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

Operation & Maintenance Manual

SEAM008701

PC1 0004

PC1 0001t4

PC1 OOOSE=i

HYDRAULIC EXCAVATOR

SERIAL NUMBERS

PC1 0004 PCIOOLC-1

- 10377 - 10377

PcinnnsEli-

andup

in377

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

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

Due to this continuous program of research and development, periodic revisions may be made to this publication.

It is recommended that customers contact their distributor for information on the latest revision.

March 1997

Copyright 1997 Komatsu America International Company

1. FOREWORD

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

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

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

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

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

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

Operators and maintenance operation or maintenance.

personnel should read this manual 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. lf this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.

The description of safety is given in SAFETY INFORMATION 1-I :

on page O-2 and in SAFETY from page

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

and other

reproductive

harm.

O-l

2. SAFETY INFORMATION

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

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

A DANGER

-

A WARNING

-

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

A

CAUTION

-

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

NOTICE

-

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

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.

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

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

O-2

3. INTRODUCTION

3.1 INTENDED USE This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following work: l Digging work l Loading work See the section "12.14 WORK POSSIBLE USING HYDRAULIC

EXCAVATOR” for further 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. Efthe 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 side of the engine cylinder viewed from the fan

on the left

.

4.3 BUCKET SERIAL NO. PLATE POSITION On the rear face left of the bucket.

AD04170

4.4 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

1

Engine

serial No.:

Distributor

name:

Phone:

Address:

Service

o-4

personnel

for your machine:

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

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

o- 4

SAFETY .... ..... ................... ... ......... .......‘..........................................................................

6.

General precautions

7.

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

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

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

7.2 ..........................................................................................................................

7.3 Transportation 7.4 7.5

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

Liftingoperation .......................................................................................................................

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

Before carrying out maintenance 8.1 ................................................................................................................

During maintenance 8.2

9.

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

I- 2

I- 8 l- 8 I-10 I-15 1-16 1-17

I-18 I-18 1-21

1-25

OPERATION IO. General view ......................................................................................................................................

10.1 IO.2

General General

view of machine ........................................................................................................ view of controls and gauges ...................................................................................

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

11.1 Machine monitor ......................................................................................................................

2- 2 2- 2 2- 3

2- 4 2- 4

11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.12 11.13 11.14 11.15 11.16 11.17 11.18

2-14 Lamp .........................................................................................................................................

2-15 Switches ....................................................................................................................................

2-20 Control levers, pedals ..............................................................................................................

2-23 Ceiling window ........................................................................................................................

2-24 Front window ...........................................................................................................................

2-26 Door lock ...................................................................................................................................

2-26 Dust indicator ...........................................................................................................................

2-27 Air conditioner .........................................................................................................................

2-30 Radio .........................................................................................................................................

2-32 Fuse ...........................................................................................................................................

2-33 Controllers ................................................................................................................................

2-33 Tool box ....................................................................................................................................

2-33 Grease pump ............................................................................................................................

2-34 Handling grease pump ............................................................................................................

2-36 Handling accumulator .............................................................................................................

2-38 Luggage box ..........................................................................................

Method of releasing pressure in control circuit on machine equipped with 2-38 accumulator ..............................................................................................................................

2-38 11.19 Location of fireextinguisher ...........................................................................

O-5

5. CONTENTS

12. Operation

12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10 12.11 12.12 12.13 12.14 12.15 12.16 12.17 12.18 12.19

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

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

Starting engine .........................................................................................................................

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

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

Steering machine .....................................................................................................................

Stopping machine ....................................................................................................................

Swinging ...................................................................................................................................

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

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

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

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

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

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

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

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

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

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

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

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

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

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

13.2 Precaution for transportation .................................................................................................

13.3 Parts for transport ...................................................................................................................

13.4 Procedure for raising chassis .................................................................................................

13.5 Securing machine ....................................................................................................................

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

2-39 2-39 2-49

2-53 2-55 2-59 2-61 2-63 2-64 2-65 2-66 2-69 2-70 2-72 2-73 2-74 2-75 2-76 2-77 2-77 2-78 2-78 2-78 2-79 2-82 2-85 2-86

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

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

14.2 Precautions after completion of work ...................................................................................

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

2-88 2-88 2-90 2-90

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

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

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

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

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

2-91 2-91 2-92 2-92 2-92

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

16.1 Phenomena that are not failures ...........................................................................................

16.2 Method of towing machine ....................................................................................................

16.3 Precautions on particular jobsites .........................................................................................

16.4 If battery is discharged ...........................................................................................................

16.5 Other trouble ............................................................................................................................

2-93 2-93 2-93 2-94 2-95 2-99

O-6

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

parts list . . .. . .. . .. . .. . . . . . .. . . . .. .. . . . .. . . .. . .. . . . . .. . . . . . .. . . . .. . ... .. . . . .. . . . .. . ..~..........................................

20. Use of fuel, coolant

and lubricants

according

to ambient

temperature

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

3- 2 3- 5 3- 5 3- 8 39 9 3-10 3-12 3-17 3-18 3-19

torques for bolts and nuts ...........................................................................

21. Standard tightening 21.1 Introduction of necessary tools ..............................................................................................

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

3-23 3-23 3-24

22. Periodic

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

3-25

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

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

3-31 3-31

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

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

24.2 Initial 250 hours service . . .. . .. ..rr..r............................................................................................ .

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

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

24.5 Every IO 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 . . . . . .. . . . . . . . . . . . . .. . .. . .. . . .. . .. . . .. .. . . ... . .. . .. . ..*.................................................

3-35 3-35 3-35 3-36 3-56 3-61 3-64 3-65 3-72 3-79 3-82 3-86

replacement

of critical safety

parts

SPECIFICATIONS 25. Specifications

OPTIONS,

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

4- 2

ATTACHMENTS

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

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

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

5- 2 5- 2 5- 3

o-7

5. CONTENTS

27. Using seat belt ..................................................................................................................................

27.1 Seat belt ....................................................................................................................................

5 4 5- 4

28. Introduction of attachments ............................................................................................................

28.1 Specification, use .....................................................................................................................

5- 6 5- 6

BACK HOE TYPE SHOVEL 29. General

locations

.. . . . . . . . . . . . ..*..*............................................................................................................

6- 2

30. Instruments and controls .................................................................................................................

30.1 Switch ........................................................................................................................................

30.2 Control levers ...........................................................................................................................

30.3 Control box ...............................................................................................................................

30.4 Fuse box ...................................................................................................................................

66666-

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

31. Operation 31.1 Operation of work equipment ................................................................................................

31.2 Check before starting engine .................................................................................................

6- 8 6- 8 6-10

32. Precautions for machine operation 32.1 Precautions during operation

6-13 6-13

33 . Precautions

when

disassembling

................................................................................................. ................................................................................................. machine

.. . . . .. . . . . . . . .. . . . . .. . . .. . . . .. .. . . . .. . . . .. . . . . .. . . . . . . .. . . .. ...*...................

3 3 4 6 7

6-15

34. Maintenance .......................................................................................................................................

34.1 Oil filler and level gauge position .........................................................................................

34.2 Adjust bucket clearance ..........................................................................................................

34.3 Check before starting ..............................................................................................................

34.4 Every 10 hours sewice ............................................................................................................

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

35. Excavator

6-22

work

36. Transportation

. . .. . .. . . . . .. . . . .. . .. . .. . .. . . .. . . . . . .. . . . . . . .. .. ... . .. . . . . . .. . . . . .. . . . . . . .. . . .. .. . . .. . .. . .. . .. . .. . . . . . . . . . .. . .. . . . .. .. .. .......... . . .. . . .. . . .. . . . . . .. . . . . .. . .. . . . .. . . . .. . . .. . . .. . .. .. . . .. . .. . . .. . . .. .. . . . .. .. . . . .. ..*................................................

6-23

37. Introduction of attachment ..............................................................................................................

37.1 Attachment installation combination table ...........................................................................

37.2 Specification, use .....................................................................................................................

6-27 6-27 6-28

38. Specifications

6-29

O-8

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

SAFETY

result in serious

injury or death.

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

7-I

A WARNING:

For reasons of safety, always follow these safety precautions.

6. GENERAL PRECAUTIONS

c

-

SAFETY

RULES

l

ONLY trained

l

Follow all safety rules, precautions on the machine.

l

When working with another operator understand all hand signals that are

-

SAFETY

and authorized

personnel

can operate

and maintain

and instructions

or a person

when

the machine.

operating

on worksite

or performing

maintenance

traffic duty, be sure all personnel

to be used.

FEATURES

Be sure all guards damaged.

Use safety features

and covers are in their proper

positions.

and covers repaired

if

such as safety lock lever and seat belts properly.

NEVER remove any safety features. ALWAYS keep them Safety lock lever + See “12.15 PARKING MACHINE”.

Seat belts + See “27. USING SEAT BELT”.

Improper

Have guards

use of safety features

could result in serious

in good operating

bodily injun/

condition.

or death.

L

-I

CLOTHING

AND

PERSONAL

PROTECTIVE

ITEMS

}

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 -

A005501 0

l-2

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

6. GENERAL PRECAUTIONS

UNAUTHORIZED

MODIFICATION

l

Any modification

made without

l

Before making a modification, consult your Komatsu distributor. Komatsu for any injury or damage caused by any unauthorized modification.

i

-I

authorization

from

Komatsu

can create

hazards. will not be responsible

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT 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.”

El67470

i

MOUNTING

AND DISMOUNTING

NEVER jump on or off the machine.

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

Do not hold any control

NEVER get on or off a moving

always face the machine

levers when

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

getting

machine.

and use the handrails,

machine

or track

on or off the machine.

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.

AE306190

AE306200

AL187320

l-3

1

g 6. GENERAL PRECAUTIONS

-I

FIRE PREVENTION

FOR FUEL AND OIL

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

always

1

Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS. l Keep a flame away from flammable fluids. l Stop the engine and do not smoke when refueling. l Tighten all fuel and oil caps securely. l Refueling and oiling should be carried out in well ventilated areas. l Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.

A0055030

A0055020

4

A0055040

PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES

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.

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

2) Allow oil to cool.

3) Slowly loosen cap to relieve pressure

removing.

l

1-4

before

A0055050

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

-j

ASBESTOS DUST HAZARD PREVENTION

6. GENERAL PRECAUTIONS

1

Asbestos dust can be HAZARDOUS to your health if it is inhaled.

If you handle materials containing asbestos fibers, follow these guidelines as given below: 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.

A0055060

-I--CRUSHING ~~ l

OR CU-fTtNG PREVENTION

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.

.

4

FIRE EXTINGUISHER

AND FIRST AID KIT

o Be sure fire extinguishers

A0066090

1

have been provided and know how to use them.

l

Provide a first aid kit at the storage point.

l

Know what to do in the event of a fire.

o Be sure you know the phone numbers of persons you should contact in case of an emergency.

_

A0055070

1-5

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

6. GENERAL PRECAUTIONS

PROTECTION

AGAINST

FALLING

OR FLYING

OBJECTS

r

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 with breakers, demolition or shear work, install a front guard and FOPS (falling object protective structure) on the windshield. Also, place a laminate coating sheet over the windshield.

l

For work in mines, tunnels or other places where there is danger of falling rocks, put FOPS or top guard 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, you should put on other guards if required by conditions at your particular site.

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

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.

TOP guard

-

Laminate sheet

A0055200

coating AE30695B

Front

coat A0084310

sheet

ina

AE30696B

FOPS (falling object protective structure)

l-6

A WARNING: Failure to follow to a serious accident.

-

-

these safety precautions

PRECAUTIONS FOR AlTACHMENTS

may lead 6. GENERAL PRECAUTIONS

r

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 resulting from the use of unauthorized attachments will not be the responsibility of Komatsu. ’

MACHINES WITH ACCUMULATOR 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 with an accumulator, follow the procedure given in the inspection and maintenance section.

Method of releasing pressure + See ‘?I.‘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 OPERATION

4

DURING

A WARNING:

For reasons of safety, always follow these safety precautions.

SAFETY AT WORKSITE 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 as horizontal operations.

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”.

-

FIRE PREVENTION Thoroughly remove wood chips, leaves, paper and other flammable things accumulated on the engine compartment. They could cause a fire.

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

Check point + See “12.1/l WALK-AROUND CHECK”.

Be sure a fire extinguisher

is present in and working order.

A0055020

-

IN OPERATOR’S CAB I a 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, steps and handrails free of oil, grease, snow, and excess dirt.

l

Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged parts.

Always use seat belts when operating your machine.

Seat belts + See “27. USING SEAT BELT”.

1-8

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

-

VENTILATION l

7. PRECAUTIONS DURING OPERATION

FOR ENCLOSED AREAS

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

Exhaust

A0055060

, -

PRECAUTIONS FOR MIRRORS, WINDOWS

AND LIGHTS

l

Remove all dirt from the surface of the windows 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 keep 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 lamps are installed to match the operating conditions.

Check also that they light up properly.

-

EMERGENCY EXIT FROM OPERATOR’S CAB 1 l

If there is an emergency and the cab door does not open, use the rear window as an emergency exit.

l

To break the rear window, use the hammer which is installed to the front of the control stand.

Hammer

i nsta

11

POSi

t i On

AE3()fj21B

1-9

g 7. PRECAUTlONS DURtNG OPERATION

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

7.2 OPERATING MACHINE

4 l

WHEN

STARTlNG

ENGINE

1

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

a NEVER start the engine if a warning tag has been attached to the controls. l

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

l

Start and operate the machine only while seated.

l

Do not allow anyone other than the operator to ride in the cab or on the machine body.

l

For machines equipped with a travel alarm buzzer, check that the warning correctly.

device operates

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

rocket AE167'510

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

OR

in dangerous places or places

Make sure that no one comes inside the swing direction of travel.

radius or

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

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-10

A0066901

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

-I- PRECAUTIONS

WHEN TRAVELING

7. PRECAUTIONS DURING OPERATION

r

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 control levers have to be operated, never operate them suddenly.

When traveling on rough ground, travel at low speed, and avoid sudden changes in direction.

Avoid traveling over obstacles as far as possible. If the machine has to travel over an obstacle, keep the work equipment as close to the ground as possible and travel at low speed. Never travel over obstacles which make the machine tilt strongly ( IO0 or more).

INCORRECT

Travel posture

AE16752

AEl67530

Traveling on hills, banks or slopes that are steep could result in the machine tipping over or slipping.

On hills, banks or slopes, carry the bucket closer to the ground, approximately 20 to 30 cm (8 to I2 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 4 See “12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS”.

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

Uphill

Down hill

AE167540

INCORRECT

AD167550

may allow

CORRECT

AE167560

I-11

g 7. PRECAUTIONS DURING OPERATION

-I

PROHl5llED

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

always

OPERATIONS

l

Do not dig the work face under an overhang. This may cause the overhang to collapse and fall on top of the machine.

l

Do not carry out deep digging under the front of the machine.

INCORRECT

AE167570

4

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

l

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

l

The following actions are effective in preventing accidents.

I) Wear shoes with rubber or leather soles.

2) Use a signalman to give warning if the machine approaches too close to the electric cable.

a If the work equipment should touch the electric cable, the operator should not leave the operator’s compartment. l

When carrying out operations near high voltage cables, do not let anyone come close to the machine.

l

Check with the electricity company about the voltage of the cables before starting operations.

Min. safety distance

Voltage _

6.6 ~~ kV 33.0 kV

I I

3m

1

IOft

4m

I

l4ft

66.0 kV 154.OkV

1 1

5m 8m

1 ‘17ft 1 27ft

275.0 kV

1

IO m

(

33ft AE167580

I-12

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

-

DO NOT HIT WORK EQUIPMENT l

7. PRECAUTIONS DURING OPERATION

1

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

t -

ENSURE GOOD VISIBILITY l

When working in dark places, install working lamps and head lamps, and set up lighting in the work area if necessary.

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.

-

OPERATE CAREFULLY ON SNOW

1

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.

--

WORKING ON LOOSE GROUND 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.

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

Install the HEAD GUARD (FOPS) if working in areas where there is danger of falling rocks and dirt.

1

-

ELECTROMAGNETIC INTERFERENCE When this machine is operating close to a source of high electromagnetic radar station, some abnormal phenomena may be observed. l

The display on the monitor panel may behave erratically.

l

The warning buzzer may sound.

These effects do not signify a malfunction source of interference is removed.

interference, such as a

and the machine will return to normal as soon as the

1-13

7.

PRECAUTIONS DURING OPERATION

-I

OPERATIONS ON SLOPES

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

}

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.

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.)

if the machine has to be used on a slope, pile the a platform that will keep the machine as horizontal (See the lower diagram on the right.)

Piled soil on slope + See “12.12 PRECAUTIONS TRAVELING UP OR DOWN

soil to make as possible.

AE167590

CORRECT Plat

WHEN HILLS”.

.

4

form

AE167600

PARKING THE MACHINE 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 PARKlNG 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 ail the equipment.

Always take the key with you.

Work equipment posture + See “12.15 PARKING MACHINE”.

Places to lock 7 See “12.19 LOCKING”.

Method of locking

AE167470

1-14

A WARNING: Failure to follow to a serious accident.

these safety precautions

may lead 7. PRECAUTIONS DURING OPERATION

7.3 TRANSPORTATION

-

LOADING AND UNLOADING

1

Loading and unloading the machine always involves potential hazards. EXTREME CAUTION SHOULD BE USED. When loading or unloading the machine, run the engine at low idling and travel at low speed.

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

ALWAYS block the wheels of the hauling vehicle and place blocks under both ramps before loading and unloading.

ALWAYS use ramps of adequate strength. Be sure the ramps are wide and long enough to provide a safe loading slope.

Be sure that the ramps are securely positioned and fastened, and that the two sides are at the same level as one another.

Be sure the ramp surface is clean and free of grease, oil, ice and loose materials. Remove dirt from the machine tracks.

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

Swing the upper structure with extreme care on the trailer to avoid a possible accident caused by body instability.

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

Loading and unloading + See “13. TRANSPORTATION”.

Tie-downs + See “13. TRANSPORTATION”.

Distance between t-amps

-

AD052900

TRANSPORTING l

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

l

Determine the transporting load.

l

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

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

route while taking into account the width, height and weight of the

A 7. PRECAUTIONS DURING OPERATION

7.4 -

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

always

BATTERY BATTERY HAZARD PREVENTION

f

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 (+) terminal and negative (-) terminal.

Tighten the battery cap securely.

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

A00551

A0055100

4

STARTING WITH BOOSTER CABLES

10

r

ALWAYS wear safety glasses or goggles when starting the machine with booster cables.

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

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

If any tool touches between the positive (+) terminal and the chassis, it will cause sparks. This is dangerous, so be sure to work carefully.

Connect the batteries in .paraIlel: positive to positive and negative to negative.

When connecting the ground cable to the frame of the machine to be started, be sure to connect it as far as possible from the battery.

Starting with booster cables + See “16.4 IF BA‘TTERY IS DISCHARGED”.

INCORRECT

AD052960

I-16

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

7.5

-

7. PRECAUTIONS DURING OPERATION

LIFTING OPERATION LiFTlNG WORK

l

Lifting work is for bidden more over PC650.

I-17

8. .PRECAUTlONS MAINTENANCE

-

WARNING

FOR

-

A WARNING:

For reasons of safety, follow these safety precautions.

always

TAG

l

If others start the engine you could suffer serious

l

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.

l

When

l

These tags are available

this warning

or operate the controls injury or death.

while you are performing

tag is not being used, keep it in the storage from your Komatsu

distributor.

service or lubrication,

compartment.

(Part No. 09963-03000)

AD304180

-

PROPER TOOLS a Use only tools suited to the task. Using damaged, cause personal injury.

Tools + See “21.1 INTRODUCTION

low quality,

faulty, or makeshift

tools could

OF NECESSARY TOOLS”.

A0055120

4

PERfODIC REPLACEMENT OF CRITICAL SAFETY PARTS l

11

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

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

Replace or repair any such components the specified time.

Replacement

I-18

of whether

hoses or not they appear

if any defect is found, even though they have not reached

of critical safety components

*

See “22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS”.

these safety precautions

A WARNING: Failure to follow to a serious accident.

may lead 8. PRECAUTIONS FOR MAINTENANCE

STOP THE ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

-i l

Always stop the machine and maintenance.

on firm flat ground

and stop the engine

l

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

l

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

l

The worker carrying out the maintenance in the moving parts.

sho uld be extremely

before carrying

out inspection

such as when cleaning the and carry out the operation

careful not to touch or get caught

OFF

AD306230

-

RULES TO FOLLOW WHEN ADDING FUEL OR OIL

El67470

r

Spilled

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

Always

tighten

Never Always

it up immediately.

the cap of the fuel and oil fillers securely.

use fuel for washing

any parts.

add fuel and oil in a well-venti

A0055020

lated place.

A0055030

A0055040

1

I-19

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

8. PRECAUTIONS FOR MAINTENANCE

-I

RADiATOR WATER LEVEL

a If it is necessary to add water to the radiator, to cool down before adding the water.. l

1

Slowly

loosen the caps to relieve

L . fuel, oil, coolant,

pressure

stop the engine

before

removing

and allow the engine

and radiator

the caps.

USE OF LIGHTING

a When checking specifications.

If such lighting equipment

I-20

or battery

is not used, there

electrolyte, is danger

always

use lighting

of explosion.

with anti-explosion

A WARNING: Failure to follow to a serious accident.

these safety piecautions -.

may lead 8. PRECAUTIONS FOR MAINTENANCE

8.2 DURING MAINTENANCE r

PERSONNEL l

-

Only authorized personnel can service and repair the machine. Extra precaution should be used when grinding, welding, and using a sledge-hammer.

ATTACHMENTS l

Place attachments that have been removed from the machine in a safe place so that they do not fall. If they fall on you or others, serious injury could result.

A0055130

-I

WORK UNDER THE MACHINE

l

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

l

Always block the track shoes of the machine securely.

l

Never work under the machine if the machine is poorly supported.

A0055140

-

KEEP THE MACHINE

CLEAN

Spilled oil or grease, or scattered tools or broken pieces ares 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.

A0055150

I-21

A

8. PRECAUTIONS FOR MAINTENANCE

-

PRECAUTIONS WITH BATTERY l

When repairing (4 terminal of

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

always

L

the electrical system or when carrying out electrical the battery to stop the flow of current.

remove the negative

welding,

A0055170

-,

HANDLING l

l

4

HIGH-PRESSURE HOSES t

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

Always

Do not use any bent or cracked

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

PRECAUTIONS

WITH HIGH PRESSURE 01L

l

Do not forget that the work equipment

l

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

l

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.

l

If you are hit by a jet of high-pressure

A0055180

1-22

circuits

are always

oil, consult

under pressure.

or inspection

before completely

a doctor immediately

releasing

for medical

A0055190

the

attention.

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

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE HIGH TEMPERATURE OR HIGH PRESSURE l

8. PRECAUTIONS FOR MAINTENANCE

AT

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.

Cleaning inside or cooling system + see “24.3 WHEN REQUIRED”.

Checking cooling water level, hydraulic oil level + see “24.4 CHECK BEFORE STARTING”.

Checking lubricating oil level, adding oil + see “24.511

PERIODIC MAINTENANCE”.

Changing oil, replacing filters + see “24.3 - 9 PERIODIC MAINTENANCE”.

A0055050

PRECAUTIONS WHEN USING HIGH PRESSURE GREASE TO ADJUST TRACK TENSION I

1

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.

the plug or

in front of any grease

Adjusting track tension --) see “24.3 WHEN REQUIRED”.

4- ROTATING

FAN AND BELT rotating

1

l

Keep away from

parts and be careful

not to let anything

l

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.

get caught in them.

A0055210

l-23

8. PRECAUTIONS FOR MAINTENANCE

-

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

always

WASTE MATERIALS l

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

l

Always put oil drained from your machine in containers. Never drain oil directly on the ground.

l

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

of harmful objects such as oil, fuel,

INCORRECT

A0055220

l-24

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

AE306240

AE306250

9. POSITION FOR AlTACHING

SAFETY LABELS

.

1.

Precaution prior to operation (201-968-7760)

3.

Precaution prior to operation (201-968-7740)

.

i

201~968-77401 AD306260

AE304220

2.

Precaution prior to operation (201-968-7780)

4.

Caution for inspection (20E-OO-K1190)

* -_ AE304230

AD306270

l-26

9. POSITION FOR AITACHING

5.

7.

Caution while engine is running (201-968-7630)

SAFETY LABELS

Precaution when opening front window (201-968-7750)

AD306280

i c

1 201-968-7630 I’ AE304240

6.

Caution on accumulator (20E-OO-K12IO) (

4

\<AlilLLlh?, __ AD306290

l-27

9. POSITION FOR All-ACHING

8.

SAFETY LABELS

Keep out of the swing range (20 I-968-7670)

9:

Keep out of the arm range (20E-OO-Kl140)

AD306300

1201-968-7670 1 I

AE304250

10. Caution for falling (20E-OO-KI I 10)

1-28

AD306310

OPERATION

2-I

IO. GENERALVIEW

’

10.1 GENERAL VIEW OF MACHINE If directions are indicated in this section, they refer to the directions shown by the arrows in the diagram below.

Arm

Bucket

Bucket

CY

i

inder

Arm

Track

Boom

cylinder

shoe

idler

Boom

Track

cylinder

frame

Sprocket

AE30632B

2-2

10. GENERAL

10.2

VIEW

GENERAL VIEW. OF CONTROLS AND GAUGES Bottom

left control

dump

Travel

switch

Machine

lever A

monitor Bottom

I

dump

switch

war k equipment I ever \

Travel selector Low start

speed switch temperature ina aid

Swing

\u\

Parking

‘Start

switch

ins

I ighter

leratian ch

1

\

Horn

/

Swing

brake

switch\

/

)

I

switch AEl67690

Hydraulic clogging

Engine water temperature \

Fue I

gauge

filter monitor

Engine

N

oil

Mode selector (OLSS) swi tch

-Radiator Radiator

water

level,

oil

level-

water

-Radiator

oi I

ic

Pre-heat ins’

Service

oi I mon i tor

switch

level‘Charge

Engine monitor

monitor

temperature Lamp

Hydraulic

level

water temperature

1HYdraul Engine

Pressure

\

level

Lamp switch (Working lamp)

meter’

\

Wiper

switch AD30633B

2-3

II

l

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

D

A

B

D

D

‘E AD306340

This monitor system consists of monitor lamp groups @, @, 01, meter group 0, switch group 0.

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, lamp will go off even if there is an abnotmality.

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

2-4

11. EXPLANATION OF COMPONENTS

B.

CAUTION

ITEMS (11.12)

~s:e:uT’oN’~l If these

monitor

items flash, check and repaw the appropriate

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 (I 1 .I .3)

3AcAuT’oNA If these monitor items flash, stop operattons then check and repair the appropriate location.

Immediately,

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.

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

D.

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 for breakage until 30 seconds after the engine has been stopped.

2-5

11. EXPLANATION OF COMPONENTS

AD306350

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 1 the periodic maintenance items or “12. OPERATlON” 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.

!

2.

AD081410

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.

AE081420

2-6

1 I. EXPLANATION OF COMPONENTS

3.

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

11.1.2B: CAUTION

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

AE084320

ITEMS

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

If the monitor lamp flashes, check the V-beft tension. If any abnormality is found, see “16.5 OTHER TROUBLE”.

I

+ rl

I

A~104360

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

11. EXPLANATION OF COMPONENTS

11.1.3 C: EMERGENCY

STOP ITEMS

AD306360

nACAUnoa/

If any monitor lamp flashes, stop the engine or run rt at low idling, and take the following action.

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.

AE081460

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.

AD081410

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 “16.5 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

AE081480

11. EXPLANATION OF COMPONENTS

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.

4.

IL.

6 Ll

cmmI(

AD081490

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.

ADO81500

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

AD306370

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.

Z-10

AE081430

11. EXPLANATION OF COMPONENTS

METERS Red

2.

ENGINE COOLING WATER TEMPERATURE GAUGE This gauge indicates the temperature of the cooling water. If the temperature is normal during operation, the green range will light.

If the red range lights during operation the alarm buzzer will sound 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.

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.

H

Green

Whited

al C AD30638B

3.

Green

,

Red AD30639B

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 While engine is running, the green pilot lamp on the service meter flashes to show the service meter is advancing. l The service meter progresses by 1 when the engine is operated for one hour, regardless of the engine speed.

AD08Y 550

2-1 I

1 I. EXPLANATION

OF COMPONENTS

11.1.5 E: SWITCHES

AD306400

1.

MODE SELECTOR (OLSS) SWITCH This switch is used to change the model.

’

H: For heavy duty work or traveling at high speed.

S: For general work L: For light duty work For guidance on the model selection, see “12.9 WORKING MODE SELECTION”.

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

AE081570

0

2.

0

0 0 E B

2-12

T 1 0

II

0

0

AE081580

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.

0 0

T 1 0

= cl

0 LI

II

0

0

AEO81580

4.

WIPER SWITCH This switch is used to turn on the front windshield wiper.

ON: For operation W: For splashing detergent over windshield glass

AEO81590

2-13

11. EXPLANATfON OF COMPONENTS

11.2 LAMP

AE167940

1. SWING LOCK LAMP

If the lamp does not light up when the swrng lock switch IS ON, please contact your Komatsu distributor.

1* cAuT’oNI This informs the operator Actuated: Lights up

that the swing

lock is being actuated.

NOTICE When the swing lock switch is turned ON (ACTUATED), the lamp lights up.

2-14

AE081620

11. EXPLANATION OF COMPONENTS

11.3 SWITCHES

AE167960

I.

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

@ (STOP) position The key can be inserted or withdrawn. All the switches for the electrical system are all turned off and the engine is stopped.

1 (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.

AE3064IO

0 (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

II.

EXPLANATION OF COMPONENTS

2.

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

1 (ON) position: Starting aid is being operated.

0 (OFF) position: Starting aid is cancelled.

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

J

I

Front

of

machine

CIGARElI-E 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.

Nothing may be connected to the cigarette lighter without the prior permission of an authorised Komatsu distributor.

AE30642B

3.

n

AE306436

4.

SWING PARKING BRAKE SWITCH This actuates the swing mechanical brake.

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. a (OFF) position: 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.

Free

a

6 (ON) position:

NOTICE During swing operations, do not put the swing parking brake switch into ON.

2-16

Front L

of

machine

AE30644B

11. EXPLANATION OF COMPONENTS

5.

SWING BRAKE SWITCH This is used to actuate the swing mechanical brake automatically.

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

I

Front

of

machine

Front

of

machine

AE30645B

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

Pl dmin

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

7.

AE30646B

Ll

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.

Front

of

machine

AE168040

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

2-17

1

11. EXPLANATION OF COMPONENTS

8.

BUCKET MOVEMENT SELECTOR SWITCH This switches between arc digging and automatic horizontal digging.

Horizontal 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 Arc diggi ng: working range.

Front

of

machine Horizonta

r

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

I Arc

With compe

Horizontal 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.

9.

AE168050

Front

of

machine

AE168060

BO-TTOM DUMP SWITCH These switches open and close the front bucket.

OPEN:

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

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

AE168070 L

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

r

AE083980

2-18

11. EXPLANATION OF COMPONENTS

AE168080

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

AE168100

A

WARNING

A

WARNING

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

1.

SAFETY LOCK LEVER

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

AE168120

‘Il.

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.

'166120

2.

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

WARNING

Do not put your foot on the pedal unless the machine is traveling. If 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.

01 N

0 AE081730

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.)

These levers (and pedals) are used to operate the left and right travel motors. @ FORWARD: The lever is pushed forward (The pedal is angled forward) @ REVERSE: The lever is pulled back (The pedal is angled back) N (Neutral): The machine stops

(

): This indicates operation of the pedal.

2-21

11. EXPLANATION OF COMPONENTS

3.

I

LEFT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device) 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.

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

Swing operation Arm operation @ Arm OUT @ Swing to right @ Arm IN @ Swing to left 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 LEVER (with auto-deceleration device)

If any lever is operated when in the deceleration range the engine speed will suddenly Increase, so be careful when operating the levers. “w*““‘“-7 AE168 140

This lever is used to operate the boom and bucket.

Bucket operation Boom operation @ DUMP @ RAISE @ CURL @ LOWER 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

a

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

WARNIN-

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 ceiiing 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, grasp the handle.

Do not push in grasping staydumper @.

2-23

Il.

EXPLANATION

11.6

OF COMPONENTS

FRONT WINDOW

with both hands and pull up. If you use only one hand; your

It is possible to store (pull up) the front window (top) in the roof of the operator’s compartment.

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

3.

Place the work equipment on flat ground and stop the engine.

2.

Securely lock the safety lock lever.

AE081770

AE167470

3.

Disconnect wiper motor cable from receptacle @.

4.

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

AE081780

2-24

1I. 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.

I 6.

AEO81760

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

I

I

I

I

AE097240

When closing

c

a WARNING When closing the window, lower it slowly and be careful not to get your hand caught.

1.

Place the work equipment on flat ground and stop the engine.

2.

Securely lock the safety lock lever.

4

AE167470

3.

Release the lock pin @

AE081780

4.

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 @ 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.

AE087790

2-25

1

11. EXPLANATION OF COMPONENTS

5.

Lock securely with lock pins @ at the left and right sides.

6.

Connect wiper motor cable from receptacle @.

11.7 DOOR LOCK Use the door lock to fix the door in position after opening it.

1.

The door will become fixed in place when it is pressed against 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.

10

11.8 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

?I. EXPLANATION OF COMPONENTS

11.9 AIR CONDITIONER 11.9.1

CONTROL PANEL

1. Outlet change-over knob Switches over air outlets

l

Knob position

Air outlet

Purpose

Floor

Heating Dehumidity

Rear

Cooling

FOOT =R

-IL?._!

FACE z -0

AE168t70

Heater temperature

knob

Controls heating temperature The nearer to WARM MAX. the knob goes, the higher heater outlet air temperature will 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

11.92

OPERATION

Cooling Set the knobs to the following positions and a cool breeze will be flowed in from the rear vents. l Outlet change-over knob (ij: FACE l Heater temperature knob 0: OFF l Blower switch 0: See table below. l Cooler temperature knob @: See table below.

1

/ co~~~~pm

HIGH I 1 MEDIUM-LOW

I

HlGH

Normal cooling

1

MEDIUM

Gradual cooling

1

I

LOW

_

Blower switch @

Quick cooling

LOW

Heating Set the knobs to the following positions, then warm breeze will be flowed in to the 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 @: OFF

(1

He~~~~p* Quick heating Normal heating Mild heating

HlGH

I ]

MEDIUM

I

LOW

/ Blower switch @ 1

HIGH

1 MEDIUM or LOW I LOW AE168190

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 @: HIGH

Control knob

Winter

2-28

Heater temp.

I

HIGH

Blower switch @

1

HIGH

Normal heating

MEDIUM

MEDIUM

Autumn

or LOW

or LOW

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 6.5OC, 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 6OC 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

11.10.1

EXPLANATION

OF COMPONENTS

b 3

AE097290

1.

TUNING KNOB (TUNING) Turn this knob in to the desired station.

Turn right in to the station. lf 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 these buttons it is possible to tune in to preset stations.

5.

POINTER

Z-30

\

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 back the 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.

AE097320

11.10.3 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. l Do not wipe the dial plate or knobs with benzine or paint thinners, etc. Afways use a dry, soft cloth (if the radio is particularly dirty, soak the cloth in alcohol). l Do not disassemble the radio. l

11.10.4 TROUBLESHOOTING GUIDE No sound l Turn the SW/VOL knob to the right and press it two or three times.

Sound quality is poor.

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

2-31

11. EXPLANATION OF COMPONENTS

11.11 FUSE

NOTiCE Before replacing a fuse, be sure to turn off the starting switch.

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

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

Replace a fuse with another of the same capacity.

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

Name of circuit @ )

10 A

1 Front lamp

@ 1

10 A

1 Working lamp

10 A

) Spare

01

IOA

IM onIl t or, OLSS, Work equipment controller

@ 1

20 A

1 Air conditioner

0

10 A

1 Swing lock brake, Travel speed, Buttom dump

@I

IOA

(I-4 orn, Room

@ I

20 A

( Wiper, Room lamp

@ 1

20 A

1 Cigarette lighter, Radio

@

2-32

1

1

lamp (engine room), Filter clogging timer

ADO52120

11. EXPLANATION OF COMPONENTS

II .I2 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

>I

~~

Machine is normal in the mode “S” and auto-

/ decelerator is not applied

oG;;eS / Lights

f;es

~~ Condition of machine

1 Fi%;hes

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

Goes

Off

Flashes slowlv

Machine is normal and auto-decelerator is applied

@ Work equipment controller Indication of LED Green

Red

Red

Red

Lights

Horizontal digging mode

Goes Off

Flashes

Goes ’ off Goes Off

Lights Lights or flashes

Condition of machine Arc digging mode

Goes off

Goes

Goes Off

ARM OUT hydraulic switch actuated BOOM RAISE/LOWER hydraulic switch actuated

Lights

Off

Horizontal digging + bucket angle compensation mode .

IN BUCKET hydraulic switch Lights ARM actuated

11.13 TOOL BOX This is used for keeping the tools

L

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

Il.

EXPLANATION OF COMPONENTS

11.15 HANDLING GREASE PUMP

Q 1

INSTRUCTIONS FOR USE 1. When the lever of grease gun @ is pulled, grease is forced out and the pump also begins to work automatically.

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

PRECAUTIONS FOR USE When greasing the machine, set the grease gun so that the nozzle is vertical to the nipple.

l

AE082080

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

l

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 @ from inside can.

4. Pack grease can @) with new grease and set folllow plate @ on top of grease in grease can.

AE082100

Fit the cone in the center of the follow plate with grease before insertion.

5.

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

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.

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

After bleeding air, tighten check valve @ securely.

2-34

AE082110

11. EXPLANATION OF COMPONENTS

8.

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

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 E-liter can. If an l8-liter can is used, more grease will be left in the can.

2-35

11. EXPLANATION OF COMPONENTS

11.16 HANDLING

ACCUMULATOR

A

WARNING ‘I

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. l If accumulators break down or have trouble, immediately ask your Komatsu distributor to carry out repairs. l Only Komatsu personnel and those licensed to service high pressure equipment may recharge an accumulator with nitrogen. l Never overhaul or dispose of an accumulator without first bleeding out all the nitrogen through the air bleeder valve. l Have your Komatsu distributor check the gas pressure once a year. l Never make any hole in the accumulator or expose it to flame or fire. l Do not weld any boss or make any hole in to the accumulator. or disposing of the accumulator, it is l When overhauling 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.

The act umulator is installed to the track frame and inside of left deck (each) .

2-36

11. EXPLANATION OF COMPONENTS

11.16.1 METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR 1. Place the work equipment on the ground.

2.

Stop the engine.

3.

Move the safety lock lever to the free position. Move the work equipment control lever and forth, right and left so as to release the pressure in the control circuit.

4.

Move the safety lock lever to the lock position. Lock the control lever. The pressure, however, will not be completely released, so when the accumulator is removed in the control circuit, gradually toosen the screws. Never stand in the oil ejection direction.

2-37

11. EXPLANATION OF COMPONENTS

II.17

LUGGAGE BOX

On rear surface of operator’s cab.

Ordinally, operation & maintenance manual should be stored in this, and able to read the manual every time.

11.18 METHOD OF RELEASING PRESSURE IN

CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR 1.

Place the work equipment on the ground.

2.

Stop the engine.

3.

Move the safety lock lever to the free position. Move the work equipment control lever and the attachment control pedal to full stroke back and forth, right and left so as to release the pressure in the control circuit.

4.

Move the safety lock lever to the lock position. Lock the control lever and attachment control pedal. The pressure, however, will not be completely released, so when the accumulator is removed in the control circuit, gradually loosen the screws. Never stand in the oil ejection direction.

11.19 LOCATION OF FIRE EXTINGUISHER When providing a fire extinguisher, install it in the position shown right.

Position for installing fire extinguisher.

\

2-38

l

'AE306480

12. OPERATION

12.1 CHECK BEFORE STARTING ENGINE Perform following checks for operator safety and maintenance of machine performance.

12.1.1 WALK-AROUND

CHECK

A l

WARNING

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 before starting the engine each day.

2

9

5

7

8

2 AE168560

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.

2-39

.

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

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 of water from radiator

7.

Check tightness of air cleaner mounting

8.

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

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

9.

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.

bolts

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

For detail see MAINTENANCE ING”.

2-40

“24.4 CHECK BEFORE START-

12. OPERATION

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

CHECK COOLANT 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.

AE168590

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the engine hood.

2.

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

3.

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

4.

The oil level should be between the H and t marks on dipstick 8 .

If the oil level is below the L mark, add engine oil through oil filler oThe dipstick is marked with the levels for ENGINE STOPPED on one side and ENGINE IDLING on the other side.

Check the oil level, STOP the engine STOPPED side.

and with the ENGINE

is

I

ii’ CI, -I

0

P

Y

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.

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

2-41

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

a fire. If you spill fuel, thoroughly

I

clean up any spillage.

I

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, add fuel through filler port @ while watching sight gauge 8.

Fuel capacity:

1140 e (301.2 US gal, 250.8 UK gal)

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

3.

After adding fuel, tighten the cap securely.

AE168640

r REMARK If breathei 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

2-42

12. OPERATION

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

l

l

a WARNING 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.

‘I.

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.

2.

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.

3.

Checksight gauge 8. The oil level is normal if between the H and L marks.

AE084210

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.

tf 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 leveI will vary depending upon the oil temperature.

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

w

AEl68670

AE082220

2-43

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 WIRlNG

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.

etc.) around the battery may cause fire, so always check and

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.

2-44

80

12. OPERATION

DRAIN WATER AND SEDIMENT FROM FUEL TANK 1. Loosen drain valve (iJ and drain the water and sediment at the under tool box of right side.

2.

After draining, tighten drain valve @ securely.

AE168690

CHECK MONITOR 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 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 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”.

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”.

AE168720

2-45

12.1.3 OPERATOR’S SEAT dh WARNING Adjust the seat position before starting operations or after changing the operator.

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

l l

A:

Fore-and-aft adjustment Move lever @ to right. After the seat is set to the desired position, release the lever.

Adjustable distance: 160 mm (6.3 in) in 10 steps B: Adjusting reclining

-

NOTICE The seat can be reclined to a large angle when the seat is pushed fully forward, but the reclining angle is reduced when the seat is moved back, so when moving the seat to the rear, return the seat back to its original position.

Pull lever @ and set the seat back to a position which is comfortable for operation, then release the lever.

Sit with your back against the seat back when adjusting. If your back is not touching the seat back, the seat back may suddenly move forward.

C: Adjusting seat tilt 1. Forward tilt ( $& ) Push lever @ down to adjust the angle of the front of the (5 stages) 1) To raise the angle at the front of the seat, keep the pushed down and apply your weight to the rear of the 2) To lower the angle at the front of the seat, keep the pushed down and apply your weight to the front of the 2.

seat. lever seat. lever seat.

Rear tilt ( 3 ) Pull lever @ up to adjust the angle of the rear of the seat. (5 stages) 1) To raise the angle at the rear of the seat, keep the lever pulled up and stand up slightly to remove your weight from the seat.

2) To lower the angle at the rear of the seat, keep the lever pulled up and apply your weight to the rear of the seat.

Amount of tilt: Up 13”, down 13” 3)

2-46

Adjusting seat height It is possible to move the seat up or down by combining adjustments 1 and 2.’

After setting the forward tilt or rear tilt to the desired height, operate the opposite part to set the seat horizontal then secure in position.

Height adjustment: 60 mm (2.4 in)

dV 3

AE306510

12. OPERATION

D: Adjusting suspension (option) Turn knob @ to the right to make the suspension harder, or to the left to make the suspension softer. Adjust the reading of the dial to match the operator’s weight and select the optimum suspension.

REMARK To obtain the optimum adjustment, turn the knob so that the indicator of the weight display (kg) in the transparent portion of knob @ is the same as the operator’s weight.

2-47

12. OPERATION

12.1.4

OPERATIONS AND CHECKS BEFORE STARTING ENGINE

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

1.

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

2.

Check the position of each lever.

Set the control fever @ to the neutral position.

3.

Insert the key in starting switch @, turn the key to the 1 (ON) position, then carry out the following checks.

(1) Check that all the monitor approx. three seconds, all gauge lamps go out.

After checking the monitor switch @ to the @ (STOP)

lamps light up, and that after the monitor lamps except the lamps, return the key of starting 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.

2-48

AE306520

12. OPERATION

12.2 STARTING ENGINE 12.2.1 NORMAL STARTING

Check that there are no persons or obstacles in the surrounding start the engine. . Aearea, then sound the horn and wARN’NG NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.

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

1.

Set fuel control lever @ at the middle position.

Half open position

2.

Turn the key in starting switch @ to the 0 engine will start.

(START) position. The

AE306530

3.

When the engine starts, release the key in starting switch 0. The key will return automatically to the 1 (ON) position.

AE306540

2-49

12. OPERATION

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

A

WARNING

l

Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.

l

Never use starting aid fluids as they may cause explosions.

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

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

When starting in low temperatures, do as follows.

I. Open the fuel lever 0 for APS. 2.

Set fuel control lever @ at the STOP position.

AE168830

3.

Hold the key in starting switch @ at the 0 (START) position, and keep the starting motor rotating for 10 seconds.

Then, set the key @ at the 1 (ON) position.

(If release the key, it will return automatically to the 1 (ON) position .)

AE306530

4.

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

AEl68850

2-50

12. OPERATION

5.

Set the low temperature starting aid switch @ to 1 (ON) position.

The low temperature starting aid monitor lamp flashes.

REMARK Even if the ambient temperature is below 15°C (59”F), 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.

& 8 9 Front

of

machine

acr •l AE30642B

I

6.

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

REMARK Preheating is completed after approx. 80 seconds, and the monitor lamp become flash to light up.

I 7.

AE081430

When the monitor lamp light up, turn the key of starting switch @ to the 0 (START) position and start the engine.

AE306560

8.

When the engine started, release the key of starting switch @ and the key will return automatically to 1 (ON).

AE306540

9.

When the engine runs smoothly and the color of exhaust gas becomes normal, put the low temperature starting aid switch @ in the 0 (OFF) position.

The low temperature starting aid monitor @ goes off.

Front

of

machine

AE30657B

2-51

I

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.

Ambient temperature

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

15 - O°C (59 - 32°F)

1 - 2 minutes

Below 0°C (32°F)

3 - 5 minutes

NOTICE 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 If 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 If the switch is moved to START while the tow temperature starting aid monitor lamp is flashes, glow plugs wiII get wet, makiirg 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.

2-52

12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE Ah WARNING l

l

Emergency stop If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position. lf 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 life. 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 80°C (122 to 176°F). If the machine is operated after raising the oil temperature to 20°C (68”F), the life of the machine will be extended.

-0 68900

After starting the engine, do not immediately start operations.

First, carry out the following operations and checks.

-

_-

AE1689

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

\

AE168920

2-53

12. OPERATION

2.

Set the safety lock lever @ to the FREE position.

AE168930

3.

Leaving bucket control lever @ in tilt side, run the engine for 1 about 5 minutes to warm up the hydraulic oil.

AE168940

NOTICE Avoid abruptly accelerating the engine until the completion of warm-up.

4.

After warm-up run is completed, check gauges, monitor lamps for proper operation.

Continue to run the engine at light load until the engine water 1 temperature gauge falls within the green range.

I 5.

2-54

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

RED

105°C (221°F) 10&3”C (21 5.&5.4°F) 97°C (206.6”F)

GREEN

90°C (194°F) 80°C (176°F)

AE082370

12. OPERATION

12.4 MOVING MACHINE OFF 12.4.1 MOVING

MACHINE

A

FORWARD WARNING

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 is safe, and sound the horn before moving.

Clear all personnel from the machine and the area.

Clear all obstacles from the path of the machine.

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.

h

1. Set swing parking brake switch @ to the ON ( u ) position and confirm that swing lock lamp @ lights up.

AE306580

2.

Set fuel control lever @ towards the full speeed position to increase the engine speed.

\

AE168980

2-55

1

12. OPERATION

3.

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

4.

Operate right and left travel levers @ or right and left trave pedals @ as follows.

0

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

Sprocket

/ AE168990

0

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.

Sprocket AE169000

2-56

12. OPERATION

12.4.2 MOVING

MACHINE

A

BACKWARD WARNING

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

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

Clear all personnel from the machine and the area.

Clear all obstacles from the path of the machine.

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

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.

60

1.

Set swing parking brake switch @ to the ON ( tj ) position and confirm that swing lock lamp @ lights up.

n

I 2.

AE306680

1

Set fuel control lever @ towards the full speed position to increase the engine speed.

Fu I i

I

\

AE168980 1

2-57

12.

OPERATION

3.

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

/

./

v ./ X.1 /

\

\

Freea

@

\ Locke

4.

Operate right and left travel levers @ or right and left travel pedals @ as follows.

c AEl68930

T mll

Sprocket

0

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.

AE169010

I

@

Sbrocket

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.

2-58

AE169020

12.5 STEERING MACHINE 12.5.1STEERING (CHANGING

A

DIRECTION)

WARNING

a Before operating the travel levers, check the position of the sprocket. l If the sprocket is at the front, the operation of the travel levers is reversed. l 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 direction of machine when stopped When turning to the left: Push the right travel lever forward to travel left when traveling forward; and pull it back to turn left when traveling in reverse.

Turning left when travel forward

ins

Turning left when traveling in reverse

REMARK When turning to the right, operate the left travel lever in the same way.

AE169050

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 the right travel lever in the same way.

Turning left when traveling forward Turning left when travel in reverse

ins

AE169060

2-59

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 iever forward.

AE169070

Z-60

12. OPERATION

12.6 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.

1

hrust

the

bucket AE167610

F

167470

AEl69090

1.

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

2-61

12. OPERATION

2.

3.

Lower the engine speed using fuel control lever 0.

Lower

the bucket horizontally

until its underside touches the

ground.

4.

Place lock lever @ to the lock position.

AE168850

2-62

12. OPERATION

12.7 SWINGING A WARNING

2 1.

l

When operating the swing, check that the area around the machine is safe.

l

During swing operatoins, do not put swing lock switch Q) to ON .

Before swing operations, put swing parking brake switch @ to OFF ( a ) and confirm that swing lock lamp @ goes off.

I 2.

Operate left work equipment control lever @ to swing the upper structure.

Right

L

3.

AE306590

%

I/-

AE169140

(8 L

When not operating the swing, turn swing lock switch @ ON

AE306580

2-63

I

12. OPERATION

12.8 OPERATION OF WORK EQUIPMENT

-J

I

Arm

in

Ar

If any lever is operated when in the deceleration range, the be careful when oper-

: 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

Swi

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.

--

om i se

Boo I ow

I

REMARK I If the levers are operated within 15 seconds, it is possible to B lower the work equipment to the ground. d The levers can also be operated to release any remaining pressure inside the hydraulic cylinder circuit.

AE189180

/

-e-

I

AE169190

ICI ose

- -

2-64

AE169210

12. OPERATION

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.

0

Guidance for use

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

Digging

/ Leveling-

Loading

/ a:(f$:gl

cr~~~~g

Carrying

I

I I

Type of soil

II

III

I

II

III

I

II

III

I

II

III

\ Soft clay

HSLHSLLLLHSL H

Crumbled sandy soil

Ho;

Compact sandy soil

HSLHSLSLLS--

Gravel and ore

H

Hp

L

H

Hp

L

S

S

L

S

-

-

Compact soil containing gravel

H

Hp

L

H

Hp

L

H

Hp’

L

L

-

-

Soft rock

H

Hp

Hp

H

Hp

Hp

H

Hp

Hp

L

-

-

Flat ground: S Slopes and long distance travel: H

MODE SELECTOR SWITCH (OLSS) The letters H, S and L in the table refer to the positions of the switch in the right figure. l Hp refers to use in H mode at partial throttle (80% of engine

l

output).

AE081570

2-65

.

32. OPERATION

12.10 PROHIBITIONS FOR OPERATION

A

WARNING

If 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.

INCORRECT

c

INCORRECT

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

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

These operations will damage the work equipment.

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.

AE1692 30

INCORRECT

AE169240

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.

A

INCORRECT

INCORRECT

I

AE169260

2-66

]

12. OPERATION

..-

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

w It is prohibited to grip rocks.

Do not use the bottom dump bucket to grip rocks.

AE169280

INCORRECT

AE169290

It is prohibited to use the bucket for leaving operations.

Using the rear bucket to carry out leveling operations will bring an excessive force to bear on the work equipment, so do not use the rear bucket in this way.

AE169300

Be careful not to spill the load.

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

INCORRECT

AE169310

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.

INCORRECT

169320

2-67

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.

2-68

12. OPERATION

12.11 PRECAUTIONS

FOR OPERATION

INCORRECT

PRECAUTIONS WHEN TRAVELING 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.

AE167530

PERMISSIBLE WATER DEPTH NOTICE When driving the machine out of water, if the angle of the machine exceeds 15”, the rear of the upper structure will go under water, and water will be thrown up by the radiator fan. This may cause the fan to break.

Be extremely careful when driving the machine out of water. c/

Do not immerse the machine in water by more than the permis- ’ sible 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)

-7

AE169340

AE1693

2-69

12. OPERATION

12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS A

WARNING

When traveling, raise the bucket approx. 20 - 30 cm (8 - 12 in) from the ground.

Do not travel downhill in reverse.

AE169360

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.

If the machine starts to slide or loses stability, bucket immediately and brake the machine.

lower the

I

1)

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

Platform

AE099790

I

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 ISo, set the work equipment in the posture shown in the figure on the right, and lower the engine speed.

\20-30cm

2)

INCORRECT

INCORRECT

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.

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.

(8tOl2id

AE167540

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

AD167550

2-70

i

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.

2-71

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 11oo.

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.

2-72

12. OPERATION

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.

AE084250

2-73

12. OPERATION

12.15 PARKING MACHINE

A suddenly.

WARNING

Give yourself ample room when

l

Avoid stopping stopping.

l

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.

l

Thrust

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

I.

Put left and right travel levers @ in the neutral position.

The machine stops.

AE082470

2-74

12, OPERATION

2.

Lower fuel control lever @ to lower the engine speed to low idling.

\ 3.

Lower the bucket horizontally ground.

AE168850

until the bottom touches the

AEOS4210

4.

Set safety lock lever @ in the LOCK position.

,El67470

12.16 CHECK AFTER FINISHING

WORK

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

engine oil pressure and

2-75

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 tow 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

3.

2-76

Turn the key in starting switch @ to the @ (STOP) position and remove the key.

idl

ins

12. OPERATION

12.18 CHECK AFTER STOPPING ENGINE 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.

Fill the fuel tank.

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

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.

AE169490

2-77

13. TRANSPORTATION

-

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

For transport, disassemble the machine into the upper structure, undercarriage, attachments and counterweight.

After disassembling, load and unload the machine body as follows.

13.1 LOADING, UNLOADING WORK

A

WARNING

l

Loading or unloading the machine can be a dangerous operation, so be particularly careful.

l

When loading and unloading the machine, stop the engine.

l

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

l

and the machine.

Always check that the door on the cab is locked, regardless of whether it is open or closed.

Do not open or close the door on ramps or on a platform.

This may cause a sudden change in the operating force.

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

When transporting the machine, place rectangular timber underneath center frame and the rear rev frame to prevent the machine from moving about. Also, hold it down with chains or rope. Be particularly careful to ensure that the machine does not slip sideways. .

AE306620

13.2 PRECAUTIONS FOR TRANSPORTATION l

l

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

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. Obsewe all regulations governing wide loads.

2-78

13. TRANSPORTATION

13.3 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 di’sassembly 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)

AE169520

Weight: 90 kg (198 lb)

AE169530

2-79

13. TRANSPORTATtON

Width: 2,000

Weight:

14,800 kg (32,630 lb)

Weight:

14,000 kg (30,870 tb)

Weight:

8,200 kg (18,080 Ib)

Weight:

2,100 kg (1,200 x 2) (4,630 lb (2,315 ~2))

Weight:

130 kg (287 lb)

AE169540

AE169550

Width: 2,800

Width: 480

AE169560

AE169570

AE169580

Z-80

13. TRANSPORTATION

Total weight: 410 kg (904 Ib) Weight 2 kg x 3 (4.4 lb x 3)

Weight 30 kg x 2 (66 lb x 2)

Weight 5 kg (11 lb)

Weight 120 kg x 2 (265 lb x 2)

Weight 60 kg (132 lb)

Weight 25 kg (55 lb)

Weight 7 kg x 2 (15 lb x 2)

AE169590

Total weight: 559 kg (1235 lb) Weight 18 kg (40 lb)

Weight 23 kg (51 lb)

Weight 27 kg (60 lb)

Weight 30 kg (66 lb)

AD306630 AD306640

AD306660

A0306650

Weight 47 kg (104 lb)

Weight 54 kg (119 lb)

Weight 360 kg (795 lb)

AD306670

AE306680

(

AE082950

2-81

13. TRANSPORTATION

13.4

PROCEDURE

FOR RAISING

A

1

CHASSIS

WARNING

l

Always use lifting equipment of ample strength. Never use damaged or deteriorated wire rope or other lifting equipment.

l

Please contact your Komatsu distributor for details of the correct methods for lifting and for information on the size and type of lifting equipment.

l

When carrying out lifting operations, set the lock lever to the LOCK position, and take other steps to prevent the machine from moving by accident.

l

Do not apply any sudden load to the wire rope or other lifting equipment.

l

Do not go under or near the machine or under the load when there is a raised load.

The procedure for raising the main units when the machine has been divided into parts is as follows.

1.

Raising upper structure

.

After opening cover @ and removing handrail @, fit the wire rope to the boom foot pin @ and the lifting holes of rev frame

Lifting load:

24 ton

Combination of wire ropes @ 5mor@6m

@ 6mor@7m When using any rope other than the rope described above, always use wire rope of the lengths given above.

Set the wire ropes so that the slinging position is immediately above the center of gravity of the machine.

Raise with the crane until there is no slack in the wire rope, then check the balance and raise slowly.

2-82

Center

of

gravity AE30669B

13. TRANSPORTATION

2.

Raising undercarriage Fit the wire rope to the holes in the links, then check the balance and raise slowly.

AD04370

3.

Raising counterweight Install hooks at 2 places on the top of the counterweight, fit the wire rope.

then

AE304280

4.

Raising cab Install hooks at 3 places on the top of the cab, then fit the wire rope.

5.

Raising arm Fit the wire rope to the bucket mounting pins at the tip and the arm cylinder mounting pin.

B/H

AE30670B

I

AE30671B

2-83

13. TRANSPORTATION

6.

Raising boom Fit the wire rope to the center boss on both sides of the boom and the arm mounting pin at the tip of the boom.

AE30672B

AE30673B

7.

Raising bucket Fit hooks and the wire rope to the bucket pin holes.

AE30675B

8.

Raising boom and arm cylinder Fit the wire rope to the cylinder head and the piston rod, and raise so that the piston rod does not extend.

AE304330

2-84

13. TRANSPORTATION

9.

Raising catwalk The catwalk is long, so sling at 2 places on diagonally opposite sides, then lift off.

AE306760

AE306770

AE306780

10. Raising FOPS Install hooks at 3 places on the top of the FOPS, then fit the wire rope.

AE304350

13.5

SECURING

MACHINE

1. Set the lock lever to the LOCK position.

2. Turn all the switches OFF and remove the key.

3.

Lock all the caps, doors, and other components.

4.

Cover the left and right console boxes, operator’s seat, and instrument panel to protect them from dust and moisture.

5.

If the undercarriage has been removed, fit wire ropes to the mounting holes in the countemveight and the boom foot mounting pin, and tie the machine down securely.

tE167470

I

/

AE304390

2-85

13.6 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE

.

REDUCING TRACK GAUGE I 1. Remove center frame mounting bolts 0. (one side, front + rear: 32 bolts)

.

A

E082960

2.

Swing the upper structure to the track frame @ side to be retracted until the upper structure is at a right angfe 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 k 300 Nm (335 A 30 kgm, 2420 f 220 Ibft)

5.

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

AE169610

AE082980

2-86

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.

AE082960

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.

AE169640

L

Pull the machine forward with the arm, and the track frame will 1 slide sideways.

Extend the track frame until it comes into contact with the stopper, then lower the machine slowly to the ground. Install bolts @ (one side, front + rear: 32) and tighten to specified torque.

Tightening torque: 3285 * 300 Nm (335 fr 30 kgm, 2420 k 220 Ibft)

\

‘80

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

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.

2-87

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 AMBfENT TEMPERATURE”.

14.1.2

IA

wARN’NG’h

Keep antifreeze fluid away from an open flame. Never smoke

NOTICE l l

l

Never use methanol, ethanol or propanol based antifreeze.

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

Do not mix one antifreeze with a different brand.

For details of the antifreeze mixture when changing the coolant, see “24;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 .... ..I..................................................................................

JIO34 O-A-548D a FEDERAL STANDARD ....... ....*.......................................

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.

2-88

.

14. COLD WEATHER OPERATION

14.1.3 BATTERY

A

WARNING

l

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

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 the rate of charge from the following conversion table.

100% 90% 80% 75%

l

2o”c

o”c

-1 o”c

-2OOC

1.28 1.26 ‘1.24 1.23

1.29 1.27 ‘I.25 1.24

1.30 1.28 1.26 1.25

1.31 1.29 1.27 1.26

’

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.

2-89

14. COLD WEATHER OPERATION

14.2

PRECAUTIONS WORK

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. l 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. l

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 in the fuel system to prevent it from freezing.

l

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.

l

If electrolyte level is found low, add distiI’led 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. l Replace the fuel and oil for all parts with oil of the viscosity specified.

For details, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. l

tf 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.

l

As the APS (Automatic Priming System) becomes useless (at 15OC(59°F) or above), be sure to close the fuel valve for the APS.

z-90

and an is used system system

15. LONG-TERM

15.1

STORAGE

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. l 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.

.

l

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

a

Apply a thin coat of grease to metal surface of the hydraulic piston rods.

l

Disconnect the negative terminals of the battery and cover it, or remove it from the machine and store it separately.

l

If the ambient temperature is expected to drop below OOC, always add antifreeze to the cooling water.

l

Lock each control lever and pedal with the lock lever and pedal lock.

AE189630

Set work equipment control lever and switch for neutral or OFF position.

2-91

15. LONG-TERM STORAGE

If it is unavoidably

necessary to carry out the rust-preventive 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 in the case of machines equipped with an airconditioner.

a

Before operating the working equipment, wipe off the grease on the hydraulic piston rod.

15.3 AFTER STORAGE NOTICE If the machine was stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service.

Carry out the following procedure when taking the machine out of long-term storage. a

Wipe off the grease from the hydraulic cylinder rods.

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”.

If the machine was stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service.

15.4 STARTING MACHINE AFTER LONG-TERM

STORAGE

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.

2-92

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.

16. TROUBLESHOOTING

16.1 PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: When the arm is pulled in, the speed of movement will drop momentarily when the arm is more or less vertical.

AE083010

The arm speed will drop momentarily when the bucket teeth are more or less horizontal.

AE083020

3. When starting or stopping the swing, noise will be emitted from the brake valve.

4. When going down a steep slope at low speed, a noise will be emitted from the travel motor.

16.2 METHOD OF TOWING MACHINE

ALWARNING l l

When towing machine, do not let any one enter the area between the towing machine and the machine being towed.

Do not pull the wire rope rapid.

a CAUTION l l. l l

The shackle must always be used.

Hold the rope level and direct it straight to the track frame.

Move the machine slowly.

Place pieces between wire rope and body to prevent damage to ropes and body.

Method of towing machine If the machine sinks in mud cannot get out under its own power, use a wire rope that has ample strength for the weight of the machine.

2-93

16. TROUBLESHOOTING

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.

2-94

16. TROUBLESHOOTING

16.4 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 removing, disconnect the cable from the ground terminal first

When handling battery, always wear protective 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.

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.

AD052940

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

2-95

16. TROUBLESHOOTING

16.4.1 REMOVAL, INSTALLATION OF BATTERY CABLE a Before removing the battery, remove the ground cable (normally connected to the negative @ terminal). If any tool touches between the positive @ terminal and the chassis, there is danger of sparks being generated. Loosen the nut of terminal and remove the wires from battery. l

When installing the battery,‘connect

l

Tightening torque of battery holder IO - 20 Nm (‘l - 2 kgm, 7.2 - 14.5 Ibft).

16.42 STARTING

the ground cable last.

ENGINE WITH BOOSTER CABLE

When starting the engine with a booster cable, do as foliows: Precautions when connecting and disconnecting booster cable

a WARNING

INCORRECT

When connecting the cables, never contact the positive @ and negative 0 terminals.

When starting the engine with a booster cable, always wear safety glasses.

Be careful not to let the normal machine and problem machine contact each other. This prevents sparks from 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.

NOTICE 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.

a

Check the cables and clips for damage or corrosion.

l

Make sure that the cables and clips are firmly connected.

2-96

k!Y

AD052960

16. TROUBLESHOOTING

Connecting the booster cables Keep the starting switch at the OFF position.

Connect the booster cable as follows, in the order of the numbers marked in the diagram.

1. Make sure that the starting switches of the normal machine and problem machine are both at the OFF position.

2.

Connect one clip of booster cable @ to the positive @ terminal of the problem machine.

3.

Connect the other clip of booster cable @ to the positive @ terminal of the normal machine.

4.

Connect one clip of booster cable @ to the negative Q terminal of the normal machine.

5.

Connect the other clip of booster cable @ to the engine block of the problem machine.

Engine block of the problem machine

my,98o

Starting the engine 1. Make sure the clips are firmly connected to the battery terminals.

2.

Start the engine of the normal machine and keep it running at high idling speed.

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. .

2-97

16. TROUBLESHOOTING

Disconnecting the booster cables After the engine has started, disconnect the booster cables in the reverse of the order in which they were connected.

1.

Remove one clip of booster cable @ from the engine block of the problem machine.

2.

Remove the other clip of booster cable @Jfrom the negative @ terminal of the normal machine.

3.

Remove one clip of booster cable @I from the positive @terminal of the normal machine.

4.

Remove the other clip of booster cable @ from the positive @ terminal of the problem machine.

16.4.3 PRECAUTIONS FOR CHARGING MOUNTED ON MACHINE a 0

BAlTERY

WHEN

WARNING

Before charging, disconnect the cable from the negative @ terminal of the battery.

Otherwise, an unusually high voltage will damage the alternator. remove all battery

plugs for

0

While charging the battery, satisfactory ventilation.

0

lf the electrolyte temperature charging for a while.

0

Turn off the charge as soon as the battery is charged.

Overcharging the battery may cause the following: I) Overheating the battery 2) Decreasing the quantity of electrolyte 3) Damaging the electrode plate

t

i

,

2-98

exceeds 45°C (113”F), stop

Engine block of the problem machine A0052981

16. TROUBLESHOOTING

16.5 OTHER TROUBLE 16.5.1 ELECTRICAL SYSTEM ): Always contact your Komatsu distributor when dealing with these items. . ( l

In cases of abnormalities distributor for repairs.

or causes which are not listed below, please contact your Komatsu

Problem

Main causes

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

(o 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

l

Insufficient battery charge

l

l

Insufficient battery charge Defective starting motor

l

Defective wiring Insufficient battery charge

(o Check, repair) l Charge

Lamp does not glow brightly even when the engine runs at high

speed

(o Check, repair loose terminals, disconnections) l Adjust fan belt tension

Lamp flickers while engine is funning

Pinion of starting motor keeps goins in and out

l

Starting motor turns engine sluggishly

l

Starting motor disengages before engine starts

l

l

Charge

Charge (0 Replace)

Oil pressure monitor does not light up when engine is stopped (starting switch at ON position)

l

Defective monitor a Defective caution lamp switch

(o Replace) (o Replace)

Charge level monitor does not light up when engine is stopped

l Defective monitor a Defective wiring

(e Replace) (o Check, repair)

Low temperature starting aid monitor does not light up

Defective wiring a Defective heater-relay l Defective monitor lamp

(0 Check, repair) (l Replace) (o Replace)

l

2-99

16. TROUBLESHOOTING

16.52 CHASSIS 1: Always contact your Komatsu distributor when dealing with these items. (

l

In cases of abnormalities distributor for repairs.

l

or causes which are not listed below, please contact your Komatsu

Problem

Main causes

Remedy Add oil to specified level

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

l

Loose fan belt Ditty oil cooler Lack of hydraulic oil

Adjust fan belt tension 0 Clean .o Add oil to specified level

Excessive rise in hydraulic oil temperature

l l

~~~~~~~~~~~~~

sprocket

Bucket rises slowly, does not rise

z-100

1.

l

l

Track too loose

l

Adjust track tension

Lack of hydraulic oil

l

Add oil to specified level

16. TROUBLESHOOTING

16.5.3ENGINE ): Always contact your Komatsu distributor when dealing with these items. (

l

l

In cases of abnormalities

or causes

which

are not listed

below,

please

contact

your Komatsu

distributor for repairs.

Engine oil pressure monitor flashes even when engine is running

a Engine oil pan oil level is low (sucking in air) l Clogged oil filter cartridge l Defective tightening of oil pipe joint, oil leakage from damaged l

Pan Defective

monitor

l

Red range of engine cooling temperature gauge flashes

l l

Add oil to specified

level

Replace cartridge (o Check, repair) l

(a Replace) Add cooling

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 attitude operation)

Steam is emitted from top part of radiator (pressure valve)

Indicator of water temperature gauge is in white range

Remedy

Main causes

Probkm

Defective thermostat Defective water temperature

water, repair

Adjust fan belt tension Change cooling water, clean inside of cooling system Clean or repair Replace thermostat) Tighten cap or replace packing

(o Replace) (o Replace)

gauge Engine does not start when starting motor is turned

l l

l

Lack of fuel Air in fuel system Defective fuel injection nozzle

l

pump or

Starting motor cranks engine sluggishly 0 Improper injecting timing l

l

Add fuel Repair place where air is sucked in (o Replace pump or nozzle) l

Defective compression o Defective valve clearance

See ELECTRICAL SYSTEM l

Adjust injection

timing

(o Adjust valve clearance)

Z-101

16. TROUBLESHOOTING

ENGINE (cont’d) (16.5.3) Problem Exhaust gas is white or blue

Main causes

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

Change to specified fuel See item “Indicator of water temperature gauge is in red range on right side of gauge”. (o Replace muffler) (o Adjust valve clearance)

Exhaust gas occasionally turns black

l Too much oil in oil pan 0 Improper fuel

Remedy

l l l

l

l l

Z-102

Damage inside muffler Excessive valve clearance

l

l l

16. TROUBLESHOOTING

16.5.4 ELECTRONIC CONTROL SYSTEM 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.

1.

l

When

normal

Indication

of LED Condition Green

Red

l

Machine is normal

in mode “S”.

Goes off

1 Lights

Goes off

1 Flashes fast

1 Machine is normal in mode “H” or “L”.

Goes off

1 Flashes slowly

1 Machine is normal and auto-decelerator

When

Goes

’

Abnormal section (system)

of machine

off

is applied.

abnormal

Goes

off

Lights

Lights

Flashes

Goes

Flashes

Flashes

Lights

Goes

Lights Lights

off

The engine stalls or slows down extremely while the machine is working (traveling).

Electric power source

The the The not

Control

engine stalls or slow down extremely while machine is working (traveling). auto-decelerator is always applied or applied at all.

The engine stalls or slow down extremely the machine is working (traveling).

The work (travel) speed is extremely

while

T.V.C. valve solenoid

Rotation

low.

box

sensor %

The mode selector does not change speed and power.

Throttle

Flashes rapidly

The auto-decelerator

is not applied

Decelerator

solenoid

A

Flashes slowly

The auto-decelerator

is always applied

Decelerator

solenoid

B

off

% While the engine is stopped,

at all.

red and green LEDs indicate this abnormality

of rotation

sensor

sensor.

Z-103

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.

Red

04 Red 0

When normal

@ Green

Indication

of LED

@ Red

@ Red

Condition

@ Red

of machine

Goes off Goes off Goes off Goes off Arc digging mode Lights Flashes

I

Goes off Goes off Goes off

1 GOeS Off 1GOeS Off / GOeS

Lights

Goes

Off

Lights Goes off Lights

Of

flashes

I

Goes

mode

Horizontal digging + bucket angle

Off 1 compensation

Off

mode

ARM OUT hydraulic switch actu ated

BOOM RAISE/LOWER hydraulic Goes Off switch actuated

IGoes off /Goes off ILights

l

Horizontal digging

ARM IN BUCKET hydraulic switch

1actuated

When abnormal Indication

of LED

Abnormal

@ Green1 @ Red 1 @ Red / @ Red Goes off 1Lights

1Lights

Goes off I Lights

] Goes off I Goes off I Boom EPC solenoid

Goes off I Goes off 1Lights

1Lights

system

I Control box

I Goes off I Bucket EPC solenoid

Goes off 1Flashes

1Lights

Goes off ( Lights

1Flashes

Goesoff/Flashes

~Goesoff(Goesoff/$!!~“UThydrau’icswitchactu-

Goes off / Goes off 1Flashes

1Lights ( Lights

( Arm angle sensor

/ Goes off / F!$$f

Goes off)Goes offlGoes off IFlashes

2-104

1Boom angle sensor

~~~~~$owER hydrau’ic’

ARM IN BUCKET hydraulic switch Iactuated

AE084270

16. TROUBLESHOOTING

16.5.5 APS (Automatic l l

Priming System)

): Always contact your Komatsu distributor when dealing with these items. ( In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs.

Engine does not start at all

Nozzle clogging (dust, paraffin precipitation, defective nozzzle) l Defective glow plug l Fuel pipe collapse, fuel leak, clogging o Defective wiring l Fuse breaking a Defective APS controller l

(o Clean, change to specified fuel, replace nozzle) (o Replace) (o Check, repair) (o Check, repair) (o Replace) (o Replace)

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) (0 Replace) (o Replace) (e Check, repair or replace)

Defective APS water temperature sensor Deposited heater relay contact point

(o Replace temperature sensor)

(o Replace)

l

Disconnection in electrical intake air heater and glow plug Defective wiring Defective timer

(o Check, repair) (o Replace)

l

Glow plug is not heated red.

l

l

Fuel is not or less sprayed. o Nozzle clogging (dust, paraffin, precipitation, defective nozzle o Defective APS controller

Engine does start smoothly but much white smoke emits or the engine stop

When loaded, the engine will emit black smoke and stop

Remedy

Main causes

Problem

l

l

(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) Burner is not ignited

l

l

See item “Preheating monitor lamp does not become bright”

(o Clean, change to specified fuel, replace nozzle) (o Replace)

2-I 05

Z-106

.

MAINTENANCE

17. GUIDES TO MAINTENANCE

Do not carry out any inspection and mai ntenance operation that is not given in this manual.

Perform maintenance work on hard, flat ground.

Check service meter: Check the service meter reading every day to see if the time has come for any necessary maintenance to be carried out.

Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement parts.

Komatsu genuine oils: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature.

Always use clean washer fluid: Use automobile window washer 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 of the oil and grease clean. Keep foreign materials away from oil and grease.

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. Keep in particular grease fittings, breathers and oil level gauges clean and avoid foreign matters from getting in them.

Be careful of hot water and oil: Draining hot oils and coolants and removing their filters immediately after the engine stops are hazardous. Allow the engine to cool.

If the oil has to be drained when it is cold, warm up the oil to a suitable temperature (approx. 20 - 4OOC) 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 is equipped with a fuel strainer, do not remove it while fueling.

Oil change: Check or change oils in the places where dust is scarce to keep foreign materials away from oils.

Adding fuel: When adding fuel, be careful not to allow the water collected at the top or bottom of drum to get into the fuel.

3-2

17. GUIDES TO MAINTENANCE

Warning tag: Attach warning tag to the starting switch or other appropriate control lever to prevent any person who is not aware of the circumstances from starting the engine.

Obey precautions: During the operation, always obey the precautions 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 cleaner or light oil for cleaning parts. Keep flame or cigarette light away from light oil.

Clamp faces: When O-rings or gaskets are removed, clean the clamp faces and replace the O-rings and gaskets with new ones. Be sure to fit O-rings and gaskets when assembling.

Objects in your pockets: Keep your pockets free of loose objects which can fall out and drop into the machinery; especially when you bend over the machinery while working on it.

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 cab. l Never spray steam or water directly at the radiator or oil cooler portions.

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 brand from the one that is used in the machine, do not add it but replace all the oil.

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. If it is soaked with water, it may not operate normally.

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.

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, bieed 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

0

Use Komatsu genuine parts for replacement.

a

When changing or adding oil, do not use a different type of oil.

l

Unless otherwise specified, the oil and coolant used at the time of shipment from the factory are as shown in the table below.

Item

Kind of fluid

Engine oil pan

SAE 15W-40 API classification CD

Swing machinery case Final drive case Damper case

SAE 30 API classification CD

Hydraulic tank

SAE IOW API classification CD

Fuel tank

ASTM 0975 No. 2 (However, ASTM D975 No. 1 is used for the winter season (October to March)

Radiator

Komatsu Super Coolant (AF-ACL) 41% added to water

18.1 OUTLINE OF OIL, FUEL, COOLANT 18.1.1 OIL Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pressure), and it deteriorates with use.

Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual. Even if the oil is not dirty, always repface 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 water or air getting into the circuit.

In such cases, please contact your Komatsu distributor.

When changing the oil, always replace the related filters at the same time.

We recommend you to have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor.

3-5

18. OUTLINES OF SERVICE

18.1.2 FUEL l

The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.

0

Be extremely careful not to let impurities get in when.storing

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.

or adding fuel.

To prevent the moisture in the air from con densing and forming . fill the fuel tan k after co mpleting the day’s work.

inside the fuel tank, always

Before starting the engine, or when IO minutes have passed after adding fuel, drain the sediment 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.

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, always observe the precautions given in the Operation \ and Maintenance 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.

Anti-freeze is inflammable,

so be extremely careful not to expose it to flame or fire.

The proportion of anti-freeze to water differs according to the ambient temperature.

For details of the mixing proportions, see “24.32 CLEAN INSIDE OF COOLING SYSTEM”.

If the engine overheats, wait for the engine to cool before adding coolant.

If the coo lant level is low, it will cause overhe ating and will also cause problems with corrosion from the air in the coolant.

3-6

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, so they do not need 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.

18.1.5 STORING OIL AND FUEL 0

Keep indoors to prevent any water, dirt, or other impurities from getting in.

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.

To prevent any change in quality during long-term storage, be sure to use in the order of first in first out (use the oldest oil or fuel first).

18.1.6 FILTERS Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering important equipment and causing problems.

Replace all filters periodically. For details, see the Operation and Maintenance Manual.

However, when working in severe conditions, it is necessary to consider replacing the filters at shorter intervals according to the oil and fuel (sulfur content) being used.

Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.

When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found, please contact your Komatsu distributor.

Do not open packs of spare filters until just before they are to be used.

Always use Komatsu genuine filters.

3-7

18. OUTLINES OF SERVICE

18.2

OUTLINE

OF ELECTRICAL SYSTEM

l

If the wiring gets wet or the insulation is damaged, the electric system leaks and this could result in hazardous malfunction of the machine.

l

Services relating to the electric system are (1) check of fan belt tension, (2) check of damage or wear of the fan belt and (3) check of battery fluid level.

l

Never remove or disassemble any electric components installed in the machine.

l

Never install any electric components other than those specified by Komatsu.

l

Be careful to keep water away from the electric system when washing the machine or when it rains.

l

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.

l

When working at the seashore, carefully clean the electric system to prevent corrosion.

l

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 OF SERVICE

18.3 OUTLINE OF HYDRAULIC 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 of the hydraulic oil level, replacement of the filter and refilling of hydraulic oil.

When the high pressure hose, etc., is removed, check the O-ring for damage. If necessary, replace it.

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 may be dangerous.

For the handling procedure, see “11.16 HANDLING ACCUMULATOR”.

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, SWING CIRCUIT, TRAVEL CIRCUIT

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.

0

2.

0

3.

4.

0 0 5.

0

Set the lock lever to the FREE position.

After stopping the engine, move each work equipment control lever to the end of its travel within 5 to 6 seconds.

AE084210

Leave the starting switch ON. Remove the cap of the hydraulic 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 control lever to the end of its travel within 5 to 6 seconds.

Repeat Steps 4 to 5 three times.

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.

AEl68930

3-10

18. OUTLINES OF SERVICE

CIRCUIT OF HYDRAULIC IDLER CUSHION

release the pressure before taking off the cap.

1.

Remove the cap of the hydraulic tank.

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 to the hydraulic oil supply circuit.

Drain valve @This is installed to the tank return circuit. l l

Use the special handle to open and close drain valve 0.

Do not loosen the drain valve @ quickly.

I/

--

Special handle

AE1696 60

AE169680

3-11

18. OUTLINES OF SERVICE

18.5

BLEEDING

AIR FROM CIRCUIT

After assembling piping disconnected during inspection and maintenance, always bleed the air from the circuit as follows.

18.5.1 PRECAUTIONS l

l

l

l

l

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 cyfinders 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 SWING PUMP

PUMP AND

Bleed the air, when changing oil in hydraulic tank or removing pump, suction, etc.

1. Add the specified amount of hydraulic oil.

2.

Loosen the plug @ of hydraulic pump one turn.

NOTICE Do not loosen plugs, more than one turn.

69700

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 @, @. /

.

/

-

AE169710

3-13

18. OUTLINES OF SERVICE

18.5.3 BLEEDING AIR FROM IDLER CUSHION

CIRCUIT

When the piping has loosened and air has entered the circuit, bleed the air as follows.

1. Open stop valve @) and drain valve @ fully.

II

2.

Loosen air bleed plugs @ (left and right, 2 places) and

3.

Start the engine and run at idling for 2 to 3 minutes.

4.

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.

5.

Check that oil comes out from air bleed plugs @ (left and right, 2 places) and @, then close drain valve @ and air bleed plugs @ and @.

6.

This completes bleeding of the air. Remove the block from in front of the right track.

7.

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.

Close stop valve @ fully.

AEI696 i60

--

Block

3-14

L

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 @, and loosen air bleed plug @ one turn.

NOTICE Do not loosen plug @ more than one turn.

3.

Operate the travel lever and move it 4 - 5 times between FORWARD and REVERSE.

4. When no more cloudy white oil comes out from air bleed plug 0, tighten air bleed plug @ 5.

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).

1. Boom cylinder 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 IO seconds.

However, do not move the lever to the end of its travel.

3.

Run the engine at low idling.

3-15

18. OUTLINES OF SERVICE

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.

Bottom open

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.

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

Arm

in

_

AE169800

18. OUTLINES OF SERVICE

18.6 OIL FILLER AND LEVEL GAUGE POSITIONS Swing machinery oil filler, level

n

case gauge Engine

oil

pan

Engine oi I oil filler

Swing drain

PTO drain

case plus

machinery plug

Hydraulic oil filler

case AE30679B

PTO level

tank

case oil sause

filler

or cock

Radiat drain

/

filler

Final drain

pan

drive plus

case

Engine drain

oi I cock

pan

AE :3068OB

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 are to be replaced at the same time.

Item

Part No.

‘Part Name

Qw

Replacement frequency

Hydraulic oil filter

07063-01210 (07000-05175)

Element (O-ring)

4 (4)

Every 250 hours service

Drain filter

21N-60-12210

Cartridge

Every 250 hours service

Engine oil filter

600-2 II- 1230

Cartridge

Every 250 hours service

Fuel filter

600-3 11-829 1

Cartridge

Every 500 hours service

Corrosion resistor

600-411-I 170

Cartridge

Every 1000 hours service

6128-81-7042

Element assembly

600-I 81-4400

Outer element assembly

209-60-52190

Element (O-ring) (Back-up ring)

Air cleaner

Line filter

(07000-12125) (502-50-I 1270)

Wear limit

Bucket Loading Horizontal pin type

2 1N-72-l 4290 (21 N-72-l 4330)

Point (Pin)

Bucket Loading Vertical pin type

21T-72-14480 (2 I N-72-l 4460) (21 N-72-l 4470)

Point (Pin ass’y) (Lock)

Bucket Back hoe Horizontal pin type

21 N-72-l 4290 (21 N-72-l 4330)

Point (Pin)

Bucket Back hoe Vertical pin type

21T-72-14480 (21T-72-14460) (2lT-72-14470)

Point (Pin ass’y) (Lock)

6 (6)

6 (6) (6)

.

0

74

Min

. k&-J

AE306810

Wear limit

AE306820

Wear limit

1 Bucket Back hoe Side cutter

21N-70-14180 21N-70-14190 21N-09-11121 21 N-09-1 1131

Cutter L.H.

Cutter R.H.

1 1

Bolt Nut

12 12

Min

1oolnla i

(3. 9 n)

\o

0

0) AE306830

3-18

20. USE OF FUEL, CO 3LANT AND LUBRICANTS ACCORDING TO AMBIENT TEN PERATURE

PROPER SELECTION OF FUEL, COOLANT

RESERVOIR

KIND OF FLUID

AND LUBRICANTS

AMBIENT TEMPERATURE -22 -30

-4 -20

14 -10

32 0

50 10

68 20

CAPACITY 86 104°F 30 40°C

Specified

Refill

61 a 16.1 US gal 13.4 UK gal

51 e 13.5 US gal 11.2 UK gal

PTO case

15 e 4.0 US gal 3.3 UK gal

15 a 4.0 US gaf 3.3 UK gal

Swing machinery case

13 e 3.4 US gal 2.9 UK gal

13 a 3.4 US gal 2.9 UK gal

45 a (each) 11.9 US gal 9.9 UK gal

45 e (each) 11.9 US gal 9.9 UK gal

Engine oil pan

Engine oil

Final drive case

Hydraulic

1200 650 317.0 US gal 171.7 US gal 264.0 UK gal 143.0 UK gal

system

Fuel tank

Cooling system

1140 e 301.2 US gal 250.8 UK gal

Diesel fuel

Water

Add antifreeze

160 &!

42.3 US gal 35.2 UK gal

% ASTM -D975No. 1

3-19

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

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/Z of regular interval

Above 1 .O%

I

l/4 of regular interval

When starting the engine in an atmospheric temperature of under 0°C (32”F), be sure to use engine oil of SAEIOW, SAEIOW-30 and SAEXW-40, even though atmospheric temperature goes up to 10°C more or less in the day time.

Use APf classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.

There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-30, sure to add single grade oil that matches the temperature in the table.

15W-40), but be

We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine Specified

and hydraulic

capacity:

Total

work equipment

amount

applications.

of oil including

oil for components

and oil in piping.

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

ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute

3-20

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

No.

1

2

Supplier

KOMATSU

AGIP

Engine Oil [CD or CEI SAElOVV, 30, 40 1ow30, 15w40 (The 15W40 oil marked * is CE.) EOIO-CD E030-CD EO IO-30CD EOl5-40CD Diesel sigma S Super dieselmultigrade *Sigma

turbo 300

Gear Oil [GL-4 or GL-51 SAE80, 90, 140

AMOCO

*Amoco

4

ARC0

*Arcofleet

5

BP

Vanellus

6

CALTEX

*RPM delo 400 RPM delo 450

7

CASTROL

*Turbomax *RX super CRD

8

CHEVRON

*Del0 400

9

CONOCO

*Fleet motor

10

ELF

Multiperformance Performance 3C

1’

EXXON (ESSO)

Essolube 03 *EssoI u be XD-3 *Essolube XD-3 Extra *Esso heavy duty Exxon heavy duty

12

GULF

Super duty motor *Super duty plus

13

MOBIL

Delvac 1300 *Delvac super 1ow-30, 15w-40

S3 plus

C3

G2-LI G2-LI-S

Rotra MP

GR MU/EP

gear oil

Litholine HEP 2 Arco EP moly D

Gear oil EP Hypogear EP

Energrease

thuban thuban

LS-EP2

Marfak all purpose 2 EP Ultra-duty grease 2

EP EPX

MS3 Spheerol

HYPOY Hypoy B HYPOY C

EPL2

Universal

gear

Ultra-duty

Universal

gear lubricant

Super-sta grease

Antifreeze

AF engine coolant

Anti-freeze

grease 2

Tranself EP Tranself EP type 2

Glacelf

Gear oil GP Gear oil GX

Beacon EP2

All season coolant

Multi-purpose gear lubricant

Gulfcrown Gulfcrown

Antifreeze

Mobilube Mobilube

Mobilux EP2 Mobilgrease 77 Mobilgrease special

3C

oil

RYKON premium grease

Arco HD gear oil

Universal Universal

oil

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

GO90 GO140

Multi-purpose

3

Grease [Lithium-Base] NLGI No. 2

Anti-freeze Coolant [Ethylene Glycol Base1 Permanent Type

GX HD

EP2 EP special

and coolant

3-21

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

No.

Supplier

Engine Oil [CD or CE] SAElOW, 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 Base1 Permanent Type

Multi-purpose white grease 705 707L White - bearing grease

Anti-freeze and summer coolant

FINA marson

FINA tamidor

14

PENNZOIL

*Supreme duty fleet motor oil

15

PETROFINA

FINA kappa TD

FINA potonic FINA potonic

16

SHELL

Rimula X

Spirax EP Spirax heavy duty

Albania

17

SUN

Sunoco GL5 gear oil

Sunoco ultra prestige 2EP Sun prestige 742

and summer coolant

18

TEXACO

*Ursa super plus Ursa premium

Multigear

Multifak Starplex

Code 2055 startex antifreeze coolant

19

TOTAL

Rubia S *Rubia X

Total EP Total transmission TM

Multis EP2

20

UNION

*Guard01

MP gear lube LS

Unoba EP

21

VEEDOL

*Turbostar *Diesel star MDC

Multigear Multigear Multigear

3-22

B C

N NE

EPL2

EP grease

EP2 2

Sunoco antifreeze

Antigellantifreeze

Antifreeze

21. STANDARD NUTS

TIGHTENING

TORQUES FOR BOLTS AND

21.1 INTRODUCTION OF NECESSARY TOOLS The following tools are needed when carrying out maintenance.

No. 1

Name of tool

Part No.

Remarks

09002-02427 09002-03032

Applicable width across fiats (SI-S2) 8mm - 12mm 12mm - 14mm 13mm - 17mm 19mm - 22mm 24mm - 27mm ;2 30mm - 32mm

09033-00190

interchangeable

09020-I 0284

Applicable width across fiats 10 mm, 13 mm, 14 mm, 17 mm, 19 mm, 22 mm, 24 mm, 27 mm, 30 mm, 32 mm Extension, Handle

Wrench 09002-00810 0900241214 09002-01317

0900241922

--

4

j Pliers

I

-.

ADO53370

fiat-head and cross-head type

0903640150 09039-00150 09055-l 0390 0901 g-08035

7

/ Filter wrench

8

/ Socket

9

1 Tool bag

09056-05513

10

1G rease pump

07952430002

II

1 Grease cartridge

07950-90403

21 N-98-l 1140

For greasing work _

(Lithium base grease, 400 g)

07951-11400 0905440009

if any of the above tools are broken, please order them from your Komatsu distributor.

3-23

21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

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 fiats @ 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 + 0.1 kgm + 0.74 lbft Thread diameter of bolt (mm)

Width across fiats (mm)

(4

(b)

@

@

Nm

kgm

A0054300

Ibft

1.35 f 0.15 9.73 +.1.03

6

10

13.2 A 1.4

8

13

31.4 2 2.9

3.2 2 0.3

23.2 2 2.1

10

17

65.7 2 6.8

6.7 A 0.7

48.5 k 5.0

12

19

112 2 9.8

11.5 I 1.0

82.6 it7.2

14

22

177 k 19

18.0 ,+2.0

131 +.14

24

279 f 29

28.5 k 3

206 2 21

16

*

18

27

383 -c39

392 3

282 + 29

20

30

549 + 58

56 zt6

405 f 43

22

32

745 2 78

76 lr8

549 + 58

24

36

927 t 98

94.5 f 10

684 2 72

27

41

1320 +.140

135 k 15

973 f 100

30

46

1720 2 190

175 zt20

1270 2 140

33

50

2210 A 240

225 2 25

1630 2 180

36

55

2750 2 290

280 2 30

2030 2 210

39

60

3280 + 340

335 t 35

2420 k 250

NOTICE When tightening panels or other parts having tightening fixtures made of plastic, be careful not to use excessive tightening torque: doing so will damage the plastic parts.

3-24

AD053380

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. ln 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 SAFE-W PARTS

CRITiCAL SAFETY PARTS No.

Critical safety parts for periodic replacement

Q’ty

1 -

Fuel hose (injection pump - fuel filter)

2

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

2

Replacement interval

Every 2 years or 4000 hours, whichever comes sooner

AE169840

3-26

22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS

No.

Critical safety parts for periodic replacement

8

T Turbocharger

9 10

lubricating hose

Q’ty

Replacement interval

I

2

I

1 No. 1 Pump outlet hose

I

2

I

/ No. 1 Pump outlet branch hose

I

2

I I

11

No. 2 Pump outlet hose

2

12

Swing pump outlet hose

2.

13

Swing pump outlet branch hose

2

14

Swing pump confluence hose

1

15

1 Heater hose (heater - engine)

I

2

Every 2 years or 4000 hours, whichever comes sooner

I

AE301890

3-27

22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS

No.

Critical safety parts for periodic replacement

Q’ty

16

Pump suction side hose

5

17

Swing line hose

4

Replacement interval Every 2 years or 4000 hours, whichever comes sooner

AE301900

3-28

22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS

No .

Critical safety parts for periodic replacement

Replacement interval

Q’ty 4

18

1 Boom cylinder line hose (B/H)

19

Arm cylinder line hose (B/H)

7

20

Bucket cylinder line hose (B/H)

5

I

I Every 2 years or 4000 hours, whichever comes sooner

AE301910

3-29

22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS

No

. 1Critical

safety parts for periodic replacement

Q’ty

21

Boom cylinder line hose (L/S)

22

Arm cylinder line hose (L/S)

23

Bucket cylinder line hose (L/S)

7

24

Bottom dump cylinder line hose (L/S)

10

25

Seat-Belt (option)

1

Replacement interval

4 *’

Every 2 years or 4000 hours, whichever comes sooner

Every 3 years

AE306840

3-30

23. MAINTENANCE

23.1

MAINTENANCE

SCHEDULE CHART

SCHEDULE

CHART PAGE

SERVICE ITEM INITIAL 100 HOURS SERVICE (only after the first 100 hours)

3-73

Clean strainer of PTO lubricating oil filter

INITIAL 250 HOURS SERVICE (only after the first 250 hours) Change fuel filter

3-74

Change oil in swing machinery case

3-79

Change oil in PTO case

3-80

Change oil in final drive case

3-82

Check engine valve clearance, adjust

3-85

WHEN REQUIRED Check, clean and replace air cleaner element

3-36

Clean inside of cooling system

3-38

Check and tighten track shoe bolts

3-42

Check and adjust track tension

3-43

Check electrical intake air heater

3-46

Replace bucket teeth (vertical pin type)

3-47

Replace bucket teeth (horizontal pin type)

3-50

Check window washer fluid level, add fluid

3-51

Check and adjust air conditioner

3-52

Clean line filter

3-53

Replacement of fan belt and adjustment of auto tensioner

3-54

Check APS (Automatic Priming System)

3-55

CHECK BEFORE STARTING Check coolant level, add water

.

3-56

Check oil level in engine oil pan, add oil

3-56

Check fuel level, add fuel

3-57

Check oil level in hydraulic tank, add oil

3-58

3-31

23. MAINTENANCE

SCHEDULE CHART

SERWCE ITEM

PAGE

(CHECK BEFORE STARTING)

Check dust indicator

3-59

Check electric wiring

3-59

Drain water and sediment from fuel tank

3-60

Check monitor system

3-60

Check oil level in PTO case

3-60

Check oil fevel in swing machinery case

3-60

CHECK EVERY IO HOURS SERVICE 3-61

Lubricating lubricating block

3-61

l

Boom concentration

l

Boom cylinder foot pin (2 points)

3-62

l

Arm concentration

3-62

l

Bucket cylinder rod end pin (2 points)

3-62

l

Bucket cylinder rod end link coupling pin (4 points)

3-62

l

Bucket cylinder foot pin (2 points)

3-62

lubricating block (4 points)

a Bucket-Link coupling pin (2 points)

3-62

o Arm-Bucket coupling pin (2 points)

3-62

l

Arm-Link coupling pin (2 points)

3-62

l

Bucket hinge pin (2 points)

3-63

l

Bottom dump cylinder foot pin (2 points)

3-63

a Bottom dump cylinder rod end pin (2 points)

3-63

EVERY 100 HOURS SERVICE Clean strainer of PTO lubrication filter

3-64

Lubricating swing circle

3-64

Drain water and sediment from fuel tank

3-64

EVERY 250 HOURS SERVICE Lubricating

3-65

l

Fan pulley assembly

3-65

l

Tension pulley assembly

3-65

3-32

3. MAINTENANCE

SERVICE ITEM

SCHEDULE CHART

PAGE

Change oil in final drive case

3-65

Check level of battery electrolyte

3-66

Change oil in engine oil pan, replace engine oil filter cartridge

3-67

Replace hydraulic filter element

3-68

Check alternator drive belt tension, adjust

3-69

Check airconditioner compressor belt tension, adjust

3-70

Check, clean fuel strainer

3-71

Check and tighten track shoe bolts

3-71

Check and tighten track frame and axle connecting bolts

3-71

EVERY 500 HOURS SERVICE Clean hydraulic tank strainer

3-72

Check and clean radiator fins

3-73

Clean pilot filter strainer

3-73

Clean strainer of PTO lubrication oil filter

3-73

Change fuel filter

3-74

Check fan belt

3-74

Check inspection of weldings structure (color check)

3-75

EVERY 1000 HOURS SERVICE Change oil in swing machinery case

3-79

Check turbocharger clamping joint

3-79

Lubricating of tension pulley (2 points)

3-79

Change oil in PTO case

3-80

Replace corrosion resistor cartridge

3-80

Replace hydraulic tank breather element

3-81

EVERY 2000 HOURS SERVICE Change oil in final drive case

3-82

Change oil in hydraulic tank, clean strainer

3-83

Clean, check turbocharger

3-83

Check turbocharger rotor play

3-83

Check swing pinion grease level, add grease

3-84

Clean engine breather

3-85

3-33

23. MAINTENANCE

SCHEDULE CHART

SERVICE ITEM

PAGE

(EVERY 2000 HOURS SERVICE)

Check alternator, starting motor

3-85

Check engine valve clearance, adjust

3-85

Check vibration damper

3-85 EVERY 4000 HOURS SERVICE

Check water pump

3-86

Check fan pulley and tension pulley

3-86

Check air compressor, adjust

3-86

3-34

24.1

INITIAL 100 HOURS

Carry out the following hours. l

SERVICE

maintenance

only after

the first

100

CLEAN STRAINER OF PTO LUBRICATING OIL FILTER

For detail of method of replacing or maintaining, see the section on EVERY 500 HOURS SERVICE.

24.2

INITIAL 250 HOURS

Carry out the following hours. l l l l l

SERVICE

maintenance

only after the first 250

CHANGE FUEL FILTER CHANGE OIL IN SWING MACHINERY CASE CHANGE OIL IN PTO CASE CHANGE OIL IN FINAL DRIVE CASE CHECK ENGINE VALVE CLEARANCE, ADJUST

For details of. the method of replacing or maintaining, see the section on EVERY 500 HOURS, 1000 HOURS and 2000 HOURS SERVICE.

3-35

24.

SERVICE PROCEDURE

24.3

WHEN

REQUIRED

24.3.1 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 wear safety glasses or goggles to protect the eyes.

CHECK If the red piston can be seen in transparent portion @ of dust indicator 0, clean the air cleaner element.

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 are broken.

4.

Set the cleaned element.

5.

Push the dust indicator reset button to return the red piston to the original position.

02

AE083060

3-36

24. SERVICE

PROCEDURE

Cleaning outer element With 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.

NOTICE l If 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.

AE083080

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.

3-37

24. SERVICE

PROCEDURE

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. If 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.

l

Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the table below.

Kind of coolant

Cleaning inside of cooling system and changing coolant

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 not using antifreeze

Every 6 months or every 1000 hours, whichever comes first

l

0

3-38

Replacing corrosion resistor

Every 1000 hours and autumn) when cleaning the inside of the cooling system and when 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.

24. SERVICE

When deciding the temperature in the given below.

It is actually better when deciding the

l

PROCEDURE

ratio of antifreeze to water, check the lowest past, and decide from the mixing rate table to estimate a temperature about 10°C lower mixing rate.

Mixing rate of water and antifreeze Min.

0

atmospheric temperature Amount of antifreeze

C

-5

“F

23,14

Q

37

US gal

-10

48

9.8

1UK gal 1 8.1 Amount of water

-

-25

-30

5

-4

-13

-22

58

66

74

15.3

17.4

19.6

80 I

21.1

1 10.6 1 12.8 1 14.5 1 16.3 1 17.6

123

112

102

94

86

80

US gal

32.4

29.5

26.9

24.8

22.6

21.1

UK gal

27.1

24.6

22.4

20.7

18.9

17.6

Antifreeze is flammable,

l

-20

Q

a l

12.7

-15

WARNING

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.

a WARNING

I

When removing drain plug, avoid pouring coolant on yourself.

3-39

24. SERVICE

PROCEDURE

1. Stop the engine, close valves @ on corrosion resistor.

2.

Turn cap @ slowly until it comes off.

-44 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 @ and plug @ and Pour in clean water (ex. city water) up to the vicinity of the water filler.

5.

When the water reaches the vicinity of the water filler, put the engine at low idling, open drain valve @ and plug @, then pass water through the cooling system for 10 minutes.

When doing this, keep the radiator filled up to the filler with water.

0

6.

After washing the cooling system, stop the engine. Open drain valve @ and plug @ to drain water and close drain valve @ and

7.

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

Follow the instructions on the detergent container.

a 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 @, 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.

3-40

24. SERVICE PROCEDURE

IO. When the water becomes completely clean, stop the engine and close drain valve @ and plug @.

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 tow idling and then for another 5 minutes at high idling to eliminate air trapped in the cooiing 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.

3-41

.

24.3.3 CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts @ loose, they wifl break, so tighten any loose bolts immediately.

eis

AEO83120

Method for tightening

1.

First tighten to a tightening torque of 784 2 78 Nm (80 k 8 kgm, 579 2 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” 2 ‘IO”.

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.

ADO53090

3-42

24. SERVICE PROCEDURE

24.3.4 CHECK AND ADJUST TRACK TENSION 9

AWARNING

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)

100 - 150 mm (3.9 - 5.9 in) AE083140

3-43

24. SERVICE

PROCEDURE

Adjusting hydraulic cushion (Hit) cylinder 1.

Check that drain valve 0 is completely closed.

60

2.

Open stop valve 0.

3.

Start the engine, and set at medium position.

Half Posit

open ion

AE168780

4.

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 Do not carry out this operation on a slippery road surface (steel plate, etc.). a 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. l

5.

Check that the protrusion @ of the plunger of the hydraulic cushion cylinder is 120 2 5 mm on both the left and right.

6.

Close stop valve @ completely.

AE169940

Cushion

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 handle when opening or closing stop valve and drain valve.

3-44

I

cylinder

AEl69950

24. SERVICE

PROCEDURE

Adjusting grease cylinder

A

WARNING

Do not loosen grease fitting @ more than one turn. There is danger that it may fly out under the high internal pressure.

Never loosen any part other than grease fitting 0. If the grease does not come out, move the machine backwards and forwards slightly. i9960

NOTICE Before pumping in grease, check that the protrusion @ of the plunger of the hydraulic cushion cylinder is 120 2 5 mm (4.7 + 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 @ one turn and let grease out to adjust. If the protrusion cannot be adjusted to 120 2 5 mm (4.7 2 0.2 in), the hydraulic cushion must be adjusted, so please contact your Komatsu distributor for adjustment.

A

CAUTION

.

If the track tension is adjusted only by using grease and not by hydraulic pressure, excessive load may be brought to bear on the undercarriage and this may cause damage.

When increasing tension prepare a grease gun.

1.

Pump in grease through grease fitting @ with a grease gun.

2. To check that the correct tension has been achieved, move the machine backward and forwards.

3.

4.

Check the tension again, and if it is not correct, adjust it again.

Grease cyhnder AE083170

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.

3-45

24. SERVICE PROCEDURE

When loosening tension

It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu 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, move the machine backwards and forwards a short distance.

4.

Tighten fitting 0.

5.

To check that the correct tension has been achieved, move the machine backwards and forwards.

6.

Check the track tension again, and if the tension is not correct, adjust it again.

24.3.5 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.

3-46

24. SERVICE

PROCEDURE

24.3.6 REPLACE BUCKET TEETH (VERTICAL PIN TYPE) Replace the point before the adapter starts to wear. 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.

AEl67470

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 @ when it is hit, the rubber pin lock _ may break. Set it against the back of the pin.)

AE169980

4

BP &?

3

After removing lock pin @ and rubber pin lock 0, check them.

2

.

1

0

b 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

1

./

\ 0

\

.

AE083 190

The lock pin is too shdrt

A

The lock pin is too short.

Align with bottom face

AE083200

3-47

24. SERVICE PROCEDURE

o

o

The rubber of the rubber pin lock is torn, and the steel balls may come out.

The rubber is broken and the steel bails come out easily.

b

The steel bails are buried when they are pressed by hand.

AE083210

The steel balls can be buried when pressed with finger AE083220

4.

Clean the surface of adapter @ 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.

6.

Clean the inside of tooth (iJ then install it to adapter @. 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 @, 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.

INCORRECT

.

Sticky materia

\

I

3-48

CORRECT

I

AE083240

1

24. SERVICE PROCEDURE

If the rear face of the hole for the pin of tooth @ is protruding to the front from the rear face of the pin hole for adapter @, 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 @ fully, knock in lock pin 0.

8.

9.

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.

After replacing a bucket tooth, always check the following.

1) 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)

1

1 1

0

AE083250

Confirm that rubber pin lock @ and lock pin @ are set as shown in the figure.

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.

Replace the rubber pin and locking pin with new pins at the same time as replacing the point to prevent the point from falling.

3-49

24. SERVICE

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 reptaced. Set the work equipment in a stable

condition, then stop the engine and apply the locks securely to the levers.

AE167470

1.

Place a block under the bucket bottom so that the pin of tooth @ 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.

AE169980

2

Place a bar on the pin head and strike the bar with a hammer to knock out pin 0. Remove tooth @.

.

REMARK Use a round bar with a smaller diameter than that of the pin.

AE083270

3.

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.

/

3-50

AE083280

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 be varied depending on atmospheric temperature, replenish washer fluid at the following mixture ratio, taking temperature into account.

I Operation area

I Mixture ratio

and season

Freezing temperature

I

Normal

Winter in cold region Winter in extremely cold region

Pure washer fluid l/3: water 213 Pure washer fluid l/2: water l/2 Pure washer fluid

- 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.

3-51

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 srght or frostbrte, so never loosen any part of the j.,..,.,...,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

Refrigerant (gas)

Filling quantity

Twice a year; spring and autumn

Condenser

Clogging of fins

Every 500 hours

Compressor

Function

Every 4000 hours

V belt

Damage and tension

I Every 250 hours

Blower motor and fan

Function (Check for abnormal sound)

When required

Control mechanism

Function (Check for normal function)

When required

Installation condition looseness of tightening connection portions gas leakage, damage

When required

Piping for connection

3-52

Sight glass Correct

pvfii z:nt

9 No refrigerant ( Colorless, transparent 1 eiver

AD053280

24. SERVICE PROCEDURE

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.

When cleaning the filter, also clean off the dirt and dust stuck to the side face of the case.

When assembling the case again, replace O-ring @ and backup ring @ together.

After assembling the line filter again, bleed the air from the system. (For details, see “18.5 BLEEDING AIR FROM CIRCUIT” .)

a

UJ AE170010

3-53

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.

I hen install a replacement.

Replace three V-belts at the same time.

‘u w

AE170020

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 A 5 mm (2.8 k 0.2 in), and tighten lock nut @ securely.

AEl70030

3-54

24. SERVICE

PROCEDURE

24.3.12 CHECK APS (Automatic Priming System) Check the APS in autumn (ambient temperature below 15°C (59OF), 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 plug.

If any abnormality SHOOTING”.

is assumed,

refer to the “16. TROUBLE

3-55

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.

AE168590

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

If the volume of coolant added is more than usual, check for possible water leakage.

AE082160

24.4.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1.

Open the engine hood.

2.

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

3.

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

4.

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

J

8 If the oil level is below the L mark, add engine oil through oil filler 00 The dipstick is marked with the levels for ENGINE STOPPED on one side and ENGINE IDLING on the other side.

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)

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”.

3-56

rr, B P d

B 9 I30 ,H / Game for ENG. STOPPED

~ Gauge for ENG. IDLING AE168610

24. SERVICE PROCEDURE

5.

If the oil is above the H mark, drain the excess engine oil from drain valve @, 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, for at least 15 minutes after stopping the engine before checking. if the machine is at an angle, make it horizontal before checking.

i20

24.4.3 CHECK FUEL LEVEL, ADD FUEL

R

ewaRNlNrj’A

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

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

If the fuel level is not within the sight gauge, add fuel through filler port @, while watching sight gauge 8.

Fuel capacity: 1140 fi (301.2 US-gal, 250.8 UK gal) For details of the fuel to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

3.

AE168640

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

3-57

.

24. SERVICE

PROCEDURE

24.4.4 CHECK OIL LEVEL IN HYDRAULIC

TANK, ADD OIL

4h 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 trave ) to full stroke in all directions to release the internal pressure.

3.

AE084210

Check sight gauge @ The oil leve I 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 1 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 86OF)) l Normal operation: around H level (Oil temperature 50 to 80°C (122 to 176°F))

AE082220

3-58

I

24. SERVICE

PROCEDURE

24.4.5 CHECK DUST INDICATOR When the air cleaner element is clogged, the red piston of dust indicator 0 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”.

i80

24.4.6 CHECK ELECTRIC WIRING

aAwARNiN=: If the fuse blows frequently, or there are traces of shortclrcultmg in the electric wiring, always locate and repair the cause.

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 for investigation rection of the cause.

and cor-

lliizZAwARN’NG’.

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

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.

3-59

24. SERVICE PROCEDURE

24.4.7DRAIN 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.

24.4.8CHECK MONITOR

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 Open the left side cover and use dipstick @ to check the oil level.

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

I. 2.

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

24.4.10CHECK OIL LEVEL IN SWING MACHINERY CASE 1. Use dipstick at under of boom foot, and inspection hole at the 2.

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”.

3-60

AE168720

24. SERVICE PROCEDURE

24.5 EVERY 10 HOURS a

SERVICE WARNING

I

If any abnormal noise comes from the greasing points of the

work equipment, apply grease regardless of the service interval.

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 in grease through fittings shown by arrows.

the grease

3.

After greasing, wipe off any old grease that was pushed out.

AE306850 4

I.

Boom concentration lubricating block Boom foot pin l Arm cylinder foot pin l Boom cylinder rod end l

AE170060

3-61

24. SERVICE PROCEDURE

10. Bucket hinge pin (2 points)

11. Bottom dump cylinder foot pin (2 points) 12. Bottom dump cylinder rod end pin (2 points)

3-63

24. SERVICE PROCEDURE

24.6

EVERY 100 HOURS SERVICE

Maintenance same time.

for every 10 hours should be carried out at the

Carry out the following hours.

maintenance

only after the first 100

24.6.1 CLEAN STRAINER OF PTO LUBRICATING FILTER

OIL

For details of the method of replacement or maintenance, see “24.8 EVERY 500 HOURS SERVICE”.

24.6.2 LUBRICATING

SWING CIRCLE

Lubricate the 4 grease fittings shown by an arrow.

AE170150

24.6.3 DRAIN WATER AND SEDIMENT TANK

FROM FUEL

1.

Carry out this procedure before operating the machine.

2.

Prepare a container to catch the fuel that is drained.

3.

Open valve @ at the bottom of the tank and drain the sediment and water that has accumulated at the bottom together with fuel.

When doing this, be careful not to get fuel on yourself.

4.

When only clean fuel comes out, close drain valve @).

NOTICE Never use trichlene for washing the inside of the tank.

3-64

AE170160 L

24. SERVICE

24.7 EVERY 250 HOURS Maintenance same time.

PROCEDURE

SERVICE

for every 10 hours should be carried out at the

For detail of the method of replacing or maintaining, see the section on EVERY 500 HOURS, 1000 HOURS AND ZOOO.HOURS SERVICE.

24.7.1 LUBRICATING Apply grease to the grease fitting 1.

Fan pulley assembiy

2.

Tension

(I

shown

by arrows.

point)

pulley assembly

(2 points)

24.7.2 CHANGE OIL IN FINAL DRIVE CASE

A WARNING

1.

l

The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation.

l

If there is still pressure remaining inside the case, the oil or plug may fly out.

Loosen the plug slowly to release the pressure.

Stop the machine

AE170180

so that the TOP mark is at the top.

2.

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”.

3-65

24. SERVICE

PROCEDURE

24.7.3 CHECK LEVEL OF BAll-ERY

r

ELECTROLYTE

a WARNING

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

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 (IO 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.

Clean the air hole in the battery cap, then tighten securely.

the cap

When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from freezing.

3-66

24. SERVICE

PROCEDURE

24.7.4 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE

The oil is at high temperature

after the engine has been oper-

tions. Wait for the oil to cool down before changing it. ~~~ Prepare the following Container to catch drained oil: Min. 51 g capacity Refill capacity: 51 e (13.5 US gal, 11.2 UK gal) Filter wrench

Remove the filler cap, remove drain plug 0, and loosen drain valve 0. After draining the oil, tighten drain valve @ and plug @a Tightening torque:

69 k IO Nm (7 2 1 kgm, 51 k 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.

Using a filter wrench, remove full-flow filter cartridges @ by turning counterclockwise.

Clean the filter holder and check that the oil seal is not stuck to the filter holder. If the old seal is stili 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.

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.

After replacing the cartridge, fill engine oil through oil filler 0.

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDl,NG 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”.

AEt70210

3-67

24. SERVICE PROCEDURE

24.7.5 REPLACE HYDRAULIC

FILTER ELEMENT

A WARNING When removing the oil filler cap, turn it slowly to release the internal pressure before removing it.

When removing cover 0, undo the bolts (4 bolts) gradually to, prevent the cover flying off under the force of spring 0.

70230

Remove cap @ of the oil filler.

Remove cover 0, spring 0, remove element 0.

valve @, and strainer @ then

Clean removed parts and install a new element.

Be sure to use a genuine Komatsu element.

REMARK Operate the machine after halting for more than 5 minutes to eliminate bubbles in the oil inside the tank.

4.

3-68

Check for oil leakage and wipe off any spilled oil.

AE170240

24. SERVICE

24.7.6 CHECK ALTERNATOR ADJUST

PROCEDURE

DRIVE BELT TENSION,

Checking The belt tension should normally deflect by about 15 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)).

AE170250

Alternator

Drive

~ullev

PUI

lev AE170260

Adjusting 1. To adjust the belt tension, loosen bolt @ 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.

70270

3-69

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

PUI tev 6 in)

Drive

Pulley AE170290

Adjusting 1. To adjust the belt tension, loosen bolts @ (4 points) and lock nut 0, and screw adjustment bolt 0.

2.

After adjustment, tighten lock nut @ and bolts Q) (4 points).

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 for adjustment, or if there is a cut or crack on belt.

5.

When the new belt is set, readjust it after operation for an hour.

3-70

24. SERVICE

PROCEDURE

24 17.8 CHECK, CLEAN FUEL STRAINER 1. ’ Close the valve @ under the fuel tank.

2. 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 (ij 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 k 78 Nm (80 2 8 kgm, 579 k 58 Ibft), check that the mating surfaces are in contact, then tighten a further 120” A IO”.

EzzEJ

AE083120

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.

ADO53d90

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 k 340 Nm (335 k 35 kgm, 2420 k 250 Ibft)

3-71

I

24. SERVICE

PROCEDURE

24.8 EVERY 500 HOURS SERVICE Maintenance for every IO, 100 and 250 hours should be carried out at the same time.

24.8.1 CLEAN HYDRAULIC

TANK STRAINER

A WARNING l

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

l

When removing cover 0, undo the bolts (4 bolts) gradually to prevent the cover flying off under the force of spring 0.

1.

Remove cap.@ of the oil filler.

2.

Remove cover @ and lift up the top of rod @from above to take out spring @ and strainer @.

3.

Wash the strainer with fuel oil. If strainer @ is damaged, replace it with a new one.

4.

When installing, check that the O-ring at the bottom of strainer @ is not out of place or twisted, then coat the surface of the Oring with grease, insert it on to tank protrusion 0, and instal

AE170340

I

3-72

AE170350

1

24. SERVICE

24.8.2 CHECK AND CLEAN RADIATOR

PROCEDURE

FINS

Remove bolts @ and cover 0.

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.

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.

with

hose hose hose

24.8.3 CLEAN PILOT FILTER STRAINER

7

dAWARNINCd The oil is at high temperature after engrne has been operated.

Wait for the oil to cool down before carrying out maintenance.

Remove

filter case (iJ

Take out the strainer and wash the strainer in the fuel. Replace the strainer if finding some defects.

Install the strainer and filter case 0.

24.8.4 CLEAN STRAINER OF PTO LUBRICATING FILTER

OIL

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 in the fuel. Replace the strainer if finding some defects.

3.

Install the strainer and filter case 0.

3-73

24. SERVICE PROC-EDURE

24.8.5 CHANGE FUEL FILTER

I

.

1. Close the valve 0,

2.

3.

4.

5.

6.

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 @, 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.

420

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”.

3-74

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.

Color check shall conform to the following procedure.

Prepare color contrast penetrant agents (cleaning agent, penetrant, developer) 2. Clean the checking zone with cleaning agent to remove dust and oil.

3. After cleaning, dry the surface completely, spray penetrant and leave for 5 to 20 minutes.

4. Spray cleaning agent again and wipe out the penetrant on the surface by a waste (cloth).

5. Wipe out excessive cleaning agent and then spray developer.

Spray so that the surface can be slightly seen.

6. Leave for 15 - 20 minutes and visually check for the crack.

Colored cracks can be found, if there is any.

7. Repair cracks, if any, according to the repair procedure.

1.

Checking area

Detail of fc

(Sketch AE170430

shows

L.H.) AEl70440

AE170450

3-75

24. SERVICE

PROCEDURE

AE170460

Detail of I

Detail of IHI

I

L. H.+ II Section (Sketch

shows

II

I seen

from

the

rear

of

4

R. H.

body

L. H.) AE170500

AE170470

Detail of IJ]

Detail of

q

Hoot side

Section

seen

from

the

rear

of

body (Sketch

shows

L. H-1 AE170510

AE170480

Detail of

q

Detail of @I

AE170490

3-76

AE170520

24. SERVICE PROCEDURE

AEl70590

AE170600

Detail of

qm Loader-Arm

AE170610

3-78

24. SERVICE

24.9 EVERY 1000

PROCEDURE

HOURS SERVICE

Maintenance for every 10, 100, 250 and 500 hours should be carried out at the same time.

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. .

Container to catch drained oil: Min. front and rear each 13 e capacity Refill capacity: front and rear each 13 fi (3.4 US gal, 2.9 UK gal)

Loosen drain valve @ at the bottom of the machine. After draining, tighten the drain valve.

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”.

AE170630

24.9.2 CHECK TURBOCHARGER

CLAMPING

JOINT

Contact your Komatsu distributor for checking.

24.9.3 LUBRICATING 1.

OF TENSION

PULLY (2 points)

Using a grease pump, pump in grease fittings

through

the

grease

shown by arrows,

0640

3-79

24. SERVICE PROCEDURE

24.9.4 CHANGE OIL IN PTO CASE

The oil is at high temperature

immediately

after the machine

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. a Contain to catch drain oil: Min. 15 4 capacity l Refill capacity: 15 e (4.0 US gal, 3.3 UK gal) 1.

Drain oil from drain plug @) 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”.

AE170660

24.9.5 REPLACE CORROSION

RESISTOR CARTRIDGE

Prepare the following.

0 Container to catch drain coolant 0 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.

(1) To fit the cartridge, put the packing face in contact with the seal face of the holder, then screw it up about Z/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.

3-80

24. SERVICE

PROCEDURE

24.9.6 REPLACE HYDRAULIC TANK BREATHER ELEMENT AWARNINC 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.

Install cover @ and snap ring 0.

I

I

I

-

AE083760

3-81

24. SERVICE

PROCEDURE

24.10 EVERY 2000 HOURS SERVICE Maintenance for every IO, 100,250,500 be carried out at the same time.

and 1000 hours should

24.10.1 CHANGE OIL IN FINAL DRIVE CASE AWARNING l

l

The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before carrying out maintenance.

If there is still pressure remaining inside the case, the oil or plug may fly out.

Loosen the plug slowly to release the pressure.

Prepare the following.

Container to catch drained oil: Min. 45 g capacity l Refill capacity: 45 4! (11.9 US gal, 9.9 UK gal) l Handle l

1.

Stop the machine so that the drain plug @ 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 oil filler @ respectively to the specified level.

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

AE170710

AE170720

3-82

24. SERVICE

24.10.2 CHANGE

OIL IN HYDRAULIC

PROCEDURE

TANK, CLEAN

STRAINER

The oil is at high temperature immediately after the machine has been operated. Wart for the orl to cool down before changing it. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it carefully. r-AwAR~NG Prepare the following.

Container to catch drained oil: min. 650 g capacity l Refill, capacity: 650 e (172 US gal, 143 UK gal) l Prepare a handle for the socket wrench set. l

1.

Retract the arm and bucket cylinder, lower the boom, put the tips of the teeth in contact with the ground, then stop the engine.

2.

Remove the cap of oil filler 0.

I

w 3.

Remove drain plug @ and loosen valve @ at the bottom of the machine body to drain off the oil. After draining off the oil, tighten up the drain valve and plug.

4.

Pour in the specified amount of engine oil through oil filler 0.

AE170730

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 ROTOR PLAY Contact your Komatsu distributor for checking.

3-83

24. SERVICE

PROCEDURE

24.10.5 CHECK SWING PINION GREASE LEVEL, ADD GREASE 1. Remove bolts @ (5 bolts) on the top of the revolving frame and remove cover 0.

2.

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.

w

Check point

Insert the scale in the portion shown in the diagram and check.

AE083800

1

If the grease is particularly milky due to ingress of water, etc., then remove bolts @ and cover @ from the bottom of the track frame and remove the grease. Replace all of the grease with new grease.

The total amount of grease is 67 g (18 US gal, 15 UK gal) (60.3 . kg)

-

3-84

AE170760

*

24. SERVICE

PROCEDURE

24.10.6CLEAN ENGINE BREATHER 1.

2.

Remove breather 0.

Rinse the breather in diesel oil or flushing oil, dry with compressed air, then install again.

Before removing the breather, clean ail the dirt from around it.

Replace the breather O-ring with a new part, and coat it with engine oil before installing.

24.10.7CHECK 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.

24.10.8CHECK ENGINE VALVE CLEARANCE, ADJUST As special tool is required for removing and adjusting the parts, request Komatsu distributor for service.

24.10.9CHECK VIBRATION

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.

3-85

24. SERVICE PROCEDURE

24.11 EVERY 4000 HOURS SERVICE Maintenance for every 10, 100, 250, 500, 1000 and 2000 hours should be carried out at the same time.

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 lea&age.

If any fault is detected, ask Komatsu distributor to disassemble and repair or replace.

24.11.3 CHECK AIR COMPRESSOR, ADJUST As special tool is required for checking and adjusting the parts, request Komatsu distributor for service.

3-86

SPECIFICATIONS

4-1

25. SPECIFICATIONS

WEIGHT l

Operating weight (including 1 operator): 80 kg

98,000

kg (216,090 Ib)

PERFORMANCE l

l

SAE Bucket capacity , (standard bucket) CECE

5.5m3 (7.2 cu.yd) 6.1m3 (8.0 cu.yd)

Width of opening I (Standard bucket)

a Travel speed

I

2650 mm (104.3 in)

Low speed

2.4 km/h (1.5 MPH)

High speed

3.4 km/h (2.1 MPH)

a Swing speed

4.5 rpm

TRACK SHOE l

710 mm (28 in) width

Double grouser shoe (standard)

ENGINE l

Model

Komatsu SAGD170-B diesel engine

l

Flywheel horsepower

405kW (542 HP) / 1700 rpm

0 Starting motor l l

24 V

Alternator

24 V

I 12 V

Battery

7.5 kW x 2 50 A

170 Ah x 2 pieces

.TOWING l

608,000 N

Towing force

SOUND LEVEL a Surrounding (sound power level L WA) dB (A) l

Operator’s (sound pressure level L PA) dB (A) measurement procedures described in IS06394 or 86/622/EEC

(

113 79

VIBRATION LEVEL l

Hands/Arms

The weighted root mean square acceleration Measurement IS07096

4-2

standard:

less than 2.5 m/s* less than 1.25 m/s*

A

Overal

I

length m

10715(35’2”) [R=4650

(15’

3”)

1

II-

-

II

Overal 3590

I width (1 1’ 9”)

4940(16’3”),

II

25. SPECIFICATIONS

Pc1000-1 Never allow other person than the operator to enter the swing range

(Max. swing range, Max. digging radius).

-

1 ,9Z> OtZ6L

.

I

(a01 ,Z1) 016E

AE30687B

4-4

2

0 2 w

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, determine signals and follow these during the operation.

When carrying 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 with the load kept suspended. Always set the load on a stand, and check that it is safe.

When removing or installing attachments, make sure that they are in a stable condition and will not fall over. . .

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 PRECAUTIONS

26.2

PRECAUTIONS

WHEN

INSTALLING

A

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 down hill with the work equipment raised

l

Traveling across slopes

INCORRECT

l

Swinging the upper structure on slopes

INCORRECT

CORRECT

\r

Platform

\

20-30cm

(8tOl2

in)

AE167540

AEl67560

AE170800

AE170810

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. lf 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. USING SEAT BELT

27.1 SEAT BELT A

WARNING

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

Replace any worn or damaged seat belt or the securing 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 the machine. l

Always use seat belt when operating the machine.

l

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

27.1.1 FASTEN THE BELT AND REMOVE IT 1. Adjust the seat so that the operator still feels that there is

2.

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”)

3.

After adjusting the seat position, sit in the seat. Grip buckle @ and tongue @ in each hand and insert tongue @ into buckle @.

Confirm by pulling the belt that the tongue is securely locked to the buckle.

4.

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.

5-4

AE306880

27. USING SEAT BELT

27.1.2 ADJUST

THE BELT LENGTH

To shorten the belt Pull the free end of the belt on either the buckle body or tongue

side.

AE078090

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.

AE078100

5-5

I

28. INTRODUCTION

28.1

SPECIFICATION, Name

I

OF ATTACHMENTS

USE

Specifications, use

Large size bucket

Capacity Outside width

7.0 m3 (9.2 cu.yd) 2650 mm (104”)

FOPS

In place where there is danger of falling rocks, always install the head guard to protect the operator.

FGPS

In place where there is danger of rocks from front, always install the front guard to protect the operator.

Track shoes

Double grouser

710 mm (28”) 910 mm (36”) 1010 mm (40”)

Following attachments are available: l l l l l l l

Low cab Seat belt Fire extinguisher Full length roller guard Roller guard Revo-frame under cover Vandalism

For details, please contact Komatsu or your Komatsu distributor.

Full length roller guide and extra counterweight as standard attachments.

5-6

29. GENERAL LOCATIONS

Arm

Arm

cylinder

I

me Track

shoe

Idler

AE30689B

6-2

30. INSTRUMENTS

30.1

AND CONTROLS

SWITCH

1

AE170890

AE170900

1.

2.

3.

4.

5.

6.

STARTING SWITCH LOW TEMPERATURE STARTING AID SWITCH SWING PARKING BRAKE SWITCH SWING BRAKE SWITCH TRAVEL SPEED SELECTOR SWITCH AUTO-DECELERATION SWITCH 7. CIGARETTE LIGHTER 8. AUTOMATIC-HORIZONTAL DIGGING SWITCH 9. BOTTOM DUMP SWITCH 8 and 9 does not equipped to back hoe type.

10. HORN SWITCH 11. ROOM LAMP SWITCH See operation

6-3

30. INSTRUMENTS AND CONTROLS

30.2

CONTROL

LEVERS

c”““““‘“.

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

AE170910

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

AE170920

30. 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 swings to the right. @I Upper structure swings to the left.

@J 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

@I Neutral: When the lever in this position, the boom and the bucket will be retained in the position in which they stop.

For machine with auto-deceleration device, the engine revolution changes as follows according to the positions of levers 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

30. INSTRUMENTS AND CONTROLS

30.3

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. 0 When normal @ Electronic OLSS controller Indication of LED

1

1

Condition of machine

Goes off 1Lights

I 1 Machine is normal in the mode ‘5”.

Goes off 1Flashes fast

) Machine is normai in the mode “H” or “L”.

Red

Greed

Goes off 1Flashes slowly 1 Machine is normal and auto-decelerator is applied.

6-6

30. INSTRUMENTS AND CONTROLS

30.4

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.

Fuse capacity

No.

Circuit

I

20A

Head lamp

I

1OA

Working tamp

0

20A

Spare

@

20A

APS

0

1OA

Monitor, Controller, OLSS

@

20A.

Air conditioner

0

?OA

@

2OA

@

20A

Wiper, Room lamp

@

IOA

Cigarette lighter, Radio

0 02 1

AD052120

.

6-7

31.1

OPERATION

OF WORK EQUIPMENT

suddenly increase, 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

31. OPERATION

Boom operation

Bucket operation

/

Boom

operation

Bucket

operat

ion

6-9

31. OPERATION

31.2

CHECK BEFORE STARTING ENGINE

Perform following checks for operator safety and maintenance of machine performance.

31.21

WALK-AROUND

CHECK

A

WARNING

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.

l

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 before starting the engine each day.

AE171020

1.

Check for damage, linkage, hoses

wear,

play in work

equipment,

cylinders,

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.

6-10

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

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.

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 is found, contact your Komatsu distributor for repair.

6-11

31. OPERATION

11. Check tightness

of air cleaner mounting bolts.

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

The oil level should be between 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 at the bottom of the tank together with fuel.

For detail see MAINTENANCE ING”.

6-12

“24.4 CHECK BEFORE START-

32. PRECAUTIONS

32.1

PRECAUTONS

FOR MACHINE OPERATION

DURING

A

OPERATION

WARNING

For machine with autodeceleration device, if the lever is operated inside the deceleration range, the engine speed will rise suddenly.

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.

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

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.

INCORRECT

A

AE171040

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.

I,,

I I

INCORRECT

INCORRECT

AE171060

6-13

32. 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

AE171070

Digging

rocky ground

INCORRECT

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 l

l

l

6-14

that do not indicate

failure

Note that the following phenomena are not faults: The arm may sometimes stop when the bucket teeth become more or less horizontal.

At the beginning and end of a swinging, a noise may sometimes be emitted from the brake valve.

When descending a steep slope at low speed, a noise may sometimes be emitted from the travel motor.

33. 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, SWING CIRCUIT, TRAVEL CIRCUIT

slowly to release the internal pressure before taking off the cap.

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.

After stopping the engine, move each work equipment control lever to the end of its travel within 5 to 6 seconds.

Leave the starting switch ON.

AE171090

Remove the cap of the hydraulic 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.

5. After stopping the engine, move each work equipment control lever to the end of its travel within 5 to 6 seconds.

Repeat Steps 4 to 5 three times.

6-15

34. MAINTENANCE

34.1 OIL FILLER AND LEVEL GAUGE POSITION Fuel Hydraulic Radiator Hydraulic

Engine

oil

pan

water

sight

gauge

drain

plus Radiator

tank

filler

oil

tank

filler

filler Fuel

/

I

I

tank

sight

gauge

\ drain

cock Hydraulic

Swing

Fuel

\ tank

machinery

drain

oil

tank

drain

cock

Plug

filler,

AE306908

level

gauge ge

Engine oil 0iI filler PTO level

Swing

machinery

drain

plus

pan case oil sause

filler,

drain

plus AE306916

34. MAINTENANCE

34.2 ADJUST BUCKET CLEARANCE

a WARNING It is dangerous if the work equipment moves by mistake when the clearance is being adjusted.

Set the work equipment in a stable condition, then stop the engine and lock the lever securely.

AE167470

If there is excessive free play on the coupling section of the bucket and arm, adjust the bucket clearance in the following manner.

Loosen 3 bolts 0,

4 bolts 0, plate @ and plate 0.

Put the O-ring @ on the shoulder of bucket boss @ or bushing Touch the ends of bucket boss 0 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.

@. @. or 0.04 in). shim, do not

Tighten 3 bolts @ and 4 bolts 0.

With this adjustment, clearance @ becomes larger, but play @ is removed.

AE171120

6-17

34.

MAINTENANCE

34.3

CHECK BEFORE STARTING

CHECK OIL LEVEL IN HYDRAULIC TANK WARNING

l

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 @.

1.

Run the engine at low speed, retract the arm cylinder, extend the bucket cyfinder, lower the boom until the bottom of the bucket touches the ground and then stop the engine.

2.

Move each operation lever (for work equipment and travel) to its full travel to release the internal pressure.

3.

If the level of hydraulic oil is not between top H and bottom L lines of sight gauge 8, pour in additional engine oil from filler o= 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.

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

AE171090

AEl71140

AE168670

34.4

EVERY 10 HOURS SERVICE.

AE306920

34.4.1 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 bIock (5 points).

Boom foot pin l Arm cylinder foot pin l Boom cylinder rod end l

2.

Boom cylinder foot pin (2 points)

I

---A AE170070

3.

Arm concentration lubricating block (3 points) l Boom-Arm coupling pin l Arm cylinder rod end l Bucket cylinder foot pin

6-19

34. MAINTENANCE

34.42 CHANGE OIL IN HYDRAULIC

TANK

AE171090

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.

VJ

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 oil filler @.

AE170730

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 fi (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

35. 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.

720

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.

AE082730

6-22

1

* 36. 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 in the diagrams are given in millimeters.

PC1000-l

[

1: PcloOOLc

{

}: PC1 OOOSE Weight:

28,400 (62,600 [35,580 [(78,450 (28,400 ((62,600

kg (14,200 x 2) lb (31,300 x 2)) kg (17,790 x 211 lb (39,225 x 2))1 kg (14,200 x 2)) lb (31,300 x 2)))

Weight:

300 kg (662 lb)

Weight:

90 kg (198 lb)

AE169510

AE169520

AE169530

6-23

36. TRANSPORTATION

I

I: PcloooLc

{

Secure the body to the shipping support with chains, blocks, etc.

Width

}: PC1 OOOSE Weight:

29,500 kg (65,050 lb) [29,500 kg (65,050 lb)1 (30,000 kg (67,500 lb))

Weight:

5,100 kg (11,250 lb) [5,100 kg (13,250 IbH (5,700 kg (12,570 Ib)I

Weight:

11,500 kg (25,360 lb) [11,500 kg (25,360 lb)] (9,900 kg (21,830 lb))

Weight:

14,000

AE169501

550 AE171250

Width

1410

AE171260

AE169550

6-24

kg (30,370

lb)

36. TRANSPORTATION

[

1: Pc1oooLc

{

}: PC’IOOOSE Weight:

4,000 kg (8,820 lb) [4,000 kg (8,820 lb)] (5,200 kg (11,470 lb))

Weight:

2,400 kg (1,200 x 2) (5,290 lb (2,645 x 2))

Weight:

60 kg (132 lb)

AE171270

AE169570

AEl71280

Total weight: Weight 2 kg x 3 (4.4 lb x 3)

Weight 30 kg x 2 (66 lb x 2)

Weight 5 kg (11 lb)

Weight 120 kg x 2 (265 lb x 2)

Weight 60 kg (132 lb)

410 kg (904 lb)

Weight 25 kg (55 lb)

Weight 7 kg x 2 (15 lb x 2)

AE169590

6-25

36. TRANSPORTATION

Total Weight: 559 kg (1,235 lb) Weight 18 kg (40 lb)

Weight 23 kg (51 lb)

Weight 27 kg (60 lb)

Weight 30 kg (66 lb) A

AD306630

-1

w AD306640

AD306660

Weight 47 kg (104 lb)

Weight 54 kg (119 lb)

Weight 360 kg (795 lb)

AE08295D AD306670

6-26

AE306680

37. INTRODUCTION

37.1

ATTACHMENT

OF ATTACHMENTS

INSTALLATION

COMBINATION

TABLE

This table lists the combination of attachments which can be installed to the standard arm, semi long 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 during oblique digging, the boom interferes with the undercarriage.

Operate the boom carefully.

Categories of use digging or loading sand, gravel, clay, etc.

For general digging: For light duty digging: digging or loading dry, uncaked earth and sand, mud, etc. loading dry, loose earth and sand For loading work: Capacity (m3) [CECEI

Name of bucket

I

II

I

2.7

I

Narrow digging

I

I

I

n

I

I

X I I

X

X

0

x I

X

n

0

I

Long arm

Semi long arm

I

0

Narrow digging I I

2500 (98.43”)

Short arm

0 I

Loading

1690 (66.54”)

3.3 I

Narrow bucket

General digging

2500 (98.43”)

4.7

Wide bucket

Standard boom

Standard arm

I I

I I

Short boom

USE

2060 (81.10”)

3.8

Standard bucket

Narrow bucket

Width (mm)

n

0 I

I

X

I

0

0

6-27

37. INTRODUCTION OF ATTACHMENTS

37.2

SPECIFICATION, Name

USE

Specifications, use

Wide bucket

Capacity Outside width

4.7 m3 (6.12 cu.yd) 2500 mm (98.4”)

Narrow bucket

Capacity Outside width

2.7 m3 (3.52 cu.yd) 1650 mm (65”)

FOPS

In place where there is danger of falling rocks, always install the head guard to protect the operator.

FGPS

In place where there is danger of rocks from front, always install the front guard to protect the operator.

Track shoes

Double grouser

710 mm (28”) 910 mm (36”) 1010 mm (40”)

Following attachments are available: Seat belt l Fire extinguisher l Full length roller guard a 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 ktachments.

6-28

38. SPECIFICATIONS

PCIOOO-I, PClOOOLC-1, PCIOOOSE-1 (BACK HOE SHOVEL) Pc1000-1

Pc1oooLc-1

PClOOOSE-1

I

WEIGHT l

Operating

weight

(including

1 operator):

80 kg 1 95,000kg (209,475 lb) 1103,300kg (277,780 lb)1 97,000 kg (213,890 lb)

PERFORMANCE

I

l

Bucket capacity (standard

l

Width of opening

l

Travel speed

l

3.8 m3 (5.0 cu.yd)

bucket)

(Standard

1,890 (74.4 in)

bucket)

Low speed

2.4 km/h (1.5 MPH)

High speed

3.4 km/h (2.1 MPH) 4.5 rpm

Swing speed

TRACK SHOE l

Double grouser shoe (standard)

/

710 mm (28 in)

I 1010 mm (40 in)

I

710 mm (28 in)

ENGINE l

Komatsu

Model

a Flywheel 0 Starting l

Alternator

l

Battery

SA6D170-B diesel engine

405 kW (542 HP) / 1700 rpm

horsepower

24 V

motor

7.5 kW x 2

24 V 12 V

50 A

170 Ah x 2 pieces

TOWING l

608,000 N

Towing force

SOUND LEVEL l

Surrounding

(sound power

level L WA) dB (A)

l

Operator’s (sound pressure level L PA) dB (A) measurement procedures described in IS06394 or 86/622/EEC

113 79

VIBRATION LEVEL l

Hands/Arms

The weighted root mean square acceleration

l

Whole body

Measurement lSO7096

standard:

fess than 2.5 m/s2 less than 1.25 m/s2

6-29

Overal

I

length

I-

50

15790(51’

(5030(16’6”)1

=

4590 (R=4650

[5950 (19’6’71

10”)

1”) (15’ (1 5’ 3”)) _.

m -

.-m&z e

-

-

-, -

-M-

w p mcr)

--J -

*

e

0

0

0 In

-N

*

9

1855

(15’2”) 4610 l”)] (16’ [4910 (4610(15’2”)1

I

width.4850(15

4, liLQ

(Overall

0

cr) -

z

m m -

0

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38. SPECIFICATIONS

Never allow other person than the operator (Max. Swing range, Max, digging radius).

to enter the swing

range

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Komatsu America International Company 440 North Fairway Drive I Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186

I

PROPOSAL FOR MANUAL REV6lON

I

FOR INTERNAL USE ONLY -- No. PMR

P R 0 P

NAME OF COMPANY:

PHONE NO:

;

DEPARTMENT: I

MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:

PROBLEM:

Attach photo or sketch.

If more space is needed, use another sheet.

1 FOR INTERNAL USE ONLY 1 CORRECTIVE ACTION:

PFMRl 081696

LOCATION:

DATE: