Komatsu PC1000-1 PC1000LC-1 PC1000SE-1 Hydraulic Excavator Operation & Maintenance Manual

SEAM007701

HYDRAULIC EXCAVATOR PC1000-10001 SERIAL NUMBERS PC1000LC-10001 and up PC1000SE-10001

WARNING Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine. This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it.

1997 All Right Reserved Printed in USA 06-97 DATAKOM

NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.

A

WARNING

Unsafe use of this machine may cause serious injury or death.

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

CALIFORNIA

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

I

CALIFORNIA Proposition 65 Warning Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer, birth defects and reproductive harm. Wash hands after handling.

KOMA�U

Printed in USA

DAlhKOM

EMISSION CONTROL WARRANTY EMISSION CONTROL WARRANTY

1.

STATEMENT

(APPLIES TO CANADA ONLY)

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

2.

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

3.

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

KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL

DAMAGES.

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

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

DES EMISSIONS

DES OMISSIONS (APPLICABLE

AU CANADA SEULEMENT):

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

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

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

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

CEHQ000700

- Komatsu America International Company 12199

AVERTISSEMENT DES BLESSURES PEUVENT RisULTER ET LA GARANTIE S’ANNULER SI LES RPM DU TAUX D’ESSENCE OU CALTITUDE EXCkDENT LES VALEURS MAXIMALES PUBLIEES POUR CE MODELE ET SON APPLIWTION.

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

.

r

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

MODEL

ISERIAL

I

I ENGINE

FAMILY

EXHAUST

EMISSION

CONTROL

SYSTEM

ADV. LOAD CHARGE

DE SORTIE

OUTPUT

Kw

ADV. E(,,sH

PORTBE

DE VALVE

DBPLACEMENT

NO. T

I

I

IDISPLACEMENT

I

FIRING (

/

LITERS

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

ORDER

RPM

HP)

/IN.

1

I\ FROID

-------

BQUENCE

DE MISE A FEU

mm3/STROKE

(mm) IDLE SPEED INITIAL TIMING RkGLAGE INJECTION

DE UALLUMAGE INITIALE

-

RPM DEG. BTDC

INJECTION

FAMILY

EMISSION

LIMIT

DATE OF MANUFACTURE

-

,’ KOMATSU MADE

KOMATSU FABRIQUI?

LTD. /

IN JAPAN

LT$E

AU JAPON

ENGINE DATAPLATE - ENGLISH / FRENCH

IMITE D’I?MISSION

DE

LA FAMILLE

1. FOREWORD

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

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

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

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

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

A WARNING lmproper operation injury or death.

and maintenance

Operators and maintenance operation or maintenance.

of this machine can be hazardous

personnel

should

read this manual

and could result in serious

thoroughly

before

beginning

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

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

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

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

The description 1-1.

of safety is given in SAFETY INFORMATlON

on page O-2 and in SAFETY from page

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

and

other

reproductive

harm.

o-1

2. SAFETY INFORMATION

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

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

4k

A

&A

DANGER

-

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

WARNING

-

This word is used on safety messages and safety labels where there is a potentially dangerous situation which could result in serious injury or death if the hazard is not avoided. These safety messages or labels usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard 1 may also result in serious damage to the machine.

CAUTION

-

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

NOTICE

-

This word is used for precautions that must be taken to avoid actions could shorten the life of the machine.

Safety precautions

are described

which

in SAFETY from page l-l.

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

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

o-2

3. INTRODUCTION 3.1 INTENDED USE This Komatsu HYDRAULIC l Digging work l Loading work See the section

EXCAVATOR

“12.14 WORK POSSIBLE

is designed

USING

to be used mainly for the following

HYDRAULIC

EXCAVATOR�

for further

work:

details.

3.2 RUNNING IN THE MACHINE Your Komatsu machine has been thoroughly adjusted and tested before shipment.

However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life.

Be sure to run in the machine for the initial 100 hours (as indicated by the service meter.)

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

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

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

o-3

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

4.1 MACHINE

SERIAL NO. PLATE POSITION

On the front bottom right of the operator’s cab

4.2

ENGINE SERIAL NO. PLATE POSITION

On the upper side of the oil cooler housing located on the left side of the engine cylinder viewed from the fan

4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No.: Enaine serial No.: 1

Distributor name:

Address:

Service personnel for your machine:

REMARKS

o-4

Phone:

5. CONTENTS

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

1.

Foreword

2.

Safety information

3.

Introduction

4.

Location of plates,

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

........................................................................................................................................ table to enter serial No. and distributor

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

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

SAFETY precautions

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

l- 2

6.

General

7.

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

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

7.1 Operating machine ..................................................................................................................

7.2 7.3 Transportation ..........................................................................................................................

Battery .......................................................................................................................................

7.4 Bucket with hook .....................................................................................................................

7.5

I- 8 I- 8 I-IO I-15 1-16 1-17

8.

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

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

8.1 8.2 During maintenance ................................................................................................................

I-20 I-20 l-23

9.

Position for attaching

l-27

safety labels

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

OPERATION 10. General view ......................................................................................................................................

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

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

2- 2 2- 2 2- 3

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

11. Explanation of components 11.1 Machine monitor.. ....................................................................................................................

11.2 Lamp .........................................................................................................................................

11.3 Switches ....................................................................................................................................

11.4 Control levers, pedals ..............................................................................................................

11.5 Ceiling window ........................................................................................................................

11.6 Front window ...........................................................................................................................

11.7 Door lock.. .................................................................................................................................

11.8 Dust indicator ...........................................................................................................................

11.9 Air conditioner .........................................................................................................................

11.10 Radio .........................................................................................................................................

11.11 Fuse ...........................................................................................................................................

11 .I 2 Controllers ................................................................................................................................

11.13 Tool box.. ..................................................................................................................................

11.14 Grease pump ............................................................................................................................

11.15 Handling grease pump.. ..........................................................................................................

11 .I6 Handling accumulator .............................................................................................................

2- 4 2- 4 2-14 2-15 2-20 2-23 2-24 2-26 2-26 2-27 2-30 2-32 2-33 2-33 2-33 2-34 2-36

o-5

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

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

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

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

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

12.5 Steering machine .....................................................................................................................

12.6 Stopping machine ....................................................................................................................

12.7 Swinging ...................................................................................................................................

12.8 Operation of work equipment ................................................................................................

12.9 Working mode selection .........................................................................................................

12.10 Prohibitions for operation .......................................................................................................

12.11 Precautions for operation .......................................................................................................

12.12 Precautions when traveling up or down hills ......................................................................

12.13 How to escape from mud .......................................................................................................

12.14 12.15 12.16 12.17 12.18 12.19

Work possible using hydraulic excavator.. ...........................................................................

Parking machine ......................................................................................................................

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

Stopping engine .......................................................................................................................

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

Locking ......................................................................................................................................

2-37 2-37 2-46 2-50 2-52 2-56 2-58 2-60 2-61 2-62 2-63 2-66 2-67 2-69 2-70 2-71 2-72 2-73 2-74 2-74

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

13. Transportation .................................................................................................

13.1 Precaution for transportation 13.2 Parts for transport ...................................................................................................................

13.3 Procedure for increasing or reducing track frame gauge.. .................................................

2-75 ^ __

14. Cold weather operation .................................................................................................................... ...........................................................................................

14.1 Precautions for low temperature 14.2 Precautions after completion of work ...................................................................................

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

2-81 2-81 2-83 2-83

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

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

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

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

15.4 Starting machine after long-term storage ............................................................................

2-84 2-84 2-85 2-85 2-85

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

16. Troubleshooting 16.1 Phenomena that are not failures ...........................................................................................

16.2 Precautions on particular jobsites .........................................................................................

16.3 If battery is discharged ...........................................................................................................

16.4 Other trouble ............................................................................................................................

2-86 2-86 2-86 2-87 2-91

O-6

Z-15

2-76 2-79

MAINTENANCE 17. Guides to maintenance

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

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

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

18.2 Outline of electrical system ....................................................................................................

18.3 Outline of hydraulic system ...................................................................................................

18.4 Releasing pressure ..................................................................................................................

18.5 Bleeding air from circuit .........................................................................................................

18.6 Oil filler and level gauge positions .......................................................................................

19. Consumable

3- 2 3- 5 3- 5 3- 8 3- 9 3-10 3-12 3-17

parts list . ... . ..... .. . .. . . . . . .. .. . .. .. ... .. . .. .. . .. .. .. . . .. . .. ... . .. . .. . . . ... .. .. .. . .. ... .. . .. .. . .. ... . . .. . .. . . .. . . .. . . . . ... .. ..

3-18

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

3-19

20. Use of fuel, coolant

and lubricants

according

to ambient

temperature

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

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

21.2 Torque list.. ...............................................................................................................................

22. Periodic replacement

of critical safety parts

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

3-23 3-23 3-24 3-25

23. Maintenance schedule chart ............................................................................................................

23.1 Maintenance schedule chart.. .................................................................................................

3-28 3-28

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

24.1 Initial 100 hours service ..........................................................................................................

24.2 Initial 250 hours service ..........................................................................................................

24.3 When required .........................................................................................................................

24.4 Check before starting ..............................................................................................................

24.5 Every 10 hours service ............................................................................................................

24.6 Every 100 hours service ..........................................................................................................

24.7 Every 250 hours service ..........................................................................................................

24.8 Every 500 hours service.. ........................................................................................................

24.9 Every 1000 hours service. .......................................................................................................

24.10 Every 2000 hours service.. ......................................................................................................

24.11 Every 4000 hours service.. ......................................................................................................

3-32 3-32 3-32 3-33 3-53 3-58 3-61 3-62 3-69 3-76 3-79 3-83

SPECIFICATIONS 25. Specifications

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

4- 2

OPTIONS, ATTACHMENTS ..........................................................................................................................

26. General precautions 26.1 Precautions related to safety.. ................................................................................................

26.2 Precautions when installing attachments .............................................................................

5- 2 5- 2 5- 3

27. Handling bucket with hook ..............................................................................................................

27.1 Checking for damage to bucket with hook ...........................................................................

27.2 Prohibited operations ..............................................................................................................

27.3 Precautions during operations ...............................................................................................

5555-

4 4 4 4

o-7

5. CONTENTS

28. Using seat belt ..................................................................................................................................

28.1 Seat belt ....................................................................................................................................

5- 5 5- 5

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

29. Introduction of attachments 29.1 Specification, use .....................................................................................................................

5-7 5- 7

BACK HOE TYPE SHOVEL 30. General

locations

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

6- 2

31. Instruments and controls .................................................................................................................

31 .I Switch ........................................................................................................................................

31.2 Control levers ...........................................................................................................................

31.3 Control box ...............................................................................................................................

31.4 Fuse box ...................................................................................................................................

6- 3 6- 3 6-4 6-6 6- 7

32. Operation ............................................................................................................................................

32.1 Operation of work equipment ................................................................................................

32.2 Check before starting engine .................................................................................................

6- 8

33. Precautions for machine operation 33.1 Precautions during operation

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

6- 8 6-10 6-13 6-13

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

6-l 5

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

35. Maintenance 35.1 Oil filler and level gauge position .........................................................................................

35.2 Adjust bucket clearance ..........................................................................................................

35.3 Check before starting ..............................................................................................................

35.4 Every 10 hours service ............................................................................................................

6-16 6-16 6-17 6-18 6-19

34. Precautions

36. Excavator

when disassembling

work

37. Transportation

machine

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

6-22

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

6-23

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

38. Introduction of attachment 38.1 Attachment installation combination table ...........................................................................

38.2 Specification, use .....................................................................................................................

6-26 6-26 6-27

39. Specifications

6-28

O-8

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

SAFETY

A WARNING Read and follow all safety precautions. result in serious injury or death.

Failure to do so may

This safety section also contains precautions ment and attachments.

for optional equip-

1-I

g

6. GENERAL PRECAUTIONS

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

SAFETY RULES l

ONLY trained

and authorized

personnel

can operate

l

Follow all safety rules, precautions on the machine.

l

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

and instructions

and maintain

the machine.

when operating

or performing

maintenance

traffic duty, be sure all personnel

SAFETY FEATURES l

Be sure all guards damaged.

l

Use safety features

l

NEVER remove any safety features. ALWAYS keep them in good operating Safety lock lever + See “12.15 PARKlNG MACHINE”.

Seat belts + See “28. USING SEAT BELT”.

l

Improper

CLOTHING

and covers are in their proper positions.

such as safety lock lever and seat belts properly.

use of safety features

AND

Have guards and covers repaired if

PERSONAL

condition.

could result in serious bodily injury or death.

PROTECTIVE

ITEMS

1

Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts and cause serious injury or death. Also, do not wear oily clothes because they are flammable.

Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the machine. Always wear safety goggles, hard hat and heavy gloves if your job involves scattering metal chips or minute materials - this is so particularly when driving in pins with a hammer and when cleaning the air cleaner element with compressed air.

Check also that there is no one near the machine.

See “24.3 WHEN REQUIRED” in service procedure.

Cleaning of air cleaner element +

AM)55010

l-2

1

A

~F$W4!~G;

Fai;ai;o

follow these safety precautions

may lead 6. GENERAL PRECAUTIONS

UNAUTHORIZED l

Any modification

made without

authorization

from

Komatsu can create hazards.

l

Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modification.

ALWAYS APPLY L When standing up from the operator’s seat, always place the safety lock lever securely in the LOCK position. If you accidentally touch the travel or swing lever when they are not locked, the work equipment may suddenly move and cause serious injury or damage.

When leaving the machine, lower the work equipment completely to the ground, set the safety lock lever to the LOCK position, then stop the engine and use the key to lock all the equipment.

Always take the key with you.

Work equipment posture + See “12.15 PARKING MACHINE.”

AE167470

MOUNTING AND DISMOUNTING NEVER jump on or off the machine.

When mounting or dismounting, frame steps, and track shoes.

NEVER get on or off a moving

always face the machine

machine.

and use the handrails,

machine

or track

Do not hold any control levers when getting on or off the machine.

Ensure safety by always maintaining handrails, steps or track shoes.

at least three-point

Always remove any oil or mud from the handrails, repair them and tighten any loose bolts.

contact

of hands

and feet with

the

steps and track shoes. If they are damaged,

If grasping the door handrail when mounting or dismounting or moving on the track, open and lock the door securely in the open position. Otherwise, the door may move suddenly, causing you to lose balance and fall.

AEl67480

AE167490

1 1-3

6. GENERAL PRECAUTIONS

RE PREVENTION

A :;,4Mzemereasons qf safety, always ty precautions.

FOR FUEL AND OIL

Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS. Keep a flame away from flammable fluids.

Stop the engine and do not smoke when refueling.

Tighten all fuel and oil caps securely.

Refueling and oiling should be carried out in well ventilated areas.

Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.

A0055020

A0055030

A0055040

l

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

l

To prevent hot water from spurting out: 1) Turn engine off.

2) Allow water to cool.

3) Slowly loosen cap to relieve pressure before removing.

l

To prevent hot oil from spurting out: 1) Turn engine off.

2) Allow oil to cool.

3) Slowly loosen cap to relieve pressure

l-4

before removing.

a E;RN;;G;

Fai;ai;o

follow these safety precautions

may lead 6. GENERAL PRECAUTIONS

ASBESTOS DUST HAZARD PREVENTlON Asbestos dust can be HAZARDOUS to your health if it is inhaled.

If you handle materials containing asbestos fibers, follow these guidelines l NEVER use compressed air for cleaning. l Use water for cleaning to keep down the dust. l Operate the machine with the’ wind to your back, whenever possible. l Use an approved respirator if necessary.

as given below:

CRUSHING OR CU l

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

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

FIRE EXTlNGUlSHER AND FIRST AID KIT Be sure fire extinguishers

have been provided

Provide a first aid kit at the storage

1

1 and know how to use them.

point.

Know what to do in the event of a fire.

Be sure you know the phone numbers

of persons you should contact in case of an emergency.

A0055070

l-5

A ~~JW~e~;ereasons yf safety, always ty precautions.

6. GENERAL PRECAUTIONS

PROTECTION AG If there is any danger of falling or flying objects hitting the operator, install protective guards in place to protect the operator as required for each particular situation. l

For work in mines, tunnels or other places where there is danger of falling rocks, put FOPS (falling object protective structure) in place. Also, place a laminate coating sheet over the windshield.

The above comments are made with regards to typical working conditions. By all means, should put on other guards if required by conditions at your particular site.

For details of safety guards, please contact your Komatsu distributor.

you

Also, even for other types of work, if there is any danger of getting hit by falling or flying objects, or of objects entering the operator’s cab, select and install a guard that matches the working conditions.

Be sure to close the front window

before

commencing

work.

When carrying out the above operations, make sure to keep all persons other than the operator outside the range of falling or flying objects. Be particularly sure to maintain a proper distance when carrying out shear operations.

,

AOO552OC

FOPS

AEO81160

FOPS (falling object protective structure)

l-6

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

6. GENERAL PRECAUTIONS

PRECAUTIONS FOR AITACHMEN’TS

I

l

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

l

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

l

Any injuries, accidents, product failures not be the responsibility of Komatsu.

MACHINES WITH ACCUMULATOR

resulting

from the use of unauthorized

attachments

will

1

On machines equipped with an accumulator, for a short time after the engine is stopped, the work equipment will lower under its own weight when the work equipment control lever is shifted to LOWER. After the engine is stopped, set the safety lock lever to the lock position.

When releasing the pressure inside the work equipment circuit on machines equipped accumulator, follow the procedure given in the inspection and maintenance section.

Method of releasing pressure -

with an

See “11.16 HANDLING ACCUMULATOR”.

The accumulator is filled with high-pressure nitrogen gas, and it is extremely dangerous if it is handled in the wrong way. Always observe the following precautions. l Never make any hole in the accumulator or expose it to flame or fire. l Do not weld any boss to the accumulator. l When carrying out disassembly or maintenance of the accumulator, or when disposing of the accumulator, it is necessary to release the gas from the accumulator. A special air bleed valve is necessary for this operation, so please contact your Komatsu distributor.

Gas in accumulator + See “11.16 HANDLING ACCUMULATOR”.

1-7

7. PRECAUTIONS DURING OPERATION

7.1 4

BEFORE STARTING SAFETY AT WORKSITE

&WARNING: For reasons

of safety, always follow these safety precautions.

ENGINE 1

Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous.

Before starting the engine, examine the terrain and soil conditions of the worksite. Determine the best and safest method of operation.

Make the slope operations.

as horizontal

as possible

before

continuing

If you need to operate on a street, protect pedestrians and cars by designating a person for worksite traffic duty or by installing fences around the worksite.

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

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

Permissible water depth + See “12.11 PRECAUTIONS FOR OPERATION”.

-I

FIRE PREVENTION

1

Thoroughly remove wood chips, leaves, paper and other flammable engine compartment.

They could cause a fire.

things accumulated

Check fuel, lubrication, and hydraulic systems for leaks. Have any leaks repaired. excess oil, fuel or other flammable fluids.

Check point + See “12.1.1 WALK-AROUND CHECK”.

Be sure a fire extinguisher

4

IN OPERATOR’S

CAB

is present

in and working

on the

Wipe up any

order.

1

l

Do not leave tools or spare parts lying around in the operator’s compartment.

They may damage or break the control levers or switches. Always put them in the tool box on the right side of the machine.

l

Keep the cab floor, controls,

l

Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged Always use seat belts when operating your machine.

Seat belts -+ See “28. USING SEAT BELT”.

l-8

steps and handrails

free of oil, grease,

snow, and excess dirt. parts.

a

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

1 l

VENTILATION FOR ENCLOSED AREAS

7. PRECAUTIONS DURING OPERATION

1

If it is necessary to start the engine within an enclosed area, provide adequate ventilation. fumes from the engine can KILL.

PRECAUTIONS FOR MIRRORS, WINDOWS AND LIGHTS all dirt from the surface of the windows

Exhaust

1

l

Remove

and lights to ensure that you can see well.

l

Adjust the rear view mirror so that you can see clearly from the operator’s seat, and always the surface of the mirror clean. If any glass is broken, replace it with a new part.

l

Check that the head lamps and working Check also that they light up properly.

lamps are installed to match the operating

keep

conditions.

l-9

a 7. PRECAUTIONS DURING OPERATION

7.2 OPERATING

MACHINE

Walk around your machine might be in the way.

again just before mounting

NEVER start the engine if a warning When starting the engine, Start and operate

CHECK DIRECTION

tag has been attached

to the controls.

only while seated.

other than the operator

equipped

it, checking for people and objects that

sound the horn as an alert.

the machine

Do not allow anyone For machines correctly.

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

with

a travel

alarm

BEFORE STARTING

to ride in the cab or on the machine buzzer, check that the warning

MACHINE

body.

device

operates

1

Before operating the travel lever, check the direction of the track frame. If the sprocket is at the front, the travel lever must be operated in the opposite direction.

Travel operations + See “12.4 MOVING

MACHINE OFF�.

Travel

in reverse direction

SProcLeet AE167510

CHECK THAT NO ONE IS IN AREA BEFORE SWINGING OR TRAVELING IN REVERSE Always position a signalman where the view is not clear.

in dangerous

1

places or places 4

Make sure that no one comes direction of travel.

inside

the

swing

radius

or

Before starting to move, sound the horn or give a signal to warn people not to come close to the machine.

c

/

A0066901

There are blind spots behind the machine, so if necessary, swing the upper structure to check that there is no one behind the machine before traveling in reverse.

l

2!!

I-IO

-

0 A0066101

a

;;RJJ$G;

2:x$

follow

these safety precautions

may lead 7. PRECAUTIONS DURING OPERATION

1

PRECAUTlOw1 Fold in the work equipment as shown in the diagram below, and keep it at a height of 40 - 50 cm (16 to 20 in) from the ground level before starting to travel.

When traveling, do not operate the work equipment control levers. If the work equipment levers have to be operated, never operate them suddenly.

When traveling

on rough ground, travel at low speed, and avoid sudden changes

control

in direction.

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

INCORRECT

Travel posture

1 TRAVELING ON SLOPES Traveling slipping.

1

on hills, banks or slopes that are steep could result in the machine

tipping

over or

On hills, banks or slopes, carry the bucket closer to the ground, approximately 20 to 30 cm (8 to 12 in) above the ground. In case of emergency, quickly lower the bucket to the ground to help the machine stop and prevent it from tipping over.

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

Method of traveling on slopes + See “12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN

HILLS”.

Do not travel up and down on grass, fallen leaves, and wet steel plates. These materials the machine to slip, if it is traveling sideways. Keep travel speed very low.

Uphill

Downhill

AEl67540

INCORRECT

may allow

CORRECT

AE167560

l-11

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

7. PRECAUTIONS DURING OPERATION

PROHIBITED OPERATIONS l

Do not dig the work face under an overhang. on top of the machine.

l

Do not carry out deep digging

This may cause the overhang

to collapse and fall

under the front of the machine.

INCORRECT

Going close to high-voltage cables can cause electric shock. Always given below between the machine and the electric cable.

The following actions are effective in preventing accidents.

1) Wear shoes with rubber or leather soles.

2) Use a signalman to give warning if the machine approaches If the work equipment compartment.

When carrying machine. l

1-12

the safe distance

too close to the electric cable.

should touch the electric cable, the operator should not leave the operator’s

out operations

Check with the electricity

Voltage

maintain

near high voltage

company

cables,

about the voltage

Min. safety distance

do not let anyone

come close to the

of the cables before starting operations.

a

V&~M~G;~;.WWIY

follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATION

DO NOT HIT WORK EQUIPMENT l

When working in places where there are height limits, such as in tunnels, under bridges, electric cables, or in garages, be extremely careful not to hit the boom or arm.

under

ENSUe l

When working in dark places, install working work area if necessary.

lamps and head lamps, and set up lighting

in the

l

Stop operations if the visibility is poor, such as in mist, snow, or rain, and wait for the weather to improve to a condition that allows the operation to be carried out safely.

l

When working on snow or icy roads, even a slight slope may cause the machine to slip to the side, so always travel at low speed and avoid sudden starting, stopping, or turning.

l

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

l

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

l

Earth laid on the ground and the soil near ditches are loose. They can collapse .under the weight or vibration of your machine.

l

Install the HEAD GUARD (FOPS) if working

OPERATE CAREFULLY ON SNOW

in areas where there is danger of falling rocks and dirt.

1-13

7. PRECAUTIONS DURING OPERATION

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

l

When working on slopes, there is danger that the machine may lose its balance and turn over when the swing or work equipment are operated. Always carry out these operations carefully.

l

Do not swing the work equipment from the uphill side to the downhill side when the bucket is. loaded. This operation is dangerous.

(See the upper diagram on the right.)

l

If the machine has to be used on a slope, pile the soil to make a platform that will keep the machine as horizontal as possible.

(See the lower diagram on the right.)

Piled soil on slope + See “12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS”.

CORRECT

AEl67600

Park on level ground whenever possible. If not possible, block the tracks, lower the bucket to the ground and thrust the bucket in the ground.

CORRECT

Thrust

the

bucket AE167610

When parking on public roads, provide fences and signs, such as flags or lights, on the machine to warn passersby to be careful. Be sure that the machine, flags or lights do not obstruct traffic.

Parking procedure + See “12.15 PARKING MACHINE”.

When leaving the machine, lower the work equipment completely to the ground, set the safety lock lever to the LOCK position, then stop the engine and use the key to lock all the equipment.

Always take the key with you.

Work equipment posture + See “12.15 PARKING MACHINE”.

Method of locking Places to lock + See “12.19 LOCKING”.

AE167470

1-14

g

EIRp&

E;g:e$~

follow

these safety precautions

may lead 7. PRECAUTIONS

DURING

OPERATION

7.3 TRANSPORTATION l

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

l

Determine load.

l

This machine can be disassembled for transport. Request Komatsu or your Komatsu to perform disassembly.

(Parts for transport -+ See “13. TRANSPORTATION”.

the transporting

route while taking into account the width,

height and weight

the

of the

distributor

1-15

A 7. PRECAUTIONS

7.4 l l l

0 l

0

l

0 l l

DURING

OPERATION

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

always

BATTERY Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing.

If you spill acid on yourself, immediately flush the area with water.

Battery acid could cause blindness if splashed into the eyes. If acid gets into the,eyes, flush them immediately with large quantities of water and consult a doctor at once.

If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil.

Call a doctor or poison prevention center immediately.

When working with batteries. ALWAYS wear safety glasses or goggles.

Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a small spark or flame.

Before working with batteries, stop the engine and turn the starting switch to the OFF position.

Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across the terminals.

When removing or installing, check which is the positive (+I terminal and negative (-1 terminal.

Tighten the battery cap securely.

Tighten the battery terminals securely. Loosened terminals can generate sparks and lead to an explosion.

A0055110

A0055100

1 STARTING WITH BOOSTER CABLES ALWAYS

1

wear safety glasses or goggles when starting the machine

When starting from another

machine,

do not allow the two machines

Be sure to connect the positive (+) cable first when installing ground or negative (4 cable first when removing them.

If any tool touches between the positive (+I terminal dangerous, so be sure to work carefully.

Connect the batteries

with booster cables. to touch.

the booster cables. Disconnect the

and the chassis, it will cause sparks. This is

in parallel: positive to positive and negative

When connecting the ground cable to the frame of the machine it as far as possible from the battery.

to negative.

to be started, be sure to connect

Starting with booster cables + See “16.3 IF BAlTERY IS DISCHARGED�.

INCORRECT

AD052960

1-16

A

bV;RsblW&

FaJgzo

follow these safety precautions

may lead 7. PRECAUTIONS

DURING

OPERATION

7.5 BUCKET WITH HOOK 7.5.1

GENERAL PRECAUTIONS

-/ SPECIAL HOOK

1

When carrying out lifting work, the special lifting hook is necessary.

The following operations are prohibited. o Lifting loads with a wire rope fitted around the bucket teeth. o Lifting loads with the wire rope wrapped directly around the boom or arm.

=‘

\ \\

B AEO81300

CHECKING HOOK l

When lifting a load, carry out the following checks to confirm that there is no abnormality starting operations. o Check that there are no cracks or deformation in the lifting equipment. o Check that there is no abnormalitv in the stopper device.

HOOKING WIRE ROPE SECURELY TO HOOK When performing

lifting operation,

1

securely fit the wire rope on the special lifting hook.

PRECAUTIONS FOR MACHINE INSTALLATlON l

1

After carrying out a preliminary inspection of ground conditions, Confirm that the machine can be safety operated without toppling

PROHIBITED OPERATIONS OTHER THAN MAIN APPLICATIONS l

When performing

lifting operation,

l

select a flat, solid location. or rolling.

1

I

never raise or lower a person.

NO PERSONS SHALL BE PERMIlTED THE WORKING AREA 1

before

TO ENTER

Due to the possible danger of the load falling or of collision with the load, no persons shall access the workina area.

1-17

I

a 7. PRECAUTIONS DURING OPERATION

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

OPERATION SUPERVISOR l

Before performing lifting operation, designate an operation supervisor.

Always execute operation according to his instructions. o Execute operating methods and procedures under his direction. o Select a person responsible for signaling. Operate only on signals given by such person.

HANDING OF WIRE ROPES ETC. l

1-18

Wear leather

gloves when

handling

1 wire ropes.

A ~~FisN~G;

z;gzo

follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATION

7.5.2

PRECAUTIONS

FOR LIFTING OPERATION

l

When carrying out lifting operations, mode).

run the engine at low idling and use the L.0 (lifting operation

l

Avoid sudden lever shifting

l

Swing speed is three to four times that of movable performing swing operation.

l

Never leave the operator’s

and acceleration. cranes. Therefore,

be especially

careful when

seat while lifting a load.

-1 NEVER CARRY OUl

Operation

exceeding

machine

performance

l

Carry out lifting operation

l

Never carry out operations

l

Never drag a load laterally or longitudinally, may result.

INCORRECT

within

specified

may result in accident load limit.

which may damage the machine such as overload or over-impact-load. nor retract the arm, otherwise,

NEVER TRAVELLING

WHILE LIFTING A LOAD

a dangerous

situation

INCORRECT

AE167620

j

or failure.

AE167630

1

l

Never travel while carrying

l

If the machine posture is not correct, the wire ropes or ring may detach from the hook. Confirm that the hook angle is correct to avoid this.

PERATING

a load.

POSTURE

1-19

8. PRECAUTIONS FOR MAINTENANCE

8.1

BEFORE CARRYING

A WARNING:

For reasons of safety, always follow these safety precautions.

OUT MAINTENANCE

WARNING TAG If others start the engine or operate the controls while you are performing you could suffer serious injury or death.

service or lubrication,

ALWAYS attach the WARNING TAG to the control lever in the operator’s cab to alert others that you are working on the machine. Attach additional warning tags around the machine, if necessary.

These tags are available

from your Komatsu

distributor.

(Part No. 09963-03000)

DO NOT operate When

this plate

is not being

keep it in the storage

used

compartment.

Q996343oGQJ AE167640

l

Use only tools suited to the task. Using damaged, low quality, cause personal injury.

Tools + See “21.1 INTRODUCTION OF NECESSARY TOOLS”.

faulty, or makeshift

-v 4

tools could

0

A0055120

PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS l

Replace the following fire-related components periodically: Fuel hose, spilling hose, and fuel tube cap Fuel system: Pump outlet hose, and front and rear pump branch hoses Hydraulic system:

l

Replace these components periodically with new ones, regardless to be defective. These components deteriorate over time.

l

Replace or repair any such components if any defect is found, even though they have not reached the specified time.

Replacement of critical safety components + See “22. PERIODIC REPLACEMENT OF CRITICAL

SAFETY PARTS”.

I-20

of whether

or not they appear

1

A ~~RsM;G;

Fai;aizc

follow these safety precautions may lead 8. PRECAUTIONS FOR MAINTENANCE

STOP THE ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Always stop the machine and maintenance.

on firm fiat ground and stop the engine before carrying out inspection

If it is necessary to run the engine when carrying out maintenance, such as when cleaning the inside of the radiator, place the safety lock lever at the LOCK position and carry out the operation with two workers.

One worker should sit in the operator’s seat so that he can stop the engine immediately if necessary. He should also be extremely careful not to touch any lever by mistake. Touch the levers only when they have to be operated.

The worker carrying out the maintenance in the moving parts.

should be extremely

AE169480

careful not to touch or get caught

AE167470

l

Spilled fuel and oil may cause you to slip, so always wipe

l

Always tighten

l

Never use fuel for washing

l

Always add fuel and oil in a well-ventilated

it up immediately.

the cap of the fuel and oil fillers securely.

A0055020

any parts. place.

AOfJ55030

A0055040

1-21

8. PRECAUTIONS FOR MAINTENANCE

RADIATOR

WATER

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

LEVEL

l

If it is necessary to add water to the radiator, stop the engine and allow the engine and radiator to cool down before adding the water.

l

Slowly

loosen the caps to relieve pressure before removing

the caps.

USE 0-m l

When checking fuel, oil, coolant, or battery electrolyte, specifications.

If such lighting equipment is not used, there is danger

always

use lighting

with anti-explosion

of explosion.

A0055160

l-22

A ;$FtNtNEG; Fai;ai;c

follow these safety precautions may lead 8. PRECAUTIONS FOR MAINTENANCE

8.2 DURING MAINTENANCE l

Only authorized personnel can service and repair the machine. when grinding, welding, and using a sledge-hammer.

l

Place attachments that have been removed from the machine fall. If they fall on you or others, serious injury could result.

Extra precaution

should be used

in a safe place so that they do not

A0055130

1

WORK UNDER THE MACHINE

1

l

Always lower all movable work equipment to the ground performing service or repairs under the machine.

l

Always

l

Never work under the machine

block the track shoes of the machine if the machine

or to their

lowest

position

before

securely. is poorly supported.

* A0055140

KEEP THE MACHINE

CLEAN

1

Spilled oil or grease, or scattered tools or broken pieces are dangerous you to slip or trip.

Always keep your machine clean and tidy.

because they may cause

If water gets into the electrical system, there is danger that the machine may not move or may move unexpectedly.

Do not use water or steam to clean the sensors, connectors, or the inside of the operator’s compartment.

AC955150

l-23

a

8. PRECAUTIONS FOR MAINTENANCE

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

always

PRECAUTIONS WITH BATTERY l

When repairing the electrical system or when carrying out electrical welding, (-1 terminal of the battery to stop the flow of current.

remove the negative

AC055170 I

I

r-j

,

HANDLING HIGH-PRESSURE HOSES

1

I

l

Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked piping, tubes or hoses. They may burst during use.

l

Always

repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.

Do not forget that the work equipment

circuits are always

Do not add oil, drain oil, or carry out maintenance internal pressure.

under pressure.

or inspection

before completely

releasing the

If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure oil hits your skin or enters your eyes. Always wear safety glasses and thick gloves, and use a piece of cardboard or a sheet of wood to check for oil leakage.

If you are hit by a jet of high-pressure

A0055180

l-24

oil, consult a doctor immediately

for medical

A0055190

attention.

A ~;RsMI;;

!%IJE~I

follow these safety precautions may lead 8. PRECAUTIONS FOR MAINTENANCE

I

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE HIGH TEMPERATURE OR HIGH PRESSURE

l

Immediately after stopping operations, the engine cooling water and oil at all parts is at high temperature and under high pressure.

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

I

Cleaning

inside or cooling system

Checking

cooling water

Checking

lubricating

Changing

oil, replacing

+ see “24.3 WHEN

level, hydraulic

AT I

REQUIRED”.

oil level + see “24.4 CHECK BEFORE STARTING”.

oil level, adding oil + see “24.5-11

filters + see “24.3 - 9 PERIODIC

PERIODIC

MAINTENANCE”.

MAINTENANCE”.

A0055050

PRECAUTIONS WHEN USING HIGH PRESSURE GREASE TO ADJUST TRACK TENSION Grease is pumped into the track tension adjustment system under high pressure.

If the specified procedure for maintenance is not followed when making adjustments, grease fitting may fly out and cause damage or personal injury. l When loosening the grease drain plug, never loosen it more than one turn. l

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

Adjusting

track tension

*

see “24.3 WHEN

the plug or

in front of any grease

REQUIRED”.

A0055200

l

I

If your body or tools touch the fan blades or fan belt, they may be cut off or sent flying, so never touch any rotating parts.

A0055210

l-25

a 8. PRECAUTIONS FOR MAINTENANCE

4

WASTE

MATERIALS

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

1

l

Never dump waste oil in a sewer system,

rivers, etc.

l

Always

in containers.

l

Obey appropriate laws and regulations coolant, solvent, filters, batteries, etc.

put oil drained from your machine

when

disposing

Never drain oil directly on the ground. of harmful

objects such as oil, fuel,

INCORRECT

P

A0055220

1-26

9. POSITION FOR ATTACHING SAFETY LABELS

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

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

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

POSITION FOR ATTACHING

SAFETY LABELS

AE167660

AElti7670

l-27

9. POSITION FOR ATTACHING SAFETY LABELS

1.

2.

Precaution prior to start operation (09651-03000)

Warning, precaution (209-00:52280)

Caution for hydraulic tank cap (09653-03000)

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

for operation

L

l

BEFORE LEAVING OPERATOR’S SEAT, ALWAYS PERFORM FOLLOWING. l LOWER WORK EQUIPMENT TO GROUND. l STOP ENGINE AND LOCK CONTROL LEVERS WITH SAFETY LOCK. WHEN MACHINE BODY HAS BEEN JACKED UP WITH BOOM OR ARM NEVER GO UNDER MACHINE. ALWAYS BLOCK TRACKS WHEN PARKING MACHINE ON A SLOPE. WHEN ADJUSTING TRACK TENSION NEVER LOOSEN VALVE MORE THAN ONE TURN. GREASE IS UNDER HIGH PRESSURE AND MAY SPURT OUT. (SEE OPERATION & MAINTENANCE MANUAL FOR DETAILS OF ADJUSTING TRACK TENSION.) 209-00-52280

3.

Caution for removing (21T-00-12130)

general

piping

09653-03000d

Caution for radiator cap (09668-03000)

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

-

6.

Caution while engine (09667-03000)

is running

WHILE ENGINE IS RUNNING: 1. DO NOT OPEN COVER. 2. KEEP AWAY FROM FAN AND FAN-BELT. -

1-28

09667-03000

J

9. POSITION FOR A-I-I-ACHING SAFETY LABELS

Caution on accumulator (09659-23000)

1. WHEN BREAK-DOWN OR TROUBLE DEVELOPS IN THE ACCUMULATOR, DO NOT All-EMPTTO DISASSEMBLE OR REPAIR. ALWAYS CONTACTYOUR NEARESTAUTHORlED SERVICE STATION. 2. DO NOT AlTEMPT TO FILL OR RE-FILL WITH GAS. AUTHORIZED SERVICEMEN, OR PERSONS LICENSED TO HANDLE HIGH-PRESSURE GASES, ARE THE ONLY PERSONS ALLOWED. 3. NEVER HAMMER A GAS-FILLED ACCUMULATOR. OR PLACE ONE CLOSE TO A FIRE. 4. NEVER ATTEMPT TO ATTACH A PART TO, OR BORE A HOLE IN THE ACCUMULATOR’S WALL. 5. ALWAYS COMPLETELY EXHAUST THE ACCUMULATOR OF ALL CONTAINED GAS WHEN DISASSEMBLING OR DISCARDING THE ACCUMULATOR. 6. TO EXHAUST THE GAS, USE THE AIRRELIEF VALVE MOUNTED ON THE ACCUMULATOR. WHEN THERE IS NO SUCH VALVE, REMOVE THE ACCUMULATOR’S GAS FILLING-VALVE CAP AND RELEASE THE GAS BY DEPRESSING THE VALVECORE (PIN) WITH SUITABLE TOOL (SCREW DRIVER).

(1) TYPE OF GAS * * . * * - NITROGEN (2) WORKING PRESSURE (MAXIMUM). . psi ( kg/cm*) (3) TESTING PRESSURE * * * psi ( kg/cm*) .

09659-23000 d

Keep out of swing range (2OY-00-11430)

1-29

I-30

10. GENERAL VIEW

10.1

GENERAL VIEW OF MACHINE

If directions are indicated diagram below.

Bucket

Ar\m

Bucket

2-2

in this section, they refer to the directions

C,Y I

Arm

i nder

Track

cylinder

shoe

Bo/om

Boom /

Idler

shown

Track

CY

frame

by the arrows in the

I

i nder

Sprocket

10. GENERAL VIEW

10.2 I

GENERAL VIEW OF CONTROLS

Bottom

dump

Travel

switch

AND GAUGES Machine

lever h

monitor Bottom

I

dump ht

k es I eve

switch

work

eauinment

cket lector

movement switch

Travel selector

speed switch

Low temperature starting aid Swing brake

parking switch

Fuel

control

lever

Starting

switch

Cigarette

lighter

switch

I

/ Horn

Swing

brak

switch AEl67690

Hydraulic clogging Engine

Engine water temperature

gauge

water

level

oil

level

Radiator

1 Radiator

Engine

oil

L

Lamp

\

level

nre-heating

Service

\

meter

*

0

0

\

water

level

water monitor

switch

Hydraulic temperature Charge

Engine monitor

pressure

Radiator temperature

\ Hydraulic

oil

Mode selector (OLSS) switch

N Fuel

filter monitor

oil monitor level

Lamp switch (working lamp)

Wiper

switch AD167730

2-3

11. EXPLANATION

OF COMPONENTS

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

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

11

.I

MACHINE

MONITOR

AD167740

This monitor system consists of monitor meter group @$, switch group 0.

lamp groups @, @, 01,

A.

BASIC CHECK ITEMS (11.1.1) This displays the basic items that should be checked before starting the engine.

If there is any abnormality, the appropriate monitor lamp will flash.

NOTICE If engine is started, mality.

lamp will go off even if there is an abnor-

REMARK When carrying out checks before starting, do not simply rely on the monitor. Always refer to the periodic maintenance items or “12.

OPERATION� to carry out the checks.

2-4

11. EXPLANATION

B. CAUTlON

OF COMPONENTS

ITEMS (11.12)

These are items which need to be observed while the engine is running. If any abnormality occurs, items which need to be repaired as soon as possible are displayed.

If there is any abnormality, the appropriate monitor lamp will flash to indicate the location of the abnormality.

C.

EMERGENCY

STOP ITEMS (11 .I.31

then check and repair the appropriate

location.

These are items which need to be observed while the engine is running. If any abnormality occurs, items which need to be repaired immediately are displayed.

If there is any abnormality, the appropriate monitor lamp will flash to indicate the location of the abnormality and the buzzer will sound intermittently.

D.

METER DISPLAY PORTION (11.1.4) This portion consists of engine water temperature gauge, preheating monitor and service meter.

gauge,

fuel

E.

SWITCHES (11.1.5) This consists of the lamp switch, mode selector switch (OLSS), wiper switch.

Functional check of the machine monitor system When the starting switch is turned ON before starting the engine, all the monitor lamps and the gauges light up and the alarm buzzer sounds for about 3 seconds. If any monitor lamp does not light up, there is probably a broken bulb or disconnection in the monitor, so ask your Komatsu distributor to inspect it.

REMARK The monitor system cannot be checked seconds after the engine has been stopped.

for breakage

until 30

2-5

11. EXPLANATION OF COMPONENTS

AD167750

11.1.1 A: BASIC CHECK ITEMS NOTICE Do not rely on the “BASIC CHECK ITEMS” only for the check before starting.

Always refer to the periodic maintenance items or “12. OPERATION” to carry out the checks.

1.

RADIATOR WATER LEVEL This warns that the radiator cooling water level is too low.

If the monitor lamp flashes, check the cooling water level in the radiator and add water.

AD104320

2.

ENGINE OIL LEVEL This warns that the oil level in the engine oil pan is too low.

If the monitor lamp flashes, check the oil level in the engine oil pan, and add oil.

2-6

11. EXPLANATION

3.

OF COMPONENTS

HYDRAULIC OIL LEVEL

This warns that the hydraulic oil level is too low.

If the monitor lamp flashes, check the hydraulic oil level, and add oil.

REMARK l l

Park the machine on level ground Confirm that these monitor lamps turning the starting switch to ON. light, ask your Komatsu distributor

11.1.2

B: CAUTION

and check the monitor lamps. light for about 3 seconds after If any monitor lamp does not to inspect that monitor lamp.

ADI 61780

ITEMS

l,,,,i.;.ecAuT’oN71 If the cautfon momtor

1.

lamp flashes, repatr the problem

as soon

CHARGE LEVEL

This monitor indicates an abnormality in the charging system while the engine is running.

If the monitor lamp flashes, check the V-belt tension. If any abnormality is found, see “16.4 OTHER TROUBLE”.

REMARK l l

l

Park the machine on level ground and check the monitor lamps.

This monitor lamp lights, when the starting switch is turned to ON immediately after the engine is started or immediately before the engine is stopped. It does not indicate an abnormality.

Confirm that this monitor lamp lights for about 3 seconds after the starting switch is turned to ON. If the monitor lamp does not light, ask your Komatsu distributor to inspect it.

2-7

7 1. EXPLANATION OF COMPONENTS

11 .I.3 C: EMERGENCY STOP ITEMS

1

.a -0 -0

--a ‘0

A

CAUTlON

lf any monitor lamp flashes, stop the engine idling, and take the following action.

or run it at low

1.

ENGINE WATER TEMPERATURE If the temperature of the engine cooling water becomes abnormally high, the monitor lamp flashes, and the overheat prevention system is automatically actuated to reduce the engine speed.

Stop operations and run the engine at low idling until the engine water temperature gauge enters the green range.

2.

RADIATOR WATER LEVEL If the radiator water level drops, the monitor lamp flashes. Stop the engine, check the radiator water level, and add water if necessary.

1

I

I

C3

I 3.

ENGINE OIL PRESSURE If the engine oil pressure drops below the normal pressure, the monitor lamp flashes. At this time, stop the engine and inspect it according to “16.4 OTHER TROUBLE.”

REMARK While the starting switch is ON, the lamp remains lit and goes off once the engine is started or stopped. When the engine starts, the buzzer may sound for a short time, however, this does not indicate a fault.

2-8

I

I AD104320

.

11. EXPLANATION OF COMPONENTS

4.

HYDRAULIC FILTER CLOGGING MONITOR

This monitor indicates clogging of the hydraulic filter.

If the monitor lamp flashes, stop the engine and check, clean the filter element.

,

AD167830

5.

HYDRAULIC OIL TEMPERATURE MONITOR

This monitor indicates a rise in the hydraulic oil temperature.

If the monitor lamp flashes, run the engine at the low idling speed or stop the engine until the hydraulic oil is cooled down.

n

& •I

REMARK l l

Park the machine on level ground and check the monitor lamps.

Confirm that these monitor lamps light for about 3 seconds after the starting switch is turned to ON. If any monitor lamp does not light, ask your Komatsu distributor to inspect that monitor lamp.

2-9

11. EXPLANATION

OF COMPONENTS

11.1.4 D: METER DISPLAY PORTION

AD167850

PILOT DISPLAY When the starting switch is ON, the pilot display lights up when the display items are functioning.

1.

ENGINE APS MONITOR

This monitor lamp indicates the APS is actuated.

The monitor lamp lights when the APS switch is turned to ON position and flashes to show that the pre-heating is completed.

REMARK Confirm that gauges 0, @ and monitor lamp @ will light, when the starting switch is turned to ON before the engine is started. If any gauge or monitor lamp does not light, ask your Komatsu distributor to inspect that monitor lamp or gauge.

2-10

11. EXPLANATION OF COMPONENTS

METERS Red

2.

ENGINE COOUNG 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 and the engine water temperature monitor lamp will flash at the same time. If this occurs, stop the machine and run the engine at a low idling speed until the green range lights.

3.

Green

Whita III,

LC AD167870

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 70 liters of fuel in the tank.

When the red range lights, add fuel.

Green

a

F

I7 B

Red AD167880

4.

SERVICE METER

This meter shows the total operation hours of the machine. The service meter advances while the engine is running - even if the machine is not traveling.

REMARK l l

While engine is running, the green pilot lamp on the service meter flashes to show the service meter is advancing.

The service meter progresses by 1 when the engine is operated for one hour, regardless of the engine speed.

AD167890

2-11

11. EXPLANATION OF COMPONENTS

11.1.5 E: SWITCHES

AD167900

1.

,Y,““E

JCLL\r

I “l-l

,“LaG,

_..I

I “I1

This switch is used to change the model.

H: S: L:

For heavy duty work or traveling For general work For light duty work

For guidance SELECTION”.

2.

on the model selection,

at high speed.

see “12.9 WORKING

MODE

AD167910

LAMP SWITCH

This lights up the head lamps and panel lamps.

Position I: Panel lamps light up Position II: Head lamps (on right and left side deck) light up

A0167920

2-12

11. EXPLANATION OF COMPONENTS

3.

LAMP SWITCH

This lights up the working lamp and panel lamps.

Position I: Panel lamps light up Position II: Working lamp (on cab) light up.

AD167920

4.

WIPER SWITCH

ON: W:

This switch is used to turn on the front windshield For operation For splashing detergent over windshield glass

wiper.

AD167930

2-13

11. EXPLANATION OF COMPONENTS

11.2

LAMP

AE167940

1.

SWING

LOCK LAMP

A

CAUTION

lf the lamp does not light up when the swing lock switch is ON, please contact your Komatsu distributor.

This informs the operator Actuated: Lights up NOTICE When the swing lamp lights up.

2-14

that the swing lock is being actuated.

lock switch

AEl67950

is turned

ON (ACTUATED),

the

11. EXPLANATION OF COMPONENTS

11.3

SWITCHES

AEI 6796( 1

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

OFF position The key can be inserted or withdrawn.

All the switches for the electrical system are all turned off and the engine is stopped.

ON position Electric current flows in the charging and lamp circuits.

Keep the starting switch key at the ON position while the engine is running.

START position This is the engine-start position. Keep the key at this position during cranking. Immediately after starting the engine, release the key which will automatically return to the ON position.

2-15

11. EXPLANATION OF COMPONENTS

2.

LOW TEMPERATURE STARTING AID SWITCH This is used when starting in cold temperatures.

ON position: OFF position:

Starting Starting

OFF

aid is being operated. aid is cancelled.

REMARK Use the low temperature starting aid monitor lamp to check the operating condition of the starting aid.

Front

of

machine

IE!CRnln

3.

ClGARElTE LIGHTER This is used to light cigarettes. To use, push the lighter in. After a few seconds it will spring back.

Pull out the lighter and light your cigarette.

AEO81650

4.

SWING PARKlNG BRAKE SWITCH This actuates the swing mechanical

ON position:

OFF position:

The swing mechanical brake is actuated, so the upper structure will not swing even if the swing lever is operated. Then the swing parking brake pilot lamp lights up.

When the swing brake switch is at release position, the swing mechanical brake is not actuated and the upper structure is held in position by hydraulic lock.

When the swing lever is operated, the upper structure will swing.

NOTlCE During swing switch into ON.

2-16

Free

brake.

operations,

do not put the swing parking

brake

Actua

Front

of

machine

AEl68020

11. EXPLANATION OF COMPONENTS

5.

SWING BRAKE SWITCH brake automatiThis is used to actuate the swing mechanical tally.

Auto position: When the swing parking brake switch is at OFF position, and the swing lever is returned to neutral, the swing mechanical brake is actuated after approx. 5 seconds to hold the upper structure in position.

Release

Front

of

machine

Front

of

machine

Front

of

machine

AE166000

Release position: When the swing parking brake switch is at OFF position, even if the wing lever is set to neutral, the swing mechanical brake is not actuated. The upper structure is held in position by hydraulic lock.

6.

AUTO-DECELERATION SWITCH When the control levers are at neutral, this switch is used to actuate the auto-deceleration to lower the engine speed.

Lamp ON: Auto-deceleration Lamp OFF: Auto-deceleration

actuated canceled

AE166000

7.

TRAVEL SPEED SELECTOR SWITCH Use this switch to select HIGH or LOW speed to suit the operating conditions.

LOW position: This is suitable for moving short distances or for high drawbar pull.

HIGH position:This is suitable for moving longer distances.

Always set this switch to LOW when high resistance to traveling causes the engine speed to drop - for example, when climbing slopes or traveling over rough ground.

NOTICE When changing speed, always stop the machine before moving the travel speed selector switch.

AEl66040

completely

2-17

7 1. EXPLANATION

8.

OF COMPONENTS

BUCKET MOVEMENT

This digging.

switches

between

SELECTOR SWITCH arc digging

and automatic

horizontal

&@I r)

Horizontal

digging:

Arc digging:

When the arm control lever is operated with the bucket near the ground, the bucket will dig the ground in a horizontal movement.

Any operation can be carried out within the working range.

Horizontal

Arc

& 8

&@ Front

of

machine

AEI68050

Horizontal

0

When using bucket with angle compensator The following positions are provided in addition to those on the standard type.

Horizontal

9.

digging

with bucket angle compensation: When the arm control lever is operated with the bucket near the ground, the bucket will dig the ground in a horizontal movement.

During BOOM RAISE operations, the angle of the bucket is automatically corrected to prevent the load from spilling.

BOTTOM DUMP SWITCH These

OPEN: CLOSE:

switches

Arc

LF & 0 With angle compensat

\i ion

w

?!!!

@ Front

of

machine

AEI68060

I

h

open and close the front bucket.

Press the button at the tip of the right work equipment control lever.

Press the button at the tip of the left work equipment control lever.

AE168070

IO. HORN SWITCH When the button at the right of the footrest is pressed, the horn sounds.

2-18

11. EXPLANATION OF COMPONENTS

11. ROOM LAMP SWITCH This lights up the cab lamp.

ON position: Lights up The cab lamp can be turned on even when the starting switch is at the OFF position, so be careful not to leave it on by mistake.

ON

0

OFF

AE081710

2-19

11. EXPLANATION OF COMPONENTS

11.4

CONTROL

LEVERS, PEDALS

A

WARNING

For machine with auto-deceleration device, careful operation of levers @ through in the deceleration range because the engine speed rises quickly.

1.

SAFETY LOCK LEVER

A

WARNING

When stopping the machine or leaving the machine, be sure to lower the bucket to the ground, then operate the lever to lock the work equipment levers and the traveling and steering levers.

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

If the safety lock lever is not placed securely in the LOCK position, the control levers may not be properly locked. Check that the situation is as shown in the diagram.

2-20

@ is necessary

I

11. EXPLANATION OF COMPONENTS

This lever locks the work equipment, swing, travel and attachment controls.

This lock lever is a hydraulic lock, so even if it is in the lock position, the work equipment control lever and travel lever will move, but the work equipment, travel motor, and swing motor will not work.

AE168120

2.

TRAVEL LEVERS (WITH PEDAL, AUTO-DECELERATION MECHANISM) g

WARNING

Do not put your foot on the pedal unless the machine is traveling. lf you leave your foot on the pedal and press it by mistake, the machine will move suddenly, and this may lead to a serious accident.

With the track frame facing to the rear, the machine will move in the reverse direction by forward traveling and in the forward direction by reverse traveling.

When the travel lever is used, check to see if the track frame is facing forward or backward. (If the sprocket is located to the rear, the track frame is facing forward.1 These levers (and pedals) are used to operate the left and right travel motors.

0 FORWARD: The lever is pushed forward (The pedal is angled forward) 0 REVERSE: The lever is pulled back (The pedal is angled back) N (Neutral): The machine stops

1

): This indicates operation

of the pedal.

2-21

11. EXPLANATION OF COMPONENTS

3.

LEFT WORK EQUIPMENT CONTROL Iwith auto-deceleration device} a

LEVER

WARNING

lf any lever is operated when in the deceleration range, the engine speed will suddenly increase, so be careful when operating the levers.

This lever is used to operate the arm and upper structure.

Arm operation Swing operation @ Swing to right @ Arm OUT @ Swing to left @ Arm IN N (Neutral) When the lever in this position, the upper structure and the arm will be retained in the position in which they stop.

4.

RIGHT WORK EQUIPMENT CONTROL (with auto-deceleration device) a

AE168130

LEVER

WARNING

lf any lever is operated when in the deceleration range, the engine speed will suddenly increase, so be careful when operating the levers.

AE168140

This lever is used to operate the boom and bucket.

Bucket operation Boom operation @ DUMP @ RAISE @ LOWER @I CURL N (Neutral) When the lever in this position, the boom and the bucket will be retained in the position in which they stop.

5.

0 0

0

l

2-22

FUEL CONTROL’ LEVER (with auto-deceleration device) This lever is used to control the engine speed and output.

Engine stop position: Push the lever forward fully.

Low idling position: Pull the lever from engine stop position @ until you feel the operating force fall off.

High idling position: Pull the lever backward fully from the low idling position.

For levers 2, 3, 4 and 5 the engine speed changes as follows because of the auto-deceleration mechanism.

When the travel lever and work equipment control levers are at neutral, even if the fuel control dial is above the mid-range position, the engine speed will drop to a mid-range speed.

If any of the levers are operated, the engine speed will rise to the speed set by the fuel control lever.

AE168150

11. EXPLANATION OF COMPONENTS

11.5

CEILING WINDOW

A

WARNING

When leaving the operator’s compartment, set the safety lock lever securely to the LOCK position.

If the control levers are not locked, and they are touched by mistake, this may lead to a serious accident.

AE167470

When opening 1. Lock the safety lock lever securely.

2. Check for any ceiling window movement by pulling lock knob located on front side, then push up and open the ceiling window grasping grip.

When closing Close the ceiling window grasping grip and lock it with lock knob. if the lock cannot be applied, open and close the ceiling window again.

REMARK When opening or closing the ceiling window, Do not push in grasping staydumper @.

AE166160

grasp the handle.

2-23

11. EXPLANATION OF COMPONENTS

11.6

FRONT WINDOW

When opening the front window always hold the grip firmly with both hands and pull up. If you use only one hand, your hand may slip and get caught. /*““““‘“” It is possible to store (pull up) the front window of the operator’s compartment.

When

(top) in the roof

opening

A

WARNING

When the front window is open, there is danger that it will fall, so always lock it with left and right lock pins @.

1.

Place the work equipment

on flat ground and stop the engine.

2.

Securely

3.

Disconnect

4.

Pull lock pins @ at the top left and right sides of the front window to the inside to release the lock.

lock the safety lock lever.

wiper

motor cable from receptacle

@I.

--

AE081780

2-24

11. EXPLANATION OF COMPONENTS

5.

From the inside of the operator’s cab, hold the bottom grip with the left hand and the top grip with the right hand, pull up the window, and push it in fully until it is locked by catch 0.

6.

Lock with lock pins @ on the left and right sides.

When closing

A When closing the window, get your hand caught.

1.

Place the work equipment

2.

Securely

WARNING lower it slowly and be careful not to

on flat ground and stop the engine.

lock the safety lock lever.

AEI 67470

3.

Release the lock pin @.

I 4.

AE081780

Hold the grip at the bottom of the front window with your left hand and the grip at the top with your right hand, release the lock of catch 0 with your right thumb, then pull the top grip slowly and lower the front window. When releasing the lock of catch 0, push release lever @ in the direction of the arrow to release the lock.

I

AE081790

2-25

1

11. EXPLANATION OF COMPONENTS

5.

Lock securely

6.

Connect wiper

11.7

with lock pins @ at the left and right sides. motor cable from receptacle

@I.

DOOR LOCK

Use the door lock to fix the door in position

after opening

it.

1.

The door will become fixed in place when catch 0.

2.

To release the lock, press knob @ down at the left side of the operator’s seat to release the catch.

When fixing the door, fix it firmly to the catch.

11.8

it is pressed against

DUST INDICATOR

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

After cleaning, push indicator button @ to return the red piston to the original position.

This is behind the air cleaner inside the engine hood.

AE081830

2-26

11. EXPLANATION OF COMPONENTS

17.9

AIR CONDITIONER

11.9.1 1. l

CONTROL PANEL

Outlet change-over knob Switches over air outlets Knob position

Air outlet

Purpose AEO99OSO

FACE ZQ

Rear

Cooling

AEl68170

2. l l l

3. l l l

4.

0 0 0

Heater temperature knob Controls heating temperature The nearer to WARM MAX. the knob goes, the higher heater outlet air temperature wil-I be.

At OFF position, water valve will be closed and heating function will stop.

Blower switch Used for both controlling the air flow in cooling and heating and as the main switch.

Changeable at three steps: low, medium and high.

Placing knob in OFF cuts off the power supply and stops the air conditioner.

Cooler temperature knob The temperature is controlled with this knob for cooling.

It is also the cooler switch.

Move the knob towards LOW to decrease the output air temperature.

When the knob is moved to OFF, the cooler switch is turned off and the cooling stops.

2-27

11. EXPLANATION OF COMPONENTS

11.9.2 OPERATION Cooling Set the knobs to the following be flowed in from the rear vents. l Outlet change-over knob 0: l Heater temperature knob 0: l Blower switch 0: l Cooler temperature knob @I:

positions

and a cool breeze will FACE OFF See table below.

See table below.

Blower switch @

Cooler temp. knob @

HIGH

HIGH

Quick cooling Normal cooling

MEDIUM-LOW

Gradual cooling

LOW

)

MEDIUM LOW AE168180

Heating Set the knobs to the following be flowed in to the feet. l Outlet change-over knob 0: l Heater temperature knob 0: l Blower switch 0: l Cooler temperature knob 0:

positions,

Heater temp. knob @ Quick heating Normal heating Mild heating

then warm breeze will FOOT See table below.

See table below.

OFF

Blower switch @

HIGH

HIGH

MEDIUM

MEDIUM or LOW

LOW

LOW

Dehumidity and heating Set the knobs to the following positions and a dry, fresh, warm breeze will be flowed from the vents at operator’s feet. l Outlet change-over knob 0: FOOT l Heater temperature knob 0: See table below. l Blower switch 0: See table below. l Cooler temperature knob @I: HIGH

Control knob

2 Z-E 13‘g EW a= c-0 o”z

2-28

Heater temp. knob @

Blower switch @

Winter

HIGH

HIGH

Normal heating

MEDIUM

MEDIUM

Autumn

or LOW

or LOW AEI 68200

11. EXPLANATION OF COMPONENTS

If very damp air is used for heating, only hot, humid air will be sent to the cab, producing an unpleasant atmosphere. This air conditioner first cools the air to dehumidify it, and then reheats it to produce the optimum heating conditions. In addition, there is no problem with the windows misting up. This setting is particularly useful in spring, autumn or on rainy days when the air is very damp.

When the outside temperature is from 2°C to 6.5X, a low pressure cut switch functions to automatically and switch the compressor off.

In this situation it is impossible to use the combination of dehumidifying and heating.

Precautions for using air conditioner When cooling, change the air occasionally.

Smoking in the air-conditioned cab will cause your eyes to get sore.

While smoking, open the window to let the smoke out of the cab.

While using the air conditioner, open the window once every hour.

When using the cooler, make sure the hot water circuit is completely stopped.

If hot water is circulating in the heater, it is like having a hot heater, it is like having a hot water bottle in the cab. Always make sure the heater temperature knob is at the OFF position.

When not using the heater for a long period, fully close the hot water outlet and inlet valves under the engine water manifold and radiator.

Be careful not to overcool the cab.

The cab should feel cool when entering there from outside (5°C or 6°C lower than the outside temperature).

It is unhealthy to have the temperature in the cab too low. Always give careful consideration to temperature regulation.

2-29

11. EXPLANATION OF COMPONENTS

11.10 RADIO 11 .lO.l

EXPLANATION

OF COMPONENTS

AEo97290

1.

TUNING KNOB (TUNING)

Turn this knob in to the desired station.

Turn right in to the station. If the tuning is off center, the sound quality will be unnatural and sensitivity will be reduced.

2.

TONE CONTROL (o TONE)

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.

3.

POWER SWITCH/VOLUME

CONTROL (o SW-VOLUME)

Press the knob to turn on (or off) the radio. When it is turned to the right, the sound level will increase, and vice-versa.

4.

STATION SELECTOR BUTTONS (5 buttons)

By pressing stations.

5.

2-30

POINTER

these

buttons

it is possible

to tune

in to preset

11. EXPLANATION OF COMPONENTS

11.10.2

HOW TO SET STATION SELECTOR BUTTONS

Set the station selector buttons to the desired stations as shown in the following figure.

Pull backthe button corresponding

to the station to be preselected.

I

AE097300

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.)

AE097310

Carefully push back the button with the fingertip until it clicks into place.

When setting the turning selector to a strong station, shorten the antenna to reduce the input as far as possible before carrying out alignment.

I

I 11.10.3 l

l

l

AE097320

PRECAUTIONS WHEN USING RADIO

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.

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).

Do not disassemble the radio.

11 .I 0.4

TROUBLESHOOTING

No sound l Turn the SW/vOL times.

GUIDE

knob to the right and press it two or three

Sound quality is poor.

Reception is noisy l Return using the station selector knob. If the problem pears, reset the tuning button. l Try lengthening the antenna to its fullest extent.

disap-

2-31

j

11. EXPLANATION OF COMPONENTS

11.11 FUSE NOTICE Before replacing

/a\\ a fuse, be sure to turn off the starting

switch.

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

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

Replace a fuse with another

d/ q \\

AEl6.5510

of the same capacity.

Fuse capacity and name of circuit Spare fuses (three of lOA, one of 20A) are kept in the spare fuse box.

No.

Fuse capacity

0

10 A

Front lamp

0

10 A

Working lamp

@ 1

10 A

0

20 A

0

10 A

@ 1

20 A

0

IO A

Swing lock brake, Travel speed, Buttom dump

8

10 A

Horn, Room lamp (engine room), Filter clogging timer

@ 1

20 A

@/

20 A

2-32

Name of circuit

AcxJ52120

) Spare Monitor, OLSS, Work equipment controller

1 Air conditioner

) Wiper, Room lamp Cigarette lighter, Radio

11. EXPLANATION OF COMPONENTS

11.12 CONTROLLERS The controllers have a self-diagnostic function. Open the left side cover behind the operator’s cab, and open the inspection cover so that the controllers can be seen. Through the monitor window installed to the cover of the box, red and green LEDs (Light Emitting Diodes) which indicate abnormalities can be seen.

When there is no abnormality, the display in the table below is shown.

For details of the LED display when an abnormality occurs, see “16.4 OTHER TROUBLE”.

\ \.

When normal @ OLSS controller

l

Condition of machine Lights

Machine is normal in the mode ‘3” and autodecelerator is not aoolied

:fY

Flashes fast

Machine is normal in the mode “H” or ‘I” and auto-decelerator is not applied

Goes

Flashes slowlv

Machine is normal and auto-decelerator is applied

Goes Off

Off

@

Work equipment controller Indication of LED

Green

Red

Red

Red

Lights

Gp

Goes

Flashes

Off

fp

Lights Lights fl:.hes

Condition of machine Arc digging mode

Goes off

Goes off

Horizontal digging mode Horizontal digging + bucket angle compensation mode ARM OUT hydraulic switch actuated

BOOM RAISE/LOWER hydraulic switch actuated Goes Lights ARM IN, BUCKET hydraulic switch Off actuated Lights

11.13 TOOL BOX This is used for keeping the tools.

11.14 GREASE PUMP The pump is stored in the case at the rear of the battery case on the right hand side of the machine. Hang the pump on the hanger in the case.

2-33

11. EXPLANATION OF COMPONENTS

11.15 HANDLING

GREASE PUMP

INSTRUCTIONS FOR USE 1. When the lever of grease gun @ is pulled, grease is forced out 2.

and the pump also begins to work automatically.

When greasing is finished, release the lever of grease gun 0 and pumping of grease will stop.

PRECAUTIONS FOR USE l

When greasing the machine, set the grease nozzle is vertical to the nipple.

l

When removing the grease gun nozzle from the nipple, bend the end of the nozzle over‘slightly, then remove the end of the nozzle carefully.

If there is too little grease the pump will run dry, so move the grease to the center or refill the grease can.

l

gun so that the

AEo82090

REFILLING GREASE CAN 1. Remove the cover in front of the right side step.

2. Loosen wing bolts @ at 3 places on grease can 0, and then remove cover @ and pump as one unit.

3. Take out follow plate @I from inside can.

4. Pack grease can @ with new grease and set follow plate @I on top of grease in grease can.

REMARK Fit the cone in the center of the follow insertion.

5.

plate with grease before

Install cover @ while carefully passing suction tube through hole in follow plate 0.

Tighten 3 wing bolts @ equally.

REMARK When the pump is used, it will function for a short time, then stop.

However, the grease pumped out first is not suitable for use, as it contains air and is a whitish color.

6.

7.

2-34

Open check valve @ and pump all the grease containing of small hole @ at the bottom of the check valve.

After bleeding air, tighten check valve @ securely.

air out

11. EXPLANATION OF COMPONENTS

8.

Pull the grease gun lever to force all grease containing the grease gun and hoses.

air out of

REMARK l When refilling with grease, be very careful not to let sand or dirt stick to the suction tube or follow plate. l If the pump runs dry even when there is sufficient grease, it means the follow plate may not be installed correctly. Stop greasing and set the follow plate correctly. l When not using the grease gun for a long time, close valve 0 and shut off the air supply, relieve the inner pressure in the gun, the hose and the pump. l The standard grease can is the 16-liter can. If an l&liter can is used, more grease will be left in the can.

2-35

11. EXPLANATION OF COMPONENTS

11.16 HANDLING

ACCUMULATOR

A

WARNING

On machines equipped with an accumulator, for a short time after the engine is stopped, if the work equipment control lever is moved to the LOWER position, the work equipment will move down under its own weight.

After stopping the engine, always place the safety lock lever in the LOCK position and lock the attachment control pedal with the lock pin.

The accumulator is filled with high-pressure nitrogen gas, and it is extremely dangerous if it is handled in the wrong way.

Always observe the following precautions.

If accumulators break down or have trouble, immediately ask your Komatsu distributor to carry out repairs.

Only Komatsu personnel and those licensed to service high pressure equipment may recharge an accumulator with nitrogen.

Never overhaul or dispose of an accumulator without first bleeding out all the nitrogen through the air bleeder valve.

Have your Komatsu distributor check the gas pressure once a year.

Never make any hole in the accumulator or expose it to flame or fire.

Do not weld any boss or make any hole in to the accumulator.

When overhauling or disposing of the accumulator, it is necessary to release the gas from the accumulator, so please contact your Komatsu distributor.

This machine is equipped with the accumulator in the control circuit.

The accumulator is a device to store the pressure in the control circuit, and when it is installed, the control circuit can be operated for a short time even after the engine is stopped. Therefore, if the control lever is moved in the direction to lower the work equipment, it is possible for the work equipment to move under its own weight.

AEl68560

The accumulator deck (each).

2-36

is installed to the track frame and inside of left

12. OPERATION

12.1

CHECK BEFORE STARTING

ENGINE

Perform following checks for operator safety and maintenance machine performance.

12.1.1

WALK-AROUND

of

CHECK

A WARNING l

Leakage of oil or fuel, or accumulation of flammable material around high temperature parts, such as the engine muffler or turbocharger, may cause fire.

Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor.

Before starting the engine, look around the machine and under the machine to check for loose nut or bolts, or leakage of oil, fuel, or coolant, and check the condition of .the work equipment and hydraulic system. Check also for loose wiring, play, and collection of dust at places which reach high temperatures.

Always carry out the items in this section engine each day.

before

starting

the

5

7

8

2 AEl68580

1.

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

2-37

2.

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

3.

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

4.

Check hoses, Check repair

5.

Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from rollers and final drive case

6.

Check for leakage

7.

Check tightness

6.

Check oil level in PTO case Check the oil level in PTO case.

The oil level should be between

9.

for oil leakage from hydraulic equipment, hydraulic tank, joints that there is no oil leakage. If any abnormality is found, the place where the oil is leaking.

of water

from radiator

of air cleaner

mounting

bolts

the L and H marks.

Check oil level in swing machinery case Check the oil level in swing machinery case.

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

10. Drain water and sediment from fuel tank Loosen drain valve and drain the water and sediment bottom of the tank together with fuel.

For detail ING�.

2-38

see MAINTENANCE

“24.4

at the

CHECK BEFORE START-

12.1.2 CHECK BEFORE STARTING Always carry out the items in this section before engine each day.

CHECK COOLANT

starting

the

LEVEL, ADD WATER A

WARNING

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

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

Remove radiator cap 0, and check that cooling water is filled up to depth indicated by shadowed portion. If not, add water.

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL Open the engine hood.

Remove

dipstick 0

and wipe the oil off with a cloth.

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

The oil level should be between

the H and L marks on dipstick

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

The dipstick is marked with the levels for ENGINE one side and ENGINE IDLING on the other side.

Check the oil level, STOP the engine STOPPED side.

and with

STOPPED

on

the ENGINE

Gauge for ENG. STOPPED

Gauge for ENG. IDLING AE168610

Checking the oil level with the engine idling may be allowed, if the following precautions are throughly satisfied.

1) Check that the engine water temperature gauge shows green range.

2) Read the dipstick on its reverse side marked with “ENGINE IDLING” 3) Remove the oil filler cap.

AND

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

2-39

5.

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

6.

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

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

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

CHECK FUEL LEVEL, ADD FUEL g

WARNING

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

1.

Use sight gauge @ on the front face of the fuel tank to check that the tank is full.

2.

if the fuel level is not within the sight gauge, filler port @ while watching sight gauge 0.

Fuel capacity:

add fuel through

1140 C (301.2 US gal, 250.8 UK gal)

AND

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

3.

After adding fuel, tighten the cap securely.

REMARK If breather hole @ on the cap is clogged, the pressure in the tank will drop and fuel will not flow.

Clean the hole from time to time.

AD054210

2-40

12. OPERATION

CHECK OIL LEVEL IN HYDRAULIC

TANK,

ADD OIL

A WARNING l

l

When removing the oil filler cap, oil may spurt out, so turn the cap slowly to release the internal pressure before removing the cap.

If oil has been added to above the H mark, stop the engine and wait for the hydraulic oil to cool down, then drain the excess oil from the drain plug 8.

If the work equipment is not in the condition shown in the diagram on the right, start the engine, run the engine at low speed, retract the arm and bucket cylinders, then lower the boom, set the bucket teeth in contact with the ground, and stop the engine.

Within 15 seconds after stopping the engine, move each control lever (for work equipment and travel) to the full stroke in all directions to release the internal pressure.

I

AE084210

Check sight gauge 0. The oil level is normal if between the H and L marks.

NOTICE Do not add oil if the level is above the H line. This will damage the hydraulic equipment and cause the oil to spurt out.

4.

If the level is below the L mark, remove the upper cover of the hydraulic tank and add oil through oil filler 0.

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

REMARK The oil level will vary depending upon the oil temperature.

Accordingly, use the following as a guide: l Before operation: around L level (Oil temperature 10 to 30°C (50 to 86°F)) l Normal operation: around H level (Oil temperature 50 to 80°C (122 to 176°F))

AEI 68670

AE082220

2-41

12. OPERATION

CHECK DUST INDICATOR When the air cleaner element is clogged, the red piston of dust indicator @ reaches the service level and gets locked.

In that case, clean or replace the element.

After cleaning the element, push the button to return the red piston.

For details of the method of cleaning the element, see “24.3.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT�.

CHECK ELECTRICAL

WIRING

A

WARNING

If fuses are frequently blown or if there are traces of short circuit on the electrical wiring, locate the cause and carry out repair.

Check for damage of the fuse and any sign of disconnection or short circuit in the electrical wiring. Check also for loose terminals and tighten any loose parts. Check the following points carefully. l Battery 0 Starting motor l Alternator Please contact your Komatsu distributor for investigation and correction of the cause.

A

WARNING

Accumulation of flammable material (dead leaves, twigs, grass, etc.) around the battery may cause fire, so always check and remove such material.

When carrying out walk-around checks or checks before starting, always check if there is any accumulation of flammable material around the battery, and remove such flammable material.

2-42

12. OPERATION

DRAIN WATER AND SEDIMENT FROM FUEL TANK 1. Loosen drain valve @ and drain the water and sediment

at the

under tool box of right side.

2.

After draining, tighten

drain valve @ securely.

CHECK MONITOR SYSTEM Carry out the following check to prevent loss of warning abiWy caused by defective operation of the buzzer or broken lamps on the monitor panel.

1. Before starting the engine, turn the starting switch to ON and check that the alarm buzzer sounds and all monitor and gauge lamps light up for about three seconds.

If any lamp does not light up or the buzzer does not sound, the cause is probably a broken bulb or disconnection, so contact your Komatsu distributor.

CHECK OIL LEVEL IN PTO CASE 1. Open the left side cover and use dipstick @to check the oil level.

2.

The oil level should be between the Land H marks. If necessary, add engine oil at the filler 0.

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

CHECK OIL LEVEL IN SWING MACHINERY CASE 1. Use dipstick at under of boom foot, and inspection

hole at the

upper side.

2.

The oil level should be between the L and H marks. If necessary, add engine oil at the filler 0.

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

2-43

12.1.3 OPERATOR’S SEAT @: Fore-and-aft

adjustment of seat Move lever @ to the right, set the seat at the desired position, then release the lever.

Fore-and-aft adjustment: 160 mm (6.3 in) (8 stages) Adjusting seat height Move lever @ right or left, set the seat to the desired height.

UP, turn right.

DOWN, turn left.

Height adjustment: 50 mm (2.0 in)

Adjusting suspension Turn knob @to adjust the hardness of the suspension as follows.

To make HARDER, turn CLOCKWISE To make SOFTER, turn COUNTERCLOCKWISE Hardness adjustment: 55 - 120 kg (121 - 265 lb) (stepless) @: Adjusting seat-back angle Pull lever @ up, adjust the seat back to the desired angle, then release the lever. l When the seat is moved to the front, it is possible to recline the seat back at a greater angle, but when moving the seat to the rear, first return the seat back to its original position.

2-44

12.1.4

OPERATIONS AND CHECKS BEFORE STARTING ENGINE

If the control lever is touched tor’s compartment,

always

by accident,

the work equipment

set the safety lock lever securely to

1.

Check that safety lock lever @ is at the LOCK position.

2.

Check the position of each lever.

3.

Set the control lever @ to the neutral

position.

Insert the key in starting switch 0, position, then carry out the following

turn the key to the ON checks.

(1) Check that all the monitor lamps light up, and that after approx. three seconds, all the monitor lamps except the gauge lamps go out.

After checking the monitor lamps, return the key of starting switch @ to the OFF position.

If the monitors or gauges do not light up, there is probably a broken bulb or disconnection in the monitor wiring, so contact your Komatsu distributor for repairs.

AEl68760

2-45

12. OPERATION

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

NOTlCE Do not keep the starting motor rotating continuously for more than 20 seconds. lf the engine will not start, wait for at least 2 minutes before trying to start the engine again.

1.

Set fuel control

lever @ at the middle

position.

Half open position

AE168780

2.

Turn the key in starting engine will start.

3.

2-46

switch

@ to the START

position.

J

The

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

OFF

I

12. OPERATION

12.2.2STARTING IN COLD WEATHER (Starting with APS (Automatic Priming System))

l

Check that there are no persons or obstacles

l

Never use starting

in the surround-

aid fluids as they may cause .explosions.

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

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

When starting in low temperatures, 1. Open the fuel lever @ for APS. 2.

do as follows.

Set fuel control lever @ at the STOP position.

\ 3.

AE168830

Hold the key in starting switch @ at the START position, and keep the starting motor rotating for 10 seconds.

Then, set the key @ at the ON position.

(If release the key, it will return automatically to the ON position.)

AE168790

4.

Set fuel control lever @ at the low idling (MIN)

position.

2-47

12. OPERATION

5.

Set the low temperature starting aid switch @I to ON position.

The low temperature starting aid monitor lamp flashes. /I6 ON-

REMARK Even if the ambient temperature is below 15°C (59”FL if the starting aid switch is set ON when the water temperature is above 13°C (55.4”F), the low temperature starting aid monitor lamp will not flash.

In this case, start the engine by normal starting.

Front

of

t-l/

machine

AEl66660

1

I 6.

Hold the low temperature starting aid switch temperature starting aid monitor lamp light up.

until

the

low

REMARK Preheating is completed after approx. monitor lamp become flash to light up.

7.

80 seconds,

and the

When the monitor lamp light up, turn the key of starting switch @ to the START position and start the engine.

OFF

I

AEI 68010

8.

When the engine started, release the key of starting and the key will return automatically to ON.

switch @

AEl66660

9.

When the engine runs smoothly and the color of exhaust gas becomes normal, put the low temperature starting aid switch @ in the OFF position.

The low temperature

starting

aid monitor

OFF

@ goes off.

Front

2-48

of

machine

AEI66680

12. OPERATION

REMARK l The time which should elapse before turning the low temperature starting aid switch off varies with the ambient temperature.

Confirm the time to the table below.

Time from the starting of engine until turning off the low temperature

NOTlCE l When the air temperature is below 15°C (59°F). leave the valve open. l If Step 5 to 7 are carried out without performing Step 1, it may shorten the nozzle life. Be sure to carry out Step 1. l lf the engine does not start through the steps specified above, return the fuel control lever to the engine stop position and repeat Steps 5 to 7 at an interval of approx. 2 minutes. l lf the switch is moved to START while the low temperature starting aid monitor lamp is flashes, glow plugs will get wet, making firing impossible. This will make it difficult to start the engine.

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.

For details of bleeding the air, see the section on replacement of the FUEL FILTER.

2-49

12.3

OPERATIONS AND CHECKS AFTER STARTING ENGINE

A 0

0

WARNING

-1

Emergency stop If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position.

If the work equipment is operated without warming the machine up sufficiently, the response of the work equipment to the movement of the control lever will be slow, and the work equipment may not move as the operator desires, so always carry out the warming-up operation. Particularly in cold areas, be sure to carry out the warming-up operation fully.

12.3.1 WHEN NORMAL NOTICE l When the hydraulic oil is at a low temperature, do not carry out operations or move the levers suddenly. Always carry out the warming-up operation. This will help to extend the machine lie. l Do not suddenly accelerate the engine before the warming-up operation is completed.

Do not run the engine at low idling or high idling continuously 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 a midrange speed. l The hydraulic oil temperature should ideally lie within the range 50 to 80째C (122 to 176째F). lf the machine is operated after raising the oil temperature to 20째C (68째F). the life of the machine will be extended.

After starting the engine, do not immediately start operations.

First, carry out the following operations and checks.

1.

2-50

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

12. OPERATION

2.

Set the safety lock lever @ to the FREE position.

3.

Leaving bucket control lever @ in tilt side, run the engine about 5 minutes to warm up the hydraulic oil.

for

AEl68940

NOTICE Avoid abruptly warm-up.

4.

accelerating

the engine

After warm-up run is completed, for proper operation.

until the completion

check gauges, monitor

Continue to run the engine at light load until the engine temperature gauge falls within the green range.

of

lamps

water RED

GREEN WHITE

105°C (221°F) 102+3”C (215.6+5.4”F) 97°C (206.6”F) 90°C (194°F) 80°C (176°F) 67°C (152.6”F) AE082370

5.

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

noise, or

2-51

12.4

MOVING

12.4.1 MOVING

MACHINE MACHINE

OFF

FORWARD

A WARNING Before operating the travel levers, check the direction track frame. If the sprocket is at the front, the operation travel levers is reversed.

of the of the

When moving off, check that the area around the machine safe, and sound the horn before moving.

Clear all personnel

from the machine

Clear all obstacles

from the path of the machine.

is

and the area.

If the lever is moved inside the deceleration range, engine speed will rise suddenly. Operate the levers carefully.

Avoid abruptly operating the traveling and steering levers with the fuel control lever fully open, as this will cause the machine to move off suddenly.

Always set the travel speed selector switch to LO (low) when high resistance to traveling causes the engine speed to drop - for example, when climbing slopes or traveling over rough ground.

1.

Set swing lock switch @ to the ON (actuated) confirm that swing lock lamp @ lights up.

position

and

I 2.

Set fuel control lever @ towards increase the engine speed.

the full speeed

position

AEI66970

to

Full

AEI68990

2-52

12. OPERATION

3.

Set safety equipment,

lock lever @ in the FREE position, fold the work and raise it 40 - 50 cm (16 to 20 in) from the ground.

4.

Operate right and left travel pedals @ as follows.

0

When the sprocket is at the rear of the machine Push levers @forward slowly or depress the front part of pedals @ slowly to move the machine off.

levers @ or right and left travel

Sprocket AEl6.3990

l

When the sprocket is at the front of the machine Pull levers @ backward slowly or depress the rear part of pedals @ slowly to move the machine off.

AE169000

2-53

12.

OPERATION

12.4.2 MOVING

MACHINE BACKWARD

A

WARNING

pI

Before operating the travel levers, check the direction of the track frame. If the sprocket is at the front, the operation of the travel levers is reversed.

When moving off, check that the area around the machine safe, and sound the horn before moving.

Clear all personnel

from the machine

Clear all obstacles

from the path of the machine.

is

and the area.

Use extreme care when reversing the machine. a blind spot behind the machine.

Note there is

If the lever is moved inside the deceleration range, engine speed will suddenly rise. Operate the levers carefully.

Avoid abruptly operating the traveling and steering levers with the fuel control lever fully open, as this will cause the machine to move off suddenly.

Always set the travel speed selector switch to LO (low) when high resistance to traveling causes the engine speed to drop - for example, when climbing slopes or traveling over rough ground.

1.

Set swing lock switch @ to the ON (actuated) confirm that swing lock lamp @ lights up.

position

and

AE168970

2.

Set fuel control lever @ towards increase the engine speed.

the full

speed

position

to

AE168980

2-54

3.

Set safety equipment,

4.

Operate right and left travel pedals @ as follows.

lock lever @ in the FREE position, fold the work and raise it 40 - 50 cm (16 to 20 in) from the ground.

levers @ or right and left travel

Sprocket AEl69010

l

When the sprocket is at the rear of the machine Pull levers @ backward slowly or depress the rear part of pedals @ to move the machine off.

w mu

Sprocket

l

When the sprocket is at the front of the machine Push levers @forward slowly or depress the front part of pedals @ to move the machine off.

12.4.3 CHANGING SPEED Before changing speed, completely stop the machine.

Move travel speed selector switch @to HI (high) or LO (low) to change the machine speed.

REMARK Setting the travel speed selector switch to HI (high) decreases the power available for the work equipment; always operate the work equipment with the travel speed selector switch in the LO (low) position.

2-55

12.5

STEERING

MACHINE

125.1 STEERING (CHANGING DIRECTION) &h WARNING l l l

Before operating the travel levers, check the position of the sprocket. lf the sprocket is at the front, the operation of the travel levers is reversed.

When turning in places where there is big resistance to turning, turn at low speed using the LO (low) position.

Use the travel levers to change direction.

Avoid sudden changes of direction as far as possible. In particular, when carrying out counter-rotation (spin turn), stop the machine first before turning.

Operate two travel levers @ as follows.

Changing When Push forward;

direction of machine when stopped turning to the left: the right travel lever forward to travel left when traveling and pull it back to turn left when traveling in reverse.

REMARK When turning same way.

I

‘y’e!Turnins

to the right, operate

the left travel

lever in the

left when traveling In reverse

AEl69050

Steering when traveling (left and right travel levers both operated in same direction) When turning to the left: If the left travel lever is returned to the neutral position, the machine will turn to the left.

REMARK When turning to the right, operate same way.

the right travel

lever in the

Turning left when traveling forward Turning left when t rave in reverse

I i na

*SF [Tj!Fj

AE169060

2-56

When making counter-rotation turn (spin turn) When turning left using counter-rotation, pull the left travel lever back and push the right travel lever forward.

REMARK When turning right using counter-rotation, pull the right travel lever back and push the left travel lever forward.

AE169070

2-57

~2.6 STOPPING

MACHINE

A

WARNING

Avoid stopping suddenly. Give yourself ample room when stopping.

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

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

When the machine is not being used after completion of work, first retract the work equipment cylinder to the stroke end, then set the work equipment in the posture shown in the diagram.

the

bucket AE167610

AE167470

1.

2-58

Put the left and right travel levers @ in the neutral position, then stop the machine.

Lower the engine

speed using fuel control lever 0.

Lower the bucket ground.

horizontally

until its underside

touches

the

Place lock lever @ to the lock position.

2-59

12.7 SWINGING

pizr-A~‘NG 1.

l

When

operating

the swing

l

During swing operatoins, ON.

check that the area around

do not put swing lock switch

the

@ to

Before swing operations, put swing lock switch @ to OFF and confirm that swing lock lamp @ goes off.

I 2.

Operate left work equipment structure.

AE169130

control lever @ to swing the upper

AEl69140

3.

When not operating (ACTUATED).

the swing, turn swing

lock switch

@ ON

I

2-60

AEl68970

12.8

OPERATION

OF WORK EQUIPMENT

A

WARNING

If any lever is operated when in the deceleration range, the engine speed will suddenly increase, so be careful when operating the levers.

Arm

The work equipment is operated by the left and right work equipment control levers. The left work equipment control lever operates the arm and swing, and the right work equipment control lever operates the boom and bucket.

The movements of the lever and work equipment are as shown in the diagrams on the right. When the levers are released, they automatically return to the neutral position and the work equipment is held in place. l

If the work equipment control lever is returned to the neutral position when the machine is stopped, even if the fuel control lever is set to FULL, the auto-deceleration mechanism will act to reduce the engine speed to a mid-range speed.

AE169180

REMARK

If the levers are operated within 15 seconds, it is possible to lower the work equipment to the ground.

The levers can also be operated to release any remaining pressure inside the hydraulic cylinder circuit.

Close

Open

_

,

2-61

12.9

WORKING

MODE SELECTION

WORKING MODE The mode selector switches can be used to switch the mode to match the conditions and purpose of work, thereby enabling efficient operation.

Use the following procedures to make the most effective use of each mode.

HOW TO READ THE TABLE AND GUIDANCE FOR SELECTION The most appropriate modes for various combination of work and soil are shown below. Select the mode according to the jobsite and type of work. l

Guidance for use

I : For heavy duty work at high speed II : For normal work III : When speed is not necessary but the fuel should be saved.

MODE SELECTOR SWITCH (OLSS) l

l

The letters H, S and L in the table refer to the positions of the switch in the right figure.

Hp refers to use in H mode at partial throttle (80% of engine output).

AD167910

2-62

12. OPERATION

12.10 PROHIBITIONS

FOR OPERATION

A

WARNING

-1

lf it is necessary to operate the work equipment control lever when the machine is traveling, stop the machine before operating the work equipment control lever.

If the lever is moved inside the deceleration range, engine speed will suddenly rise. Operate the levers carefully.

Never operate the machine on a rock bed (hard or soft rock).

Never carry out digging operations with the track gauge retracted.

It is dangerous to travel over obstacles, so avoid such operations.

If it is necessary for the machine to travel over boulders or tree stumps, a large shock will be brought to bear on the machine (particularly the undercarriage), so lower the travel speed and travel so that the center of the tracks passes over the obstacle.

When doing this, keep the work equipment close to the ground.

Prohibited operations using swing force Do not use the swing force to compact soil or break mounds or walls.

When swinging, do not dig the bucket teeth into the soil.

These operations will damage the work equipment.

INCORRECT

AH69220

earth

Prohibited operations using travel force Do not leave the bucket dug into the ground and use the travel force to excavate. This will bring excessive force to bear on the rear of the machine.

Precautions when operating hydraulic cylinders to end of stroke If the cylinder is operated to the end of its stroke during operations, force will be brought to bear on the stopper inside the cylinder, and this will reduce the life of the machine. To prevent this, always leave a small safety margin when operating the cylinders.

Prohibited operations using dropping force of bucket Do not use the dropping force of the bucket as a pickaxe, breaker, or pile driver. This will bring excessive force to bear on the rear of the machine, and will not only damage the machine, but is also dangerous.

INCORRECT

AU69260

2-63

Be careful of stability when swinging.

During swing operations, the stability of the machine differs to the front, rear, left and right, and there is danger that itmay tip over.

AE169270

It is prohibited to use the tilt operation for digging.

Do not set the teeth vertically when the bucket is pulled in, and then use the tilt operation to carry out digging.

INCORRECT

AE169280

It is prohibited to grip rocks.

Do not use the bottom dump

INCORRECT

bucket to grip rocks.

AE169290

It is prohibited to Using the rear an excessive force rear bucket in this

use the bucket for leaving operations. bucket to carry out leveling operations will bring to bear on the work equipment, so do not use the way.

INCORRECT I

AE169300

Be careful When the boom danger to

not to spill the load.

1 INCORRECT the bucket is fully loaded, do not raise the boom fully. If is raised fully, the load will spill to the rear and cause the operator.

I Be careful not to hit the undercarriage.

If the upper structure is set diagonally to the track frame when carrying out digging operations, the work equipment will hit the track links.

2-64

AE169310

Scraping-down operations are prohibited.

Never use the front bucket of a bottom-dump down rocks or soil.

INCORRECT

bucket to scrap

AE169330

Digging rocky ground It is better to excavate hard rocky ground after breaking it up by some other means.

This will not only reduce damage to the machine but make for better economy.

2-65

12.11 PRECAUTIONS

FOR OPERATION

INCORRECT

PRECAUTIONS WHEN TRAVEUNG When traveling over obstacles such as boulders or tree stumps, the machine (in particular, the undercarriage) is subjected to a large shock, so reduce the travel speed and travel over the obstacle at the center of the tracks. As far as possible, remove such obstacles or avoid traveling over them.

AEI67530

PERMISSIBLE WATER DEPTH NOTlCE When driving the machine out of water, if the machine exceeds I!?, the rear of the upper structure water, and water will be thrown up by the radiator cause the fan to break.

Be extremely careful when driving the machine out

angle of the will go under fan. This may of water.

Do not immerse the machine in water by more than the permissible depth (under swing circle 0).

In addition, for parts that have been immersed in water for a long time, pump in grease until the old grease comes out from the bearings. (Around the bucket pins, and swing circle)

2-66

1

w

AEi69340

12. OPERATION

12.12 PRECAUTIONS DOWN HILLS

WHEN TRAVELING

UP OR

A WARNING When traveling, raise the bucket approx. in) from the ground.

Do not travel downhill in reverse.

20 - 30 cm (8 - 12

AEl69360

When traveling over ridges or other obstacles, keep the work equipment close to the ground and travel slowly.

It is dangerous to turn on slopes or to travel across slopes.

Always go down to a flat place to perform these operations.

It may be longer, but it will ensure safety. lf the machine starts to slide or loses stability, bucket immediately and brake the machine.

lower

the

Turning or operating the work equipment when working on slopes may cause the machine to lose its balance and turn over, so avoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded. lf such operations have to be carried out, pile soil to make a platform on the slope so that the machine can be kept horizontal when operating.

AE099790

Do not travel on slopes of over 30” as there is danger that the machine may overturn.

1) When traveling down steep hills, use the travel lever and fuel control lever to keep the travel speed low.

When traveling down slopes of more than 15”, set the work equipment in the posture shown in the figure on the right, and lower the engine speed.

AE167540

2)

When traveling up a steep hill of more than 15”, set the work equipment in the posture shown in the diagram on the right.

AD167550

2-67

12. OPERATION

Braking when traveling downhill To brake the machine during downhill runs, put the travel lever in the neutral position. This will cause the brake to be automatically applied.

If shoes slip When traveling uphill, if the shoes slip or it is impossible to travel uphill using the force of the track only, it is possible to use the pulling force of the arm to help the machine travel uphill.

If engine stops If the engine stops when traveling uphill, move the travel levers to the neutral position, lower the bucket to the ground, stop the machine, then start the engine again.

When engine trouble causes the engine to stop with the work equipment (boom) raised, place the traveling and steering levers in NEUTRAL and immediately (within 2 or 3 minutes) operate the boom lever fully to the LOWER side and lower the work equipment until it is in contact with the ground.

Precautions on slopes l If the engine stops when the machine is on a slope, never use the left work equipment control lever to carry out swing operations. The upper structure will swing under its own weight. l Do not open or close the door on the cab if the machine is on a slope. This may cause a sudden change in the operating force.

Always keep the door locked.

2-68

12. OPERATION

12.13 HOW TO ESCAPE FROM MUD Always operate carefully to avoid getting stuck in mud. If the machine does get stuck in mud, use the following procedures to get the machine out.

12.13.1 WHEN ONE SIDE IS STUCK When only one side is stuck in mud, use the bucket to raise the track, then lay boards or logs and drive the machine out. If necessary, put a board under the bucket also.

NOTICE When using the boom or arm to raise the machine, always have the bottom of the bucket in contact with the ground. (Never push with the teeth). The angle between the boom and arm should be 90� to 110�.

The same applies when using the bucket inverted.

12.13.2 WHEN BOTH SIDES ARE STUCK When the tracks on both sides are stuck in mud and the machine will not move, lay boards as explained above, and dig the bucket into the ground in front. Then pull in the arm as in normal digging operations and put the travel levers in the FORWARD position to pull the machine out.

2-69

12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR In addition to the following, it is possible to further increase the range of applications by using various attachments.

12.14.1

LOADING WORK

In places where the swing angle is small, work efficiency can be enhanced by locating the dump truck in a place easily visible to the operator.

Loading is easier and capacity greater if you begin from the front of the dump truck body than if loading is done from the side.

A5084250

2-70

12.15 PARKING MACHINE a

I Avoid stopping stopping.

suddenly.

Give yourself

WARNING ample

room

when

When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert blocks underneath the track shoes.

As an additional safety measure, thrust the bucket into the ground.

the

bucket AE167610

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

AE167470

1.

Put left and right travel levers @I in the neutral The machine stops.

position.

AE082470

2-71

12. OPERATION

2.

Lower fuel control idling.

lever @ to lower

the engine

speed to low fl

\ 3.

Lower the ground.

bucket

horizontally

until

the

bottom

touches

the

AEI 66650

I

AEOfJ4210

4.

Set safety lock lever @ in the LOCK position.

AEl67470

12.16 CHECK AFTER FINISHING

WORK

Check the engine water temperature, fuel level on the monitor gauge.

engine

2-72

oil pressure

and

12. OPERATION

12.17 STOPPING

ENGINE

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

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

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

2.

Set the fuel control lever @ towards the STOP position and stop the engine.

Low idling

AE169470

3.

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

OFF

I

AE169480

2-73

12. OPERATION

12.18 CHECK AFTER STOPPING

ENGINE

1. Walk around the machine and check the work equipment, paintwork, and undercarriage, and check also for leakage of oil or water. If any abnormalities are found, repair them.

2.

Fill the fuel tank.

3.

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

4.

Remove any mud stuck to the undercarriage.

12.19 LOCKING Always lock the following places. @ Door of operator’s cab Always remember to close the window. @ Fuel tank filler port @ Hydraulic tank oil filler @ Battery box cover @ Left side door of the machine @ Radiator cap REMARK Use the starting switch key to open and close all these places.

2-74

13. TRANSPORTATION

13.1

PRECAUTIONS

FOR TRANSPORTATION

7twARN’NGl l

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

l

Always check that the door on the cab is closed and locked before transporting the machine.

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

2-75

13. TRANSPORTATION

13.2

PARTS FOR TRANSPORT

The dimensions

in the diagrams

are given in millimeters.

For ease of transport, the machine may be disassembled into the parts shown in the diagrams: the body, operator’s cab, track frames, platform, attachments and counterweight.

Ask your Komatsu distributor to carry out the disassembly work.

Weight: 29,500 kg (65,050 lb)

Width: 3,480

AE169500

Weight: 28,400 kg (14,200 x 2) (62,600 lb (31,300 x 2))

AE169510

Weight: 300 kg (662 lb)

AEl69520

Weight: 90 kg (198 lb)

AE169530

2-76

13. TRANSPORTATION

Width:

Weight:

14,800 kg (32,630

lb)

Weight:

14,000 kg (30,870

lb)

Weight:

8,200 kg (I 8,080 lb)

Weight:

2,100 kg (1,200 x 2)

AEI69540

2,000

AE169550

Width:

2,800

AEl69560

(4,630 lb (2,315 x2))

Width:

480

AE169570

Weight:

130 kg (287 lb)

AE169560

2-77

13. TRANSPORTATION

Weight 2 kg x 3

Weight 30 kg x 2

(4.4 lb x 3)

Weight 5 kg (11 lb)

(66Ibx2)

Weight 120

x2

kg (265 lb x 2)

Weight 60 kg (132 lb)

Total weight: 410 kg (904 lb) 25 Weight kg (904 lb)

Weight 7 kg x 2 (15 lb x 2)

AE169590

2-78

13. TRANSPORTATION

13.3

PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE

A Never use the machine

WARNING

for operations

with

the track frame

retracted.

REDUCING TRACK GAUGE 1. Remove center frame 32 bolts)

mounting

bolts 0.

(one side, front + rear:

/ 2.

Swing the upper structure to the track frame @ side to be retracted until the upper structure is at a right angle to the tracks.

Then, jack up the track frame, making use of the work equipment.

3.

Put the block (20 to 30 cm (8 to 12 in) square) from outside of track frame @. Using the boom cylinder, slowly lower the machine until the track frame reaches the stoppers.

4.

Lower the machine carefully and install bolts 0. (one side, front + rear: 12 bolts out of bolts 0) Tightening torque: 3285 f 300 Nm (335 r 30 kgm, 2420 + 220 Ibft)

5.

Follow the same procedure to retract the track frame on the other side.

AE082960

2-79

13. TRANSPORTATION

INCREASING TRACK GAUGE 1. Remove center frame mounting bolts @ (one side, front + rear: 12) from the front and rear of the track frame on the side to be extended.

2.

Swing the upper structure to the side opposite track frame @to be extended until the upper structure is at a right angle to the tracks.

REMARK Height H of the track frame being raised should be less than 50 mm (2 in). Take care not to raise the track frame so much that the stopper bolt is distorted.

3.

Pull the machine forward slide sideways.

with the arm, and the track frame will

4.

Extend the track frame stopper, then lower the bolts @ (one side, front torque.

Tightening torque: 3285 (335

until it comes into contact with the machine slowly to the ground. Install + rear: 32) and tighten to specified r 300 Nm + 30 kgm, 2420 -c 220 Ibft)

5.

Follow the same other side.

0

The track gauge should be changed on level, hard ground.

When changing the track gauge, it is dangerous to operate any cylinder suddenly. Always operate the control levers slowly.

l

2-80

procedure

to extend

the track frame

on the

14. COLD WEATHER OPERATION

14.1

PRECAUTIONS

FOR LOW TEMPERATURE

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

14.1.1 FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

14.1.2

COOLANT

Keep antifreeze

fluid away from an open flame.

Never smoke

NOTICE l Never use methanol, ethanol or propanol based antifreeze. l Absolutely avoid using any water leak preventing agent irrespective of whether it is used independently or mixed with an antifreeze. l Do not mix one antifreeze with a different brand.

For details of the antifreeze mixture when changing the coolant, see “24.3 WHEN REQUIRED”.

Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the standard requirements as shown below. With permanent antifreeze, no change of coolant is required for a year. If it is doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for information.

Standard requirements for permanent antifreeze l SAE .. . .. .. .. . ... . .. . ... . . . ... . . . .... . .. . ... .. . .. . .. . . .. . .. . .. . ... . ... . ... . ... .. . ... .. .. .. .. . J1034 l FEDERAL STANDARD ... . ... . .. . . .. .. . . .. . . . . .. . . .... .. . .. ... . ... .. .. .. . O-A-548D REMARK 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.

2-81

14. COLD WEATHER

OPERATION

14.1.3 BAllTRY &L WARNING l

To avoid gas explosions, battery.

do not bring fire or sparks near the

l

Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a doctor.

When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low, the battery electrolyte may freeze. Maintain the battery charge as close as possible to lOO%, and insulate it against cold temperature so that the machine can be started easily the next morning.

REMARK Measure the specific gravity and calculate from the following conversion table.

l

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

the rate of charge

When electrolyte level is low, add distilled water in the morning before work instead of after the day’s work. This is to prevent fluid from freezing at night.

2-82

14. COLD WEATHER OPERATION

14.2

F;;;lJTIONS

AFTER COMPLETION

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.

Mud and water on the machine body should be completely removed. This is to prevent damage to the seal caused by mud or dirt getting inside the seal with frozen drops of water.

Park the machine on hard, dry ground. If this is impossible, park the machine on wooden boards. The boards help protect the tracks from being frozen in soil and the machine can start next morning.

Open the drain valve and drain any water collected system to prevent it from freezing.

in the fuel

As the battery capacity drops markedly in low temperatures, cover the battery or remove it from the machine, keep it in a warm place, and install it again the next morning.

If electrolyte level is found low, add distilled water in the morning before beginning work. Do not add the water after the day’s work so as to prevent fluid in the battery from freezing in the night.

14.3

AFTER COLD WEATHER

When season changes and the weather becomes warmer, do as follows.

Replace the fuel and oil for all parts with oil of the viscosity specified.

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

If for any reason permanent antifreeze cannot be used, ethyl glycol base antifreeze (winter, one season type) instead, or if no antifreeze is used, drain the cooling completely, then clean out the inside of the cooling thoroughly, and fill with fresh water.

,

and an is used system system

As the APS (Automatic Priming System) becomes useless (at 15°C (59°F) or above), be sure to close the fuel valve for the APS.

2-83

15. LONG-TERM STORAGE

15.1

BEFORE STORAGE

NOTICE To protect the cylinder rod when the machine is not being used, set the work equipment in the posture shown in the diagram.

(This prevents rusting of the cylinder rod) When putting the machine in storage for a long time, do as follows.

After every part is washed and dried, the machine shall be housed in a dry building. Never leave it outdoors.

In case it is indispensable to leave it outdoors, park the machine on well-drained concrete and cover it with canvas etc.

Completely storage.

fill the fuel tank, lubricate and change the oil before

Apply a thin coat of grease to metal piston rods.

surface of the hydraulic

Disconnect the negative terminals of the battery and cover it, or remove it from the machine and store it separately.

If the ambient temperature is expected to drop always add antifreeze to the cooling water.

below

O�C,

Lock each control lever and pedal with the lock lever and pedal lock.

Set work equipment position.

2-84

control lever and switch for neutral or OFF

AElBOE30

15. LONG-TERM STORAGE

15.2

DURING STORAGE

A

WARNING

If it is unavoidably necessary to carry out the rust-preventive operation while the machine is indoors, open the doors and windows to improve ventilation and prevent gas poisoning.

Operate the engine and move the machine for a short distance once a month so that a new film of oil will be coated over movable parts and component surfaces. At the same time, also charge the battery. l

Also carry out cooler operation with an airconditioner.

l

Before operating the working the hydraulic piston rod.

15.3

in the case of machines equipped

equipment,

wipe off the grease on

AFTER STORAGE

NOTlCE If the machine was stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service.

Carry out the following of long-term storage.

procedure

when taking the machine

l

Wipe off the grease from the hydraulic cylinder

l

Add oil and grease to all places.

l

Bleed air from hydraulic cylinder circuit.

Refer to the item of “18.5 BLEEDING AIR FROM CIRCUIT�.

out

rods.

If the machine was stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service.

15.4

WVtlE;

MACHINE

AFTER LONG-TERM

When starting the machine after a long-term storage, first cancel the automatic warming-up function as follows.

1. Turn the starting switch key to the ON position.

2.

Turn the fuel control lever from the low idling (MIN) position to the full (MAX) position, hold it there for 3 seconds, then return it to the low idling (MIN) position and start the engine.

2-85

16. TROUBLESHOOTING

16.1 1.

2.

PHENOMENA

THAT ARE NOT FAILURES

Note that the following phenomena are not failures: When starting or stopping the swing, noise will be emitted from the brake valve.

When going down a steep slope at low speed, a noise will be emitted from the travel motor.

16.2

PRECAUTIONS

ON PARTICULAR JOBSITES

1.

When carrying out digging operations in water, if the work equipment mounting pin goes into the water, carry out greasing every time the operation is carried out.

2.

For heavy-duty operations and deep digging, carry out greasing of the work equipment mounting pins every time before operation.

After greasing, operate the boom, arm and bucket several times, then grease again.

2-86

16.

16.3

TROUBLESHOOTING

IF BATTERY IS DISCHARGED

A WARNING When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position before starting.

The battery generates hydrogen gas, so there is danger of explosion. Do not bring lighted cigarettes near the battery, or do anything that will cause sparks.

Battery electrolyte is dilute sulphuric acid, and it will attack your clothes and skin. If it gets on your clothes or on your skin, wash it immediately off with large amounts of water. If it gets in your eyes, wash it out with fresh water, and consult a doctor.

When handling

battery,

always

wear

protective

When removing, disconnect the cable from the ground terminal first

goggles.

When removing the battery, first disconnect the cable from the ground (normally, from the negative 0 terminal). When installing, install the positive @terminal first. If a tool touches the cable connecting the positive terminal and the chassis, there is danger that it will cause sparks.

When installing, connect the cable

If the terminals are loose, there is danger that the defective contact may generate sparks that will cause an explosion.

When installing the terminals, install them tightly.

When removing or installing, check which terminal and negative 0 terminal.

is the positive

@

2-87

16. TROUBLESHOOTING

16.3.1 STARTING When

Precautions

ENGINE WITH BOOSTER CABLE

starting the engine with a booster cable, do as follows:

when

connecting

and disconnecting

booster

cable

A WARNING When connecting the cables, and negative @ terminals.

INCORRECT

never contact

the positive

When starting the engine with a booster cable, always safety glasses.

@

wear

Be careful not to let the normal machine and problem machine contact each other. This prevents sparks from generating near the battery which could ignite the hydrogen gas given off by the battery. If hydrogen gas explodes, it could cause serious injury.

Make sure that there is no mistake in the booster cable connections. The final connection is to the revolving frame, but sparks will be generated when this is done, so connect to a place as far as possible from the battery. (However, avoid connecting the cable to the work equipment, as conduction is poor.)

Use care when removing the cables from the machine that has been started. Do not allow the cable ends to contact each other or the machine, to avoid hydrogen explosion.

NOTlCE The size of the booster cable and clip should be suitable for the battery size.

l

l

The battery of the normal machine must be the same capacity as that of the engine to be started.

l

Check the cables and clips for damage

l

Make

2-88

or corrosion.

sure that the cables and clips are firmly connected.

Connecting the booster cables Keep the starting switch at the OFF position.

Connect the booster cable as follows, in the order of the numbers marked in the diagram.

1. Make sure that the starting switches of the normal machine and problem machine are both at the OFF position.

2.

Connect one clip of booster cable @ to the positive @ terminal of the problem machine.

3.

Connect terminal

4.

Connect one clip of booster cable @I to the negative of the normal machine.

5.

Connect the other clip of booster cable Q$ to the engine block of the problem machine.

the other clip of booster of the normal machine.

cable @ to the positive

Engine block of the problem machine

ADo5298o

@

0 terminal

Starting the engine 1. Make sure the clips are firmly connected to the battery terminals.

2.

Start the engine of the normal high idling speed.

machine

and keep it running

at

3.

Turn the starting switch of the problem machine to the START position and start the engine. If the engine doesn’t start at first, try again after 2 minutes or so.

2-89

Disconnecting the booster cables After the engine has started, disconnect the booster cables in the reverse of the order in which they were connected.

Remove one clip of booster cable @I from the engine block of the problem machine.

Remove the other clip of booster cable @ from the negative terminal of the normal machine.

Remove one clip of booster cable @from of the normal machine.

Remove terminal

the positive @ terminal

the other clip of booster cable @ from the positive @ of the problem machine.

16.32 PRECAUTIONS FOR CHARGING MOUNTED ON MACHINE

IA

WARNING

BAlTERY

WHEN

-1

Before charging, disconnect the cable from the negative 0 terminal of the battery.

Otherwise, an unusually high voltage will damage the alternator.

While charging the battery, satisfactory ventilation.

If the electrolyte temperature charging for a while.

remove

all battery

exceeds

45°C

plugs

(113”F),

Turn off the charge as soon as the battery is charged.

Overcharging the battery may cause the following: 1) Overheating the battery 2) Decreasing the quantity of electrolyte 3) Damaging the electrode plate

2-90

@

for

stop

I

I

normal machine&J

1

W’

DrObiem machine

-==a Engine blodtofthe problem machine Aw5298,

16. TROUBLESHOOTING

16.4

OTHER TROUBLE

16.4.1 ELECTRICAL SYSTEM ): Always contact your Komatsu distributor when dealing with these items. l ( l

In cases of abnormalities distributor for repairs.

or causes which

are not listed below,

please

contact

Main causes

Problem

Komatsu

Remedy

l

Defective wiring

l

Defective adjustment of fan belt tension

Charge level monitor does not go off even when engine is running

l l

Defective alternator Defective wiring

(o Replace) (o Check, repair)

Abnormal noise is generated from alternator

l

Defective alternator

(0 Replace)

Starting motor does not turn when starting switch is turned to ON

l

l

Defective wiring Defective starter Insufficient battery charge

(o Check, repair) (o Replace) l Charge

Pinion of starting motor keeps going in and out

l

Insufficient battery charge

l

Starting motor turns engine sluggishly

l

Insufficient battery charge a Defective starting motor

l

Starting motor disengages before engine starts

l

Oil pressure monitor does not light up when engine is stopped (starting switch at ON position)

l

Lamp does not glow brightly even when the engine runs at high speed

your

(o Check, repair loose terminals, disconnections) l Adjust fan belt tension

Lamp flickers while engine is running

Charge level monitor does not light up when engine is stopped Low temperature starting aid monitor does not light up

l

l

l

l l

l l l

Charge

Charge (o Replace)

Defective wiring Insufficient battery charge

(o Check, repair) l Charge

Defective monitor Defective caution lamp switch

(o Replace) (o Replace)

Defective monitor Defective wiring

(o Replace) (o Check, repair)

Defective wiring Defective heater-relay Defective monitor lamp

(o Check, repair) (o Replace) (o Replace)

2-91

16. TROUBLESHOOTING

16.4.2 CHASSIS 1: Always contact your Komatsu distributor when dealing with these items. (

l

In cases of abnormalities distributor for repairs.

l

or causes

Problem

which

are not listed

below,

please contact

Main causes

your Komatsu

Remedv

Speed of travel, swing, boom, arm, bucket is slow

l

Lack of hydraulic oil

l

Pump generates abnormal noise

l

Clogged element in hydraulic tank strainer

0 Clean

Excessive rise in hydraulic oil temperature

l

l

Loose fan belt Dirty oil cooler Lack of hydraulic oil

l Adjust fan belt tension 0 Clean l Add oil to specified level

l

Track too loose

l

Adjust track tension

l

Lack of hydraulic oil

l

Add oil to specified level

Track comes off

l

Add oil to specified level

Abnormal wear of sprocket Bucket rises slowly, does not rise

2-92

16. TROUBLESHOOTING

16.4.3ENGINE 1: Always contact your Komatsu distributor when dealing with these items.

0 ( l

In cases of abnormalities distributor for repairs.

or causes which

l

l l

l

Steam is emitted from top part of radiator (pressure valve)

Red range of engine cooling temperature gauge flashes

Indicator of water temperature gauge is in white range

below,

please

contact

l l

Engine oil pan oil level is low (sucking in air) Clogged oil filter cartridge Defective tightening of oil pipe joint, oil leakage from damaged pan Defective monitor

your

Komatsu

Remedy

Main causes

Problem Engine oil pressure monitor flashes even when engine is running

are not listed

l

Add oil to specified level

Replace cartridge (e Check, repair)

l

(e Replace)

Cooling water level low, water leakage Loosen fan belt Dirt or scale accumulated in cooling system Clogged radiator fins or damaged fins Defective thermostat Loose radiator filler cap (high altitude operation)

l

Add cooling water, repair

l

Adjust fan belt tension Change cooling water, clean inside of cooling system Clean or repair

Defective thermostat Defective water temperature

(e Replace) (e Replace)

l

l

(e Replace thermostat) l Tighten cap or replace packing

gauge Engine does not start when starting motor is turned

l l

Lack of fuel Air in fuel system

l

Defective fuel injection pump or nozzle

l

Starting motor cranks engine sluggishly Improper injecting timing

l l

Defective compression o Defective valve clearance

Add fuel Repair place where air is sucked in (e Replace pump or nozzle)

l l

See ELECTRICAL SYSTEM l

Adjust injection timing

(0 Adjust valve clearance)

2-93

16. TROUBLESHOOTING

ENGINE (cont’d) (16.4.3) Problem Exhaust gas is white or blue

Main causes

I

l

Add oil to specified level Change to specified fuel

l

Clogged air cleaner element Defective nozzle Defective compressoin Defective turbo-charger

0 (o (o (0

Clean or replace Replace nozzle) Adjust valve clearance) Clean or replace)

Combustion noise occasionally makes breathing sound

l

Defective nozzle

(o Replace nozzle)

Abnormal noise generated (combustion or mechanical)

l

Low grade fuel being used Overheating

l

Exhaust gas occasionally turns black

l Too much oil in oil pan 0 Improper fuel

Remedy

l l l

l

l l

2-94

Damage inside muffler Excessive valve clearance

l

Change to specified fuel See item “Indicator of water temperature gauge is in red range on right side of gauge”.

10 Replace muffler) 10 Adjust valve clearance)

l

16.4.4 ELECTRONIC CONTROL SYSTEM 1.

l

ELCTRONIC OLSS CONTROLLER If the abnormalities given on the left appear, lower the work equipment to the ground, and check the LED display of the controller. Contact your Komatsu distributor for repairs.

If there is any abnormality or cause not listed below, contact your Komatsu distributor for repairs.

When normal indication of LED Red Goes off Goes

off

Goes off

l

Green 1 Lights

I

Abnormal section (system)

Condition of machine

I I

I Machine is normal in mode 5”.

Flashes fast

Machine is normal in mode “H” or “L”.

Flashes slowly

Machine is normal and auto-decelerator is applied.

When abnormal The engine stalls or slows down extremely while the machine is working (traveling).

Electric power source

The engine stalls or slow down extremely while the machine is working (traveling).

The auto-decelerator is always applied or not applied at all.

Control box

Flashes

Goes off

The engine stalls or slow down extremely while the machine is working (traveling).

T.V.C. valve solenoid

Flashes

Flashes

The work (travel) speed is extremely low.

Rotation sensor %

Lights

Goes off

The mode selector does not change speed and power.

Throttle sensor

The auto-decelerator is not applied at all.

Decelerator solenoid A

The auto-decelerator is always applied

Decelerator solenoid B

% While the engine is stopped, red and green LEDs indicate this abnormality of rotation sensor.

2-95

16. TROUBLESHOOTING

2.

WORK EQUIPMENT AUTOMATIC CONTROL CONTROLLER If the following abnormalities occur, lower the work equipment to the ground, and check the LED display on the controller.

Then contact your Komatsu distributor for repairs.

If there is thought to be any abnormality or cause not listed below, please contact your Komatsu distributor for repairs.

03 Red 04 Red

l

When normal

l

When abnormal

2-96

AEO84270

16. TROUBLESHOOTING

16.4.5 APS (Automatic

Priming System)

): Always contact your Komatsu distributor

l

(

l

In cases of abnormalities distributor for repairs.

or causes

l

l l

l l l

Engine does start smoothly but much white smoke emits or the engine stop

When loaded, the engine will emit black smoke and stop

when dealing with these items. are not listed below, please contact

Main causes

Problem Engine does not start at all

which

l

l

your

Komatsu

Remedy

Nozzle clogging (dust, paraffin precipitation, defective nozzzle) Defective glow plug Fuel pipe collapse, fuel leak, clogging Defective wiring Fuse breaking Defective APS controller

(o Clean, change to specified fuel, replace nozzle) (o Replace) (o Check, repair)

Nozzle clogging (dust, paraffin precipitation, defective nozzle) Defective glow plug Fuse breaking Alternator functional defect (Alternator output shortage) Defective APS water temperature sensor Defective APS controller

(o Clean, change to specified fuel, replace nozzle) (o Replace) (o Replace) (o Check, repair or replace)

Defective APS water temperature sensor Deposited heater relay contact point

(o Replace temperature sensor)

(o Replace)

l

(o Check, repair) (0 Replace) (o Replace)

(o Replace temperature sensor) (o Replace)

(o Replace heater relay)

Burner is ignited and preheating monitor lamp remaining lighted Preheating monitor lamp does not become bright (when the temperature of the engine cooling water exceeds 20°C (68°F). the engine preheating system is in normal condition)

l

l

Disconnection in electrical intake air heater and glow plug Defective wiring Defective timer

Burner is not ignited

l

Glow plug is not heated red.

l

Fuel is not or less sprayed. o Nozzle clogging (dust, paraffin, precipitation, defective nozzle o Defective APS controller

l

(o Check, repair) 10 Replace)

See item “Preheating monitor lamp does not become bright”

(o Clean, change to specified fuel, replace nozzle) (0 Replace)

2-97

MEMO

2-98

17. GUIDES TO MAINTENANCE

Do not carry out any inspection and maintenance Perform maintenance work on hard, flat ground.

operation

that is not given in this manual.

Check service meter: Check the service meter reading every day to see if the time has come for any necessary maintenance to be carried out.

Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement Komatsu genuine oils: Use Komatsu genuine oils and grease. ambient temperature.

Always use clean washer fluid: Use automobile window washer

Choose

parts.

oils and grease with proper viscosities

specified

for

fluid and be careful not to let any dirt get into it.

Always use clean oil and grease: Use clean oil and grease. Also, keep containers from oil and grease.

of the oil and grease clean. Keep foreign

materials away

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

Adding fuel: When adding fuel, be careful not to allow the water collected

at the top or bottom of the drum to get

into the fuel.

Keeping the machine clean: Always keep the machine clean. This makes is easier to find parts causing problems. grease fittings,

breathers

and oil level gauges clean and avoid foreign

Keep in particular matters from getting in them.

Be careful of hot water and oil: Draining hot oils and coolants and removing their filters immediately after the engine stops are hazardous. Allow the engine to cool.

If the oil has to be drained when it is cold, warm up the oil to a suitable temperature (approx. 20 - 40°C) before draining it.

Checking for foreign materials in drained oil and on filter: After oil is changed or filters are replaced, check the oil and filters for metallic particles and foreign materials. If large quantities of metallic particles or foreign materials are found, consult your Komatsu distributor.

Fuel strainer: If your machine Oil change: Check or change

is equipped

with a fuel strainer,

oils in the places where

do not remove

dust is scarce to keep foreign

Adding fuel: When adding fuel, be careful not to allow the water collected the fuel.

3-2

it while fueling.

materials

away from oils.

at the top or bottom of drum to get into

17. GUIDES TO MAINTENANCE

Warning tag: Attach warning tag to the starting switch or other appropriate is not aware of the circumstances from starting the engine.

Obey precautions: During the operation,

always

obey the precautions

control lever to prevent any person who

on the safety label attached

to the machine.

Welding instructions: l Turn off the engine starting switch. l Do not apply more than 200 V continuously. l Connect the grounding cable within 1 m from the area to be welded. l Avoid seals or bearings from being between the area to be welded and the position of grounding point.

Fire prevention: Use nonflammable oil.

cleaner or light oil for cleaning

parts. Keep flame or cigarette

light away from light

Clamp faces: When O-rings or gaskets are removed, clean the clamp faces and replace the O-rings and gaskets with new ones. Be sure to fit O-rings and gaskets when assembling.

Objects in your pockets: Keep your pockets free of loose objects which can fall out and drop into the machinery; you bend over the machinery while working on it.

especially

when

Checking undercarriage: When working in rocky areas, check for damage to the undercarriage and for looseness, flaws, wear and damage to bolts and nuts. Loosen the track tension a little when working in such areas.

Precautions when washing machine: l Never spray steam or water directly on the connectors or mechatronics parts. l Do not allow water to get on the monitors and controllers inside the operator’s l Never spray steam or water directly at the radiator or oil cooler portions.

cab.

Pre-and post-work checks: Before starting work in mud, rain, snow or at the seashore, check plugs and valves for tightness.

Wash the machine immediately after the work to protect components from rusting.

Lubricate components more frequently than usual. Be sure to lubricate work equipment pins daily if they are submerged in water.

Dusty worksites: When working at dusty worksites, do as follows: l Inspect the dust indicator to see whether the air cleaner is blocked up. Clean the air cleaner at shorter intervals than specified. l Clean the radiator core frequently to avoid clogging. l Clean and replace the fuel filter frequently. l Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.

Avoid mixing oils: Never mix oils of different brands. If you have only oil which is a different used in the machine, do not add it but replace all the oil.

brand from the one that is

3-3

17. GUIDES TO MAINTENANCE

Check oil level: When adding oil or checking the oil level, ensure that the oil is at the correct level.

Electrical equipment: When washing the machine, take care not to splash water over the electrical equipment. with water, it may not operate normally.

If it is soaked

Working at seashore: When working at seashore, check that the various plugs and valves, etc., are tightened up properly. After completion of work, thoroughly wash the machine and carefully clean all electrical equipment to ensure that is does not corrode. l

Controller: When installing

car radio and a walkie-talkie

or citizen band, contact your Komatsu distributor.

Bleed air: After changing the oil, replacing the filter element, or cleaning the strainer, bleed the air from the circuit.

After changing the oil in the hydraulic tank, replacing the element, removing the hydraulic cylinders or work equipment piping, or replacing or cleaning the line filter element, bleed the air from the circuit after completing the operation. For details of the method of bleeding the air, see BLEEDING AIR FROM CURCUIT. Check welds and steel casting portion: If it leave the crack of welded or steel casting portion, which should result in serious injury.

Check the crack of welded or steel casting portion, at specified interval. If not, please contact your Komatsu distributor.

3-4

18. OUTLINES OF SERVICE

l

Use Komatsu

genuine

l

When

l

Unless otherwise specified, the oil and coolant used at the time of shipment from the factory are as shown in the table below.

changing

parts for replacement.

or adding oil, do not use a different

Kind of fluid

Item

Engine oil pan

SAE 15W-40 API classification CD

Swing machinery case Final drive case Damoer case

SAE 30 API classification CD

Hydraulic tank

SAE IOW API classification CD

Fuel tank

ASTM D975 No. 2 (However, ASTM D975 No. 1 is used for the winter season (October to March)

Radiator

Komatsu Super Coolant (AF-ACL) 41% added to water

18.1

type of oil.

OUTLINE OF OIL, FUEL, COOLANT

18.1.1 OIL Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pressure), and it deteriorates with use.

Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual. Even if the oil is not dirty, always replace it after the specified interval.

Oil corresponds to blood in the human body, so always be careful when handling it to prevent any impurities (water, metal particles, dirt, etc.) from getting in.

The majority of problems with machines are caused by the entry of such impurities.

Take particular care not to let any impurities get in when storing or adding oil.

Never mix oils of different

grades or brands.

Always add the specified amount of oil.

Having too much or too little oil are both causes of problems.

If the oil in the work equipment is not clear, there is probably In such cases, please contact your Komatsu distributor.

When changing

the oil, always

water or air getting

into the circuit.

replace the related filters at the same time.

We recommend you to have an analysis made of the oil periodically to check the condition machine.

For those who wish to use this service, please contact your Komatsu distributor.

of the

3-5

78. OUTLINES

OF SERVICE

18.1.2 FUEL l

The fuel pump is a precision properly.

instrument,

l

Be extremely

l

Always use the fuel specified in the Operation and Maintenance Manual.

Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15°C (5”F)), so it is necessary to change to a fuel that matches the temperature.

l

To prevent the moisture in the air from condensing fill the fuel tank after completing the day’s work.

l

Before starting the engine, or when and water from the fuel tank.

l

If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.

careful not to let impurities

and if fuel containing

water or dirt is used, it cannot work

get in when storing or adding fuel.

10 minutes

and forming

water inside the fuel tank, always

have passed after adding fuel, drain the sediment

18.1.3 COOLANT l

River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the engine and radiator, and this will cause defective heat exchange and overheating.

Do not use water that is not suitable for drinking.

l

When using anti-freeze, Manual.

l

Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped.

This anti-freeze is effective in preventing corrosion of the cooling system.

The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as it is even in hot areas.

l

Anti-freeze

l

The proportion of anti-freeze to water differs according to the ambient temperature.

For details of the mixing proportions, see “24.3.2 CLEAN INSIDE OF COOLING SYSTEM”.

l

If the engine overheats,

l

If the coolant level is low, it will cause overheating the air in the coolant.

3-6

always

is inflammable,

observe

the precautions

so be extremely

given in the Operation

careful not to expose

it to flame

and Maintenance

or fire.

wait for the engine to cool before adding coolant. and will also cause problems

with corrosion from

18. OUTLINES OF SERVICE

18.1.4 GREASE l

Grease is used to prevent twisting

and noise at the joints.

l

The nipples not included in the maintenance section are those for overhaul, grease.

If any part becomes stiff after being used for long time, add grease.

l

Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe off the old grease in places, where sand or dirt sticking in the grease would cause wear of the rotating parts.

so they do not need

18.1.5 STORING OIL AND FUEL l

Keep indoors to prevent any water,

dirt, or other impurities

l

When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at the side. (To prevent moisture from being sucked in) If drum cans have to be stored outside, cover them with a waterproof sheet or take other measures to protect them.

l

To prevent any change in quality during long-term first out (use the oldest oil or fuel first).

storage,

from getting

in.

be sure to use in the order of first in -

18.1.6 FILTERS l

Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering important equipment and causing problems.

Replace all filters periodically. For details, see the Operation and Maintenance Manual.

However, when working in severe conditions, it is necessary to consider replacing the filters at shorter intervals according to the oil and fuel (sulfur content) being used.

l

Never try to clean the filters (cartridge

l

When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found, please contact your Komatsu distributor.

l

Do not open packs of spare filters until just before they are to be used.

l

Always

use Komatsu genuine

type) and use them again. Always

replace with new filters.

filters.

3-7

18. OUTLINES OF SERVICE

18.2 OUTLINE OF ELECTRICAL SYSTEM If the wiring gets wet or the insulation is damaged, in hazardous malfunction of the machine.

the electric system leaks and this could result

Services relating to the electric system are (I) check of fan belt tension, of the fan belt and (3) check of battery fluid level.

Never remove

or disassemble

any electric

Never install any electric components

components

installed

other than those specified

(2) check of damage or wear

in the machine.

by Komatsu.

Be careful to keep water away from the electric system when washing

the machine

or when it rains.

Since the controller for the control system may cause malfunction due to external wave interference, before installing a radio receiver and a walkie-talkie or citizen band, consult your Komatsu distributor.

When working

at the seashore,

carefully

clean the electric system to prevent corrosion.

When installing a car cooler or any other electrical equipment, connect it to an independent power source connector. The optional power source must never be connected to the fuse, starting switch, or battery relay.

3-8

18. OUTLINES

18.3

OUTLINE OF HYDRAULIC

OF SERVICE

SYSTEM

During operation and immediately after operation is ended, the temperature of the hydraulic system still remains high.

In addition, high hydraulic pressure is applied to the system. Take care when inspecting and maintaining the hydraulic system. o Stop the machine on level ground, lower the bucket to the ground, then set so that there is no pressure applied to the cylinder circuit. o Always stop the engine. o Immediately after operations, the hydraulic oil and lubricating oil are at high temperature and high pressure, so wait for the oil temperature to go down before starting maintenance.

Even when the temperature goes down, the circuit may still be under internal pressure, so when loosening the plug or screw, or the hose joint, do not stand in front of the part. Loosen it slowly to release the internal pressure before removing it. o When carrying out inspection or maintenance of the hydraulic circuit, always bleed the air from the hydraulic tank to remove the internal pressure.

Periodic maintenance includes the inspection refilling of hydraulic oil.

of the hydraulic oil level, replacement

When the high pressure hose, etc., is removed, it.

check the O-ring for damage.

of the filter and

If necessary,

replace

After the hydraulic filter element and strainer are cleaned or replaced, or after the hydraulic system is repaired or replaced or the hydraulic piping is removed, bleed air from the hydraulic circuit.

The accumulator is charged with high-pressure nitrogen gas. Incorrect handling For the handling procedure, see “11.16 HANDLING ACCUMULATOR�.

may be dangerous.

3-9

18. OUTLINES OF SERVICE

18.4

RELEASING

PRESSURE

When disassembling the machine or removing the piping during inspection or maintenance, always release the pressure as follows.

RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUIT, TRAVEL CIRCUIT

A

CIRCUIT, SWING

WARNING

When removing the oil filler cap of the hydraulic tank, turn it slowly to release the internal pressure before taking off the cap.

1. Lower the work equipment to the ground in a stable flat place as shown in the diagram, then stop the engine.

Set the lock lever to the FREE position. stopping the engine, move each work equipment lever to the end of its travel within 5 to 6 seconds.

2’.After

Leave the starting switch ON. the cap of the hydraulic

:. Remove 4. l l

5. l

control

tank.

Start the engine, run it for approx. 10 seconds, then stop the engine again.

When running the engine, do not raise the speed above 1000 rpm.

Set the work equipment control levers to neutral.

After stopping the engine, move each work equipment lever to the end of its travel within 5 to 6 seconds.

Repeat Steps 4 to 5 three times.

control

RELEASING PRESSURE IN ACCUMULATOR CIRCUIT Pilot circuit Stop the engine, set lock lever to the FREE position, then move each work equipment control lever 3 to 4 times to the end of its travel. After 1 minute passes, the pressure is relieved. l Do not loosen the piping less than 1 minute after releasing pressure.

Lockev AEl68930

3-10

18. OUTLINES OF SERVICE

CIRCUIT OF HYDRAULIC

IDLER CUSHION

A

WARNING

When removing the filler cap of hydraulic tank, turn it slowly to release the pressure before taking off the cap.

1.

Remove the cap of the hydraulic

2.

Slowly loosen drain valve @ installed on the inside of the axle, and after one minute the pressure is released.

Stop valve 0: This is installed Drain valve @This is installed l l

tank.

to the hydraulic oil supply circuit. to the tank return circuit.

Use the special handle to open and close drain valve @_ Do not loosen the drain valve @ quickly.

Special handle

AEl69660

3-l 1

18. OUTLINES

18.5

OF SERVICE

BLEEDING AIR FROM CIRCUIT

After assembling maintenance, always

piping disconnected during inspection bleed the air from the circuit as follows.

18.5.1 PRECAUTIONS l

l l

l l

and

WHEN BLEEDING AIR

Bleed the air in order as follows.

1. Pump (work equipment, swing) 2. Idler cushion circuit 3. Travel motor circuit 4. Work equipment circuit Run the engine at less than 1000 rpm and operate the cylinders slowly.

Do not raise the pressure inside the cylinder by suddenly operating the cylinder, and do not operate the cylinder to the end of its stroke.

For the first return movement of each cylinder, be particularly careful to operate the cylinder slowly.

During the first stroke of the cylinder, there is a large amount of air inside the circuit, so the work equipment will not move for more than 10 seconds.

However, do not move the lever to the end of its travel.

REMARK When adding oil to the pump and motor, be careful not to let dirt get into the circuit.

3-12

18. OUTLINES OF SERVICE

18.5.2 BLEEDING AIR FROM HYDRAULIC PUMP AND SWING PUMP Bleed the air, when changing oil in hydraulic pump, suction, etc.

1. Add the specified amount of hydraulic oil.

2.

Loosen the plug @ of hydraulic

tank or removing

pump one turn.

NOTICE Do not loosen plugs, more than one turn.

AE169690

3.

Loosen the plug @ of swing pump one turn.

4.

Run the engine at low idling to bleed the air. When no more couldy white oil comes out from the hydraulic pump and swing pump plugs @, @ the operation is completed.

Tighten plugs @, @I.

3-13

18.5.3 BLEEDING AIR FROM IDLER CUSHION CIRCUIT When the piping has loosened bleed the air as follows.

and air has entered

the circuit,

1. Open stop valve @ and drain valve @ fully.

I

2.

Loosen air bleed plugs @I (left and right, 2 places) and 0.

3.

Start the engine

11-w

AEl69660

and run at idling for 2 to 3 minutes.

Put a block under the front of the right track to lock the track, then operate the right travel lever 2 to 3 times to the FORWARD position.

Check that oil comes out from air bleed plugs @ (left and right, 2 places) and 0, then close drain valve @ and air bleed plugs @ and 0.

Block

This completes bleeding front of the right track.

of the air. Remove the block from

in

Check the track tension.

For details, see WHEN REQUIRED, “24.3.4 CHECK AND ADJUST TRACK TENSION�.

The oil is pressurized by this adjustment.

8.

3-14

Close stop valve @ fully.

AE169760

18. OUTLINES OF SERVICE

18.5.4 BLEEDING AIR FROM TRAVEL MOTOR CIRCUIT If the piping of the travel motor circuit has been removed, run the engine at low idling after reassembling to bleed the air as follows.

1.

Start the engine and run at idling.

2.

Remove the travel motor cover 0, one turn.

and loosen air bleed plug @

NOTICE Do not loosen plug @ more than one turn.

Operate the travel lever and FORWARD and REVERSE. When no more cloudy white 0, tighten air bleed plug 0.

move

it 4 -

5 times

between

oil comes out from air bleed plug

Install the travel motor cover 0.

18.5.5 BLEEDING AIR FROM WORK EQUIPMENT

CIRCUIT

Bleed the air, when changing oil in hydraulic tank, replacing the line filter, removing the works equipment piping or hydraulic cylinder, removing pump or suction, etc.

1.

Start the engine and run at low idling.

2.

Extend and retract each cylinder in the order shown below 4 5 times without operating it to the end of its stroke (stop approx.

100 mm from the end of the stroke).

Boom cylinder 1.

2. Arm cylinder 3. Bucket cylinder 4. Bottom cylinder

REMARK During the first stroke of the cylinder, there is a large amount of air inside the circuit, so the work equipment will not move for more than 10 seconds.

However, do not move the lever to the end of its travel.

3.

Run the engine at low idling.

3-15

4.

Extend the cylinder to a point 100 mm (4 in) before the end of stroke, then use fine control to extend the cylinder to the end of its stroke.

(Boom cylinder, bucket cylinder, arm cylinder) Hold the control lever in this position for 3 minutes.

5.

Extend the bottom cylinder to a point 100 mm (4 in) before the end of stroke (OPEN position), then use fine control to extend the bottom cylinder to the end of its stroke.

Hold this position for 3 minutes.

6.

Run the engine at full throttle.

7.

Retract the cylinder to a point 100 mm (4 in) before the end of stroke, then use fine control to retracted.

The cylinder to the end of its stroke.

(Boom, cylinder, bucket cylinder, arm cylinder) Hold the control lever in this position for 3 minutes.

Bottom

8.

Retract the bottom cylinder to a point 100 mm (4 in) before the end of stroke (CLOSE position), then use fine control to retract the bottom cylinder to the end of its stroke.

Hold this position for 3 minutes.

NOTICE If the engine is operated at first at high speed, or the cylinder is operated to the end of its stroke, the air inside the cylinder may damage the piston packing.

3-16

open

AEl69800

18. OUTLINES OF SERVICE

18.6

OIL FILLER AND LEVEL GAUGE POSITIONS

Swing machinery oi I f i I ler, level

case sause Ensine level

n

oil sause

pan oil ler

Swing drain

machinery plus

pan

case

AEl69610

Hvdrau I ic oil filler

PTO case drain plus Fuel

tank

f (Iler

tank PTO level

\

case oil sause

\

Radiator drain

e oi cock Final

drive

case

filler

Final drain

drive plus

filler

cock

I pan

case AEl69820

3-17

19. CONSUMABLE

PARTS LIST

Consumable parts such as the filter element, bucket tooth, etc., are to be replaced at the time of periodic maintenance or before their abrasion limits.

The consumable parts should be changed correctly in order to use the machine economically.

For part change, Komatsu genuine parts should be used.

When ordering parts, please check the part number in the parts book.

The parts in parentheses

Item

are to be replaced

Part No.

at the same time.

Replacement frequency

Part Name

07063-01210 (07000-05175)

Element (O-ring)

21N-60-12210

Cartridge

Every 250 hours service

Engine oil filter

600-21 I-1230

Cartridge

Every 250 hours service

Fuel filter

600-311-8291

Cartridge

600-41 l-l 170

Cartridge

Hydraulic

oil filter

1

Drain filter

Corrosion

resistor

1

Element

t :,

1

assembly assembly

209-60-52190 (07000-12125) (502-50-I 1270)

Element (O-ring) (Back-up ring)

21 N-72-l 4290 (21 N-72-l 4330)

Point (Pin)

Bucket Loading Vertical pin type

21T-72-14480 (21 N-72-l 4460) (21 N-72-l 4470)

Point (Pin ass’y) t Lock)

Bucket Back hoe Horizontal

21 N-72-14290 (21N-72-14330)

Point (Pin)

21T-72-14480 (21T-72-14460) (21T-72-14470)

Point (Pin ass’y) (Lock)

Line filter

Bucket Loading Horizontal

pin type

pin tvpe

Bucket Back hoe Vertical pin type

3-18

Every 500 hours service Every 1000 hours service

Air cleaner Outer element

Every 250 hours service

1

2, (5)

Ii, (6)

EL, COOLANT AND LUBRICANTS ACCORDING UT TEMPERATURE

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS KIND OF FLUID

l-

AMBIENT TEMPERATURE 22 30

-4 -20

14 -10

32 0

50 10

66 20

86 104’F 30 4O’C

CAPACITY

Specified

Refill

61 Q 16.1 US gal 13.4 UK gal

51 Q 13.5 US gal 11.2 UK gal

PTO case

15 e 4.0 US gal 3.3 UK gal

15 Q 4.0 US gal 3.3 UK gal

Swing machinery case

13 Q 3.4 US gal 2.9 UK gal

13 Q 3.4 US gal 2.9 UK gal

Final drive case

45 Q (each) 11.9 US gal 9.9 UK gal

45 Q (each) 11.9 US gal 9.9 UK gal

Hydraulic system

1200 650 117.0 US gal 171.7 US gal !64.0 UK gal 143.0 UK gal

Engine oil pan

Engine oil

Fuel tank

Cooling system

I

I

I

I

I

1140 e 301.2 US gal 250.8 UK gal

Diesel fuel

Water

I

Add antifreeze

160 Q 42.3 US gal 35.2 UK gal

% ASTM D975 No. 1

3-19

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

REMARK When fuel sulphur content is less than 0.5%, change oil in the oil pan at every periodic maintenance interval given in this manual.

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

Fuel sulphur content

Change interval of oil in engine oil pan

0.5 to 1.0%

l/2 of regular interval

Above

1.0%

1

l/4 of regular interval

When starting the engine in an atmospheric oil of SAEIOW, SAEIOW-30 and SAE15W-40, more or less in the day time.

Use API classification interval to half.

CD as engine

temperature of under O’C (32”F), be sure to use engine even though atmospheric temperature goes up to IO’C

oil and if API classification

CC, reduce the engine

There is no problem if single grade oil is mixed with multigrade oil (SAElOW-30, sure to add single grade oil that matches the temperature in the table.

We recommend Komatsu genuine oil which has been specifically in engine and hydraulic work equipment applications.

Specified capacity: Total amount of oil including oil for components Refill capacity: Amount of oil needed to refill system during normal ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute

3-20

formulated

oil change

15W-401, but be

and approved for use

and oil in piping. inspection and maintenance.

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

JO.

1

2

Supplier

KOMATSU

AGIP

Engine Oil [CD or CEl SAEIOW, 30, 40 lOW30, 15w40 (The 15W40 oil marked * is CE.) EOIO-CD E030-CD EOIO-30CD E01540CD Diesel sigma S Super dieselmultigrade

Gear Oil [GL-4 or GL-51 SAE80, 90, 140

Grease [Lithium-Base] NLGI No. 2

Anti-freeze Coolant [Ethylene Glycol Base1 Permanent Type AF-ACL AF-PTL AF-PT (Winter, one season type

GO90 GO140

G2-LI GS-LI-S

Rotra MP

GR MU/EP

-

RYKON premium grease

-

*Sigma turbo 3

AMOCO

*Amoco

4

ARC0

*Arcofleet

5

BP

6

Multi-purpose

300

gear oil

Arco HD gear oil

Litholine HEP 2 Arco EP moly D

Vanellus C3

Gear oil EP Hypogear EP

Energrease LS-EPP

CALTEX

*RPM delo 400 RPM delo 450

Universal thuban ,Marfak all purpose 2 Universal thuban EP Ultra-duty grease 2

AF engine coolant

7

CASTROL

“Turbomax *RX super CRD

EP EPX HYP~Y HYP~Y B HYP~Y C

MS3 Spheerol EPLP

Anti-freeze

8

CHEVRON

*Delo 400

Universal gear

Ultra-duty

9

CONOCO

*Fleet motor oil

Universal gear lubricant

Super-sta grease

10

ELF

Multiperformance Performance 3C

I’

EXXON (ESSO)

Essolube D3 *EssoIube XD-3 *EssoIube XD-3 Extra *ESSO heavy duty Exxon heavy duty

12.

GULF

13

MOBIL

S3 plus

3C

Antifreeze

grease 2 -

Tranself EP Tranself EP type 2

Glacelf

Gear oil GP Gear oil GX

Beacon EP2

Ail season coolant

Super duty motor oil *Super duty plus

Multi-purpose gear lubricant

Gulfcrown Gulfcrown

Antifreeze

Delvac 1300 *Delvac super 1ow-30, 15w-40

Mobilube Mobilube

Mobilux EP2 Mobilgrease 77 Mobilgrease special

GX HD

EP2 EP special

and coolan

3-21

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

Engine Oil [CD or CEl No.

Supplier

SAE 1OW, 30, 40 1ow30, 15w40 (The 15W40 oil marked * is CE.)

Gear Oil [GL-4 or GL-51

SAE80, 90, 140

Multi-purpose Multi-purpose

4092 4140

Grease [Lithium-Base]

NLGI No. 2

Anti-freeze Coolant [Ethylene Glycol Base] Permanent

Type

Multi-purpose white grease 705 707L White - bearing grease

Anti-freeze and summer coolant

FINA tamidor

14

PENNZOIL

*Supreme duty fleet motor oil

15

PETROFINA

FINA kappa TD

FINA potonic N FINA potonic NE

FINA marson EPL2

16

SHELL

Rimula X

Spirax EP Spirax heavy duty

Albania

17

SUN

Sunoco GL5 gear oil

Sunoco ultra prestige 2EP Sun prestige 742

Sunoco antifreeze and summer coolant

18

TEXACO

*Ursa super plus Ursa premium

Multigear

Multifak EP2 Starplex 2

Code 2055 startex antifreeze coolant

19

TOTAL

Rubia S *Rubia X

Total EP Total transmission TM

Multis EP2

Antigel/antifreeze

20

UNION

‘Guardol

MP gear lube LS

Unoba EP

21

VEEDOL

*Turbostar *Diesel star MDC

Multigear Multigear Multigear

3-22

-

B C

EP grease

-

Antifreeze

21. iTA&DARD

21.1

INTRODUCTION

The following

TIGHTENING

TORQUES FOR BOLTS AND

OF NECESSARY

tools are needed when carrying

TOOLS

out maintenance.

Remarks

Part No.

2 3

4

1 Screwdriver Socket wrench set

1 Pliers

+-Is--7

1 Filter wrench

09002-00810 09002-01214 09002-01317 09002-01922 09002-02427 09002-03032

Applicable width 8mm - 12mm 12mm - 14mm 13mm - 17mm 19mm - 22mm 24mm - 27mm 30mm - 32mm

09033-00190

Interchangeable

09020-I

Applicable 10 mm, 13 24 mm, 27 Extension,

0284

across flats 61-W i UI ADO53370

flat-head

and cross-head

type

width across flats mm, 14 mm, 17 mm, 19 mm, 22 mm, mm, 30 mm, 32 mm Handle

09038-00150 09039-00150 09055-I 0390 09019-08035 21N-98-11140 0905845513 07952-80002

For greasing

07950-90403

(Lithium

12

1 Nozzle

07951-I 1400

13

I Gauge

0905440009

work

base grease,

400 g)

If any of the above tools are broken, please order them from your Komatsu

distributor.

3-23

21.STANDARDTlGHTENlNGTORQUESFORBOLTSANDNUTS

21.2

TORQUE

LIST

Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table.

The tightening torque is determined by the width across the flats @ of the nut and bolt.

If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

Nm (newton meter): INm i 0.1 kgm % 0.74 Thread

diameter

Width

Ibft

across

of bolt (mm)

flats (mm)

(a)

(b)

@ Nm

69 kgm

AD054300 Ibft

6

10

13.2 + 1.4

1.35t 0.15 9.73 2 1.03

8

13

31.4 + 2.9

3.2 2 0.3

23.2 2 2.1

10

17

65.7 + 6.8

6.7 k 0.7

48.5 + 5.0

12

19

112 k 9.8

11.5+ 1.0

82.6 + 7.2

14

22

Ink19

18.0+ 2.0

131 t 14

16

24

279 f 29

28.5 + 3

206 t 21

18

27

383 2 39

39 + 3

282 t 29

20

30

549 2 58

56 + 6

405 f 43

22

32

745 + 78

76+ 8

24

36

927 2 98

94.5 t 10

27

41

1320 f 140

135 c 15

973 + 100

30

46

1720 t 190

175It.20

1270 + 140

33

50

2210 k 240

225 + 25

1630 + 180

36

55

2750 + 290

280 + 30

2030 k 210

39

60

3280 t 340

335 + 35

2420 + 250

549258 684 k 72

NOTICE When tightening panels or other parts having tightening fixtures made of plastic, be careful not to use excessive tightening torque: doing so will damage the plastic parts.

3-24

b

AcxG3380

22. PERIODIC REPLACEMENT OF CRITICAL 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. These parts are particularly closely connected to safety and fire prevention.

With these parts, the material changes as time passes, 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 time as the hoses.

When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.

Ask your Komatsu distributor to replace the critical safety parts.

3-25

22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS

CRITICAL SAFETY PARTS No.

Critical safety parts for periodic

replacement

Q’ty

1

Fuel hose (injection

2

Fuel hose (over flow)

2

3

Fuel spill hose

5

4

Fuel hose (APS)

3

5

Fuel hose (Fuel pump - fuel strainer)

1

6

Fuel hose (Fuel tank - fuel strainer)

1

7

Fuel return hose

1

pump - fuel filter)

Replacement

interval

2

Every 2 years or 4000 hours, whichever comes sooner

AE169840

3-26

22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS

No. 1Critical safetv parts for oeriodic

8

Turbocharger

9

No. 1 Pump outlet hose

10

lubricating

Q’ty 1

reolacement

Replacement

interval

2

hose

2

1 No. 1 Pump outlet branch hose

I

2

11

No. 2 Pump outlet hose

2

12

Swing pump outlet hose

2

13

Swing pump outlet branch hose

2

14

Swing pump confluence

1

15

Seat belt (option)

hose

1

I Every 2 years or 4000 hours, whichever comes sooner

Every 3 years

AE169.350

3-27

23. MAINTENANCE

23.1

MAINTENANCE

SCHEDULE CHART

SCHEDULE CHART SERVICE ITEM

PAGE

INITIAL 100 HOURS SERVICE (only after the first 100 hours) Clean strainer

of PTO lubricating

oil filter

3-61

INlTlAL 250 HOURS SERVICE (only after the first 250 hours) Replace fuel filter cartridge

3-32

Change

oil of swing machinery

case

Change

oil of PTO case

3-32

Change

oil of final drive case

3-32

Check engine valve clearance,

3-32

adjust

3-32

WHEN REQUIRED Check, clean and replace air cleaner

element

3-33

Clean inside of cooling system

3-35

Check and tighten track shoe bolts

3-39

Check and adjust track tension

3-40

Check electrical

3-43

intake air heater

Replace

bucket teeth (vertical

Replace

bucket teeth (horizontal

Check window

pin type)

3-44

pin type)

3-47

washer fluid level, add fluid

3-48

Check and adjust air conditioner

3-49

Clean line filter

3-50

Replacement

of fan belt and adjustment

Check APS (Automatic

Priming

of auto tensioner

System)

3-51 3-52

CHECK BEFORE STARTING Check coolant

level, add water

3-53

Check oil level in engine oil pan, add oil

3-53

Check fuel level, add fuel

3-54

Check oil level in hydraulic

3-28

tank, add oil

3-55

23. MAINTENANCE

SERVICE ITEM

SCHEDULE

CHART

PAGE

(CHECK BEFORE STARTING)

Check dust indicator

3-56

Check electric wiring

3-56

Drain water and sediment Check monitor

from fuel tank

3-57 3-57

system

3-57

Check oil level in PTO case Check oil level in swing machinery

case

3-57

CHECK EVERY 10 HOURS

SERVICE

Lubricating

3-58

l

Boom concentration

lubricating

l

Boom cylinder foot pin (2 points)

3-59

l

Arm concentration

3-59

l

Bucket cylinder

rod end pin (2 points)

l

Bucket cylinder

rod end link coupling

l

Bucket cylinder foot pin (2 points)

3-59

l

Bucket-Link coupling

pin (2 points)

3-59

l

Arm-Bucket

pin (2 points)

3-59

l

Arm-Link

l

Bucket hinge pin (2 points)

3-60

l

Bottom dump cylinder foot pin (2 points)

3-60

l

Bottom dump cylinder

3-60

lubricating

coupling

coupling

block

3-58

block (4 points)

3-59 pin (4 points)

pin (2 points)

Clean strainer of PTO lubrication Lubricating

3-59

rod end pin (2 points)

EVERY 100 HOURS

SERVICE

filter

3-61

swing circle

Drain water and sediment

3-59

3-61 from fuel tank

EVERY 250 HOURS

3-61

SERVICE 3-62

Lubricating l

Fan pulley assembly

3-62

l

Tension

3-62

pulley assembly

3-29

3. MAINTENANCE SCHEDULE CHART

SERVICE Change

ITEM

oil in final drive case

3-62

Check level of battery electrolyte

3-63

Change

oil in engine oil pan, replace engine

Replace

hydraulic filter element

Check alternator

oil filter cartridge

3-64 3-65

drive belt tension,

Check airconditioner

PAGE

compressor

adjust

belt tension,

3-66 adjust

3-67

Check, clean fuel strainer

3-68

Check and tighten track shoe bolts

3-68

Check and tighten track frame

and axle connecting EVERY 500 HOURS

bolts

3-68

SERVICE

Clean hydraulic tank strainer

3-69

Check and clean radiator fins

3-70

Clean pilot filter strainer

3-70

Clean strainer of PTO lubrication Change

oil filter

3-70

fuel filter

3-71

Check fan belt Check inspection

3-71 of weldings

structure

(color check)

EVERY 1000 HOURS Change

oil in swing machinery

Check turbocharger Lubricating

clamping

of tension

3-72 SERVICE

case

3-76 3-76

joint

pulley (2 points)

3-76

Change

oil in PTO case

3-77

Replace

corrosion

3-77

Replace

hydraulic tank breather

resistor cartridge element

EVERY 2000 HOURS

3-78

SERVICE

Change

oil in final drive case

3-79

Change

oil in hydraulic tank, clean strainer

3-80

Clean, check turbocharger

3-80

Check turbocharger

3-80

rotor play

Check swing pinion grease level, add grease

3-81

Clean engine

3-82

3-30

breather

23. MAINTENANCE SCHEDULE CHART

SERVICE

ITEM

PAGE

(EVERY 2000 HOURS SERVICE) Check alternator,

starting motor

Check engine valve clearance, Check vibration

3-82

adjust

3-82

damper

3-82 EVERY 4000 HOURS

SERVICE

Check water pump

3-83

Check fan pulley and tension pulley

3-83

Check air compressor,

3-83

adjust

3-31

24. SERVICE PROCEDURE

24.1

INITIAL 100 HOURS SERVICE

Carry out the following hours. l

maintenance only after the first 100

CLEAN STRAINER OF PTO LUBRlCATlNG OIL FILTER

For detail of method of replacing or maintaining, on EVERY 500 HOURS SERVICE.

24.2

INITIAL 250 HOURS SERVICE

Carry hours. l l l l l

see the section

out the following

maintenance

only after the first 250

REPLACE FUEL FILTER CARTRIDGE CHANGE OIL OF SWlNG MACHINERY CASE CHANGE OIL OF PTO CASE CHANGE OIL OF FINAL DRIVE CASE CHECK ENGINE VALVE CLEARANCE, ADJUST

For details of the method of replacing or maintaining, section on EVERY 500 HOURS, 1000 HOURS and 2000 SERVICE.

3-32

see the HOURS

24. SERVICE PROCEDURE

24.3 24.3.1

WHEN REQUIRED CHECK,

CLEAN

AND

REPLACE

AIR

CLEANER ELEMENT

A

WARNING

l

Never clean or replace the air cleaner element with the engine running.

l

When using pressure air to clean the element glasses or goggles to protect the eyes.

CHECK If the red piston can be seen in transparent indicator 0, clean the air cleaner element.

wear

safety

portion

CLEAN, REPLACE OUTER ELEMENT 1. Loosen wing nut 0, then remove the outer element

0.

2.

Clean the air cleaner body interior

3.

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

1) Remove one seal from the outer element. The number of times the outer element has been cleaned can be seen by the . number of removed seals.

2) Replace an outer element which has been cleaned 6 times repeatedly or used throughout a year. Replace the inner element at the same time.

3) Replace the element when the air cleaner clogged warning lamp lights up soon after installing a cleaned element even though it has not been cleaned 6 times.

4) Check inner element mounting nuts for looseness and, if necessary, retighten.

5) Replace seal washer @ or wing nut @ with new parts if they 1 are broken.

4.

Set the cleaned element.

5.

Push the dust indicator reset button to return the red piston to the original position.

AED

w

1

AE083060

3-33

Cleaning

outer element

Wiih

compressed air Direct dry compressed air (less than 700 kPa (7 kg/cm2, 100 psi)) to element from inside along its folds, then direct it from outside along its folds and again from inside, and check element.

NOTlCE . _~_ lf small holes or thinner parts are found on element when it is checked by shining a light through it after cleaning and drying, replace the element. l When cleaning element, do not hit or beat it against anything. l Do not use element whose folds, gasket or seal are damaged.

l

Replacing inner element 1. First remove the outer element, and then remove the inner element.

2. Place the cover over the air intake part to prevent dust entering.

3. Clean the air cleaner body interior, then remove the cover from the air intake port.

4. Fit a new inner element and tighten it with nuts.

5. Install the outer element.

Push the dust indicator reset button.

NOTICE l Do not attempt to reinstall a cleaned inner element. l If small holes or thinner parts are found on element when a light is shone through it after cleaning and drying, replace the element. l When cleaning element, do not hit it or beat against anything. l Do not use element whose folds or gasket, seal are damaged.

3-34

AM83070

24. SERVICE PROCEDURE

24.3.2 CLEAN INSIDE OF COOLING SYSTEM

A WARNING Soon after the engine has been stopped, the coolant is hot and can cause personal injury. Allow the engine to cool before draining water.

Since cleaning is performed while the engine is running, it is very dangerous to enter the rear side of the machine as the machine may suddenly start moving. lf the under cover is left removed, it may interfere with the fan. While the engine is running, never enter the rear side of the machine.

Never remove the radiator cap when the engine is at operating temperature.

At operating temperature, the coolant is under pressure. Steam blowing up from the radiator could cause personal injury. Allow the engine to cool until the radiator filler cap is cool enough to touch with your hand.

Remove the filler cap slowly to allow pressure to be relieved.

Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the table below.

l

Kind of coolant

Cleaning inside of cooling system and changing coolant

Permanent type antifreeze (All season type)

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

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

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

When

Every 6 months or every 1000 hours, whichever comes first

l

0

not using antifreeze

Replacing corrosion resistor

Every 1000 hours and autumn) when cleanin

. .

t,hst~~d~n~f~~e~ol’n’ changing

coolant.

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.

3-35

24. SERVICE PROCEDURE

l

When deciding the temperature in the given below.

It is actually better when deciding the

Mixing

rate of water

ratio of antifreeze to water, check the lowest past, and decide from the mixing rate table to estimate a temperature mixing rate.

about 10°C lower

and antifreeze

Min. atmospheric temperature Amount of antifreeze

Amount water

of

A WARNING Antifreeze l

l

is flammable,

so keep it away

from any flame.

Use city water for the cooling water.

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

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

When removing

3-36

AL WARNING drain plug, avoid pouring

coolant on yourself.

24. SERVICE PROCEDURE

1. Stop the engine, close valves @ on corrosion

2.

resistor.

Turn cap @ slowly until it comes off.

AE169870

3.

Loosen drain valve @ at the bottom of radiator and drain plug @ at the side of cylinder block and drain off the cooling water.

4.

Close up drain valve @I and plug @ and pour in clean water (ex. city water) up to the vicinity of the water filler.

5.

When engine water When water.

l

6.

the water reaches the vicinity of the water filler, put the at low idling, open drain valve @ and plug 0, then pass through the cooling system for 10 minutes. doing this, keep the radiator filled up to the filler with

1

\-

/

AE169660

After washing the cooling system, stop the engine. Open drain valve @ and plug @I to drain water and close drain valve @ and plug 0.

7.

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

Follow the instructions on the detergent container.

8.

After washing the cooling system, drain off all the water, then close up drain valve @ and plug @ and pour in clean water (ex. city water) slowly 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 @ and plug 0, then pass water through the cooling system until clean water comes out from the drain valves.

When doing this, keep the radiator filled up to the filler with water.

3-37

24. SERVICE PROCEDURE

10. When the water becomes completely close drain valve @ and plug 0.

clean, stop the engine and

11. Replace the corrosion resistor cartridge and open valves 0.

For details of replacement of the corrosion resistor, see “24.9 EVERY 1000 HOURS SERVICE�.

l

12. Supply water until it overflows

from the water filler.

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

14. Stop the engine and wait for about 3 minutes. Supply cooling water up to the vicinity of the water filler. Tighten the cap.

3-38

24. SERVICE PROCEDURE

24.3.3 CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts @ loose, they will break, so tighten any loose bolts immediately.

Method for tightening 1. First tighten to a tightening torque of 784 + 78 Nm (80 -c 8 kgm, 579 ? 58 lb ft) then check that the nut and shoe are in close contact with the link contact surface.

2.

After checking, tighten a further

120� f 10�.

Order for tightening Tighten the bolts in the order shown in the diagram on the right.

After tightening, check that the nut and shoe are in close contact with the link mating surface.

3-39

24. SERVICE PROCEDURE

24.3.4 CHECK AND ADJUST TRACK TENSION

A WARNING Carry out this operation with two workers. The operator must move the machine in accordance with the signals from the other worker. The track tension is checked with the chassis raised, so it is extremely dangerous if the machine is lowered by mistake during the inspection. Never move the machine while anyone is carrying out measurements.

The wear of pins and bushings on the undercarriage will vary with the working conditions and soil properties. It is thus necessary to continually inspect the track tension so as to maintain the standard tension.

Carry out the check and adjustment under the same conditions as when operating (on jobsites where the track becomes clogged with mud, measure with the track clogged with mud).

Inspection 1. Raise the chassis with the boom and arm.

When doing this, operate the levers slowly.

2. Measure the clearance between the sprocket and the top of the track shoe at a position that is safe even if the chassis should come down.

Standard

clearance:

100 to 150 mm (3.9 to 5.9 in)

i

I

3-40

IOO- 150 mm (3.9 - 5.9 in)

I AEo83140 1

24. SERVICE PROCEDURE

Adjusting

hydraulic cushion

(Hi4

cylinder

1.

Check that drain valve @ is completely

2.

Open stop valve 0.

3.

Start the engine, and set at medium

closed.

position.

Half open position

\ 4.

AE1687.30

Operate the right travel lever suddenly (2 - 3 seconds) to turn the steering (or relieve the travel motor). Carry out this operation four times.

The operation can be carried out either in forward or in reverse.

NOTICE l Do not carry out this operation on a slippery road surface (steel plate, etc.). l Even when protrusion amount @ of the hydraulic cushion is within the standard value, the HIC charge pressure may be low, so always carry out the above operation exactly.

5.

Check that the protrusion @ of the plunger of the hydraulic cushion cylinder is 120 -c 5 mm on both the left and right.

6.

Close stop valve @I completely.

Stop valve This is Stop valve This is

0: installed to the hydraulic oil supply circuit.

0: installed to the tank return circuit.

Always use the special valve and drain valve.

handle

when

opening

or closing stop

3-41

24. SERVICE PROCEDURE

Adjusting

grease cylinder

Do not loosen grease fitting @ more than one turn. There danger that it may fly out under the high internal pressure. does not come out, move the machine backwards

is

and forwards

NOTlCE Before pumping in grease, check that the protrusion @ of the plunger of the hydraulic cushion cylinder is 120 I 5 mm (4.7 f 0.2 in) on both the left and right.

Check again after pumping in grease.

If the protrusion is not within this range, loosen grease fitting @I one turn and let grease out to adjust. If the protrusion cannot be adjusted to 120 z 5 mm (4.7 + 0.2 in), the hydraulic cushion must be adjusted, so please contact your Komatsu distributor for adjustment.

lf the track tension is adjusted only by using grease and not by hydraukc pressure, excessive load may be brought to bear on the undercarriage and this may cause damage. /AcAuT’oN/

When increasing

tension

prepare

a grease gun.

1.

Pump in grease through

2.

To check that the correct tension has been achieved, machine backward and forwards.

3.

Check the tension

4.

Continue to pump in grease until @ becomes 155 mm (6.1 in).

If the tension is still loose, the pin and bushing are excessively worn, so they must be either turned or replaced. Please contact your Komatsu distributor.

3-42

grease fitting

@ with a grease gun. move the

again, and if it is not correct, adjust it again.

Grease cyhder AE083170

24. SERVICE

PROCEDURE

When loosening tension

It is extremely dangerous to release the grease by any method relieved by this procedure, please contact your Komatsu dis-

1.

Loosen fitting @ gradually

to release the grease.

2.

Turn fitting @ a maximum

of one turn.

3.

If the grease does not come out smoothly, backwards and forwards a short distance.

4.

Tighten fitting 0.

5.

To check that the correct tension has been achieved, machine backwards and forwards.

6.

Check the track tension again, and if the tension adjust it again.

move the machine

move the

is not correct,

24.3.5 CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections.

Remove the electrical intake air heater from the engine intake connection, and check it for possible open-circuits and dirt.

When inspecting and replacing the electrical intake air heater, replace the gasket with new one.

3-43

24. SERVICE RPOCEDURE

24.3.6 REPLACE BUCKET TEETH (VERTICAL PIN Replace the point before the adapter starts to wear.

TYPE)

A WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the levers.

Place a block under the bucket bottom to allow the pin of tooth @ to be knocked out with a hammer. Carry out full stroke operation of the control levers within 15 seconds after stopping the engine. After confirming that the work equipment is in a stable condition, lock the safety lock lever.

Set so that the bottom face of the bucket is horizontal.

Use a hammer and drift to knock out lock pin @ (If the drift is set against rubber pin lock @I when it is hit, the rubber pin lock may break. Set it against the back of the pin.)

After removing

lock pin @ and rubber pin lock 0,

check them.

If lock pins and rubber pin locks with the following defects are used, the point may come off the bucket. Replace them with new ones. o

AE169980

The lock pin is too short

The lock pin is too short.

Align with bottom face

3-44

AE083200

24.

0

The rubber of the rubber pin lock is torn, and the steel balls may come out.

SERVICE PROCEDURE

The rubber is broken and the steel balls come out easily. \

@ 0

The steel bails are buried when they are pressed

AEo83210

by hand.

The steel balls can be buried when pressed witi finger AE033220

4.

Clean the surface of adapter @I and remove the soil from it with a knife.

5.

Use your hand or a hammer to push rubber pin lock @ into the hole of the adapter.

When doing this, be careful that the rubber pin lock does not fly out from the adapter surface.

INCORRECT

a- a AEO83230

6.

Clean the inside of tooth 0, then install it to adapter 0. If there is mud stuck to it or if there are protrusions, the point will not enter the adapter properly, and there will not be proper contact at the mating portion.

7.

Fit tooth @ to adapter 0, and confirm that when the pointer is pressed strongly, the rear face of the hole for the pin of the point is at the same level as the rear face of the hole for the pin of the adapter.

Sticky material

AE083240

3-45

24.

SERVICE

PROCEDURE

If the rear face of the hole for the pin of tooth 0 is protruding to the front from the rear face of the pin hole for adapter 0, do not try to knock the pin in. There is something preventing tooth @from entering adapter @ fully, so remove the obstruction. When tooth 0 enters adapter @I fully, knock in lock pin 0.

8.

Insert lock pin @ in the hole of the point and hit it until its top is the same level as the surface of tooth 0.

9.

After replacing a bucket tooth, always check the following.

I) After the lock pin has been knocked in completely, check that it is being secured by the point and surface.

2) Lightly hit lock pin @ in the reverse direction from which it was hit in.

3) Lightly hit the tip of the point from above and below, and hit its sides from right and left.

4)

Confirm that rubber shown in the figure.

pin lock @ and lock pin @ are set as

The life of the point can be lengthened and the frequency of its replacement can be reduced by turning it upside down so that it will wear evenly.

time

3-46

Replace the rubber pin and locking pin with new pins at the same as replacing the point to prevent the point from falling.

. .

24. SERVECE PROCEDURE

_.__

-

24.3.7 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) Replace the teeth before the wear

reaches the adapter.

A WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the levers.

1.

Place a block under the bucket bottom so that the pin of tooth 0 can be knocked out with a hammer.

Carry out full stroke operation of the control levers within 15 seconds after the engine has stopped. After confirming that the work equipment is in a stable condition, lock the safety lock lever.

Set so that the bottom face of the bucket is horizontal.

2

Place a bar on the pin head and strike the bar with a hammer knock out pin 0. Remove tooth 0.

REMARK Use a round bar with a smaller

3.

diameter

to

than that of the pin.

Clean the mounting face. Fit a new tooth @ in the adapter, push in pin @ partially by hand, then lock it with a hammer to install the tooth to the bucket.

3-47

24. SERVICE PROCEDURE

24.3.8 CHECK WINDOW FLUID

WASHER FLUID LEVEL, ADD

If air is ejected with the window washer fluid, check the fluid level in window washer tank 0. If showing under the level, fill with automobile window washer fluid.

When

adding fluid,

be careful

not to let dirt or dust get in.

l Mixture ratio of pure washer fluid and water Since the ratio should bevaried depending on atmospheric temperature, replenish washer fluid at the following mixture ratio, taking temperature into account.

Operation

area

and season

Mixture

ratio

Pure washer

Normal

fluid

113: water 213

Winter

in cold region

Winter

in extremely

cold region

Pure washer l/2: water

fluid

l/2

Pure washer

fluid

Freezing temperature - 10°C (14°F)

- 20°C (- 4°F)

- 30°C (- 22°F)

Pure washer fluid comes in two types: for -10°C (14°F) (for general use) and for -30°C (-22°F) (cold regions).

Use pure washer fluid according to operation area and season.

3-43

24. SERVICE PROCEDURE

24.3.9 CHECK AND ADJUST AIR CONDITIONER CHECK LEVEL OF REFRIGERANT

(GAS)

If the liquid gets into your eyes or on your hands, it may cause loss of sight or frostblte, so never loosen any part of the I,.,,,,,AwARN’NG If there is a lack of refrigerant (Freon 134a), the cooling performance will be poor.

When operating the cooler at high speed, there should be no bubbles in the sight glass (inspection window) mounted on the condenser unit receiver. l No bubbles in refrigerant flow: Correct l Bubbles in refrigerant flow (bubbles continuously pass through): Refrigerant level low l Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low, so contact your refrigerant dealer to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.

Check in off-season When not being used for a long period, operate the cooler for 3 to 5 minutes once a week to supply lubricant to each component of the compressor.

Inspection

and maintenance

items list for cooler

Inspection and maintenance items

Contents

Maintenance interval

Filling quantity

Twice a year; spring and autumn

Condenser

Clogging

Every 500 hours

Comoressor

Function

V belt

Damage

Blower motor and fan

Function (Check for abnormal sound)

When

required

Control mechanism

Function (Check for normal functionJ

When

required

When

required

Refrigerant

Piping for connection

(gas)

of fins

Every 4000 hours and tension

Installation condition looseness of tightening connection portions gas leakage, damage

Every 250 hours

3-49

24.3.10 CLEAN LINE FILTER If there is any abnormality in the pump or other hydraulic equipment, remove the dirt from inside the line filter as follows.

Before removing the line filter, release the pressure inside the hydraulic circuit. For details, see “18. OUTLINES OF SERVICE”.

1.

Loosen drain plug 0.

2.

Remove case 0, and clean filter 0.

(I) When cleaning the filter, also clean off the dirt and dust stuck to the side face of the case.

(2) When assembling the case again, replace O-ring @I and backup ring @ together.

(3) After assembling the line filter again, bleed the air from the system. (For details, see “18.5 BLEEDING AIR FROM CIRPl II-r” \

AE170010

3-50

24. SERVICE PROCEDURE

24.3.11 REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER As this machine is provided with a device which keeps a constant fan belt tension without regard to elongation of the V-belt, no adjustment is required until the belt is broken.

Replacement 1. Loosen lock nut @ and completely release the spring.

2. Press tension pulley @ in the direction indicated by the arrow to remove the V-belt.

Then install a replacement.

Replace three V-belts at the same time.

Adjustment Check the size A to see that it is maintained at 73 mm (2.8 in).

If not, adjust the fan belt as follows: Tighten adjusting bolt @ until size A becomes 70 + 5 mm (2.8 + 0.2 in), and tighten lock nut @ securely.

AE170030

3-51

24.3.12 CHECK APS (Automatic

Priming System)

Check the APS in autumn (ambient temperature below 15°C (59”F), engine cooling water temperature below 13°C (55.4”F)).

If it is necessary to inspect the APS when the engine cooling water is above 13°C (55.4”F), so please contact your Komatsu distributor.

Open fuel valve @ of the APS and remove hoses @ of the nozzle inlet.

Move feed pump @ up and down to bleed air until no air bubbles comes out of the hose connecting port.

At the same time, check for fuel leakage and clogging of fuel pipe.

Place the fuel control lever in the “engine stop” position. Turn the starting switch to ON position. Turn on the preheater switch.

Then, confirm the following. l Confirm that the preheater monitor lamp stays on for about 80 seconds. l Confirm that when the preheater monitor lamp goes off, the two glow plugs are red hot. l With preheater monitor lamp off, turn the starting switch key to START position (do not keep the key in this position for more than 20 seconds), and check for proper fuel combustion inside the intake manifold.

When

checking the glow plug, remove

If any abnormality SHOOTING”.

3-52

is assumed,

plug.

refer to the

“16. TROUBLE

24. SERVICE

PROCEDURE

24.4 CHECK BEFORE STARTING 24.4.1 CHECK COOLANT LEVEL, ADD WATER

A WARNING

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

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

Remove radiator cap 0, and check that cooling water is filled IJ to depth indicated by shadowed portion. If not, add water.

If the volume of coolant added is more than usual, check fa possible water leakage.

AE082160 L

24.4.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL Open the engine

hood.

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

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

The oil level should be between

the H and L marks on dipstick

0.

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

‘d

The dipstick is marked with the levels for ENGINE STOPPED on one side and ENGINE IDLING on the other side.

I Check the oil level, STOP the engine and with the ENGINE STOPPED side.

Checking the oil level with the engine idling may be allowed, if the following precautions are throughly satisfied.

1) 2) 3)

u

w

Check that the engine water temperature gauge shows green range.

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

Remove the oil filler cap.

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

3-53

24. SERVICE

PROCEDURE

5.

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

6.

If the oil level is correct, tighten close the engine hood.

the oil filler cap securely

and

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

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

24.4.3

CHECK FUEL LEVEL, ADD FUEL Ah WARNING

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

I.

Use sight gauge 0 on the front face of the fuel tank to check that the tank is full.

2.

If the fuel level is not within the sight gauge, add fuel through filler port 0, while watching sight gauge 0.

Fuel capacity:

AND

1140 !Z (301.2 US gal, 250.8 UK gal)

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

AE166640

3.

After adding fuel, tighten the cap securely.

REMARK If breather hole @ on the cap is clogged, the pressure in the tank will drop and fuel will not flow.

Clean the hole from time to time.

AD054210

3-54

24. SERVICE PROCEDURE

24.4.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL g WARNING l

l

When removing the oil filler cap, oil may spurt out, so turn the cap slowly to release the internal pressure before removing the cap.

If oil has been added to above the H mark, stop the engine and wait for the hydraulic oil to cool down, then drain the excess oil from the drain plug @.

1.

If the work equipment is not in the condition shown in the diagram on the right, start the engine, run it at low speed, retract the arm and bucket cylinders, then lower the boom, set the bucket teeth in contact with the ground, and stop the engine.

2.

Within 15 seconds after stopping the engine, move each control lever (work equipment and travel) to full stroke in all directions to release the internal oressure.

3.

AE084210

Check sight gauge 0. The oil level is normal if between the H and L marks.

NOTlCE Do not add oil if the level is above the H line. This will damage the hydraulic equipment and cause the oil to spurt out.

4.

If the level is below the L mark, remove the upper cover of the hydraulic tank and add oil through oil filler 0.

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

REMARK The oil level will vary depending upon the oil temperature.

Accordingly, use the following as a guide: l Before operation: around L level (Oil temperature 10 to 30°C (50 to 86°F)) l Normal operation: around H level (Oil temperature 50 to 80°C (122 to 176°F))

AND

\ $

AE168670 1

0 I

H L

j

AE082220

3-55

24.4.5 CHECK DUST INDICATOR When the air cleaner element is clogged, the red piston of dust indicator @ reaches the service level and gets locked.

In that case, clean or replace the element.

After cleaning the element, push the button to return the red piston.

For details of the method of cleaning the element, see “24.3.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT�.

24.4.6 CHECK ELECTRIC WIRING

If the fuse blows frequently, or there are traces of shortclrcurtmg in the electric wiring, always locate and repair the cause.

IawaRNINcI 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. l Battery 0 Starting motor l Alternator Please contact your Komatsu distributor rection of the cause.

for investigation

and cor-

A WARNING Accumulation of flammable material (dead leaves, twigs, grass, etc.) around the battery may cause fire, so always check and remove such material.

When carrying out walk-around-checks or checks before starting, always check if there is any accumulation of flammable material around the battery, and remove such flammable material.

3-56

24. SERVICE PROCEDURE

24.4.7 DRAIN WATER AND SEDIMENT TANK 1.

2.

FROM FUEL

Loosen drain valve @ and drain the water and sediment under tool box of right side.

After draining, tighten drain valve @ securely.

24.4.8 CHECK MONITOR

at the

SYSTEM

Carry out the following check to prevent loss of warning ability caused by defective operation of the buzzer or broken lamps on the monitor panel.

1. Before starting the engine, turn the starting switch to ON and check that the alarm buzzer sounds and all monitor and gauge lamps light up for about 3 seconds.

If any lamp does not light up or the buzzer does not sound, the cause is probably a broken bulb or disconnection, so contact your Komatsu distributor.

24.4.9 CHECK OIL LEVEL IN PTO CASE 1. Open the left side cover and use dipstick @to check the oil level.

2.

The oil level should be between the L and H marks. If necessary, add engine oil at the filler 0.

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

24.4.10 CHECK OIL LEVEL IN SWING MACHINERY 1.

2.

CASE

Use dipstick at under of boom foot, and inspection hole at the upper side.

The oil level should be between the L and H marks. If necessary, add engine oil at the filler 0.

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

3-57

24. SERVICE

PROCEDURE

24.5 EVERY 10 HOURS SERVICE If any abnormal equipment,

IAwork

noise comes from the greasing points of the apply grease regardless of the service interval.

WARN’NG

24.5.1 LUBRICATING 1. Set the work equipment in the greasing posture below, then lower the work equipment to the ground and stop the engine.

2.

Using a grease pump, pump fittings shown by arrows.

3.

After greasing,

in grease

through

the grease

wipe off any old grease that was pushed out.

AE170050

1.

3-58

Boom concentration lubricating l Boom foot pin l Arm cylinder foot pin l Boom cylinder rod end

block

24. SERVICE PROCEDURE

2.

Boom cylinder foot pin (2 points)

1 3.

Arm concentration lubricating l Boom-Arm coupling pin l Arm cylinder rod end

4.

5.

Bucket cylinder Bucket cylinder

AEl70070

block (4 points)

rod end pin (2 points) rod end link coupling pin (4 points)

AE170090

6.

Bucket cylinder foot pin (2 points)

/ 7.

8.

Bucket-Link coupling Arm-Bucket coupling

9.

Arm-Link

coupling

pin (2 points) pin (2 points)

pin (2 points)

3-59

24. SERVICE PROCEDURE

IO. Bucket hinge pin (2 points)

11. Bottom dump cylinder foot pin (2 points) 12. Bottom dump cylinder rod end pin (2 points)

AE170140

3-60

24. SERVICE

24.6

PROCEDURE

EVERY 100 HOURS SERVICE

Maintenance same time.

for every

Carry out the following hours.

10 hours should

maintenance

be carried

only after

the first

24.6.1 CLEAN STRAINER OF PTO LUBRICATING FILTER For details of the method of replacement “24.8 EVERY 500 HOURS SERVICE”.

24.6.2 LUBRICATING

out at the

100

OIL

or maintenance,

see

SWING CIRCLE

Lubricate the 4 grease fittings shown

by an arrow.

AEl70150

24.6.3 DRAIN WATER AND SEDIMENT TANK Carry out this procedure Prepare a container

before operating

FROM FUEL the machine.

to catch the fuel that is drained.

Open valve @ at the bottom of the tank and drain the sediment and waterthat has accumulated at the bottom together with fuel.

When doing this, be careful not to get fuel on yourself.

AE170160

When only clean fuel comes out, close drain valve 0.

NOTICE Never use trichlene

for washing

the inside of the tank.

3-61

24.7 EVERY 250 HOURS SERVICE Maintenance for every 10 hours should be carried out at the same time.

For detail of the method of replacing or maintaining, see the section on EVERY 500 HOURS, 1000 HOURS AND 2000 HOURS SERVICE.

24.7.1 LUBRICATING Apply grease to the grease fitting shown 1.

Fan pulley assembly

2.

Tension

by arrows.

(1 point)

pulley assembly

(2 points)

24.7.2 CHANGE OIL IN FINAL DRIVE CASE

l

The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before

l

If there is still pressure remaining

inside the case, the oil or

Loosen the plug slowly to release the pressure.

1.

Stop the machine

2.

so that the TOP mark is at the top.

Remove plug @ and check that the oil level is near the bottom of the plug hole.

If necessary, add engine oil through plug hole 0.

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

3-62

I

AEl70180

/

24. SERVICE PROCEDURE

24.7.3 CHECK LEVEL OF BATTERY ELECTROLYTE

A WARNING l l

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

Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a doctor.

Carry out this check before operating

the machine.

1.

Open the battery box cover on the right side of the machine.

2.

Remove cap, and check that the electrolyte is at the specified level (10 to 12 mm (0.40 to 0.47 in) above the plate). If the electrolyte level is low, add distilled water to the specified level.

If the battery electrolyte

is spilled, have dilute sulphuric acid added.

3.

in the battery

Clean the air hole securely.

cap, then tighten

the cap

When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from freezing.

3-63

24. SERVICE PROCEDURE

24.7.4 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE

A WARNING The oil is at high temperature after the engine has been operated, so never change the oil immediately after finishing opera-

tions. Wait for the oil to cool down before changing it.

Prepare the following Container to catch drained oil: Min. 51 I? capacity l Refill capacity: 51 e (13.5 US gal, 11.2 UK gal) l Filter wrench l

1. Remove the filler cap, remove drain plug 0, and loosen drain valve 0. After draining the oil, tighten drain valve @ and plug 0.

Tightening

69 f 10 Nm (7 -c 1 kgm, 51 2 7 Ibft) Take care not to loosen the drain valve so much that the stopper pin in the valve is distorted.

Do not operate machine installed with the hose provided.

2. Usina a filter wrench. remove full-flow filter cartridaes 0-, bv _ turni;g counterclockwise.

Clean the filter holder and check that the oil seal is not stuck to the filter holder. If the old seal is still stuck to the filter holder, it will cause oil leakage.

If filter cartridges @ are removed immediately after stopping the engine, oil will spill. Wait at least 10 minutes after stopping the engine before replacing the filter cartridge.

3. Fill the new cartridge with clean engine oil and refit it after applying a dab of oil to the packing face.

To refit the cartridge, place the packing face in contact with the seal face of the filter holder, then screw up the cartridge 3/4 to 1 turn.

4. After replacing the cartridge, fill engine oil through oil filler 0.

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

5. Start the engine and run for a short time at idling to check that there is no leakage of oil from the filter seal surface. Then stop the engine and check that the oil is at the specified level. For details, see “24.4 CHECK BEFORE STARTING”.

3-64

torque:

AE170210

24. SERVICE PROCEDURE

24.7.5 REPLACE HYDRAULIC FILTER ELEMENT

When removing

the oil filler cap, turn it slowly

\

to release the

When removing cover 0, undo the bolts (4 bolts) gradually prevent the cover flying off under the force of spring 0.

Remove

A

to

cap @ of the oil filler.

Remove cover 0, spring remove element 0.

0,

valve

0,

and strainer

@ then

Clean removed parts and install a new element.

Be sure to use a genuine Komatsu element.

1 REMARK Operate the machine after halting for more than 5 minutes to eliminate bubbles in the oil inside the tank.

4.

AEl70240 ]

Check for oil leakage and wipe off any spilled oil.

3-65

24. SERVICE PROCEDURE

24.7.6 CHECK ALTERNATOR ADJUST

DRIVE BELT TENSION,

Checking The belt tension should normally deflect by about 75 mm (0.6 in) when pressed with the finger at a point midway between the alternator pulley and the drive pulley (approx. 6 kg (13 lb)).

Adjusting 1. To adjust the belt tension, loosen bolt 0 and nut @ and shift alternator @ slightly.

2. After adjustment, tighten bolt @ and nut @ securely.

Check each pulley for damage, and V-grooves and V-belt for wear. Particularly, check whether V-belt is in contact with bottom of V-groove through wear.

Replace belt if it has stretched, leaving no allowance for adjustment, or if there is a cut or brack on belt.

When adjusting the V-belt, do not attempt to push alternator @ directly with a bar or the like, but use a wooden block to prevent damage to the core.

3-66

24. SERVICE PROCEDURE

24.7.7 CHECK AIRCONDITIONER TENSION, ADJUST

COMPRESSOR BELT

Checking If the belt is loose, it will slip and the cooling effect will be reduced.

The belt should normally deflect by about 15 mm (0.6 in) when pressed with the finger (with a force of approx. 6kg (13 lb)) at a point midway between the drive pulley and compressor pulley.

Compressor

~ullev

Drive

~ulleu AE170290

Adjusting 1. To adjust the belt tension, loosen bolts @ (4 points) and lock nut 0, and screw adjustment bolt 0.

2.

After adjustment,

3.

Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove.

4.

Replace belt if it has stretched, leaving no allowance ment, or if there is a cut or crack on belt.

5.

When the new belt is set, readjust it after operation

tighten

lock nut @ and bolts @ (4 points).

for adjust-

for an hour.

3-67

24. SERVICE PROCEDURE

24.7.8 CHECK, CLEAN FUEL STRAINER 1.

2.

Close the valve @ under the fuel tank.

Open the engine hood, remove cap @ of the strainer under the air cleaner, and take out the strainer.

Clean the strainer and the strainer case.

24.7.9 CHECK AND TIGHTEN TRACK SHOE BOLTS Shoe bolts @ which secure track shoes to links will break if used in a loosened state, so loose bolts must always be retightened.

Tightening torque: Tighten to an initial torque of 784 + 78 Nm (80 + 8 kgm, 579 + 58 Ibft), check that the mating surfaces are in contact, then tighten a further 120” + 10”.

Order for tightening: Tighten the bolts in the order shown in the diagram. After tightening, check that the nut and shoe are in close contact with the link mating surface.

24.7.10 CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS Bolts @ connecting the track frame and axle will break if they remain loose, so loose bolts must always be retightened.

Tightening torque: 3280 2 340 Nm (335 2 35 kgm, 2420 f 250 Ibft)

3-68

24. SERVICE PROCEDURE

24.8 EVERY 500 HOURS SERVICE Maintenance for every 10,100 out at the same time.

and 250 hours should be carried

24.8.1 CLEAN HYDRAULIC TANK STRAINER 7

AWARNING l

When removing sure.

l

When removing cover 0, undo the bolts (4 bolts) gradually to prevent the cover flying off under the force of spring 0.

Remove

the cap, turn it slowly to relieve inner pres-

cap @ of the oil filler.

Remove cover @I and lift up the top of rod @from out spring @ and strainer 0.

above to take

Wash the strainer with fuel oil. If strainer @ is damaged, it with a new one.

AU70340

replace

When installing, check that the O-ring at the bottom of strainer @I is not out of place or twisted, then coat the surface of the Oring with grease, insert it on to tank protrusion 0, and install.

I

AEl70350

3-69

24.8.2 CHECK AND CLEAN RADIATOR 1. Remove

FINS

dA

bolts @ and cover 0.

2.

Remove the mounting bolts of the air conditioner condenser, and rotate the condenser towards the front of the machine.

Carry out the cleaning from the rear face of the condenser.

3.

Clean the radiator fins clogged with mud, dust and leaves compressed air.

Stream or water may be used instead of compressed air.

The rubber hose should be checked at the same time. If the is found to have cracks or to be hardened by ageing, such should be replaced by new one. Further, looseness of clamps should also be checked.

24.8.3

with

hose hose hose

CLEAN PILOT FILTER STRAINER

A WARNING The oil is at high temperature after engine has been operated.

Wait for the oil to cool down before carrying out maintenance.

1. Remove filter case 0.

2.

Take out the strainer and wash the strainer the strainer if finding some defects.

3.

Install the strainer

24.8.4

in the fuel. Replace

and filter case 0.

CLEAN STRAINER OF PTO LUBRICATING FILTER

OIL

Wait for the oil to cool down before carrying out maintenance.

1.

Remove filter case 0.

2.

Take out the strainer and wash the strainer the strainer if finding some defects.

3.

Install the strainer

3-70

and filter case 0.

in the fuel. Replace

A

24. SERVICE PROCEDURE

24.8.5 CHANGE FUEL FILTER 1.

2.

3.

4.

5.

6.

Close the valve 0, under the fuel tank.

Using a filter wrench, remove cartridge @ by turning it counterclockwise.

Clean the filter holder and check that the oil seal is not stuck to the filter holder. If the oil seal is still stuck to the filter holder, it will cause oil leakage.

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

To refit the cartridge, place the packing face in contact with the seal face of the filter holder, then screw up the cartridge l/2 to 3/4 of a turn.

Open the valve 0, under the fuel tank.

After replacing the cartridge, loosen air bleeding plug 0.

Loosen feed pump knob @ and move the pump up and down to draw off fuel until air ceases to come out of air bleeding plug 0.

Tighten air bleeding plug 0, push feed pump knob @ into place, and tighten it.

Be sure to use a genuine Komatsu cartridge.

After replacing the cartridge, start up the engine and check the filter seal face for possible oil leakage.

24.8.6 CHECK FAN BELT Check the V-belt and when the following conditions exist, replace the V-belt: l When the V-belt makes contact with the bottom of the groove in each pulley. l When the V-belt is worn, and its surface is lower than the outer diameter of the pulley. l When cracking and peeling of the V-belt occurs.

\

‘II

AE170420

REMARK An auto tensioner is installed, so it is unnecessary to adjust the fan belt.

For details of the replacement procedure, see “24.3.11 REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER”.

3-71

24. SERVICE PROCEDURE

24.8.7 CHECK INSPECTION OF WELDING

STRUCTURE (COLOR CHECK)

When the cracks are hard to be checked visually, verify them by color contrast penetrant examination.

1.

2.

3.

4.

5.

6.

7.

Color check shall conform to the following procedure.

Prepare color contrast penetrant agents (cleaning agent, penetrant, developer) Clean the checking zone with cleaning agent to remove dust and oil.

After cleaning, dry the surface completely, spray penetrant and leave for 5 to 20 minutes.

Spray cleaning agent again and wipe out the penetrant on the surface by a waste (cloth).

Wipe out excessive cleaning agent and then spray developer.

Spray so. that the surface can be slightly seen.

Leave for 15 - 20 minutes and visually check for the crack.

Colored cracks can be found, if there is any.

Repair cracks, if any, according to the repair procedure.

Detail of

Checking area

(Sketch AE170430

AE170450

3-72

shows

q

L. H.) AE170440

24. SERVICE PROCEDURE

Detail of

Detail of 0

q

R. H.

L. H. Section (Sketch

shows

seen

from

the

rear

of

body

L. H.) AE170500

AEl70470

Detail of

Detail of &!I

L:

, I

\ ,

Sect

ion

seen

from

‘:

‘To.

side+

q

]a

Hoot

side

-

the

rear

of

body (Sketch

shows

L. H.) AE170510

AE170480

Detail of

Detail of W

--.

----._ --_.

1

q

lEQ4$a Ii -

-_____

----

_-’

AE170490

AEl70520

3-73

AE170530

Detail of

(Sketch

q

shows

Detail of

q

L. H.) AE170570

AEl70540

Detail of H

Detail of l?i

Section the rear

seen of

Detail of

from body

AEl70550

q

AE170560

3-74

AE170580

24. SERVICE

PROCEDURE

AEi70590

AEl70600

Detail of !!d

q

Loader-Arm

n

AE170610

3-75

24. SERVICE PROCEDURE

24.9 EVERY 1000 HOURS SERVICE Maintenance for every 10, 100, 250 and 500 hours should be carried out at the same time.

24.9.1 CHANGE OIL IN SWING MACHINERY

CASE

The oil is at high temperature immediately after the machine has been operated. Walt for the oil to cool down before carrying

IAwAarnlG-l Container to catch drained oil: Min. front and rear each 13J? capacity Refill capacity: front and rear each 13 P, (3.4 US gal, 2.9 UK gal)

Loosen drain valve @ at the bottom draining, tighten the drain valve.

Pour in the specified

AND

amount

After

oil filler 0.

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

Contact your Komatsu

24.9.3 LUBRICATING

3-76

machine.

of engine oil through

24.9.2 CHECK TURBOCHARGER

1.

of the

CLAMPING JOINT

distributor

for checking.

OF TENSION

Using a grease pump, pump fittings shown by arrows.

PULLY (2 points)

in grease

through

the grease

24. SERVICE PROCEDURE

24.9.4 CHANGE OIL IN PTO CASE

A WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before carrying out maintenance.

NOTICE Park the machine on flat ground and stop the engine. After waiting for more than 30 minutes after stopping the engine, check the oil level.

Prepare the following.

Contain to catch drain oil: Min. 15 e capacity l Refill capacity: 15 e (4.0 US gal, 3.3 UK gal) l

1.

Drain oil from drain plug @I at the bottom of the PTO case. After draining, tighten drain plug 0.

2.

Pour in the specified

amount

of engine

oil through

oil filler 0.

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

24.9.5 REPLACE CORROSION RESISTOR CARTRIDGE Prepare the following. l Container to catch drain coolant l Filter wrench 1. Close valves @ (2 places) on the upper side of the corrosion resistor.

2. Using the filter wrench provided, remove cartridge @ by turning it counterclockwise.

Fit a new cartridge after applying a dab of engine oil to the packing face.

After replacement, open the valves.

(I) To fit the cartridge, put the packing face in contact with the seal face of the holder, then screw it up about 2/3 of a turn.

(2) Be sure to use a genuine Komatsu cartridge.

(3) After replacing the cartridge, start the engine and check that there is no leakage of water from the filter seal surface.

3-77

24. SERVICEPROCEDURE

24.9.6 REPLACE HYDRAULIC TANK BREATHER ELEMENT

I

AWARNING When replacing the element, turn cap of the oil filler slowly to release the internal pressure.

1.

Remove snap ring @ of breather 0, then replace filter element @ with a new part.

2.

1�

Install cover @ and snap ring 0.

*

3-78

AE170660

AEO83760

24.10 EVERY 2000 HOURS SERVICE Maintenance for every 10,100,250,500 be carried out at the same time.

and 1000 hours should

24.10.1 CHANGE OIL IN FINAL DRIVE CASE 7

AWARNING l

0

1

The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before carrying out maintenance. lf there is still pressure remaining inside the case, the oil or plug may fly out.

Loosen the plug slowly to release the pressure.

Prenare the following.

‘Container to catch drained oil: Min. 45 !?,capacity l Refill capacity: 45 !J (11.9 US gal, 9.9 UK gal) l Handle 0

1. Stop the machine

so that the drain plug @I is at the lowest

position.

2.

Drain the oil from drain plug 0. After draining the oil, tighten the drain plug.

3.

Drain the oil from drain plug @ at the inside.

After draining the oil, tighten the drain plug.

4.

Supply engine oil through fied level.

oil filler @ respectively

to the speci-

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

w

AEl70710

3-79

24. SERVICE PROCEDURE

24.10.2 CHANGE OIL IN HYDRAULIC STRAINER

TANK,

CLEAN

The oil is at high temperature immediately after the machine ing it. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it carefully.

Prepare the following.

Container to catch drained oil: min. 650 I? capacity l Refill, capacity: 650 !J.(172 US gal, 143 UK gal) l Prepare a handle for the socket wrench set. l

Retract the arm and bucket cylinder, lower the boom, put the tips of the teeth in contact with the ground, then stop the engine.

Remove

the cap of oil filler 0.

Remove drain plug @ and loosen valve @I at the bottom of the machine body to drain off the oil. After draining off the oil, tighten up the drain valve and plug.

Pour in the specified

amount

of engine oil through

oil filler 0.

For details of engine oil filling, see “24.4.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL”.

For details of releasing the air inside the hydraulic tank and the pressure inside the hydraulic circuit, see “18.5 BLEEDING AIR FROM CIRCUIT”.

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

24.10.3

CLEAN,

CHECK

TURBOCHARGER

Excessive carbon or oil sludge adhering to turbocharger blower impeller may deteriorate normal performance of turbocharger and may sometimes damage it.

Ask your Komatsu distributor to clean the turbocharger and check rotation of the rotor impeller.

24.10.4 CHECK TURBOCHARGER Contact your Komatsu distributor

3-80

ROTOR PLAY for checking.

AE082220

24.

24.10.5 CHECK SWING GREASE

PINION

GREASE

LEVEL,

SERVICE

PROCEDURE

ADD

Remove bolts @ (5 bolts) on the top of the revolving frame and remove cover 0.

Insert a scale into the grease and check that the depth of the grease is approx. 40 mm (1.6 in). Add grease if necessary.

Insert the scale in the portion shown in the diagram

-

Check point

and check.

If the grease is particularly milky due to ingress of water, etc., then remove bolts @ and cover @I from the bottom of the trackframe and remove the grease. Replace all of the grease with new grease.

The total amount of grease is 67 J?(18 US gal, 15 UK gal) (60.3 kg).

3-81

24. SERVICE PROCEDURE

24.10.6 1.

2.

CLEAN ENGINE BREATHER

Remove breather 0.

Rinse the breather in diesel oil or flushing pressed air, then install again.

oil, dry with com-

Before removing the breather, clean all the dirt from around it.

Replace the breather O-ring with a new part, and coat it with engine oil before installing.

24.10.7

CHECK ALTERNATOR,

STARTING MOTOR

The brushes may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair.

If the engine is started frequently, carry out inspection every 1000 hours.

24.10.8

CHECK ENGINE VALVE CLEARANCE, ADJUST

As special tool is required for removing request Komatsu distributor for service.

24.10.9 CHECK VIBRATION

and adjusting the parts,

DAMPER

Check that there are no cracks or peeling in the outside surface of the rubber.

If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced.

3-82

24. SERVICE PROCEDURE

24.11 EVERY 4000 HOURS SERVICE Maintenance for every 10, 100,250,500, should be carried out at the same time.

1000 and 2000 hours

24.11.1 CHECK WATER PUMP Check if there is oil leakage, water leakage, or clogging of the drain hole. If any abnormality is found, contact your Komatsu distributor for disassembly and repair or replacement.

24.11.2 CHECK FAN PULLEY AND TENSION PULLEY Inspect the pulley for play and grease leakage.

If any fault is detected, ask Komatsu distributor and repair or replace.

to disassemble

24.11.3 CHECK AIR COMPRESSOR, ADJUST As special tool is required for checking and adjusting the parts, request Komatsu distributor for service.

3-83

0 2 cn

c)

m

w

cn

25. SPECIFICATIONS

PC1000-l WEIGHT / l

Operating weight (including 1 operator): 80 kg

98,000 kg (216,090 lb)

PERFORMANCE l

l

Width of opening

l

Travel speed

l

SAE

Bucket capacity (standard bucket)

5.5m3 (7.2 cu.yd)

CECE

6.1m3 (8.0 cu.yd)

(Standard bucket)

2650 mm (104.3 in)

Low speed

2.4 km/h (1.5 MPH)

1 High speed

3.4 km/h (2.1 MPH)

Swing speed

4.5 rpm

TRACK SHOE l

710 mm (28 in) width

Double grouser shoe (standard)

ENGINE l

Model

Komatsu SA6D170-B diesel engine

l

Flywheel horsepower

405kW (542 HP) / 1700 rpm

0 Starting motor l l

4-2

Alternator Battery

24 V

I

7.5 kW x 2

24 V 12 V

50 A

170 Ah x 2 pieces

25. SPECIFICATIONS

Pc1000-1

-

LE)

OZ6

AE170780

4-3

PC1000-l Never allow other person than the operator to enter the swing range (Max. swing range, Max. digging radius).

(,.11.6&) OLLZL

(..Ol.Zl) OL6E

Ml70790

4-4

26. GENERAL PRECAUTIONS

26.1

PRECAUTIONS

RELATED TO SAFETY

If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety.

When installing attachments not listed in this Operation and Maintenance Manual, please contact your Komatsu distributor first.

If you do not contact Komatsu, we cannot accept any responsibility for any accident or failure.

A

WARNING

Precautions for removal and installation operations When removing or installing attachments, obey the following precautions and take care to ensure safety during the operation.

Carry out the removal and installation operations on a flat, firm ground surface.

When the operation is carried out by two or more workers, during the operation.

When carrying

determine

signals and follow these

heavy objects (more than 25 kg (55 lb)), use a crane.

When removing heavy parts, always support the part before removing it.

When lifting such heavy parts with a crane, always pay careful attention to the position of the center of gravity.

It is dangerous to carry out operations stand, and check that it is safe.

When removing not fall over.

with the load kept suspended.

or installing attachments,

Always

set the load on a

make sure that they are in a stable condition

and will

Never go under a load suspended from a crane.

Always stand in a position that is safe even if the load should fall.

NOTICE Qualifications are required to operate a crane. Never allow the crane to be operated by an unqualified person.

For details of the removal and installation operations, please contact your Komatsu distributor.

5-2

26. GENERAL

26.2

PRECAUTIONS

WHEN INSTALLING

A

PRECAUTIONS

ATTACHMENTS

WARNING

Long work equipment reduces the stability of the chassis, so if the swing is operated on a slope, or when going down a steep hill, the machine may lose its balance and overturn.

The following operations are particularly dangerous, so never operate the machine in these ways.

Going downhill with the work equipment

l

Traveling

across slopes

raised INCORRECT

l

Swinging structure

INCORRECT

the upper on slopes CORRECT

x.b

Platform \20-30cm

&to12

in)

AEl67540

AEI67560

AE170800

AEl70810

If heavy work equipment is installed, the overrun of the swing becomes greater (the distance from the point where the operator operates the control levers to stop the swing to the point where the upper structure stops completely), so there is danger of mistaking the distance and hitting something.

Always operate so that there is an ample margin to the stopping point.

Furthermore, the hydraulic drift also becomes larger (when the work equipment is stopped in mid-air, it will gradually move down under its own weight).

Always follow the correct procedure when installing the boom and arm. If the correct procedure is not followed, this may lead to serious damage or injury, so please consult your Komatsu distributor before carrying out installation.

long work equipment is installed, the working range will suddenly become larger, so there is danger of mistaking the distance and hitting something.

Always operate the work equipment so that there is ample space from any obstacles in the area.

5-3

27. HANDLING BUCKET WITH HOOK

27.1

fiH6oCKK’NGFOR DAMAGE

TO BUCKET WITH

Check that there is no damage to the hook, stopper, or hook mount. If any abnormality is found, please contact your Komatsu distributor.

27.2

PROHIBITED OPERATIONS

INCORRECT

The standard work equipment must not be used for lifting loads.

If this machine is to be used for lifting loads, it is necessary to install the specified bucket with hook.

AE170820

27.3

PRECAUTIONS

DURING OPERATIONS

When carrying out lifting operations, reduce the engine speed and use the lifting operation mode.

Depending on the posture of the work equipment, there is danger that the wire or load may slip off the hook.

Always be careful ,to maintain the correct hook angle to prevent this from happening.

Never steer the machine while lifting a load.

If the bucket with hook is turned and used for operations, it will hit the arm during dumping operations, so be careful when using it.

Loads suspended must never exceed the limit indicated in the “LIFTING CAPACITY TABLE” stuck on the right-side lower portion of the driver’s seat.

If you wish to install a hook in the future, please contact your Komatsu distributor.

CORRECT

AE083920

I

INCORRECT

AE083930

5-4

28. USING SEAT BELT

28.1 IA

SEAT BELT WARNING

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

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

Even if there appears to be no abnormality with the seat belt, always replace it once every three years. The data manufacture is woven on the reverse side of the belt.

Adjust and fasten the seat belt before operating Always

use seat belt when

operating

the machine.

the machine.

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

28.1.1 FASTEN THE BELT AND REMOVE IT Adjust the seat so that the operator still feels that there is sufficient knee room when fully depressing the pedal while seated, with operator’s back against the backrest.

Adjust adjuster belt @ after adjusting the seat position. (See “28.1 SEAT BELT”) After adjusting the seat position, sit in the seat. Grip buckle @ and tongue @ in each hand and insert tongue @ into buckle 0.

Confirm by pulling the belt that the tongue is securely locked to the buckle.

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

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

5-5

28.1.2

ADJUST THE BELT LENGTH

To shorten the belt Pull the free end of the belt on either the buckle body or tongue side.

AH)78090

To lengthen the belt Pull the belt while holding it at a right angle to buckle or tongue.

Inspect bolts and fittings on the chassis for tightness. Retighten any loose bolts to 20 to 29 Nm (2 to 3 kgm, 15 to 20 Ibft) torque.

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

5-6

AE078100

29. INTRODUCTION

29.1

SPECIFICATION,

OF ATTACHMENTS

USE

Specifications, use

Name Large size

Capacity

bucket

Outside

width

7.0 m3 (9.2 cu.yd) 2650 mm (104”)

In place where there is danger of falling rocks, always install the head guard to protect the operator.

Track shoes

Double

grouser

710 mm (28”) 910 mm (36”) 1010 mm (40”)

Following attachments are available: Low cab l Free swing l Seat belt l Fire extinguisher l Full length roller guard l Roller guard l Revo-frame under cover l Vandalism

l

For details, please contact Komatsu or your Komatsu distributor.

Full length roller guide and extra counterweight as standard attachments.

5-7

BACK HOE TYP E SHOV EL This section applies when a back hoe shovel is installed.

Only the portions which differ from the loading shovel are noted.

6-l

30.

GENERAL LOCATIONS

Arm

cylinder

Arm \

Bucke

/ Bucket

Track

I

shoe

\

Track

flame

Idler

AE170880

6-2

31. INSTRUMENTS AND CONTROLS

31.2

CONTROL LEVERS

VA WARN’NG For machine with auto-deceleration device, careful operation of levers @ through @ IS necessary in the deceleration range because the engine speed rises quickly.

AEl70910

1.

LOCK LEVER

2.

FUEL CONTROL LEVER (with auto-deceleration device)

3.

TRAVELING AND STEERING LEVERS (AND PEDALS) (with auto-deceleration device)

Details of the above equipment 1, 2, 3 are given in CONTROL LEVERS, PEDAL on the previous pages.

6-4

AEl70920

31. INSTRUMENTS AND CONTROLS

4.

LEFT WORK EQUIPMENT LEVER (arm/swing control lever) (with auto-deceleration device)

Arm operation @Arm moves out. @Arm

moves in.

Swing operation @ Upper structure to the right. @Upper structure to the left.

swings swings

@I Neutral: When the lever in this position, the upper structure and the arm will be retained in the position in which they stop.

5.

RIGHT WORK EQUIPMENT LEVER (boom/swing control lever) (with auto-deceleration device)

Boom operation @ Boom raises. @Arm lowers. @

Bucket operation @Bucket dumps. @ Bucket tilt

Neutral: When the lever in this position, the boom and the bucket will be retained in the position in which they stop.

AEl68140

For machine with auto-deceleration device, the engine revolution changes as follows according to the positions of levers 0, 0, 0, @ because of the function of the auto-deceleration device: When the traveling and steering levers and work equipment levers are all at the neutral position, even if the fuel control lever is above the medium speed position, the engine speed will drop to a medium speed.

If any of the levers or pedals is operated, the engine speed rises to the level set by the fuel control lever.

6-5

31. INSTRUMENTS AND CONTROLS

31.3

CONTROL BOX

The control box has a self-diagnostic function. Open the left side cover behind the operator’s cab, and open the inspection cover so that the control box can be seen. Through the monitor window installed to the cover of the box, red and green LEDs (Light Emitting Diodes) which indicate abnormalities can be seen,.

When there is no abnormality, the display in the table below is shown.

For details of the LED display when an abnormality occurs, see TROUBLESHOOTING GUIDE. l

@

When normal Electronic OLSS controller

Machine is normal in the mode “H” or “L”.

6-6

31. INSTRUMENTS AND CONTROLS

31.4

FUSE BOX

The fuses protect

the electrical

equipment

and wiring

from

fuse is loose in a fuse holder, replace it.

Rplace a fuse with another of the same capacity.

Fuse arrangement and circuit Spare fuses (three of IOA, one of 20A) are kept in the spare fuse box.

No.

a

I

0 @

1

Fuse capacity

Circuit

/

20A

Head lamp

1OA

Working lamp

20A

1 Spare

0

20A

APS

0

10A

Monitor, Controller, OLSS

@

/

20A

1 Air conditioner

a

10A

-

@

2OA

-

CO a0

)

2OA IOA

I

)

AC052120

Wiper, Room lamp Cigarette lighter, Radio

6-7

32. OPERATION

32.1

OPERATION

suddenlv

increase,

OF WORK EQUIPMENT

so be careful when

operating

the levers.

The work equipment is operated by left and right control levers, and the bottom dump switches.

The LEFT work equipment control lever controls SWING, ARM and bottom dump closing.

The RIGHT work equipment control lever controls BOOM, BUCKET and bottom dump opening.

The levers and switches, and movement of the work equipment are as shown in the diagrams.

If the levers and switches are released, they will return to the NEUTRAL position, and the work equipment will be held in position. l If the work equipment control lever is returned to the neutral position when the machine is stopped, even if the fuel control lever is set to FULL, the auto-deceleration mechanism will act to reduce the engine speed to a mid-range speed (for the machine with auto-deceleration device).

Arm operation

Swing operation

6-8

Swing operation

32. OPERATION

Boom operation

Bucket operation

Bucket

operation

6-9

32. OPERATION

32.2

CHECK BEFORE STARTING

ENGINE

Perform following checks for operator safety and maintenance machine performance.

322.1 WALK-AROUND

l

of

CHECK

Leakage of oil or fuel, or accumulation of flammable material around high temperature parts, such as the engine muffler or Check carefully, and if any abnormality contact your Komatsu distributor.

is fouhd, repair it or

Before starting the engine, look around the machine and under the machine to check for loose nut or bolts, or leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system. Check also for loose wiring, play, and collection of dust at places which reach high temperatures.

Always carry out the items in this section engine each day.

before starting

the

AE171020

1.

6-10

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

32. OPERATION

2.

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

3.

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

4.

Check hoses, Check repair

5.

Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from rollers and final drive case

6

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

7.

Check for damage to gauges, monitor, loose bolts Check that there is no damage to the gauges and ‘monitor in the operator’s cab. If any abnormality is found, replace the parts.

Clean off any dirt on the surface.

for oil leakage from hydraulic equipment, hydraulic tank, joints that there is no oil leakage. If any abnormality is found, the place where the oil is leaking.

REMARK Check monitor system Before starting the engine, turn the starting switch to ON and check that the alarm buzzer sounds and all monitor and gauge lamps light up for about three seconds.

8.

Clean rear view mirror, check for damage Check that there is no damage to the rear-view mirror. If it is damaged, replace it with a new mirror. Clean the surface of the mirror and adjust the angle so that the view to the rear can be seen from the operator’s seat.

9.

Seat belt and mounting clamps Check that there is no abnormality in the seat belt or mounting clamps. If there is any damage, replace with new parts.

10. Check bucket with hook for damage.

Check the hook, catcher and hook foot for damage. If damage found, contact your Komatsu distributor for repair.

is

6-11

32. OPERATION

11. Check tightness

of air cleaner

mounting

12. Check oil level in PTO case Check the oil level in PTO case.

The oil level should be between

bolts.

the L and H marks.

13. Check oil level in swing machinery case Check the oil level in swing machinery case.

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

14. Drain water and sediment from fuel tank Loosen drain valve and drain the water and sediment bottom of the tank together with fuel.

For detail ING”.

6-12

see MAINTENANCE

“24.4

at the

CHECK BEFORE START-

33. PRECAUTIONS FOR MACHINE OPERATION

33.1

PRECAUTONS

DURING

A

OPERATION

WARNING

l

For machine with autodeceleration device, if the lever is operated inside the deceleration range, the engine speed will rise suddenly.

l

Turning or operating the work equipment when working on slopes may cause the machine to lose its balance and turn over, so avaoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded.

If such operations have to be carried out, pile soil to make a platform on the slope so that the machine can be kept horizontal when operating.

l

Never carry out digging retracted.

operations

with

the track

gauge

It is prohibited to use the swing force for operations.

Be careful not to compact the soil or damage earth mounds as a result of the swinging force. When swinging, do not dig the bucket teeth into the soil.

INCORRECT

81%

AE171030

It is prohibited to use the travel force for operations.

Do not move off and excavate with the bucket left dug into the ground.

Do not carry out operations

with the hydraulic cylinder at the end of its stroke.

When working with the machine, do not move the cylinder to the end of its stroke but leave a small safety margin.

It is prohibited to use the dropping force of the bucket for operations.

Do not use the dropping force of the bucket for digging.

Do not use the dropping force of the bucket as a pickaxe, breaker, or pile driver.

6-13

33. PRECAUTIONS FOR MACHINE OPERATION

Scraping-down operations are prohibited.

Never use the front bucket of a bottom-dump down rocks or soil.

INCORRECT bucket to scrap

Digging rocky ground It is better to excavate hard rocky ground after breaking it up by some other means.

This will not only reduce damage to the machine but make for better economy.

Phenomena that do not indicate failure Note that the following phenomena are not faults: l The arm may sometimes stop when the bucket teeth become more or less horizontal. l At the beginning and end of a swinging, a noise may sometimes be emitted from the brake valve. l When descending a steep slope at low speed, a noise may sometimes be emitted from the travel motor.

6-14

INCORRECT

34. PRECAUTIONS WHEN DISASSEMBLING

MACHINE

When disassembling the machine or removing the piping during inspection or maintenance, always release the pressure as follows.

RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUIT, TRAVEL CIRCUIT

CIRCUIT, SWING

A WARNING When removing the oil filler cap of the hydraulic tank, turn it slowly to release the internal pressure before taking off the cap.

1.

Lower the work equipment to the ground in a stable flat place as shown in the diagram, then stop the engine.

Set the lock lever to the FREE position.

2.

After stopping the engine, move each work equipment lever to the end of its travel within 5 to 6 seconds.

Leave the starting switch ON.

control AE171090

3.

Remove the cap of the hydraulic

tank.

4.

Start the engine, run it for approx. IO seconds, then stop the engine again.

When running the engine, do not raise the speed above 1000 rpm.

Set the work equipment control levers to neutral.

5.

After stopping the engine, move each work equipment lever to the end of its travel within 5 to 6 seconds.

Repeat Steps 4 to 5 three times.

control

6-15

35. MAINTENANCE

Fuel Hydraulic

I ic

Hydrau

tank

Radiator

water

sight

gauge

tank

oil

tank

filler

filler Fuel

filler

tank /

3

1

*

Engine

oi

pan

drain

plug drain

t ank

Fuel

I

Radiator

gau se

sight

cock

dra

\

Hydraulic

tank

drain

PI ug AE171100

Swing

machinery

oil

filler.

level Engine

gauge oil

pan

gauge

level

Engine oil oil filler /

PTO

pan

oil case I gauge

filler.

/

PTO

V Swing

machinery

drain

case

drain

DIU~

plug AE171110

6-16

35.2 ADJUST

BUCKET CLEARANCE

A WARNING it is dangerous if the work equipment the clearance is being adjusted.

Set the work equipment in a stable engine and lock the lever securely.

moves by mistake condition,

then

when

stop the

AEl67470

If there is excessive free play on the coupling section of the bucket and arm, adjust the bucket clearance in the following manner.

1. Loosen 3 bolts 0, 2.

4 bolts 0,

plate @ and plate 0.

Put the O-ring @ on the shoulder

of bucket boss @I or bushing

@.

Touch the ends of bucket boss @I and arm boss Take out shims @ equivalent in size to free play Thickness of shim @ is 0.5 mm or 1.0 mm (0.02 When free play @ is less than a thickness of compress the shims by tightening bolt 0.

3.

Tighten 3 bolts @ and 4 bolts 0.

With this adjustment, clearance @ becomes is removed.

@.

0. or 0.04 in). shim, do not

larger, but play @

AE171120

6-17

35. MAINTENANCE

35.3

CHECK BEFORE STARTING

CHECK OIL LEVEL IN HYDRAULIC

TANK

WARNING When removing the cap of oil filler 0, turn it slowly to release the internal pressure before taking off the cap.

If oil has been added to above the H mark, stop the engine and wait for the hydraulic oil to cool down, then drain the excess oil from the drain plug @.

l

AE1710SO

Run the engine at low speed, retract the arm cylinder, extend the bucket cylinder, lower the boom until the bottom of the bucket touches the ground and then stop the engine.

Move each operation lever (for work equipment full travel to release the internal pressure.

and travel) to its

AE171140

If the level of hydraulic oil is not between top H and bottom L 1 lines of sight gauge 0, pour in additional engine oil from filler 0.

The type of lubricant used depends on the ambient temperature.

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

Do not pour in additional oil if the level is above the top line H of the sight gauge.

1 The oil level will vary depending upon the oil temperature.

Accordingly, use the following as a guide: l When the oil temperature is close to the ambient temperature range (IO to 30°C (50 to 86”F)), the level will be close to bottom line L on the sight gauge. l When the oil temperature is the normal operating temperature range (50 to 80°C (122 to 176”F)), the level will be close to top line H on the sight gauge.

6-18

’

lgm’

AE168670

35. MAINTENANCE

35.4

EVERY 10 HOURS SERVICE

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

If any abnormal noise comes from the greasing points of the work equipment, apply grease regardless of the service interval.

1.

Boom concentration lubricating Boom foot pin l Arm cylinder foot pin l Boom cylinder rod end

block (5 points)

l

2.

Boom cylinder foot pin (2 points)

AE170070

3.

Arm concentration lubricating l Boom-Arm coupling pin l Arm cylinder rod end l Bucket cylinder foot pin

block (3 points)

6-19

35. MAINTENANCE

5.

Arm-Link coupling pin (I point) Arm-Bucket coupling pin (I point)

6.

Bucket-link

7.

Bucket cylinder

8.

Link coupling

4.

coupling

pin (I point)

I

AE171200

1

AE171210

rod end pin (1 point)

pin (2 points)

I

I

6-20

AEl69910

35.4.2 CHANGE OIL IN HYDRAULIC

A

TANK

WARNING

When removing the cap of oil filler 0, inner pressure.

turn it slowly to relieve

AEl71090

1. Retract the arm cylinder, extend the bucket cylinder, lower the boom and put the bottom of the bucket in contact with the ground, then stop the engine.

2.

Remove the cap of oil filler 0.

I 3.

Remove drain valve @ and loosen plug @ at the bottom of the machine body to drain off the oil. After draining off the oil, tighten up the drain valve and plug.

Drain valve @ and plug @ are 2 points. (left or right)

4.

Pour in the specified amount

of engine oil through

AEl70730

oil filler 0.

For details of hydraulic oil filling, see “24.4.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL”.

For details of releasing the air inside the hydraulic tank and the pressure inside the hydraulic circuit, see “18.5 BLEEDING AIR FROM CIRCUIT”.

Refill capacity: 650 e (172 US gal, 143 UK gal) For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

6-21

1

36. EXCAVATOR WORK

In addition to the following, it is possible to further increase the range of applications by using various attachments.

BACKHOE WORK When excavating, use this angle effectively to optimize your work efficiency.

The range for excavating with the arm is from a 45� angle away from the machine to a 30� toward the machine.

There may be some differences depending on the excavation depth, but try to use within the above range rather than going all the way to the extreme end of the cylinder stroke.

LOADING WORK In places where the swing angle is small, work efficiency can be enhanced .by locating the dump truck in a place easily visible to the opertor.

Loading is easier and capacity greater if you begin from the front of the dump truck body than if loading is done from the side.

6-22

37. TRANSPORTATION

For ease of transport, the machine may be disassembled into the parts shown in the diagrams: the body, operator’s cab, track frames, ladder, platform, attachments and counterweight.

Ask your Komatsu distributor to carry out the disassembly work.

PARTS FOR TRANSPORT The dimensions

Pc1000-1

[

in the diagrams

1: PcloooLc

are given in millimeters.

{

}: PC1OOOSE Weight: 28,400 kg (14,200 x 2) (62,600 lb (31,300 x 2)) 135,580 kg (17,790 x 211 f(78.450 lb (39,225 x 2))I 128,400 kg (14,200 x 211 ((62,600 lb (31,300 x 2)))

AE169510

Weight: 300 kg (662 lb)

AEl69520

Weight: 90 kg (198 lb)

AEl69530

6-23

37. TRANSPORTATION

1

I: PcloooLc

{

1: PC1 OOOSE Weight:

Secure the body to the shipping support with chains, blocks, etc.

kg (65,050

lb)

[29,500

kg (65,050

lb)1

(30,000

kg (67,500

lb)1

~E,6950, Weight:

Width

29,500

5,100

kg (11,250

lb)

[5,100

kg (11,250

lb)]

(5,700

kg (12,570

lb))

11,500

kg (25,360

lb)

550 AE171250

Weight:

[II,500 19,900

Width

kg (25,360 kg (21,830

lb)1 lb))

1410 AE171260

Weight:

AE169550

6-24

14,000

kg (18,080

lb)

37. TRANSPORTATION

t

1: PcloooLc

{

1: PCIOOOSE Weight:

4,000 kg (8,820 lb) 14,000 kg (8,820 lb)1 15,200 kg (11,470

lb)1

AEl71270

Weight:

2,400 kg (1,200 x 2) (4,630 lb (2,315 x 2))

AEl69570

Weight:

60 kg (132 lb)

AE171280

Total weight: Weight 2 kg x 3

Weight 30 kg x 2

Weight 120 kg x 2

Weight 25 kg

(4.4 lb x 3)

(66 lb x 2)

(265 lb x 2)

(904 lb)

Weight 5 kg (11 lb)

Weight 60 kg (132 lb)

410 kg (904 lb)

Weight 7 kg x 2 (15 lb x 2)

AEl69590

6-25

38. INTRODUCTION

38.1

ATTACHMENT

OF ATTACHMENTS

INSTALLATION

COMBINATION

This table lists the combination of attachments arm and long arm. o : Can be used n : Can be used only for light-duty work x : Cannot be used NOTICE When the boom is fully lowered Operate the boom carefully.

Categories of use For general digging: For light duty digging: For loading work:

during oblique

of bucket [CECEI

Standard Wide

bucket

bucket

digging,

the boom interferes

with the undercarriage.

digging or loading sand, gravel, clay, etc. digging or loading dry, uncaked earth and sand, mud, etc. loading dry, loose earth and sand CalPa$jity

Name

TABLE

which can be installed to the standard arm, semi long

Short Width (mm)

USE

2060 (81.10”)

General

4.7

2500 (98.43”)

Loading

3.8

digging

Standard

boom

boom

Standard arm

Short arm

Semi long arm

Long arm

0

0

a

X

0

a

X

X

Narrow

bucket

3.3

1690 (66.54”)

Narrow

digging

x

0

0

a

Narrow

bucket

2.7

2500 (98.43”)

Narrow

digging

X

X

0

0

6-26

38. INTRODUCTION

38.2

SPECIFICATION, Name

I

USE

Specifications,

use

Wide bucket

Capacity Outside width

4.7 m3 (6.12 cu.yd) 2500 mm (98.4”)

Narrow

Capacity Outside width

2.7 m3 (3.52 cu.yd) 1650 mm (65”)

FOPS

Tble

bucket

OF ATTACHMENTS

In place where there is danger of falling rocks, always install the head guard to protect the operator. grouser

,Hii

~v’I$ iii.i

Following attachments are available: Free swing l Seat belt l Fire extinguisher l Full length roller guard l Roller guard l Revo-frame under cover l Vandalism l

For details, please contact Komatsu or your Komatsu distributor.

Full length roller guide and extra counterweight as standard attachments.

6-27

39. SPECIFICATIONS

PCIOOO-1,

PClOOOLC-1, PCIOOOSE-1 (BACK HOE SHOVEL) Pc1000-1

PCIOOOSE-1

Pc1oooLc-1

WEIGHT l

Operating

weight (including

1 operator):

80 kg

95,000 kg (209,475lb) 103,300kg (277,780lb) 97,000 kg (213,890lb)

PERFORMANCE l

Bucket capacity (standard bucket)

l

Width of opening (Standard bucket)

l

Travel speed

l

1,890 (74.4 in)

Low speed

2.4 km/h (1.5 MPH)

High speed

3.4 km/h (2.1 MPH) 4.5 rpm

Swing speed

TRACK l

3.8 m3 (5.0 cu.yd)

SHOE

Double grouser shoe (standard)

710 mm (28 in)

1010 mm (40 in)

710 mm (28 in)

ENGINE l

Model

l

Flywheel

Komatsu SA6D170-B diesel engine 405 kW (542 HP) / 1700 rpm

horsepower

24 V

0 Starting motor l l

6-28

Alternator Batten/

I

7.5 kW x 2

24 V 12 V

50 A

170 Ah x 2 oieces

39. SPECIFICATIONS

t I

(..Zl OS

ILZI) IL. 1.61) OZ891 [(.. 1.

I: Pc1oooLc-1 1: PC1 OOOSE-1

1 0 1891 (,6 1) 0089 l’-If’!aq lleJa*O [--

1 (..&.ci 1) OP9P SPLEI (.a1,Z1) 9891 911 lL.S.S) 9P911 L.Z.9) 98S1

AE171290

6-29

39. SPECIFICATIONS

Never allow other person than the operator (Max. Swing range, Max, digging radius).

to enter the swing range

1 I

ILLS&) W301~

i(..P,8&) 089111

(..P,8E) 08911

I: Pc1oooLc-1 }: PCIOOOSE-1

{(..6,SZ) OP8L) [(..L.O&) 09161 (..l.OE) 0916

n

I

1

I I(oZ.LZ)96Z8Il(,OL,62) 00161 (..9,6Z1 0006 k,Ot,ZP) OSOEL} L(.PP) OOPELl (.PP)OOPEL

AE171300

6-30

DataKom Publishing Corporation 440 North Fairway Drive

Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186

PROPOSAL FOR MANUAL OR CSS REVISION

DATE:

FOR INTERNAL

USE ONLY -- No. PMR

NAME OF COMPANY:

CITY:

)

STATE OR PROVINCE::

’

DEPARTMENT:

COUNTRY:

;

NAME:

FAX NO:

ANUAL DESCRIPTION:

CSS PROGRAM

- e.g: Lookup, Parts or Service

ANUAL OR CSS CD NO:

CSS PROGRAM

RELEASE VERSION:

ANUAL OR CSS CD ISSUE DATE:

CSS BOOK PUBLISHER:

SOOK DESCRIPTION IACHINE MODEL 8 S/N: IANUAL SECTION/PAGE

NUMBERS OR CSS REFERENCE

‘ROBLEM:

,ttach photo or sketch. more space is needed, use another sheet.

FOR INTERNAL :ORRECTIVE

m

PROPFREV.WPD

071:

USE ONLY

ACTION:

& PAGE NUMBERS:

SEAM007701

HYDRAULIC EXCAVATOR PC1000-10001 SERIAL NUMBERS PC1000LC-10001 and up PC1000SE-10001

WARNING Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine. This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it.

1997 All Right Reserved Printed in USA 06-97 DATAKOM

NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.