if any abnormality should occur, see “Trouble shooting guide”.

-

l-36 -

INSTRUMENTS AND CONTROLS

SAFETY PIN This is a safety device for the dump body and is used when carrying out inspection and maintenance with the body raised.

Raise the dump body fully, insert safety pin (I), then insert lock pin (2). + Always insert the safety pins on both sides.

When A dump

carrying out inspection with the body raised, always set the dump lever at HOLD, lock it in position, and then use the safety pin.

Storage of safety pin The safety pin is stored at the bottom rear of the body.

Insert safety pin (I), then insert lock pin (2) to store the pin.

DUST INDICATOR This device indicates clogging of the air cleaner element. When red piston (1) appears in the transparent part of this indicator, the element is clogged. Immediately clean element.

After cleaning, push indicator button (2) to return red piston to original position.

-

l-37 -

0

Q.. a

F,ms

INSTRUMENTS AND CONTROLS

OPERATOR’S SEAT A: Forward-backward adjustment Move lever (1) to the right, move the seat to the best position and release the lever. The seat can be moved forward or backward within a range of 140 mm in 7 stages.

B: Seat angle adjustment Move lever (2) up, set the seat to the desired angle, and release the lever.

The seat can be tilted up or down about 2.7”.

C: Seat cushion adjustment Rotate grip (3) under the seat to adjust scale (4) on the cushion adjustment to your own weight. (50 to 120 kg) D: Backrest adjustment Pull lever (5), move the backrest to the best position and release the lever. The backrest can be set to 28 steps. (56”) E: Seat height adjustment Move lever (6) upward, set the seat to the desired height and release the lever.

The seat can be set within 50 mm. * If it is desired to make the seat softer, make the seat adjustment lighter; If it is desired to make the seat harder, make the seat adjustment heavier. + For poor road surfaces, set the seat harder than usual.

-

l-38 -

INSTRUMENTS AND CONTROLS

SEAT BELT

A Before

using seat belt, make sure that no unusual conditions are observed in the belt fittings and the belt itself.

FASTENING THE SEAT BELT Sit in the seat and adjust the seat so that your back will be against the backrest when the brake pedal is fully depressed.

Sit in the seat. Holding buckle (1) with your right your (3) with left hand and tongue hand, put the tongue into the buckle. Make sure that the belt is securely locked by pulling the belt.

To remove the belt, press button (2) on the buckle to unlock the belt.

Make sure the belt is not twisted when fastened. Adjust the belt length on both sides in the so that the buckle will be positioned front center of your body.

ADJUSTMENT OF BELT LENGTH To shorten the belt: Pull the free end of the belt side or tongue side.

on the

buckle

To lengthen the belt: Bend the belt at a right angle to the buckle and pull the belt on the fixed or the tongue or with the tongue. buckle the with side * Check the belt fixtures on the machine body the bolts if for loose bolts and retighten necessary. the belt gets shabby or worn out, damaged get parts metal the when deformed, replace the entire seat belt.

* When

-

1-39 -

or or

rr_

INSTRUMENTS AND CONTROLS

FUSES Fuses protect the electrical parts and wiring from burning out.

If the fuse becomes corroded, and there is white powder in the fuse, or if the fuse is loose in the fuse holder, replace it.

A When power

replacing fuses, always turn off the first (turn the starting switch to the OFF position).

t

When replacing fuses, always replace fuse with a fuse of the same capacity.

Fuse capacities Fuse box I

the

and names of circuits

No.

Fuse capacity

0

10A

Car radio

0

10A

Horn switch, Front brake off solenoid

0

1OA

Cigarette lighter

Circuit

BCV relay solenoid, Back-up lamp, Back-up buzzer, Stop lamp, Room lamo Head lamps (high beam), Clearance

b @

10A

Emergency steering switch

-

I-40 -

INSTRUMENTS AND CONTROLS

Fuse box II No.

Fuse capacity

0

10A

0

Circuit

Remarks Spare

20A

-

Spare

63

20A

-

Spare

63

10A

-

Spare

03

20A

Payload indicator lamp

~ controller, Exhaust brake solenoid

@I

5A

@a

5A

1 Maintenance monitor

I

Payload meter, Payload relay

Fuse box III Remarks

8

10A

Air compressor (For air conditioner)

@

IOA

Air compressor blower motor (For air conditioner)

I 8

1

1OA

I 1 Engine stop motor

I

* When using the terminal of the spare fuse, consult your Komatsu distributor.

-

1-41 -

r13735

OPERATING

YOUR MACHINE

OPERATING YOUR MACHINE The following is an explanation of the checks before starting, method of starting the engine, and controls for the machine needed to operate the machine. Please read this section carefully to acquire basic knowledge of methods of operation.

CHECKS BEFORE OPERATING THE MACHINE Always carry out the following checks to ensure safety for the operator and the maintenance of the machine performance.

CHECKS BEFORE STARTING (WALK-AROUND CHECK) Before starting the engine, check around and under the machine to check the work equipment and hydraulic system for any loose nuts or bolts, or leakage of oil, fuel, or coolant.

Check also for any loose electric wires, play, and collection of dirt around places that reach hinh

temneratllrnn

-

l-42 -

OPERATING YOUR MACHINE

1. Check electric wires Check if fuses are broken, and check for any traces of disconnections or short circuits in the electric wiring.

Check also for any loose terminals, and tighten if necessary.

In particular, check the wiring of the following: 0 Battery 0 Starting motor l Alternator 2. Check for loose mounting cleaner

bolts of air

3. Check for leakage of water from radiator 4. Check for leakage of oil or water from around engine 5. Check for leakage of oil from transmission piping 6. Check for leakage of axle oil 7. Check coolant level, add water Check the coolant level.

The coolant level must be between and LOW marks on the reserve tank.

the FULL

8. Check oil level in front brake oil tank, add oil Check the level of the oil in the front brake tank. The oil level must be between the FULL and LOW marks on the tank.

9. Check dust indicator Check that the red piston of the dust tor has not reached the service level.

IO. Drain water from air tank Open the drain valve of the the water.

tank

and

-1-43-

indica-

drain

OPERATING YOUR MACHINE

11. Check oil level in transmission case, add oil Check the transmission oil level.

The oil level must be visible in the sight gauge.

12. Check oil level in engine oil pan, add oil Check the engine oil level.

The oil level must be between the H and L marks on the level gauge.

13. Check oil level in steering and hoist oil tank, add oil Check the steering and hoist oil level.

The oil level must be visible in the

sight

gauge.

14. Check oil level of rear brake cooling oil tank, add oil Check the rear brake cooling oil level.

The oil level must be visible in the

sight

gauge.

15. Drain water and sediment from fuel tank Loosen the drain valve and drain the water and sediment.

16. Check fuel level Check the fuel level on the fuel gauge.

17. Check wheel hub nuts, tighten 18. Check tire inflation tires

pressure, damage to

19. Check central warning 20. Check machine warning

lamp device

-l-44-

OPERATING YOUR MACHINE

21. Check braking action of service brake 22. Check braking capacity of service brake 23. Check braking action of retarder

brake

24. Check braking capacity of retarder

brake

25. Check braking action of parking brake 26. Check braking capacity of parking brake 27. Check braking action of emergency

brake

28. Check braking capacity of emergency brake 29. Check emergency

steering

30. Check body mount rubber 31. Checkaction

of steering

32. Check direction undermirror

of rear view mirror,

33. Check lights 34. Check horn 35. Check action of gauges during operation 36. Check exhaust gas color, noise 37. Check for sediment separator

and water in water

-

l-45 -

OPERATING YOUR MACHINE

BEFORE STARTING THE ENGINE Before starting the engine, of all levers and pedals.

check the position

1. With your back against the back rest of the operator’s seat, adjust the seat position so that the brake pedal can be easily depressed.

Is parking position?

brake

switch

(1) in the

PARKING

Is gear shift lever (2) in the N (neutral) position?

The engine will not start while gear shift lever (2) is in any position other than N (neutral).

If the gear shift lever is at any position except N (Neutral), and the starting switch is turned ON, the central warning lamp will flash and the alarm buzzer will sound.

Is dump lever (3) in the FLOAT position?

-

l-46 -

I

8, ‘$

_

OPERATING YOUR MACHINE

5. Is retarder control lever (4) in the lease position?

brake

re-

/

6. Check for any abnormalities in the machine warning device and maintenance monitor when starting switch (5) is turned ON.

OFF

PI�*

TO START THE ENGINE NORMAL STARTING Before starting the engine, surrounding area is safe.

1. Turn the key START position

check

of starting switch to start the engine.

that

the

(1) to

the

2. When

the engine is started, release the key of starting switch (1) and the key will return automatically to ON. * Do not leave the key in START for more than 20 seconds.

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

-1-47-

(

OPERATING YOUR MACHINE

STARTING THE ENGINE IN COLD WEATHER becomes low, start the enIf the temperature gine as follows.

1. Turn the key of starting position.

2. Depress accelerator

(1) to the ON OFF

pedal (2) half way.

3. Keep quick start switch wait for 2 - 3 seconds.

4. Turn the key START position

switch

(3) depressed

switch of starting to crank the engine.

(1) to

and

the OFF :

-1-48-

,,%

OPERATING YOUR MACHINE

5. While cranking the engine, release quick start switch (3) and start the engine.

I

I

F,.?&7

6. When the engine starts, return the key of starting switch (1) to the ON position. (Release the key and it will return automatically.)

If the engine speed does not increase, repeat the pushing operation of the quick start switch 2 - 3 times while cranking.

After starting, if the engine speed drops and the engine is about to stop, operate the quick start switch to spray ether. When doing this, adjust the number of times of operating the spray so that the engine does not rise too far.

Do not raise the engine speed above 1000 rpm while operating the quick start switch.

When starting, and cranking the starting motor, the monitor may flash, but if it goes out after the engine starts, there is no abnormality.

If the engine does not start with the above operation, wait for approx. 2 minutes and repeat Steps 2 - 5.

During normal operation, do not operate the ether spray under any circumstances.

Do not spray more ether than is necessary.

If too much ether is sprayed, there will be an explosion.

Be extremely A ether cylinder.

careful

when

handling

-1-49-

the

OFF ~

oh/

OPERATING YOUR MACHINE

Precautions when handling ether 0 Never bring any flame close to the ether.

0 After using, do not throw the cylinder into a fire or make holes in it.

0 Do not keep the ether cylinder in a place at a temperature of more than 40°C. 0 Do not touch or inhale the ether gas.

0 Do not bring the ether cylinder into the operator’s compartment.

0 Keep the cylinder out of the reach of children. * When not using the ether cylinder, such as in the summer, remove it from the machine. * If the ambient temperature goes below -25X, remove the ether cylinder from the machine until the machine is started again, and keep it in storage at room temperature.

SPECIAL STARTING 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.

Refer to FUEL FILTER in every 500 hours services.

-

I-50 -

OPERATING YOUR MACHINE

AFTER STARTING After starting the engine, do not immediately start operations.

First, carry out the following operations and checks.

1. After warming up the engine, check that the vehicle monitor is normal.

It Run the engine under light load until the engine water temperature gauge and air pressure gauge are in the green range. + Do not run the engine at idling for more than 20 minutes. If it is necessary to run the engine at idling, apply a load from time to time, or run the engine at midrange speed.

2. Check if the exhaust color is normal or whether there is any abnormal noise or vibration. t Avoid abruptly accelerating the engine until the completion of warm-up.

-

1-51 -

OPERATING YOUR MACHINE

TO MOVE THE MACHINE OFF Before moving the machine off, check that the surrounding area is safe, give a signal or sound the horn, then start the machine.

1. Check that there is no warning display on the machine warning device.

2. Fasten your seat belt, and check lever (1) is in the FLOAT position.

that

dump

3. Check that air pressure gauge (2) is in the green range, and set parking brake lever (3) to the TRAVEL position to release the parking brake.

4. Check that rear brake (retarder) pilot lamp (4) is OFF, then move gear shift lever (5) to the desired position. * When operating the gear shift lever, set it securely in position.

If it is not set securely in position, the shift position display on the panel may go out, and the transmission warning monitor may light up. * When moving the gear shift lever from N (neutral) to the R (reverse) or F (forward) POsitions, always release the accelerator pedal.

-

l-52 -

OPERATING YOUR MACHINE

5. Depress machine.

accelerator

pedal

(6) and

drive

t

the

If the gear shift lever is moved to any position other than N when the parking brake is applied, the central warning lamp will flash and the alarm buzzer will sound. * If the gear shift lever is moved to any position other than N when the dump lever is at a position other than FLOAT, the central warning lamp will light up and the alarm buzzer will sound. t Do not operate the gear shift lever while depressing the accelerator pedal.

This action will cause a large shock, and will also shorten the service life of the machine.

-

l-53 -

OPERATING YOUR MACHINE

CHANGING GEAR SPEED Shift gear as follows.

This machine is equipped with automatic transmission, so if the gear shift lever is set to the desired position, gear shifting is carried out automatically to match the travel speed of the machine. * When switching between FORWARD and REVERSE, always stop the machine completely before moving the lever. * Do not operate the gear shift lever while depressing the accelerator pedal.

This action will cause a large shock, and will also shorten the service life of the machine.

-

l-54 -

OPERATING

TRAVEL Shift up (accelerating) 1. If the accelerator pedal is depressed to accelerate the machine, the lock-up clutch is engaged and the transmission enters direct drive.

2. If the machine is accelerated further, the transmission is automatically shifted up.

Shift down (decelerating) If the accelerator pedal is released, the machine slows down, and the transmission is automatically shifted down.

Down-shift inhibit This prevents overrunning of the engine caused by mistaken operation of the gear shift lever.

Overrun preventive mechanism If the machine is accelerated beyond the maximum speed for any gear position while going downhill, the overrun preventive mechanism actuates, causing the retarder to work to slow down the machine.

-

T-55 -

YOUR MACHINE

OPERATING YOUR MACHINE

DOWNHILL TRAVEL When traveling downhill, travel at a safe speed for the road conditions (condition of road surface, road width, etc.).

1. Before starting downhill, release accelerator pedal (I), and operate retarder control lever (2) to reduce speed.

2. Move the gear shift lever to the position (5, 4, 3, L) that corresponds to the maximum permitted speed for the retarder brake performance.

(Refer to “Brake performance graph�.)

On the downhill slope, operate retarder control lever (2) to keep the engine speed above 1800 rpm, and travel so that the retarder brake oil temperature gauge is within the green range.

When traveling downhill, do not use the service brake except in emergencies. The brake will overheat and the service life will be reduced.

When operating the ratarder, operate the lever slowly. Sudden braking is dangerous and will cause the tires to slip.

-

1-56 -

OPERATING YOUR MACHINE

PRECAUTIONS

FOR DOWNHILL

TRAVEL

+ The maximum allowable travel speed when going downhill with the retarder applied depends on the downhill travel distance and the hill gradient. (Refer to the brake performance graph.) * If the machine continues traveling downhill at a speed exceeding the maximum allowable value indicated in the brake performance graph, it may damage the retarder brake, resulting in a serious accident. t When traveling downhill using the retarder, if the retarder oil temperature monitor lamp on the vehicle monitor flashes, shift down.

(When this happens, the central warning lamp flashes and the alarm buzzer sounds.)

If the monitor lamp does not go out even after shifting down, stop the machine immediately, return the gear shift lever to neutral, run the engine at 2000 rpm, and wait until the monitor lamp goes out.

It By operating the retarder control lever when traveling downhill, it is possible to shift down more quickly than with normal deceleration.

It is also possible to travel without shifting up.

If the retarder should stop working while traveling downhill, do the following: 1. Completely release the retarder control lever once and then operate the lever again.

2. If the retarder has no effect even when the retarder is operated again, return the retarder lever completely to the RELEASE position, depress the service brake, stop the machine, and contact your Komatsu distributor. t

stopping the machine, A After under the tires immediately.

put

-

blocks

l-57 -

OPERATING YOUR MACHINE

REVERSING Stop the machine and the area to the rear is safe.

check

carefully

that

Set gear shift lever (1) in the R position, and depress accelerator (2) gradually to drive the machine.

If the dump lever is in any position other than FLOAT, it is impossible to travel in reverse. Place the lever in the FLOAT position before setting the gear shift lever at the R position.

Do not operate the gear shift lever while depressing the accelerator pedal.

This action will cause a large shock, and will also shorten the service life of the machine. * When switching between FORWARD and REVERSE, always stop the machine completely before moving the lever.

-

1-58 -

YOUR MACHINE

OPERATING

OPERATING DUMP BODY Operate the dump body as follows.

Set gear shift lever (1) at the N position, and set parking brake lever (2) at the PARKING position.

Set dump lever (3) at the RAISE position, depress the accelerator pedal, and the dump body will rise.

When the dump lever is placed in the RAISE position, it is held at the RAISE position even when released, and the body will continue to rise.

The speed rises in proportion to the engine speed.

When the dump body rises to the set position (adjusted position of body positioner), dump lever (3) returns to the HOLD position.

The body is then held at this position.

If it is desired to raise the body further, move dump lever (3) to the RAISE position and the dump body will rise.

In this condition, lever (3) is if dump released, lever (3) will return to the HOLD position and the dump body will stop in that position.

-l-59-

I

N

Raise

‘\

\ ’ -3, ‘t :, /I

\ 6

/ 6 +-q

I

J F,0a)7

OPERATING YOUR MACHINE

4. Move dump lever (3) to the LOWER position and the dump body will start to move down.

Lower

5. After lowering the dump body a certain distance, move dump lever (3) to the FLOAT position. (Release the lever and it will return automatically to the FLOAT position.) The body will move down under its own weight. * When traveling, always set the dump lever at the FLOAT position, regardless of whether the truck is loaded or not. * If the gear shift lever is moved to any position other than N (neutral) when the dump lever is not at the FLOAT position, the central warning lamp will light up and the alarm buzzer will sound. + When raising the body, reduce the pressure on the accelerator pedal when the body is near the maximum angle to reduce any shock load on the hydraulic circuit and hoist cylinders. dumping A When dumping speed.

Never load the A body is raised.

large

dump

rocks,

reduce

body while

the

the dump

A When ance

carrying out inspection or maintenwith the dump body raised, always use the safety pin and lock the dump lever in the HOLD position.

-

I-60 -

OPERATING

YOUR MACHINE

TO STOP THE MACHINE Do not stop the machine suddenly. As far as possible, always stop the machine with room to spare.

pedal (I), and Release accelerator brake pedal (2) to stop the machine.

depress

Place gear shift lever (3) at the N (neutral) and set parking brake lever (4) at position, to apply the parking the PARKING position brake.

When sitting pull retarder the retarder.

A When

in the control

compartment, operator’s lever (5) fully to apply

leaving the machine, parking brake.

I

always apply the

-

1-61 -

Flum

/

OPERATING YOUR MACHINE

Emergency stop If the service as follows.

1. Pull retarder the retarder.

brake fails, stop the machine

control

lever

(I)

fully to apply

2. If operating the retarder lever alone does not give sufficient braking force, set emergency brake lever (2) to the APPLIED position to apply the emergency brake. * When emergency brake lever (2) is set to the APPLIED position, the parking brake is also automatically applied.

3. Move parking brake lever (3) to the right to the PARKING position.

When the machine stops, A the tires immediately.

put blocks under

* After making an emergency

stop, locate the cause and repair it on the spot as far as possible. * After making an emergency stop, adjust the parking brake again.

A

immediately after an emergency making stop, the parking brake discs are at a high temperature, so let them cool before carrying out any repair or adjustment.

-

1-62 -

OPERATING YOUR MACHINE

TO STOP THE ENGINE Allow the engine to cool down gradually before stopping it.

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

2. Return the key of starting switch OFF position and remove the key.

(1) to the OFF ;% ‘“i 2 mx14,

*

t

If the engine is abruptly stopped before it has cooled down, engine life may be greatly do not abruptly Consequently, shortened. 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.

-

l-63 -

BRAKE PERFORMANCE GRAPH

BRAKE PERFORMANCE GRAPH l Way of viewing graph Example Downhill distance: 1500 m Travel resistance: -11% Grade resistance: -13% Rolling resistance: 2% Payload: 46 ton Use the graph to obtain the maximum permitted speed and speed range when traveling downhill under the above conditions.

1. Use the brake performance curve for a downhill distance of 1500 m.

2. Pilot machine gross weight A in the graph and draw a line straight down from point A..

3. Find point B where the vertical line intersects the minus 11% travel resistance line, and draw a horizontal line from point B.

l

Brake performance (length of slope: 1506 m) (Standard tire 21 .OO-35)

iample

-1-64-

BRAKE PERFORMANCE GRAPH

line interFind point C where the horizontal Draw a line curve. sects the performance straight down from point C, and find point D where the vertical line intersects the machine speed scale line. the following process, the above Through values can be obtained. permissible D, the maximum point From speed is 26.8 km/h and from point C, the gear speed should be F4. permissible maximum for the This value speed is only a rough target value based on At the actual the retarder brake performance. the safe driving speed will jobsite, however, almost always be lower than the maximum speed because of the road condipermissible select a tions and other factors. Therefore, speed at which the retarder brake oil temperature gauge will be kept in the green range.

(length of slope: 450 m) Brake performance (Standard tire 21 .OO-35)

-

l-65 -

BRAKE PERFORMANCE GRAPH

0 Brake performance (length of slope: (Standard tire 21 .OO-35)

600 m)

0 Brake performance (length of slope: (Standard tire 21 .OO-35)

900 m)

BRAKE PERFORMANCE GRAPH

l

Brake performance (length of slope: (Standard tire 21 .OO-35)

0 Brake performance-(length (Standard tire 21 .OO-35)

of slope:

1500 m)

continuous)

6

-

l-67 -

BRAKE PERFORMANCE

GRAPH

0 Brake performance (length of slope: (Large size tire 24.00-35)

450 m)

0 Brake performance (length of slope: (Large size tire 24.00-35)

600 m)

-

l-68 -

BRAKE PERFORMANCE

l

Brake performance (length of slope: (Large size tire 24.00-35)

0 Brake performance (length of slope: (Large size tire 24.00-35)

900 m)

1500 m)

e

-

l-69 -

GRAPH

BRAKE PERFORMANCE GRAPH

l

Brake performance (length of slope: (Large size tire 24.00-35)

continuous)

-

I-70 -

PRECAUTIONS REGARDING TYPE OF LOAD

PRECAUTIONS REGARDING TYPE OF LOAD When using a large loader to load large rocks, if the rocks are loaded directly into the body, they may cause deformation of the body at that place. To avoid this problem, first load sand or soil to act as a cushion before loading the large rocks. This will reduce the shock when the rocks are loaded into the body.

When loading rocks that exceed the conditions given below, install the optional reinforced plate to the body.

0 Rocks where one side is longer than 0.5 m 0 Rocks above 4.5 on the Mohs’ scale of hardness 0 Rocks weighing more than 300 kg.

0 Trucks used for carrying steel ingots * For details of the types of dump body and procedure for selection, see “Selection of dump body”.

-

1-71 -

PRECAUTIONS FOR MACHINE OPERATION

PRECAUTIONS FOR MACHINE OPERATION It When traveling on roads during or after rain or snow, or when traveling in mud or soft ground, consider the condition of the dump truck load to prevent the tires from slipping or sinking into the ground. t When traveling on roads with curves, release the accelerator before the curve, shift down to as low a speed range as possible, then depress the accelerator again, to continue traveling. Do not travel at high speed and drift around curves. t When the engine stops during running of the machine, stop the machine immediately.

Move the gear shift lever to NEUTRAL and start the engine. * If the central warning lamp and the pilot lamps for the emergency warning items of the machine monitor start to flash and the buzzer sounds, immediately stop the machine and investigate the cause.

(For details, see “TROUBLE SHOOTING GUIDE�.) t When loading the machine, take care to distribute the load evenly over the entire dump body. Do not overload the front section of the dump body. dumping, always A When instructions of a signalman.

following

the

* When traveling, the angle of the steering wheel may change (the position of the spokes varies slightly), but this is not a failure. * If the steering wheel is forced when the tires are already turned fully to the left or right, the steering wheel will turn a little at a time, but this is not a failure. * Do not continue to force the steering wheel when it has already been turned fully to the left or right. It will cause the temperature of the oil in the circuit to rise, and this will result in overheating.

-

l-72 -

PRECAUTIONS

*

t

After driving through water, the water may have got into the front brakes, thereby causing an extreme drop in braking capacity, so be extremely careful. In such cases, apply the brake several times to dry the pad and disc with friction heat while driving.

If any emergency occurs, such as brake failure, pull the retarder brake fully and apply the emergency brake. When the machine stops, immediately put blocks under the tires.

-

I.-73 -

FOR MACHNE

OPERATION

MEMO

-

1-74 -

MAINTENANCE PRECAUTIONS FOR MAINTENANCE .........................................

OIL FILLER AND LEVEL GAUGE POSITIONS ..................................

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

CHECK BEFORE STARTING ...............................................

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

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

EVERY 1000 HOURS SERVICE .............................................

EVERY 2000 HOURS SERVICE .............................................

EVERY 4000 HOURS SERVICE .............................................

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

ADJUSTMENT ..............................................................

PERIODICAL REPLACEMENT OF SAFETY PARTS .............................

-

2-l -

2- 2 2-10 2-l 2 2-17 2-29 2-38 2-43 2-49 2-54 2-55 2-64 2-68

I

PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS FOR MAINTENANCE

A For safety

when carrying out maintenance.

Even simple operations, if carried out carelessly, can be the cause of injuries. At least the following points should be followed, but safety should always be borne in mind when carrying out anv ooeration.

Wear a well-fitting hard hat, safety shoes and working clothes. If the nature of the work so. requires, wear protective goggles, gloves or other protection.

Never wear loose or unbuttoned clothes as they may catch on protruding parts of the machine.

Never wear clothes covered in oil.

Unless you have special instructions to the contrary, maintenance should always be carried out with the engine stopped. If maintenance is carried out with the engine running, there must be two men present: one sitting in the operator’s seat and the other one performing the maintenance.

Both should confirm the operation is safe.

The body should always be lowered before carrying out any maintenance.

However, if the nature of the maintenance requires the dump body to be raised for inspection or maintenance, always use the safety pin, and lock the dump lever in the HOLD position.

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2-2 -

PRECAUTIONS FOR MAINTENANCE

on firm, flat ground Park the maintenance and lower the dump body. Stop the engine, return the gear shift lever to NEUTRAL and out apply the parking brake before carrying the maintenance.

with others, choose a group When working and work leader, decide the work procedure Check to the leader’s instructions. according Do before doing anything. with the others and do warning not move any part without the beyond any maintenance not perform agreed work.

Always stop the engine machine or charging oil.

before

washing

the

of be used instead never should Flames lamps.

Never use a naked flame to check leaks or the level of oil, fuel, antifreeze or electrolyte. gas is given off by batHighly inflammable teries.

Do not smoke, make sparks or bring naked flames near the battery. Never check whether the battery is charged by striking the terminal with metal.

During charging, gas is given off. To prevent make sure there is good it from collecting, do not allow sparks In addition, ventilation. or flames near the battery. Never smoke or allow naked flames near when handling fuel or oil.

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2-3 -

PRECAUTIONS FOR MAINTENANCE

Never inspect the fan belt or attempt any maintenance when the engine is running.

Always stop the engine before carrying out maintenance on this or other moving parts, or near any moving parts.

When working under the machine, hang a caution sign in the operator’s compartment, and if necessary, also put signs around the machine.

Do not remove the radiator cap when the water is hot. There is danger that boiling water may spurt out. First release the internal pressure before removing the cap.

When carrying out maintenance, pay careful attention to persons in the vicinity. In particular, do not allow anyone to approach the machine unnecessarily.

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2-4 -

CJ Servicing

PRECAUTIONS

FOR MAINTENANCE

Always remember that the hydrau!ic oil circuit is under pressure. When filling or draining the oil tank or carrying out inspection and maintenance, release the pressure first.

When carrying out maintenance, pay careful attention to other workers and persons in the vicinity. Care is particularly needed when grinding, welding, or swinging a sledge hammer.

When working on top of the machine, be careful not to lose your balance and fall.

Arrange things beforehand so that no one starts the engine or moves the machine by mistake.

Immediately floor of the the handrail. slips on floor

remove any oil or grease on the operator’s compartment, or on It is very dangerous if someone plates.

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2-5 -

\

/ Oil.

\.

PRECAUTIONS FOR MAINTENANCE

0 If air gets into the hydraulic brake line, the brakes will not work properly.

In such cases bleed all the air from the circuit. If the air pressure in the air brake line drops, the brakes will not work.

Check for leaks in the air circuit, and if any faults are found, repair them.

l

When leaning over to inspect cases, there is a risk of dropping things in. Before removing the covers to inspect such cases, empty everying from your pockets.

Be particularly careful to remove wrenches and nuts.

Precautions when changing tires 0 When replacing the tires, please contact your Komatsu distributor.

It is dangerous to jack up the machine without taking due care.

0 Always block the wheels on the opposite side before jacking up the machine.

After jacking up the machine, always insert blocks under the machine to prevent it from falling.

l

Do not loosen or remove any part except those needed to be removed when taking off the tire. The tire is under high pressure, so it is extremely dangerous to loosen anything carelessly. In particular, repair of tires should be left to the tire manufacture’s dealer.

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2-6 -

PRECAUTIONS

GENERAL POINTS TO BE BORNE IN MIND WHEN CARRYING OUT MAINTENANCE In particular, wash the machine.

0 Thoroughly be careful to clean the filler caps, grease fittings and the area around the dipsticks. Be careful not to let any dirt or dust into the system. use always the parts, replacing 0 When genuine Komatsu parts specified in the Parts Book. of grease and oil use the grades 0 Always Choose the visby Komatsu. recommended cosity specified for the ambient temperature.

0 Always use pure oil or grease, and be sure to prevent any dirt to use clean containers, from getting in.

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

0 Before draining the oil, warm it up to a temperature of 20 to 40X. the racareful when removing 0 Be paticularly diator cap or the hydraulic oil tank filler cap. or cleaning the oil filter ele0 After replacing ment or strainer, bleed the air from the circuit.

0 When the strainer is located in the oil filler, the strainer must not be removed while adding oil.

0 There should be neither too much nor too When adding oil or checking little lubricant. the oil level, check that the oil is at the correct level. up, always wipe off the old 0 After greasing grease that was forced out. the oil or filter, check the 0 When changing drained oil and filter for any signs of excesmaterisive metal particles or other foreign als.

O-rings, containing parts removing 0 When surface gaskets or seals, clean the mounting and replace with new sealing parts.

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2-7 -

FOR MAINTENANCE

PRECAUTIONS FOR MAINTENANCE

0 Special measuring apparatus is needed for testing hydraulic pressure. When carrying out other difficult maintenance work, carrying them out carelessly can cause unexpected accidents. If you consider the maintenance is too difficult, always request your Komatsu distributor to carry out it.

0 Bleed the air from the hydraulic brake line.

If there is air in the hydraulic brake line, the braking effect will be poor.

0 If this happens, bleed the air fully from the circuit.

Check the air circuit for any leakage of air, and repair if any defect is found.

0 When welding, be careful of the followng: 1) Turn OFF the power (starting switch).

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

4) Do not insert any seal or bearing between the weld and ground.

0 Greasing the rod end Because the rod end is of the oilless type, no greasing is required, although a grease nipple is fit to the rod end on the lever linkage.

The rod end should be greased only when it becomes stiff after using it for a long span of time.

0 When installing car radio and a waklie-talkie or citizen band, contact your Komatsu distributor.

0 When washing the machine, take care not to splash water over the electrical equipment. If it is soaked with water, it may not operate normally.

0 Do not direct the steam jet directly at any mechatronic parts or connectors.

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2-8 -

PRECAUTIONS

STANDARD TIGHTENING TORQUE 06 BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of “MAINTENANCE”.

Thread diameter of bolt (mm) (a) 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39

Width across fiat (mm) (b) 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Nm

kSm 1.35 f 0.15 3.2 f 0.3 6.7 f 0.7 11.5 f 1.0 18.0 f 2.0 28.5 f 3 39 f 3 56 f 6 76 f 8 94.5 f 10 135 f 15 175;20 225 f 25 280 f 30 335 f 35

13.2 31.4 65.7 112 177 279 383 549 745 927 1320 1720 2210 2750 3280

f 1.4 f 2.9 f 6.8 f 9.8 f 19 k 29 f 39 f 58 f 78 f 98 f 140 I190 f 240 f 290 f 340

* The tightening torque is determined by the width across the flats (b) of the nut and bolt. t 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.

This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or which require tightening to otherwise specified torque. * Nm (newton meter): INm + 0.1 kgm

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2-9 -

FOR MAINTENANCE

OIL FILLER AND LEVEL GAUGE POSITIONS

OIL FILLER AND LEVEL GAUGE POSITIONS 1. Fuel tank oil filler 2. Fuel tank level gauge 3. Fuel tank drain valve 4. Final drive case drain plug 5. Final drive case oil filler 6. Differential case drain plug 7. Differential case oil filler

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OIL FILLER AND LEVEL GAUGE POSITIONS

8.

9.

IO. 11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

Front brake oil tank level gauge and oil filler Transmission case oil filler Rear brake cooling oil tank oil filler Rear brake cooling oil tank level gauge Steering, hoist oil tank oil filler Rear brake cooling oil tank drain plug Transmission case level gauge Steering, hoist oil tank drain plug Steering, hoist oil tank level gauge Transmission case drain plug Engine oil pan oil filler and level gauge Engine oil pan drain plug Radiator drain valve Radiator water inlet Sub-tank water level gauge Sub-tank water inlet

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2-11 -

MAINTENANCE TABLE

MAINTENANCE

TABLE

No.

ITEM

SERVICE

PAGE

CHECK BEFORE STARTING a

Cooling water

Check and supply

2-17

b

Front brake oil tank

Check and supply

2-17

C

Dust indicator

Check

2-17

d

Air tank

Drain water

2-18

e

Transmission

Check and supply

2-18

f

Engine oil pan

Check and supply

2-19

9

Steering

Check and supply

2-20

h

Rear brake cooling

Check and supply

2-20 2-20

case

and hoist oil tank oil tank

i

Fuel tank

Drain water sediments

j

Fuel

Check and supply

2-21

k

Wheel hub nuts

Check and retighten

2-21

I

Tires

Check inflation pressure and damage

2-22

Check

2-22

Check

2-23

lamp

and

m

Central warning

n

Machine

0

Service

brake

Check action

2-25

P

Service

brake

Check capacity

2-25

o

Retarder

Check action

2-25

r

Retarder

Check capacity

2-25

S

Parking brake

Check action

2-26

t

Parking brake

Check capacity

2-26

U

Emergency

brake

Check action

2-26

V

Emergency

brake

Check capacity

2-26

W

Emergency

steering

Check function

2-27

X

Steering

Check function

2-27

warning

device

system

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2-12 -

MAINTENANCE

No.

TABLE

SERVICE

ITEM Check

2-27

Lamps

Check

2-27

a’

Horn

Check

2-27

b’

Gauges

Check

2-27

C’

Exhaust gas and color

Check

2-27

d’

Body mount

Check

2-27

e’

Electric wiring

Check

2-27

f

Wter a

Check

2-28

Y

Rear and under-view

z

mirror

rubber

separator

EVERY 250 HOURS SERVICE (The items marked

* are carried

out after the first 250 hours

only for new machines.)

*

Fuel filter

*

Transmission

*

Transmission

*

Steering, hoist oil tank and rear brake cooling oil tank filters

*

Steering

*

Brake cooling

*

Final drive case

*

Differential

*

Engine valve clearance

a

Lubricating

-1

Dump body hinge pin

Lubricate

2 points

2-29

-2

Rear suspension

Lubricate

4 points

2-29

-3

Differential

Lubricate

8 points

Z-30

-4

Hoist cylinder

Lubricate

4 points

Z-30

Replace cartridge

2-29

filter

Replace element

2-29

case

Change oil and clean strainer

2-29

Replace elements

2-29

and hoist oil tank

Change oil

2-29

oil tank

Change oil

2-29

Change oil

2-29

Change oil

2-29

Check and adjust

2-29

case

2-29

support pin

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2-13 -

MAINTENANCE TABLE

No.

ITEM (EVERY 250 HOURS SERVICE)

-5

Front suspension

Lubricate 2 points

2-30

-6

Steering cylinder pin

Lubricate 4 points

2-30

-7

Steering link pin

Lubricate 5 points

2-30

-8

Steering linkage

Lubricate 6 points

2-30

-9

Drive shaft

Lubricate 4 points

2-31

b

Breathers

Clean

2-31

C

Drive shaft

Check

2-32

d

Differential case

Check and supply

2-32

e

Final drive case

Check and supply

2-32

f

Engine oil pan and filter

Change oil and replace cartridge

2-32

g

Main frame

Check

2-34

h

Alternator belt

Check tension

2-34

i

Air conditioner compressor belt

Check tension

2-35

j

Battery electrolyte

Check fluid level

2-36

k

Parking brake

Check clearance

2-36

I

Automatic suspension

Check and clean

2-37

EVERY 500 HOURS SERVICE a

Transmission filter

Replace element

2-38

b

Fuel filter

Replace cartridge

2-39

C

Front disc brake

Check and replace pad

2-40

d

Radiator fins

Check and clean

2-41

e

Fan belt

Check and replace

2-41

f

Ether spray

Check

2-42

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2-14 -

MAINTENANCE

No.

ITEM

SERVICE

TABLE

PAGE

EVERY 1000 HOURS SERVICE a

Lubricating

-1

Transmission mount

Lubricate 1 point

2-43

-2

Automatic suspension link

Lubricate 1 point

2-43

-3

Parking brake linkage

Lubricate 3 points

2-43

-4

Accelerator control link

Lubricate 2 points

2-43

-5

Dump control link

Lubricate 2 points

2-44

-6

Tension pulley and fan pulley

Lubricate 3 points

2-44

b

Transmission case

Change oil and clean strainer

2-44

C

Steering, hoist oil tank and rear brake cooling oil tank filters

Replace elements

2-45

d

Corrosion resistor

Replace cartridge

2-45

e

Rear brake disc

Check wear

2-46

f

Turbocharger various fasteners

Check and retighten

2-47

g

Turbocharger

Check play

2-48

2-43

rotor

EVERY 2000 HOURS SERVICE a

Steering and hoist oil tank

Change oil

2-49

b

Rear brake cooling oil tank

Change oil

2-50

C

Final drive case

Change oil

2-50

d

Differential case

Change oil

2-51

e

Turbocharger

Check and clean

2-51

f

Engine breather

Clean

2-52

9

Emergency relay valve

Clean

2-52

h

Differential case breather

Clean

2-52

i

Alternator and starting motor

Check

2-53

j

Safety parts

Replace

2-53

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2-15 -

MAINTENANCE

TABLE

(EVERY 2000 HOURS SERVICE) k

Engine valve clearance

Check

2-53

EVERY 4000 HOURS SERVICE a

Water pump

Check

2-54

b

Safety parts

Replace

2-54

C

Air compressor

Check

2-54

d

Fan pulley and tension pulley

Check

2-54

WHEN REQUIRED a

Cooling system

Clean

2-55

b

Air cleaner element

Check, clean or replace when required

2-59

C

Window washer fluid

Check and supply

2-61

d

Filter of air conditioner

Clean

2-61

e

Air conditioner

Check

2-62

f

Dump body

Check

2-62

g

Water separator

Drain water

2-63

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2-16 -

CHECK BEFORE STARTING

CHECK BEFORE STARTING a. CHECK COOLANT LEVEL Check that the water is between the FULL and LOW marks on reserve tank gauge (G).

If the water level is low, add more water through water filler (1). t If the volume of coolant added is more than usual, check for possible water leakage.

A

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

water

b. CHECK OIL LEVEL IN FRONT BRAKE OIL TANK Check that the oil level is between the FULL and LOW marks on sight gauge (G).

If the oil level is low, add engine oil through oil filler (F). t If oil decreases after added, check for oil leak from oil line. * The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL, COOLANT AND LUBRICANTS”. c. CHECK DUST INDICATOR When the air cleaner element is clogged, the red piston of dust indicator (1) reaches service level and gets locked.

In that case, clean or replacing the element referring to the section “WHEN REQUIED”.

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2-17 -

CHECK BEFORE STARTING

d. DRAIN WATER FROM AIR TANK After starting the engine, pull ring (1) of the tank drain valve to drain the water. Do this after completing work. that the is danger there t In cold weather, operwater will freeze, so after completing ations, always drain the air tank while it is still warm.

CASE e. CHECK OIL LEVEL IN TRANSMISSION Run the engine at low idling and check with level gauge (G.J. Add oil through oil filler (F) if oil level is low.

The oil level differs according to the oil temperature, so check the oil level after completion of warming up the engine. after operor immediately During operations may go idling the oil level when ations, above (GJ. check As a guideline, to level gauge (G,) gine.

The type of lubricant ambient temperature. table “FUEL, COOLANT

that the oil level is up the enbefore starting used depends on the Select according to the AND LUBRICANTS�.

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2-18 -

CHECK BEFORE STARTING.

f. CHECK OIL LEVEL AND REFILL IN ENGINE OIL PAN 1. Use dipstick (G) to check the oil level.

2. The oil level should be between mark L and H, if necessary, add oil from oil filler (F). t When checking the oil level, park the machine on a level surface. + When checking the oil level with the engine stopped, wait for at least 15 minutes after stopping the engine before checking the level. * The type of lubricant used depends on the ambient temperature.

Select according to the table “FUEL, COOLANT AND LUBRICANTS”. * After adding oil, securely tighten the handle of the filler cap. * The dipstick is marked with the levels for ENGINE STOPPED on one side and ENGINE IDLING on the other side. * When measuring the oil level with the engine stopped, use the marks on the ENGINE STOPPED side.

It is also possible to check the oil level with the engine idling, but be sure to remember the following points.

0 Check that the engine water temperature gauge shows green range.

0 Read the dipstick on its reverse side marked with “ENGINE IDLING”.

0 Remove the oil filler cap.

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2-19 -

‘6iiECK BEFORE STARTING

g. CHECK OIL LEVEL IN STEERING AND HOIST OIL TANK 1. Check with sight gauge (G).

2. If the oil level is not up to the window of gauge (G), add engine oil through oil filler (F). * When checking the levels, stop the machine on flat ground, lower the dump body, and stop the engine before checking. * The type of lubricant used depends on the ambient temperature.

Select according to the table “FUEL, COOLANT AND LUBRICANTS”.

A When slowly

removing the oil filler to relieve inner pressure.

cap,

turn

it

h. CHECK OIL LEVEL IN REAR BRAKE COOLING OIL TANK 1. Check with sight gauge (G).

2. If the oil level is not up to the window of gauge (G), add engine oil through oil filler (F).

* When

checking the levels, stop the machine on flat ground, lower the dump body, and stop the engine before checking. * The type of lubricant used depends on the ambient temperature.

Select according to the table “FUEL, COOLANT AND LUBRICANTS”.

A When slowly

removing the oil filler to relieve inner pressure.

i. DRAIN WATER AND TANK Loosen drain valve fuel tank, and drain collected at the bottom

SEDIMENT

cap,

turn

it

FROM FUEL

(1) at the bottom of the the water and sediment together with the fuel.

-

2-20 -

CHECK BEFORE STARTING

j. CHECK FUEL LEVEL Check fuel level with fuel gauge or sight gauge (G). At the end of a day’s job, be sure to refill fuel from filler (F) so that fuel tank will be filled. * When adding fuel, never let the fuel overflow. This may cause a fire. * Fuel capacity: 780 Q

*

If breather hole (1) in the cap is blocked up, fuel flow to the engine may stop. Accordingly, clean it from time to time.

k. CHECK WHEEL HUB NUTS FOR TIGHTNESS Check that the hub nuts are properly tightened.

If they are loose, retighten to the specified torque by repeating three or four tightening cycles in the order shown in the drawing. * Tightening torque 135 it 15 kgm (when threaded portions are not coated with molybdenum disulphide grease) 94.5 k 10.5 kgm (when threaded portions are coated with molybdenum disulphide grease) *

Fit a socket wrench to a pipe, and apply a force of 135 kg at a point 1 m from the fulcrum. This will give a tightening torque of 135 kgm.

-

2-21 -

Front

CHECK BEFORE STARTING

When a wheel has been remounted, as after tire replacement, tighten the hub nuts once again after running for 5 or 6 kilometers.

Compared with the front wheels, the rear wheels take longer for the contact surfaces to fit well with each other. Repeat retightening the hub nuts until about 50 hours after replacing the wheels.

However, on the rear wheels, there are also hub nuts on the inside (3 places), but these are for temporarily assembling, so after tightening the outside nuts, it is not necessary to tighten the inside hub nuts.

CHECK TIRES FOR INFLATION PRESSURE AND DAMAGE Check the air pressure before starting work, when they are cold. Also inspect tire surfaces for cuts, hollows, sticking nails or pieces of metal that might lead to puncture.

Standard air pressure 5.0 kg/cm* 21 .OO-35-32PR: 5.5 kg/cm* 21 .OO-35-36PR: 4.5 kg/cm* 24.00-35-36PR:

m.CHECK CENTRAL WARNING LAMP Check for any broken bulb in central warning lamp (1). To prevent any inability to give warning because of defective operation of the buzzer, carry out the following check. l Stop the engine, place the starting switch in ON and the parking brake valve lever in BRAKE, and the gear shift lever in any position other than NEUTRAL. If the lamp flashes, it is normal. l Place the starting switch key in ON when air pressure is below the specified value.

If the lamp flashes and the buzzer sounds, they are normal.

-

2-22 -

CHECK BEFORE STARTING

n. CHECK MACHINE WARNING DEVICE With the starting switch at the ON position (engine stopped), check the following items, Check for blown lamp bulbs (CHECK BEFORE STARTING).

Push caution, pilot lamp bulb check switch (1). The caution, pilot lamps (2) x 12 and the central warning lamp will light up.

If any lamp does not light up, the bulb is probably broken, so replace the bulb.

If it still does not light up even when the bulb is changed, there is probably some failure or disconnection, so contact your Komatsu distributor.

When recognizing abnormality in warning device, functional check should be carried out as follows: Check air pressure detection circuit If the pressure in the air reservoir drops below the specified pressure (5.2 kg/cm2), the pilot lamp and central warning lamp light up and the buzzer sounds.

When the pressure goes above 5.2 kg/cm2, the lamps go out and the buzzer stops.

Check radiator coolant level detection circuit Drain the cooling water a little at a time from the radiator lower tank. When the specified amount is drained, the water level pilot lamp and central warning lamp light up and the buzzer sounds.

Check engine cooling water temperature detection circuit Remove the wiring from the engine cooling water temperature sensor and connect that part to the chassis ground. The pilot lamp and central warning lamp light up and the buzzer sounds.

-

2-23 -

CHECK BEFORE STARTING

5. Check engine oil pressure detection circuit Turn the starting switch to the ON position with the engine stopped. The pilot lamp and central warning lamp light up and the buzzer sounds.

When the engine starts, the lamps go out and the buzzer stops. oil temperature converter torque 6. Check detection circuit Remove the wiring from the torque converter oil temperature sensor and connect that part to the chassis ground. The pilot lamp and central warning lamp light up and the buzzer sounds. detection 7. Check rear brake oil temperature circuit Remove the wiring from the rear brake oil temperature sensor and connect that part to the chassis ground. The pilot lamp and central warning lamp light up and the buzzer sounds.

8. Check transmission oil filter element clogging caution circuit Remove the wiring from the filter element oil pressure sensor and connect that part to the chassis ground. The pilot lamp and central buzzer light up and the lamp warning sounds.

(Actuating pressure 2.8 kg/cm2) 9. Check parking brake caution circuit If the parking brake valve is at the PARKING position and the transmission shift lever is at any position other than N (neutral), the pilot lamp and central warning lamp light up and the buzzer sounds.

If the parking brake valve is placed at the shift TRAVEL position or the transmission lever is returned to the N (neutral) position, the lamps go out and the buzzer stops. This system is to prevent seizure of the parking brake.

-

2-24 -

CHECK BEFORE STARTING

o. CHECK BRAKING ACTION OF SERVICE BRAKE Carry out checks before starting, and if the effect of the brakes is poor, adjust the brakes.

For details, see “Adjustment”. p. CHECK BRAKING CAPACITY OF SERVICE BRAKE Check the capacity of the service brake as follows.

1. Raise the air pressure to the maximum, stop the machine on level ground and depress brake pedal (1).

2. Place gear shift lever (2) in the “D” position, gradually increase the engine speed, and check that the machine does not move even when the engine speed reaches 1850 rpm. g. CHECK BRAKING ACTION OF RETARDER Carry out check before starting. r. CHECK BRAKING CAPACITY OF RETARDER Check the capacity of the retarder as follows.

1. Raise the air pressure to the maximum, stop the machine on level ground and pull retarder lever (1) fully.

2. Place gear shift lever (2) in the “D” position, gradually increase the engine speed, and check that the machine does not move even when the engine speed reaches 1320 rpm.

-

2-25 -

CHECK BEFORE STARTING

s. CHECK BRAKING ACTION

BRAKE Check after completing

OF PARKING

work.

t. CHECK BRAKING CAPACITY OF PARKING BRAKE Check the capacity of the parking brake as follows.

1. Raise the air pressure to the maximum, stop the machine on level ground and place parking brake lever (1) in the PARKING position.

2. Place gear shift lever (2) in the “D” position, gradually increase the engine speed, and check that the machine does not move even when the engine speed reaches 1430 rpm.

U.

IS BRAKING OPERATION OF EMERGENCY BRAKE NORMAL? Carry out checks before starting.

V.

CHECK BRAKE CAPACITY OF EMERGENCY BRAKE Check the brake capacity of the emergency brake as follows.

1. Raise the air pressure to the maximum, and operate emergency brake lever (1) on flat ground.

2. Place gear shift lever (2) in the D position, gradually raise the engine speed, and check that he machine does not move even when the engine is at full throttle.

-

2-26 -

CHECK BEFORE STARTING

w. CHECK EMERGENCY STEERING 1. Turn the key of the starting switch to the ON position. steering switch (1) ON, and 2. Turn emergency check that the steering can be turned for 20 t

seconds. cannot wheel If the steering contact your Komatsu distributor.

be

operated,

x. CHECK THAT THE STEERING SYSTEM WORKS PROPERLY y. CHECK THAT THE REAR AND UNDER-VIEW MIRRORS ARE WELL ADJUSTED z. CHECK THAT ALL LIGHTS WORK PROPERLY a’. CHECK THE HORN b’.CHECK THAT THE GAUGES FUNCTION PROPERLY IN OPERATION c’. CHECK THAT ENGINE EKHAUST GAS COLOR AND SOUND ARE NORMAL d’.CHECK BODY MOUNT RUBBER materials, or Check cracks, bitting unexpected tightening

of bolts.

e’. CHECK ELECTRICAL WIRING Check for damage of the fuse and any sign or short circuit in the electric of disconnection and tighwiring. Check also for loose terminals ten any loose parts.

Check the following points carefully.

0 Battery 0 Starting motor 0 Alternator fuse is damaged A ofIf theshortcircuiting in always investigate *

or there is any sign wiring, the electric the cause and correct it.

distributor Please contact your Komatsu and correction of the cause. investigation

-

2-27 -

for

1

CHECK BEFORE STARTING

f’. CHECK FOR SEDIMENT AND WATER IN WATER SEPARATOR The water separator separates water mixed in the fuel. If float (2) is at or above red line (I), drain the water. For the draining procedure, refer to section “WHEN REQUIRED”. * Even if a water separator is installed, be sure to check the fuel tank to remove water and sediment in the fuel.

-

2-28 -

EVERY 250 HOURS SERVICE

EVERY 250 HOURS SERVICE only after Carry out the following maintenance the first 250 hours. . FUEL FILTER, REPLACE CARTRIDGE FILTER, REPLACE ELEMENT . TRANSMISSION CASE, CHANGE OIL AND . TRANSMISSION CLEAN STRAINER . STEERING, HOIST OIL TANK AND REAR BRAKE COOLING OIL TANK FILTERS, REPLACE ELEMENTS . STEERING AND HOIST OIL TANK, CHANGE OIL . BRAKE COOLING OIL TANK, CHANGE OIL . FINAL DRIVE CASE, CHANGE OIL . DIFFERENTIAL CASE, CHANGE OIL . ENGINE VALVE CLEARANCE, CHECK AND ADJUST For details of method of replacing or maintaining, see the section on EVERY 500 HOURS, 1000 HOURS AND 2000 HOURS SERVICE. a. LUBRICATING Apply grease to the grease fittings shown by arrows. * Carry out greasing every day for operations in places where the grease is likely to flow out, such as when traveling on muddy or wet ground. (each 1 point) 1. Dump body hinge pin

2. Rear suspension

(each 2 points)

-

2-29 -

EVERY 250 HOURS

SERVICE

3. Differential support

(each 4 points)

4. Hoist cylinder pin

(each 2 points)

5. Front suspension

(each 1 point)

6. Steering cylinder pin 7. Steering link pin

8. Steering linkage

(4 points) (5 points)

(each 3 points)

-

2-30 -

EVERY 250 HOURS SERVICE

(4 ponts)

9. Drive shaft *

Supply grease grease comes places).

to the spider out from the

portion until cap seal (4

b. BREATHERS Remove all the dirt and mud from around the breathers, then remove the breather and wash it in clean diesel or flushing oil to flush out the dirt from inside.

Transmission case

Hydraulic tank Remove nut (1) of the breather and cover (2), and clean element (3).

Install element (3), then install cover (2) and nut (1).

-

2-31 -

EVERY 250 HOURS

SERVICE

c. DRIVE SHAFT Check the drive shaft for any abnormality such as loose joints, worn splines or bearing, unusual vibration of the shaft, etc. If any, have the shaft serviced by a Komatsu distributor.

d. DIFFERENTIAL CASE Remove plug (G) and check the oil level. If the oil level is not at or near the lower end of the plug hole, refill engine oil through the plug hole. * The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL, COOLANT AND LUBRICANTS”. e. FINAL DRIVE CASE 1. Stop the machine so that casting line (1) is horizontal and drain plug (P) is at the bottom.

Remove plug (G) and check for the oil level.

If the oil level is not near the lower edge of the plug hole, add engine oil through the same plug hole.

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

ENGINE OIL PAN AND FILTER Remove drain plug (1) and loosen drain valve (2) to drain the oil. After draining, tighten drain valve (2) and drain plug (1).

Take care not to rotate drain valve (2) so much that the stopper pin in the valve is distorted.

Tightening torque kgm 7fl drain plug (1): drain valve (2): 6.5 k 1.5 kgm

-

2-32 -

/

1

EVERY 250 HOURS SERVICE-

2. Using a filter wrench, remove filter cartridge (3) by turning it counterclockwise. t If filter cartridge (3) is removed immediately after stopping the engine, oil will spill. Wait at least 10 minutes after stopping the engine before replacing the filter cartridge.

3. Clean the filter holder, coat the seal and thread of the new filter cartridge with engine oil (a thin coat of grease is also possible), then install the cartridge. * When installing, go prevent overtightening, screw in until the seal surface contacts the filter holder, then tighten a further 3/4 to 1 of a turn.

4. Add engine oil to the specified level through oil filler (F).

5. Idle the engine for a while and check the oil level. For details, refer to section CHECK BEFORE STARTING. * Refill capacity: 61 II It The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL, COOLANT AND LUBRICANTS�. t Use a genuine Komatsu filter cartridge. * Replace these parts once every six months regardless of the hours of service.

-

2-33 -

EVERY 250 HOURS SERVICE

9 MAIN FRAME 1. Clean the frame and make it easy to check.

2. Check all parts of the frame for damage.

In particular, check the shaded area in the diagram, and carry out repairs if any cracks or other damage are found.

For details of the repair procedure, contact your Komatsu distributor. h. ALTERNATOR BELT Checking The belt tension should normally deflect by about 15 mm when pressed with your thumb at a point midway between the alternator pulley and the drive pulley (approx. 6 kg).

Alternator pulley

Drive pulley

Adjustment To adjust the belt tension, loosen bolt and (2) and shift alternator (3) slightly.

After adjustment, tighten bolt (1) and nut securely.

Check for pulley damage, wear of the V-groove and V-belt, and especially that the V-belt is not in contact with the bottom of the V-groove.

Replace the belt if it stretched beyond the point of adjustment or if it has cuts or fissures.

When adjusting the V-belt, do not attempt to push alternator (3) directly with a bar or the like, but use a wood pad to prevent damage to the core.

When the belt has been replaced, adjust it again after operating for one hour.

-

2-34 -

EVERY 250 HOURS

i. AIR CONDITIONER COMPRESSOR BELT Checking The belt tension should normally deflect by about 10 mm when pressed with your thumb at a point midway between the compressor pulley and the drive pulley (approx 6 kg).

Adjustment When adjusting, loosen bolt (1) and locknut (3), then turn adjustment bolt (2) to adjust.

After adjusting, tighten locknut (3) and bolt (I). of the wear Check for pulley damage, V-groove and V-belt, and especially that the V-belt is not in contact with the bottom of the V-groove.

Replace the belt if it has stretched beyond the point of adjustment or if it has cuts or fissures.

New belts will stretch during the first period after they are installed, so adjust again after 2 or 3 days of operation.

-

2-35 -

SERVICE

EVERY 250 HOURS SERVICE

BATTERY ELECTROLYTE Remove hook (I), then open inspection cover

(2).

Remove cap (3) and check the electrolyte level.

If the electrolyte level is less than 10 to 12 mm above the battery plates, add distilled water to the battery.

Should any of the acid be spilt, have it replenished by the nearest battery shop with acid of the correct specific gravity.

When inspecting electrolyte level, clean the air hole of the battery cap. avoid A To sparks

gas explosions, near the battery.

do not bring fire or

If the A clothes,

electrolyte gets on your skin immediately wash with plenty clean water.

or of

k. PARKING BRAKE Measure the thickness of pad, and if the thickness is less than 1.5 mm, contact your Komatsu distributor.

A Take

care not to stain the brake the disc surface with oil or grease.

-

pad and

2-36 -

1.5 m/m

(wear limit)

.., EVERY 250 HOURS

SERVICE

I. AUTOMATIC SUSPENSION 1. Remove cover (1).

2. Check the position of the link.

When the machine is empty, it is normally at SOFT. Check that it moves to MEDIUM when the brake pedal depressed, and to HARD when the dump lever is at any position other than FLOAT. * If any abnormality is found, contact your Komatsu distributor for inspection and adjustment. * When working on muddy or wet ground, if mud sticks to the link, the response will become slower, so check and clean.

-

2-37 -

SOFT

F10218

EVERY 500 HOURS

SERVICE

EVERY 500 HOURS SERVICE *

Maintenance for every 250 hours should carried out at the same time.

be

a. TRANSMISSION OIL FILTER 1. Remove drain plug (1) at the bottom of the filter case, and drain the oil. After draining the oil, tighten the plug.

2. Hold case (2) and loosen center bolt (3), then remove case (2).

3. Remove the element, and clean the inside of the case. Assemble a new element, then install the case. t Be careful not to apply excessive torque to center bolt (3).

15.5 f 1.5 kgm Tightening torque: 4. Run the engine for a short time at idling speed, then stop the engine. Check that the oil is at the specified level (for details, see CHECK BEFORE STARTING.) * Use a genuine Komatsu element. * Replace the filter gasket and O-rings with new parts. Coat the gasket and O-rings with clean engine oil before installing.

-

2-38 -

EVERY 500 HOURS SERVICE

b. FUEL FILTER 1. Close supply valve (1) of fuel tank.

2. Remove drain plug (P) and drain the fuel.

Using the filter wrench, remove filter cartridge (2) by rotating it counterclockwise.

3. Clean the filter head, coat the gasket surface of the new filter cartridge thinly with engine oil, and install.

4. To install cartridge, bring their heads into contact with gasket surface and then tighten cartridge II2 to 314 of a turn. * Use a genuine Komatsu filter cartridge.

5. After replacing the filter cartridge, open supply valve (1) of the fuel tank.

6. Loosen air bleed plug (3), then loosen knob (4) of the feed pump, and pump up and down until no more bubbles come out with the fuel from air bleed plug (3).

7. When no more bubbles come out, tighten air bleed plug (3) and knob (4). * After replacing the cartridge, start up the engine and check the filter seal face for possible oil leakage.

-

2-39 -

EVERY 500 HOURS SERVICE

FRONT DISC BRAKE PAD Insert an inspection gauge into wear inspection hole (1) of the caliper to inspect the wear.

If the stepped portion of the gauge contacts the caliper, the wear limit has been reached (remaining pad thickness: 3 mm), so replace the pad.

If the pad continues to be used after it has A reached the wear limit, there will not any be damage to the disc, but there will also be the danger that the brakes will not work.

Therefore, when the pad comes near to the wear limit, check more frequently and replace the pad at the correct time.

If the result of the inspection shows that the pad must be changed, please contact your Komatsu distributor.

The amount of pad wear is not necessarily be same for the left and right wheels, so always check both the left and right sides.

If any of the pads has reached the wear limit, always replace all eight pads.

When operating on muddy ground, mud sticks to the caliper or disc. If it is left in this condition, the wear of the pad will be accelerated, so wash the surrounding area carefully after work.

On jobsites A where the

where there is a lot of sand or foot brake is used frequently, carry out this check every 250 hours.

-

2-40 -

Pa Caliper (A) Near Wear Limit

B Wear Limit Replace Pads KIM9

EVERY 500 HOURS SERVICE

d. RADIATOR FINS If the radiator fins are clogged or bent, this may cause overheating, so clean or inspect, and ask for repairs to be made.

Clean the radiator fins with air, steam, or water, but be careful not to let the nozzle contact the fins.

Air pressure: Max. 10 kg/cm2 Steam pressure: Max. 4 kg/cm2 When washing the radiator, always direct air or steam at 90� to the radiator.

Also check rubber hose connections to radiator. If they have cracks or become fragile, replace with a new one. In addition, check hose clamp for loosening.

C-Correct

FAN BELT Check the V-belt and when the following conditions exist, exchange the V-belt: When the V-belt makes contact with the bottom of the groove in each pulley.

When the V-belt is worn, and its surface is lower than the outer diameter of the pulley.

When cracking and peeling of the V-belt occurs.

Replacement Exchange V-belt as follows: Insert a bar about 500 mm in length into the hole (I 18 mm) of the tension pulley bracket and pull forward strongly.

The spring tension loosens and the tension pulley moves inward, so remove the old belt.

In the same way, install a new belt.

When changing belts, do not only change one belt. Always change as a set.

-

2-41 -

1

EVERY 500 HOURS

SERVICE

f. ETHER SPRAY 1. Loosen wingnut der (2).

(I),

and remove

ether cylin-

2. Operate the quick start switch, and check the operation of the valve. * To prevent dirt from getting inside the valve, wipe all the dirt off from around the valve inlet port before removing the ether cylinder.

3. Remove tube (3) from atomizer (4).

4. Remove atomizer (4) from the intake air pipe.

5. Connect tube (3) and atomizer (4).

6. Operate the quick start switch and check that a fine mist of ether is sprayed out from each orifice of the atomizer.

7. After confirming that there is no abnormality, assemble in the original position.

If any abnormality is found, please contact your Komatsu distributor.

Never bring A spection.

,

any flame

close during

the in-

* This device is only used for starting the engine in cold weather. For details, see “Starting the engine in cold weather�.

-

2-42 -

EVERY 1000 HOURS

EVERY 1000 *

HOURS SERVICE

Maintenance for every 250 and 500 should be carried out at the same time.

hours

a. LUBRICATING Apply grease to the grease fittings shown by arrows.

1. Transmission mount

(1 point)

2. Automatic suspension link

(1 point)

3. Parking brake linkage

(3 points)

4. Accelerator control link

(2 points)

-

2-43 -

SERVICE

EVERY

1000

HOURS

5. Dump control

6. Tension t

SERVICE

link

pulley and fan pulley

(2 points)

(3 points)

Supply grease to the grease fittings grease comes out from the seal portion.

until

b. TRANSMISSION CASE 1. Remove drain plug (I), and loosen drain valve (2) to drain the oil. After draining the oil, tighten them.

Remove bolts (3) and cover, and take out strainers (4).

Clean the case interior and the strainers.

Replace the filter element in the transmission case. (Refer to EVERY 500 HOURS SERVICE.)

Pour in the specified amount of engine oil from oil filler (F).

Refill capacity: 69 P For the method of checking the oil level refer to section CHECK BEFORE STARTING. The type of lubricant used depends on the ambient temperature.

Select according to the table “FUEL, COOLANT AND LUBRICANTS�.

-2-44-

I

/

.i

EVERY

c. STEERING, HOIST OIL TANK AND REAR BRAKE COOLING OIL TANK FILTERS 1. Turn the cap of oil filler (F) slowly to release the internal pressure, then remove the cap.

2. Remove bolts (I), then remove cover (2).

3. Take out the element, and clean the removed parts and the inside of the case.

4. Install a new element, then tighten cover (2) with bolts (1).

A When

removing the cap, turn relieve inner pressure.

* t

it slowly

to

Be sure to use a genuine Komatsu cartridge.

If the filter element clogging caution lamp lights up when the engine water temperature is in the green range and the engine speed is 1200 - 2100 rpm, replace the element immediately.

d. CORROSION RESISTOR 1. Close the valve (1) on the upper side of corrosion resistor.

2. Using a filter wrench, remove cartridge (2) by turning counterclockwise.

3. Apply a dab of oil to the seal face of the new cartridge. t To install cartridge, put the seal face in contact with head, tighten it up about 213 of a turn. (Be careful not to apply excessive torque.)

5. After replacement, open valve (1) fully. * Be sure to use a genuine Komatsu cartridge.

-

2-45 -

1000

HOURS

SERVICE

EVERY 1000 HOURS

SERVICE

e.

REAR BRAKE DISC 1. Set the parking brake lever to the PARKING position, check that the other brakes are not applied, then inspect the brake wear.

Carry out A temperature

inspection when is below 60°C.

the

brake

oil

2. Remove air bleeding plug (1) of rear brake and insert disc wear gauge into the air bleeding valve.

3. Turn starting switch to “ON”, check air pressure gauge pointer indicates in green range.

4. When air pressure is low, run the engine as to keep 2000 rpm till the air pressure gauge indicates in the green range, then, run off the starting key to “OFF”.

5. At same time, pull retarder control lever to full stroke and push the wear gauge in till it contacts with the piston (See illustration). * When the retarder control lever is pulled, the rod will shoot out under hydraulic pressure, so support it by hand when carrying out this operation.

6. When mark (A) shown on the gauge passes through in the valve case, this means wear of disc is in the limit of wear.

In such a case, contact your Komatsu distributor for maintenance.

7. Tighten air bleeding plug (1).

8. Bleed the air thoroughly from the system.

For details, see ADJUSTMENT. If the disc wear is near the A carry out inspection frequently

service limit, regardless of

the service interval.

Check the retarder capacity carefully also.

-

2-46 -

EVERY

f. TURBOCHARGER VARIOUS FASTENERS Connect your Komatsu distributor for repairs, or check as follows.

Tighten if necessary. l V band of blower housing side 1.27 - 1.50 kgm Tightening torque: l V band of turbine housing side 1.27 - 1.50 kgm Tightening torque: l Mounting bolt for the exhaust manifold and turbine housing 4.5 - 5.5 kgm Tightening torque: l Turbocharger oil feed pipe (Inlet) 6.0 - 7.5 kgm Tightening torque: 0 Turbocharger oil feed pipe (Outlet) 6.0 - 7.5 kgm Tightening torque:

-2-47-

1000

HOURS

SERVICE

EVERY 1000 HOURS

SERVICE

g. TURBOCHARGER ROTOR PLAY Contact your Komatsu distributor ing, or proceed as follows:

for

check-

1. Axial play Check axial play by moving rotor in axial diStandard 0.028 - 0.25 mm rection.

2. Radial play Measure radial play by moving rotor holding both ends by hands in radial direction in parStandard 0.08 - 0.18 mm allel.

3. Press the shaft end at impeller side of the rotor blower in four radial directions (up. down, left and right), and confirm that there is a clearance. t If the play exceeds the allowable limit, ask Komatsu distributor for repair or replacement. t If the rotor is excessively soiled with dust or carbon or if any oil leakage caused by turbocharger trouble is noted, have the turbocharger repaired by your Komatsu distributor.

-

2-48 -

EVERY 2000 HOURS

EVERY 2000 HOURS SERVICE t

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

a. STEERING AND HOIST OIL TANK 1. Lower the dump body and stop the engine.

2. Turn the cap of oil filler (F) slowly to release the internal pressure, then remove the cap.

3. Remove drain plug (I), and loosen plug (2) to drain the oil. After draining the oil, tighten both plugs again.

4. Pour in the specified amount of engine oil from oil filler (F).

5. After adding the oil, check that the oil is at the specified level (for details, see CHECK BEFORE STARTING). t Refill capacity: 95 II * The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL, COOLANT AND LUBRICANTS”.

A When

removing the oil filler slowly to relieve inner pressure.

cap,

-2-49-

turn

it

SERVICE

EVERY 2000 HOURS

SERVICE

b. REAR BRAKE COOLING OIL TANK 1. Lower the dump body and stop the engine.

2. Turn the cap of oil filler (F) slowly to release the internal pressure, then remove the cap.

3. Remove drain plug (I), and loosen plug (2) to drain the oil. After draining the oil, tighten both plugs again.

4. Pour in the specified amount of engine oil from oil filler (F).

5. After adding the oil, check that the oil is at the specified level (for details, see CHECK BEFORE STATING.) * Refill capacity: 143 II * The type of lubricant used depends on the ambient temperature.

Select according to the table “FUEL, COOLANT AND LUBRICANTS”.

A When

removing the oil filler slowly to relieve inner pressure.

cap,

turn

it

c. FINAL DRIVE CASE 1. Stop the machine so that casting line (1) is horizontal and drain plug (P) is at the bottom.

2. Remove drain plug (P) to drain the oil. After draining, tighten up it.

3. Pour in the specified quantity of engine oil from hole of plug (G).

4. For the method of checking the oil level, refer to section EVERY 250 HOURS SERVICE. * Refill capacity: 31.5 P (each side) * The type of lubricant used depends on the ambient temperature.

Select according to the table “FUEL, COOLANT AND LUBRICANTS”.

-

2-50 -

EVERY 2000 HOURS

cl. DIFFERENTIAL CASE 1. Remove drain plug (P) to drain the oil. After draining, tighten up it. quantity of engine oil 2. Pour in the specified from hole of plug (G).

3. For the method of checking the oil level, refer to section EVERY 250 HOURS SERVICE. * Refill capacity: 95 L * The type of lubricant used depends on the ambient temperature.

Select according to the table “FUEL, COOLANT AND LUBRICANTS�. e. TURBOCHARGER Excessive carbon or oil sludge adhering to turbocharger blower impeller may deteriorate normal performance of turbocharger and may sometimes damage it.

Ask Komatsu distributor to clean the turbocharger and check rotation of the rotor impeller, or perform the following.

1. Remove the turbocharger oil supply tube and the drain tube. Then, remove the connection area of the intake manifold and the blower housing so that the blower inpeller can be seen.

2. Using light oil, wash the impeller to eliminate carbon adhered on the surface. * Do not use wire brushes or the like to prevent damage to the impeller surface.

3. Pour light oil through the turbocharger oil filler. Turn the blower impeller several turns so that foreign materials such as sludge can be washed away.

4. Using your fingers, turn the impeller vigorously for one revolution or more. If there is no sigh of interfering with or being caught in somewhere, the impeller is normal. t If the impeller seems to turn heavily, contact your Komatsu distributor to ask to repair or replace it.

5. If the impeller is found normal after this check, supply engine oil to the turbocharger.

-

2-51 -

SERVICE

EV;RY

2000

HOURS

SERVICE

f. ENGINE BREATHER 1. Remove the bolts and the breather body from the cylinder block, and rinse the element together with the breather body in diesel oil or flushing oil.

2. After rinsing, pour in clean diesel oil in the direction marked by the arrow A. * Before removing the breather, clean all the dirt from around the breather. * If the element is damaged, replace with a new one. * Replace the breather O-ring with a new part, and coat it with engine oil before installing.

9. EMERGENCY RELAY VALVE Request your Komatsu distributor out disassembly and cleaning. h. DIFFERENTIAL

to

carry

CASE BREATHER

Remove all the dirt and mud from around the breather, then remove the breather and wash it in clean diesel or flushing oil to flush out the dirt from inside.

-

2-52 -

_

EVERY

i. ALTERNATOR AND STARTING MOTOR As the hours of engine employment indicate that the brushes are already worn out, you should request repair from a Komatsu distributor. * They should be repaired every 1000 hours, if the machine is frequently operated at night. j.

PERIODIC REPLACEMENT SAFETY PARTS KIT Use the periodic replacement safety parts service kit when replacing the parts.

For details, see PERIODICAL REPLACEMENT OF SAFETY PARTS.

k. ENGINE VALVE CLEARANCE Contact your Komatsu distributor because special tools are required for maintaining and removing parts.

-

2-53 -

2000

HOURS

SERVICE

EVERY

4000

HOURS

SERVICE

EVERY 4000 HOURS SERVICE *

Maintenance 2000 hours same time.

for every 250, 500, 1000 and should be carried out at the

a. WATER PUMP Inspect the water pump for play in the pulley, grease leakage and water leakage.

If any fault is detected, ask Komatsu distributor to disassemble and repair or replace. b. PERIODIC REPLACEMENT SAFETY PARTS KIT Use the periodic replacement safety parts service kit when replacing the parts.

For details, see PERIODICAL REPLACEMENT OF SAFETY PARTS. c. CHECK AIR COMPRESSOR Ask your Komatsu distributor repair it. d. FAN PULLEY AND TENSION Check the pulley to see if pulley and any leaking grease. ity is found, ask your Komatsu pair or replace it.

to

check

and

PULLEY there is play of If any abnormaldistributor to re-

-

2-54 -

WHEN REQUIRED

WHEN REQUIRED a. CLEAN

INSIDE

OF COOLING

SYSTEM

of the cooling system, change the coolant, according to the table. * Stop the machine on level ground when cleaning or changing the coolant. * Use a permanent type of antifreeze.

If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol. * Use city water for the cooling water.

If river water, well water or other such water supply must be used, contact your Komatsu distributor.

Clean

the

inside

Antifreeze is flammable, A from any flame.

Type of antifreeze solution

so keep

it away

Cleaning inside of cooling system and changing coolant

Permanent type antifreeze (All season type)

Every year (autumn) or ever-y 2000 hours whichever comes first

Non permanent type antifreeze containing ethylene glycol (Winter, one season type)

Every 6 months (spring, autumn) (Drain antifreeze in spring, add antifreeze in autumn)

When not using antifreeze

Every 6 months or every 1000 hours whichever comes first

-

2-55 -

Replacing corrosion resist0

Every 1000 hours and whel cleaning the inside of the cooling system and when changing coolant

-

�

WHEN REQYIRED

0 Add antifreeze in the cooling water 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 lower when deciding the mixing rate.

Mixing rate of water and antifreeze Min. atmospheric temperature (‘C)

-5

-10

-15

-20

-25

-30

Amount of antifreeze (Q)

40

52

63

71

80

87

Amount of water (2)

134

122

111

103

94

87

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

1. Stop the engine resistor valve (1).

and

tighten

up corrosion

,

2. Remove the cover until it comes off.

A

and turn cap (2) slowly

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

Wait until the water temperature goes down, and press the botton on the cap to release the pressure before removing the cap.

-

2-56 -

WHEN REQUIRED

3. Open drain valve (3) at the bottom of the radiator and plugs (4) and (5) on the side of cylinder block and to drain off the cooling water.

4. Drain off all the water, then close up drain valve (3), plugs (4) and (5), and pour in soft water (ex: city water) up to the vicinity of the water filler.

5. When the water reaches the vicinity of the water filler, put the engine at low idling, open drain valve (3), and plugs (4) and (5), then pass water through the cooling system for 10 minutes. * When doing this, adjust the inflow and outflow of water so that the radiator is always full.

6. After flushing with water, stop the engine.

Close drain valve (3), drain plugs (4) and (5), after draining water.

7. After draining water, use a flushing agent to clean. * We recommend the use of Korriatsu genuine goods as the flushing agent. Follow the instructions on the label of the flushing agent to clean the system.

8. After washing the cooling system, drain off all the water, then close up drain valve (3), plugs (4) and (5), and pour in soft water (ex: city water) up to the vicinity of the water filler.

9. When the water reaches the vicinity of the water filler, put the engine at low idling, open drain valve (3) and plug (4) and (5) then pass water through the cooling system until clean water comes out from drain valve (3), plugs (4) and (5). * When doing this, adjust the inflow and outflow of water so that the radiator is always full.

-

2-57 -

:

‘\jV:HEN REQUIRED

10. When the water becomes completely clean, stop the engine, close drain valve (3), plugs (4) and (5).

11. Replace the corrosion resistor cartridge and open corrosion resistor valve (1) fully. * For details of replacement of the corrosion resistor, see EVERY 1000 HOURS SERVICE. 12. Supply water until water over flows from the water filler.

13. Run the engine for 5 minutes at low idling to eliminate air trapped in the cooling system, and run the engine for 5 minutes at high idling. (leave water filler cap (2) off during this operation.)

14. Stop the engine and 3 minutes later supply water again up to vicinity of the water filler and tighten water filler cap (2).

15. Drain the cooling water inside sub-tank, (6), then clean the inside of the sub-tank and fill again with water to a point between the H 7 and L lines.

-

2-58 -

,..-.WHEN REQUIRED

b. CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT Checking Whenever the red piston in dust indicator (1) appears, clean the air cleaner element. Stop the engine when cleaning the element.

Cleaning or replacing outer element I 1. Loosen wing nut (2) and outer element (3).

2. Clean the air cleaner body interior.

3. Clean and inspect the element. (See the item “Cleaning outer element� for cleaning procedure.)

4. Install the cleaned element.

5. Push the dust indicator reset button to return the red piston to the original position. * Replace the outer element which has been cleaned 6 times repeatedly or used throughout a year.

Replace the inner element at the same time. * Replace both inner and outer elements when the dust indicator red piston appears soon after installing the cleaned outer element L even though it has not been cleaned 6 times. * Check inner element mounting nuts for looseness and, if necessary, retighten. * When inspecting or cleaning the air cleaner, remove evacuator valve (4) and clean with compressed air.

-

2-59 -

\

i WHEN REQUIRED

Replacing inner element 1. kemove the outer element.

2. Remove the nut and take out the inner element.

3. Cover the air connector with a clean cloth or tape.

4. Clean inside the body, then remove the cover fitted in Step 3.

5. Install the new element.

6. After replacing the element, return the red piston in the dust indicator to its original position. * Do not attempt to reinstall a cleaned inner element.

Do not clean or replace the air A ment with the engine running.

cleaner

ele-

Cleaning outer element With compressed air Direct dry compressed ’ air (less than 7 kg/cm*) to element from inside along its folds, then’ direct it from outside along it folds and again from inside, and check element. using compressed A When glasses and other things

air, wear safety required to main-

tain safety.

If small holes or thinner parts are found on element when it is checked with an electric bulb after cleaning and drying, replace the element.

When cleaning element, do not hit ir ot beat it against something.

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

-

2-60 -

1

WHEN REQUIRED

CHECK AND REFILL WINDOW WASHING FLUID Do this when there is air in the window washing fluid.

Check the washing fluid level in washer tank (1). When the fluid has run short, add automotive window washing fluid. t To prevent the nozzles from clogging, be careful not to let dust get into the fulid.

C.

d. CLEAN FILTER OF AIR CONDITIONER If the air filter of the air inlet is clogged, the cooling effect becomes poor. Clean the filter every week.

1. Remove cover (1) at the front of the cab.

2. Take out the air filter and clean it with compressed air.

-

2-61 -

WHEN REQUIRED

e. CHECK AIR CONDITIONER If the cooling effect is poor, the level of the refrigerant (gas) is probably low.

In this case, check the sight glass of the receiver dryer on the left inside the radiator guard.

When the engine is running at idling with the cooling switched on, if there are bubbles in the sight glass, it means that the refrigerant level is low, so contact your Komatsu distributor to have it recharged. used in the cooler is colorrefrigerant A The less and odorless, and is harmless when re-

T

However if it leased into the atmosphere. gets in the eyes,or on the hands, it will be cause of burn or loss of sight, so never loosen any part of the refrigerant circuit.

f. CHECK DUMP BODY Check that there are no cracks in the dump body.

1. Clean the dump body and make it easy to check. body for 2. Check all parts of the dump damage.

Carry out repairs if any cracks or other damage are found.

For details of the repair procedure, contact your Komatsu distributor.

-

2-62 -

WHEN REQUIRED

g. WATER SEPARATOR When float (2) is at or above red line (I), drain the water according to the following procedure: 1. Loosen drain plug (3) and drain the accumulated water until the float reaches the bottom.

2. Tighten drain plug (3).

3. If the air is sucked into fuel line when drain the water, be sure to bleed air in the same manner as for the fuel filter.

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

-

2-63 -

ADJUSTMENT

ADJUSTMENT BLEEDING AIR FROM REAR BRAKE Pull the retarder control lever, and loosen air bleed plug (1) to bleed the air from the circuit. After closing plug (I), release the retarder control lever.

Repeat this procedure until no more bubbles come out from air bleed plug (1). After bleeding the air, tighten plug (1) securely.

To make the operation easier, raise the oil temperature to 40°C or above before starting to bleed the air.

BLEEDING AIR FROM FRONT BRAKE Start the engine and raise the pressure of the air pressure gauge to the highest point in the green range.

Fill oil reservoir (1) with engine oil.

Remove the cap of bleeder screw (2), insert a vinyl hose (inside diameter: 8 mm), then loosen the bleeder screw approx. 314 turns, and slowly depress the brake pedal. Tighten the bleeder screw, then release the brake pedal.

Repeat this procedure until no more bubbles come out from the vinyl hose. continuously Do not keep the pedal depressed.

Slowly depress the pedal each time.

-2-64-

ADJUSTMENT

After bleeding the air, tighten bleeder screw (2) fully and install the cap.

After completing the air bleeding, add oil to the oil reservoir to the specified level (MAX).

Carry out the same procedure on both the left and right sides.

When carrying out this procedure at the same time for both the front brake and rear brake, bleed the air from the rear brake first.

INSPECTION OF SUSPENSION CYLINDER LENGTH AND OIL LEVEL If the machine bounces excessively when traveling, or the cylinder retracts and hits the stopper, or if the unevenness of the road surface is felt directly on the machine, inspect as follows.

I Check for cylinder length With the machine unloaded and on a level surface, check if the bottom edge of the suspension cylinder cover is in the suitable range marked on the label.

1

Y

-j-

At the same time, with the machine unloaded, measure the distance from the shoulder of the suspension cylinder rod head to the top surface of the flange. * After checking at the front and rear, if any abnormality is found, contact your Komatsu distributor.

mm

Rear

-

2-65 -

Suitable range

ADJUSTMENT

ADJUSTING

BODY POSITIONER

It is possible

to stop the body automatically without any shock when it reaches the lift position (body turning angle) specified by the positioner.

Adjustment 1. Set the dump lever at the HOLD position.

2. Adjust push cable (1) to the standard length. * Standard length (A): 188 mm 3. Raise the body to 50 mm before the end of the stroke of the hoist cylinder, then adjust plate (2) so that the hoist valve lever is released from the detent. * Reference dimension (B): 149 mm 4. After adjusting, start the engine and operate the dump lever to check that the lever returns automatically to the HOLD position when the body reaches the specified lift position.

ADJUSTING

PARKING BRAKE

If the holding effect of the parking brake is poor, adjust as follows.

1. Check that the display of the air pressure gauge is within the green range, then release the parking brake.

2. Press bolt retainer (1) and turn bolt (2) clockwise to bring both pads (3) into tight contact with disc (4).

3. Keep bolt retainer (1) pressed and turn bolt (2) l/2 turn counterclockwise.

-

2-66 -

ADJUSTMENT

4. Return bolt retainer (I) and check that the retainer is in the position where it locks bolt (2).

A When block

carrying out the adjustment, always the wheels to prevent the machine from moving.

A

When carrying out the adjustment, raise the air pressure sufficiently high to prevent the parking brake from being automatically applied. Then hang a warning notice on the parking brake switch to prevent any other preson from operating the brake.

Measure the thickness of the pad, and if the thickness is less than 1.5 mm, please contact your Komatsu distributor.

A

0

There must be no oil or grease stuck to the surface of the pad and disc. * When carrying out the first adjustment after replacing the pad, turn bolt (2) back one turn (6 clicks) in a counterclockwise direction.

-

2-67 -

1.5 m/m (wear limit)

__

PERIODICAL REPLACEMENT

OF SAFETY PARTS

PERIODICAL REPLACEMENT OF SAFETY 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 on the next page. 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.

Carry out the following inspection for hydraulic hoses in addition to the periodic replacement parts listed on the next page. If any abnormality is found, tighten, replace, or take any other necessary action.

Category

t

of inspection

Inspection item

Check before starting

Leakage from joints or caulked portion of fuel or hydraulic hoses

Periodic inspection (monthly inspection)

Leakage from joints or caulked portion of fuel or hydraulic hoses Damage (cracks, wear and tear) or fuel or hydraulic hoses

Periodic inspection (yearly inspection)

Leakage from joints or caulked portion of fuel or hydraulic hoses Interference, deterioration, twisting, damage (cracks, wear and tear, crushed parts) of fuel or hydraulic hoses

When replacing the hoses, such parts at the same time. + Ask your Komatsu distributor

always

replace

the

for this replacement.

-

2-68 -

O-rings,

gaskets,

and

other

PERIODICAL REPLACEMENT OF SAFETY PARTS

F40.

Safety parts of periodical replacement

1

Fuel hose (Fuel tank - injection pump)

2

Fuel hose (Injection pump - filter)

3

Fuel hose (Injection pump - adapter)

4

Fuel hose (Adapter - fuel tank)

5

Fuel spill hose (Nozzle - fuel tank)

6

Fuel spill hose (between nozzle)

7

Fuel hose (Cold starting aid - intake manifold)

8

Turbocharger

9

Rubber hoses of brake piping

lo

High pressure hoses in steering circuit (Pump * demand valve - steering valve * steering cylinder)

I1

Outlet hose of retarder cooling oil pump

12

Outlet hose of transmission oil pump

I3

Brake valve parts

14

Parking brake valve parts

15

Relay valve parts

16

Air governor parts

17

Retarder control valve parts

18

Emergency relay valve parts

19

Emergency brake valve parts

20

Quick release parts

21

Parking brake chamber parts

22

Brake chamber parts (Front and rear)

Replacement interval

Remarks

-

’ Every 4000

lubricating hose

hours or every two years, whichever comes first

Replace as assembly

zoo Krz every one

year,

whichever comes first

-

2-69 -

Replace as a service ki

MEMO

-

Z-70 -

OPERATING J

INSTRUMENTS

PLANNING AND CONSTRUCTION OF HAUL ROADS ..........................

METHOD OF RELEASING PARKING BRAKE AND EMERGENCY BRAKE WHEN ACTUATED IN A EMERGENCY .....................................

INSTRUCTION FOR TOWING THE MACHINE ..................................

HANDLING THE TIRES .......................................................

OPERATING THE PAYLOAD METER ..........................................

OPERATING THE AIR CONDITIONER .........................................

OPERATING THE CAR RADIO ................................................

OPERATING THE CAR STEREO ..............................................

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

COLD WEATHER OPERATION ................................................

STORAGE ................................................................... t

3- 2

.3- 4 3- 7 3- 8 3-l 1 3-21 3-24 3-26 3-29 3-32 3-35

This section gives details of the handling of standard equipment and optional parts or attachments.

Please refer to these in accordance with the specification of the customer’s machine.

-

3-l -

PLANNING AND CONSTRUCTION OF HAUL ROADS

PLANNING AND CONSTRUCTION Maintenance of haul roads in the job site is of utmost importance, not only for safety but also for reduction of cycle time.

To ensure safety when operating, do as follows.

PLANNING OF HAUL ROADS As far as possible, roads should be for oneway trafic.

Where it is impossible to make oneway roads, the road should have ample width to allow trucks to pass each other easily.

Where it is impossible to make the road wide enough, lay-bys should be constructed at frequent intervals.

Roads must always be constructed to allow loaded trucks to pass on the inside (away from the edge).

Place convex mirrors at blind curves or places with poor visibility.

Place warning signs at least 1.5 meters in from soft road shoulders or from places where there is danger of subsidence.

To allow night driving, it is important to install lighting or reflectors.

Gradients should be kept to within about 10%.

In case of brake failure, down-hill slopes should be provided with lay-bys.

Make as many straight stretches as possible.

Especially in the central area where the truck is traveling at high speed, the radius of curves should be made as large as possible.

Avoid tight S-bends as they are particularly dangerous. The radius of the curve should be at least 12 to 15 meters.

-

3-2 -

OF HAUL ROADS

PLANNING AND CONSTRUCTION HAUL ROADS

c-

Turning radius should be made large enough to have room to spare.

Road width should be made larger than for straight roads.

Outer edge should be made slightly higher than inside.

Outer shoulder should be made much stronger than for other roads.

As far as possible, avoid having the haul road intersect another road. Particularly on slopes, if the roads intersect at an angle, a ramp is formed, and at high speed, this causes heavy rolling which is dangerous.

Cut out a level haul road across the slope.

MAKE THE HAUL ROAD LEVEL When hauling, always drive at a speed suited to the road conditions.

Fill in holes, remove bumps,J and correct any tilting of the road to one side. Strengthen the road and correct sagging shoulders.

Remove rocks, trees or other obstacles.

The best method is to use bulldozers or motor graders occasionally to maintain the haul road surface.

Dust can reduce visibility , so it is important to use a sprinkler periodically to keep the dust down.

-

3-3 -

OF

METHOD OF REPLEASING PARKING BRAKE AND EMERGENCY BRAKE WHEN ACTUATED IN A EMERGENCY

METHOD OF REPLEASING PARKING BRAKE AND EMERGENCY BRAKE WHEN ACTUATED IN A EMERGENCY If the pressure inside the air tank drops abnormally due to some problem, such as leakage of air from the air circuit, the parking brake and emergency brake are automatically actuated.

RELEASE OF PARKING BRAKE If the parking brake can not be released after its emergency application even if the parking brake valve lever is put in RELEASE position, take the following actions to release the parking brake.

1. Remove air charge socket (1) from the front air tank.

2. Install socket (1) on parking brake chamber (2) after removing the air hose connected to parking brake chamber (2).

3. Connect one end of air charge hose (3) to air charge socket (1).

(They can be installed at a touch.)

4. Press the other end of hose (3) to wheel’s valve (4) and the brake will be released as air is supplied to the brake chamber.

5. When the parking brake is released, immediately move the machine to a safe place by traction. r

-

3-4 -

METHOD OF REPLEASING PARKING BRAKE AND EMERGENCY BRAKE WHEN ACTUATED IN A EMERGENCY

When the pneumatic system has trouble, the brake does not operate.

This is very dangerous.

Be sure to tow the machine at low speed, keeping the engine running and always being ready to steer. * Refer to INSTRUCTIONS FOR TOWING THE MACHINE.

t

A When safety

releasing the parking brake, confirm in the surrounding area.

If it is absolutely necessary to release the parking brake on a slope, put chocks against the tires.

-

3-5 -

METHOD OF REPLEASING PARKING BRAKE AND EMERGENCY BRAKE WHEN ACTUATED IN A EMERGENCY

RELEASE OF EMERGENCY BRAKE If the emergency brake can not released after its emergency application even if the emergency brake valve lever is put in RELEASE position, release the emergency brake in the following manner. the emergency brake has been appliA When ed, do not continue to drive the machine.

This will cause seizure of the brake disc and lining.

1. After making preparations to tow the machine, pull rings (1) on the 3 drain valves on the air tank to release the air pressure so that the emergency brake can be released.

2. After releasing the emergency brake, release rings (1).

Before releasing the air pressure from the A emergency brake reservoir, confirm safety in the surrounding against the tires.

area

and

put

-

chocks

3-6 -

INSTRUCTIONS

INSTRUCTIONS

FOR TOWING THE MACHINE

This machine must not be towed except in emergencies.

When towing the machine, take the following precautions.

1) When the engine is in operation; Always keep the engine running when towing the machine, so that the steering and braking can be used.

A

If there is a failure in the air circuit, the brakes cannot be used, so be extremely careful when towing.

2) When the engine is out of operation; Never haul the machine over 800 m.

* If the towing distance surpasses that limit, be

* * *

*

FOR TOWING

sure to remove the drive shaft between the transmission and the differential case.

The towing speed must be within 8 km/h.

The hook towing a machine is installed under the front frame.

When air pressure in air reservoir abnormally drops due to leakage from air circuit, parking brake and emergency brake are actuated.

When towing machine, release both brakes.

If the engine does not start, it is possible to steer using the emergency steering, but do not use it for more than 90 seconds, and travel at a speed of less than 5 km/h.

-

3-7 -

THE MACHINE

HANDLING THE TIRES

HANDLING THE TIRES Ton-Km-Per-Hour

Rating

Tires of construction machinery are used under conditions incomparably severe with passenger cars, buses and trucks. They are specially designed to survive such working conditions.

OR tires generate much more heat in the rubber layer during operation than ordinary tires. If they are used continuously in excess of their load and speed limits, the inside temperature might exceed the permissible limit, leading to softening of rubber and separation of layers.

The ton-km-per-hour rating serves as a standard to use tires safely and prevent such trouble.

If a tire is forced to work beyond its ton-kmper-hour rating, troubles will occur frequently.

In such cases, take the following measures: 1) Ease the working conditions: reduce the tonkm-per-hour rating of the work.

2) Replace the tires with those having a higher ton-km-per-hour rating.

Ton-km-per-hour

tire rating and maximuh

T

continuous

Tire ton-km-per-hour rating with ambient

Size: 21 .OO-35-32PR Structure: CR Cord No. (TRA): E3

speed

Maximum continuous traveling speed (km/h) with ambient temperature

-

\Tire

traveling

16oc

I16’C I2PC

138°C 149°C

230 11

285

Size: 21 .OO-35-36PR Structure: CR Cord No. (TRA): E4

196

Size: 24.00-35-36PR Structure: CR Cord No. (TRA): E3

.

Without load (front-wheel basis)

28

26

24

22

With load (rear-wheel basis)

17

16

15

14

Without load (front-wheel basis)

37

35

33

3o

With load (rear-wheel basis)

23

22

2o

”

270

-

3-8 -

HANDLING THE TIRES

Calculation method of actual T.Km.P.H. value: A = Actual T.Km.P.H. B = Average load per tire C = Average traveling speed per day D = Tire load on the empty machine E = Tire load on the loaded machine F = Turnaround distance G = Turnaround frequencies for one day H = Total operation hour for one day A=BxC

B,D+E 2 C,FxG H Sr The total operation hour for one day includes the operator’s break time and the time during which the machine is not in operation. * The values of ton-km-per-hour rating given in the table vary somewhat with tire makers. If you must travel near the maximum speeds given, consult your Komatsu distributor.

Defective tires as shown in 1) to 6) below A should be replaced with new tires for safe operations:

1) Tires 2)

with cuts, broken or excessively deformed bead wire.

Excessively worn tires in which the carcass ply (excluding breaker) is exposed along l/4 the circumference.

Tires whose carcass is damaged more than l/3 the tire width.

Tires with ply separation.

Tires with radial cracks which reach the carcass.

Aged, deformed or abnormally damaged tires.

When replacing the tires, please contact your Komatsu distributor.

It is dangerous to jack up the machine without taking due care.

-

3-9 -

Bead wire

FO1999

HANDLING THE TIRES

INSTRUCTIONS WHEN TRAVELING OVER A LONG DISTANCE When the machine travels continuously over a long distance at high speed, the tires produce extreme heat. This may cause the tires to be worn. To prevent this, the following instructions should be observed: 1) The machine should be operated without load or with the minimum load.

2) The tire inflation pressure should be checked and adjusted, when the tires are still cold before operation.

Correct 21 .OO 21 .OO24.00 -

inflation pressure: 35 - 32PR 5.0 kg/cm* 35 - 36PR 5.5 kg/cm* 35 - 36PR 4.5 kg/cm*

3) The tire inflation pressure should not be reduced during operation.

4) The maximum traveling speed should be 40 km/h, and the machine should be stopped for at least one hour after travel of every hour to cool down the tires and components.

5) The machine should not be operated with the tires filled with water or dry-ballast.

-

3-10 -

OPERATING THE PAYLOAD METER

OPERATING THE PAYLOAD METER The payload meter receives signals input from the pressure sensor, clinometer, body float sensor, and neutral sensor, and processes these with its built-in microprocessor to calculate the payload. It displays the payload on the panel, and also displays the loaded condition with external display lamps.

It is also possible to print out the data in the memory together with the earth-dumping time and number.

1. CALIBRATION SWITCH 2. NIGHT-TIME DIMMER SWITCH 3. CLOCK SETTING ADJUSTMENT SWITCH 4. CLOCK ADJUSTMENT SHIFT SWITCH 5. CLOCK ADJUSTMENT INCREASE SWITCH 6. MEMORY DATA CLEAR SWITCH 7. PRINTER FEED SWITCH 8. PRINT SWITCH 9. EXTERNAL DISPLAY LAMPS 0 The lamps light up as followings to display the payload.

Lamp 1 (green): 14 tons and up but less than 21 tons Lamp 2 (green): 21 tons and up but less than 41 tons Lamp 3 (green): 41 tons and up but less than 51 tons Lamp 4 (yellow): 51 tons and up but less than 55 tons 55 tons and up Lamp 5 (red): If the gear shift lever is not at neutral and the dump lever is not at FLOAT, all the lamps go out.

All the lamps light up for 10 seconds after the power is switched ON. To prevent overloading, load only until the three green lamps light up.

-

3-l 1 -

OPERATING

THE PAYLOAD

METER

Estimations display 0 When the payload changes in stages with every bucket load, the average load up to that point is calculated to estimate what the payload will be if one more bucket is loaded.

The corresponding lamp of load level flashes, and this prevents overloading. t It displays the estimated load and the payload simultaneously.

[Example] If the dump truck is loaded as follows, the external lamps will light up as shown in the table below.

1st load: 10 tons 2nd load: 12 tons (22 tons) 3rd load: 12 tons (34 tons) 4th load: 11 tons (45 tons) No. of

Remarks

External lamp display

loads

Yellow Green Green Green

*The actual amount loaded is 10 tons, so no lamp lights up. *The estimated load is 20 tons (10 tons x 2), so 1st green lamp flashes.

Yellow Green GCW� Green

-The actual amount loaded is 22 tons (10 tons + 12 tons), so two green lamps lights up. .The estimated load is 33 tons (22 tons + 2212 tons), so no lamp flashes.

Yellow Green Green G,W�

-The actual amount loaded is 34 tons (22 tons + 12 tons), so two green lamps remain.

-The estimated load is 45.3 tons (34 tons + 3413 tons), so the 3rd green lamp flashes.

Yellow Green

.The actual amount loaded is 45 tons (34 tons + 11 tons), so three green lamps lights up. . The estimated load is 56.3 tons (45 tons + 4514 tons), the red lamp flashes.

1st load

!nd load Red

3rd load Red

Ith load Red

-

3-12 -

OPERATING THE PAYLOAD METER

OPERATION OF PAYLOAD METER Reset the power (this is carried out by turning the power ON).

0 For the first 3 seconds, the display reads 88:88, and for the following 7 seconds, it shows the time.

0 For the first 10 seconds, the external display lamps all light up.

Check for any broken bulb in this time.

10 seconds, the normal display 0 After appears.

0 The printer feeds the paper one line, and then stops at the home position.

DETAILS OF DISPLAYS 0 When the dump lever is at FLOAT and the gear shift lever is at neutral, the actual load is displayed.

0 When the payload is less than 3.9 tons, or when the dump lever is not at FLOAT, the display is “0”.

0 If the dump lever is at FLOAT, but the gear shift lever is not at neutral, the time is displayed. t A maximum of 200 items of data can be kept in memory.

If this amount is exceeded FULL is displayed.

If FULL is displayed, print out the data, then clear the memory.

For details, see “when deleting data from memory“. t After completing the work, we recommend that you stop the machine and print out the data, then clear the data from the memory. * There may be a slight difference in the displayed weight at the loading point and dumping point. * The data is recorded when the dump lever is moved to the RAISE position.

If you wait until the machine is completely still before starting to dump, the weight measurement can be carried out more accurately. t Wait for the payload meter display to show a stable value before raising the dump lever. If the swaying of the machine is excessive, ***** is displayed when the dump lever is raised.

-

3-13 -

dPERATlNG THE PAYLOAD METER

*

After moving the dump lever from LOWER to FLOAT, wait for at least 5 seconds before turning the starting key to the OFF position.

OPERATION OF SWITCHES When carrying out calibration Carry out calibration in the following cases.

0 When the machine is delivered and once every month.

0 When the gas pressure and oil of the suspension cylinder are adjusted (when adjusting the suspension).

0 When the machine is modified and the empty-truck weight change is more than 100 kg.

0 When the suspension pressure sensor is replaced.

0 When any other modification is made to the suspension or related parts.

Method of carrying out calibration 1. Set the machine with no load.

2. Set the gear shift lever to N, and press calibration switch (1) for at least 2 seconds. (The letters CAL flash.)

3. Drive the machine, and when the travel reaches lOkm/h, press calibration speed switch (1) again. (CAL lights up.) When the display returns to the time display, the calibration is completed. * When carrying out calibration, drive the machine on flat even ground. * Travel in a straight line. (Distance approx.

100 m) * When traveling, maintain the travel speed at IO km/h. * The calibration data is stored in the internal RAM, and is preserved even when the power is switched off. * If you wish to stop the calibration before completing it (when at neutral), press calibration switch (I), and the display changes from flashing letters CAL to flashing letters SCH. Press calibration switch (1) again, and the normal display will appear.

-

3-14 -

OPERATING THE PAYLOAD METER

When checking the sensor.

Travel with the truck empty on flat ground.

Set the gear shift lever to N, and press calibration switch (1) for at least 2 seconds, then switch (1) again for at least press calibration 2 seconds. (The letters SCH flash.)

When the travel speed is IO km/h, press calSCH (the letters (1) again. switch ibration light up.) If the display shows the time, the operation is completed. in the sensor, an If there is any abnormality error code is displayed.

Check the sensor at least once a month.

When printing out Press print switch (1) for at least 2 seconds, and the data is printed out. to stop the print during If it is necessary print out, keep the print switch pressed for at least 2 seconds.

Do not hold down the paper coming out of the print out. This will during the printer cause lines to overprint.

Press print feed switch (2) for at least 2 seconds to feed the paper.

When deleting data from memory 1. Before deleting anything, print out the necessary data.

2. Press the memory data clear switch (1) for at least 2 seconds. (The letters CLEA flash) 3. Press memory data clear switch (1) again for at least 2 seconds to complete the deletion.

-

3-15 -

0 -

OPERATING THE PAYLOAD METER

When correcting the clock switch (1) for 1. Press clock setting adjustment at least 2 seconds and the minute display display Press clock adjustment flash. will increase switch (2) to correct the minute display. shift switch (3) and 2. Press clock adjustment the hour display will flash. Press clock adjustment display increase switch (2) to correct the hour display. shift switch (3) again 3. Press clock adjustment and year as each month, day, the and adjust is necessary, flashes in turn. If any correction increase display adjustment clock press switch (2) to correct. the time, 4. After correcting adjustment switch (1).

Never try to correct the truck is traveling.

A

press

clock

set

clock

when

the

When operating dimmer switch of If it is desired to change the bringhtness the display, adjust it as follows.

1. Each time dimmer switch (1) is pressed, the display will become one stage darker. When it reaches the darkest level, if the switch is once more, it will change to the pressed brightest level.

The brightness can be adjusted * If the switch is held down, will change continuously.

t

in ten stages. the brightness

-

3-16 -

OPERATING THE PAYLOAD METER

Setting paper When there is only 30 cm of print paper remaining, a red line appears at the left edge to give warning that it is time to replace the print paper.

Press the FEED switch to feed out the remaining small amount of paper.

Do not pull the paper out using force.

Use Komatsu genuine printer paper (7818-272910).

Remove the paste from the new printer paper, bend back the paper strongly at a point approx. 3 cm from the end. then use this fold to cut the paper straight.

\6

/�

3cm

Do not cut the paper shown in the diagram the paper to jam.

in any of the ways below. It will cause

(

I Qx . Do not cut to a point.

x Q -Do not leave a rough edge.

Put the surface of the print paper facing up, and insert the paper straight into the paper loading port. Press the FEED switch while pushing the paper in , and the paper will start to feed.

When the paper comes out of the printer, pass the paper through the slit in the printer lid, then close the lid.

-

3-17 -

Printed circuit board

~~~35,

OPERATING THE PAYLOAD METER

Method of cutting printer paper 1. Press the FEED switch to feed the paper as far as necessary.

2. Put the printer paper against the cutter in the cover, then pull the paper up and cut the paper slowly from the right or left side. * Always use the paper cutter. Do not pull the paper out and then cut it.

Storage of printer paper The printer uses thermal paper, so store it within a temperature range of 0°C - 40X. t Do not leave the paper exposed to direct sunlight.

If error message E-33 is displayed The payload meter has a built-in battery to record the load data even if the starting switch key is turned to the OFF position.

If the battery voltage drops, error message so please contact your E-33 is displayed, Komatsu distributor to have the battery replaced. + Replace the battery within is 48 hours. + The life of the battery is approx. 2 years. t After replacing the battery, always carry out calibration, then move the dump lever from FLOAT + LOWER + FLOAT with the dump truck unloaded.

Operation after replacing controller After replacing the controller, always carry out calibration, then move the dump lever from FLOAT 4 LOWER -. FLOAT with the dump truck unloaded.

-

3-18 -

k

OPERATING THE PAYLOAD METER

When error message PAPE flashes (paper jam) If the paper jams, PAPE is displayed in the payload meter load display area. If this happens, move the machine to a safe place, and take the following action.

1. Turn the starting switch key to the OFF position.

the screws 2. Remove payload meter, then out to the front.

(M6 x 4) holding the pull the payload meter

the connector, remove 3. Remove the screws (top surface M4 x 8, rear face M4 x 3) of top cover (1) of the payload meter, then remove top cover (1).

C

4. Remove the paper caught between the printer head (2) and guide (3) with tweezers. * Do not wear gloves when carrying out this work.

Do not touch the printer head (white) under A any circumstances.

If the printer head is removed, it is impossible

to restore it.

* When removing the paper with tweezers, press the guide with your fingers. This will make a gap between the printer head and guide, and paper will be easier to remove.

-

3-19 -

0

Remove the

OPERATING THE PAYLOAD METER

t

If paper is left immediately under the printer head, rotate gear (4) with your finger and the head will move.

If gear (4) is rotated in a counterclockwise direction, the head will move to the right.

5. After removing the paper, install the connector once before installing the top cover.

careful not to left A Be inside the controller.

any dirt or metal

get

6. Remove the printer paper remaining inside the printer, and cut off the end of the paper. * For details of the method of cutting the end of the paper, see CUTTING PRINTER PAPER. 7. Turn the starting switch key back to the ON position and press the FEED switch. * For details of inserting the paper, see SElTING PAPER. Be careful not to let A inside the controller.

any dirt or metal

get

8. Turn the starting switch key to the OFF position, remove the connector, and assemble to the original condition.

-

3-20 -

Printer paper

OPERATING

OPERATING THE AIR CONDITIONER Outside air enters through a filter and is sent to the cab to increase the pressure inside the cab. In this way, a pleasant working environment is always maintained even on dusty jobsites.

CONTROL PANEL 1. Air conditioner switch When the switch is pressed, the blue lamp inside the button lights up, and the air conditioner starts to work. This is used to provide cold air or to dehumidify the air. * Press the air conditioner switch after turning on the blower switch.

2. Temperature adjustment lever This is used to adjust the temperture cooling or heating.

COOL: Low temperature WARM: High temperature

when

3. Blower switch This acts as the wind force adjustment switch and air conditioner switch.

The positions are as follows.

OFF . : Low l : Medium 0 : High t When it is turned OFF, the power is turned off and the air conditioner is stopped.

-

3-21 -

THE AIR CONDITIONER

OPERATING

THE AIR CONDITIONER

4. Air selector lever This lever selects the source of air.

RECIRC (recirculation) Only the air inside the cab is used. (This is generally used to cool the cab quickly.)

FRESH (outside air) Air is taken from outside in addition to the air inside the compartment.

5. Vent selector lever This lever selects the vents for the cool or warm air.

Lever position

Vent

VENT

Use

I

Front vents

Cooling, heating

METHOD OF OPERATION DPERATION OF CONTROL PANEL Air conditioner switch

Blower switch

Temperature control lever

Air ,s,ee$or

1 s&i;ro;t/eeer

VENT (Front outlet)

zc

Normal

Defrosting

Strong -Weak

I

Strong

I

ON

I Ventilation or pressurizing

Strong -Weak

WARM -

OFF

Middle

WARM - Middle (to remove frost quickly or to prevent the I window from misting up, move the lever fully to WARM side)

I

COOL (move fully to COOL side)

OFF

-

3-22 -

FRESH

(Defroszii

outlet

OPERATING THE AIR CONDITIONER

Precautions for using air conditioner When cooling, change the air occasionally. cab will cause Smoking in the air-conditioned your eyes to get sore. While smoking, open the window to let the smoke out of the cab. open the using the air conditioner, While hour. every window once

Be careful not to overcool the cab.

The cab should feel cool when entering Phere from outside (5°C or 6’C lower than the outIt is not good for the side temperature). in the cab health to have the temperature to too low. Always give careful consideration temperature

regulation.

I

Inspection and maintenance To prevent lack of oil in the var.ious parts of is not when the air conditioner the compressor at low speed being used, run the compressor (Run, the once a week. minutes for several engine at low speed and set the temperature adjustment lever to the medium position.) t Clean the air filter and check the refrigerant.

For details, see WHEN REQUIRED. to display its pert To allow the air conditiner fully, and to provide a comfortable formance work always ask the specified environment, and refrigerant of charging out carry to shop other checks and maintenance.

-

3-23 -

FIG%:

i

OPERATING THE CAR RADIO

OPERATING THE CAR RADIO How to set station selector buttons 1. Pull back the button corresponding station to be preselected.

to the

1

/

,

2. Turn the station selector knob until the pointer is in front of the desired station. + Carefully tune in so that noise disappears and the broadcast is heard plainly.

3. Carefully push back the button with the fingertip until it clicks into place.

Precautions when using radio 0 To prevent possible- breakdown, keep water well away from the speaker case and interior of the radio. In particular, close’the window during rain or when washing the machine. l Do not wipe the dial plate or knobs with benzine or paint thinners, etc. Always use a dry, soft cloth (if the radio is particularly dirty, soak the cloth in alcohol).

0 Do not disassemble the radio.

r

TUNING KNOB Tune this knob in to the desired station.

Tune right in to the station. If the tuning is off center, the sound quality will be unnatural and sensitivity will be / reduced.

Pointer /

r---

STATION SELECTOR BUTTONS (5 buttons) By pressing these buttons it is possible to tune in to oreset stations.

-

3-24 -

TONE CONTRO; Use this knob to adjust the tone as desired.

When it is turned to the right the high tones will be emphasized, and when it turned to the left the high tones will be cut, resulting in a mellow tone.

POWER SWITCH/ VOLUME CONTROL Press this knob to turn on (or off) the radio. When it is turned to the right, the sound level will increase, and vice-versa.

OPERATING THE CAR RADIO

ADJUSTMENT OF ANTENNA TRIMMER The antenna trimmer is pre-adjusted, but adjust it as required to reduce the background noise.

Adjustment procedure 1. Fully extend the antenna and pick up a weak radio broadcast having a frequency of 1400 to 1500 KHz. 2. Adjust the trimmer by turning it with a screwdriver until the volume is maximized.

Trouble shooting guide No sound 0 Turn the SWNOL knob to the right and press it two or three times.

Sound quality is poor Reception is noisy 0 Return using the station selector knob. If the problem disappears, reset the tuning button.

0 Try lengthening the antenna to its fullest extent. t When setting the tuning selector to a strong station, shorten the antenna to reduce the input as far as possible before carrying out alignment.

-

3-25 -

OPERATING

THE CAR STEREO

OPERATING THE CAR STEREO HOW TO USE To play a cassette tape: 1. Power source When the power switch is turned clockwise, power will be supplied to the car stereo.

2. Setting When a cassette tape is inserted into the slot, the tape is set, causing the program indicator lamp to light.

3. Stopping When both the FF and REW buttons are depressed simultaneously, the cassette will spring out of place and the stereo will stop.

4. Selection of program 1) Automatic selection When one side of the tape is finished, the tape will change direction so that there is no interruption. i 2) Manual selection When the program selection switch is depressed before one side of the tape is finished, the tape will change direction.

5. Program indicators The direction in which the tape is moving during PLAY is indicated by two indicators.

Radio power switch Volume control Balance control

Program selection switch Tape selection button \

Tape slot /

/

FF/REW button Eject button /

knob changeover

Tone quality co’,trol

Program i:dicator

-

3-26 -

lamp

changeove;

program b&on

button

OPERATING THE CAR STEREO

6. FF (fast forward), REW (rewind) When the FF or REW button is depressed, the button will be locked and the tape will run in fast forward or rewind.

To release the button, button which is not 0 depress the depressed, or 0 depress both the FF and REW buttons simultaneously (At this time, the cassette tape will spring out of place), or 0 wait until the tape finishes playing. (After the button is automatically released, the opposite side of the tape will start playing), or 0 depress the program selection button.

(After the button is released, the other side of the tape will PLAY.) 7. Volume control As the volume control knob is turned clockwise, the tape plays louder.

8. Balance control When the balance control knob is pulled out and turned clockwise, the volume from the R.H. speaker increases. When turned counterclockwise, the volume from the L.H. speaker increases.

9. Tone quality control When the tone quality control knob is turned clockwise, high tones will be intensified. When turned counterclockwise, the low tones will be intensified.

10. Roundness control When the roundness control switch is depressed, both the high tones and low tones will be intensified, even if the volume of the sound is low.

11. APC (automatic program changeover button) The song now playing can be played again from the beginning or the next song can be played again from the beginning.

-

3-27 -

OPERATING THE CAR STEREO

When listening to the radio (AM/FM): 1. AM/FM changeover When the changeover button is kept down (-_), the radio will receive FM stations.

When the button is raised (1), the radio will receive AM stations.

The button is changed over by simply pressing it.

2. Station selection button When this button is depressed, the preset station can be heard.

3. Manual tuning The desired station can be selected by turning the tuning knob.

4. How to preset a station 1) Pull out the button you want to use for the station.

2) Turn the tuning knob until it is set on the desired station.

3) Then push the button back in.

PRECAUTIONS FOR HANDLING THE CAR STEREO 1. When the head gets dirty, clean it with a head cleaning tape.

2. Never touch the head with a magnet, screwdriver, or other hard object.

3. Before using a tape, take up the looseness by lightly turning it outward with a pencil.

4. Store tapes in a case, away from direct sunlight and dust.

5. Do not use C-120 tapes.

6. If the stereo is not going to be used for a long time, take the cassette out of the stereo. Do not leave the cassette in the stereo.

7. This stereo cassette is specified for use at 12v.

Do not remove the converter.

-

3-28 -

HANDLING OF BATTERY

HANDLING OF BATTERY PRECAUTIONS FOR CHARGING BATTERY When inspecting or servicing a battery, be sure to stop the engine and turn the starting switch to (OFF) position.

Before charging, disconnect the cable from the negative (-_) terminal of the battery.

Otherwise, an unusually high voltage will damage the alternator.

While charging the battery, remove all battery plugs for satisfactory ventilation. avoid gas explosions, A To sparks near the battery.

do not bring fire or

0 If the electrolyte temperature exceeds 45’C, stop charging for a while.

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

Overcharging the battey may cause followings: 1) Overheating the battery 2) Decreasing the quantity of electrolyte 3) Damaging the electrode plate If the A clothes,

electrolyte gets on your skin immediately wash with plenty clean water.

0

0

or of

Do not mix up cables (positive (+) to negative (-_) or negative (-_) to positive (+)), as it will damage the alternator.

When performing any service to battery besides checking the electrolyte level or measuring the specific gravity, disconnect cables from the battery.

-

3-29 -

.I HANDLING OF BATTERY

REMOVAL AND INSTALLATION OF BATTERY 0 When removing battery, first disconnect the cable from the ground (normally, from the negative (-) terminal). If a tool touches a cable connecting the positive terminal and the chassis, there is danger of sparks being emitted.

0 When installing battry, the ground cable should be connected to the ground terminal as the last step.

CONNECTION AND DISCONNECTION OF THE BOOSTER CABLES When starting up the engine with a booster cable, do as follows: Connecting the booster cables Connect one clip of booster cable A to the positive (+) terminal of the engine to be started.

Connect the other clip tothe positive (+) terminal to the engine which is running.

Connect one clip of booster cable B to the negative (--) terminal of the engine which is . running.

Connect the other clip to the engine block of the machine to be started.

-

3-30 -

HANDLING OF BATTERY

Disconnecting the booster cables 1) Disconnect the clip of booster cable B from the engine block of the machine which was started.

2) Disconnect the other clip from the negative (-_) terminal of the running engine.

3) Disconnect the clip of booster cable A from the positive (+) terminal of the running engine.

4) Disconnect the other clip from the positive (+) terminal of the engine which was started.

Precautions for handling the booster cables * Size of booster cable and clip should be suitable for the battery size. * The battery of the running engine must be the same capacity as that of engine to be started. + After connecting the cables, make sure cables and clips are firmly secured.

When connecting the cables, never contact A the positive (+) and negative (-) terminals.

A

Make sure that the booster cable connections are correct. Connect the booster cable to the engine block as far as possible from the battery.

-

3-31 -

h

was started

F&Z

,_+-

1

j

COLD WEATHER OPERATION

COLD WEATHER OPERATION PREPARATION FOR LOW TEMPERATURE If the temperature becomes low, it becomes the coolant may freeze, so do as follows.

difficult to start the engine, and

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

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

AND

COOLANT After cleaning inside of the cooling system, add antifreeze to the coolant to prevent the coolant from freezing when the machine is not being used. * For details of the antifreeze mixture when changing the coolant, see WHEN REQUIRED. Care in using Antifreeze 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 . SAE . . .. .. ... ... ... ... .. .... .. .... ... .. ... .... .. ... ... ... ... .... .. ... ... ... ... ... ... .... .. .... ... .. ... ... .. ... ... ... J1034 . FEDERAL STANDARD . ... .. ... .... .. .... . .. . ... .... ... .. ... .... ... ... ... ... .... ... ... .. ... ... .. ... .O-A-54BD Never use methanol, 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.

A Antifreeze

is flammable,

so keep it away from any flame.

-

3-32 -

COLD WEATHER

OPERATION

BATTERY As ambient temperature drops, battery capacity will drop, and electrolyte may sometimes freeze if battery charge is low. Maintain battery at a charge level of approx. 100% and insulate it against cold temperature so that machine can be readily started the next morning. + Measure specific gravity of fluid and obtain rate of charge from the following conversion table:

-20°C

100%

1.28

1.29

1.30

1.31

90%

1.26

1.27

1.28

1.29

80%

1.24

1.25

1.26

1.27

75%

1.23

1.24

1.25

1.26

* When electrolyte instead of after night.

A

-10°C

If the electrolyte ty of clean water.

level is low, add distilled water in the morning before work the day’s work. This is to prevent fluid from freezing at

gets on your skin or clothes,

A To avoid gas explosions,

immediately

wash with

do not bring fire or sparks near the battery.

-

3-33 -

plen-

..

COLD WEATHER OPERATION

CAUTIONS AFTER COMPLETION WORK

OF

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions.

0 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.

0 Park the machine on concrete or hard ground. If this is impossible, park the machine on wooden boards.

0 Drain water collected in air tank and fuel system so that such water may be frozen at night.

0 As battery capacity drops at low ambient temperature, cover the battery or remove it from the machine to be kept warm at night.

AFTER COLD WEATHER When weather becomes warm, perform the following without fail: 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.

0 Replace lubricating oils for various units with the ones specified for warmweather use. l

INSTALLATION

OF RADIATOR CURTAIN

If the engine water temperature gauge does not enter the green range, install a radiator curtain.

It is possible to adjust the amount of opening of the radiator curtain. it can be used fully closed, closed on one side, or open on both side. Select the amount of opening to match the ambient temperature so that the engine water temperature gauge enters the green range.

-

3-34 -

STORAGE

STORAGE BEFORE STORAGE To place the machine in storage for an extended period of time, the following measures must be taken to insure that it can be returned to operation with minimum of service.

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, lay wood plates on the ground, and park the machine on the wood plates and cover it with canvas etc.

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

0 Apply a thin coat of grease to metal surface (hydraulic piston rods and splined shaft).

0 As to batteries, remove the terminals and cover them, or remove them from the machine and store separately.

0 When the ambient temperature is anticipated to drop below O’C, always add antifreeze in the cooling water.

0 Set each control levers to neutral or hold position, lock them and apply the parking brake.

0 Since low pressure tire would be easily damaged, check tire pressure (from 4 kg/cm* to the specified pressure for the tire).

0 Open the valves on the air tank to release the air pressure, and close the valves.

0 The retarder control lever should be set to “RELEASE” position.

0 The gear shift lever should be set to “NEUTRAL” position.

0 The starting switch should be put in the “OFF“ position.

-

3-35 -

DURING STORAGE 0 Operate the engine and move the machine for a short distance once a month so that new oil film will be coated over movable parts and component surfaces.

0 Before operating the work equipment, wipe off the grease on the hydraulic piston rod.

If it is unavoidably necessary A the machine is indoors, open

operation while to carry out rust-preventive up doors and windows to improve vetilation

and prevent the gas poisoning.

AFTER STORAGE Carry out the following procedure when taking the machine out of long-term storage.

0 Wipe off the grease on the hydraulic piston rod.

0 Completely fill fuel tank, lubricate and add oil. t If the machine is stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service.

0 Precautions before traveling after long period of storage 1. Before traveling, check all the oil and water levels.

2. Travel in FORWARD for 5 minutes or 1 km at 10 ‘- 15 km/h to run in the machine, then shift to normal travel.

-

3-36 -

__

OPTIONAL

PARTS, ATTACHMENT

SELECTION OF DUMP BODY ..................................................

OPTIONAL PARTS, ATTACHMENTS ...........................................

-4-l

-

4-2 4-3

SELECTION

OF DUMP BODY

SELECTION OF DUMP BODY Select the dump body from the following table.

Use

Hauling ;and and soil

Body type

Linerless body

Features

Body shape

*This is suitable for jobsites loading sand or soil.

There is no liner installed to the body.

Example: Quarrying soil for refill site

* With a side extension

Hauling rocks

(Special specifications) lauling of ‘aste rock

Rock body

-This is used for loading rock such as at crushed rock sites, limestone mines, or civil engineering jobsites.

The inside of the body is fitted with a liner over the whole surface.

Example: Limestone quarry

Rubber liner body

*This is suitable for jobsites loading large rocks and other waste rock.

A rubber liner is installed to the body.

-This is effective in reducing the noise when loading.

Example: Waste rock jobsite

*: This body can be equipped with a side extension.

-

4-2 -

OPTIONAL

OPTIONAL PARTS, ATTACHMENTS HIGH-SPEED FUEL SUPPLY DEVICE This can be connected directly to the fuel tank and reduces the fuel charging time of the fuel supply hose.

TIRE CHAIN This is used to prevent the tires from slipping on snow or in cold areas.

RADIATOR AUTO SHUTTER This automatically controls the amount of air flowing to the radiator to prevent overcooling when operating the machine in cold areas.

RADIATOR CURTAIN This limits the amount of air flowing to the radiator to prevent overcooling when operating the machine in cold areas.

BODY WEAR PLATE This plate reinforces the inside of the body to protect the body when loading large rocks or steel.

DIFFERENTIAL LOCK This is used to improve the travel performance and to prevent the tires from slipping on snow or soft ground.

There are various other optional parts available, including the following.

0 Tachograph 0 Spare rim 0 Spare tire 0 Fuel tank cap lock 0 Body extension 0 Fog lamp 0 Revograph For details, please contact your Komatsu distributor.

-

4-3 -

PARTS, ATTACHMENTS-

MEMO

-

4-4 -

TROUBLE SHOOTING

GUIDE

-

5-l -

TROUBLE SHOOTING GUIDE

TROUBLE SHOOTING

GUIDE

This guide is not intended to cover every conditions, more common possibilities are listed.

however

many of the

ENGINE The engine oil pressure caution lamp lights. a Add the oil to the specified level.

0 Check oil leakage from the pipe or the joint.

0 Check and repair wiring to the sensor.

Steam is emitted from the top part of the radiator (the pressure valve).

The radiator coolant level caution lamp lights.

The pointer of the water temperature gauge is in red range on right side of the gauge.

The cooling water temperature caution lamp lights. a Supply the cooling water and check leakage.

0 Adjust fan belt tension.

0 Wash out inside of cooling system.

0 Clean or repair the radiator fin.

0 Replace the water temperature gauge.

0 Repalce the thermostat and the seal. l Tighten the radiator cap firmly or replace the cap.

0 Check and repair wiring to, the sensor.

The pointer of the water temperature side of the gauge. a Replace the water temperature gauge.

0 Replace the thermostat.

0 Install the radiator curtain.

gauge

is in white

range on left hand

The engine does not start when the starting motor is turned over.

0 Add fuel.

0 Repair where air is leaking into fuel system.

0 Fill the fuel filter with fuel.

0 Refer to the section of electrical system.

0 Check the valve clearance.

Fuel flow occasionally

stops.

0 Replace the breather tube.

-

5-2 -

hand

TROUBLE SHOOTING GUIDE

Oil consumption is large.

Exhaust gas is white or blue.

0 Check and repair oil leakage. l Adjust to specified oil quantity. l Replace piston, ring and cylinder liner. l Replace with specified fuel. l Check and replace the turbocharger.

Exhaust gas occasionaly turns black.

Clean or replace the air cleaner element. l Check and repair piston, ring and cylinder liner.

0 Adjust valve clearance. l Check and replace the turbocharger. l

Combustion noise occasionally changes to breathing 0 Repair air leakage into fuel supply line.

Unusual combustion noise or mechanical l Replace with specified fuel.

0 Check over-heating.

-

noise.

5-3 -

sound.

TROUBLE SHOOTING GUIDE

ELECTRICAL SYSTEM Lamp does not glow brightly even when engine runs at high speed.

Lamp flickers while engine runs. l Check for loose terminals and open-circuit wiring.

0 Change the battery.

0 Add the battery electrolyte.

0 Adjust belt tension.

Charge lamp does not go out even when engine runs at high speed. l Repalce the alternator. l Check and repair wiring.

Unusual noise is emitted 0 Replace the alternator.

from the alternator.

Starting motor does not turn when starting switch is turned on. l Inspect and repair wiring.

0 Replace the starting switch.

0 Charge the battery.

0 Replace the battery switch.

Starting motor turns the engine sluggishly. l Check and repair wiring.

0 Charge the battery.

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

0 Check and repair wiring.

0 Charge the battery

-

5-4 -

TROUBLE SHOOTING GUIDE

CHASSIS The torque converter oil temperature caution lamp lights.

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

0 Check and replace gear pump. l Add the oil to the specified level of transmission case.

0 Check and replace the fan belt.

0 Clean and replace the oil cooler. l For a long distance, travel the machine in the direct drive range.

0 Check and repair wiring to the sensor.

Steering wheel is heavy.

0 Lubricate steering linkage. l Replace steering cylinder seal.

Steering wheel drags.

0 Adjust so that both left and right tires have same inflation pressure.

0 Check and adjust the front brake pod.

Brake is not effective if the brake pedal is depressed.

Brake effect is unbalanced. l Replace brake pad.

0 Replace rear disc.

0 Charge the air to the specified level.

0 Add brake oil.

0 Bleed the air from the brake circuit.

Dump body operation speed is tdo low.

0 Replace gear pump.

0 Refill oil to the specified level.

Suspension is hard.

0 Replace U-packing.

0 Replace valve core.

Only the single side of the rear wheel is likely to slip.

0 Bleed air (from the right and left of rear brake) 0 Replace tires.

0 Level the load.

0 Disassemble the brake and check.

-

5-5 -

TROUBLE SHOOTING GUIDE

MECHATRONICS

RELATED PARTS

If any abnormality occurs as listed on the left, stop the machine, apply the parking brake, check the LED display of the controller, and then contact your Komatsu distributor for repair.

(1) Shift controller (2) Suspension controller

SHIFT CONTROLLER During travel, if the central warning lamp flashes and the alarm buzzer also sounds, act calmly and do as follows.

Use the brake to reduce speed, and stop the machine in a safe place.

Open the cover at the rear of the operator’s compartment, and check the number given on the self-diagnostic display at the top of the shift controller.

If necessary, place the shift lever at N, then pull out the emergency escape connector (connectors No. A-l, A-2, black one-pole connector) then insert it again. Operate the shift lever without depressing the accelerator pedal, and move the machine.

If the shift lever is operated with the accelerator pedal depressed, the emergency escape function is not actuated.

Also, depending on the failure mode, the emergency escape function may not be actuated.

-

5-6 -

TROUBLE

SHOOTING

GUIDE

+ When normal: 0.0 (Normal temperature) 0.C (Low temperature: 10°C or below)

Display

Trouble shooting item Controller

power source

I

b.b, 0.1, 0.2

N safety

0.3

Controller

b.b, 0.4, 0.5

Transmission

cut relay

I

0.6

Rear brake solenoid

0.8

Exhaust brake solenoid

0.9

Engine rotation sensor

I

1.0

Transmission

middle shaft rotation sensor

1.2

Transmission

output shaft rotation sensor

1.3

Clutch sliper rotation sensor

2.2 -

Model select signal

I

Accelerator Transmission

sensor valve oil temperature

I sensor

%

1.4

1 0.7,

Shift lever

2.8

1.5, 1.6

1.7 1.9

Pressure control valve

3.2 3.8 4.2 - 4.8

%

Flow control valve

5.2 -

5.8

%

Pressure control solenoid

7.1 9.1 -

7.8 9.8

%

% The digit after the decimal point in number 2.0 - 9.0 indicates the following clutches. b: blank 1: Lock-up 2: H 3: L 4: 1st

-

5-7 -

5: 6: 7: 8:

2nd 3rd 4th Rev

TROUBLE SHOOTING

SUSPENSION

GUIDE

CONTROLLER

LED display Trouble shooting item Green

Red

Power source

Goes off Lights up

Goes off

(Normal) Pressure sensor (right)

Flashes slowly simultaneously Flashes fast

Goes off

Travel speed sensor

Flashes slowly

Lights up

Steering

Flashes fast

Flashes slowly

Model selection i Pressure sensor (left)

Flashes fast simultaneously

I

sensor

I

Goesoff

Solenoid

(1)

Lights up fl

0 0 0

Fast flashing: 0.5 set/l time Slow flashing: 4 set/l time Solenoids (I), (2) and (3) are distinguished ber.

Solenoid 1: CNSLI Solenoid 2: CNSLP Solenoid 3: CNSLB

-

5-8 -

by the solenoid connector

num-

TROUBLE SHOOTING

GUIDE

PAYLOAD METER

Content

Display

Priority rank 1

3 _ _ _‘_I

Internal CPU stops (CPU reset function possible) (Controller power, etc. is normal)

‘_ - 3; II

Abnormality

I_

,- - :;a:’ --

2

I

,r

Short circuit in relay

.- _ 3;; ,_

Drop in backup battery voltage

I0

i_ _ ,-. ,_ ,_’

in sensor power (18V)

Rear right wheel . Disconnection

in voltage sensor signal

3 I

I-

,r -

li, I’

I

Front left wheel

i

,-_- ;;

I

I_

Rear right wheel

. Pressure sensor signal line

4

r

,I

5

,I,

-

-,

Disconne~ction in signal line or contact with chassis

I

_ _ ‘_ _ ‘_;<I 1.

i ;:;:;;;;,;;;

6

Signal line in contact with power line

1Prmter .

REDY signal not given (paper jammed)

,.a*,,_

_I

7

: I-_ _ I

8

- _ :; ;: :-:_

I

It

I

,_a_L . . . ..I._

:

Data stored in memory

.

c- _,I’; I_

9

in contactwith

1 Calibration

I

has reached 200 (overflow)

needed

Rear right wheel

I

.-I

. Sensor output drift

Front left wheel

Once an error pressed.

message

is output,

it stays displayed

-

5-9 -

until the CAL switch

is

-

5-10 -

SERVICE METER, SERIAL NUMBERS, LUBRICANTS SERVICE METER .............................................................

MACHINE AND ENGINE SERIAL NUMBERS ....................................

FUEL, COOLANT AND LUBRICANTS ...........................................

6-2 6-3 6-4

I

-

6-l -

_

, SERVICE METER

SERVICE METER This meter indicates the integrated work hours. So, use it according to the following instructions. l Record the readings at the start and the end of work, this is the work record of the machine.

0 This record will indicate, when periodical maintenance is due.

0 It also indicates the integrated working hours when machine problems are encountered. * How the meter progresses The service meter progresses by 1 when the engine is operated for one hour, regardless of the engine speed.

Consequently, if the engine is running, the service meter will advance even if the machine does not move.

0 While engine is running, the indicator on the service meter turns to show the service meter advances.

-

6-2 -

MACHINE AND ENGINE SERIAL NUMBERS

MACHINE AND ENGINE SERIAL NUMBERS When calling for the services of a mechanic parts, be sure to or when ordering replacement the machine and give your Komatsu distributor as well as the service engine serial numbers mentioned before. meterreading These numbers are stamped in the locations shown in the figures.

0 Location of the machine serial number plate plate is on the The machine serial number left front end of the frame.

0 Location of the engine serial number plate The engine serial number plate is on the upper right side of the cylinder block.

FUEL, COOLANT AND LUBRICANTS

FUEL, COOLANT AND LUBRICANTS PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

RESERVOR

<ING OF FLUID

AMBIENT 14 -10

CAPACITY(n)

TEMPERATURE 50 10

32 0

2”:

86’F 30%

Specified

61

Engine oil pan

Transmission case (incl. torque convener

Refill

69

Engine oil

Front brake oil tank Hydraulic tank Steering hoist oil tank Rear brake cooling oil tank Front suspension Rear suspension 95 31.5 (each)

Differential case Final drive case

Fuel tank

Cooling system

780

Diesel fuel

water

I Add antifreeze

I

% ASTM D975 No.1

-

6-4 -

174

FUEL, COOLANT AND LUBRICANTS

NOTE: (1) 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%.

Change interval of oil in engine oil pan

Fuel sulphur content

0.5 to 1.0 % Above 1.0%

I I

l/2 of regular interval l/4 of regular interval

(2) When starting the engine in an atmospheric temperature of lower than oâ&#x20AC;?C, be sure to use engine oil of SAEIOW, SAEIOW-30 and SAEI 5W-40, even though an atmospheric temperature goes up to 10°C more or less in the day time.

(3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.

ASTM: SAE: API:

American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute

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.

-

6-5 -

OPERATION AND MAINTENANCE (EQUIPPED WITH A MACHINE MONITOR) This section applies when equipped with A MACHINE MONITOR. Only the portions which differ from previous sections are noted.

OPERATION INSTRUMENTS AND CONTROLS .............................................

OPERATING YOUR MACHINE ................................................

CHECKS BEFORE OPERATING MACHINE .................................

BEFORE STARTING THE ENGINE .........................................

TO START THE ENGINE ..................................................

AFTER STARTING ........................................................

TO MOVE THE MACHINE OFF .............................................

CHANGING GEAR SPEED .................................................

TRAVEL ..................................................................

REVERSING ..............................................................

OPERATING DUMP BODY .................................................

TO STOP THE MACHINE ..................................................

TO STOP THE ENGINE ....................................................

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

CHECK BEFORE STARTING ..................................................

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

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

-

7-l -

7- 2 7-39 .7-39 .7-43 .7-44 7-48 7-49 7-51 7-52 7-55 7-56 7-58 7-60

7-61 7-63 7-68 7-76

I

INSTRUMENTS AND CONTROLS

INSTRUMENTS

AND CONTROLS

of devices and operation The role, action, follows. as are operation for needed LAMPS, METERS AND MONITOR, MACHINE MECHAPEDALS, LEVERS AND SWITCHES, SAFETY CONTROLLER, TRONICS EQUIPMENT SEAT, PINS, DUST INDICATOR, OPERATORâ&#x20AC;&#x2122;S SEAT BELT, FUSES of these devices is necessary for Knowledge Make sure that operation. safe and pleasant you understand them thoroughly. when For details of the order of operation see OPERATING YOUR the machine, starting MACHINE.

MACHINE MONITOR The machine display warning display (Q).

monitor system (69, 03, 0, 0)

consists of the and the meter

@CHECK GROUP (Checks before starting) in any check is any abnormality If there before starting item, the monitor of the abnormal location flashes. Check the location indicated by the flashing monitor to carry out checks before starting.

C

E

C

B

II

0

C

c

B

B -

7-2 -

ll

INSTRUMENTS AND CONTROLS

*

Once the lamps will mality.

engine is started, these monitor go out even if there is any abnor-

@CAUTION GROUP (Caution items) If any abnormality occurs in any caution item while the engine is running, the monitor for the abnormal location flashes, and the central warning lamp also flashes. * In @I caution group, even if the retarder wear and air cleanser monitor flash, the central warning lamp does not flash. * It is possible to continue work even if the monitor is flashing, but inspect and repair the abnormal part as soon as possible.

@CAUTION GROUP (Emergency caution items) If there is any abnormality in any emergency item while the engine is running, the alarm buzzer will sound intermittently, the monitor lamp for the abnormal location and the central warning lamp will flash. * If the monitor flashes, stop work immediately and check and repair the abnormal part.

@METER DISPLAY The meter display area consists of the gauges and the monitor lamps for the following: Air pressure gauge, engine water temperature gauge, torque converter oil temperature gauge, retarder oil temperature gauge, speedometer, turn signal pilot lamps, service meter, tachometer, odometer, shift indicator (with lockup display), transmission shift lever position pilot, shift limiter pilot, fuel gauge, power mode display lamp, suspension mode display lamp, cold start monitor, exhaust brake pilot, rear brake pilot and differential lock pilot lamp.

-

7-3 -

INSTRUMENTS AND CONTROLS

@CENTRALWARNING LAMP This lamp flashes when the machine is in the following condition.

0 An abnormality has occurred in one of the caution items of @I9CAUTION GROUP (except for the retarder wear and air cleaner monitor).

This lamp flashes and at the same time, the alarm buzzer sounds intermittently when the machine is in the following condition.

0 An abnormality has occurred in one of the caution items of 0 CAUTION GROUP. 0 The parking brake is applied and the gear shift lever is not at neutral.

CHECK OPERATION OF MACHINE MONITOR SYSTEM When the starting switch is turned to the ON position before starting the engine, all the monitor lamps, gauges, and the central warning lamp will light for approx. 3 seconds, and the alarm buzzer will sound for approx. 2 seconds.

When this happens, the speedometer display should read 88.

If any monitor does not light, there has probably been some failure or disconnection, so contact your Komatsu distributor.

When the starting switch is turned to the ON position, if the gear shift lever is not at neutral, the central warning lamp will flash, and the alarm buzzer will sound intermittently. If this happens, place the gear shift lever at neutral; the lampâ&#x20AC;&#x2122; will go out and the buzzer will stop.

CHECK FOR BLOWN BULBS IN CAUTION LAMPS AND PILOT LAMPS Before starting the engine, turn the starting switch to ON and press bulb check switch (1) to check if any caution lamp or pilot lamp bulb is broken. * If any lamp does not light up, the bulb is probably broken, so replace the bulb.

If it still does not light up even when the bulb is changed, there is probably some failure or disconnection, so contact your Komatsu distributor.

-

7-4 -

INSTRUMENTS

METERS AND LAMPS @CHECK GROUP (Checks before starting) * When carrying out checks before starting, do not simply rely on the monitor. Always refer to the periodic maintenance items to carry out the checks.

1. ENGINE OIL LEVEL MONITOR This monitor indicates a low oil level in the engine oil pan.

If the monitor lamp flashes, check the oil level in the engine oil pan and add oil as required.

OIL LEVEL MONITOR 2. TRANSMISSION This monitor indicates a low oil level in the transmission oil pan.

If the monitor lamp flashes, check the oil level in the transmission oil pan and add oil as required.

I

AND CONTROLS

INSTRUMENTS AND CONTROLS

3. HYDRAULIC OIL LEVEL MONITOR This monitor indicates a low oil level in the steering and hoist oil tank.

If the monitor lamp flashes, check the oil level in the steering and hoist oil tank and add oil as required. * Check the oil level with the dump body lowered fully.

4. RETARDER OIL LEVEL MONITOR This monitor indicates a low oil level in the retarder oil tank (rear brake cooling oil tank).

If the monitor lamp flashes, check the oil level in the retarder oil tank (rear brake cooling oil tank) and add oil as required.

5. BRAKE OIL LEVEL MONITOR This monitor indicates a low oil level in the front brake oil tank.

If the monitor lamp flashes, check the oil level in the front brake oil tank and add oil as required.

-

7-6 -

1 Retarder oil level

INSTRUMENTS

6. BATTERY ELECTROLYTE LEVEL MONITOR This monitor indicates a low electrolyte level in the battery.

If the monitor lamp flashes, check the electrolvte level and add distilled water as reauired.

7. ENGINE OIL OIL 8. TRANSMISSION 9. HYDRAULIC OIL 10. RETARDER OIL 11. FINAL DRIVE CASE OIL 11. DIFFERENTIAL CASE OIL 12. FULL-FLOW FILTER 13. FUEL FILTER 14. CORROSION RESISTOR OIL FILTER 15. TRANSMISSION 16. HYDRAULIC OIL FILTER 17. RETARDER FILTER 18. MAINTENANCE TIMER 19. CHANGE INTERVAL CHECK SWITCH (OIL) 20. CHANGE SWITCH 21. CANCEL SWITCH 22. CHANGE INTERVAL CHECK SWITCH (FILTER) * Refer to OPERATING MAINTENANCE MONITOR and check the monitor for item 7 to 22. * Stop the machine in a level place when checking the monitor.

-

7-7 -

I

AND CONTROLS

I

INSTRUMENTS AND CONTROLS

OPERATING MAINTENANCE

MONITOR

When carrying out checks before starting When the starting switch is turned to ON, all the monitor lamps light up, and go out after 3 seconds. If any lamp remains on or flashing, it indicates that that item requires maintenance.

After starting the engine, when the air pressure gauge shows the normal condition (the green range lights up), set the shift lever to the N position, pull the retarder control lever fully for at least 10 seconds, and check that the brake wear does not exceed the wear limit.

If the wear limit is exceeded, the lamp lights.

Even if the oil level is normal, the caution lamp may flash if insufficient time has passed since the engine was stopped. The necessary time is as follows: Engine oil: Wait for at least 15 minutes Transmission oil: Wait for at least 8 hours.

If the lamp flashes, carry out inspection and maintenance.

For details, see EVERY 1000 HOURS SERVICE. Display of abnormalities during operations If any abnormality occurs during operations, the lamp flashes.

If the filters are clogged, the lamp flashes, and if the replacement interval has been exceeded, it lights up.

-

7-8 -

INSTRUMENTS AND CONTROLS

time for oil 0 When checking the replacement and filters 1. When the starting switch is turned ON, all the lamps light up, and 3 seconds later the display shows the engine oil replacement interval. intervals, checking the oil change 2. When press the left change interval check switch, and when checking the replacement intervals for the filters, press the right change interval check switch.

They display in order from the top.

3. When the display time lights up, it indicates when the time . remaining until replacement; it flashes, it indicates the time that has interval was passed since the replacement reached.

0 Operation of switches when the oil and filters have been replaced.

1. After replacing the oil and filters, follow the procedure for checking the replacement time and set the display to the item that has been replaced.

2. Press the change switch for at least 2 secto the time onds. The display switches replacement. next the until remaining This completes the operation of the switch. start the 3. After the switch was operated, engine. * If the wrong replacement item is pressed by mistake, press the cancel switch to return the setting to the condition before the switch was operated, then operate the switch again. t Always stop the engine before operating the switches.

-

7-9 -

INSTRUMENTS AND CONTROLS

*

The initial set times

item

1 Final drive oil Differential case oil

are as follows.

1 Time

1

1 2000

1

I 2000

Full-flow filter (Engine of filter)

I Hydraulic filter Retarder filter

250

I

IilOO

I

1000

- 7-10 -

INSTRUMENTS AND CONTROLS

@CHECK GROUP (Caution items) Sr If the monitor lamps

flash or light up, take the necessary action as quickly as possible.

1. CHARGE MONITOR This monitor indicates an abnormality in the charging system while the engine is running.

If the monitor lamp flashes, check the charging circuit.

2. EMERGENCY STEERING MONITOR If the emergency steering is used, this lamp lights up.

It also lights up when the auto emergency steering is actuated because some abnormality has occurred in the steering hydraulic circuit during travel.

-3. PARKING BRAKE MONITOR This lights up when the parking brake is applied.

-7-11

-

INSTRUMENTS AND CONTROLS

4. BODY FLOAT CAUTION MONITOR When the dump body control lever is set to any position other than FLOAT, this lamp lights up. When traveling, always set the lever to the FLOAT position.

5. TRANSMISSION FILTER MONITOR This informs the operator that the transmission filter is clogged. If it flashes, replace the filter element.

I

6. ENGINE (MECHATRONICS) MONITOR This flashes when any abnormality occurs in the mechatronics related parts of the engine control system.

F10152 7. AUTOMATIC TRANSMISSION (MECHATRONICS) MONITOR This flashes when any abnormality occurs in the mechatronics related parts of the transmission control system.

-

7-12 -

TRANS CONT.

I-:

F10153

INSTRUMENTS AND CONTROLS

8. SUSPENSION (MECHATRONICS) MONITOR This flashes when any abnormality occurs in the mechatronics related parts of the suspension control system. t If any of the lamps for items 6, 7 or 8 flashes and the alarm buzzer sounds intermittently, open the rear cover inside the cab, check for any abnormal display of the controller, and request your Komatsu distributor to carry inspection.

9. FUEL LEVEL MONITOR This flashes when the remaining fuel in the fuel tank goes below 120 liters.

If it flashes, check the fuel level and add fuel.

10. RETARDER WEAR MONITOR When the machine stops and the air pressure gauge shows the normal condition (the green range lights up), set the shift lever to the N position, pull the retarder control lever fully for at least IO seconds, and check.

If the lamp flashes, check the amount of disc wear. * For details of the check, see EVERY 1000 HOURS SERVICE. * Even if this lamp flashes, the central warning lamp does not flash.

11. AIR CLEANER MONITOR This informs the operator that the air cleaner is clogged.

If it flashes, check the dust indicator and clean the air cleaner element. or Even if this lamp flashes, the central warning lamp does not flash.

-

7-13 -

I*

INSTRUMENTS AND CONTROLS

@CAUTION GROUP (Emergency caution items) * If any monitor flashes, stop the

engine immediately or run it at low idling and take the necessary action.

1. AIR PRESSURE MONITOR This monitor indicates a drop in the air pressure in the air tank.

If the lamp flashes, increase the engine speed and wait until the lamp goes out.

2. COOLANT TEMPERATURE MONITOR This monitor indicates a rise in the cooling water temperature.

When the monitor lamp flashes, run the engine with no load at midrange speed until the green range of the engine water temperature gauge lights.

3. TORQUE CONVERTER OIL TEMPERATURE MONITOR This monitor indicates a rise in the torque converter oil temperature.

When the monitor lamp flashes, stop the machine and run the engine with no load at midrange speed until the green range of the temperature gauge lights.

INSTRUMENTS

4. RETARDER OIL TEMPERATURE MONITOR This lamp warns that the retarder oil temperature has risen.

If it flashes, stop the machine, return the gear shift lever to N (neutral), and run the engine under no load at midrange speed until the warning lamp goes out.

5. COOLANT LEVEL MONITOR This monitor indicates a low radiator coolant level.

Check the coolant level when the monitor lamp flashes, stop engine and add water as required.

6. ENGINE OIL PRESSURE MONITOR This monitor indicates a low engine oil pressure.

If the lamp flashes, stop the engine.

7. TILT WARNING MONITOR This lamp warns if the machine tilts to the left or right and exceeds the safety limit with the dump body raised.

If it flashes, lower the dump body and move the machine to a safe and stable place.

-7-15-

AND CONTROLS

INSTRUMENTS AND CONTROLS

@METER DISPLAY PILOT DISPLAY When the starting switch is turned to ON, the lamps for the display items that are functioning light up.

1. COLD START PILOT LAMP This lamp lights up when switch is turned ON.

the

quick

2. EXHAUST BRAKE PILOT LAMP This pilot lamp lights up when brake is actuated.

start

the exhaust

3. REAR BRAKE [RETARDER) PILOT LAMP This lamp lights up when the service brake is depressed or the retarder control lever is pulled to actuate the rear brake.

-

7-16 -

I

I

INSTRUMENTS

AND CONTROLS

4. DIFFERENTLAL LOCK PILOT LAMP This lamp lights up when the differential lock pedal is depressed and the differential lock is actuated.

5. LOCK-UP PILOT LAMP This lamp lights up when the torque converter is locked up and the transmission enters direct drive.

EI 6. SHIFT LIMITER PILOT LAMP This lamp lights up when switch is operated.

7. HIGH BEAM PILOT LAMP This lamp lights up when at high beam.

the

shift

limiter

the head lamp is

8. TURN SIGNAL PILOT LAMP When the turn signal lamp flashes, the pilot lamp also flashes. t If the wiring of the turn signal lamp is disconnected, the pilot lamp will-flash faster.

9. SHIFT INDICATOR This indicates the speed range of the transmission. t If the engine is stopped, this indicator will display N even if the starting switch is turned ON and the shift lever is operated.

-

7-17 -

I

I

INSTRUMENTS AND CONTROLS

10. TRANSMISSION SHIFT LEVER POSITION PILOT LAMP This indicates the position of the transmission shift lever.

11. SUSPENSION MODE DISPLAY LAMP This displays the suspension mode.

This machine mounts an automatic suspension that automatically switches the damping characteristics of the suspension according to whether the machine is carrying a load, or whether the brake, steering, or dump control are being operated.

Normally, the soft mode is used when traveling empty, and medium is used when traveling loaded. When using the service brakes or turning sharply, or when operating the dump control, the suspensionâ&#x20AC;&#x2122; mode is switched to maintain the stability of the machine to the front and rear, and left and right. t When installing a liner to the dump body, it is necessary to adjust the suspension control system, so please contact your Komatsu distributor.

12. POWER MODE DISPLAY LAMP This displays the power mode.

The. ,mode is selected by using mode selector switch.

-

the

power

7-18 -

r--r-I!

INSTRUMENTS AND CONTROLS

METERS 1. SPEEDOMETER This indicates the travel speed of machine. t A speedometer for MPH is also available.

the

2. TACHOMETER This indicates the engine speed.

I

I

0

10

15

20

25 xlOORPM r>,l,A,

3. SERVICE METER This displays the total number of operating hours for the machine.

The service meter advances when the engine is running, even if the machine is not moving. + The service meter advances by 1 for every hour of operation, regardless of the engine speed.

-

7-19 -

0 fl -1, SERVICE METER F,O,dS

INSTRUMENTS AND CONTROLS

4. ODOMETER This indicates the total distance that the machine has traveled in kilometers.

Sr An odometer for MILES is also available. This unit is known by speedometer.

ODOMETER

5. FUEL GAUGE This gauge indicates the amount of fuel in the fuel tank. If there is enough fuel in the tank while the engine is running, the green range lights. If the red range lights, there is less than 120 liters of fuel in the tank.

When the red range lights, add fuel.

6. AIR PRESSURE GAUGE This gauge indicates the air pressure in the air tank. The green range should be lighted during normal operation.

If the red range lights up during operations, the alarm buzzer will sound, the central warning lamp will flash, and the air pressure monitor lamp will flash at the same time.

If this happens, stop the machine, increase the engine speed and wait until the green range lights up.

-

7-20 -

Fi0166

INSTRUMENTS AND CONTROLS

t

If the air pressure drops even lower, parking brake will be automatically applied.

the

7. ENGINE COOLING WATER TEMPERATURE GAUGE This gauge indicates the temperature of the cooling water. If the temperature is normal during operation, the green range will light. If the red range lights during operation, the alarm buzzer will sound, the central warning lamp will flash and the coolant temperature monitor lamp will flash at the same time. If this occurs, stop the machine and run the engine with no load at midrange speed until the green range lights.

8. TORQUE CONVERTER OIL TEMPERATURE GAUGE This gauge indicates the temperature of the torque converter oil. If the temperature is normal during operation, the green range will light.

If the red range lights during operation, the alarm buzzer will sound, the central warning lamp will light up and the torque converter oil temperature monitor lamp will flash at the same time. If this occurs, stop the machine and run the engine with no load at midrange speed until the green range lights.

9. RETARDER OIL TEMPERATURE GAUGE This indicates the temperature of the retarder cooling oil. During normal operation, a lamp in the green range should light up.

If the lamp in the red range lights up during operation, the alarm buzzer will sound, the central warning lamp will flash, and the retarder oil temperature monitor lamp will flash at the same time. If this happens, stop the machine and run the engine at midrange speed under no load, and wait until the lamps in the green range light up.

-

7-21 -

H WATER TEMP.

$

HI

C

F10169

., INSTRUMENTS AND CONTROLS

SWITCHES 1. STARTING SWITCH This switch is used engine.

to

start

or

stop

OFF Key insertion-withdrawal position. None electrical circuits activate.

To stop the engine, turn the switch to OFF.

the

of

ON Charging and lamp circuits activate.

START At this key position, the starting motor will crank the engine. Release the key immediately after starting, and the key will return automatically to ON.

-

7-22 -

INSTRUMENTS AND CONTROLS

2. LAMP SWITCH This switch turns on the head lamps, clearnace lamps, tail lamps, internal lighting for the machine monitor, and the rear lamps.

0 OFF 0; o~ocposition: Clearance lamps, tail lamps, rear lamps, and internal lighting of vehicle monitor light up.

8 :D* position: The -head lamps light up in addition to the lamps at position 0. * The lamp switch can be operated regardless of the position of the lever.

2. TURN SIGNAL LEVER This lever operates the turn signal lamps. @ RIGHT TURN: Push lever FORWARD. @ LEFT TURN: Pull lever BACK. When the lever is operated, the turn signal pilot lamp will also flash.

When the steering wheel is turned to the neutral position, the turn signal lever will return automatically to OFF. If not, return the lever to OFF manually.

DIMMER SWITCH This switches the beam and low beam. @ Low beam @I High beam

I

.â&#x20AC;&#x153;...

I

// head

lamp

between

high

3. ROOM LAMP SWITCH This switch turns the room lamp on and off. @ OFF @ON

-

7-23 -

\\

INSTRUMENTS AND CONTROLS

4. CAUTION, PILOT LAMP BULB CHECK SWITCH Turn the starting switch to ON and press this switch to check if any bulbs are broken.

5. FOG LAMP SWITCH This turns on the fog lamp.

OFF mposition: ON -position:

6. EXHAUST BRAKE SWITCH (the lamp OFF): lposition or the If the service brake is depressed retarder control lever is operated when the torque converter is locked up, the exhaust brake is actuated.

-

7-24 -

INSTRUMENTS AND CONTROLS

-position (the lamp ON): If the accelerator pedal is released and the torque converter is locked up, the exhaust brake is actuated.

The pilot lamp inside the switch lights up.

7. FRONT BRAKE OFF SWITCH This switch is used to change the braking method according to the road conditions. lposition (the lamp OFF): When the brake pedal is depressed, the brakes are applied to the front and rear wheels.

-position (the lamp ON): Even when the brake pedal is depressed, the brakes are not applied to the front wheels; the brakes are only applied to the rear wheels.

On icy road A faces where

surfaces, on snow, or on surthe machine is likely to slip, control of the steering is needed, so set the front brake switch to the (ON) position and travel slowly at a safe speed.

8. PANEL DIMMER SWITCH This switch is used to adjust the brightness of the lighting inside the monitor panel and pilot lamp.

Adjust as follows: To INCREASE brightness, turn CLOCKWISE To DECREASE brightness, turn COUNTERCLOCKWISE 9. QUICK START SWITCH This is used when starting in cold areas.

When the switch is pressed and then released, ether is sprayed into the intake manifold. * For details of the method of operation, see â&#x20AC;&#x153;Starting the engine in cold weatherâ&#x20AC;?.

-

7-25 -

â&#x20AC;&#x2DC;-.

INkTRUMENTS AND CONTROLS

10. EMERGENCY STEERING SWITCH This switch is used to actuate the emergency steering pump. Push the switch, and the emergency pump is actuated, so the steering can be operated. * When the switch is ON, the pilot lamp (red) inside the switch lights up. * The emergency steering pump can be used for a period of up to 90 seconds. + When using the emergency steering, drive at a speed of less than 5 km/h. * When the emergency steering is actuated, it is possible to raise the body with the dump lever. * An automatic emergency steering mechanism is installed that is actuated when the oil pressure in the steering circuit drops.

When the automatic emergency steering is actuated, stop the machine quickly and check the machine. * When the machine is stopped, ,if the starting switch is turned ON and the parking brake switch is OFF, the automatic emergency steering is actuated 3 seconds later, so turn the parking brake switch ON.

-

7-26 -

INSTRUMENTS AND CONTROLS

11. POWER MODE SELECTOR SWITCH (If equipped with electrical governer) By switching the power mode to match the operating conditions, it is possible to travel economically.

A. Economy (Work on level ground) Used for travel on flat ground where high output is not needed, and where the emphasis is on fuel consumption.

B. High power (General operations) Used for normal standard working conditions.

12. SHIFT LIMITER SWITCH This switch is used to limit the highest speed range when the gear shift lever is in D or L ranges.

1

position: D range L range position: D range L range -

F2 to F7 Fl to F2 F2 to F6 Fl

13. EMERGENCY BRAKE LEVER This lever actuates the emergency brake.

Applied: Emergency brake is actuated Travel: Emergency brake is released t If the air pressure inside the air tank drops below 2.2 kg/cm2, the emergency brake is automatically applied. t If the emergency brake is actuated because of a failure in the air circuit, the central warning lamp will flash and the buzzer will sound.

For details of the method of releasing the brake when this happens, see â&#x20AC;&#x153;Method of releasing parking brake and emergency brake when actuated in a emergencyâ&#x20AC;?.

-

7-27 -

i

INSTRUMENTS AND CONTROLS

14. PARKING BRAKE VALVE LEVER This is used to applied the parking brake.

Parking: Parking brake is actuated Travel: Parking brake is released * If the lever is palced in the PARKING position, the parking brake pilot lamp will light t

%ren the lever is placed in the PARKING position, and the gear shift lever is in any position other than N (neutral), the central warning lamp will flash and the alarm buzzer will sound. * When the air pressure drops below 2.2 kg/cm2, the emergency brake and parking brake are automatically applied.

For details of the method of releasing the brake when the parking brake is actuated because of a failure in the air circuit, see â&#x20AC;&#x153;Method of releasing parking brake and emergency brake when actuated in a emergencyâ&#x20AC;?.

When parking the A the parking brake.

machine,

always

apply

loading operations, do not apply the A During parking brake. Pull the retarder control lever to apply the brakes.

-

7-28 -

INSTRUMENTS AND CONTROLS

15. ENGINE EMERGENCY STOP SWITCH (If equipped with electrical governor) This is used if the engine does not stop when the starting switch is turned OFF. switch must not be A This ing the engine normally.

used when stoppIf the switch has been used, when the engine has stopped completely, return the switch to the ON (travel) position.

16. CIGARETTE LIGHTER This is used to light cigarettes. To use, push the lighter in. After the few seconds it will spring back. At that time, remove the lighter and light your cigarette.

17. HORN BUl-l-ON When the button in the center of the steering wheel is pressed, the horn will sound.

18. WIPER SWITCH This operates the wipers.

INT: Operates intermittently OFF: OFF LOW: Operates at low speed HI: Operates at high speed Press this switch to spray washer liquid.

-

7-29 -

\

INSTRUMENTS AND CONTROLS

LEVERS AND PEDALS 1. BRAKE PEDAL This pedal is used to apply the wheel brakes.

2. ACCELERATOR PEDAL This pedal is used to adjust the engine speed.

It can operate the engine speed freely from low idling to full throttle.

r

I

INSTRUMENTS AND CONTROLS

3. GEAR SHIFT LEVER Select the gear shift range to match the travel conditions.

Position D This is used for normal travel.

If the lever is placed in this position, the shifted between is automatically transmission 2nd torque drive and 7th according to the travel speed. + The maximum speed at this position is 66 km/h (70 km/h with large diameter tires).

Position R Ths is used when traveling in reverse.

Torque converter drive is used in this position. * If the dump lever is in any position except FLOAT, the machine cannot travel in reverse.

Place the dump lever at FLOAT first, then operate the gear shift lever to the R position.

Positions 5 - L These ranges are used on jobsites where high speed travel is difficult, or when traveling on soft ground, or when startig on slopes when loaded, or when going downhill and the engine is used as a brake.

0 The speed ranges for each position are as follows.

Position 5 4 3 L

t

1:

I

Speed ranges 1st 5th 1st 4th 1st 3th 1st 2th

torque direct torque direct torque direct torque direct

converter converter converter converter -

Speeds for machines diameter tires.

1

Max. sDeed 37.5 (39) km/h 28 (29.5) km/h 20.5 (21.5) km/h 15.5 (16) km/h

with

fitted

-

large-

7-31 -

_. ., INSTRUMENTS AND CONTROLS

t

t

*

t

*

*

* t

*

When operating the gear shift lever, put it securely into each position.

If the lever is not set securely in position, the shift position display on the panel may go out, and the transmission warning monitor may light up.

When shifting between FORWARD and REVERSE, always stop the machine completely before operating the lever.

When starting the engine, check that the gear shift lever is at N (neutral). If it is in any other position, the engine will not start.

If the starting switch is turned ON with the gear shift lever at any position other than N, the central warning lamp will flash and the alarm buzzer will sound.

If the gear shift lever is moved to any position other then N when the parking broke is applied, the central warning lamp will flash and the alarm buzzer will sound.

If the gear shift lever is moved to any position other than N when the dump lever is at a position other than FLOAT, the central warning lamp will light up and the alarm buzzer will sound.

When traveling, never shift the gear shift lever back to the N position.

When moving the gear shift lever from N to the FORWARD or REVERSE positions, always release the accelerator pedal.

When moving the gear shift lever from N to R, or from D to 5, press the lock button on the gear shift lever before moving the gear shift lever.

-

7-32 -

_INSTRUMENTS AND CONTROLS

4. SAFETY LOCK This device locks the dump lever. carrying A When machine with the

out inspection on the dump body raised, always lock the dump lever in the HOLD position, and then install the safety pin.

5. DUMP LEVER This lever operates the dump body.

0 RAISE 0 HOLD: This holds the dump body in the same position.

8 FLOAT: This allows the dump body to move freely in response to external force.

0 LOWER sr When traveling, always use the FLOAT position. t For details, see “Operating dump body”.

INSTRUMENTS AND CONTROLS

6. RETARDER CONTROL LEVER This lever operates retarder that is gether with the rear brake when downhill.

The harder the lever is pulled, the the braking force becomes. * When the retarder is operated, brake pilot lamp lights up. + For details, see “DOWNHILL TRAVEL”. retarder A The brake.

used totraveling stronger the

rear

must not be used as a parking

* When leaving the operator’s apply the parking brake.

compartment,

7. STEERING TILT LEVER This lever is used when tilting the steering wheel forward or back, or moving it up or down.

Lift up the lever and set the steering wheel at the desired position, then push the lever down to lock the steering wheel securely in position. t Amount of adjustment Fore-aft: 5” Up: 30 mm Down: 20 mm

INSTRUMENTS AND CONTROLS

Always stop the machine before A the tilt of the steering wheel.

adjusting

8. DIFFERENTIAL LOCK PEDAL This operates the differential lock control.

When the pedal is depressed, the differential lock is actuated; when the pedal is released, the differential lock is canceled.

-

7-35 -

INSTRUMENTS AND CONTROLS

MECHATRONICS CONTROLLER

EQUIPMENT

This informs the location of any abnormality in the mechatronics equipment system.

1. SHIFT CONTROLLER 2-digit failure code is displayed inside the inspection window, so that it is possible to know the location of the abnormality.

The.normal display is ‘:I:. [:J err i-7. iI _I. 2. ENGINE CONTROLLER 3. SUSPENSION CONTROLLER There are green and red LEDs (Light Emitting Diodes) inside the inspection window, and these light up, flash, or go out.

The combination of these conditions shows the location of the abnormality.

Normally, the green LED lights up. * For details of the display if any abnormality should occur, see “Trouble shooting guide.”

SAFETY PINS DUST INDICATOR OPERATOR’S SEAT SEAT BELT * Details of the above equipment are given on the OPERATION volume at the beginning of this manual.

-

7-36 -

INSTRUMENTS AND CONTROLS

FUSES Fuses protect the electrical parts and wiring from burning out.

If the fuse becomes corroded, and there is white powder in the fuse, or if the fuse is loose in the fuse holder, replace it.

A When

replacing fuses, always turn off the power first (turn the starting switch to the OFF position).

* When replacing fuses, always replace fuse with a fuse of the same capacity.

Fuse capacities Fuse box I

and names of circuits

-

7-37 -

the

I1

INSTRUMENTS AND CONTROLS

Fuse box II No.

Fuse capacity

0

IOA

0

5A 5A

@

5A

1

0

/ ;

;

Remarks

Circuit Emergency steering switch, Automatic emergency steering timer relay Electronic display panel monitor lamps, Central warning lamp, Buzzer Suspension control solenoid, Suspension controller

1 Maintenance monitor

I

/ ;Moadmeter,Pyloadrekw

/ Spare,

Payload meter external display

Fuse box III

I

Remarks

Circuit

*

-

0

10A

8

1OA

Wiper motor, Washer motor

8

10A

Wiper motor, Washer motor

@

10A

@

10A

0

10A

Spare

Air compressor (For air conditioner) Air compressor blower motor (For air conditioner) Engine stop motor

When using the terminal of the spare fuse, consult your Komatsu distributor.

-

7-38 -

OPERATING YOUR MACHINE

OPERATING YOUR MACHINE The following is an explanation of the checks before starting, method of starting the engine, and controls for the machine needed to operate the machine.

Please read this section carefully to acquire basic knowledge of methods of operation.

CHECKS BEFORE OPERATING THE MACHINE Always carry out the following checks to ensure safety for the operator and the maintenance of the machine performance.

CHECKS BEFORE STARTING (WALK-AROUND CHECK) Before starting the engine, check around and under the machine to check the work equipment and hydraulic system for any loose nuts or bolts, or leakage of oil, fuel, or coolant.

Check also for any loose electric wires, play, and collection of dirt around places that reach high temperatures.

317

17,18

1

4,i2

17:18

2,9

10

5:11

i

-

7-39 -

15,16

lhl

17,18

I;

OPERATING YOUR MACHINE

1. Check electric wires Check if fuses are broken, and check for any traces of disconnections or short circuits in the electric wiring. Check also for any loose terminals, and tighten if necessary.

In particular, check the wiring of the following: 0 Battery 0 Starting motor 0 Alternator 2. Check for loose mounting cleaner

bolts of air

3. Check for leakage of water from radiator 4. Check for leakage of oil or water from around engine 5. Check for leakage of oil from transmission piping 6. Check for leakage of axle oil 7. Check coolant level, add water Check the coolant level.

The coolant level must be between and LOW marks on the reserve tank.

the FULL

8. Check oil level in front brake oil tank, add oil Check the level of the oil in the front brake tank. The oil level must be between the FULL and LOW marks on the tank.

9. Check dust indicator Check that the red piston of the dust indicator has not reached the service level.

TO. Drain water from air tank Open the drain valve of the the water.

tank

and

-7-40-

drain

OPERATING YOUR MACHINE

11. Check oil level in transmission case, add oil Check the transmission oil level.

The oil level must be visible in the sight gauge.

12. Check oil level in engine oil pan, add oil Check the engine oil level.

The oil level must be between the H and L marks on the level gauge.

13. Check oil level in steering, hoist oil tank, add oil Check the steering and hoist oil level.

The oil level must be visible in the sight gauge.

14. Check oil level of rear brake cooling oil tank, add oil Check the rear brake cooling oil level.

The oil level must be visible in the gauge.

sight

15. Drain water and sediment from fuel tank Loosen the drain valve and drain the water and sediment.

16. Check fuel level Check the fuel level on the fuel gauge.

17. Check wheel hub nuts, tighten 18. Check tire inflation tires

pressure, damage to

19. Check central warning

lamp

20. Check machine monitor system

-7-41-

OPERATING YOUR MACHINE

21. Check braking action of service brake 22. Check braking capacity of service brake 23. Check braking action of retarder brake 24. Check braking capacity of retarder brake 25. Check braking action of parking brake 26. Check braking capacity of parking brake 27. Check braking action of emergency

brake

28. Check braking capacity of emergency brake 29. Check emergency

steering

30. Check body mount rubber 31. Check action of steering 32. Check direction undermirror

of rear view mirror,

33. Check lights 34. Check horn

cy ,

35. Check action of gauges during operation 36. Check exhaust gas color, noise 37. Check for sediment separator

and water in water

-

7-42 -

OPERATING

BEFORE STARTING THE ENGINE Before starting the engine, check the position of all levers and pedals.

1. With your back against the back rest of the operatorâ&#x20AC;&#x2122;s seat, adjust the seat position so that the brake pedal can be easily depressed.

2. Is parking position?

brake switch

(1) in the PARKING

3. Is gear shift lever (2) in the N (neutral) position? t The engine will not start while gear shift lever (2) is in any position other than N (neutral).

If the gear shift lever is at any position except N (Neutral), and the starting switch is turned ON, the central warning lamp will flash and the alarm buzzer will sound.

4. Is dump lever (3) in the FLOAT position?

-

7-43 -

YOUR MACHINE

OPERATING YOUR MACHINE

5. Is retarder control release position?

lever

(4)

in the

brake

6. Check for any abnormalities in the machine monitor and maintenance monitor when starting switch (5) is turned ON.

TO START THE ENGINE NORMAL STARTING Before starting the engine, surrounding area is safe.

check

1. Turn the key of starting switch START position to start the engine.

that

the

(1) to the OFF I

%

’

,’

__-- i”

Jiib5 \

‘2. When the engine is started, release the key of starting switch (1) and the key will return automatically to ON. * Do not leave the key in START for more than 20 seconds.

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

-7-44-

OFF

OPERATING

YOUR MACHINE

STARTING THE ENGINE IN COLD WEATHER If the temperature becomes low, start the engine as follows.

1. Turn the key of starting position.

2. Depress accelerator

(1) to the ON OFF

pedal (2) half way.

3. Keep quick start switch wait for 2 - 3 seconds.

4. Turn the key START position

switch

(3) depressed

and \\

of starting switch to crank the engine.

(1) to

the OFF (

-7-45-

I

%

OPERATING YOUR MACHINE

5. While cranking the engine, release quick start switch (3) and start the engine.

6. When the engine starts, return the key of starting switch (1) to the ON position.

(Release the key and it will return automatically.)

If the engine speed does not increase, repeat the pushing operation of the quick start switch 2 - 3 times while cranking.

After starting, if the engine speed drops and the engine is about to stop, operate the quick start switch to spray ether. When doing this, adjust the number of times of operating the spray so that the engine does not rise too far.

Do not raise the engine speed above 1000 rpm while operating the quick start switch.

When starting, and cranking the starting motor, the monitor may flash, but if it goes out after the engine starts, there is no abnormality.

If the engine does not start with the above operation, wait for approx. 2 minutes and repeat Steps 2 - 5.

During normal operation, do not operate the ether spray under any circumstances.

Do not spray more ether than is necessary.

If too much ether is sprayed, there will be an explosion.

Be extremely A ether cylinder.

careful

when

handling

-

7-46 -

the

OFF ~ :

% ,,â&#x20AC;&#x2122;

OPERATING YOUR MACHINE

Precautions when handling ether 0 Never bring any flame close to the ether. l After using, do not throw the cylinder into a fire or make holes in it.

0 Do not keep the ether cylinder in a place at a temperature of more than 40°C. 0 Do not touch or inhale the ether gas. l Do not bring the ether cylinder into the operator’s compartment.

0 Keep the cylinder out of the reach of children. * When not using the ether cylinder, such as in the summer, remove it from the machine. t If the ambient temperature goes below -25”C, remove the ether cylinder from the machine until the machine is started again, and keep it in storage at room temperature.

SPECIAL STARTING 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.

Refer to FUEL FILTER in every 500 hours services.

-

7-47 -

OPERATING YOUR MACHINE

AFTER STARTING After starting the engine, do not immediately start operations. First, carry out the following operations and checks.

After warming up the engine, check that the vehicle monitor is normal.

Run the engine under light load until the engine water temperature gauge and air pressure gauge are in the green range.

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

Check if the exhaust color is normal or whether there is any abnormal noise or vibration.

Avoid abruptly accelerating the engine until the completion of warm-up.

-

7-48 -

OPERATING YOUR MACHINE

TO MOVE THE MACHINE OFF Before moving the machine off, check that the surrounding area is safe, give a signal or sound the horn, then start the machine.

1. Check that the machine

there is no warning monitor.

display

Fasten your seat belt, and check lever (1) is in the FLOAT position.

that

on

dump

Check that air pressure gauge (2) is in the green range, and set parking brake lever (3) to the TRAVEL position to release the parking brake.

Check that rear brake (retarder) pilot lamp (4) is OFF, then move gear shift lever (5) to the desired position.

When operating the gear shift lever, set it securely in position.

If it is not set securely in position, the shift position display on the panel may go out, and the transmission warning monitor may light up.

When moving the gear shift lever from N (neutral) to the R (reverse) or F (forward) positions, always release the accelerator pedal.

-749-

OPERATING YOUR MACHINE

5. Depress machine.

accelerator

pedal

(6) and

drive

the

If the gear shift lever is moved to any position other than N when the parking brake is applied, the central warning lamp will flash and the alarm buzzer will sound.

If the gear shift lever is moved to any position other than N when the dump lever is at a position other than FLOAT, the central warning lamp will light up and the alarm buzzer will sound.

Do not operate the gear shift lever while depressing the accelerator pedal.

This action will cause a large shock, and will also shorten the service life of the machine.

-

7-50 -

1

I

OPERATING YOUR MACHINE

CHANGING GEAR SPEED Shift gear as follows.

This machine is equipped with automatic transmission, so if the gear shift lever is set to the desired position, gear shifting is carried out automatically to match the travel speed of the machine. + When switching between FORWARD and REVERSE, always stop the machine completely before moving the lever. * Do not operate the gear shift lever while depressing the accelerator pedal.

This action will cause a large shock, and will also shorten the service life of the machine.

-

7-51 -

_I

OPERATING YOUR MACHINE

TRAVEL Shift up (accelerating) If the accelerator pedal is depressed to accelerate the machine, the lock-up clutch is engaged and the transmission enters direct drive.

If the machine is accelerated further, the transmission is automatically shifted up.

Shift down (decelerating) If the accelerator oedal is released, the machine slows down, and the transmission is automatically shifted down.

Down-shift inhibit This prevents overrunning of the engine caused by mistaken operation of the gear shift lever.

Overrun preventive mechanism If the machine is accelerated beyond the maximum speed for any gear position while going downhill, the overrun preventive mechanism actuates, causing the retarder to work to slow down the machine.

-

7-52 -

I

OPERATING YOUR MACHINE

DOWNHILL

TRAVEL

When traveling downhill, travel at a safe speed for the road conditions (condition of road surface, road width, etc.).

Before starting downhill, release accelerator pedal (I), and operate retarder control lever (2) to reduce speed.

Move the gear shift lever to the position (5, 4, 3, L) that corresponds to the maximum permitted speed for the retarder brake performance.

On the downhill slope, operate retarder control lever (2) to keep the engine speed above 1800 rpm, and travel so that the retarder brake oil temperature gauge is within the green range.

When traveling downhill, do not use the service brake except in emergencies. The brake will overheat and the service life will be reduced.

When operating the ratarder, operate the lever slowly. Sudden braking is dangerous and will cause the tires to slip.

-

7-53 -

-

_ .: i- â&#x20AC;&#x2DC;,

OPERATING YOUR MACHINE

PRECAUTIONS

FOR DOWNHILL

TRAVEL

The maximum allowable travel speed when going downhill with the retarder applied depends on the downhill travel distance and the hill gradient. (Refer to the brake performance graph.)

If the machine continues traveling downhill at a speed exceeding the maximum allowable value indicated in the brake performance graph, it may damage the retarder brake, resulting in a serious accident.

When traveling downhill using the retarder, if the retarder oil temperature monitor lamp on the vehicle monitor flashes, shift down.

(When this happens, the central warning lamp flashes and the alarm buzzer sounds.)

If the monitor lamp does not go out even after shifting down, stop the machine immediately, return the gear shift lever to neutral, run the engine at 2000 rpm, and wait until the monitor lamp goes out.

By operating the retarder control lever when traveling downhill, it is possible to shift down more quickly than with normal deceleration.

It is also possible to travel without shifting up* If the retarder should stop working while traveling downhill, do the following: Completely release the retarder control lever once and then operate the lever again.

If the retarder has no effect even when the retarder is operated again, return the retarder lever completely to the RELEASE position, depress the service brake, stop the machine, and contact your Komatsu distributor. stopping the machine, A Afâ&#x20AC;&#x2122;ter under the tires immediately.

put

-

blocks

7-54 -

OPERATING

REVERSING Stop the machine and the area to the rear is safe.

check

carefully

that

Set gear shift lever (1) in the R position, and depress accelerator (2) gradually to drive the machine.

If the dump lever is in any position other than FLOAT, it is impossible to travel in reverse. Place the lever in the FLOAT position before setting the gear shift lever at the R position.

Do not operate the gear shift lever while depressing the accelerator pedal.

This action will cause a large shock, and will also shorten the service life of the machine.

When switching between FORWARD and REVERSE, always stop the machine completely before moving the lever.

-

7-55 -

RW

YOUR MACHINE

OPERATING YOUR MACHINE

OPERATING DUMP BODY Operate the dump body as follows.

1. Set gear shift lever (1) at the N position, and set parking brake lever (2) at the PARKING position.

2. Set dump lever (3) at the RAISE position, depress the accelerator pedal, and the dump body will rise. * When the dump lever is placed in the RAISE position, it is held at the RAISE position even when released, and the body will continue to rise. + The speed speed.

rises in proportion

to the engine

3. When the dump body rises to the set position (adjusted position of body positioner), dump lever (3) returns to the HOLD position.

The body is then held at this position. * If it is desired to raise the body further, move dump lever (3) to the RAISE position and the dump body will rise.

(3) is lever In this condition, if dump released, lever (3) will return to the HOLD position and the dump body will stop in that position.

-

7-56 -

Raise.

OPERATING

4. Move dump lever (3) to the LOWER position and the dump body will start to move down.

After lowering the dump body a certain distance, move dump lever (3) to the FLOAT position. (Release the lever and it will return automatically to the FLOAT position.) The body will move down under its own weight.

When traveling, always set the dump lever at the FLOAT position, regardless of whether the truck is loaded or not.

If the gear shift lever is moved to any position other than N (neutral) when the dump lever is not at the FLOAT position, the central warning lamp will light up and the alarm buzzer will sound.

When raising the dump body, reduce the pressure on the accelerator pedal when the body is near the maximum angle to reduce any shock load on the hydraulic circuit and hoist cylinders. dumping A When dumping speed.

A A

large

Never load the dump body is raised.

rocks,

reduce

body while

the

the dump

When carrying out inspection or maintenance with the dump body raised, always use the safety pin and lock the dump lever in the HOLD position.

-

7-57 -

YOUR MACHINE

OPERATING YOUR MACHINE

TO STOP THE MACHINE Do not stop the machine suddenly. As far as possible, always stop the machine with room to spare.

1. Release accelerator pedal (I), and brake pedal (2) to stop the machine.

depress

2. Place gear shift lever (3) at the N (neutral) position, and set parking brake lever (4) at the PARKING position to apply the parking brake.

3. When sitting in the operatorâ&#x20AC;&#x2122;s compartment, pull retarder control lever (5) fully to apply the retarder. leaving the A When parking brake.

machine,

always apply the

-

7-58 -

OPERATING

Emergency stop If the service as follows.

Pull retarder the retarder.

brake fails, stop the

control

lever

machine

(1) fully to apply

If operating the retarder lever alone does not give sufficient braking force, set emergency brake lever (2) to the APPLIED position to apply the emergency brake.

When emergency brake lever (2) is set to the APPLIED position, the parking brake is also automatically applied.

Move parking brake lever (3) to the right to the PARKING position. the machine stops, A When the tires immediately.

put blocks under

* After making an emergency

stop, locate the cause and repair it on the spot as far as possible. * After making an emergency stop, adjust the parking brake again.

Immediately after making an emergency A stop, the parking brake discs are at a high temperature, so let them cool before carrying out any repair or adjustment.

-

7-59 -

YOUR MACHINE

OPERATING YOUR MACHINE

TO STOP THE ENGINE Allow the engine to cool down gradually before stopping it.

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

Return the key of starting switch OFF position and remove the key.

(1) to the

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.

BRAKE PERFORMANCE GRAPH PRECAUTIONS REGARDING TYPE OF LOAD PRECAUTIONS FOR MACHINE OPERATION * Details of the above items are given on the OPERATION manual.

volume

at the beginning

-

of this

7-60 -

MAINTENANCE TABLE

TABLE

MAINTENANCE No.

SERVICE

ITEM

PAGE

CHECK BEFORE STARTING a

Cooling water

Check and supply

2-l 7

b

Front brake oil tank

Check and supply

2-l 7

C

Dust indicator

Check

2-l 7

d

Air tank

Drain water

2-18

e

Transmission case

Check and SUDDIV

2-l 8

f

Engine oil pan

Check and supply

2-19

g

Steering and hoist oil tank

Check and supply

2-20

h

Rear brake cooling oil tank

Check and supply

2-20

i

Fuel tank

Drain water and sediments

2-20

i

Fuel

Check and SUDDIV

2-21

k

Wheel hub nuts

Check and retighten

2-21

I

Tires

Check inflation pressure and damage

2-22

m

Central warning lamp

Check

7-63

n

Machine monitor

Check

7-64

0

Foot brake

Check action

7-64

P

Foot brake

Check capacity

7-64

q

Retarder

Check action

7-65

r

Retarder

Check capacity

7-65

S

Parking brake

Check action

7-65

t

Parking brake

Check capacity

7-65

U

Emergency brake

Check action

7-65

V

Emergency brake

Check capacity

7-65

W

Emergency steering

Check function

7-65

Steering system

Check function

7-65

X

-

7-61 -

MAINTENANCE TABLE

No.

ITEM

SERVICE

PAGE

(CHECK BEFORE STARTING) Y

Rear and under-view

z

mirror

Check

7-66

Lamps

Check

7-66

a’

Horn

Check

7-66

b’

Instruments

Check

7-66

Exhaust gas and color

check

7-66

d’

Body mount

Check

7-66

e’

Electric wiring

Check

7-66

f

Water separator

Check

7-67

rubber

-

7-62 -

CHECK BEFORE STARTING

CHECK BEFORE STARTING a. CHECK COOLANT LEVEL b. CHECK OIL LEVEL IN FRONT BRAKE OIL TANK CHECK DUST INDICATOR DRAIN WATER FROM AIR TANK CHECK OIL LEVEL IN TRANSMISSION CASE CHECK OIL LEVEL IN ENGINE OIL PAN CHECK OIL LEVEL IN STEERING AND HOIST OIL TANK h. CHECK OIL LEVEL IN REAR BRAKE COOLING TANK i. DRAIN WATER AND SEDIMENT FROM FUEL TANK i- CHECK FUEL LEVEL k. CHECK WHEEL HUB NUTS FOR TIGHTNESS I. CHECKTIRES FOR INFLATION PRESSURE AND DAMAGE * Details of the above items are given on the MAINTENANCE volume at the beginning of this manual. m.CHECK CENTRAL WARNING LAMP Check for any broken bulb in central warning lamp (1). To prevent any inability to give warning because of defective operation of the buzzer, carry out the following check.

Stop the engine, place the starting switch in ON and the parking brake valve lever in PARKING, and the gear shift lever in any position other than NEUTRAL. If the lamp flashes, it is normal.

Place the starting switch key in ON when air pressure is below the specified value.

If the lamp flashes and the buzzer sounds, they are normal.

-

7-63 -

CHECK BEFORE STARTING

n. CHECK MACHINE MONITOR SYSTEM Before starting the engine, turn the starting switch to the ON position, and for approx. 3 seconds all the monitor lamps, gauge Imaps, and the central warning lamp will flash, and the alarm buzzer will sound for approx. 2 seconds.

When this happens, the speedometer will display 88.

When the starting switch is turned to the ON position, if the gear shift lever is not at N (neutral), the central warning lamp will flash, and the alarm buzzer will sound intermittently. However, if the gear shift lever is returned to N (neutral), the lamp will go out and the buzzer will stop.

The monitor cannot be checked until at least 30 seconds has passed after stopping the engine.

Check the caution lamps and pilot lamps for broken bulbs at the same time as checking the monitor.

Before starting the engine, turn the starting switch to the ON position, press bulb check switch (I), and check if there are any broken bulbs in the caution lamps or pilot lamps.

If any of the monitor lamps, caution lamps, or pilot lamps do not light up, there is probably some failure or disconnection, so contact your Komatsu distributor. o. CHECK BRAKING ACTION OF SERVICE BRAKE Carry out checks before starting, and if the effect of the brakes is poor, adjust the brakes.

For details, see “Adjustment”. p. CHECK BRAKING CAPACITY OF SERVICE BRAKE Check the capacity of the service brake as follows.

1. Raise the air pressure to the maximum, stop the machine on level ground and depress brake pedal (1).

2. Place gear shift lever (2) in the “D” position, gradually increase the engine speed, and check that the machine does not move even when the engine speed reaches 1850 rpm.

-7-&l-

CHECK BEFORE STARTING

q. CHECK BRAKING ACTION OF RETARDER Carry out check before starting. r. CHECK BRAKING CAPACITY OF RETARDER Check the capacity of the retarder as follows.

1. Raise the air pressure to the maximum, stop the machine on level ground and pull retarder lever (1) fully.

Place gear shift lever (2) in the ‘9” position, gradually increase the engine speed, and check that the machine does not move even when the engine speed reaches 1320 rpm.

CHECK BRAKING ACTION OF PARKING BRAKE Check after completing work.

CHECK BRAKING CAPACITY OF PARKING BRAKE Check the capacity of the parking brake as follows.

1. Raise the air pressure to the maximum, stop the machine on level ground and place parking brake lever (1) in the PARKING position.

2. Place gear shift lever (2) in the “D” position, gradually increase the engine speed, and check that the machine does not move even when the engine speed reaches 1430 rpm. u. IS BRAKING OPERATION OF EMERGENCY BRAKE NORMAL? Carry out checks before starting. v. CHECK BRAKE CAPACITY OF EMERGENCY BRAKE Check the brake capacity of the emergency brake as follows.

1. Raise the air pressure to the maximum, and operate emergency brake lever (1) on flat ground.

2. Place gear shift lever (2) in the “D” position, gradually raise the engine speed, and check that the machine does not move even when the engine is at full throttle.

-

7-65 -

CHECK BEFORE STARTING

w.CHECK EMERGENCY STEERING 1. Turn the key of the starting switch to the ON position.

2. Turn emergency steering switch (1) ON, and check that the steering can be turned for 20 seconds. * If the steering wheel cannot be operated, contact your Komatsu distributor.

CHECK THAT THE STEERING SYSTEM WORKS-PROPERLY. Y- CHECK THAT THE REAR AND UNDER-VIEW MIRRORS ARE WELL ADJUSTED. 2. CHECK THAT ALL LAMPS WORK PROPERLY. a’. CHECK THE HORN b’.CHECK THAT THE INSTRUMENTS FUNCTION PROPERLY IN OPERATION. c’. CHECK THAT ENGINE EXHAUST GAS COLOR AND SOUND ARE NORMAL. d’.CHECK BODY MOUNT RUBBER Check cracks, bitting unexpected materials, or tightening of bolts.

X.

e’. CHECK ELECTRICAL WIRING Check for damage of the fuse and any sign of disconnection or short circuit in the electric wiring. Check also for loose terminals and tighten any loose parts.

Check the following points carefully.

0 Battery 0 Starting motor 0 Alternator fuse is damaged A ofIf theshortcircuiting in always investigate t

or there is any sign the electric wiring, the cause and correct it.

Please contact your Komatsu distributor investigation and correction of the cause.

-

7-66 -

for

_

CHECK BEFORE STARTING

f’. CHECK FOR SEDIMENT AND WATER IN WATER SEPARATOR The water separator separates water mixed in the fuel. If float (2) is at or above red line (I), drain the water. For,the draining procedure, refer to section “WHEN REQUIRED”. + Even if a water separator is installed, be sure to check the fuel tank to remove water and sediment in the fuel.

-

7-67 -

..

TR6UBLE SHOOTING GUIDE

TROUBLE SHOOTING

GUIDE

This guide is not intended to cover more common possibilities are listed.

every

conditions,

however

many

ENGINE The engine oil level l Add the oil to the 0 Check oil leakage 0 Check and repair

monitor flashes. specified level. from the pipe or the joint. wiring to the sensor.

Steam is emitted from the top part of the radiator (the pressure valve).

The radiator cooling water level monitor flashes.

The red range of the cooling water temperature gauge lights.

The cooling water temperature monitor flashes.

0 Supply the cooling water and check leakage.

0 Adjust fan belt tension.

0 Wash out inside of cooling system.

0 Clean or repair the radiator fin.

0 Replace the water temperature gauge.

0 Repalce the thermostat and the seal. l Tighten the radiator cap firmly or replace the cap.

0 Check and repair wiring to the sensor.

The white range of the cooling water temperature 0 Replace the water temperature gauge.

0 Replace the thermostat.

0 Install the radiator curtain.

gauge lights.

The engine does not start when the starting motor is turned over.

0 Add fuel.

0 Repair where air is leaking into fuel system.

0 Fill the fuel filter with fuel.

0 Refer to the section of electrical system.

0 Check the valve clearance.

Fuel flow occasionally stops.

0 Clean the breather hole on the cap.

0 Replace the breather tube.

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7-68 -

of the

TROUBLE SHOOTING GUIDE

Oil consumption is large.

Exhaust gas is white or blue.

0 Check and repair oil leakage.

0 Adjust to specified oil quantity.

0 Replace piston, ring and cylinder liner.

0 Replace with specified fuel.

0 Check and replace the turbocharger.

Exhaust gas occasionaly turns black.

0 Clean or replace the air cleaner element. s Check and repair piston, ring and cylinder liner.

0 Adjust valve clearance.

0 Check and replace the turbocharger.

Combustion noise occasionally changes to breathing 0 Repair air leakage into fuel supply line.

Unusual combustion noise or mechanical 0 Replace with specified fuel.

0 Check over-heating.

-

noise.

7-69 -

sound.

TROUBLE SHOOTING GUIDE

ELECTRICAL SYSTEM Lamp does not glow brightly even when engine runs at high speed.

Lamp flickers while engine runs. l Check for loose terminals and open-circuit wiring.

0 Change the battery.

0 Add the battery electrolyte.

0 Adjust belt tension.

Charge monitor does not go out even when engine runs at high speed.

0 Repalce the alternator. l Check and repair wiring.

Unusual noise is emitted 0 Replace the alternator.

from the alternator.

Starting motor does not turn when starting switch is turned on. l Inspect and repair wiring.

0 Replace the starting switch.

0 Charge the battery.

0 Replace the battery switch.

Starting motor turns the engine sluggishly. l Check and repair wiring.

0 Charge the battery.

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

0 Check and repair wiring.

0 Charge the battery.

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7-70 -

TROUBLE

SHOOTING

CHASSIS The torque converter oil temperature monitor flashes. l Check and repair where air is leaking into oil pipe and pipe joint. l Check and replace gear pump. l Add the oil to the specified level of transmission case. l Check and replace the fan belt. l Clean and replace the oil cooler.

0 For a long distance, travel the machine in the direct drive range.

0 Check and repair wiring to the sensor.

Steering wheel is heavy.

0 Lubricate steering linkage.

0 Replace steering cylinder seal.

Steering wheel drags.

0 Adjust so that both left and right tires have same inflation l Check and adjust the front brake pod.

Brake is not effective if the brake pedal is depressed.

Brake effect is unbalanced.

0 Replace brake pad.

0 Replace rear disc.

0 Charge the air to the specified level. l Add brake oil.

0 Bleed the air from the brake circuit.

Dump body operation speed is too low.

0 Replace gear pump. l Refill oil to the specified level.

Suspension is hard. l Replace U-packing.

0 Replace valve core.

Only the single side of the rear wheel is likely to slip. l Bleed air (from the right and left of rear brake). l Replace tires.

0 Level the load.

0 Disassemble the brake and check.

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7-71 -

pressure.

GUIDE

TROUBLE

SHOOTING

GUIDE

MECHATRONICS

RELATED PARTS

If any abnormality occurs as listed on the left, stop the machine, apply the parking brake, check the LED display of the controller, and then contact your Komatsu distributor for repair.

(1) Engine controller (2) Shift controller (3) Suspension controller ENGINE CONTROLLER

Trouble

e-

Goes

off

item

1 (Normal)

Lights Flashes slow1

shooting

Goes off

Flashes slow simultaneously Flashes slow alternately

1 Rack

sensor

fL)

1 Rotation

sensor

(A)

Rotation

sensor

(6)

Flashes fast

Rack sensor

Lights

Accelerator

power

source

Flashes slow

off

Goes

Governor

sensor cut relay (L)

Flashes fast Flashes slow

Governor

solenoid

1 Governor

servo

(L)

Flashes fast alternately

Governor

servo

(R)

Flashes fast

Water

Flashes fast simultaneously

Lights Goes

Lights

off

Flashes slow 1 Flashes fast

Lights simultaneously

temperature

Governor

1 Rack

sensor

cut relay (R)

sensor

1 Governor

(L)

(R)

solenoid

(R)

Controller

0 Fast flashing: 0.5 set/l time 0 Slow flashing: 4 set/l time

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7-72 -

TROUBLE

SHIFT CONTROLLER During travel, if the central warning lamp flashes and the alarm buzzer also sounds, act calmly and do as follows.

Use the brake to reduce speed, and stop the machine in a safe place.

Open the cover at the rear of the operatorâ&#x20AC;&#x2122;s compartment, and check the number given on the self-diagnostic display at the top of the shift controller.

If necessary, place the shift lever at N, then pull out the emergency escape connector (connectors No. A-l, A-2, black one-pole connector) then insert it again. Operate the shift lever without depressing the accelerator pedal, and move the machine.

If the shift lever is operated with the accelerator pedal depressed, the emergency escape function is not actuated.

Also, depending on the failure mode, the emergency escape function may not be actuated.

When normal: 0.0 (Normal temperature) 0.C (Low temperature: 10°C or below)

% The digit after the decimal point in number 2.0 - 9.0 indicates the following clutches. b: blank 1: Lock-up 3: L 5: 2nd 7: 4th 2: H 4: 1st 6: 3rd 8: Rev -

7-73 -

SHOOTING

GUIDE

SUSPENSION

CONTROLLER

-1

Trouble

Goes

Power

I ~~~

(Normal) I---

slowly

simultaneously

Pressure

Lights

up

item

source

off

Goes Flashes

off

shooting

sensor

(right)

~ Flashes

Goes

Lights

slowly

off

Model

selection

Solenoid

(1)

Flashes slowly

Solenoid

(2)

Flashes fast

Solenoid

(3)

up

Lights

up

Controller

0 Fast flashing: 0.5 set/l time Slow flashing: 4 set/l time 0 Solenoids (I), (2), and (3) are distinguished by the solenoid connector number.

Solenoid 1: CNSLI Solenoid 2: CNSL2 Solenoid 3: CNSLS l

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7-74 -

TROUBLE

SHOOTING

GUIDE

PAYLOAD METER

Priority rank

Display

1

2

Content

-1, _ _ _‘_I

Internal CPU stops (CPU reset function possible) (Controller power, etc. is normal)

.-__3: I_

Abnormality

I-_ _ j,? c -

Short circuit in relay

I-, -, 1: - j ;

Drop in backup battery voltage

in sensor power (18V)

. Disconnection

,- - :_x -

Front left wheel

I-__ I_

Rear right wheel

,I

;;

in voltage

sensor signal

. Pressure 4

sensor signal line in contact with power line

1-1

Front left wheel F_ _ ‘_’ ’ ,_ )L 5

I

Disconnection

in signal line or contact with chassis

I

:r _‘-’ 1’

Signal line in contact with power line

IL

,,1,,,.*

-. ,-,;,-,: r-,,-u-w--,,*,I* .- i_‘,’ ;; ;’ _ :.,t-,I,_h I- : I It .1*1111. : .- I-”: I *. _ -.,L 111, I.

6 7

, 8

Printer REDY signal not

given (paperjammed)

Data stored in memory

has reached 200 (overflow)

Calibration

needed

Rear right wheel

9

-1

. Sensor output drift

‘I _,“”

I_

Once an error pressed.

’

message

I

Front left wheel

is output,

I

it stays displayed

-

7-75 -

until the CAL switch

is

SERVICE

METER

SERVICE METER This meter indicates the integrated work hours. So, use it according to the following instructions.

Record the readings at the start and the end of work, this is the work record of the machine.

This record will indicate, when periodical maintenance is due.

It also indicates the integrated working hours when machine problems are encountered.

How the meter progresses The service meter progresses by 1 when the engine is operated for one hour, regardless of the engine speed.

Consequently, if the engine is running, the service meter will advance even if the machine does not move.

While engine is running, green pilot lamp on the service meter flashes to show the service meter advances.

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7-76

-

-1

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