KOMATSU PC1800-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:PC1800-6 -10002 and up)

& Maintenance Operation Manual

SEAM022902

HYDRAULIC EXCAVATOR

SERIAL NUMBERS

up PC1800-6-10002 and

This material is proprietary to Komatsu Mining Systems and is not to be reproduced, used, or disclosed except in accordance with wriien authorization from Komatsu Mining Systems. the right to make It is our policy to improve our products whenever it is possible and practical to do so. We reserve on products sold changes such install to changes or add improvements at any time without incurring any obligation previously. this publication.

Due to this continuous program of research and development, periodic revisions may be made to It is recommended that customers contact their distributor for information on the latest revision.

December 1999

Copyright 1999 Komatsu DataKom Publishing Corporation

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

A

__._-

____

_-

WARNING

l

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

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

Keep this manual in the luggage box behind the operator’s seat for easy reference, and have all workers who handle the machine read it periodically.

Where to keep this manual. + “11.6 POCKET�.

l

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.

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

l

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. lf there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.

l

The description of safety is given in SAFETY INFORMATION on page O-2 and in SAFETY from page l-l.

CALIFORNIA Proposition 65 Warning Dieselengine exhaust and some of its

constituents are known to the State of California to cause cancer, birth defects,

and other

reproductive

harm.

O-l

2. SAFETY INFORMATION

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

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

A DANGER

-

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

A WARNING

-

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

A CAUTION

-

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

-

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

NOTICE

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 l Digging work l Loading work

EXCAVATOR

See the section “12.14 WORK

POSSIBLE

is designed

USING

to be used mainly for the following

HYDRAULIC

EXCAVATOR”

for further

work:

details.

3.2 FEATURES l

l l l l l l

3.3

This Komatsu HYDRAULIC EXCAVATOR is equipped with various controls based on an advanced electronics system. o The monitor panel greatly facilitates daily maintenance and self-diagnosis. o The monitor panel and machine control system monitor greatly facilitates daily maintenance, self-diagnosis and maintenance control. o Working mode, travel speed and swing priority are selectable.

Adjustable semi wrist control levers make operations smooth and easy.

Air-conditioned operator’s cab assures comfortable operation.

Improved operator comfort due to noise and vibration, and smart urban-style design and color, Enhanced safety by addition emergency stop lever, rear-view mirror and grill.

Superb operating performance provided by powerful engine and high-performance hydraulic pumps.

Low fuel consumption controlled by an electronic control system provides an environment-friendly machine.

RUNNING

IN THE MACHINE

Your Komatsu machine has been thoroughly adjusted and tested before shipment.

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

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

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

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

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

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

4.1 MACHINE

SERIAL NO. PLATE POSITION

On the front bottom left of the operator’s cab (side of upper frame)

4.2

ENGINE SERIAL NO. PLATE POSITION

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

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

1

Address:

Service personnel for your machine: REMARKS

o-4

Phone:

5. CONTENTS

.. . . .. .. . . . .... . .. . .. . .. . ... . .. . . . .. .. . . . .. .. . . . . .._.................................._................................._...................

1.

Foreword

2.

Safety

3.

Introduction

4.

Location

information

.. . . . ... . . .. . . .. .. .. .. . . .. . . . . .. . . .. . ...-..-............................~...................................................

..,......................................-.............................................................,................................

of plates,

table to enter serial No. and distributor

..L......._...........................................

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

SAFETY precautions

. . .. ... . . . .. . .. . . . .. . . . . . . . . . .. . .. . . . . .. . . .. .. .. .. .. . .. . .. . .. .. . . . .. .. . ... .. . . . . .. .. .._. .. .. . . . . .... . ... .. . . .. . . .. .. ... .. .

I- 2

6.

General

7.

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

Precautions during operation Before starting engine .............................................................................................................

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

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

7.3 Transportation 7.4 Battery .......................................................................................................................................

7.5 Towing ......................................................................................................................................

Lifting operations .....................................................................................................................

7.6

I- 9 I- 9 l-l 1 l-78 1-19 l-21 I-21

8.

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

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

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

8.2

l-22 l-22 1-26

9.

Position

for attaching

safety labels

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

I-31

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

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

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

2- 2 2- 2 2- 3

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

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

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

11.3 Lamp .........................................................................................................................................

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

11.5 Door lock.. .................................................................................................................................

11.6 Pocket ........................................................................................................................................

11.7 Handling air conditioner .........................................................................................................

11.8 Emergency escape hammer ...................................................................................................

11.9 Emergency escape iadder .......................................................................................................

11 .lO Cap, cover with lock ................................................................................................................

11.11 Ashtray ......................................................................................................................................

11.12 Car radio ...................................................................................................................................

11.13 Fuse ...........................................................................................................................................

11.14 Circuit-breaker ..........................................................................................................................

11.15 Controllers ................................................................................................................................

11.16 Tool box ....................................................................................................................................

II .I7 Grease pump ............................................................................................................................

11.18 Handling grease pump ............................................................................................................

11 .I9 Handling accumulator .............................................................................................................

11.20 Health monitor .........................................................................................................................

2- 5 2- 5 2-14 2-21 2-22 2-25 2-25 2-26 2-29 2-30 2-31 2-31 2-32 2-37 2-38 2-38 2-38 2-39 2-39 2-41 2-43

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12. Operation .........................._. ... .. .._...._.._................................................................................................

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

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

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

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

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

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

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

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

12.9 Handling working mode ..........................................................................................................

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

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

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

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

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

12.15 Phenomena that are not failures ........................................................................................... i.. ........

12.16 Parking machine ...........................................................................................................

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

12.18 Stopping engine .......................................................................................................................

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

12.20 Locking ......................................................................................................................................

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

13.1 Precaution for transportation .................................................................................................

13.2 Parts for transport ...................................................................................................................

2-54 2-54 2-68 2-71 2-77 2-80 2-82 2-83 2-84 2-85 2-86 2-88 2-89 2-91 2-92 2-92 2-93 2-94 2-95 2-98 2-98 2-99 2-99 2-100

14. Cold weather operation ....................................................................................................................2-108 2-108 14.1 Precautions for low temperature ...........................................................................................

2-110 14.2 Precautions after completion of work ...................................................................................

2-110 14.3 After cold weather ...................................................................................................................

15. Long-term storage .............................................................................................................................2-111 2-111 15.1 Before storage ..........................................................................................................................

2-112 15.2 During storage .........................................................................................................................

2-112 15.3 After storage .............................................................................................................................

2-112 15.4 Starting machine after long-term storage ............................................................................

16. Troubleshooting .................................................................................................................................2-l 13

O-6

16.1 16.2

When fuel runs out .................................................................................................................2-113 2-l 13 Phenomena that are not failures ...........................................................................................

16.3 16.4 16.5 16.6

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

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

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

Other trouble ............................................................................................................................

2-113 2-l 13 2-114 2-l 17

MAINTENANCE ..... ....................... ....... ... ....................... .... ..... ......

17. Guides to maintenance .......... ......._.................. _._._

3- 2

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

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

3- 6

18.2 18.3 18.4 18.5

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

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

Releasing pressure ..................................................................................................................

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

19. Consumable parts list . .. . .. .. . . ... .. . .. .. . . ... _. . . . .. ._.. . ... . ._. . . .. . . . . . . .. .. . . . . . . .__....................................................

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

....a..............................

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

21.1 Introduction of necessary tools.. ............................................................................................

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

22. Periodic replacement

of critical safety parts

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

3- 6 3- 9 3-10 3-11 3-13 3-19

3-20 3-24 3-24 3-25 3-26

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

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

3-28 3-28

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

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

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

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

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

24.5 Every 70 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.. ......................................................................................................

24.12 Every 5000 hours service.. ......................................................................................................

3-32 3-32 3-32 3-33 3-49 3-50 3-53 3-54 3-61 3-66 3-68 3-71 3-72

SPECIFICATIONS 25. Specifications . .. . .. . ... .. ... . . .. .. . . .. .. . . .. . . . . .. .. . . .. . .. . . .. .. .. .. .. .. . . .. . . . . ._. .. . . . .. . .. . . .. . ..- _. . .. . .. .. . . .. . . . .. . . .. . .. . . .. . . . .. . ..-

OPTIONS,

4- 2

A-ITACHMENTS

26. General precautions ..........................................................................................................................

26.1 Precautions related to safety.. ................................................................................................

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

5- 2 5- 2 5- 3

27. Introduction of attachments

5- 4 5 4

27.1

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

Guards.. .....................................................................................................................................

28. Auto-greasing system . ... . .. . . . ... .. . .. . .. . . ... .. . ... . . . .. . .. .. . .. . . . . . . . .. .. . . . .. . . . . . . .. . ... . .. .._........._..............................

5- 5

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SAFETY

A

WARNING

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

Failure to do so may

This safety section also contains precautions ment and attachments.

for optional equip-

l-1

A ~~14~~~~;e~;ereasons

of safety, always ty precautions.

6. GENERAL PRECAUTIONS

SAFETY RULES

}

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

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

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

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

Always follow all rules related to safety.

l l l l

Be sure that all guards and covers are in their proper position. if damaged.

Use safety features such as safety lock levers 0 and the seat Never remove any safety features. Always keep them in good Safety lock lever - See ‘12.16 PARKING MACHINE�.

Improper use of safety features could result in serious bodily

Have guards and covers repaired belt properly. operating condition. injury or death.

AN364156

CLOTHING AND PERSONAL PROTECTIVE ITEMS

1

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

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

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

or in moving

parts

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

a 422 AE30.5770

Any modification made without authorization from Komatsu can create hazards. modification, consult your Komatsu distributor. Komatsu will not be responsible damage caused by any unauthorized modification.

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Before making a for any injury or

1

A ;tR;;Et;

l

FaIaIic

follow these safety precautions may lead 6. GENERAL PRECAUTIONS

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

When leaving the machine, lower the blade and ripper completely to the ground, set the safety lock levers @ to the LOCK position, then stop the engine. Use the key to lock all the equipment.

Always remove the key and take it with you. posture + See “12.16 PARKING MACHINE”.

Work equipment Locking -+ See “12.20 LOCKING”

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

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

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

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

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

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

Always lock the door securely.

Method of locking door -) See ‘11.4 DOOR LOCK”.

AM332430

AL187320

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a 6. GENERALPRECAUTIONS

~A&J;M~e~;ereasons qf safety, always ty precautions.

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

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

Fuel,

mnom

A0055030

A0055040

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

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

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

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

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

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A LVtR;;Et;

Faiai~$

follow these safety precautions may lead 6. GENERAL PRECAUTIONS

ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be hazardous to your health if it is inhaled.

Komatsu does not use asbestos in its products, but if you handle materials containing asbestos fibers, follow the guidelines given below: l Never use compressed air for cleaning. l Use water to keep down the dust when cleaning. l If there is danger that there may be asbestos dust in the air, operate the machine from an upwind position whenever possible. l Use an approved respirator if necessary.

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

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

If it is necessary to go between movable parts, always lock the levers and be sure that the work equipment cannot move. For details, see ‘8. PRECAUTIONS FOR MAINTENANCE�.

AoossOso

-j

FIRE EXTlNGUISHER AND FIRST AID KlT

1

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

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

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

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

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

A0055070

1-5

6. GENERAL PRECAUTIONS

A ~~V,“~~~lePc;,rasons cf safety, always ty precautrons.

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

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

The above comments are made with regards to typical working conditions. By all means 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.

Se 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.

FOPS (falling object protective structure)

l-6

a

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

6. GENERAL PRECAUTIONS

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 and also lock the attachment pedal with the lock pin.

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 “11.19 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 l l

Never make any hole in the accumulator or expose Do not weld any boss to the accumulator.

it to flame

or fire.

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.

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& E;!WN& 6. GENERAL PRECAUTIONS

FWereasons of safety, always ty precautrons.

Exhaust fumes from the engine can kill.

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

l

l

If opening the doors and windows still does not provide adequate ventilation, set up fans.

WINDOW TO ESCAPE OF OPERATOR’S CAB l

Should the door of the cab be jammed, break the left-hand window to escape.

There is a ladder in the box on the left side of the operator’s compartment, so use it if necessary.

For details of the method of using the ladder + EMERGENCY ESCAPE LADDER”.

l

In this case, break the left-hand window using the hammer installed to the left-hand control stand.

For details of the method of using the hammer EMERGENCY ESCAPE HAMMER”.

1-8

see ‘11.9

see “11.8

7. PRECAUTIONS DURING OPERATION

7.1 -I

BEFORE STARTING SAFETY AT WORKSfTE

A WARNING:

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

ENGINE

1

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

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

Make the g,round surface as hard and horizontal as possible before carrying out operations.

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

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

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

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

Permissible water depth + See “12.11 PRECAUTIONS FOR OPERATION”

AE341250

CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the days work.

Failure to carry out these checks may lead to serious injury or damage. l Completely remove all flammable materials accumulated around the engine and battery, return all fuel containers to their proper place, remove all parts and tools from the operator’s compartment, and remove any dirt from the mirrors, handrails, and steps.

Walk-around

checks +

See “12.1.1

WALK-AROUND

CHECK”.

l

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

l

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

Checks before starting

l

+

See “12.12

CHECK BEFORE STARTING”.

Adjusting operator’s seat + See ‘12.1.3 OPERATORS SEAT”.

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

position.

Method of checking operation of gauges See ‘12.1.6 OPERATIONS AND CHECKS BEFORE STARTING ENGINE”. l Check that the mirrors and window glass provide a clear view.

If the above inspections show any abnormality, carry out repairs immediately. l If any of the machine’s mirrors are broken, replace them. l Removal and installation of mirrors for replacement or transportation. / f f For adjustment of the mirrors + For removal

See “12.1.4 ADJUSTMENT OF MIRRORS.” and installation of the mirrors + See “13.1 PRECAUTIONS FOR TRANSPORTATION.”

&

A& A0055020

A ~+i$JJie 7. PRECAUTIONS DURING OPERATION

WHEN

STARTING

Foiereasons of safety, always ty precautions.

ENGINE

I

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

Never start the engine if a warning tag has been attached to the work equipment control lever.

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

Start and operate the machine only while seated.

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

Do not short circuit the starting motor circuit to start the engine. It is not only dangerous, but will also cause damage to the equipment.

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

099634WOJ

I-10

A E:;MEf;

FaiJaito follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATlON

7.2

AFTER STARTfNG

ENGfNE

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

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

-I

PRECAUTIONS WHEN STARTING OFF 1

Check the direction of the track frame before operating the travel lever.

When the sprocket is at the front, the operation of the travel lever is reversed, so operate the machine carefully.

Method of steering machine + See “12.4 MOVING MACHINE OR”.

Before moving the machine off, check again that there are no persons or obstacies in the surrounding area.

When moving the machine off, sound the horn to warn people in the surrounding area.

Always sit in the operator’s seat when driving the machine.

Fasten your seat belt securely.

The operator must not let any other person sit anywhere except in the assistant’s seat.

Check that the travel alarm (option) works properly.

Always close the door of the operator’s cab and check that the door is locked in position securely.

CHECK WHEN CHANGING DIRECTION

Travel

in

reverse

direction

1

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

leveling work.

Before changing between forward and reverse, reduce speed and stop the machine. l Before operating the machine, sound the horn to warn people in the area. l Check that there is no one near the machine. Be particularly careful to check behind the machine. l When operating in areas that may be hazardous or have poor visibility, designate a person to direct worksite traffic. l Ensure that no unauthorized person can come within the direction of turning or direction of travel.

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

1-11

A )Vfgl;P4?ge 7. PRECAUTIONS DURING OPERATION

Foiereasons of safety, always ty precautions.

PRECAUTIONSWHEN TRAVELING 1 Never turn the key in the starting switch to the OFF position when traveling.

It is dangerous if the engine stops when the machine is traveling, because it becomes impossible to operate the steering.

It is dangerous to look around you when operating. Always concentrate on your work.

It is dangerous to drive too fast, or to start suddenly, stop suddenly, turn sharply, or zigzag.

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

Set the work equipment to a height of 40 - 50 cm (16 - 20 in) from the ground level and travel on level ground.

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

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

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

Avoid traveling over obstacles as far as possible. If the machine has to travel over an obstacle, keep the work equipment as close to the ground as possible and travel at low speed. Never travel over obstacles which make the machine tilt strongly (10” or more).

When traveling or carrying out operations, always keep your distance from other machines or structures to avoid coming into contact with them.

NEVER be in water which is in excess of the permissible water depth.

Permissiblewater depth + See “12.11 PRECAUTIONS FOR OPERATION”.

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

Travel posture

INCORRECT

AE341200

1-12

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

7. PRECAUTIONSDURING OPERATION

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

When traveling on slopes, keep the blade approximately 20 - 30 cm (8 - 12 in) above the ground.

In case of emergency, quickly lower the bucket to the ground to help the machine to stop.

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

Method of traveling on slopes * See “12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS�.

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

If the engine stops on a slope, place the travel lever at the neutral position and lower the bucket to the ground. Do not operate the steering. There is danger that the machine will turn under its own weight.

Uphill

Downhill

CORRECT INCORRECT

AE341310

A034129A

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

Do not carry out deep digging under the front of the machine. The ground under the machine may collapse and cause the machine to fall. Take emergencies into consideration and set with the travel motor at the rear and the track (undercarriage) at right angles to the road shoulder before digging to enable the machine to move back quickly. If the ground under the machine collapses and there is no time to drive in reverse, do,not suddenly raise the arm and boom. In some cases, it may in fact be safer to lower the arm and boom.

Do not swing the work equipment to the side when it is carrying a heavy load. The stability to the side is less than the stability to the front, so there is danger that the machine may turn over.

Limits on use To prevent accidents caused by breakage of the work equipment or tipping over of the machine under excessive load, do not use the machine in excess of its capacity. Always be sure to keep within the maximum specified load and safe angle determined for the structure.

INCORRECT

INCORRECT

AD34132A

7. PRECAUTIONSDURING OPERATION

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

PRECAUTIONS WHEN OPERATING l l

l

Be careful not to approach too close to the edge of cliffs.

Carry out only work that is specified as the purpose of the machine.

Carrying out other operations will cause breakdowns.

Specifiedoperations + See “12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR”.

Do the following to ensure good visibility.

When operating in dark places, turn on the working lamps and front lamps, and install lighting at the jobsite if necessary.

Do not carry out operations in fog, mist, snow, or heavy rain, or other conditions where the visibility is poor. Wait for the weather to clear so that visibility is sufficient to carry out work.

Always do as follows to prevent the work equipment from hitting other objects.

When operating in tunnels, under bridges, under electric wires, or other places where the height is limited, be extremely careful not to -let the bucket, boom, or arm hit anything.

To prevent accidents caused by hitting other objects, always operate the machine at a speed which is safe for operation, particularly in confined spaces, indoors, and in places where there are other machines.

Never pass the bucket over the head of any worker or over the operator’s cab on a dump truck. l

l

l

l

l

l

1-14

A E;RNN~J; FaiJaizc follow these safaty precautions may lead 7. PRECAUTIONS DURING OPERATION

DO NOT GO CLOSE TO l

l

Do not let the machine touch overhead electric cables. Even going close to high-voltage cables can cause electric shock. Always maintain the safe distance given below between the machine and the electric cable.

To prevent accidents, always do as follows.

Cn jobsites where there is danger that the machine may touch the electric cables, consult the electricity company before starting operations to check that the actions determined by the relevant laws and regulations have been taken.

Wear rubber shoes and gloves. Lay a rubber sheet on top of the operatofs seat, and be careful not to touch the chassis with any exposed part of your body.

Use a signalman to give warning if the machine approaches too close to the electric cables.

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

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

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

Voltage 3 5.

2$ & 2 P .c 0 E 2 P

100

Min. safety distance

200 v

2m

6,600 v

2m

22,000 v

3m

66,000 v

4m

154,000 v

5m

l

187,000 V

6m

275,000 V

7m

500,000 v

11 m

OPERATE CAREFULLY ON SNOW

AE2.41340

J

1

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

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

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

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

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

1-15

For reasons of safety, always follow these safety precautions.

A WARNING: 7. PRECAUTIONS DURING OPERATION

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

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

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

Install the head guard (FOPS) when working in areas where there is danger of falling stones.

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

PRECAUTIONS WHEN WORKING ON SLOPES 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.

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

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

INCORRECT

CORRECT

AD34136A

1-16

1

A y$RNNFs

follow these safety precautions may lead

Fsisi;;~

7. PRECAUTIONS DURING OPERATION

.

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

If it is necessary to park the machine on a slope, set blocks under the tracks to prevent the machine into the ground. from moving, then dig the work equipment After stopping the engine, operate the right work equipment control lever several times to the RAISE and LOWER positions to release the remaining pressure in the hydraulic circuit.

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

Parking procedure + See “12.16 PARKING MACHINE”.

When leaving the machine, set the safety lock lever @to the LOCK position, stop the engine, and use the key to lock all the equipment.

Always

remove

the key and take it with you.

Work equipment posture -( See “12.16 PARKING MACHINE”.

Locks + See “12.20 LOCKING”.

Always close the door of the operator’s compartment.

Method

CORRECT

Thrust

the bucket

of locking

AD3413lA

AN364

15E

remove all water, snow, or mud stuck to the wiring harness, operations, After completing connector 0, switches, or sensors, and cover these parts. of the machine when it is next used, which may If the water freezes, it will cause malfunctions accidents. unexpected to lead If the machine is not thoroughly warmed up operation thoroughly.

Carry out the warming-up before the control levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.

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

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

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

Battery charge rate -

See “14. COLD WEATHER OPERATION”.

AE305820

a )4M&M~;e 7. PRECAUTIONSDURING OPERATION

Fciereasons cf safety, always ty precautions.

7.3 TRANSPORTATION When transporting the machine, follow the relevant rules and regulations, and take steps to ensure safety.

When selecting the transportation route, take into consideration the maximum width, height, and weight of the machine when loaded on the trailer.

Height, width, weight when loaded + See ‘13. TRANSPORTATION”.

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

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

The machine can be divided into units for transportation, so please contact your Komatsu distributor when transporting.

Transportation posture -) See “13. TRANSPORTATION”.

1-18

A I&l;RN;INt; Fai;ai;o

follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATION

7.4 -I

BATTERY BATTERY HAZARD PREVENTION-

1

Battery electrolyte contains sulphuric acid, and batteries generate hydrogen gas, so mistaken handling can lead to serious injury or fire. For this reason, always observe the following-. precautions.

Never bring any lighted cigarette or flame near the battery: When working with batteries, ALWAYS wear safety glasses and,rubber gloves.

If you spill acid on your clothes or skin, immediately flush the area with large amounts of water.

Battery acid could cause blindness if splashed into the eyes. If acid gets into your eyes, flush them immediately with large quantities of water and see a doctor at once. if you accidentally drink electrolyte, drink a large quantity of water or milk, beaten egg or vegetable oil. Call a doctor or poison prevention center immediately.

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

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

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

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

If the battery electrolyte is near the LOWER LEVEL, add distilled water. Do not add distilled water above the UPPER LEVEL. When cleaning the top surface of the battery, wipe it with a damp cloth. Never use gasoline, thinner, or any other organic solvent or cleaning agent.

Tighten the battery caps securely.

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

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

Always remove the battery from the chassis before charging it.

Qy2 @

cE9

@a dk AE305830

A0055110

1-19

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

7. PRECAUTIONSDURING OPERATION

4

STARTING WITH-1

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

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

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

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

Be sure to connect the positive @ cable first when installing the booster cables. Disconnect the ground or negative 0 cable first when removing them.

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

Starting procedure when using booster cables - See “16.5 IF BAlTERY IS DISCHARGED”.

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

INCORRECT

1 CHARGINGI

1

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

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

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

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

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

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

INCORRECT

l-20

Faiiaito

A ~;“,“~M~;

follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATION

7.5

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

Do not tow in a different way from the method given in the section “16.3 METHOD OF TOWING

MACHINE”.

Always wear leather gloves when handling wire rope.

When carrying out the preparation for towing with another worker, agree on signals before starting the operation.

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

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

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

If a problem machine is towed by another machine, ALWAYS use a wire rope with a sufficient

7.6 1

of the problem

machine.

towing

capacity for the weight

Do not

use a wire rope which has cut strands @, kinks @, or reduced diameter 0.

LIFTING OPERATIONS PROHIBITIONS

FOR LIFTING

OPERATIONS

1

l

to carry out lifting operations. do not do the following.

Do not weld a hook to the bucket to lift a load.

l

Do not fit a wire rope to the bucket teeth to lift a load.

l

Do not wind a wire rope directly around the boom or arm to lift a load.

Do not use the work equipment In particular,

1-21

8. PRECAUTIONS FOR MAINTENANCE

8.1

BEFORE CARRYING NOTIFICATION

A gN!l;W& Fc;sreasons of

safety, always ty pracautlons.

OUT MAINTENANCE

OF FAILURE

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

Please contact your Komatsu distributor for repairs.

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

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

Warning tag Part No. 09963-03000 /

AE167640

4

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

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

When washing the machine, always do as follows.

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

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

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

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

1-22

J

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

8. PRECAUTIONSFOR MAINTENANCE

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

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

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

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

{

RADIATOR

WATER

LEVEL

1

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

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

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

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

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

STOP ENGINE BEB MAINTENANCE

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

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

Put blocks under the track to prevent the machine from moving.

The worker carrying out the maintenance should be extremely careful not to touch or get caught in the moving parts.

OFF

BlOCkS

1034 13%

AW34987B

AN364156

1-23

8. PRECAUTIONS FOR MAINTENANCE

4

A )Vf~$J;M~e Foiereasons of safety, always ty precautions.

SAFETY DEVICES FOR -1

When carrying out inspection and maintenance with the work equipment raised, fit stand @ securely to the boom to prevent the work equipment from coming down.

Place the work equipment control levers at HOLD, and set safety lock lever @ to the LOCK position.

AU'364158

PROPER TOOLS Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause personal injury.

Broken pieces of chisels or hammers could fly into your eyes and blind .you.

Tools -) See ‘21.1 INTRODUCTlON OF NECESSARY TOOLS”.

Hoses and other parts of the fuel, hydraulic, and brake system are critical parts for ensuring safety, so they must be replaced periodically.

Replacement of safety critical parts requires skill, so please ask your Komatsu distributor to carry out replacement. l Replace these components periodically with new ones, regardless of whether or not they appear to be defective.

These components deteriorate over time, and can cause fire because of oil leakage or failure in the work equipment system. l Replace or repair any such components if any defect is found, even though they have not reached the time specified.

Replacement of safety critical parts + See “q. PERIODIC REPLACEMENT OF SAFETY CRlTlCAL PARTS”.

l-24

A E;RMMt;

Fa&-t$

follow these safety precautions may lead 8. PRECAUTIONS FOR MAINTENANCE

1

USE OF LIGHTING

1

When checking fuel, oil, or battery electrolyte, always use lighting with anti-explosion specifications.

If such lighting equipment is not used, there is danger of explosion.

If work is carried out in dark places without installing lighting, there is danger of injury, so always install proper lighting.

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

When using the machine as the power supply for the lighting, follow the instructions in this Operation and Maintenance Manual.

A0055160

4

PREVENTION OF FIRE

1

There is danger of the fuel and battery gas catching fire during maintenance, so always follow the precautions below when carrying out maintenance.

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

Use non-flammable materials as the flushing oil for cleaning parts. Do not use diesel oil or gasoline. There is danger that they will catch fire.

Never smoke when carrying out inspection or maintenance. Always smoke in the prescribed place.

When checking fuel, oil, or battery electrolyte, always use lighting with anti-explosion specifications. Never use lighters or matches as lighting.

When carrying out grinding or welding materials to a safe place.

operations on the chassis, remove any flammable

Be sure that a fire extinguisher is present at the inspection and maintenance point.

1-25

8. PRECAUTIONSFOR MAINTENANCE

8.2

DURING

1

PERSONNEL

a

;fU41;;Me

Fo;ereasons of safety, always ty precautrons.

MAINTENANCE }

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

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

ATTACHMENTS l

Appoint a leader before starting removal or installation operations for attachments.

l

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

l

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

4 A0055130

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

Always block the track shoes securely.

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

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

Do not spill oil or grease.

Do not leave tools lying around.

Mind your step when you are walking. l

l

l

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

Use protective equipment if necessary.

1-26

A &VtR;;Et;

Pa&x$

follow these safe*/ precautions may lead 8. PRECAUTIONSFOR MAINTENANCE

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

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

1 MAINTENANCE WITH ENGINE RUNNING

1

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

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

All workers must maintain contact with the other workers.

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

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

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

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

DO NOT DROP l

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

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

l

When carrying out inspection, do not carry any unnecessary tools or parts in your pocket.

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

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

AE3058BO

l-27

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

8. PRECAUTIONSFOR MAINTENANCE

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

The qualified welder must follow the precautions given below. l Disconnect the battery terminals to prevent explosion of the battery. l Remove the paint from the place being welded to prevent gas from being generated. l If hydraulic equipment or piping, or places close to these are heated, flammable vapor or spray will be generated, and there is danger of this catching fire, so avoid applying heat to such places. l If heat is applied directly to rubber hoses or piping under pressure, they may suddenly burst, so cover them with fireproof sheeting. l Always wear protective clothing. l Ensure that there is good ventilation. l Clear up any flammable materials, and make sure that there is a fire extinguisher at the workplace.

When repairing the electrical system or when carrying out electrical welding, remove the negative 0 terminal of the battery to stop the flow of current.

Handling battery + See “16.5 IF BATTERY IS DISCHARGED�.

AE309890 4

WHEN ABNORMALITY

IS LOCATED

1

l

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

l

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

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

l-28

A lV$Fl;;l~;

Fai;gtc~

follow these safety precautions may lead 8. PRECAUTIONS FOR MAINTENANCE

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

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

When loosening grease drain valve 0, never loosen it more than one turn.

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

Adjusting track tension + See “24.3 WHEN REQUIRED”.

l

-3 ,’ “)

,’

,’

Aw55200

HANDLING HIGH-PR l

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

l

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

{

PRECAUTlONS WlTH HIGH-PRESSURE]

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

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

Wear safety glasses and leather gloves.

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

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

If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention. iNCORREgp

COFmE;_

A0055180

A0055190

1-29

A g41J~f;~ 8. PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE HIGH TEMPERATURE

r

Foiereasons of safety, always ty precautrons.

AT

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

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

Cleaning inside of cooling system -) See “24.3 WHEN REQUIRED”.

Checking coolant level, oil level in hydraulic tank + see “12.12 CHECK BEFORE STARTING”.

Checking lubricating oil level, adding oil + see “12.1 CHECK BEFORE STARTING, 24.5-7 PERIODIC MAINTENANCE”.

Changing oil, replacing filters + see ‘24.7-12 PERIODIC MAINTENANCE”.

1

CHECKS AFTER INSPECTION AND MAINTENANCE

1

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

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

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

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

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

l

l

l

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

MAINTE-

Do the inspection and maintenance locations work normally?

Is there any oil leakage when the engine speed is raised and load is applied to the hydraulic system?

WASTE MATERlALS To prevent pollution, particularly in places where people or animals are living, always follow the procedures given below.

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

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

Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, and batteries.

l-30

INCORRECT

lNG SAFETY LABELS CH TA A7 R FO ON TI SI PO 9. with them again or replace them lost or damaged, attach are they tf n. clea ls Always keep these labe in the same way a new label. d below, so handle them to the safety labels liste ition add in ls ls are available; labe labe r t There are othe English. To find out wha le in languages other than ilab ava be may lab& Safety distributor. contact your Komatsu

POSITION FOR AITACHING

l-

SAFETY LABELS

9. POSITION FORAlTACHfNG SAFETYLABELS

1.

Warnings for operation, inspection and maintenance (09651-03001)

3.

Warnings for leaving operator’s seat (09654-03001)

~_~~

A

WARNING

A WARNING

Improper operation and maintenance can cause serious injuly or death.

To avoid hiing unlocked operationlevers, lower equipment to ground and move SAFETY LOCK LEVER (located near seat) to LOCK position before dtanding up from operator’s seat.

Read manual and labels before operation and maintenance.

Follow instructions and wamings in manual and in labels on machine.

Sudden and unwanted machine movementcan cause serious injury or death.

09654-03001

Keep manual in machine cab near operator.

Contact Komatsu distributor for a replacement manual.

09651-03001,

2.

Warnings before operating machine (09802-03000)

A

1-32

WARNING

4.

Warnings for high voltage (09801-03001~

A DANGER

I

9. POSITION FOR ATTACHING SAFETY LABELS

5.

Warnings for hot oil hazard (09653-03001)

a

7.

Warnings for handling accumulator (09659-53000)

8.

Warnings for adjusting track tension (09657-03003)

WARNING

HOtOilhazard.

To preventhot oil

fromspurt-

inawt: . Turn engineoff. . l

6.

Allow oil to cool.

Skmly&osencaptodiie pressurebefore removing.

Warnings for hot water hazard (09668-03001)

[ A

WARNING

Hot water hazard.

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

0 Allow water to cool.

0 Slowly loosen cap to relieve pressure before removing.

1

A WARNING13 Compressed spring lubricator and grease are under hazardous high pressure and can cause serious injury or death. . When adjusting track tension only turn lubricator ONE TURh tuming Iubrkator further could cause lubricator and grease to fly off and hurt you.

See manual for adjustment instructions. . When loosening track shoe, if it dose not loosen after turning lubricator ONE TURN ask Komatsu dealer or distributor to disassemble.

096!57-v3oo3~

l-33

9. POSITION FOR ATTACHING SAFETY LABELS

9.

12. Keep off swing area (09133-23000)

Warnings for battery cable (09808-03000)

A

WARNING

Improperuseofboostercables

\

andbatterycablescancause anexpbsionresulfinginsed-

Keep off swing area

ousinjutyordeath. l

Follow instmtions in

manual when using booster cable andbattwycables. os60843wo-

10. Caution while engine is running (09667-03001)

A

13. Warnings for battery (09664-30082)

CAUTION

A

While engine is running: 1. Do not open cover.

2. Keep away from fan and fan-belt.

0966743001

11 Explanation of escape method in

emergency (2OY-00-228803

_

.-. --

EMERGENCY 'I'/~'asla.z5a4taSaa PULL RING AND REMOVE RUBBER

WARNING

EXPLOSIVE GASES

EXIT-

. fiSIJ-?i3~?8<bb PUSH CORNER OF GLASS STORONGLY

/

9. POSITION FOR ATTACHING SAFE-I-Y LABELS

9.2 CONTENT 1.

AND USE OF WARNING

PLATES

Warning to prevent operation during maintenance (09963-03000) Hang this warning plate on the controls in the operatorâ&#x20AC;&#x2122;s compartment.

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

09963-03000

J

1-35

OPERATION

10. GENERAL VIEW 10 1 GENERAL VIEW OF MACHINE â&#x20AC;&#x2DC;If directionsare indicatedin this section, diagram

below.

they refer to the directions

shown by the arrows

in the

1

AX371450

1.

2.

3.

4.

5.

2-2

Bucket Bucket cylinder Arm Arm cylinder Boom

6.

7.

8.

9.

10.

Boom cylinder Sprocket Track frame Idler Track shoe

10.2 GENERAL VIEW OF CONTROLS

AND GAUGES

;;

17 18 19 20 21 22 23 24 25 26 27 28

AU371460

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Air conditioner control panel 2 Lubrication switch Safety lock lever Air conditioner control panel 1 Swing parking brake switch Cigarette lighter Left work equipment control lever Car radio Horn switch Right work equipment control lever Starting switch Travel lever Monitor Health monitor Preheating switch

16.

77.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

Engine emergency stop lamp Auto-greasing caution lamp (if equipped) Ladder caution lamp Fuel control dial (F. engine) Starter selector switch Fuel control dial (R. engine) Lamp switch Step light switch Room lamp switch Machine push-up switch Fog lamp switch Rotating lamp switch Shockiess boom control switch Alarm buzzer stop switch Wiper switch

2-3

; 6 5

17 18 -

_

tn IY

-I.

20 21 22

AW371470

1. Engine water temperature, hydraulic oil temperature display selector switch 2. Heavy life switch 3. Working mode selector switch 4. Air cleaner clogging monitor (R. engine) 5. Engine oil pressure monitor (FL engine) 6. Charging level monitor (R. engine) 7. Air cleaner clogging monitor (F. engine) 8. Engine oil pressure monitor (F. engine) 9. Charging level monitor (F. engine) 10. Engine water temperature, hydraulic oil temperature monitor 11. Engine water temperature gauge hydraulic oil temperature gauge

2-4

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

Display (for clock and fault indication) Service meter Fuel gauge Fuel level monitor Hydraulic filter clogging monitor Hydraulic oil level monitor Radiator water level monitor Engine pre-heating monitor Swing lock monitor Engine oil level monitor Auto-deceleration switch

11. EXPLANATION

OF COMPONENTS

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

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

11.l

MACHINE MONITOR

An C

AW371480

This monitor system and meter group Q.

consists of monitor

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

If there is any abnormality, the appropriate flash.

lamp groups

(@, @N

A.

be checked monitor

before

lamp will

NOTICE If engine is started, lamp will go off even if there is an abnormalii.

When carrying out checks before starting, do not simply rely on the monitor. Always refer to the periodic maintenance items or â&#x20AC;&#x153;12.

OPERATIONâ&#x20AC;? to carry out the checks.

2-5

11. EXPLANATION OF COMPONENTS

8. CAUTION ITEMS (11.1.2) If these monitor items flash, checkand repair the appropriate IAlocation as soon as possible.

CAUTâ&#x20AC;&#x2122;oN These are items which need to be observed while the engine is running. If any abnormality occurs, items which need to be repaired as soon as possible are displayed.

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

C. EMERGENCY STOP ITEMS (11.1.31

A

CAUTION

ff these monitor items flash, stop operationsimmediately,then checkand repair the appropriate location.

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

D. METER DISPLAY PORTION (11.1.4) This portion consists of pm-heating monitor, swing lock monitor, engine water temperature and hydraulic oil temperature gauge, fuel gauge, service meter and display.

E. SWITCHES (11.1.5) This selectworking mode, and time setting of clock.

2-6

11. EXPLANATION OF COMPONENTS

B

--i--l AW371490

11.1.1

A: BASIC CHECK ITEMS

NOTICE Do not rely on the “BASIC CHECK lTEMS” only for the check before starting Always refer to the periodic maintenance items or “12. OPERATION” to carry out the checks.

1.

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

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

1

I

AD314020

i

2.

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

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

3.

HYDRAULIC OIL LEVEL This warns that the hydraulic oil level is too low. lf the monitor lamp flashes, check the hydraulic oil level, and add oil.

cc> l-l 0

0

1

AD314030

/

2-7

11. EXPLANATION OF COMPONENTS

11.1.2 B: CAUTION ITEMS

A

CAUTION

If the caution monitor lamp flashes, repair the problem as soon as possible.

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-belt tension. If any abnormality is found, see “16.6 OTHER TROUBLE”.

0

-+ rl I

A0313350

REMARK While the starting switch is ON, the lamp will remain lit and will go off once the engine is started.

2.

FUEL LEVEL If the fuel drops below 169 liters (44.6 US gal, 37.5 UK gal), the lame will flash. TOD UD the fuel before this.

I

I

_I 3.

AIR CLEAN CLOGGING If the air cleaner element clogged, the monitor lamp flashes.

Stop the engine, check the air cleaner element and clean it.

A0313370

4.

HYDRAULIC FILTER CLOGGING MONlTOR I This monitor indicates clogging of the hydraulic filter.

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

2-8

I

11. EXPLANATION OF COMPONENTS

11.1.3 C: EMERGENCY

STOP ITEMS

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

rA

1.

cAuTâ&#x20AC;&#x2122;oN/

ENGINE WATER TEMPERATURE, TURE

If the temperature temperature become

HYDRAULIC OIL TEMPERA-

of the engine cooling water and hydraulic oil abnormally high, the monitor lamp flashes.

lf the front engine cooling water temperature

is abnormally high:

The overheat prevention system is automatically actuated and the engine speed goes down.

Lamp @ of the display selector switch lights up and the cooling water temperature of the front engine is displayed on the engine cooling water and oil temperature gauge.

1

I

1 1 F

lf the rear engine cooling water temperature is abnormally high: The overheat prevention system is automatically actuated and the engine speed goes down.

Lamp @I of the display selector switch lights up and the cooling water temperature of the rear engine is displayed on the engine cooling water and oil temperature gauge.

R

lf the hydraulic oil temperature is abnormally high: Lamp @ of the display selector switch lights up and the hydraulic oil temperature is displayed on the engine cooling water and oil temperature gauge.

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.

3.

0 @

ENGINE OIL PRESSURE

If the engine oil pressure drops below the normal pressure, the monitor lamp flashes. At this item, stop the engine and inspect it according to â&#x20AC;&#x153;16.6 OTHER TROUBLE.*

1 1 J LO314020

REMARK While the starting switch is ON, the lamp remains off once the engine is started. When may sound for a short time, however,

lit and goes the engine starts, the buzzer this does not indicate a fault.

REMARK l Stop the machine on level ground and check the monitor. l

Stop the engine, then turn the starting switch to the ON position and check that the monitor lights up for 3 seconds.

If it does not light up, please contact your Komatsu distributor to have the monitor inspected.

I

A0313410

2-9

I

11. EXPLANATION OF COMPONENTS

11.1.4 D: METER DISPLAY PORTION

A1371520

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

1.

ENGINE PRE-HEATING MONITOR This monitor lamp indicates the pm-heating time required when starting the engine at an ambient temperature below 0°C. The monitor lamp lights when the starting switch is turned to HEAT position and flashes after about 30 seconds to show that the pre-heating is completed. (The monitor lamp will go off after about IO seconds.)

I

n

I

I

I AD313430

2.

SWING LOCK LAMP This informs the operator that the swing lock is being actuated.

Actuated: Lights up When the swing parking brake switch is turned ON (ACTUATED), the monitor lamp lights up.

When the swing parking brake release switch is turned on, this monitor lamp flashes.

REMARK A disc brake is installed in the swing motor to mechanically motor rotation.

The brake is always applied while the swing lock is actuated.

2-10

0 d!b

I stop

cl 0

AD313440

11. EXPLANATION OF COMPONENTS

METERS 3.

ENGINE WATER TEMPERATURE GAUGE - HYDRAULIC OIL TEMPERATURE GAUGE

This gauge indicates the engine cooling hydraulic oil temperature.

0 0 0

water

temperature

or

and 0.

The content of the display is switched by switches a,@, This displays the front engine water temperature.

This displays the rear engine water temperature.

The hydraulic oil temperature is displayed only while the switch is being pressed.

When the switch is released, the display returns to the display that was shown before the switch was pressed.

The green range should light up during normal operations. If the red range lights up during operations, monitor @ will flash and the alarm buzzer will sound at the same time. system is actuated only when the The overheat prevention is abnormal. cooling water temperature is If the cooling water temperature or hydraulic oil temperature abnormally high, applicable lamp 0, 0, or @ flash and the temperature of that item is displayed on the meter.

The overheat prevention system acts as follows.

When red range @ flash: Engine speed is lowered further to low idling, engine water temperature -monitor @ flashes, and alarm buzzer sounds as the same time.

The overheat prevention system is actuated ture enters the green range.

until the tempera-

is When red range @ lights, if the engine water temperature reduced and the fuel control dial is turned to the low idling position, 1 w4iw&wB the overheat prevention system will be canceled.

4.

FUEL GAUGE

This gauge indicates the amount of fuel in the fuel tank.

If the fuel level is normal during operation, the green range will light up.

If only the red range lights up during operation, there is less than 169 liters (44.6 US gal, 37.5 UK gal) of fuel remaining in the tank, so check and add fuel.

When red range @ lights up: Fuel gauge monitor @ flashes.

een

After the starting switch is turned ON, the correct level may not be displayed for a moment, but this does not indicate any abnormality.

When stopping the engine, turn the starting switch ON and check that the monitor lamps on items A, B, C and D and the meters light up*

2-11

I 1. EXPLANATION OF COMPONENTS

5.

DISPLAY When the starting switch is ON, the time and service meter reading is displayed if the condition is normal. If the condition is abnormal, the content of the failure is displayed.

When setting the time, the 6 symbol flashes.

If there is a failure on the machine, the type of failure is displayed when the starting switch is turned ON. The failures all flash in turn on the display.

688~88 AM101350

L

Failure mode

Monitor display E02

TVC system error

E03

Swing brake system error

E05

Governor system error

EOE

Continuation

E23

VSM controller system error

of work impossible

If these displays flash, see “16.5.4 ELECTRONIC CONTROL SYSTEM”.

6.

SERVICE METER This displays the accumulated hours of operation of the machine.

Use the display to determine the intervals for periodic maintenance.

The service meter will advance while the engine is running even if the machine is not moving.

The service meter reading advances by 1 for every hour that the engine is running, regardless of the engine speed.

7.

GREASE PRESSURE GAUGE This indicates the grease pressure when greasing.

The gauge should indicate 4.9 - 19.6 MPa (50 - 200 kg/cm2, 710 - 2940 psi) when greasing.

REMARK l If the pressure is below 4.9 MPa (50 kg/cm*, 710 psi), the grease can is empty, so replace the grease can. l If the pressure is above 19.6 MPa (200 kg/cm2, 2840 psi), there is probably clogging. For details, see “24.5 EVERY 10 HOURS SERVICE”.

2-12

B88888.8h AM101380

11. EXPLANATION OF COMPONENTS

11.1.5 E: SWITCHES

)F

-

2

1.

WORKING MODE SELECTOR SWITCH (Basic mode)

This switch is used to set the movement or power for the work By selecting the mode to match the working conditions, equipment. it is possible to carry out operations more easily.

DH lights up: Powerful operation for heavy-duty H lights up: Normal operations G lights up: Light-duty operations

I

operations AA307320

When starting the engine, H (heavy-duty operation) mode is selected. Each time the switch is pressed, the mode automatically selection changes.

4

2.

AW371560

AUTO-DECELERATION

1

SWITCH (Selection switch)

This switch acts to activate the function that automatically lowwhen the ers the engine speed and reduces fuel consumption control lever is at neutral. is actuated.

ON lights up: Auto-deceleration is canceled.

Auto-deceleration OFF: Each time the switch ated or canceled.

3.

is pressed, the auto-deceleration

is actu-

HEAVY LIFT SWITCH

Operate this switch to increase the lifting power during operations.

When the switch is turned ON during independent operations of the boom, the boom lifting power is increased.

-

2-13

Il.

EXPLANATION OF COMPONENTS

11.2

SWITCHES

AU371510

1.

STARTER SELECTOR SWITCH When starting engines, select the starting operation engine.

Front

2-14

enein

11. EXPLANATION OF COMPONENTS

2.

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

OFF position The key can be inserted or withdrawn. The switches for the electric system except the cab lamp and clock, are all turned off and the engine is stopped.

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

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

Electricity flows to all electrical circuits except the START and HEAT circuit.

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.

3.

PREHEATING SWlTCH Use this switch when starting the engine in cold weather. @ When the switch is pressed, the preheating monitor lights up. @ Keep the switch pressed until the preheating monitor goes out. @ When the preheating monitor goes out, release the switch immediately. @ When the switch is released, it will return to the OFF position.

Turn the starting switch immediately to the START position to start the engine.

HEAT

Aw37llB I

4.

FUEL CONTROL DIAL (FRONT ENGINE) (WlTH AUTO-DECELERATION MECHANISM) This adjusts the engine speed and output. @ Low idling (MIN): Turned fully to the left @ Full speed (MAX): Turned fully to the right 5.

FUEL CONTROL DIAL (REAR ENGINE) This adjusts the engine speed and output. @I Low idling (MINI: Turned fully to the left @ Full speed (MAX): Turned fully to the right

2-15

11. EXPLANATION OF COMPONENTS

CIGARETTE 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.

By removing the cigarette lighter, the socket is available as a power source for the yellow flashing lamp. Max. current is 3.5 A (85 WI. 6.

I

AM069410

7.

LAMP SWKCH This switch is used to turn on the front lamps, working lamps, additional lamp at the top front of the cab, rear lamps, and monitor lighting.

8. STEP LIGHT SWlTCH Use this switch when getting off the machine at night. l When the switch is pressed, the step light will light up for approx. 60 seconds. l Even if the starting switch key is at the OFF position, the step light will light up for approx. 60 seconds when the switch is pressed.

9.

SWlNG PARKING BRAKE SWITCH

A WARNING. l

When the machine is traveling under its own power, or when the swing is not being operated, always set the switch to the ON fACTUATED) position.

l

On a slope, the work equipment may swing to the down side even if the swing parking brake switch is located at the ON position.

Be careful concerning this point.

ON

This switch is used to lock the upper structure so that it cannot

ON position (actuated): The swing lock is always applied, and the upper structure will not swing even if the swing is operated. In this condition, the swing lock lamp lights up.

OFF position (canceled): The swing lock is applied only when all work equipment control levers are at neutral; when any work equipment control lever is operated, it is canceled.

The swing lock is actuated approx. 4 seconds after all work equipment control lever is placed in neutral.

2-76

I

11. EXPLANATION OF COMPONENTS

10. ROOM LAMP SWITCH This is used to turn on the room lamp.

ON: Lights up It is possible to turn on the room lamp even when the starting switch is at the OFF position, so be careful not to forget to turn it off.

AM099420

11. MACHINE PUSH-UP SWITCH This switch is used to switch the safety valve set pressure at the head end of the boom cylinder to two levels.

The boom thrust force is weak,so the @ Low pressure setting: swaying of the chassis is small during digging operations, and digging operations can be carried out smoothly.

This is used for general digging operations on normal ground, soft rock, or blasted rock. @ High pressure setting: The thrusting force of the boom becomes more powerful, so it is easy to twist and swing or escape from soft ground. It is effective in carrying out digging operations using the bucket and the weight of the machine in confined areas.

12. EGG LAMP SWITCH This lights up the fog lamps.

ON position: Lamp lights up.

13. SHOCKLESS BOOM CONTROL SWITCH This controls the shaking of the work equipment when the boom is stopped.

Effect l The shaking and spillage of load from the bucket is reduced. l Operator fatigue when operating for long periods is reduced, so operations can be carried out in safety.

REMARK

I

AM099450

ON

ON

AM099420

When the switch is at the ON position and the boom is stopped, the movement of the boom until it stops will increase slightly. Be careful when using this operation until you become accustomed to it.

2-17

I 1. EXPLANATION OF COMPONENTS

14. ROTATING LAMP SWITCH

This lights up the rotating lamp.

ON position: Lamp lights up.

15. ALARM BUZZER STOP SWlTCH This is used to stop the alarm buzzer if it sounds to warn of an abnormality during operation.

16. WIPER SWITCH

This actuates the wiper for the front glass.

OFF: Wiper stops ON: Wiper moves continuously Window washer fluid is sprayed out. When switch is released it returns to position 0.

ON: Wiper moves intermittently Window washer fluid is sprayed out. When switch is released it returns to position @.

17. GREASING SWlTCH This actuates the grease pump.

Greasing is started. When the switch is released, 0 START: greasing will continue for 15 minutes and then stop.

This switch is used to forcibly stop the grease pump @ STOP: during greasing operations. @I Pilot lamp: This lights up when the grease pump is operating.

18. HORN SWlTCH

Press the switch on the right work equipment control lever to sound the horn.

At the same time, the flashing light (option) at the top front of the cab will flash for approx. 5 seconds to give a signal to the dump truck.

2-18

I

I

11. EXPLANATION OF COMPONENTS

19. ROOM LAMP SWITCH [FOR ENGINE ROOM) This lights up the lamp inside the engine

OFF

room.

ON

ON position:

Lamp lights up.

AE178470

I 20. ROOM LAMP SWITCH (FOR ROOM IN CAB) This lights up the lamp in the room of the cab.

OFF ON

ON position:

Lamp lights up.

AE178470

21. ROOM LAMP SWITCH (FOR PUMP ROOM) This lights up the lamp inside the pump

OFF

room.

ON

ON position:

Lamp

lights up.

I

AE176470

2-19

11. EXPLANATION OF COMPONENTS

22. PUMP CONTROL OVERRIDE SWlTCH When normal: Switch is pushed down When abnormal: When the monitor display shows E02 (NC valve system error), move the switch up to make it possible to carry out work.

The pump prolix switch is provided to make it possible to carry out work for a short time when there is a failure in the pump control system (TVC valve system error). It is necessary to repair the abnormal location as soon as possible.

When abno

I When normal AM089520

SWING LOCK OVERRIDE SWlTCH When normal: Switch is pushed down When abnormal: When the monitor display shows E03 (Swing brake system error), the brake is canceled, and it becomes possible to actuate the swing and carry out normal operations. However, the swing brake remains released.

The swing prolix switch is provided to make it possible to carry out swing operations for a short time even when there is an abnormality in the swing brake electric system. It is necessary to repair the abnormality as soon as possible.

When abno

( When normal

24. ENGINE EMERGENCY STOP SWllCH Use this switch only when stopping the engine in an emergency.

A6671666

Stop

switch

inside

en6ine

mm

11666

2-20

11. EXPLANATION OF COMPONENTS

11.3 LAMP

1.

ENGINE EMERGENCY STOP LAMP

This lamp lights up when the engine emergency stop button at the side of the left side step is pressed, or when the engine emergency stop button inside the engine room is pressed to the OFF position. l If this lamp is lighted up, the engine cannot be started. l When the engine emergency stop button is pressed again to set it to the ON position, the lamp goes out and the engine can be started.

For details of stopping the engine in emergencies, STOPPING IN EMERGENCY”.

see “12.18.2

2.

AUTO-GREASING CAUTION LAMP (IF EQUIPPED) This lamp lights up if an abnormality occurs in the auto-greasing system. Check the engine from the content of the display on the auto-greasing controller inside the cab base, then carry out repair work.

For details, see “28. AUTO-GREASING SYSTEM”.

3.

LADDER CAUTION LAMP

This lamp fights up when the ladder is lowered.

If the lamp is lighted up, the upper structure cannot be swung.

When the ladder is stored away, the caution lamp goes out and it is possible to swing the upper structure.

For details of the method of using the ladder, see “11.9 EMERGENCY ESCAPE LADDER”.

2-21

11. EXPLANATION OF COMPONENTS

11.4 CONTROL LEVERS, PEDALS 1

A1371680

1.

SAFETY LOCK LEVER

I

A

WARNING

When leaving the operatorâ&#x20AC;&#x2122;s compartment, set the safety lock lever securely to the LOCK position. lf the control levers are not locked, and they are touched by mistake, this may lead to a serious accident. lf 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.

When the safety lock lever is lowered, take care not to touch the work equipment control lever. lf the safety lock lever is not properly locked at the lower position, the work equipment and swing will move, creating a potentially dangerous situation.

When the safety lock lever is raised, take care not to touch the work equipment control lever.

This lever iocks the controls for the work travel, and optional attachments.

Push the lever down apply the lock.

2-22

equipment,

swing,

AU364178

I

11. EXPLANATION OF COMPONENTS

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.

AY36416E

2.

r

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

WARNING

Do not put your foot on the pedal unless the machine is

traveling. lf you leave your foot on the pedal and press it by mistake, the machine will move suddenly, and this may lead to a serious accident.

AM81730

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.)

0 0 N

(

FORWARD: The lever is pushed forward.

(The pedal is angled forward) REVERSE: The lever is pulled back.

(The pedal is angled back) (Neutral): The machine stops.

I: This indicates

operation

of the pedal.

REMARK

Machines equipped with travel alarm (If equipped) If the lever is shifted to the advance or reverse position from the neutral position, the alarm starting to advance.

sounds

to warn

that the

machine

is

2-23

11. EXPLANATION OF COMPONENTS

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

3.

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

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

Swing operation Arm operation @ Swing to right @ Arm OUT @ 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.

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

4.

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

This lever is used to operate the boom and bucket.

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

For levers 2, 3 and 4, the engine speed changes as follows because of the auto-deceleration mechanism. l 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 dial. l If all control levers are set to neutral, the engine speed will drop by approx. 100 rpm, and after approx. 4 seconds, the engine speed will drop to the deceleration speed (approx. 1300 - 1500 rpm).

2-24

11. EXPLANATION OF COMPONENTS

11.5

DOOR LOCK

Use the door lock to fix the door in position 1.

2.

after opening

Hook lock @ to portion @ to hold the door in position.

When opening the door, lift lock CJI up slightly and remove from portion 0.

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

11.6

it.

it

POCKET

Behind the operatorâ&#x20AC;&#x2122;s seat Ordinally, operation manual should be stored in this pocket, and able to read the manual every time.

2-25

I I. EXPLANATION OF COMPONENTS

11.7 HANDLING AIR CONDITIONER 11.7.1 GENERAL LOCATIONS

AIR

CONDITIONER

CONTR0.L

ON CONTROL PANEL

PANEL

1

AIR

CONDITIONER

CONTROL

PANEL

2

M371698

The pilot lamp for the switches light up to indicate that the switch is functioning.

1. VENT SELECTOR SWITCH This is used to select the vents which match the purpose of use.

Control panel Purpose of â&#x20AC;&#x2DC;use

r

AIR CONDITIONER

Sending breeze from front

AN1 13550

2-26

Sending breeze to feet

r

AIR CONDlTlONER CONTROL PANEL 2

Sending breeze to upper part of body

Ar4113560

Sending breeze from rear

LD

GD

Switch

Vent

CONTROL PANEL 1

AN1135M

AN113560

1

11. EXPLANATION OF COMPONENTS

FRESH/RECIRC SELECTOR SWlTCH (AIR CONDlTlONER TROL PANEL 1 AND 2 THE SAME)

2.

This switch is used to intake fresh air or recirculate

CON-

the internal

air.

--_ or cool the operatorâ&#x20AC;&#x2122;s

cab

taking in clean

fresh air

Switch AN113600

AN1 13590

3.

TEhPERATURE CONTROL SWlTCH (AIR CONDlTlONER CONTROL PANEL 1 AND 2 THE SAME)

This switch is used to adjust the temperature low and high.

Purpose of use

steplessly between

Heating

Cooling

WARM

COOL D

a

AN113620

AN113610

Switch

The more lamps in the blue range light up, the lower the temperature becomes; the more lamps in the red range light up, the higher the temperature becomes.

The range is divided into 7 levels, and each range is divided further steplessly.

4.

WIND FLOW SELECTOR SWlTCH (AIR CONDlTlONER CONTROL PANEL 1 AND 2 THE SAME) The wind flow can be adjusted to 3 levels.

Purpose of use

Switch

Low wind flow

(a

Medium flow

wind

[01 AN113640

High wind flow

i ANl13ma

AN113660

2-27

11. EXPLANATION OF COMPONENTS

5.

AIR CONDlTlONER SWlTCH

0 @

(AIR

CONDITIONER

CONTROL PANEL 1 AND 2 THE SAME) This is used to switch the air conditioner ON/OFF. 6.

OFF SWlTCH

(AIR CONDlTlONER CONTROL PANEL

1 AND 2 THE SAME) This switch is use to stop the fan.

7.

DEFROSTER This is used to clear the mist from the front glass in cold or rainy conditions. l Open the defroster vent and adjust the direction so that the air blows on the front glass. (During normal operations, use with the defroster vent closed.) l If it is desired to remove the mist quickly, close the other vents when using the defroster vent.

The defroster can be used under the following conditions: When air conditioner control panel 1 vent selector is at ~2 When air conditioner control panel 2 vent selector is at pâ&#x20AC;?

I

11.7.2

PRECAUTIONS CONDITIONER

WHEN USING AIR

Carry out ventilation from time to time when using the cooler. l

If you smoke when the cooler is on, the smoke may start to hurt your eyes, so turn the lever to FRESH to remove the smoke while continuing the cooling.

l

When running the air conditioner for a long time, turn the lever to the FRESH position once an hour to carry out ventilation and cooling.

Be careful not to make the temperature in the cab too low.

When the cooler is on, set the temperature so that it feels slightly cool when entering the cab (5 - 6°C lower than the outside temperature). This temperature difference is considered to be the most suitable for your health, so always be careful to adjust the temperature properly.

l

2-28

!

11. EXPLANATION OF COMPONENTS

11.8

EMERGENCY

ESCAPE HAMMER

NOTICE When escaping, remove the broken pieces of the glass from the sash so that you will not cut yourself with them. Take care not to slip on the broken and scattered pieces.

In case it becomes impossible to open the door, a hammer to be used for escape from the cab is installed.

When escaping, break the left-hand window glass with hammer.

2-29

11. EXPLANATION OF COMPONENTS

11.9

EMERGENCY

ESCAPE LADDER

There is a rope ladder in the box by the passage of the left side of the operator’s compartment. Use it for escape in emergencies.

When using the ladder to escape, fit the hooks at the end of the ladder to the handrail, then lower the ladder. Check that the condition of the ladder is normal before going down it.

When

Hook /

Han

\

When ladder iB ^.^_^A

A-A

2-30

.’ D’y’=u

11. EXPLANATION OF COMPONENTS

11.10

CAP, COVER WITH LOCK

The fuel filler, operator’s cab, engine hood, battery box cover, right side door and left side door of the machine body are fitted with locks.

Use the starting switch key to lock or unlock these places.

11.10.1

METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port)

To open the cap 1.

2.

Insert the key into the cap.

Turn the key clockwise, align the match mark on the cap with the rotor groove, then remove the cap.

To lock the cap 1. Turn the cap into place.

2. Turn the key counterclockwise

i and take the key out.

Match mark on the cap

ADO53820

Insert the key as far as it will go. If the key is turned inserted all the way, it may break.

before it is

Shoulder

11.102

METHOD OF OPENING AND CLOSING COVER WITH LOCK (For the cover with lock)

AL067870

To open the cover 1. Insert the key in the key hole of the cover.

2. Turn the key counterclockwise and pull out the cover glip, then open the cover.

To close the cover 1. Close the cover, and insert the key in the key hole.

2. Turn the key counterclockwise and take the key out.

11.11 ASHTRAY This is on the left side of the operator’s seat.

Always make sure that you extinguish the closing the lid.

cigarette

before

2-31

11. EXPLANATIONOF COMPONENTS

11.12

CAR RADIO

11.12.1

EXPLANATION

OF COMPONENTS

I I f

I

1

I

I

L

I

I

I I

.

\ I .

I

o SW-VOLUME

\ \ I

Câ&#x20AC;&#x2122;TONE

PU BAL

\

JJ

L 1.

POWER SWITCH/VOLUME CONTROL KNOB (SW-VOLUME) BALANCE CONTROL KNOB /Pull BALI Press this knob to turn the power for the radio on. The frequency is displayed on display 0. Press again to turn the power off.

Turn the knob to adjust the volume as follows.

Turn CLOCKWISE to INCREASE volume Turn COUNTERCLOCKWISE to REDUCE volume If the knob is pulled until it locks, it can be turned to the left or right to adjust the balance of the left and right speakers.

Turn CLOCKWISE to increase volume from RIGHT speaker Turn COUNTERCLOCKWISE to increase volume from LEFT speaker After adjusting the left and right balance, press lightly to return the knob to its original position. (If it is left pulled out, the overall volume cannot be adjusted.)

2.

TONE CONTROL KNOB (TONE) Turn the knob to adjust the tone as follows.

Turn CLOCKWISE to emphasize the high sounds Turn COUNTERCLOCKWISE to suppress the high sounds -1

AMOwl

2-32

11. EXPLANATION OF COMPONENTS

3.

FM/AM SELECTOR BUlTON (AM/FM) Press this button and select the desired band.

Each time the button is pressed, it switches AM +

FM + AM . . .

AM099390

4.

DISPLAY SELECTOR BUTTON (TIME)

gives priority to the frequency display. If the This equipment button is pressed when the frequency is displayed, display will give the present time for 5 seconds. After 5 seconds pass, the display will return to the frequency display. If any button other automatically than TIME SET (H, M, SET) is pressed within the 5 seconds, the display will return to the frequency display.

I

5.

AM099990

TUNING BUlTONS (TUNING) MANUAL TUNING (MANUAL)

Use the buttons to change the frequency.

Up button (A): Each time the button is pressed, the frequency will go up in steps (FM: 0.1 MHz, AM: 9 kHz).

Down button WI: Each time the button is pressed, the frequency will go down in steps (FM: 0.1 MHz, AM: 9 kHz).

6. PRESET BUlTONS (I, 2, 3, 4, 5,6) (PRESET STATION) If these buttons are set to the frequency of the desired broadcasting station, the station can be selected at a touch.

For details of the method of presetting, see “11.12.2 METHOD OF OPERATION”.

I

AMO9OQOO 1

AM090010

7.

DISPLAY

The reception displayed.

band,

frequency,

preset

number,

and time

are

I

AM90020

8. TIME CORRECTIONBUITON This is used to correct the time. : Hour H M : Minute SET: Sets to start of hour (00 minutes)

2-33

1

11. EXPlANATiON

OF COMPONENTâ&#x20AC;&#x2122;S

9.

STEREO INDICATOR (ST) This lamp lights up when a stereo broadcasting is when receiving an FM broadcasting station.

11.122

METHOD OF OPERATION

METHOD OF SETTING PRESET BUTTONS 1. Press power switch @I and display the frequency on display 0.

2. Turn the tuning button (manual, auto) to adjust to the desired frequency.

3. Select a preset button to use for recording the frequency setting, and keep that button pressed for at least 1.5 seconds. The sound will disappear, but when the setting is recorded, the sound will appear and the preset number will appear on display QI to show that the station has been preset.

After completion of presetting, press preset button @, and release it within approx. 1.5 seconds. The setting wili change to the frequency of the broadcasting station recorded for that button. One AM station and one FM station can be recorded for each preset button.

MANUAL TUNING Press tuning button @ and set to the desired frequency.

Each time the button is pressed, the frequency will move up or down in steps of 9 kHz (AM) or 0.1 MHz (FM).

V button: Move to a higher frequency station A button: Move to a lower frequency station l If the frequency reaches the top or bottom limit, it will automatically change as follows: top limit + bottom limit, or bottom limit + top limit _ AUTOMATIC TUNING Keep tuning button @I pressed for at least 0.5 seconds. When a broadcasting station is picked up, it will automatically stop. To search for the next station, press tuning button @I again for at least 0.5 seconds.

V button: Move to a higher frequency station A button: Move to a lower frequency station l If tuning button @ is pressed during auto tuning, the auto tuning will be canceled and the frequency at the point where it is canceled will be picked up.

2-34

11. EXPLANATION OF COMPONENTS

SETTING CORRECT TIME 1. Press display selector button @ to display the time.

After 5 seconds, the display will return to the frequency display and the time cannot be corrected. If this happens, press display selector button @ again.

2. Press time adjustment button @I and adjust the hour and minute.

H button: Adjusts hour (advances one hour each time it is pressed) M button: Adjusts minute (advances one minute each time it is pressed) If the H or M button are kept pressed, the time will advance continuously until the button is released.

SET button: Sets to start of hour (when it is pressed, the minute returns to 00) If the minute display is between 0 and 29, and the SET button is pressed, the minute reading will return to 00. If it is pressed when the minute display is between 30 and 59, the minute display will return to 00 and the hour will advance by 1.

Example lo:29 - IO:00 10:30 -) 1 l:oo Press the H, M, and SET buttons to set to the correct time.

ANTENNA In areas where the reception is weak or there is interference, extend the antenna. If the radio is set to a station with strong radio waves, retract the antenna to set to a weaker input.

NOTICE

Always retract the antenna before transporting the machine or driving the machine into a work shop or garage.

2-35

1I. EXPLANATION OF COMPONENTS

11.12.3 PRECAUTIONS WHEN USING To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during operation. l If water gets into the speaker case or car radio (auto tuning), it may lead to an unexpected failure, so be careful not to get water on the equipment. l Do not wipe the scales or buttons with benzene, thinner, or any other solvent. Wipe with a soft dry cloth. Use a cloth soaked in alcohol if the equipment is extremely dirty. l When the battery is replaced, the settings for the preset buttons are all cleared, so set again. l

11.12.4

SPECIFICATIONS

PLL synthesizer method AM 522 kHz - 1629 kHr (in 9 kHz steps) FM 76.0 MHz - 90.0 MHz (in 0.1 MHz steps) Actual max. sensitivity: AM 30 dB FM 75 dB lOWx2 Actual max. output: Current consumption: Max. 2 A Width 184 mm (7.24 in), External dimensions: Height 56 mm (2.20 in), Depth 116 mm (4.57 in) 0.65 kg (1.43 lb) Weight:

Tuning method: Reception frequency:

2-36

Il.

EXPLANATION OF COMPONENTS

11.13 FUSE This forms

one unit with the circuit breaker.

NOTICE Before replacing

a fuse, be sure to turn off the starting

switch.

and wiring from The fuses protect the electrical equipment 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.

If there is a surge of current, the circuit breaker cuts the circuit to protect the wiring. To restore the circuit that has been cut off by the breaker, press in the button that has popped out.

If the electrical circuit is working normally, the button will stay after it is pushed in, it is pushed in. If it springs out immediately necessary to check the electrical circuit.

Fuse, breaker

capacity

and name of circuit

Circuit

2-37

11. EXPLANATION

OF COMPONENTS

11.14 CIRCUIT-BREAKER

(Installed

outside cab)

If the engine does not start even when the turned to the ON position, the electrical circuit has by the circuit breaker. Open the side door closest machine on the left side and check the breaker battery.

starting switch is probably been cut to the front of the button under the

If the button is protruding, push it in.

If the electrical circuitis working normally, the button will stay pushed in. If it springs out immediately after it is pushed in, it is I necessary to check the electrical circuit.

1

REMARK A circuit-breaker refers to the large-sized fuse breaker installed in the high current flow portion of the circuit to protect electrical components and wiring from burning, similarly to an ordinary fuse.

11 .15 CONTROLLERS The engine throttle and pump controller and the VHMS controller are installed inside the cab base.

Governor

Puma

controller front ine

I r rear sine

NOTICE l Never splash or spill water, mud or drink over the controllers as l

thii may cause a fault. lf a fault occurs in the controller, do not attempt repair, but consult your Komatsu distributor.

11.16 TOOL BOX This is used for keeping the tools.

2-38

(VHWS controller)

VHMS.

Il.

EXPLANATION OF COMPONENTS

11.17 GREASE PUMP The pump is instituted machine.

by the inlet of the cab lower room on the

11.18 HANDLING GREASE PUMP 11.18.1 1.

2.

INSTRUCTIONS

FOR USE

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

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

REMARKS When greasing with grease gun, close stop valve, to close the other line.

After finished the greasing work, open stop valve.

Use the special handle when opening or closing stop valve.

When greasing with the grease gun, run the front engine at a mid-range speed.

Turn the starting switch ON, then set the greasing switch to START. (The greasing operation stops after 15 minutes, but if it is desired press the START button again. to carry out more greasing, the lamp in the hatched portion (center of During auto-greasing, switch) will

11.18.2

light up.)

PRECAUTIONS

FOR USE gun so that the

l

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

l

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

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

l

2-39

11. EXPLANATIONOF COMPONENTS

11.18.3 1.

2.

3.

RERLLING GREASE CAN

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

Take out follow plate @ from inside can.

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

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

4.

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.

5.

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.

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.

2-46

11. EXPLANATION OF COMPONENTS

11.19 HANDLING

ACCUMULATOR

A

WARNING

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

After stopping the engine, always place the safety lock lever in the LOCK position.

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

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

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

The accumulator is installed to inside of track frame (1 point) and inside of left deck (1 point).

Inside of track frame

IInside of left de&

2-41

11. EXPLANATIONOF COMPONENTS

11.19.1

METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR

Place the work equipment on the ground.

Stop the engine.

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.

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 loosen the screws. Never stand in the oil ejection direction.

2-42

11. EXPLANATION OF COMPONENTS

11.20 1.

HEALTH MONITOR

Health monitor The health monitor displays the condition of the machine, the maintenance status, and messages to the operator and service man, and is also used to input the necessary data.

The surface of screen 0 is equipped with touch switches to switch the screen and input the data.

REMARK When the starting switch is turned ON, the opening screen is displayed for approx. 5 seconds. The condition of the machine is not displayed.

If the ambient temperature of the monitor goes below -30°C or above 55â&#x20AC;?C, the back light is turned off to protect the screen. The display cannot be seen, but this is not an abnormality.

When the temperature returns to the operating range, the display will appear again, so carry out operations according to the machine monitor.

2-43

17. EXPLANATION OF COMPONENTS

2.

Switching screens There are 5 screens. The screen can be switched bv ooeratinaâ&#x20AC;&#x2DC; the touch switch on the surface. it takes approx. 5 second; after the-starting switch is turned ON for the Opening screen: condition of the machine to be displayed. During this time, the opening screen is shown.

The screen automatically switches to the normal screen approx. 5 seconds Normal screen: after the starting switch is turned ON. The oil temperatures, water temperatures, and oil pressures are displayed on the meters.

It is possible to switch from this screen to screens @I and @I, by pressing the touch switch.

Maintenance screen: This displays the time remaining until the next maintenance is to be performed.

This screen is used to set the date and time.

Setting screen: With this screen, it is possible to set the user ID. Abnormality screen: If any abnormality occurs, the screen switches automatically to this display.

When the abnormality is removed, the screen automatically returns to the display shown before the abnormality occurred.

A

CAUTION

As far as possible, set the data and time to the local time. lf it is not set, the operating data will not be correctly recorded.

/

I

1

1Starting switch ON 1 1

After approx. 5 seconds

2-44

\

)

11. EXPLANATION OF COMPONENTS

3. Explanation of screen 3.1 Opening screen It takes approx. 5 seconds from the time the staning switch turned ON until the condition of the machine is displayed.

During this time, the opening screen is displayed.

is

3.2 Normal screen The screen automatically switches to the normal screen approx.

30 seconds after the starting switch is turned ON. The oil temperatures, water temperatures, and oil pressures are displayed on the meters.

I-

-J

R COOLANT

R PTO

Hello !

Welcome to VHMS system The srstem is nowbuildino Please wait a moment.

UP

-

OIL

AU364470

Meter

display:The oil temperatures, water temperatures, and oil pressures are displayed. The display item screen can be changed by touching switch 0.

Brightness control button: This adjusts the brightness. For details of the method of adjusting the brightness, see Section 3.3.

Operating hours/ tachometer display button: This switches to the operating hours and tachometer display screen.

Setting screen display button: This switches to the setting screen.

Display selector button: This switches the display to the next screen. Each time it is pressed, the display screen switches in the following cycle: @ + @I - @ + @ @ Front engine water temperature, rear engine water temperature, front PTO oil temperature, rear PTO oil temperature @I Front engine oil temperature, rear engine oil temperature, front engine oil pressure, rear engine oil pressure @ Front PTO oil temperature, rear PTO oil temperature, hydraulic oil temperature Maintenance screen display This switches to the maintenance screen. button: The color of the letters on the panel for each item changes according to the remaining time.

(40 h remaining: Yellow; 0 h remaining: Red) Time display: This displays the present time.

2-45

11. EXPLANATION

OF COMPONENTS

3.3 Brightness control screen When the brightness control button is pressed, brightness control sub-panel @ is displayed on top of the present screen. If the subscreen is not touched within 5 seconds, it will disappear and the original screen will be displayed.

P3

I

II

II

I /

II

Brightness

and

C ntrast P

Settings II

Contrast r;â&#x20AC;&#x153;lpq

.

01-Q

m I

,

next I

maint I

I

J

@

Contrast control slide:

This is used to adjust the contrast of the screen.

Press the desired position on the slide bar.

@

Brightness control slide:

This is used to adjust the brightness of the screen.

Press the desired position on the slide bar.

2-46

AW364430

EXPLANATION

11.

OF COMPONENTS

3.4 Maintenance screen This displays the items to be performed up the next time for each maintenance item.

When the remaining time becomes short, the color of the letters on the screen and the color of the maintenance screen selector button on the normal screen change.

Yellow 40h remaining: Red Oh remaining:

P I

MAINTENANCE

@N___

II/

Change

MONITOR-1 engine

250/500h

oil J

Chance Change

Change

enoine

oil

hydraulic

hydraulic

filter

1

170H 170H

filter drain

170H

filter

170H

hW37IBlE

Standard maintenance interval display:

This displays the standard

Maintenance display:

This displays the maintenance

Remaining display:

interval.

item

.

items.

time

Maintenance item selector button (back):

0

maintenance

Maintenance item selector button (next):

This displays the time remaining

until the next time

of maintenance.

This switches the maintenance item display to the previous display.

Each time it is pressed, the display changes @ + @ + @ + @.

This switches the maintenance item display to the next display.

Each time it is pressed, the display changes @ + @ + @ - @. @ Maintenance items for every 250 h @ Maintenance items for every 500 h @ Maintenance items for every 1000 h @ Maintenance items for every 2000 h

2-47

11. EXPLANATION OF COMPONENTS

@ Maintenance items for every 250 h l Change oil in engine oil pan l Replace engine oil filter cartridge l Replace hydraulic filter element l Replace drain filter cartridge l Replace hydraulic tank breather filter element @ Maintenance items for every 500 h l Replace fuel filter @ Maintenance items for every 1000 h l Change oil in swing machinery case l Change oil in PTO case l Replace corrosion resistor cartridge @I Maintenance items for every 2000 h l Change oil in hydraulic tank l Wash engine breather element l Change oil in final drive case This screen displays typical change and replacement items, but there are also other inspection and adjustment items. When carrying out maintenance, see the inspection and maintenance schedule chart in Section 23 of this manual. @

2-48

Normal screen display button: This switches to the normal screen. The item previously displayed on the normal screen is displayed.

11.

3.5 Setting screen Use this screen to input the date, time, display

EXPLANATION

OF COMPONENTS

unit, and user ID.

DATE SETTING

4

5

6

7

8

6

0

BS

Enter

USERID

Au372720

@

Date setting button:

Press this button when inputting the date.

Screens @to @Jare displayed. When the item to be changed is pressed, the screen for ten-key pad @ used for the input is displayed and data can be input.

@

Data display:

The present settings

@

Time setting button:

Press this button when inputting the time.

The input procedure is the same as for item 0.

@

Unit setting button: METRIC:

Only metric units can be set.

Metric units are displayed (km/h,

are displayed.

kg/cm*, â&#x20AC;&#x153;C, J?,Metric TON)

2-49

11. EXPLANATION OF COMPONENTS

@

User ID:

This is used when giving an ID number to the machine.

A maximum of IO alphanumeric characters can be input.

@

input sub-screen : (ten-key pad)

Input with ten-key pad then confirm by pressing ENTER key.

If any mistake is made in the input, press the backspace key. Each time it is pressed, the last character on the right is deleted. When the ENTER key is pressed to confirm the input, the sub-screen will go out, the display will return to the setting screen, and the input data will be displayed.

@I

Normal screen display button :

@

2-50

Time setting button :

This switches to the normal screen. The item previously being displayed is displayed again.

The clock will start when this button is pressed. If the button is not pressed, the time will not be updated.

11.

EXPLANATION OF COMPONENTS

3.6 Abnormality screen If any abnormality occurs on the machine, the screen automatically changes to display the type of failure and the action to take. Carry out the action given on the screen.

When the abnormality screen is being displayed, press CANCEL button @to view the other screens. The screen will go out. Even when the screen is cancelled, if the abnormality still exists, if the starting switch is not turns OFF and then ON again, the screen will not be displayed.

G1.F

engine

-Stop

work and

until

in the

3.6.1

of now

run

Pointer

occurrence being

and

reserve

temp.

engine

enters

engine

-StOD

Order Proble

coolant

oreen

check tank

idle

low sDeed

range.

cooling and

at

hioh

water

level

add.

Toial existing

of displayed.

number of Problems.

AU371828

Basic check items

NOTICE Even if this screen is not displayed, the items for check before starting must never be omitted.

Always carry out the basic checks according the MAINTENANCE section, or “12. OPERATION”.

bo 6

R. enaine

‘Stoo in oil

engine Dan

and and

oil

level

check

engine

low

oil

level

add.

El CANCEL

AN371838

This screen displays typical basic check items, but there are also other check items. For details, see section 3.6.4 Abnormality display item table.

2-51

1I. EXPLANATION OF COMPONENTS

3.6.2

CAUTION

items

A

CAUTION

lf thii scraenis displayed, carry out inspectionand maintenanceof the problem locationas soon as possible. ,

‘Check

the

‘Chatoine

battery

volt

chargino

system.

is

This screen displays typical caution items, but there are also other CAUTION section 3.6.4 Abnormality display item table.

3.6.3 Emergency

items. For details, see

stop items

A

CAUTION

lf this screenis displayed,stop the engine immediatelyor run at low idling and carryout the action given on the monitor display.

OPI

R PTO oil

6

‘Stop add

enoine

and

temperature check

PTO

oil

hioh level

and

oil.

This screen displays typical emergency stop items, but there are also other emergency For details, see section 3.6.4 Abnormality display item table.

2-52

stop items.

11. EXPLANATION OF COMPONENTS

3.6.4 Abnormality display item table The following abnormalities are displayed

on the health monitor.

@

Basic check items Drop in front oil level Front radiator water level (before starting) Drop in rear oil level Rear radiator water level (before starting) Hydraulic oil level

@

CAUTION items Clogging of front air cleaner Abnormality in front battery charge Abnormality in front water temperature Clogging of rear air cleaner Abnormality in rear battery charge Abnormality in rear water temperature

0

sensor system

sensor system

Emergency stop items Abnormality in front PTO oil temperature Error in front NC valve system Drop in front engine oil pressure Abnormality in front engine oil temperature Front overheating Error in front governor system Abnormality in front radiator water level Abnormality in front engine oil pressure Abnormality in rear PTO oil temperature Error in rear TVC valve system Abnormality in rear engine water temperature Drop in rear engine oil pressure Abnormality in rear engine oil temperature Error in rear governor system Abnormality in rear radiator water level Abnormality in rear engine oil pressure Error in swing brake system Error in network system Hydraulic oil temperature Hydraulic oil clogging Abnormality in #l relief pressure Abnormality in #2 relief pressure Abnormality in #3 relief pressure Abnormality in #4 relief pressure Abnormality in #5 relief pressure Abnormality in gear pump pressure

2-53

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 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

I--

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.

1.

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

2.

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

3.

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

4.

Check for 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.

2-54

7.

Check for damage to gauges, monitor, loose bolts Check that there is no damage to the gauges and monitor in the operatorâ&#x20AC;&#x2122;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 damaged, mirror and seen from

9.

there is no damage to the rear-view mirror. If it is replace it with a new mirror. Clean the surface of the adjust the angle so that the view to the rear can be the operatorâ&#x20AC;&#x2122;s seat.

Check seat belt and mount fittings Check that there is no abnormality in the seat belt or mount fittings. If any damage is found, replace with new parts.

10. Check tightness of air cleaner mounting bolts.

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

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

12. 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.

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

at the

2-55

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 0

0

WARNING

Do not open the radiator cap unless necessary. When checking the coolant, always check the radiator reserve tank when the engine is cold.

Do not remove the cap when the radiator water is hot. Boiling water may spurt out. After the water temperature goes down, turn the cap slowly to release the pressure, then remove it.

Open the left rear cover on the machine and check that the cooling water level is between the FULL and LOW marks on radiator reserve tank @ (shown in the diagram on the right).

If the water level is low, add water through the water filler of reserve tank 0 to the FULL level.

F. ENi I NE

R. Ek I NE 11111~11

After adding water, tighten the caps securely.

If the reserve tank becomes empty, first inspect for water leaks and then fill the radiator and the reserve tank with water.

REMARK l When adding water to the radiator, remove cover 0, then loosen radiator cap @I slowly. After checking that the pressure has been released, push in the cap, keep it pushed in, then loosen it further and remove it. l Check that the level of the coolant is above the hatched portion in the diagram on the right. If the water level is low, add water through the water filler port. l After adding water, install radiator cap 0.

When operating in cold areas, see “14. COLD WEATHER OPERATION”.

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL I. Open the left cover (rear engine) and the front cover (front engine) at the center of 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. I]

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

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

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

2-56

AEo82160

12. OPERATION

5.

If the oil is above the H mark, drain the excess engine drain plug 81, @Z and check the oil level again.

6.

If the oil level is correct, close the engine hood.

tighten

oil from

the oil filler cap securely

and

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

1. Use sight gauge f@ on the side of the fuel tank to check that the tank is full.

2.

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

Fuel capacity:

add fuel through

2300 e (608 US gal, 506 UK gal)

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

3.

After adding fuel, tighten

AEl76690

the cap securely.

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

Clean the hole from time to time.

in the tank

2-57

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

A

WARNING

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.

l

lf 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.

1.

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.

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

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

4.

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

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

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

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

1

r

CHECK FOR CLOGGING OF AIR CLEANER 1.

Confirm

that the air cleaner clogging

2.

If it flashes,

immediately

monitor

clean or replace

does not flash.

the element.

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

“24.3.1

CHECK ELECTRIC WlRlNGS I

I

A

WARNING

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

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

Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the breather hole.

Check for damage and wrong capacity 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 wiring of the “battery”, “starting motor” and “alternator” carefully in particular.

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.

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

CHECK FUNCTION OF HORN switch to the ON position.

1.

Turn the starting

2.

Press the horn switch and check that the horn sounds immediately.

If the horn does not sound, please contact your Komatsu distributor for repairs.

2-59

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 oil at the dipstick guide hole.

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

Check the oil level with the engine stopped or running at low idling.

When the engine stopped, wait for at least 15 minutes after stopping the engine before checking.

When checking at idling, run the engine at idling for at least 15 minutes before checking.

DRAIN WATER AND SEDIMENT FROM FUEL TANK 1. Pull out the hose from holder @ at the bottom of the tank.

2. Loosen drain valve @ and drain the water and sediment at the bottom of the tank together with fuel.

3. After draining, tighten drain valve @ securely and set the hose at the original position.

2-50

CHECK CENTRAL MONITOR Carry out the following checks 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.

2-61

.

12. OPERATION

12.1.3 ADJUST OPERATOR’S SEAT

l

Adjust the seat position before starting operations or after

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

Adjustable distance: 100 mm (3.9 in) in IO 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 @I Push lever @I down to adjust the angle of the front of the seat.

(4 stages) I. To raise the angle at the front of the seat, keep the lever pushed down and apply your weight to the rear of the seat.

2. To lower the angle at the front of the seat, keep the lever pushed down and apply your weight to the front of the seat.

2. Rear tilt @I Pull lever @ up to adjust the angle of the rear of the seat. (4 stages) 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.

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” 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)

2-62

AM364200

D:

Adjusting armrest angle Armrest @ can be made to spring up by hand approx. 90”.

In addition, by turning the bottom @ of the armrest by hand it is possible to make fine vertical adjustments of the armrest angle.

Armrest adjustment angle: 25” REMARK If the seat back is tipped to the front without the armrest will rise automatically.

raising the armrest,

E:

Overall fore-and-aft adjustment of seat Pull up lever @, set to the desired position, then release the lever. In this case, the operator’s seat, left and right control levers, and safety lock lever all slide together.

Fore-and-aft adjustment: 120 mm (4.8 in)

F:

Adjusting suspension Turn knob 0 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 0 is the same as the operator’s weight.

ADJUSTMENT OF MONITOR PANEL ANGLE Turn the monitor panel so that the operator can view the monitor with ease. When adjusting the angle, the panel should be set to the desired position using both hands. The panel is automatically locked at that position.

Amount of adjustment: 30” (stepless)

2-63

12. OPERATION

12.1.4 ADJUSTMENT

OF MIRRORS

ADJUSTMENT OF MIRRORS Loosen nut @ of each mirror and adjust the mirror angle at which you can see the reflected view most easily from the operatorâ&#x20AC;&#x2122;s seat.

In particular, adjust the mirrors so that you can see persons on both side of the rear end of the machine.

INSTALLATION PROCEDURE OF MIRRORS install and adjust mirror so that anyone in both LHS and RHS of machine rear position (or any object of dimension approximately 1 m high and 30 cm diameter) is clearly visible.

Refer to dimensions shown in right chart for position of mirror.

Field of visibility reference value is shown below.

Mirror @: Mirror @:

2-64.

Hatched @ area (opposite side of @I to be visible (option) Hatched @I area to be visible.

12.1.5 USING SEAT BELT A WARNING

I

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

Replace any worn or damaged seat belt or the brackets.

Adjust and fasten the seat belt before operating Always

use seat

brackets securing

the machine.

belt when operating the machine.

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

FASTEN THE BELT AND REMOVE lT 1. Sit in the seat and adjust the seat to a position where it is easy to carry out operations with your back against the backrest.

2.

For machines with a suspension seat, adjust the position of the seat, then adjust tether belt 0. Install the tether belt so that it is tensed when no one is sitting in the seat. (Only machines equipped with suspension seat)

3.

After adjusting the seat position, sit in the seat. Grip buckle @ and tongue @ in each hand and insert tongue @ into buckle 0.

Confirm by pulling the belt that the tongue is securely locked to the buckle.

4.

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

I--%--

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.

AH364210

ADJUST To

THE BELT LENGTH

shorten the belt

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

AM091850

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 loose bolts to 20 to 29 Nm (2 to 3 kgm, 15 to 20 Ibft) torque.

any

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.

NOTICE Even if there appears to be no abnormality in the belt, always replace the seat belt once every 3 years. The date of manufacture is shown on the back of the belt.

1

AMOS1860

2-65

12.1.6OPERATIONS AND CHECKS BEFORE STARTING ENGINE ff the control lever is touched by accident, the work equipment or the machine may move suddenly. When feavmg the opera torâ&#x20AC;&#x2122;s compartment, always set the safety lock fever securely to the LOCK position.

A WARNfNG :] 1.

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

2.

Check the position of each lever.

Set the control lever to the neutral position.

When starting the engine, never touch the knob button.

3.

Insert the key in starting switch 0, turn the key to the ON position, then carry out the following checks.

(I) The buzzer will sound for approx. 1 set, and the following monitors and gauges will light up for approx. 3 sec.

I 4 Radiator water level monitor @ 0 Engine oil level monitor @ 4 Hydraulic oil level monitor @ 0 Charge level monitor @ 0 Fuel level monitor 0 4 Engine water temperature, hydraulic oil temperature monitor @ 0 Engine oil pressure monitor @I 0 Engine water temperature gauge @I 0 Fuel gauge @ 0 Engine pm-heating monitor @I 0 Air cleaner clogging @I l Swing lock lamp @ 0 Hydraulic filter clogging monitor @

OFF

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

After approx. 3 set, the following gauges will remain on and the other monitors will go out.

0 Engine water temperature gauge @I 4 Fuel gauge @

(2) Press lamp switch @I to turn on the head lamps.

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

2-66

ON

3.

Check that engine emergency stop lamp @ is off. If it is lighted up, engine stop switch @ inside the engine room or engine stop switch @ at the side of the left side step is at the OFF position, or there is a disconnection.

If the switch is OFF, press the engine stop switch ON. If there is a disconnection, please contact your Komatsu distributor for repairs.

2-67

12.2 STARTING ENGINE 12.2.1 NORMAL STARTING

area, then sound the horn and start the engine.

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

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

1. Turn the staner motor selector switch @ to FRONT engine.

Front

2.

ene in

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

Low idling

3.

4.

5.

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

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

Turn the starter selector switch @ to REAR engine.

Set fuel control dial @ at the low idling (MINI position, and repeat steps 3 - 4 to start the engine.

2-68

OFF

1

OFF I

_o34o

122.2 STARTING IN COLD WEATHER

Check that there are no persons or obstacles in the surround-

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 3 and afâ&#x20AC;&#x2122;ter waiting for about 2 minutes.

When

1.

starting in low temperatures,

do as follows.

Turn the starter motor selector switch @ to FRONT engine.

Rear Front

2.

Set fuel control position.

dial @ at 3 notch from the low idling

engine

enein

(MINI

REMARK There are 10 notches for the dial rotation, felt by hand.

and the click can be Low idling

3.

Hold the preheating switch @ at the HEAT position, and check that preheating monitor @ lights up.

After about 30 seconds, preheating monitor lamp @will flash for about 10 seconds to indicate that preheating is finished.

When the preheating switch is released, it will go off automatically.

AM096510

HEAT

REMARK The monitor and gauge also light up when the key is at the HEAT position, but this does not indicate any abnormality.

2-69

12. OPERATION

4.

When preheating monitor flashes, turn the key in starting switch @ to the START position to start the engine.

5.

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

6.

Turn the starter selector switch @ to REAR engine.

Set fuel control dial @ at the low idling (MIN) position, and repeat steps 3. - 5. to start the engine.

OFF I

2 -zD 5p -4 AW350040

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. .

2-70

12.3

OPERATIONS AND CHECKS AFTER STARTING ENGINE

7

a l

l

WARNING

I

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

If the work equipment is operated without warming the machine up sufficiently, the response of the work equipment to the movement of the control lever will be slow, and the work equipment may not move as the operator desires, so cold areas,

12.3.1

WHEN

be sure to carry out the warming-up

operation

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. This will cause leakage of oil from the turbocharger oil supply piping. If it is necessary to run the

engine at idling, apply a load from time to time or run the engine at a mid-range speed. o

The hydrauiic oil temperature should ideally lie within the range 60 to 80°C (122 to 176°F). lf the machine is operated after raising the oil temperature to 20°C (68°F). the life of the machine will be extended.

After starting the engine, do not immediately start operations.

First, carry out the following operations and checks.

Turn fuel control dial @ and @ to the center position between low idling (MINI and high idling (MAX) and run the engine at medium speed for about 5 minutes with no load.

r

Low idling AMO¶O410

2.

While running the engine at medium speed, press working mode switch @ until the heavy-duty operation mode lamp is turned on.

2-71

Push greasing switch @ to START side and carry out greasing of the work equipment and swing circle. Grease will be supplied automatically for 15 minutes. If you wish to stop before completing the 15 minutes, push greasing switch @ to STOP side.

During greasing, the lamp in the hatched portion (center of switch) will light up.

Carry out greasing around the bucket.

For details see “11.17 GREASE PUMP”.

5.

Set the safety lock lever @ to the FREE position, and raise the bucket from the ground.

6.

Operate bucket control lever @I and arm control lever @ slowly to move the bucket cylinder and arm cylinder to the end of the stroke.

Arm operation

Bucket operation

g:“RLK

AMo9oua

7.

Carry out bucket and arm operation for 5 minutes at full stroke, alternating between bucket operation and arm operation at 30 second intervals.

If the swing lock switch @I is set to the ON (actuated) position and swing control lever @I is operated at full stroke, oil temperaturerise can be increased earlier.

NOTICE When the work equipment is retracted, take care that it does not interfere with the machine body or ground.

2-72

Le*

12. OPERATION

8. l 0 0

9.

After carrying out the warming-up operation, check that each gauge and monitor lamp is in the following condition.

Engine water temperature gauge @I: Inside green range Fuel gauge 0: Inside green range Engine water temperature hydraulic oil temperature monitor 0: OUT Radiator water level monitor @I: OUT Engine oil pressure monitor @I: OUT Charge level monitor @: OUT Fuel level monitor 0: OUT Air cleaner clogging monitor @: OUT Engine pre-heating monitor @I: OUT Engine oil level monitor @I: OUT Hydraulic oil level monitor 0: OUT Hydraulic filter clogging monitor @: OUT Check that there is no abnormal exhaust gas color, noise, vibration. If any abnormality is found, repair it.

10. Press working monitor mode switch @ until required mode lamp is turned on.

or

operation

2-73

12.3.2 IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION) When starting the engine in cold areas, carry out the automatic warming-up operation after starting the engine.

When the engine is started, if the engine water temperature is low (below 30X), the warming-up operation is carried out automatically.

The automatic warming-up operation is canceled if the engine water temperature reaches the specified temperature (30°C) or if the warming-up operation is continued for 10 minutes. If the engine water temperature or hydraulic oil temperature are low after the automatic warming-up operation, warm the engine up further as follows.

NOTICE 0 When the hydraulicoil is at a low temperature,do not carryout operations or move the leverssuddenly. Always carry out the warming-up operation.This will help to extendthe machinelife.

0 Do not suddenly acceleratethe 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.This will causeleakageof oil from the turbocharger oil supply piping. lf it is necessaryto run the engine at idling, apply a load from time to time or run the engine at a mid-range speed.

11572040

1.

Set fuel control dial @ and @to the low idling (MINI position and run the engine for about 5 minutes without load.

I

I 2.

I

Low idling AMO9EWl

Press working mode switch @ on the monitor panel until the H.0 (heavy-duty operation) mode lamp lights up.

I .

3.

Turn fuel control dial @ and @ to the medium speed position.

Low idling AM090410

2-74

4.

Set safety lock lever 0 to the FREE position and raise the bucket from the ground.

AW364166

5.

6.

Operate bucket control lever @I and arm control lever @ slowly to move the bucket cylinder and arm cylinder to the end of their stroke.

is retracted, take care that it does body or ground.

7.

Turn fuel control dial @ and @ to the full speed (MAX) position and carry out the operation is Step 6. for 3 - 5 minutes.

8.

0 0

Repeat the following operation 3 Boom operation RAISE Arm operation IN Bucket operation CURL Swing operation LEFT Travel (Lo) operation FORWARD

l

0

Bucket operation

Operate the bucket for 30 seconds and the arm for 30 seconds in turn fully for 5 minutes.

NOTICE When the work equipment not interfere with the machine

l

Arm operation

5 times and operate c) LOWER ti OUT c) DUMP t) RIGHT t) REVERSE

slowly.

REMARK In the above operation is not carried out, there may be a delay in response when starting or stopping each actuator, so continue the operation until it becomes normal.

9.

Use working mode switch @ on the monitor working mode to be used.

pane! to select the

11

1

AA307550

2-75

NOTICE Canceling automatic warming-up operation lf it becomes necessary in an emergency to lower the engine speed to low idling, cancel the automatic warming-up operation as follows.

1. Turn fuel control dial @to the full speed (MAX) position and hold it for 3 seconds.

2.

When fuel control dial 0 is returned to the low idling (MINI position, the engine speed will drop.

Low idling

2-76

AM090340

12.4 MOVING MACHINE OFF 12.4.1 MOVING

MACHINE

A

FORWARD WARNING

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

of the of the

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

Clear all personnel Clear all obstacles

from the machine

is

and the area.

from the path of the machine.

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

For machines equipped with the travel alarm (option), that the alarm works properly.

check

1.

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

2.

Turn fuel control dial @ towards increase the engine speed.

3.

Set safety equipment,

the full speeed

and

position

to

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

2-77

4.

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

l

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

l

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

5.

For machines equipped with the travel alarm (option), check that the alarm sounds.

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

124.2

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 an blind spot behind the machine. if the lever is moved inside the deceleration range, engine speed will suddenly rise. Operate the levers carefully.

For machines equipped with the travel alarm (option), check that the alarm works properly.

1.

Set swing lock switch @ to the ON (actuated} position and confirm that swing lock monitor lamp @ lights up.

2-78

2.

Turn fuel control dial @I towards to increase the engine speed.

the full speed (MAX)

position

Full M

I 3.

Set safety equipment,

4.

Operate right and left travel pedals @ as follows.

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.

0

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.

AMwow)

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

levers @ or right and left travel

Sprocket

5.

mnoas

For machines equipped with the travel alarm (option), check that the alarm sounds.

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

2-79

72.5

STEERING

MACHINE

12.5.1 STEERING (CHANGING DIRECTION) a

l

I l

I l

1

WARNING

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

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

Use the travel levers to change direction.

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

Operate two travel levers @ as follows.

Changing 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.

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

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.

2-80

Turning left when traveline

Turning left when traveling in reverse

12. OPERATION

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

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

2-81

12.6

STOPPING

MACHINE a

I

WARNING

Avoid stopping suddenly. Give yourself ample room when stopping.

When stopping the machine, select flat hard ground and avoid dangerous places. lf 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 operatorâ&#x20AC;&#x2122;s compartment, always set the safety lock lever securely to the LOCK position.

Thrust the bucket

AW36416B

1.

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

2.

Lower the engine speed using fuel control dial 0.

3.

Lower the bucket horizontally until its underside touches the ground.

4.

Place lock lever @ to the lock position.

Low idling

,

2-82

AMo903u)

,

12. OPERATION

12.7 SWINGING

I

A WARNING

i 1.

l

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

l

During swing operatins, do not put swing parking brake switch @ to ON. Before swing operations, put swing parking brake switch @ to OFF and confirm that swing lock lamp @ goes off.

NOTICE Check that swing lock monitor @ goes out at the same time.

2.

Operate left work equipment structure.

3.

When not operating @ ON (ACTUATED).

control

lever @ to swing the upper

the swing, turn swing parking brake switch

Leftswing

1

2-83

12.8

OPERATION

OF WORK EQUIPMENT

If any lever is operated when in the auto-deceleration actuated

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

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

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

Swine

owmtion

I r Boom

oeerrtioo

Bucketo,eration

2-84

12.9

HANDLING

WORKING

MODE

WORKING MODE The mode selector switch can be used to switch the mode to match the operating conditions and purpose, thereby enabling work to be carried out efficiently.

Make effective use of each mode as follows.

When the starting switch is turned ON, the working mode is set to the most commonly used general operation mode, so normal operations can be carried out without setting the mode.

Use the working mode switch to set the mode efficient mode to match the type of work.

to the most

-

AA307550

Working

Applicable

mode

DH mode

Powerful digging time in quarry

H mode

Normal

digging

G mode

Leveling, operations

operation and

loading

for

short

and loading operations

finishing

operations,

hauling

NOTICE Do not use the heavy-duty operation mode for breaker operations. If breaker operations are carried out in the heavy-duty operation mode, there is danger that the hydraulic equipment may be damaged or broken.

2-85

12.10

PROHlBlTlONS

FOR OPERATION

A

WARNING

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

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.

AE171030

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

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

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

2-86

:

Margin

Prohibited operations using dropping force of machine Do not use the dropping force of the machine for digging.

INCORRECT

INCORRECT

AE171080

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.

2-87

12.11 PRECAUTIONS

FOR OPERATION

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.

PERMISSIBLE WATER DEPTH NOTlCE When driving the machine out of water, if the angle of the machine exceeds 15â&#x20AC;?, 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.

Do not immerse the machine in water by more than the permis- 1 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)

12.12 PRECAUTIONS DOWN HILLS

WHEN TRAVELING

UP OR

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

Do not travel downhill in reverse.

20 - 30 cm (8 - 12

AE34152A

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

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

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

lower

the

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

INCORRECT

CORRECT

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

1) When traveling

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

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

AD34129A

2)

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

2-83

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. lf 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.

Ii engine stops l 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.

l

Precautions on slopes l

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.

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.

2-90

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.

l

Place the machine push-up switch at position 0. This will increase the pushing power of the boom and make it easier to escape.

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 90â&#x20AC;&#x2122; to 110â&#x20AC;?.

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.

2-91

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

DIGGING WORK

This machine is designed to dig places lower than the level of the machine.

If the arm digging angle is set to a range of 30â&#x20AC;? to the rear and 45â&#x20AC;? to the front, the arm cylinder can be used effectively to carry out work efficiently.

12.14.2

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.

1 12.15 PHENOMENA 1.

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.

2.

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

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.

2-92

AEO82730

12.16 PARKING MACHINE

A

I Avoid stopping stopping.

suddenly.

Give yourself

WARNING

ample

room

1 when

When stopping the machine, select flat hard ground and avoid dangerous places. lf 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.

Thrust the bucket

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 operatorâ&#x20AC;&#x2122;s compartment, always set the safety lock lever securely to LOCK position.

1.

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

position.

2.

Turn fuel control dial @ to lower the engine speed to low idling.

Low idling

AM0903401

2-93

3.

Lower the bucket horizontally ground.

until the bottom touches the

I 4.

AD34 1570

Set safety lock lever @ in the LOCK position.

AU364168

12.17 CHECK AFTER FINISHING Check the engine water temperature, fuel level on the monitor gauge.

2-94

WORK engine oil pressure and

12.18 STOPPING 12.18.1

ENGINE

NORMAL STOPPING

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

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

1.

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

2.

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

3.

Remove

and stop OFF I

the key from starting switch @_

2-95

12.182

STOPPING IN EMERGENCY

a CAUTION Use the engine stop switch only when stopping the engine in an emergency. When stopping normally, use the procedure in 12.18.1.

Using engine stop switch, fuel cut knob from ground 1.

Press the red switch @ immediately beside the left steps.

I 2.

Turn fuel cut knob @ to the left to release the lock.

3.

Pull the knob and turn it to the right to lock it and stop the engine.

l

When starting the engine again after stopping it, turn the fuel cut knob to the leti to release the lock, then press the knob back in, and press the engine stop switch. Check that engine emergency stop lamp @ on the panel on the right side of the operatorâ&#x20AC;&#x2122;s seat inside the cab is OFF, then start the engine.

l

Turn the fuel cut knob to the right to lock it.

M372220

P OFF

2-96

I

Using engine stop switch

inside engine

room

NOTICE The switch inside the engine room is provided to make it impossible to start the engine from inside the cab when carrying out inspection and maintenance inside the engine room. Normally, keep this switch at the ON position (red lamp lighted up).

l

Press red switch @ at the side of the steps for the engine in the center of the engine hood to stop the engine.

room

l

When starting the engine again after stopping it, press the switch again. Check that engine emergency stop lamp @ on the p on the right side of the operatorâ&#x20AC;&#x2122;s seat inside the cab is OFF, start the engine.

m

I

I

IcmXon\

2-97

12.

OPERATION

12.19 CHECK AFTER STOPPING

ENGINE

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

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

2.

Fill the fuel tank.

3.

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

4.

Remove any mud stuck to the undercarriage.

12.20 LOCKING @ @ @ @ @ @ @ @

Always lock the following places.

Door of operatorâ&#x20AC;&#x2122;s cab Always remember to close the window.

Fuel tank filler port Battery box cover Left side door of the machine (7 positions) Right side door of the machine (2 positions) Operator cab under box door Engine hood (3 positions) Box for storing emergency escape ladder

REMARK Use the starting switch key to open and close all these places.

2-98

13. TRANSPORTATION

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

13.1

PRECAUTIONS

all related

laws and

FOR TRANSPORTATION g

WARNING

l

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

l

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

NOTICE Always

retract the radio antenna.

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

REMOVAL AND INSTALLATION OF MIRRORS Mirrors are installed to the positions shown at right (The one marked with % is optional). When removing and installing them for replacement or transportation, observe the following procedure.

Removal 1. Loosen nut @ of mirror 0, 2.

0.

Loosen bolt 0, .. handrail.

and remove

and remove

the latter from support

support @ and clamp @ from the

Installation 1. Install support @ and clamp @ to the handrail, then secure it with bolt 0.

2. Install mirror @ to support 0. then tighten nut 0.

2-99

13. TRANSPORTATION

13.2

PARTS FOR TRANSPORT

The dimensions in the diagrams are given in millimeters.

For ease of transport, the machine may be disassembled into the parts shown in the diagrams: the body, operatorâ&#x20AC;&#x2DC;s cab, track frames, ladder, platform, attachments and counterweight.

Ask your Komatsu distributor to carry out the disassembly work.

s 0

PC1800-6 Weight:

I--

: Lifting position

21000 kg x 2 = 42000 kg (46200 lb x 2 = 92400 lb)

7436 w

AU372310

Weight:

c

44000 kg (96800 lb)

8731

Am372320

2-100

13. TRANSPORTATION

Weight:

2100

1606. 7

1230 kg (2712 lb)

J AU372330

Weight:

1000 kg (2200 lb)

AE179190

Weight: 50 kg (110 lb)

I

650

c

596 AU372340

2-101

13. TRANSPORTATION

Weight:

12000 kg (26500 lb)

AU372350

Weight:

22000 kg (46400 lb)

0

i!i 700

A1312360

Weight:

17500 kg (36500 lb)

AU372370

2-102

13. TRANSPORTATION

Weight: 11600 kg (25520 lb)

Weight: 9370 kg (11m3) (20657 lb) 9985 kg ( 12m3) (22013 lb)

I

I

-

Weight: 1288 kg x 2 = 2750 kg (2834 lb x 2 = 5668 lb) Weight: 1928 kg x 2 = 3856 kg (4242 lb x 2 = 8484 lb)

Ml80460

2-103

13. TRANSPORTATION

Weight:

135 kg (298 lb)

Weight: 80 kg (187 lb)

AEl79270

AE179280

Weight: 70 kg (154 lb)

Weight:

AE179290

Weight: 45 kg (99 lb)

e

,

1037

1

c

Weight: 215 kg (474 lb)

1 1”_?.

I.-

5310

r

667 A

AE179310

2-104

AE179300

T-

I

16 kg (35 lb)

Y

\

n n -

u

u

I

Weight:

Weight:

9 kg

20 kg

Weight:

(44 lb)

(20 lb)

(46 lb)

AEl79350

AE179330

Weight:

35 kg

Weight:

I-

llld?

2464

B

,” 03

I-_

I-

j

2464

-I AEl79370

AE179360

Weight:

35 kg (77 lb)

(77 lb)

1

21 kg

Weight:

24 kg

30 kg (66 lb)

(53 lb)

I

1070

1

1

786

_/

AEl79390

2-105

13. TRANSPORTATION

Weight: 28 kg (62 lb)

Weight:

I 90

Weight: 8 kg (18 lb)

11354350

Z-106

17 kg (37 lb)

AW364340

Weight: 8 kg (18 lb)

A1364360

13. TRANSPORTATION

Weight: 16 kg (35 lb)

31 kg (68 lb)

Weight:

AE179410

AE179400

Weight: 37 kg (82 lb)

20 kg (44 lb)

Weight:

46

AE179430

AE179420

Weight: 45 kg (99 lb)

29 kg (64 lb)

Weight:

3823

r

1892

â&#x20AC;&#x2DC;1

AU364380

2-107

14. COLD WEATHER OPERATION

14.1

PRECAUTIONS

FOR LOW TEMPERATURE

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

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

14.1.2 COOLANT

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

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 .... ....... .... .............. ......... ........... ... ...... .............................. . 31034 l FEDERAL STANDARD ... ................. .............. ................. O-A-548D REMARK Where no permanent antifreeze is available, an ethylene glycol antifreeze without corrosion inhibitor may be used only for the cold season. In this case, clean the cooling system twice a year (in spring and autumn). When refilling the cooling system, add antifreeze in autumn, but do not add any in spring.

2-108

14. COLD WEATHER OPERATION

14.1.3 BATTERY

A

WARNING do not bring fire or sparks near the

l

To avoid gas explosions, 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 from the following conversion table.

l

the rate of charge

100%

1.28

1.29

130

1.31

90%

1.26

1.27

1.28

1.29

80%

1.24

1.25

1.26

1.27

75%

1.23

1.24

1.25

1.26

When electrolyte level is low, add distilled water in the morning before work instead of after the dayâ&#x20AC;&#x2122;s work. This is to prevent fluid from freezing at night.

2-109

14.

COLDWEATHEROPERATION

14.2

F;‘RE;UTIONS

AFTER COMPLETION

OF

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions.

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

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

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

As the battery capacity drops markedly in low temperatures, cover the battery or remove it from the machine, keep it in a warm place, and install it again the next morning.

If electrolyte level is found low, add distilled water in the morning before beginning work. Do not add the water after the day’s work so as to prevent fluid in the battery from freezing in the night.

14.3

AFTER COLD WEATHER

When season changes and the weather becomes warmer, do as follows. l Replace the fuel and oil for all parts with oil of the viscosity specified.

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

If for any reason permanent antifreeze cannot be used, 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.

2-110

and an is used system system

15. LONG-TERM STORAGE

15.1

BEFORE STORAGE

NOTICE To protect the cylinder rod when the machine is not being used, set the work equipment in the posture shown in the diagram.

(This prevents rusting of the cylinder rod) When putting the machine in storage for a long time, do as follows.

After washing and cleaning each portion, store the machine indoors. When you must leave the machine outdoors, park the machine on a level place where it will not suffer from flooding or other natural disasters, and cover it with canvas, etc..

Completely storage.

fill the fuel tank, lubricate

Apply a thin coat of grease to metal piston rods.

A0341570

and change the oil before

surface of the hydraulic

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

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

0°C.

Set the fuel control dial to the engine low idling position and place the other control levers and switches at the N or OFF position.

Set the lock lever to the LOCK position.

2-111

15. LONG-TERM STORAGE

15.2

DURING STORAGE

A WARNING If it is unavoidably necessary to carry out the rust-preventive operation while the machine is indoors, open the doors and windows to improve ventilation and prevent gas poisoning.

Operate the engine and move the machine for a short distance once a month so that a new film of oil will be coated over movable parts and component surfaces. At the same time, also charge the battery. l

Also carry out cooler operation in the case of machines equipped with an airconditioner.

l

Before operating the working equipment, the hydraulic piston rod.

15.3

wipe off the grease on

AFTER STORAGE

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

Carry out the following of long-term storage.

procedure

when taking the machine

l

Wipe off the grease from the hydraulic

l

Add oil and grease to all places.

l

Bleed air from hydraulic cylinder circuit.

Refer to the item of BLEEDING AIR FROM CIRCUIT.

15.4

~;W&l~~

MACHINE

cylinder

out

rods.

AFTER LONG-TERM

When starting the machine after a long-term storage, first cancel the automatic warming-up function as follows.

1. Turn the starring switch key to the ON position.

2.

Turn the fuel control dial from the low idling (MINI position to the full (MAX) position, hold it there for 3 seconds, then return it to the low idling (MINI position and start the engine.

2-112

16. TROUBLESHOOTING

16.1

WHEN FUEL RUNS OUT

Once the fuel runs out, supply fuel and bleed air from the fuel piping, then start the engine. For air bleeding method, see â&#x20AC;&#x153;24.8 EVERY 500 HOURS SERVICEâ&#x20AC;?.

16.2

PHENOMENA

Note that the following

THAT ARE NOT FAILURES phenomena

1. The arm speed will drop momentarily more or less horizontal.

are not failures: when the bucket teeth are

2.

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

3.

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

16.3

METHOD

OF TOWING

MACHINE

A WARNING When towing the machine, use a wire rope that has ample strength for the weight of the machine that is being towed.

If the machine sinks in mud and cannot get out under its own power, or if the drawbar pull of the excavator is being used to tow a heavy object, use a wire rope as shown in the diagram on the right.

Place pieces of wood between wire ropes and body to prevent damage to ropes and body.

At this time, never use the hook for light-weight towing.

16.4

PRECAUTIONS

ON PARTICULAR

JOBSITES

1.

When carrying out digging operations in water, if the work equipment mounting pin goes into the water, carry out greasing every time the operation is carried out.

2.

For heavy-duty operations and deep digging, carry out greasing of the work equipment mounting pins every time before operation.

After greasing, operate the boom, arm and bucket several times, then grease again.

2-113

16. TROUBLESHOOTING

16.5

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. lf it gets on your clothes or on your skin, wash it immediately off with large amounts of water. lf it gets in your eyes, wash it out with fresh water, and consult a doctor.

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. lf a tool touches the cable connecting the positive terminal and the chassis, there is danger that it will cause sparks. lf the terminals are loose, there is danger that the defective contact may generate sparks that will cause an explosion.

When installing the terminals, install them tightly.

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

16.51 PRECAUTIONS FOR CHARGING BATTERY When charging the battery without removing it from the machine. l

l l l

l

l

Before charging, disconnect the wiring of the battery terminals, since abnormal voltage may be applied to the alternator to break it.

Keep all battery caps removed while charging to release the gas produced.

If the battery is overheated (the battery fluid temperature exceeds 45â&#x20AC;?CL stop charging for a while.

After the battery is charged fully, stop charging immediately.

Overcharging can cause the following.

1) Overheating of battery 2) Reduction of battery fluid 3) Battery trouble Do not connect the cables to the battery inversely (connect the @ cable to the 0 terminal, and the @ cable to the @ terminal).

If they are connected so, the alternator, etc. may be broken.

When handling the battery for a purpose other than check of the battery fluid level or measurement of specific gravity of the battery fluid, disconnect the cables from it.

2-114

When removing, disconnect the cable from the ground terminal first

16. TROUBLESHOOTING

16.5.2 STARTING When

Precautions

ENGINE WITH BOOSTER CABLE

starting

the engine

when

connecting

with a booster cable, do as follows:

and disconnecting

WARNING a When connecting the cables, never contact and negative 0 terminals.

booster

cable

the positive

@

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. lf 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.

l

Check the cables and clips for damage

l

Make

or corrosion.

sure that the cables and clips are firmly connected.

2-115

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 terminal

4.

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

5.

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

the other clip of booster of the normal machine.

cable @ to the positive

@

0 terminal

block of

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

2.

Start the engine of the normal high idling speed.

machine

and keep it running

at

3.

Turn the starting switch of the problem machine to the START position and start the engine. If the engine doesnâ&#x20AC;&#x2122;t start at first, try again after 2 minutes or so.

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 @I from the engine block of the problem machine.

2.

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

3.

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

4.

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

Z-116

0

the positive @terminal

@

I

I c

normal machine@J

Batten/ of the problem machhne

v

-Ql Engine blodc ofthe problem machine Awu98,

16. TROUBLESHOOTING

16.6

OTHER TROUBLE

16.6.1 ELECTRICAL SYSTEM ): Always contact your Komatsu distributor 0 ( l

In cases of abnormalities distributor for repairs.

or causes

which

when dealing with these items. are not listed below, please contact

Main causes

Problem

Defective wiring

l

Defective adjustment of fan belt tension

Charge level monitor flashes even when engine is running

l l

Defective alternator Defective wiring

(o Replace) (o Check, repair)

Abnormal noise is generated from alternator

l

Defective alternator

(0 Replace)

Starting motor does not turn when starting switch is turned to ON

l

l

Defective wiring Defective starter Insufficient battery charge Defective safety relay

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

l

Insufficient battery charge

l

l

Insufficient battery charge Defective starting motor

l

Defective wiring Insufficient battery charge Disconnection heater plug

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

Defective wiring Defective heater relay Defective monitor

(o Check, repair) (o Replace) (o Replace)

Defective monitor Defective caution lamp switch

(o Replace) (o Replace)

Defective monitor Defective wiring

(o Replace) (o Check, repair)

Lamp flickers while engine is running

l l

Pinion of starting motor keeps going in and out Starting motor turns engine sluggishly Starting motor disengages before engine starts

l

l l l

Pm-heating monitor does not light

l l l

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

l

Charge level monitor does not light up when engine is stopped

l

l

l

Komatsu

Remedy

l

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

your

(o Check, repair loose terminals, disconnections) l Adjust fan belt tension For details, see EVERY 260 HOURS SERVICE

Charge

Charge (o Replace)

2-117

16. TROUBLESHOOTING

16.6.2 CHASSIS ): Always contact your Komatsu distributor when dealing with these items. (

0 l

In cases of abnormalities distributor for repairs.

or causes

Problem

which

are not listed below,

please

Main causes

contact

your

Komatsu

Remedy

Speed of travel, swing, boom, arm, bucket is slow

l

Lack of hydraulic oil

l

Add oil to specified level, see CHECK BEFORE STARTING

Pump generates abnormal noise

l

Clogged element in hydraulic tank strainer

l

Clean, see EVERY 2000 HOURS SERVICE

Excessive rise in hydraulic oil temperature

l

Loose fan belt

l

l

Dirty oil cooler

l

l

Lack of hydraulic oil

l

Adjust fan belt tension, see EVERY 250 HOURS SERVICE Clean, see EVERY 566 HOURS SERVICE Add oil to specified level, see CHECK BEFORE STARTING

l

Track too loose

l

I

Track comes off

l

2-118

Adjust track tension, see WHEN REQUIRED

Add oil to specified level, see CHECK BEFORE STARTING

16.6.3 ENGINE 1: Always contact your Komatsu distributor when dealing with these items. (

l l

In cases of abnormalities distributor for repairs.

or causes which

Problem Engine oil pressure monitor lights up

l

are not listed

below,

l

l

Radiator water level monitor lights up

Add oil to specified level, see CHECK BEFORE STARTING l Replace cartridge, see EVERY 250 HOURS SERVICE (e Check, repair)

Dirt or scale accumulated in cooling system

l

Lack of fuel

l

Air in fuel system

l

Engine does not start when starting motor is turned

Cooling water level low, water leakage Loosen fan belt

l

l

Komatsu

Engine oil pan oil level is low (sucking in air) Clogged oil filter cartridge

Clogged radiator fin or damaged fin Defective thermostat Loose radiator filler cap (high altitude operation) Defective water level sensor Defective monitor

l

your

Remedy

part Defective engine oil pressure sensor Defective monitor l

contact

Main causes

Defective tightening of oil pipe joint, oil leakage from damaged

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

please

Defective fuel injection pump or nozzle Starting motor cranks engine sluggishly Preheating monitor does not light up Defective compression 0 Defective valve clearance

l

(e Replace sensor) (e Replace monitor) Add cooling water, repair, see CHECK BEFORE STARTING l Adjust fan belt tension, sea EVERY 250 HOURS SERVICE l Change cooling water, clean inside of cooling system, see WHEN REQUIRED l Clean or repair, see EVERY 500 HOURS SERVICE (e Replace thermostat) a Tighten cap or replace packing l

(e Replace sensor) te Replace monitor) a Add fuel, see CHECK BEFORE STARTING l Repair place where air is sucked in, see EVERY 500 HOURS SERVICE le Replace pump or nozzle)

See ELECTRICAL SYSTEM I[O Adjust valve clearance)

2-119

16. TROUBLESHOOTING

ENGINE kont’d) (16.6.3) Main causes

Problem Exhaust gas is white or blue

l

Too much oil in oil pan

0 Improper fuel Clogged air cleaner element

Exhaust gas occasionally turns black

Remedy l

l

Add oil to specified level, see CHECK BEFORE STARTING Change to specified fuel

Defective turbocharger Clogged air cooled after cooler fin

Clean or replace, see WHEN REQUIRED (0 Replace nozzle) (0 See defective compression above) l Clean or replace turbocharger l Clean or replace, see WHEN REQUIRED

Defective nozzle Defective compression

l

Combustion noise occasionally makes breathing sound

l

Defective nozzle

(e Replace nozzle)

Abnormal noise generated (combustion or mechanical)

l

Low grade fuel being used Overheating

l

l

l l

2-120

Damage inside muffler Excessive valve clearance

Change to specified fuel Refer to “Radiator water level monitor lights up” as above (o Replace muffler) (o Adjust valve clearance)

l

16.6.4 ELECTRONIC CONTROL SYSTEM If an error code is displayed on the machine monitor (normally this displays the time), follow the self-diagnostic table below.

Machine

monitor

Monitor

failure

display remedy

display Failure mode

display

Remedy

E02

lVC valve system

E03

Swing brake system error

Turn swing prolix switch ON and release brake.

When applying swing brake, operate swing lock switch manually. In this case, carry out inspection immediately.

(Z)

Governor

The governor cannot carry out control. Operate the governor lever manually. To secure at the full position, there is a mounting hole for the lock bolts in the bracket. In this case, carry out inspection immediately.

E05

system

error

error

I

When pump prolix switch is turned ON, normal operations become normal, but carry out inspection immediately. (%_)

Stop the engine, PTO oil level.

check the engine

Normal operation is possible, inspection immediately.

EOE

Abnormality in network (pump absorption torque reduced or engine stopped)

If no error code is displayed but work equipment or swing cannot be operated

%: For details of handling

the pump

oil level and

but carry out

If the engine can be run, move the machine to a safe posture, then carry out inspection immediately.

If the engine is started and then stalls, turn the TVC prolix switch ON, move the machine to a safe posture, then carry out inspection immediately.

If the engine is stopped, also carry out inspection immediately.

Carry out inspection

prolix switch

and swing

immediately.

prolix switch,

see â&#x20AC;&#x153;11.2 SWITCHESâ&#x20AC;?.

2-121

MAINTENANCE

17. GUIDES TO MAINTENANCE

Do not carry out any inspection and maintenance Perform maintenance work on hard, flat ground.

operation

that is not given in this manual.

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

Komatsu genuine replacement parts: Use Komatsu genuine parts specified

in the Parts Book as replacement

Komatsu genuine oils: Use Komatsu genuine oils and grease. ambient temperature.

Always use clean washer fluid: Use automobile window washer

Choose

fluid and be careful

Always use clean oil and grease: Use clean oil and grease. Also, keep containers from oil and grease.

Wipe off the old grease: After greasing, up, always wipe

oils and grease

with

parts.

proper viscosities

specified

for

not to let any dirt get into it.

of the oil and grease clean. Keep foreign materials

away

off the old grease that was forced out.

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 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. before draining it.

stops are 20 - 40°C)

Checking for foreign materials in drained oil and on filter: After oil is changed or filters are replaced, check the oil and filters for metallic particles and foreign materials. If large quantities of metallic particles or foreign materials are found, consult your Komatsu distributor.

Fuel strainer: If your machine Oil change: Check or change

is equipped

with a fuel strainer,

oils in the places where

do not remove

dust is scarce to keep foreign

Adding fuel: When adding fuel, be careful not to allow the water collected into the fuel.

3-2

it while fueling.

materials

at the top or bottom

away from oils.

of the drum to get

17. GUIDES TO MAINTENANCE

Warning tag: Attach warning tag to the starting switch or other appropriate is not aware of the circumstances from starting the engine.

Obey precautions: During the operation,

always

obey the precautions

control lever to prevent any person who

on the safety label attached

to the machine.

Welding instructions: l Turn off the engine starting switch. l Do not apply more than 200 V continuously. l Connect the grounding cable within 1 m from the area to be welded. l Avoid seals or bearings from being between the area to be welded and the position of grounding point. l Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.

Fire prevention: Use nonflammable oil.

cleaner

or light oil for cleaning

parts. Keep flame or cigarette

light away from light

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

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

especially when

Checking undercarriage: When working in rocky areas, check for damage to the undercarriage and for looseness, flaws, wear and damage to bolts and nuts. Loosen the track tension a little when working in such areas.

Precautions when washing machine: l Never spray steam or water directly on the connectors or mechatronics parts. l Do not allow water to get on the monitors and controllers inside the operatorâ&#x20AC;&#x2122;s l Never spray steam or water directly at the radiator or oil cooler portions.

cab.

3-3

17. GUIDES TO MAINTENANCE

Pre-and post-work checks: Before starling 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.

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.

3-4

17. GUIDESTO MAINTENANCE

Precautions when carrying out maintenance on hydraulic equipment, circuit, and hvdraulii system:

Stop the machine on level ground, lower the bucket to the ground, and set so that there is no pressure in the cylinder circuit.

Stop the engine.

Immediately after operations, the hydraulic oil and lubricating oil is at high temperature and pressure, so wait for the oil temperature to cool down before starting maintenance.

Even when the temperature has gone down, the circuits may be under internal pressure, so when loosening the plugs, bolts, or hose connections, do not stand directly in front, and loosen gradually to release the internal pressure.

When carrying out inspection or maintenance of the hydraulic circuit, always release the internal pressure inside the hydraulic tank before starting.

Bleed air:

After changing the oil, replacing the filter element, or cleaning the strainer, bleed the air from the circuit.

After changing the oil in the hydraulic tank, replacing the element, removing the hydraulic cylinders or work equipment piping, or replacing or cleaning the line filter element, bleed the air from the circuit after completing the operation. For details of the method of bleeding the air, see BLEEDING AIR FROM CIRCUIT.

3-5

18. OUTLINES OF SERVICE

l

Use Komatsu

genuine

l

When

l

Unless otherwise specified, shown in the table below.

changing

or adding

Swing machinery case Final drive case Damper case Hydraulic tank

parts for replacement. oil, do not use a different

type of oil.

the oil and coolant used at the time of shipment

from the factory are as

SAE 30 API classification CD

I

SAE low API classification CD

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

Fuel tank

Komatsu Super Coolant

Radiator

I (AF-ACL) 41% added to water

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

Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual. Even if the oil is not dirty, always replace it after the specified interval.

Oil corresponds to blood in the human body, so always be careful when handling it to prevent 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

any

or brands.

Always add the specified amount of oil.

Having too much or too little oil are both causes of problems.

If the oil in the work equipment is not clear, there is probably In such cases, please contact your Komatsu distributor.

When

changing

the oil, always

water or air getting

into the circuit.

replace the related filters at the same time.

We recommend you to have an analysis made of the oil periodically to check the condition machine.

For those who wish to use this service, please contact your Komatsu distributor.

3-6

of the

18. OUTLINES OF SERVICE

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

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

Always use the fuel specified in the Operation and Maintenance Manual.

Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15°C (VF)), so it is necessary to change to a fuel that matches the temperature.

To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank after completing the dayâ&#x20AC;&#x2122;s work.

Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from the fuel tank.

If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.

18.1.3 COOLANT River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the engine and radiator, and this will cause defective heat exchange and overheating.

Do not use water that is not suitable for drinking.

When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.

Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped.

This anti-freeze is effective in preventing corrosion of the cooling system.

The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as it is even in hot areas.

Anti-freeze is inflammable, so be extremely careful not to expose it to flame or fire.

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

For details of the mixing proportions, see 24.3.2 CLEAN INSIDE OF COOLING SYSTEM. If the engine overheats, wait for the engine to cool before adding coolant.

If the coolant level is low, it will cause overheating and will also cause problems with corrosion from the air in the coolant.

3-7

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 l

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.

l

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.

8-8

18.2

OUTLINE

OF ELECTRICAL SYSTEM

If the wiring gets wet or the insulation is damaged, in hazardous malfunction of the machine.

the electric system leaks and this could result

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

Never remove

or disassemble

any electric

Never install any electric components

components

installed

other than those specified

or wear

in the machine.

by Komatsu.

Be careful to keep water away from the electric system when washing

the machine

or when it rains.

Since the controller for the control system may cause malfunction due to external wave interference, before installing a radio receiver and a walkie-talkie or citizen band, consult your Komatsu distributor.

When

working

at the seashore,

carefully

clean the electric system to prevent corrosion.

When installing a car cooler or any other electrical equipment, connect it to an independent power source connector. The optional power source must never be connected to the fuse, starting switch, or battery relay.

3-9

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 â&#x20AC;&#x153;11.19 Handling accumulatorâ&#x20AC;?.

3-10

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 CIRCUlT, TRAVEL ClRCUlT A

CIRCUlT, SWING

WARNING

When removing the oil filler cap of the hydraulic tank, turn it slowly to release the internal pressure before taking off the cap.

1. Lower the work equipment to the ground in a stable flat place as shown in the diagram, then stop the engine.

Set the lock lever to the FREE position. :. 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. :. Remove the cap of the hydraulic tank.

4. 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 l 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.

0 Repeat Steps 4 to 5 three times.

I

A

1

CAUTION

When the piping for the work equipment circuits is removed, for safety, insert a hose with quick coupler into the coupler installed to each circuit to completely remove the remaining pressure.

1.

2.

3.

4.

5.

6.

Boom cylinder head end Boom cylinder bottom end Arm cylinder head end Arm cylinder bottom end Bucket cylinder head end Bucket cylinder bottom end

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.

3-11

18. OUTLINES OF SERVICE

Hydraulic idler cushion circuit Slowly loosen stop valve @ installed on the inside of the axle,

and after one minute the pressure is released.

Do not loosen the valve quickly.

This will generate high pressure inside the tank circuit. l Use the special knob to open and close stop valve 0.

l

Specialhandle

3-12

Ml 69680

18. OUTLINES OF SERVICE

18.5

BLEEDING AIR FROM CIRCUIT

After assembling maintenance, always

piping disconnected during inspection bleed the air from the circuit as follows.

and

PRECAUTIONS WHEN BLEEDING AIR Bleed the air in order as follows.

1. Pump (for swing, for travel, work equipment) 2. Motor (for swing, for travel) 3. Idler cushion circuit 4. Work equipment circuit Run the engine at less than 1000 rpm and operate the cylinders slowly.

Do not raise the pressure inside the cylinder by suddenly operating the cylinder, and do not operate the cylinder to the end of its stroke.

For the first return movement of each cylinder, be particularly careful to operate the cylinder slowly.

During the first stroke of the cylinder, there is a large amount of air inside the circuit, so the work equipment will not move for more than 10 seconds.

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

3-13

18. OUTLINES

OF SERVICE

BLEEDING AIR FROM PUMP Bleed the air at the same time from the swing, travel, hydraulic, and pilot pumps.

If the pump assembly has been removed, or the oil in the hydraulic tank has been changed, bleed the air from the pump as follows to prevent the pump from seizing.

Rear

Front

ene ine

engine

AUâ&#x20AC;&#x2122;372428

L Name of pump

Front engine

Rear engine

Hydraulic pump

Pl, P2

P3. P4

Swing pump

PSl

PS2

Gear pump

PGl

PG2

l

Install tube @I to the plug to prevent spurting out.

1.

Loosen bleeders turns.

2.

Add oil to fill the hydraulic tank to the specified level.

Keep the oil filler cap @ off after adding oil to the hydraulic tank.

3.

Sheck that oil flows out from gear pump @ and @ and hydraulic oump bleeders 0, 0, 0, and 0, then temporarily tighten plugs TJ,@, 0, 0, 0, and @.

4.

Check that the air has stopped spurting out from swing pump plugs @ and 8, then temporarily tighten rear engine plug 8.

Leave front engine plug @ loosened.

the discharge

@ - @I (14 places) of each pump

oil from

one or two

I

3-14

I

r

\I\

Y AEl78710

I

18. OUTLINES OF SERVICE

BLEEDING AIR FROM MOTOR Travel motor 1. Start the engine and run at low idling.

2.

Loosen plug @ of the travel motor 1 - 2 turns.

Loosen the plugs for all four motors.

3.

When no more cloudy white oil comes out frm the tip of plug 0, the air bleeding is completed.

4.

Tighten plug 0.

Tightening torque: 8.8 f 1 Nm (0.9 -c 0.1 kgm, 6.5 A 0.7 Ibft)

Swing motor Loosen plug @ of the swing

motor

1 - 2 turns.

Start the engine and run at low idling.

When no more cloudy white oil comes out from the port of plug 0, the air bleeding is completed.

Tighten plug 0.

Tightening torque: 8.8 r 1 Nm (0.9 t 0.1 kgm, 6.5 + 0.7 Ibft) Carry out the same procedure for the front and rear motors.

3-16

18. OUTLINES

OF SERVICE

BLEEDING AIR FROM IDLER CUSHION CIRCUlT Before pumping the air.

grease

into the grease cylinder,

always

bleed /

1.

Loosen grease fitting @ of the greae cylinder one turn. (left and right, 2 places) Grease fitting @I can be loosened until it contacts the stopper, but do not remove the stopper and loosen it any further.

2.

Open stop valves @ and @ on the inside of the accelerator fully.

3.

Loosen air bleed plug @I of the cushion cylinder turn. (left and right, 2 places)

4.

Start the engine

5.

When no more cloudy white oil comes out from air bleed plug @ of the cushion cylinder, close stop valve 0.

Leave stop valve @ open.

6.

Operate the right travel lever 2 or 3 times to the FORWARD REVERSE position.

7.

Check that oil comes out from air bleed plugs @ (left and right, 2 places) and 0, then close stop valve @ and air bleed plugs @ and 0.

8.

Tighten

approx.

one

and run at idling for 2 to 3 minutes.

grease fittings

and

AE179HO

@ (left and right, 2 places).

REMARKS l

l l

Always tighten grease fitting @ last.

This completes bleeding of the air and pumping in of pressure oil.

Check that all the stop valves and air bleed plugs are closed.

Check that protrusion @ of the cushion cylinder plunger -c 5 mm (5.3 * 0.2 in).

AEl79550

is 135

Hydrauric CYI inder

cushion

i.i-_AE176570

3-17

18. OUTLINES OF SERVICE

BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT After changing the oil in the hydraulic tank or replacing the line filter, after reassembling the cylinders or piping, or after reassembling the pumps or suction piping, always bleed the air from the hydraulic circuit.

Run the engine at low idling and do as follows:

1.

Operate each cylinder 4 - 5 times to a point 100 mm from the end of its stroke.

When operating for the first time, there is a large amount of air in the circuit, so the work equipment will not move for approx. 10 seconds. Be careful not to operate the lever to the full stroke.

2.

Keep the engine at low idling and operate each cylinder from the point 100 mm from the end of its stroke slowly (take at least 10 seconds) to extend the cylinder to the end of its stroke. Hold the work equipment control lever for 3 minutes at the full stroke.

3.

Run the engine at high idling and operate each cylinder from the point 100 mm from the end of its stroke slowly (take at least 10 seconds) to extend the cylinder to the end of its stroke. Hold the work equipment control lever for 1 minute at the full stroke.

l

The operation cylinders.

0

If the engine is run immediately at high speed or the cylinder is operated to the end of its stroke, the air inside the cylinder may cause damage to the piston packing.

3-18

in Steps 1. - 3. will bleed the air from inside the

Do not contact ground surface

I

ADZ.41 59A

19. CONSUMABLE

PARTS LIST

Consumable parts such as the filter element, bucket tooth, etc., are to be replaced at the time of periodic maintenance or before their abrasion limits.

The consumable parts should be changed correctly in order to use the machine economically.

For part change, Komatsu genuine parts should be used.

When ordering parts, please check the part number in the parts book.

The parts in parentheses

Item

are to be replaced

at the same time.

Part Name

Part No.

Replacement frequency

Qw

07063-01210 (07009-15180)

Element (O-ring)

Every 250 hours service

07063-51210 (07000-15180)

Element (O-ring)

Every 500 hours service

Drain filter

113-60-23160

Cartridge

2

Every 250 hours service

Engine oil filter

600-211-1231

Cartridge

4

Every 250 hours service

Engine bypass filter

600-212-1511

Cartridge

2

Every 250 hours service

Fuel filter

600-311-7732

Cartridge

2

Every 250 hours service

Line filter

209-60-63210 209-60-63310

Element Element

600-41 l-l 171

Cartridge

285-62-17320

Element

Hydraulic

Corrosion

oil filter

resistor

Hydraulic oil tank breather element

6128-81-7042

Element

I

2 4

I

2

I I 2

assembly

Every 1000 hours service Every 1000 hours service

2

Air cleaner 600-181-4400

Bucket

Komatsu tooth 21T-72-74311 (21T-72-74320)

Outer

element

assembly

2

Point (Pin)

3-19

IEL, COOLANT AND LUBRICANTS ACCORDING UT TEMPERATURE

PROPER SELECTION

RESERVOIR

OF FUEL, COOLANT AND LUBRICANTS

FLUID

CAPACITY

AMBIENT TEMPERATURE

KINDOF 2 0

-4 -20

14 -10

32 0

50 IO

68 20

86 104-F 30 4O’C

Specified

Refill

Engine oil pan

38 Q 33.5 e zront & rear) (Front & rear) 10.0 US gal 8.9 US gal

PTO case

20 e 20 e ‘rant & rear) (Front & rear) 5.3 US gal 5.3 US gal

Swing machinery case

30 e 30 e Front & rear) (Front & rear) 7.9 US gal 7.9 US gal

Engine oil

Final drive case

Hydraulic system

Fuel tank

Grease fitting

Cooling system

85 Q 22.5 US gal (each)

2400 Q 634 US gal

1600 Q 396 US gal

2300 Q 608 US gal

Diesel fuel

Grease

85 Q Front & rear) 22.4 US gal

Water

% ASTM D975 No. 1

3-20

85 Q 22.5 US gal (each)

-

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

REMARK When fuel sulphur content is less than 0.5%, change oil in the oil pan at every periodic maintenance interval given in this manual.

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

Change interval of oil in engine oil pan

Fuel sulphur content 0.5 to 1.0%

1

Above 1.0%

1 l/4 of regular interval

l/2 of regular interval

When starting the engine in an atmospheric oil of SAElOW, SAElOW-30 and SAE15W-40, more or less in the day time.

Use API classification interval to half.

CD as engine

temperature of under O’C (32“F), be sure to use engine even though atmospheric temperature goes up to 10°C

oil and if API classification

CC, reduce the engine

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

We recommend Komatsu genuine oil which has been specifically in engine and hydraulic work equipment applications.

Specified capacity: Total amount of oil including oil for components Refill capacity: Amount of oil needed to refill system during normal

formulated

oil change

15W-40),

but be

and approved

for use

and oil in piping. inspection and maintenance.

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

3-21

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

rl0.

Supplier

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

Gear Oil [GL4 or GL-51 SAE80, 90, 140

Grease [Lithium-Base1 NLGI No. 2

Anti-freeze Coolant [Ethylene Glycol Base1 Permanent Type AF-ACL AF-PTL AF-PT (Winter, one season type

KOMATSU

EOIO-CD E030-CD EOIO-30CD E015-40CD

GO90 GO140

G2-LI GZ-LI-S

2

AGIP

Diesel sigma S Super dieselmultigrade *Sigma turbo

Rotra MP

GR MU/EP

3

AMOCO

*Amoco 300

Multi-purpose gear oil

RYKON premium grease

4

ARC0

*Arcofleet S3 plus

Arco HD gear oil

Litholine HEP 2 Arco EP moly D

5

BP

Vanellus C3

Gear oil EP Hypogear EP

Energrease LS-EP2

6

CALTEX

*RPM delo 400 RPM delo 450

Universal thuban Marfak all purpose 2 Universal thuban EP Ultra-duty grease 2

AF engine coolant

7

CASTROL

*Turbomax *RX super CRD

EP EPX HYP~Y HYP~Y B HYP~Y C

MS3 Spheerol EPL2

Anti-freeze

8

CHEVRON

*Delo 400

Universal gear

Ultra-duty grease 2

9

CONOCO

*Fleet motor oil

Universal gear lubricant

Super&a

10

ELF

Multiperformance 3C Performance 3C

â&#x20AC;?

EXXON (ESSO)

Essolube D3 *Essolube X0-3 lEssolube XD-3 Extra lEsso heavy duty Exxon heavy duty

12

GULF

13

MOBIL

1

3-22

Antifreeze

grease

Tranself EP Tranself EP type 2

Glacelf

Gear oil GP Gear oil GX

Beacon EP2

All season coolant

Super duty motor oil *Super duty plus

Multi-purpose gear lubricant

Gulfcrown EP2 Gulfcrown EP special

Antifreeze and coolan

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

Mobilube GX Mobilube HD

Mobilux EP2 Mobilgrease 77 Mobilgrease special

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENTTEMPERATURE

No.

14

Supplier

PENNZOIL

Engine Oil [CD or CEI SAElOW, 30, 40 1ow30, 15w40 (The 15W46 oil marked * is CE.)

*Supreme duty fleet motor oil

15 1 PETROFINAI FINA kappa TD

16 1 SHELL

17

/ Rimula X

SUN

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

Grease [Lithium-Base] NLGI No. 2

Multi-purpose 4092 Multi-purpose 4140

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

/ Liii

~~:~~~~ :E

Anti-freeZ Coolant [Ethylene Glycol Base1 Permanent Tvpe

Anti-freeze and summer coolant

1 FINA marson EPL2 TFINA

tamidor

Spirax EP Spirax heavy duty

Albania EP grease

Sunoco GL5 gear oil

Sunoco ultra prestige 2EP Sun prestige 742

Sunoco antifreeze and summer coolant

Multifak EP2 Starplex 2

Code 2055 startex antifreeze coolant

Antigel/antifreeze

/ Multigear

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 B Multigear C

Antifreeze

3-23

21. &lililDARD

21.1

INTRODUCTION

TIGHTENING

OF NECESSARY

TORQUES FOR BOLTS AND

TOOLS

The following tools are needed when carrying out maintenance.

No. 1

Name of tool

09002-01214 09002-01317 09002-01922 09002-02427 09002~3032

Applicable width across flats (S1-S2) 8mm-IOmm 12mm-14mm 13mm-17mm 19mm-22mm 24mm-27mm 30mm-32mm

0903340190

Interchangeable flat-head and cross-head type

09020-l 0284

Applicable width across flats 10 mm, 13 mm, 14 mm, 17 mm, 19 mm, 22 mm, 24 mm, 27 mm, 30 mm, 32 mm, 36 mm Extension, Handle joint bar

Wrench 0900240810

3

Socket wrench set

Remarks

Part No.

09019-08035 07952-80002

For nreasinn work

07951-21045 07951-l 1400 07950-80403

(Lithium base grease, 400 g)

09038-00150

09055-l 0390 09036-00150 195-98-I

1590

178-96-11120 09054-00009

9 leave 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.10, 0.15, 0.20

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

3-24

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): 1Nm + 0.1 kgm + 0.74 Ibft Thread diameter of bolt (mm)

Ia)

b

Width across flats (mm) (b) Nm

kgm

Ibft

6

10

13.2 + 1.4

1.35 f 0.15

3.73f 1.03

8

13

31.4 -c2.9

3.2 2 0.3

23.2 + 2.1

10

17

65.7 + 6.8

6.7 t 0.7

48.5 5 5.0

12

19

112 f 9.8

11.5 + 1.0

62.6 + 1.2

14

22

177*19

18.0 t 2.0

131 + 14

16

24

279 + 29

28.5 +i3

206 z 21 282 i 29

18

27

383239

39 f 3

20

30

549258

56 2 6

405 t 43

22

32

745 578

76 + 8

549 + 58

24

36

927 +-98

94.5 f 10

684~ 72

27

41

1320 2 140

135 + 15

973 2 100

30

46

1720 2 190

175 t 20

1270 2 140

33

50

2210 + 240

225 2 25

1630 + 180

36

55

2750 = 290

280 r 30

!030 f 210

39

60

3280% 340

335 f 35

!42Oz 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.

3-25

22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS

To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out periodic maintenance.

In addition, to further improve safety, the user should also carry out periodic replacement of the parts given in the table. These parts are particularly closely connected to safety and fire prevention.

With these parts, the material changes as time passes, or they easily wear or deteriorate. However, it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed time has passed, regardless of their conditipn. 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.

3-26

22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS

CRITICAL SAFETY PARTS Unit

Part name

No. @

Fuel hose (fuel tank - fuel strainer)

2

@

Fuel hose (fuel strainer - injection pump)

2

@

Fuel hose (injection pump - fuel filter)

4

@I

Fuel return hose (fuel pump - adapter)

2

@/F

ue I ret urn hose (adapter - fuel tank) Spill hose (between

0

Spill hose (nozzle -fuel

@

1 Turbocharger

4 2

tank)

lubricating

hose

I

12

@

No.1 pump discharge port hose

2

@I

No.2 pump discharge port hose

2

@I

Swing No.1 pump discharge port hose

1

@

Swing No.1 pump outlet branch hose

1

@I

No.3 pump discharge

port hose

2

@I

No.4 pump discharge port hose

2

0

Branch hose

4

@

] Swing No.2 pump discharge port hose

@I

I Swing No.2 pump outlet branch hose Heater hose (engine - heater)

8

@

Pump suction hose

8

I

Every 4000 hours or every 2 years, whichever comes sooner

I I

II II

@I

@J 1 Swing line hose

intervals

I

12

nozzles)

@

Replacement

4

@

I Boom cylinder line hose (B/H)

@

Arm cylinder line hose (B/H)

8

@I

Bucket cylinder line hose (B/H)

8

@

Bucket suction coupling

3

@

Seat belt (option)

1

I I

18

Every 3 years

3-27

23. MAINTENANCE

23.1

MAINTENANCE

SCHEDULE CHART

SCHEDULE CHART SERVICE

l-l-EM

PAGE

INITIAL 100 HOURS SERVICE (only after the first 100 hours) Clean strainer of PTO lubricating oil filter

3-62

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

3-63

Change oil in swing machinery case

3-66

Change oil in PTO case

3-67

Change oil in final drive case

3-68

Check engine valve clearance, adjust

3-70

WHEN REQUIRED Check, clean and replace air cleaner element

3-33

Clean inside of cooling system

3-35

Check and tighten track shoe bolts

3-39

Check and adjust track tension

3-40

Check electrical intake air heater

3-42

Replace bucket teeth (horizontal pin type) (KOMATSU TOOTH)

3-43

Adjust bucket clearance

3-44

Check window washer fluid level, add fluid

3-45

Check and adjust airconditioner

3-46

Cleaning, removing dirt from line filter

3-47

Replacement of fan belt and adjustment of auto tensioner

3-48

CHECK BEFORE STARTING Check coolant level, add water

2-56

Check oil level in engine oil pan, add oil

2-56

Check fuel level, add fuel

2-57

Check oil level in hydraulic tank, add oil

2-58

3-28

23. MAINTENANCE SCHEDULE CHART

SERVICE ITEM

PAGE

(CHECK BEFORE STARTING) Check for clogging

of air cleaner

2-59

Check electric wiring

2-59

Check function

2-59

of horn

Check oil level in PTO case, add oil

2-60

Drain water and sediment

2-60

from fuel tank

2-61

Check central monitor

CHECK EVERY 10 HOURS SERVICE Lubricating

3-50

l

Arm - Bucket coupling

pin (2 points)

3-50

l

Arm - Link coupling

l

Bucket cylinder

l

Link coupling

l

Bucket - Link coupling

l

Boom cylinder foot pin

3-52

l

Boom foot pin

3-52

l

Boom cylinder

l

Arm cylinder foot pin

3-52

l

Bucket cylinder foot pin

3-52

l

Boom - Arm coupling

3-52

l

Arm - Link coupling

3-50

pin (2 points)

rod end pin (2 points)

3-51 3-51

pin (4 points) pin (2 points)

3-51

3-52

rod end pin

pin

3-52

pin

3-52

0 Swing circle EVERY 100 HOURS SERVICE Check oil level in swing

machinery

case

3-53

EVERY 250 HOURS SERVICE 3-54

Lubricating l

Fan pulley assembly

l

Tension

(2 points)

pulley assembly

(2 points)

3-54 3-54

3-29

23. MAINTENANCE SCHEDULE CHART

SERVICE ITEM

PAGE

Check oil level in final drive case, add oil

3-54

Change drain filter cartridge

3-55

Change oil in engine oil pan, replace engine oil filter cartridge and bypass filter cartridae (Front and rear enaine)

3-55

Check alternator drive belt tension, adjust

3-56

Check air conditioner compressor belt tension, adjust (Only for machines equipped with air conditioner)

3-57

Check level of battery electrolyte

3-58

Check, clean fuel strainer

3-59

Check and tighten track shoe bolts

3-59

Check and tighten track frame and axle connecting bolts

3-59

Replace filter element of hydraulic tank breather

3-60

EVERY 566 HOURS SERWCE Clean and inspect radiator fins, oil cooler fins, after cooler fins, condenser fins (Only for machines equipped with air conditioner)

3-61

Clean pilot filter strainer

3-62

Clean strainer of PTO lubrication oil filter

3-62

Replace fuel filter cartridge

3-63

Clean fresh/recirc air filters of air conditioner (Only for machines equipped with air conditioner)

3-64

Check fan belt

3-64

Change hydraulic filter element

3-65 EVERY 1000 HOURS SERVICE

Change oil in swing machinery case

3-66

Check turbocharger clamping joint

3-66

Change oil in PTO case

3-67

Replace corrosion resistor cartridge

3-67

Check inspection of welding structure (Color check)

3-67

EVERY 2000 HOURS SERVICE Change oil in final drive case

3-68

Clean, check turbocharger

3-68

Check turbocharger rotor play

3-69

Check swing pinion grease level, add grease

3-69

Clean engine breather

3-69

Clean hydraulic tank strainer

3-70

3-30

23. MAINTENANCE SCHEDULECHART

SERVICE ITEM

PAGE

(EMRY 2000 HOURS SERVICE1 Check alternator, starting motor

3-70

Check engine valve clearance, adjust

3-70

EVERY 4000 HOURS SERVICE Check water pump

3-71

Check vibration damper

3-71

Check fan pulley and tension pulley

3-71

Check air compressor, adjust

3-71

EVERY 5000 HOURS SERVICE Channe oil in hvdraulic tank, clean strainer

3-72

3-31

24. SERVICE PROCEDURE

24.1

INITIAL 100 HOURS SERVICE

Maintenance for every 10 hours service should be carried out at the same time.

Carry out the following maintenance only after the first 100 hours. l

CLEAN STRAINER OF P-TO LUBRICATING OIL FILTER

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

24.2

INITIAL 250 HOURS SERVICE

Maintenance for every 10 hours service should be carried out at the same time.

Carry out the following maintenance only after the first 250 hours. l l l l l

CHANGE FUEL FILTER CARTRIDGE CHANGE OIL IN SWlNG MACHINERY CASE CHANGE OIL IN PTO CASE CHANGE OIL IN FlNAl DRfVE 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.

3-32

24. SERVICE PROCEDURE

24.3

WHEN REQUIRED

24.3.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT

Never clean or replace the air cleaner element

l

with the engine

CHECK If the air cleaner clogged warning cleaner element.

safety

wear

When using pressure air to clean the element glasses or goggles to protect the eyes.

lamp @ lights up, clean the air

CLEAN. REPLACE OUTER ELEMENT 1. Open the engine hood, loosen wing nut 0, then remove the outer element 0.

To prevent entry of dirt and dust, cover the air connector side of the rear end of the air cleaner with a clean cloth and adhesive tape. body interior

2.

Clean the air cleaner

3.

Direct dry compressed air (less than 700 kPa (7 kg/cmz, 100 psi)), to element @ from inside along its folds, then direct it from outside along its folds and again from inside.

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 a year. Replace the inner repeatedly or used throughout 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. nuts for looseness and, if 4) Check inner element mounting 5)

4.

necessary, retighten.

Replace seal washer @ or wing nut @ with new parts if they are broken.

If small holes or thinner parts are found on the element when it reolace the is checked with an electric bulb after cleanina. element. .

1.

NOTICE whose folds or gasket or seal are Do not use an element damaged. do not hit it or beat it against When cleaning the element, something.

Wrap up unused elements and store them in a dry area.

1

the cloth and tape used for cover in Step 1.

5.

Remove

6.

Install the cleaned

element

and fix it with the wing

nut.

3-33

24. SERVICE PROCEDURE

Replacing inner element 1. First remove the outer element.

element,

and then

remove

the inner

2.

Place the cover over the air intake part to prevent dust entering.

3.

Clean the air cleaner the air intake port.

4.

Fit a new inner element

5.

Install the new outer element.

Push the dust indicator reset button.

body interior, then remove the cover from

and tighten

it with nuts.

NOTICE l Do not attempt to reinstall a cleaned inner element. l Do not attempt the air cleaner replacing, while engine running. l When replacing the inner element, also replace the outer element new one.

3-34

24. SERVICE PROCEDURE

24.3.2 CLEAN INSIDE OF COOLING SYSTEM

a

WARNING

Soon after the engine has been stopped, the coolant is hot and can cause personal injury. Allow the engine to cool before draining water.

Since cleaning is performed while the engine is running, it is very dangerous to enter the rear side of the machine as the machine may suddenly start moving. lf the under cover is left removed, it may interfere with the fan. While the engine is running, never enter the rear side of the machine.

Never remove the radiator cap when the engine is at operating temperature.

At operating temperature, the coolant is under pressure. Steam blowing up from the radiator could cause personal injury. Allow the engine to cool until the radiator filler cap is cool enough to touch with your hand.

Remove the filler cap slowly to allow pressure to be relieved.

l

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

1 Kind of coolant

Cleaning inside of cooling system and changing coolant

Permanent type antifreeze (All season type)

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

Non permanent type ethylene glycol Winter, one season type)

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

When

Every 6 months or every 1000 hours, whichever comes first

/

Replacing corrosion resistor

Every 1000 hours and autumn) when cleaning tshetinnd~n~f~~eooâ&#x20AC;&#x2122;ing changing

l

0

not using antifreeze

coolant.

Stop the machine on level ground when cleaning or changing the coolant.

Use a permanent type of antifreeze.

If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol.

3-35

24. SERVICE PROCEDURE

l

When deciding the temperature in the given below.

It is actually better when deciding the

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

about

70°C lower

Mixing rate of water and antifreeze

A WARNING Antifreeze is flammable, so keep it away from any flame. l

l

Use city water for the cooling water.

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

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

A WARNING When removing drain plug, avoid pouring coolant on yourself.

3-36

24. SERVICE PROCEDURE

1.

Prepare a container to catch drained coolant: Min. 85 f?capacity Refill capacity: Each 85 I? (22.5 US gal) capacity.

Stop the engine, close valves @ on corrosion resistor.

2.

Turn cap @ slowly until it comes

3.

Loosen drain valve @ and @ at the bottom of engine and drain off the cooling water.

4.

Close up drain valves @ and @ 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 valves @ and 0, then pass water through the cooling system for 10 minutes.

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

0 0

off.

6.

After washing the cooling system, stop the engine. Open drain valves @ and @to drain water and close drain valves @ and 0.

7.

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

Follow the instructions on the detergent container.

8.

After washing the cooling system, drain off all the water, then close up drain valves @ and @ 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 valves @ and 0, then pass water through the cooling system until clean water comes out from the drain valves.

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

-

Ml79690

3-37

24. SERVICE PROCEDURE

IO. When the water becomes completely close drain valves @ and 0.

clean, stop the engine and

11. Replace the corrosion resistor cartridge.

For details of replacement of the corrosion EVERY 1000 HOURS SERVICE”.

12. Open valve @ of corrosion

resistor, see “24.8

resistor.

13. Supply water until it overflows

from the water filler.

14. Run the engine for 5 minutes at low idling and then for another 5 minutes at high idling to eliminate air trapped in the cooling system (leave the water filler cap off during the operation).

15. After draining off the cooling water of reserve tank, clean the inside of the reserve tank and refill the water between FULL and LOW level.

16. Stop the engine and wait for about 3 minutes. Supply cooling water up to the vicinity of the water filler. Tighten the cap.

3-38

front

eneine’zenoine

Au364396

24. SERVICE PROCEDURE

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

Method for tightening 1. First tighten to a tightening torque of 687 2 69 Nm (70 = 7 kgm, 507 + 51 lb ft) then check that the nut and shoe are in close contact with the link contact surface.

2.

After checking, tighten

a further

120â&#x20AC;? f IOâ&#x20AC;?.

Order for tightening Tighten the bolts in the order shown in the diagram on the right.

After tightening, check that the nut and shoe are in close contact with the link mating surface.

3-39

24. SERVICE PROCEDURE

24.3.4 CHECK AND ADJUST TRACK TENSION

A WARNING Carry out this operation with two workers. The operator must move the machine in accordance with the signals from the other worker. The track tension is checked with the chassis raised, so it is extremely dangerous if the machine is lowered by mistake during the inspection. Never move the machine while anyone is carrying out measurements.

The wear of pins and bushings on the undercarriage will vary with the working conditions and soil properties. It is thus necessary to continually inspect the track tension so as to maintain the standard tension.

Carry out the check and adjustment under the same conditions as when operating (on jobsites where the track becomes clogged with mud, measure with the track clogged with mud).

Inspection

1.

2.

Raise the chassis with the boom and arm.

When doing this, operate the levers slowly.

Measure the clearance between the tread of the fourth track roller from the sprocket and the roller contact face of track link 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) AC383140

If the track tension is not at the standard value, adjust it in the following manner.

3-40

24. SERVICE PROCEDURE

Adjusting Hit cylinder 1. Check that stop valve @ is copietely 2.

closed.

Open stop valve 0.

'CC

3.

Start engine

and run at a medium

cccnl

speed.

Low idling AMO?30410

4.

Operate the right control lever to the FORWARD position intermittently (2 - 3 seconds) 3 - 4 times to relieve the travel motor.

NOTICE Do not carry out this operation plate, etc.).

0

on a slippery road surface (steel

l

Even when protrusion amount @ of the hydraulic cushion is within the standard value, the HIC charge pressure may be low, so always carry out the above operation exactly.

5.

Check that the protrusion @ of the plunger of the hydraulic cushion cylinder is 135 f 5 mm (5.3 k 0.2 in) on both the left and right.

6.

Close stop valve @ completely.

3-41

24. SERVICE PROCEDURE

Adjusting

1

grease cylinder

A

WARNING

3

l

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

l

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

iE!XI!?

0 Ic

a AEl79730

I

1

NOTICE Before pumping in grease, check that the protrusion @ of the plunger of the hydraulic cushion cylinder is 135 + 5 mm (5.3 + 0.2 in) on both the left and right.

Check again after pumping in grease. lf 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 135 d 5 mm (5.3 + 0.2 in), the hydraulic cushion must L be adjusted, so please contact your Komatsu distributor for adjustment.

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.

AcAmloN7 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, machine backwards and forwards.

3.

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

4.

Continue to pump in grease until @ becomes 190 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.

0

Always use the special valves @ and 0.

l

Please ask your Komatsu distributor abnormality.

knob when

opening

move the

or closing

stop

to check once a year for any

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.

3-42

Cushion

cylinder AV364400

24. SERVECE PROCEDURE

24.3.6 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) (KOMATSU Replace the teeth before the wear

TOOTH)

reaches the adapter.

moves by mistake when It is dangerous if the work equipment 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.

AW364166

1.

Place a block under the bucket bottom so that the pin of tooth Carry out full stroke @ can be knocked out with a hammer. operation of the control levers within 15 seconds after the engine is in a has stopped. After confirming that the work equipment stable condition, lock the safety lock lever.

Set so that the bottom face of the bucket is horizontal.

2

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

REMARK Use a round bar with a smaller

diameter

to

than that of the pin.

AEO83270

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.

3-43

24. SERVICE PROCEDURE

24.3.7 ADJUST

BUCKET CLEARANCE

A WARNING It is dangerous

if the work equipment the clearance is being adjusted.

Set the work equipment in a stable engine and lock the lever securely.

moves by mistake condition,

then

when

stop the

AU364166 i

if there is excessive free play on the coupling section of the bucket and arm, adjust the bucket clearance in the following manner.

1. Set the work equipment to the position shown in the diagram at

right, stop the engine position.

and set the lock lever to the locked

2.

Loosen 3 bolts 0, 6 bolts 0,

plate @ and plate 0.

3.

Take out shims @I equivalent in size to free play 0.

Thickness of shim @I is 0.5 mm or 1.0 mm (0.02 or 0.04 in).

When free play @ is less than a thickness of shim, do not compress the shims by tightening bolt 0.

4. Tighten 3 bolts @ and 6 bolts 0.

With this adjustment, clearance @ becomes larger, but play @I is removed.

3-44

24. SERVICE PROCEDURE

24.3.8 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID 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.

Operation

area

and season

Mixture

Normal

l/3:

Winter

in cold region

Winter

in extremely

cold region

temperature I

Pure washer water

2f3

Pure washer l/2: water

fluid

fluid

l/2

Pure washer

fluid

tank

Freezing

ratio

I I

\ \

I - 10-C (14’F)

I

AE179760

- 2O’C (- 4-F)

- 30-C (- 22-F)

Pure washer fluid comes in two types: for -1o’C (14’F) (for general use) and for -3OC (-22°F) (cold regions).

Use pure washer fluid according to operation area and season.

3-45

24.3.9 CHECK AND ADJUST

AIRCONDITIONER

CHECK LEVEL OF REFRIGERANT (GAS)

lf the liquid gets into your eyes or on your hands, it may cause loss of sight or frostblte, so never loosen any part of the ~AwARNâ&#x20AC;&#x2122;NG If there is a lack of refrigerant (Freon 134aL 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 compressor.

Inspection and maintenance

items list for cooler

Inspection and maintenance items Refrigerant

(gas)

Condenser

Filling quantity

Twice a year; spring and autumn

Clogging

Every 500 hours

T Function

V belt

I Damage

of fins

Every 4000 hours Every 250 hours

and tension

Blower motor and fan

Function (Check for abnormal sound)

Control mechanism

Function (Check for normal function)

3-46

Maintenance interval

Contents

Compressor

Piping for connection

of the

Instaflation condition looseness of tightening connection oortions 1 gas leakage; damage

II

]

When

required

When

required

When

required

No refrigerant 1 Colorless. iranspamit )

24. SERVICE PROCEDURE

24.3.10

CLEANING,

REMOVING

DIRT FROM LINE FILTER

I

As seen

from

left

of

chassis

As

seen

from

rear

of

chassis

AU332550

If there is any abnormality in the pumps or other hydraulic equipment, do as follows, and remove the dirt from inside the line filter.

1.

Loosen the air suctin plug KiJ - 0) corresponding to be removed 1 - 2 turns.

l

Relationship

of line filter and air suction

Line filter A

-_)

plug 0

Line filter B

+

duo

Line filter C

+

plug 0

to the line filter

plug

(7,

Line filter D

+

plug 0

Line filter E

+

plug 0

Line filter F

+

plug 0

2.

Remove 4 bolts @, and flange 0, then temporarily insert 2 of bolts @ into cover 0.

Temporarily insert bolts @ on diagonally opposite sides.

3.

Loosen clamp 0.

4.

Remove cover @, and clean filter @I. (1) When cleaning the filter, also clean off the dirt and dust stuck to the side face of the case.

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

(3) Tightening torque for cover: 108 + 10 Nm (11 f 1 kgm, (79 f 7 Ibft)) (4) After assembling the line filter again, bleed the air from the system. (For details, see â&#x20AC;&#x153;18.5 BLEEDING AIR FROM CIRCUITâ&#x20AC;?)

3-47

24. SERVICEPROCEDURE

243.11

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.

2.

Loosen lock nut @ and completely release the spring.

Press tension pulley @ in the direction indicated by the arrow to remove the V-belt.

Then install a replacement.

Replace three V-belts at the same time.

Adjustment Check the size A to see that it is maintained at 54 f 3 mm (2.1 * 0.1 in).

If not, adjust the fan belt as follows: Tighten adjusting bolt @ until size A becomes 54 f 3 mm (2.1 & 0.1 in), and tighten lock nut @ securely.

3-45

24. SERVICE PROCEDURE

24.4

CHECKS BEFORE STARTING

24.4.1 CHECK COOLANT See 12. OPERATION,

LEVEL, ADD WATER

12.1 Check before starting

engine.

24.4.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL See 12. OPERATION,

12.1 Check before starting

engine.

24.4.3 CHECK FUEL LEVEL See 12. OPERATION,

12.1 Check before starting engine.

24.4.4 CHECK OIL LEVEL IN HYDRAULIC See 12. OPERATION,

24.4.5 CHECK FOR CLOGGING See 12. OPERATION,

TANK, ADD OIL

12.1 Check before starting

engine.

OF AIR CLEANER

12.1 Check before starting

engine.

24.4.6 CHECK ELECTRICAL WIRING See 12. OPERATION,

12.1 Check before starting

24.4.7 CHECK FUNCTION See 12. OPERATION,

engine.

OF HORN

12.1 Check before starting

engine.

24.4.8 CHECK OIL LEVEL IN PTO CASE, ADD OIL See 12. OPERATION,

12.1 Check before starting

24.4.9 DRAIN WATER, SEDIMENT See 12. OPERATION,

engine.

FROM FUEL TANK

12.1 Check before starting

engine.

24.4.10 CHECK CENTRAL MONlTOR See 12. OPERATION,

12.1 Check before starting

engine.

3-49

24. SERVICE PROCEDURE

24.5 EVERY 10 HOURS

A

SERVICE WARNING

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 lower the work equipment to the ground

2.

Using a grease pump, pump fittings shown by arrows.

3.

After greasing,

wipe

in grease

posture below, then and stop the engine. through

the grease

off any old grease that was pushed

out.

AW372460

1.

2.

3-50

Arm-Bucket coupling pin (2 points) Arm-Link coupling pin (2 points)

24. SERVICE PROCEDURE

3.

4.

Bucket cylinder rod end pin (2 points) Link coupling pin (4 points)

5.

Bucket-Link

coupling

pin (2 points)

AE130420

Method for greasing with grease gun 1.

Tighten stop valve @ in the room below the operatorâ&#x20AC;&#x2122;s cab to the CLOSED position.

Use the special handle when opening or closing stop valve 0.

2.

Pull the hose out from the reel, and pump in grease through the grease fitting.

Operate the engine at low speed or midrange speed to carry out the greasing.

It is efficient to carry out the greasing while warming up the engine before starting operation.

Special handle

AEl69680

3-51

1

24. SERVICE PROCEDURE

Other greasing The following reasing points can be greased greasing switch in the operatorâ&#x20AC;&#x2122;s compartment.

6.

7.

8.

9.

10.

11.

12.

13.

by operating

the

Boom cylinder foot pin Boom foot pin Boom cylinder rod end pin Arm cylinder foot pin Bucket cylinder foot pin Boom-Arm coupling pin Arm-Link coupling pin Swing circle

1. Set stop valve @ of the grease pump outlet port in the room under the operatorâ&#x20AC;&#x2122;s cab to the OPEN position.

2.

Turn the greasing switch START Continue greasing for approx. 15 minutes. When doing this, run the engine at low speed or midrange speed.

When greasing, grease pressure gauge @ should indicate 4.9 19.6 MPa (50 - 200 kg/m*, 710 - 2840 psi).

If the pressure is below 4.9 MPa (50 kg/cm*, 710 psi), the grease can is empty, so replace the grease can.

AE178280

If the pressure is above 19.6 MPa (200 kg/cm*, 2840 psi), check the distributor indicator at the top face of the boom foot. If the plunger is protruding, that line is clogged, so check and repair.

3-52

24. SERVICE PROCEDURE

24.6 EVERY 100 HOURS SERVICE Maintenance same time.

for every

10 hours should

be carried

24.6.1 CHECK OIL LEVEL IN SWING MACHINERY 1.

2.

out at the

CASE

Use dipstick @ to check the oil level.

The oil level should be between the L and H marks. If necessary, add oil at the dipstick guide hole.

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

3-53

24. SERVICE PROCEDURE

24.7 EVERY 250 HOURS SERVICE Maintenance for every 10 hours should be carried out at the same time.

Carry out the following maintenance only after the first 250 hours. l l l l l

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

For detail of the method of replacing or maintaining, see the section on EVERY 100 HOURS, 500 HOURS, 1000 HOURS AND 2000 HOURS SERVICE.

24.7.1 GREASE FAN PULLEY ASSEMBLY, TENSION PULLEY ASSEMBLY 1.

2.

F. ENGINE FAN PULLEY

Add grease through the fittings marked by arrows.

Fan pulley assembly (2 points) Tension pulley assembly (2 points)

24.7.2 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL

A WARNING

7

The oil is at high temperature immediately after the machine has been operated.

Wait for the oil to cool down before starting the operation. lf there is still pressure remaining inside the case, the oil or plug may fly out.

Loosen the plug slowly to release the pressure.

1.

Stop the machine so that the plug @ on the outside of machine is at the lowest position.

2.

Remove plug @ and check that the oil level is near the bottom of the plug hole.

If necessary, add engine oil through oil filler 0.

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

3-54

F. ENGINE TENSI ON

R. ENGINE FAN PULLEY

24. -7.3

CHANGE DRAIN FILTER CARTRIDGE

1.

Using a filter wrench, counterclockwise.

remove

cartridge

0

by turning

it

2.

Fill the new cartridge with 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 stand, then screw up the cartridge l/2 to 314 turn.

AE17QQ70

24.7.4 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE AND BYPASS FILTER CARTRIDGE (FRONT AND REAR ENGINE) I

AWARNING ,-I The oil is at high temperature after the engine has been operated, so never change the oil immediately after finishing operations. Wait for the oil to cool down before changing it.

Prepare the following Container to catch drained oil: Min. 33.5 f? capacity Refill capacity: 33.5 fi (8.9 US gal) 0 Filter wrench 0 0

1.

Remove the filler cap, remove drain plug @I, install the hose provided and loosen drain valve @2. After draining the oil, remove the hose and tighten drain valve 81 and plug @.

2.

Using a filter wrench, remove oil filter cartridges @ and bypass filter cartridge @ 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 still stuck to the filter holder, it will cause oil leakage.

If filter cartridges @ are removed immediately after stopping the engine, oil will spill. Wait at least 10 minutes after stopping the engine before replacing the filter cartridge.

3.

Fill the new cartridge with clean engine oil and refit it after applying a dab of oil to the packing face.

To refit the cartridge, place the packing face in contact with the seal face of the fitter holder, then screw up the cartridge 3/4 to 1 turn.

3-55

24. SERVICE PROCEDURE

4.

After replacing the filter cartridge, add engine oil through oil filler @ until the oil level is between the H and L marks on dipstick 0.

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

5.

Run the engine at idling for a short time, then stop the engine, and check that the oil level is between the H and L marks on the I dipstick. For details, see “12.1 CHECK BEFORE STARTING”.

I

Even if the machine has not been operated for 250 hours, the oil and filter cartridge must be replaced when the machine has been operated for 6 months.

In the same way, even if the machine has not been operated for 6 months, the oil and filter cartridge must be replaced when the machine has been operated for 250 hours.

Change the oil and replace the filter cartridge for both the front and rear engine.

24.7.5

CHECK ALTERNATOR ADJUST

ADO52340

DRIVE BELT TENSION,

Checking The standard deflection for the drive belt is 13 - 16 mm (0.51 0.63 in) when pressed with a thumb [at approx. 98.1 N (approx. 10 kgf)] at a point midway between the drive pulley and alternator pulley.

Alternator

13--16am (0.51-0.63

i n)

fl

Drive

Adjusting 1. Loosen bolts and nuts @ - @ in order, then turn nut @I to move the alternator and adjust the belt tension.

Turn nut 0 as follows.

TIGHTEN to INCREASE belt tension LOOSEN to DECREASE belt tension 2.

After adjusting the belt tension, tighten the bolts and nuts in order from @ to @ to secure the alternator in position. Finally, tighten nut 0.

Check each pulley for damage, wear of the V-groove, and wear of the V-belt. Check in particular that the V-belt does not contact the bottom of the V-groove.

If the V-belt is elongated and there is no more allowance for adjustment, or if the belt is cracked or cut, replace the belt.

3-56

~uilev

DuI leu

A8308578

24.

SERVICE PROCEDURE

24.7.6 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER) Checking 1. Remove 2.

bolts @ and 0,

then remove

cover 0.

The standard deflection for the drive belt is approx. IO mm (0.4 in) when pressed with a thumb [at approx. 98.1 N (approx. 10 kgfll at a point midway between the drive pulley and air conditioner compressor pulley.

Adjusting 1. Loosen bolts and nuts @ - @I in order, then turn nut @I to move the compressor and adjust the belt tension.

Turn nut @ as follows.

TIGHTEN to INCREASE belt tension LOOSEN to DECREASE belt tension 2.

After adjusting the belt tension, tighten the bolts and nuts in order from @ to @ to secure the compressor in position. Finally, tighten nut 0.

Check each pulley for damage, wear of the V-groove, and wear of the V-belt. Check in particular that the V-belt does not contact the bottom of the V-groove.

If the V-belt is elongated and there is no more allowance for adjustment, or if the belt is cracked or cut, replace the belt.

3.

Install cover 0.

Compressor

pulley

@ â&#x20AC;&#x2DC;I

10 mm (0.4 in)

k

Drive pulley

I/

AEo83620

-A6306600

3-57

24. SERVICE PROCEDURE

24.7.7 CHECK LEVEL OF BATTERY ELECTROLYTE

A WARNING l l

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

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

Carry out this check before operating the machine.

1. Open the battery box cover.

2.

Remove cap @ and check that the battery electrolyte is up to the UPPER LEVEL line. If the level is low, add distilled water to the UPPER LEVEL line.

Do not add water above the UPPER LEVEL line. This may cause leakage of the electrolyte, which may cause fire.

If the battery electrolyte is spilled, have dilute sulphuric acid added. 1 ’ 3.

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

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

3-58

”

-,” AEl80020

24. SERVICE PROCEDURE

24.7.8 CHECK, CLEAN FUEL STRAINER 1. Tighten valve @ on the bottom of the fuel tank.

2.

Open the cover on the rear body, remove cap @ under the air cleaner, and take out the strainer. And clean the strainer and the strainer case.

AE180030

24.7.9 CHECK AND TIGHTEN TRACK SHOE BOLTS Shoe bolts @ which secure track shoes to links will break if used in a loosened state, so loose bolts must always be retightened.

Tightening torque: Tighten to an initial torque of 687 + 69 Nm (70 f 7 kgm, 507 2 51 Ibft), check that the mating surfaces are in contact, then tighten a further 120” -c 10”.

Order for tightening: Tighten the bolts in the order shown in the diagram.

After tightening, check that the nut and shoe are in close contact with the link mating surface.

I 24.7.10

ADo-

J

CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS

Bolts @ connecting the track frame and axle will break if they remain loose. If any loose bolts are found, please contact your Komatsu distributor to have them tightened.

Tightening torque: 4658 f 250 Nm (475 2 25 kgm, 3436 + 180 Ibft)

3-59

24. SERVICE PROCEDURE

24.7.11

REPLACE FILTER ELEMENT OF HYDRAULIC TANK BREATHER

A WARNING When replacing the element, turn the cap of oil filler slowly to release the internal pressure.

I 1.

Remove snap ring @ of breather 0, @ with a new part.

2.

Install cover @ and snap ring 0.

3-60

then replace filter element

h

WI

I

AE180070

24. SERVICE PROCEDURE

24.8 EVERY 500 HOURS SERVICE Maintenance for every 10,100 out at the same time.

and 250 hours should be carried

24.8.1 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)

1. Open the engine machine.

hood and rear duct on the right side of the iator

2.

Blow off mud, dust or leaves clogging the radiator fins, oil cooler fins and after cooler fins using compressed air.

At the same time, clean the net in front of the oil cooler. Clean the condenser fins on machines equipped with air conditioner.

Steam or water may be used instead of compressed air.

When cleaning the radiator core, remove 4 covers @ at the top of the hood and oil cooler recirculation cover 0, then use compressed air or steam to carry out the cleaning through clearance C.

NOTICE When using compressed air, if the nozzle is brought too near the fins, the fins may be damaged. Especially for the aftercooler, blow the air from a distance of at least 300 mm and at an angle of 45â&#x20AC;&#x2122;.

3.

Check the rubber hose. Replace with a new one if the hose is found to have cracks or to be hardened by ageing.

Further, check hose clamps for looseness.

Cleani:

After cooler

hose clamp tightening

torque:

nozzle

8.8 f 0.49 Nm (0.9 2 0.05 kgm) (6.5 + 0.36 Ibft)

NOTICE When use the compressed air, keep a distance from air nozzle, to prevents damage to the fins. Especially for after cooler, blow the air from 300 mm or more, and across the 45â&#x20AC;?.

To prevent damage to the fins, apply compressed air from and appropriate distance. Damaged fins may cause water leakage or overheating.

In a dusty site, check the fins daily, irrespective of the maintenance interval.

Right side of machine

Oil

cooler

3-61

24. SERVICE PROCEDURE

24.8.2 CLEAN PILOT FILTER STRAINER

A WARNING The oil is at high temperature after engine has been operated.

Wait for the oil to cool down before carrying out maintenance.

1.

Remove filter case 0.

2.

Take out the strainer and wash the strainer the strainer if finding some defects.

3.

Install the strainer and filter case 0.

in the fuel. Replace

24.8.3 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 tube 0.

3-62

24. SERVICE PROCEDURE

24.8.4 REPLACE FUEL FILTER CARTRIDGE

l

Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before

l

Do not bring fire or sparks near the fuel.

Prepare a filter wrench

and a container

to catch the fuel.

1. Close valve @ (fuel supply side) of the bottom 2.

Set the container

3.

Using a filter wrench, turn filter cartridge remove it.

of the fuel tank.

to catch the fuel under the filter cartridge. @ counterclockwise

to AE180030

4.

Clean the filter holder, fill a new filter cartridge with clean fuel, coat the packing surface with engine oil, then install it to the filter holder.

5.

When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten a further Z/3 turn.

If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten to the correct amount.

6.

After replacing the fuel filter cartridge, system.

Bleed the air as follows.

7.

Fill the fuel tank with fuel (to the position where the fuel gauge shows FULL).

8.

After replacing filter cartridge

9.

Loosen the knob of feed pump 0, operate it up and down, and continue until no more bubbles come out with the fuel from air bleed plug 0.

9.

Tighten air bleed plug 0.

Use a genuine Komatsu filter cartridge.

After replacing the filter cartridge, start the engine, and check that there is no leakage of fuel from the filter seal surface.

0,

bleed the air from

the

loosen air bleed plug @I.

3-63

24. SERVICE PROCEDURE

24.8.5 CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER- (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)

i

The FRESH filter is in box @ under the sub-seat.

Loosen screw 0, open cover 0, then pull filter @ out to the front to remove it.

There are 2 air conditioners installed in the room under the cab.

Open cover @ of the air conditioner, then pull out FRESH filter

03.

Clean filters @ and @ with compressed air. If there is oil on the filter or it is extremely dirty, wash it in a neutral washing agent.

After washing it, dry it completely before using it again.

If the dirt clogging the filter cannot be removed by blowing it with air or washing it in water, replace the filter with a new part. NOTICE As a guideline, the filters should be cleaned every 500 hours, but on dus$jobsites, clean the filters more frequently.

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.

An auto tensioner is installed, so it is unnecessary to adjust the fan belt.

For details of the replacement procedure, refer to “24.3.11 REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER”.

3-64

1W371660

24. SERVICE PROCEDURE

24.8.7 CHANGE HYDRAULIC FILTER ELEMENT

c

When removing the oil filler cap, turn it slowly to release the internal pressure before removrng It When removing cover 0, undo the bolts (4 bolts) gradually to prevent the cover flying off under the force of spring 0.

1. Remove

the cover over the hydraulic tank.

2.

Remove the pressure.

cap from

oil filler

0,

and

3.

Loosen 4 bolts, then remove cover 0.

When doing this the cover may fly out under the force of spring 0, so hold the cover down when removing the bolts.

4.

After removing

6.

Clean the removed

6.

Install a new element installed.

7.

Set valve @I and spring @ on top of the element.

8.

Set cover @ in position, push it down by hand, and install the cover with the mounting bolts.

9.

Screw

spring @ and valve 0,

release

the internal

take out element

@I.

parts in diesel oil. in the place where

old element

@ was

in the oil filler cap @ and install the cover.

10. To bleed the air, start the engine according to â&#x20AC;&#x153;12.2 STARTING ENGINEâ&#x20AC;? and run the engine at low idling for IO minutes.

j

11. Stop the engine.

REMARK Starting the engine after halting for more than 5 minutes eliminate bubbles in the oil inside the tank.

12. Check for oil leakage

-

-

AEm

to

and wipe off any spilled oil.

3-65

24. SERVICE PROCEDURE

24.9 EVERY 1000 HOURS SERVICE Maintenance for every 10,100,250 be carried out at the same time.

and 500 hours service should

24.9.1 CHANGE OIL IN SWING MACHINERY

CASE

A WARNING

1

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

Container to catch drained oil: Min. 30 e capacity Refill capacity: 30 P (7.93 US gal)

Set a container under drain hose under the machine body to catch the oil.

Loosen drain valve @ under the machine body, drain the oil, then tighten the drain plug again.

Remove dipstick @ and air bleed plug 0, then add the specified amount of engine oil through filler port @ of the,dipstick guide.

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

4.

After adding oil, install air bleed plug 0.

5.

Wipe off the oil on the dipstick with a cloth.

6.

Insert dipstick @$Ifully into the dipstick guide, and then pull it out again.

7.

The oil level should be between H and L marks on the dipstick 0. If the oil does not reach the L mark, add engine oil through oil filler port 0.

8.

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

9.

Immediately after changing the oil, oil level is variable.

So operate for one hour, then check the oil level again.

24.9.2 CHECK TURBOCHARGER

CLAMPfNG JOINT

Contact your Komatsu distributor for checking, or proceed as follows:

3-56

Rear

swing

machinery

24. SERVICE PROCEDURE

24.9.3 CHANGE OIL IN PTO CASE a WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before carrying out maintenance.

NOTICE Park the machine on flat ground and stop the engine. After waiting for more than 30 minutes after stopping the engine, check the oil level.

Prepare the following.

Contain to catch drain oil: Min. 40 l? capacity l Refill capacity: 20 e each (10.6 US gal)

l

1.

Drain oil from drain plug @ at the bottom draining, tighten drain plug 8.

2.

Pour in the specified

amount

of engine

of the PTO case. After

oil through

oil filler 0.

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

24.9.4 REPLACE CORROSION RESISTOR CARTRIDGE 1.

Screw in valve @ (2 pieces) at the top of the corrosion

2.

Using a filter wrench,

3.

Coat the seal surface of the new filter cartridge with engine oil, then install it.

When installing, bring the packing surface into contact with the seal surface of the filter holder, then tighten a further 2/3 turn.

Always use a genuine Komatsu cartridge.

4.

Open valve 0.

5.

Run the engine and check that there is no leakage of water from the seal surface.

turn cartridge

to the left to remove

24.9.5 CHECK INSPECTION OF WELDING (COLOR CHECK) When hours.

the service

meter

over

4000

resistor

hours,

it.

STRUCTURE check every

1000

3-67

24. SERVICE PROCEDURE

24.10 EVERY 2000 HOURS SERVICE and 1000 hours should

Maintenance for every 50,100,250,500 be carried out at the same time.

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. lf 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. 85 e capacity Refill capacity: 85 e (22.5 US gal) Handle Set the drain plug bottom.

on the outside

of the machine

is at the

2.

Set a container

3.

Remove plug @ with the handle and drain the oil, then tighten the olua.

4.

Set a container

5.

Remove plug @ with the handle and drain the oil, then tighten the plug.

6.

Add engine

under plug @ to catch the oil.

under plug @ to catch the oil.

oil through

the hole of plug 0.

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

7.

After adding For details,

oil, check oil level. see “24.7 EVERY 250 HOURS

SERVICE”.

24.10.2 CLEAN, CHECK TURBOCHARGER Excessive carbon or oil sludge adhering to turbocharger blower of turbocharger and impeller may deteriorate normal performance damage it. may sometimes and Ask your Komatsu distributor to clean the turbocharger check rotation of the rotor impeller, or perform the following.

3-68

24. SERVICE PROCEDURE

24.10.3 CHECK TURBOCHARGER Contact your Komatsu

distributor

ROTOR PLAY for checking.

24.10.4 CHECK SWING PINION GREASE LEVEL, ADD GREASE 1.

Remove 4 bolts @ on the inside of track frame, cover @_

2.

Insert a scale into the grease and check that the depth of the grease is approx. 156 mm (6.2 in). Add grease if necessary.

If the grease is particularly milky due then remove bolts @ and cover @from the and remove the grease. Replace all of the The total amount of grease is 170 f? (45

then

remove

to ingress of water, etc., bottom of the track frame grease with new grease.

US gal) (153 kg, (337 lb)).

24.10.5 CLEAN ENGINE BREATHER 1.

2.

Remove breather 0.

Rinse the breather in diesel oil or flushing pressed air, then install again.

oil, dry with

com-

Before removing the breather, clean all the dirt from around it.

Replace the breather O-ring with a new part, and coat it with engine oil before installing.

3-69

24. SERVICE

PROCEDURE

24.10.6 CLEAN HYDRAULIC

TANK STRAINER

l

When removing the cap, turn it slowly to relieve inner pres-

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 @I from above to take out spring @ and strainer 0.

3.

Wash the strainer with fuel oil. If strainer @ is damaged, 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 install.

replace

AEl80090

24.10.7 CHECK ALTERNATOR,

STARTING

MOTOR

The brushes may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair.

If the engine is started frequently, carry out inspection every 1000 hours.

24.10.8 CHECK ENGINE VALVE CLEARANCE, ADJUST As special tool is required for removing request Komatsu distributor for service.

3-70

and adjusting

the parts,

24. SERVICE

PROCEDURE

24.11 EVERY 4000 HOURS SERVICE for every 10, 100, 250, 500, 1000 and 2000 hours Maintenance 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 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.

24.11.3 CHECK FAN PULLEY AND TENSION PULLEY Inspect the pulley for play and grease leakage.

If any fault is detected, ask Komatsu distributor and repair or replace.

to disassemble

24.11.4 CHECK AIR COMPRESSOR, ADJUST As special tool is required for checking and adjusting request Komatsu distributor for service.

the parts,

3-71

24. SERVICE PROCEDURE

24.12 EVERY 5000 HOURS SERVICE Maintenance for every 10,100,250,500 be carried out at the same time.

24.12.1

and 1000 hours should

CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER AWARNING

The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before changing it. When removing the oil filter cap, turn it slowly to releasa the internal pressure, then remove it carefully.

Prepare the following.

Cantainer to catch drained oil: min. 1500 !J capcacity l Refill, capacity: 1500 e (396 US gal) l Prepare a handle for the socket wrench set. l

AE171090 I

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

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

the cap of oil filler 0.

amount

-

of engine oil through

oil filler 0.

NOTICE

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

5.

After changine the oil level.

For details IN HYDRAULIC For details pressure inside ClRCUlT”.

When

the oil, fleed the air from the circuit, and check

of engine oil filling, see “12.1.2 CHECK OIL LEVERL TANK, ADD OIL”. of releasing the air inside the hydraulic tank and the the hydraulic circuit, see “18.5 BLEEDING AIR FROM

loosening

valve 0,

be careful not to get oil on yourself.

NOTICE This applies only when using the Komatsu specified oil + a hybrid filter (07063-51210) and replacing the hybrid filter every 500 hours. When using other oil and the standard filter (07063-01210). the replacement interval for the filter is 250 hours and the interval for changing the hydraulic oil is 2000 hours.

3-72

I Y

25. SPECIFICATIONS

PC1 800-6

Item

I

Operating weight (including 1 operator, 80 kg) Bucket capacity (standard bucket)

SAE CECE

Unit

I

kg (lb)

180000 (396828)

m3 (cu.yd) m3 (cu.vd)

12 (15.5) 11 (14.2)

1 Name of engine

1

1 Engine horsepower A 1 Overall lenath

1 kW (HPYrpm 1 I mm (ft in) I

B 1 Overall height

I mm (ft in)

C

Overall width

D E

Track width Heiaht of cab

F G H

Tail swing radius Length of track Tumbler center distance Min. ground distance Travel speed Swina sDeed

PC1800-6

mm Vt in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) km/h (MPH) ram

I

Komatsu SAA6Dl40

diesel engine x 2

338 (454)/1800 17185 (56’5”) 6745 (22’) 6015 (19’9”) 810 (2’8”) 6510 (21’4”) 6235 (20’5”) 7436 (24’5”) 5780 (18’12”) 2080 (6’10”) 2.7 (1.7) 4.5

9JYO1459

4-2

PC1 800-6 Working A

Max. digging

ranges

Unit

PC1 800-6

reach

mm (ft in)

15780 (51’7”)

B

Max. digging

depth

mm (ft in)

9265 (30’5”)

C

Max. digging

height

mm (ft in)

13380 (43’11”)

D

Max. vertical wall depth

E

Max. dumping

F

Max. reach at ground

height level

mm (f-t in)

2740 (8’12”)

mm (ft in)

8620 (28’3”)

mm (ft in)

15305 (50’3”)

AW365000

4-3

OPTIONS, ATTACHMENTS

26. GENERAL PRECAUTIONS

26.1

PRECAUTIONS

RELATED TO SAFETY

If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety.

When installing attachments not listed in this Operation and Maintenance Manual, please contact your Komatsu distributor first.

If you do not contact Komatsu, we cannot accept any responsibility for any accident or failure.

A WARNING Precautions for removal and installation operations When removing or installing attachments, obey the following precautions and take care to ensure safety during the operation.

Carry out-the removal and installation operations on a flat, firm ground surface.

When the operation is carried out by two or more workers, during the operation.

When carrying

heavy objects

determine

signals and follow

(more than 25 kg (55 lb)), use a crane.

When removing heavy parts, always support the part before removing it.

When liiing such heavy parts with a crane, always pay careful attention to the position center of gravity. lt is dangerous to carry out operations stand, and check that it is safe.

When removing not fall over.

or installing

these

with the load kept suspended.

attachments,

Always

of the

set the load on a

make sure that they are in a stable condition

and will

Never go under a load suspended from a crane.

Always stand in a position that is safe even if the load should fall.

NOTICE Qualifications are required to operate a crane. Never allow the crane to be operated by an unqualified person.

For details of the removal and installation operations, please contact your Komatsu distributor.

5-2

26. GENERAL 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. l

Going downhill with the work equipment raised

l

Traveling

across slopes CORRECT

l

Swinging structure INCORRECT

the upper on slopes CORRECT

INCORRECT

AD34129A

AE341310

AD341MA

lf 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. INTRODUCTION

OF A-ITACHMENTS

27.1 GUARD Name

FOPS

54

Specifications/Use Used to protect operator. Must be installed when machine is operated in a place where rocks and other heavy materials may fall

Weight: 130 kg (287 lb)

28. AUTO-GREASING

SYSTEM

of the operation is an explanation The following system. needed for the optional auto-greasing

1. AUTO-GREASING

and equipment

SWITCH

I I

câ&#x20AC;?11710

I

This switch is inside the base under the cab and is used to switch between automatic and manual greasing.

Normally, keep this switch at the AUTO position.

When using a grease gun, set the switch to MANUAL. 2.

AUTO GREASE/GREASE

GUN selector lever

This lever is used to select automatic or manual greasing in the switch. same way as the auto-greasing Normally, keep this lever at the AUTO GREASE position.

When using a grease gun, check first that the grease pump is not [if it is carrying out auto-greasing, carrying out auto-greasing wait until the grease pump stops (within approx. 1 minute)], then set the lever to the GREASE GUN position.

5-5

28. AUTO-GREASING SYSTEM

AUTO-GREASING LAMP

3.

When the auto-greasing switch is operated, the auto-greasing lamp (green) on the panel at the right side of the operatorâ&#x20AC;&#x2122;s seat will light up at the AUTO or MANUAL position.

AUTO-GREASING CAUTION LAMP

b.

This lamp lights up if an abnormality occurs in the auto-greasing system. Check the engine from the content of the display on the auto-greasing controller inside the cab base, then carry out repair work.

Set the auto-greasing controller to the OFF position when carrying out repair work. If the starting switch is turned OFF, the controller is also turned OFF.

Lamp

Controller Controller failure

display rest

Nature

of abnormality

Pressure inside grease piping does not rise when pump is working

Lights up

l

0 l

1 Vent pressure SW alarm

Vent valve does not return, injector cannot be recharged

REMARK If the engine is not running but the starting switch is left at the ON position, the controller display will show CONTROLLER REST FAILURE and the caution lamp will light up, but this does not indicate any abnormality.

When the starting switch is turned OFF, the condition will return to normal.

5-6

Cause

l l

Failure of pump Pump running empty Cracked grease piping, leakage Failure of vent valve Crushed, clogged grease piping upstream from injector

28. AUTO-GREASING SYSTEM

5. GREASE NIPPLE FOR GREASE SUPPLEMENT The grease nipple @ for supplement is located inside the cab base room. It is possible to refill with grease without replacing the grease pail. Use a grease gun to refill. The refilling operation is completed when the oil level rod @ reaches the FULL position.

5-7

PC18OO-s HYDRAULIC EXCAVATOR Form No.

SEAM022902T

"1999 KomAlb

All Rights Reserved 10-99 (01-I)

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