Komatsu Wheel Loader WA800-2 Operation & Maintenance Manual SN A20001 and up - PDF DOWNLOA

Operation 81Maintenance Manual

SERIALNUMBERS

WA800.2L

I

A20001

CEAM000401

and up

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

It is our policy to improve our products whenever it is possible and practical to do so. We resew8 the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.

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

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

November 1997

Copyright 1997 Komatsu America International Company

PRODUCT PUBLICATIONS

INFORMATION

VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION AND MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS.

SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SERVICE MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & SERVICE MANUALS IN FOREIGN LANGUAGES.

THE PUBLICATIONS

LISTED BELOW ARE AVAILABLE

FOR THIS PARTICULAR

MACHINE(S).

DESCRIPTION

FORM NUMBER

PARTS BOOK - PAPER: ChassisandEngine

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

BEPB000701

PARTS BOOK - MICROFICHE: Chassisand

OPERATION

Engine

. . .._._..._._.__.................................

AND MAINTENANCE

Chassisand

Engine

BEPM000701

MANUAL:

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

CEAM000401

SHOP MANUAL: Chassis

. . .._........__............................................

Engine............................................................

STANDARD Chassis

MAN-HOUR

SEBM04280113 SEBE62150105

GUIDE:

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

Engine............................................................

SAFETYMANUAL.......................................................

SEKQ3352 SEKQ3907

WLT70-1

PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS, USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INVENTORY PROCESSING SYSTEM (PIPS).

IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDCSID IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.

REQUISITION FOR TECHNICAL

COMPLETE

SERVICJ

PUBLICATIONS

AND SERVICE FORMS

FORM

AND RETURN

Komatsu America International Company

TO -

440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A.

Attn: Technical Publications Fax No. (847) 9704186 Tel No. (847) 970-5887 COMPANY NAME

SHIP TO

/

l

ATi-N. STREET ADDRESS

TYPE or PRINT ONLY

.

CITY, STATE. ZIP CODE COUNTRY I

I

PHONE NO.

FAX NO.

SHIPPING METHOD

DISTR/BRANCH CODE I

IMPORTANT

- TO ASSURE

SHIPMENT

OF THE CORRECT

PUBLICATION(S),

SERIAL NUMBER MUST BE SHOWN.

KDCSI D 022597

CURRENT PRICES WILL BE CHARGED

THE MODEL NUMBER

AND MACHINE

1. FOREWORD

This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically.

If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.

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

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

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

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

A

WARNING

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

Operators and maintenance operation or maintenance.

personnel

should read this manual thoroughly

before beginning

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

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

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

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

The description

of safety is given in SAFETY INFORMATION

on page O-2 and in SAFETY from page

1-1.

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

and other

reproductive

harm.

o-1

2. SAFETY INFORMATION

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

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

used.

-

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

A WARNING

-

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

A CAUTION

-

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

-

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

A

DANGER

NOTICE Safety

precautions

are described

in SAFETY from

must

be taken

to avoid actions which

page 1-I.

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

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

o-2

3. INTRODUCTION

3.1 l

0

3.2 1.

2.

3.

4.

3.3

INTENDED

USE

This machine is intended mainly for the following operations.

Digging operations l Pushing operations Leveling operations l Loading operations For details of the operating procedure, see “12.10 WORK POSSIBLE

USING

WHEEL

LOADER”.

FEATURES Easy to operate work equipment l By using the kick-down switch installed to the knob on the boom control lever, it is possible to shift down from 2nd to lst, thereby providing speedy digging and loading operations. l The powerful digging force and drawbar pull make it easy to dig and scoop up loads. l The large dumping clearance and reach make it easy to load dump trucks. l The excellent acceleration and production per unit of fuel make this a very economical machine. l Installation of bucket corner teeth and wear plates between the teeth give the bucket a large resistance to wear.

Easy to operate machine l The electrical transmission control provides light gear shifting, enabling finger control. l The length of both the directional and speed levers can be adjusted individually. l The PPC valve (proportional pressure type) provides good response when raising the boom and little operating force is required. l A wrist rest is provided by the control levers to improve the ease of control.

Operating comfort l The sealed pressurized cab with air conditioner make pleasant operations possible. l A fabric seat is used for the operator’s seat to give the operator a good ride. l A low-vibration cab and viscous mount are employed.

High levels of safety l Safety is ensured by the good visibility from the cab, the wide area around the operator’s seat, steps for getting on and off the machine, and the walk-through floor at the rear of the cab. l The rear access step offers increased safety when the operator gets on and off the machine with something in his hands. l With the handrail and nonskid treatment on the top of the hood, the operator can check the radiator water level and add water to it more safely. l Checks before starting and checks for abnormalities during operation can be carried out using the machine monitor. l Maintenance free wet-type multiple disc brakes are used.

BREAKING

IN THE MACHINE

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

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

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

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

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

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

o-3

4. LOCATION OF PLATES, TABLE TO ENTER

SERIAL NO. AND DISTRIBUTOR

4.1

MACHINE On the center

4.2

ENGINE

SERIAL NO. PLATE POSITION

right of the front frame.

SERIAL NO. PLATE POSITION

On the right of the cylinder

4.3

block, when seen from the fan side.

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine

serial No.:

Engine serial Distributor

No.:

name:

Address:

Service

REMARKS

o-4

Phone:

personnel

for your machine:

5. CONTENTS

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

Foreword

information

Safety

Introduction Location

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

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

of plates, table to enter serial No. and distributor

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

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

SAFETY precautions

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

6.

General

7.

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

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

7.1

7.2 7.3 7.4 7.5

Operating machine ...................................................................................................................

Transportation.. .........................................................................................................................

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

Towing .......................................................................................................................................

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

Precautions for maintenance Before carrying out maintenance.. .........................................................................................

8.1

maintenance

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

8.2

During

8.3

Tires . . . . .. . . .. . .. . . .. . . .. . . . .. . .. . . . . .. . . .. .. .. . . .. . . . . .. . .. . .. . .. ... . .. . . . .. .. . . . . . . . . .. . .. .. .. . . . . . . .. .. . . .. .. . .. .. .. . .. .. ...................

I- 2 I- 7 I- 7 I- 9 1-13 1-14 1-15 I-16 1-16 1-18 l-22

. . ..__....__........................._........._.._._.._...................._....................

1-24

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

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

2- 2

Position

for attaching

safety labels

OPERATION

10.2

General view of controls

and gauges ...................................................................................

of components ..............................................................................................................

11. Explanation II:1 Machine monitor ......................................................................................................................

11.2 11.3

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

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

11.3.1 Engine mechanical stop lever handles .......................................... .............................................................

Dustindicator 11.4 .......................................................

Circuitbreaker(Main) 11.5 Safety bar ................................................................

11.6 Steering column tilt lever .....................................................

11.7 Door-open lock ............................................................

11.8 Capwithlock ..........................................................................................................................

11.9 11.10 Fuelstoplever 11.11 ........................................................................... ..~ ....................................

11.12 Fuse .............................

11.13 Carradio .................................................................

11.14 Cab heater and air conditioner ................................................

11.15 Using accumulator .........................................................

11.16 Operation of joystick steering system ...........................................

Switches

2- 2 2- 3 2- 4

2- 4 2-l 4 2-20 2-25 $$ZB ;2EB 2-26 2;: 2X?: 2-30 z:zz 2-36

o-5

5. CONTENTS

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

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 Changing gear speed ...............................................................................................................

12.6 Changing direction ...................................................................................................................

12.7 Turning ......................................................................................................................................

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

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

12.10 Work possible using wheel loader.. .......................................................................................

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

12.12 Adjusting work equipment 12.13 Parking machine ....................................................................................................................... of operation ...................................................................................

12.14 Checks after completion 12.15 Stopping engine .......................................................................................................................

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

12.17 Locking.. .....................................................................................................................................

12.18 Handling the tires .....................................................................................................................

12.19 Removal and installation of the bucket.. ...............................................................................

13. Transportation

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

Z-40 2-40 2-53 2-56 2-57 2-58 2-59 2-59 2-60 2-61 2-62 2-67 2-69 2-71 2-72 2-72 2-73 2-73 2-74 2-76 2-80

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

14. Cold weather operation 14.1 Precautions for low temperature ............................................................................................. of work ...................................................................................

14.2 Precautions after completion 14.3 After cold weather.. ..................................................................................................................

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

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

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

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

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

2-84 2-84 2-84 2-84

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

16.1 When machine runs out of fuel .............................................................................................

16.2 Towing the machine ................................................................................................................

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

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

2-85 2-85 2-86 2-90 2-94

O-6

5. CONTENTS

MAINTENANCE 17. Guides to maintenance

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

3- 2

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

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

18.2 Outline of electric system .......................................................................................................

3- 5 3- 5 3- 8

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

3- 9

20. Use of fuel, coolant

and lubricants

according

to ambient

temperature

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

3-10

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

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

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

3-14 3-14 3-15

22. Periodic

3-16

replacement

of safety critical

schedule chart 23. Maintenance 23.1 Maintenance schedule

parts

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

............................................................................................................ chart.. .................................................................................................

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

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

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

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

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

24.5 Every 100 hours service ..........................................................................................................

24.6 Every 250 hours service ..........................................................................................................

24.7 Every 500 hours service ..........................................................................................................

24.8 Every 1000 hours service. .......................................................................................................

24.9 Every 2000 hours service ........................................................................................................

24.10 Every 4000 hours service ........................................................................................................

3-19 3-19 3-23 3-23 3-24 3-42 3-48 3-49 3-53 3-58 3-62 3-68 3-77

SPECIFICATIONS 25. Specifications

.._............_.__..................................................................................................................

OPTIONS,

ATTACHMENTS

26. Optional

part and attachments

27. Selecting

buckets

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

and tires ..............................................................................................................

28. Explanation of operation of ‘joy stick steering system ................................................................

28.1 Functions and structure of joy stick steering .......................................................................

28.2 Operation method of joy stick steering system ...................................................................

28.3 Precautions for steering with joy stick ..................................................................................

28.4 Adjustment of joy stick console .............................................................................................

28.5 Adjustment of seat ..................................................................................................................

4- 2

5- 2 5- 3 5- 4 5- 4 5- 7 5- 9 5-12 5-13

o-7

MEMO

O-8

SAFETY

a

WARNING

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

This safety section also contains ment and attachments.

Failure to do so may result

precautions

for optional

equip-

& gfi;~fje Fc;ereasons

of safety, always ty precautrons.

6. GENERAL PRECAUTIONS

SAFETY RULES l

ONLY trained

and authorized

l

Follow all safety rules, precautions on the machine.

a When working with another understand all hand sianals

personnel

can operate

and instructions

and maintain when

operating

operator or a person on worksite that are to be used.

the machine. or performing

maintenance

traffic duty, be sure all personnel

SAFETY FEATURES Be sure all guards damaged.

Proper position

and covers are in their proper

See “12.1.1 WALK-AROUND

position.

Have guards

and covers repaired

CHECK”.

Use safety features such as the safety lock lever and seat belts properly.

NEVER remove any safety features. ALWAYS keep them in good operating Safety lock lever -+ See “12.13 PARKING MACHINE”.

Seat belts + See “12.1.3 ADJUSTMENT Improper

use of safety features

if

condition.

BEFORE OPERATION”.

could result in serious

bodily injury or death.

CLOTHING AND PERSONAL PROTECTIVE ITEMS l

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

l

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

Check also that there is no one near the machine.

Cleaning of air cleaner element + See “24.2 WHEN REQUIRED” in service procedure.

1-2

A gJRN;E;;

Faiail~-ge$~~ follow these safety precautions

may lead 6. GENERAL PRECAUTIONS

UNAUTHORIZED

MODIFICATION

l

Any modification

made without

l

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

authorization

from

Komatsu

can create hazards. not be responsible

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

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

Always take the key with you.

Work equipment posture -+ See “12.13 PARKING MACHINE”.

Locks + See “12.17 LOCKING”.

1

MOUNTING NEVER jump When

getting

AND DISMOUNTING on or off the machine. on or off the machine,

Never hold any control Always maintain yourself.

levers when

three-point

contact

NEVER get on or off a moving face the machine getting

machine.

and use the handhold

and steps.

on or off the machine.

with the handholds

and steps to ensure that you support

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

Always

keep

AE428540

l-3

1

a

;fti:;G_ze

6. GENERAL PRECAUTIONS

FIRE PREVENTION

FOR FUEL AND

Lz;exasons of safety, y precautrons.

always

OIL

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

Stop the engine and do not smoke when refueling.

Tighten all fuel and oil tank caps securely.

Refueling and oiling should be made in well ventilated areas.

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

PRECAUTIONS

WHEN

HAND

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

Before removing the radiator cap, stop the engine and let the radiator to release the internal pressure before removing the cap.

cool. Turn the cap slowly

As a result, oil may spurt out when the hydraulic tank cap is removed.

Always turn the cap slowly to release the internal pressure before removing

l-4

the cap.

a

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

6. GENERAL PRECAUTIONS

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

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

-j

CRUSHING OR CUTTING PREVENTION l

as given

below:

}

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

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

Be sure fire extinguishers

have been provided

Provide a first aid kit at the storage

and know how to use them.

point.

Know what to do in the event of a fire.

Be sure you know the phone numbers

of persons you should contact

in case of an emergency.

1-5

a 6. GENERAL PRECAUTIONS

-I

PRECAUTIONS

WHEN

If ROPS is installed,

USING

ROPS

)M$.R~$keFo;ereasons of safety, always ty precautions.

1

the ROPS must never be removed

when

operating

the machine.

The ROPS is installed to protect the operator if the machine should roll over. It is designed not only to support the load if the machine should roll over, but also to absorb the impact energy.

The Komatsu ROPS fulfills all of the regulations and standards for all countries, but if it is rebuilt without authorization or is damaged when the machine rolls over, the strength will drop and it will not be able to fulfill its function properly. It can only display its performance if it is repaired or .. Fe moomed in the specified way.

When

modifying

or repairing

the ROPS, always

contact your Komatsu

distributor.

Even if the ROPS is installed, it cannot show its full effect if the operator belt properly. Always fasten the seat belt when operating.

does not fasten the seat

I

l

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

l

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

l

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

l-6

resulting

manual for the attachment

from the use of unauthorized

attachments

will

7. PRECAUTIONS OPERATION 7.1

DURING

BEFORE STARTING

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

ENGINE

(Also see “12.1.2 CHECKS BEFORE STARTING”

-----

on page 243)

SAFETY AT WORKSITE I

1

I

Before entering the operator’s compartment, personnel and obstructions.

Before starting the engine, thoroughly

walk completely

around the machine and clear the area of

check the area for any unusual conditions

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

of the worksite.

If you need to operate on a street, protect pedestrians and cars by designating traffic duty or by installing barriers around the worksite, If water lines, gas lines, telephone lines, and high-voltage electrical lines may be buried under the worksite, contact each utility and identify their locations. Be careful not to sever or cut any of these lines.

that could be dangerous.

Determine the best

a person for worksite

-

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

See “12.11 PRECAUTIONS Permissible water depth FOR OPERATION” on page 2-67.

1 l l

l l l

l l

FIRE PREVENTION

Carry out the following checks before starting the engine at the beginning of the day’s work.

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

Completely remove all wood chips, leaves, grass, paper and other flammable materials accumulated in the engine compartment and around the battery. Check fuel, lubrication, and hydraulic system for leaks, and a have any leaks repaired. Wipe up any excess oil, fuel or other flammable fluids. Return all containers to their proper place,.

Check for damage to the electrical wiring.

Be sure a fire extinguisher is present and check the method of using it.

Do not operate the machine near any fire or flame.

Check that the coolant level, fuel level and oil level in the engine oil pan.

Check for clogging of the air cleaner.

Check points See “12.1.1 WALK AROUND CHECK” on page 240.

1-7

7.

PRECAUTIONS

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

DURING OPERATION

IN OPERATOR’S

CAB I

I

Do not leave tools, spare parts or personal items lying around in the operator’s compartment. damage, break or jam the control levers or switches. Always put them in their proper place.

They may

Keep the cab floor, controls, steps and handrails free of oil, grease, snow, and excess dirt.

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

NEVER use bleach, dye or solvents on the seat belt because this may weaken the webbing and result in personal injury. Clean the seat belt with warm water and a mild detergent.

ALWAYS use seat belts when operating your machine.

Adjust the operator’s seat to a position where it is easy to carry out operations.

Seat belts + See “12.1.3 ADJUSTMENT BEFORE OPERATION” on page 2-49.

Check that the safety lock is at the LOCK position

and the control levers are at the PARKING

Check that the gauges work properly, For method of checking operation of gauges see “12.1.4 OPERATIONS STARTING ENGINE” on page 2-52.

Know the alternate exit routes from the operator’s compartment

VENTILATION

FOR ENCLOSED

I l

l

--I

1-8

AND CHECKS

position.

BEFORE

for use in an emergency.

AREAS I

If it is necessary to start the engine within an enclosed area, then provide adequate ventilation. fumes from the engine can be FATAL. If you handle fuel or flushing of oil or paint within an enclosed area, then provide adequate ventilation to prevent gas poisoning.

PRECAUTIONS

FOR MIRRORS,

WINDOWS,

Exhaust

AND LIGHTS

l

Remove all dirt from the surface of the windows

and lights to ensure good visibility.

l

Adjust all mirrors to give the best view from the operator’s seat and clean the surface of the mirrors. the mirror glass is damaged, replace it.

l

Check that the head lamps and working lamps are installed to match the operating also that they light up properly. Correct and repair any abnormalities.

conditions.

Check

If

a

~aRshlW&

Fai;ai;o

follow these safety precautions

may lead 7. PRECAUTIONS DURING OPERATION

7.2 OPERATING

MACHINE

WHEN STARTING ENGINE Walk around your machine might be in the way.

NEVER start the engine When

again just before

if a warning

starting the engine,

Start and operate

1 for people

and objects that

to the control.

sound the horn as an alert.

the machine

equipped

it, checking

tag has been attached

only while

seated.

Do not allow any person other than the operator on the machine.

For machines

mounting

in the operator’s

compartment

or any other place

with a back-up alarm buzzer, check that the alarm buzzer works properly.

CHECK WHEN TRAVELING IN REVERSE Before operating the machine or work equipment, do as follows.

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 If necessary, designate a person to check the safety. This is particularly necessary when traveling in reverse. l When operating in areas that may be hazardous or have poor visibility, designate a person to direct worksite traffic. l Do not allow any one to enter the line of travel of the machine.

This rule must be strictly observed even on machines equipped with a back-up alarm or rear view mirror. l

CHECK SAFETY Before traveling or operating, check that the safety curely fixed in the free condition.

bar is se-

PRECAUTIONS WHEN TRAVELING l l

l

Travel on level roads with the bucket 60 - 70 cm (24 - 28 in) above the ground surface.

When traveling on rough ground surfaces, travel at low speed, and avoid sudden turning when changing direction.

If the engine stops when the machine is traveling, the steering will not work. This is dangerous, so apply the brakes immediately and stop the machine.

1-9

g 7. PRECAUTIONS DURING OPERATION

Traveling slipping.

on hills, banks or slopes that are steep could

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

result in the machine

tipping

over or

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

Do not turn on slopes or travel across slopes. Always operations.

go down to a flat place to perform

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

When

traveling

down

a slope,

use the braking

force of the engine

If the engine stops on a slope, depress the brake immediately, parking brake to stop the machine.

When

carrying

a load, travel forward

when

going

these

may allow

and travel slowly.

lower the bucket, and apply the

uphill and in reverse when

going downhill.

CORRECT

INCORRECT

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Going close to high-voltage cables can cause electric shock. Always given below between the machine and the electric cable.

The following actions are effective in preventing accidents.

I) Wear shoes with rubber or leather soles.

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

When carrying machine.

should touch the electric cable, the operator

out operations

Check with the electricity

company

154.0 kV

1

8 m

275.0

I

10 m

kV

cables,

about the voltage

Min. safet Y distance

Voltage

I-10

near high voltage

/ I

27ft 33ft

maintain

the safe distance

too close to the electric cable. should not leave the operator’s

do not let anyone

of the cables

come

before starting

close to the

operations.

g ~~F$JI_~G;~J_J;J$

follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATION

1 PRECAUTIONS WHEN OPERATING

1

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

When making embankments or landfills, or when dropping use the next pile of soil to push the first pile.

soil over a cliff, dump

Be careful not to let the bucket hit the dump truck or the side of the excavated

one pile, then

ditch.

The load suddenly becomes lighter when the soil is pushed over a cliff or when the machine reaches the top of a slope. When this happens, there is danger that the travel speed will suddenly increase, so be sure to reduce the speed.

Always

carry out loading

operations

up-wind

When the bucket is fully loaded, be particularly

to protect yourself

from dust.

sure to avoid sudden starting, turning,

or stopping.

When loading a dump truck, check that there is no one in the area. Be careful also that the load does not drop when it is being loaded.

4

ENSURE GOOD VISIBILITY

t

l

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

lamps and head lamps, and set up lighting

in the

l

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

OPERATE CAREF When working on snow or icy roads, there is danger that the machine may slip to the side on even the slightest slope, so always travel slowly and avoid sudden starting, turning, or stopping.

Be extremely careful when carrying out snow-clearing objects are buried in the snow and cannot be seen.

When traveling

on snow-covered

roads, always

operations.

The road shoulder

install tire chains.

When traveling on snow-covered slopes, never use the brakes to stop the machine Lower the bucket to the ground to stop the machine.

The load will change greatly according to let the machine slip.

and other

suddenly.

to the type of snow, so reduce the load and be careful not

DO NOT HIT WORK EQUIPMENT l

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

under

1-11

a

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

7. PRECAUTIONS DURING OPERATION

METHOD OF USING BRAKES

your foot on the brake pedal unless necessary.

l

Do not put

l

Do not depress

the brake pedal repeatedly

l

When

downhill,

traveling

use the engine

unless necessary. as a brake, and always

use the right brake pedal.

WORKING ON LOOSE GROUND n.._:_J

nvuu

^_^__~L:____

____..

uf.maa~~~~y yuur

.___

_I_:.__

_I___

~z~acrt~f~aLUU uuse A-

_

._

&_I__

__a___

LU LII~ auye

_.__I _I_-__ _IlA_L__ IJz2.L-,_+ _.B:Lc_ UI L~~~~s,overiiaiigs,arlu uaap u~~c;lita.11 uIe:3e

areas collapse, your machine could fall or tip over and result in serious injury or death. Remember that the soil after heavy rain or blasting is weakened in these areas.

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

Install the HEAD GUARD

(FOPS) if working

in

areas

When operating in places where there is danger over, always install ROPS and a seat belt.

4

PARKING THE MACHINE

under the weight

where there is danger of falling rocks and dirt.

of failing

rocks or danger of the machine turning

1

Park on level ground whenever wheels to prevent the machine

possible. If the machine frorp moving.

must be stopped

ThrUSt

on a slope, block the

the

bucket

~~26376

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

Parking procedure + See “12.13 PARKING MACHINE”.

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

Always take the key with you.

Work equipment posture - See “12.13 PARKING MACHINE”.

Places to lock + See “12.17 LOCKING”.

1-12

a

~$sMgZi;

FaiJaizo

follow these

safety

precautions

may

lead 7. PRECAUTIONS

7.3

DURING

OPERATION

TRANSPORTATION SHIPPING

l

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

the

1-13

ty precautrons.

7. PRECAUTIONS DURING OPERATION

7.4

BATTERY BAlTERY

l

l

l

0 l

l l l l l

HAZARD PREVENTION

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

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

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

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

Call a doctor or poison prevention center immediately.

When working with batteries. ALWAYS wear safety glasses or goggles. arlii is Batteries generate hydrogen gas. iiycirogeri gas is very EXPiGSiVE, small spark or flame.

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

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

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

Tighten the battery cap securely.

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

ig,iiieii

wi~i-,

a

STARTING WITH BOOSTER CABLES ALWAYS When

wear safety glasses or goggles

starting

from another

machine,

when

starting

the machine

do not allow the two machines

Be sure to connect the positive (+) cable first when installing ground or negative (-1 cable first when removing them.

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

Connect

the batteries

in parallel:

positive

to positive

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

with booster to touch.

the booster cables.

1-14

Disconnect

the

and the chassis, it will cause sparks. This is

and negative

of the machine

to negative.

to be started,

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

INCORRECT

cables.

(3

be sure to connect

a

~~~~!~~;

FaiLai;~$ follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATION

7.5 TOWING

1

WHEN TOWING, FIX WIRE TO HITCH PIN Towing

in the wrong

way may lead to serious

When using another machine weight of this machine.

Never tow a machine Do not use any towing

personal

to tow this machine,

injury or damage.

use a wire

rope with ample

strength

for the

on a slope. rope that has kinks or is twisted.

Do not stand astride the towing

cable or wire

rope.

When connecting a machine that is to be towed, do not let any one come between the towing machine and the machine that is being towed.

Set the coupling of the machine being towed in a straight line with the towing portion of the machine, and secure it in position.

Towing method -

See “16. TROUBLESHOOTING�.

1-15

8. PRECAUTIONS MAINTENANCE

8.1 4

FOR

BEFORE CARRYING WARNING

TAG

A )W$.~.;‘$iie Fo;ereasons

of safety, always ty precautrons.

OUT MAINTENANCE

1

If others start the engine or operate the controls you could suffer serious injury or death.

while you are performing

service or lubrication,

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

These tags are available

_i 0

PROPER TOOLS

from your Komatsu

(Part No. 09963-03000)

1

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

Tools + See “21.1 INTRODUCTION

1-16

distributor.

low quality,

OF NECESSARY TOOLS”.

faulty,

or makeshift

tools could

a bV$RbJbJ~G;~;;;;~&;

follow these safety precautions

may lead 8. PRECAUTIONS FOR MAINTENANCE

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Replace the following Fuel system: Hydraulic system:

fire-related components periodically: Fuel hose, spilling hose, and fuel tube cap Pump outlet hose

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

Replace or repair any such components the time specified.

of whether

or not they appear

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

Replacement of safety critical components

+

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

STOP THE ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Always stop the machine on firm flat ground and stop the engine before carrying out inspection and maintenance.

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

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

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

LOCK FRONT AND

REAR FRAMES

Lock the front and rear frames

-j

with the safety bar.

WORK EQUIPMENT SUPPORT

1

When carrying out inspection and maintenance with the work equipment raised, fit a stand under the lift arm securely to prevent the work equipment from coming down. In addition, set the work equipment control levers to the HOLD position and lock with the safety lock.

I-17

a 8. PRECAUTIONS FOR MAINTENANCE

8.2

DURING

~~~~;~~~eFooeeasons cf safety, always y precautrons.

MAINTENANCE

PERSONNEL l

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

Extra precaution

should be used

ATTACHMENTS l

1

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

WORK

UNDER

THE MACHINE

in a safe place so that they do not

1

l

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

l

Always

l

Never work under the machine

block the tires of the machine

or to their

lowest

position

before

securely.

if the machine

is poorly supported.

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

Always keep your machine clean and tidy.

because they may cause

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

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

I-18

A ;$FW~G;Fhi;hi;;tto

follow these safety precautions may lead 8. PRECAUTIONS FOR MAINTENANCE

RULES TO FOLLOW WHEN ADDING FUEL OR OIL l

Spilled

fuel and oil may cause you to slip, so always

wipe

it up immediately.

l

Always

tighten

l

Never

l

Always

l

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

Slowly loosen the caps to relieve pressure before removing

the cap of the fuel and oil fillers securely.

use fuel for washing

any parts.

add fuel and oil in a well-ventilated

place.

I

l

l

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

If such lighting equipment is not used, there is danger

and allow the engine

always

use lighting

and radiator

with anti-explosion

of explosion.

PRECAUTIONS WITH BA-ITERY l

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

remove the negative

1-19

A ~~,4$~~~eFo;ereasons of safety, always ty precautrons.

8. PRECAUTIONS FOR MAINTENANCE

HANDLING

HIGH-PRESSURE

HOSES

l

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

l

Always

l

Do not forget that the work equipment

l

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

l

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

l

If you are hit by a jet of high-pressure

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

circuits are always

oil, consult

before completely

a doctor immediately

releasing the

for medical

attention.

AT

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

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

Clean inside or cooling system, check lubricating Check cooling

I-20

under pressure.

or inspection

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE HIGH TEMPERATURE OR HIGH PRESSURE l

Do not use any bent or cracked

water

level, engine

Checking

hydraulic

oil level, adding

Changing

oil, replacing

filters

oil level, add oil -+ see “24.2 WHEN

REQUIRED”.

oil pan, oil level, brake oil level, add oil or water + see “24.3 CHECK BEFORE STARTING”. oil + see “24.5 PERIODIC

+ see “24.7 - 9 PERIODIC

MAINTENANCE”.

MAINTENANCE”.

a

follow these safety precautions

g$RN;;G;I?;-;e$o

may lead 8. PRECAUTIONS

rotating

parts and be careful

not to let anything

get caught

FOR MAINTENANCE

l

Keep away from

in them.

l

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

WHEN OPERATING WITH CHASSIS RAISED l

l

1

When carrying out operations with the work equipment or chassis frames with the safety lock, always place the control levers in the control levers with the safety lock, and block the work equipment Always fit blocks underthe wheels on the opposite side when jacking up the machine, set blocks under it to hold it in position.

TIRE MAINTENANCE

raised, lock the front and rear HOLD position, then lock the and chassis. up the machine. After jacking

1

Disassembly, repair, and assembly of tires requires specialist equipment specialist tire repair shop to carry.out repairs.

rf

WASTE MATERIALS

}

I

I

and skill, so please ask your

I

l

Never dump waste

oil in a sewer

l

Always

l

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

put oil drained

system,

from your machine

rivers, etc. in containers. disposing

Never drain oil directly on the ground. of harmful

objects

such as oil, fuel,

INCORRECT

1-21

a 8. PRECAUTIONS FOR MAINTENANCE

)M$.R$~,“,:,~;e6zasons of safety, y precautrons.

always

8.3 TIRES HANDLING

TIRES

If tires are not used under the specified conditions, they may overheat and burst or be cut and burst by sharp stones on rough road surfaces. This may lead to serious injury or damage.

To maintain safety, always keep to the following conditions.

Inflate the tires to the specified pressure. Abnormal heat is generated particularly when the inflation pressure is too low. + See “12.18 HANDLING THE TIRES”.

Suitable inflation pressure Avoid overioading.

Suitable load + Normal

load for bucket:

18900 kg (41675 lb) (When 10.5 m3 (13.7 cu.yd) standard

bucket is installed)

Use the specified tires.

The values given in this manual for the tire inflation pressure and permissible speed are general values. The actual values may differ depending on the type of tire and the condition under which they are used. For details, please contact your Komatsu distributor or tire maker.

If the tire is heated when installed to the wheel, flammable gas is produced. If this catches fire, the tire may explode and cause serious injury or damage. Unlike when a tire is punctured and burst, if a tire explodes, it produces a highly destructive force, so the following operations are strictly prohibited when the tire is installed to the wheel. l Welding of the rim l Lighting fires or carrying out welding operations near the wheel or tire

If you do not understand the proper procedure for carrying out maintenance or replacement of the wheel or tire, and you use the wrong method, the wheel or tire may burst and cause serious injury or damage. When carrying out such maintenance, please consult your Komatsu distributor or tire maker.

1-22.

A E;RNI_;r$

F,“;y;;o

follow these safety precautions

may lead 8. PRECAUTIONS FOR MAINTENANCE

STORING TIRES AFTER REMOVAL As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter. If the tires are stored outside, always erect a fence around the tires and put up “No Entry” and other warning signs that even young children can understand.

Stand the tire on level ground,

and block it securely

so that it cannot

roll or fall over.

If the tire should fall over, get out of the way quickly. The tires for construction extremely heavy, so trying to hold the tire may lead to serious injury.

60” - 70” AZ0355W

equipment

are

Axanm

l-23

9. POSITION FOR ATTACHING

SAFETY LABELS

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

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

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

9.1

POSITION

FOR ATTACHING

SAFETY LABELS

I View W

View Y

l-24

9. POSITION FOR ATTACHING SAFETY LABELS

1.

Precautions when (09653-03000)

I.

ALWAYS

STOP

REMOVING 2. Do

3.

NOT

ENGINE

tank cap

WHEN

CAP WHEN

LOOSEN

OIL

IEMPERATURE

IS HIGH.

IF LOOSENED.

OIL MAY GUSHOUT.

SLOWLY

HYDRAULIC

NAl

hydraulic

CAP.

OPEN

T,ANK CAP AND

6.

removing

PRESSURE

OIL

RELEASE

INIER-

COMPLETELY.

DO NO1 OPEN DRAIN

PLUG WHEN

10965303000011 TEMPERATURE

2.

IS HIGH.

Precautions when (427-93-11520)

connecting

iEN ME MlERlES

or disconnecting

battery

ARE DRAINED

cable

TO EACHOTHER.

RNlTHDRPllNEDBA

ICLE CARI

CONNECTTHE POSlTlVETERMlNALSTO EAC” OTHER. ,“SETHEB~~RESOFANOTHEA”EHlaE~EG”IPPEOWI~H21”BA~RIESITOSTARTTHEENGINE.CONNECTME BOOSTERCABLE: THE ORDERSHOWNABOVE. TERSTARTINGTHE ENGINE, MSCONNECTTHE BOOSTER CABLES INTHE REVEASEORDERINWHlCHTHEYWERE CONM’XO. IR DETAILS, SEE OPERATlON AND MAINTENANCE

3.

Precautions when (09668-03000)

DO

NOT

WATER IF

LOOSEN

CAP

TEMPERATURE

LOOSENED.

MAY

GUSH

INTERNAL

removing

WHEN IS

BOIUNG OUT

BECAUSE

HIGH. WATER OF

HIGH

PRESSURE.

09668-03000-

FMNUAL

radiator

cap

427-9%1,520

4.

Precautions when (362-54-27390)

,

engine

is running

WHILE ENGINE IS RUNNING: KEEP AWAY FROM FAN AND FAN-BELT. 362-54-27390 l-25

9. POSITION FOR ATTACHING SAFETY LABELS

8.

:eep Out (423-93-11420)

FRONT AND REAR FRAMES CAN PIVOT RAPIDLY-STAY CLEAR OF TIRES AND CENTER HINGE AREA WHILE ENGINE IS RUNNING. DONOT !xFALk OKath3ovt rn,cOCiAL Precautions for articulate (362-98-12160)

Precautions for operation (362-98-12 150)

or maintenance

1. WHEN STARTING THE MACHINE OR TRAVELING OBSERVE THE FOLLOWING.

WHEN

II) WHEN WITH BACK-HOE WITHDRAW OUTRIGGER PERFECTLY. (2) CHECK EACH GAUGE AND PILOT LAMP. -.. .._ ^_.__ Ai\iD DlH”, (3) RELEASE ~AH~QIIV~ BRAKE MACHINE. (4) USE PARKING BRAKE ONLY AFTER MACHINE HAS STOPPED COMPLETELY, EXCEPT IN EMERGENCIES. (5) WHEN DESCENDING A SLOPE TRAVEL AT A SPEED SUFFICIENTTO ASCEND THE SLOPE, AND DO NOT SET THE GEARSHIFT LEVER IN NEUTRAL.

lock

2. WHEN CARRYING OUT MAINTENANCE:

MAKE

SURE OF SETTING

LOCK

TO FIX

THE FRONT/REAR

IN THE COLLOWNG 1. INSPECTION CENTER

ITS

VICINITY.

2.TRANSPORTlNG 3. HOISTING BEFORE

START

DISCONNECT

FRAMES

CASES. AND

THE

(1) PARK THE MACHINE ON LEVEL GROUND. (2) LOWER WORK EQUIPMENT ON THE GROUND AND LOCK THE LEVER. (3) DO NOT GO UNDER MACHINE WHEN IT IS RAISED BY THE WORK EQUIPMENT.

THE ARllCUiATE

OF

MAINTENACE THE

VEHICLE

IN AND

362-98-12150

-

VEHICLE.

9.

VEHICLE. A DRIVE ARTICULATE

MAKE

SURE

OF

Precautions temperature

with torque converter (419-93-I 1980)

oil

LOCK. 362-90~12160

Precautions when starting engine machine (421-93-11940) _ _

or leaving

READ THE OPERATION & MAINTENANCE MANUAL FOR SAFETY OPERATION AND ALWAYS PAY MAXIMUM ATTENTION FOR SAFETY. 1. WHEN STARTING THE ENGINE OR LEAVING THE MACHINE. ANYTIME FOLLOW THE PROCEDURE DESCRIBED BELOW. (1) PLACE THE DIRECTION LEVER IN NEUTRAL POSITION IN).

(2)APPLY THE PARKING BRAKE. 13) LOWER THE BUCKET (OR THE FORKS, ETC.) TO THE GROUND AND APPLY THE CONTROL LEVER LOCK. (4) STOP THE ENGINE. ‘;IIES;;; ;E;t$ FOR 5 MINUTES PRIOR !. WHEN PARKi& AT’ INCLINED PLACE. ADDING To THE ABOVE DESCRIBED, APPLY THE WHEEL STOPPERS FOR BOTH WHEELS (FRONT OR REAR).

121-93-l,940

I-26

NORMAL OPERATING CONDITIONS, I. UNDER INDICATOR LIGHTS SHOULD REMAIN IN THE GREEN RANGE. 2. IF THE INDICATOR LIGHT MOVES INTO THE RED RANGE ON WORKING OR PROLONGED TRANSPORT DRIVING, REDUCE LOAD OR DECREASE MACHINE SPEED BY DOWNSHIFT OR REDUCING ENGINE SPEED. 3. IF THE ALARM BUZZER SOUNDS AND WARNING LAMP FLASHES DUE TO FURTHER OPERATION, STOP THE MACHINE AND RUN THE ENGINE AT MIDRANGE SPEED WITH NO LOAD UNTIL THE INDICATOR LIGHT GOES INTO THE GREEN RANGE. IF THE INDLCATOR LIGHT REMAINS IN THE RED RANAGE. DETERMINE THE CAUSE OF THE PROBLEM. 419-93-11980

-

9. POSITION FOR ATTACHING SAFETY LABELS

Precautions for joy stick steering (428-S33-A160)

JOYSTICK STEERING PRECAUTIONS

A

A A

JOYSTICK CONSOLE SHOULD BE MOVED AND LOCKED IN REARMOST POSITION BEFORE ENTERING OR LEAMNG SEAT. OBSERVE LED UGHT ON DASH TO CONFIRM THE TRANSMISSION DlRECTlON SELECTION. JOYSTlCK ON-OFF SWITCH Sl3lING SHOULD BE SWITCHED OULY WHEN THE MACHINE IS STOPPED AND IN NEUTRAL

L02AD256

I-27

9. POSITION

MEMO

l-28

FOR ATTACHING

SAFETY

LABELS

OPERATION

10. GENERAL VIEW

10.1

GENERAL VIEW OF MACHINE

If directions diagram below.

are indicated

in this section,

they

refer to the directions

Lift

arm

Head

iamD

shown

Turn

by the arrows

signal

lami,

whee

Front

I Bucket

in the

I

\ Front

wheel

Left

AE42859B

IO.

10.2 GENERAL VIEW OF CONTROLS

GENERAL

VIEW

AND GAUGES Machine Air conditioner

Hazard Horn button \ Directional

control

panel

lamp switch \

Parking

lever

brake switch Working

Transmission cut-off selector

lamp switch

Preheater

Engine low idling selector switch Speed control lever

switch

Lamp switch Turn signal lever Dimmer switch Starting >

switch

Kickdown

switch

- Lift arm control

L\\\w

Bucket control Safety

column

Brake pedals

Accelerator

lever

lock lever

-Cigarette Steering

lever

lighter

pedal

tilt lever MO30101

Turn signal uel level monitor Brake oil leve Brake line failure Engine cooling water temperature

Engine

Radiator coolant level monitor

Coolant

oil pressure

temperature

Torque converter oil temperature monitor

Torque converter oil temperature

-ransmission cutielector pilot lam

Service

meter

operation

monitor

2-3

11. EXPLANATION

OF COMPONENTS

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

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

11.1

MACHINE

MONITOR

The machine monitor system consists of the caution displays (A, B, C, E) and the meter display (D).

WARNING A.

DISPLAYS (A, B, C, E) (11.1.1)

CHECK items (brake oil level, engine oil level, radiator coolant level) B. CAUTION items (battery charge, fuel level, transmission oil filter) C. Emergency CAUTION items (brake line failure, engine oil pressure, radiator coolant level, air pressure, engine coolant temperature, torque converter oil temperature, emergency steering operation) E. Centralized warning lamp The caution display consists of the following.

2-4

11. EXPLANATION OF COMPONENTS

METER DISPLAY (D) (11.1.2) This consists of the meters (torque converter oil temperature gauge, engine water temperature gauge, air pressure gauge, fuel gauge, speed meter, service meter) and the pilot lamps (parking brake, working lamp, engine pre-heating monitor, transmission cutoff selector, turn signal, and high beam).

CHECK OPERATION OF MACHINE MONITOR SYSTEM To check the monitor system, turn the starting switch to ON before starting the engine. Then all the monitor lamps, the gauges and the warning lamp light up for about 3 seconds and the alarm buzzer sounds for about 1 second. Three figures, 188, are displayed on the speedometer while the monitor system is being checked.

After that all lamps go off and the buzzer stops. If any monitor lamp does not light up, ask your Komatsu distributor to inspect that monitor lamp.

When the starting switch is turned to ON, if the directional lever is not at neutral, the warning lamp will flash and the alarm buzzer will continue to sound. If this happens, return the lever to neutral. The lamp will go out and the buzzer will stop.

To check the monitor immediately when the engine is stopped, wait for at least 30 seconds after the engine is stopped.

2-5

11. EXPLANATION OF COMPONENTS

11 .I .I WARNING

DISPLAYS

L-

A.

CHECK ITEMS

A

WARNING

If these monitor lamps flash, carry out inspection and maintenance of the problem location as soon as possible.

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

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

If any abnormality is found in the CHECK items before starting the engine, the monitor for the location of the abnormality will flash.

Check the location where the monitor is flashing and carry out checks before starting.

When the engine is started, these monitor lamps will go off even if there are abnormalities.

Do not ‘carry out the checks before starting using only the monitor; always carry out also the items specified for the periodic maintenance.

1.

BRAKE OIL LEVEL MONITOR This monitor indicates a low brake oil level.

If the monitor lamp flashes, check the oil level and add brake oil as required.

2-6

11. EXPLANATION OF COMPONENTS

2.

ENGINE OIL LEVEL MONITOR This monitor indicates a low oil level in the engine oil pan.

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

3.

RADIATOR COOLANT LEVEL MONITOR This monitor indicates a low radiator coolant level.

If the monitor lamp flashes, check the coolant level and add water as required.

B.

CAUTION

ITEMS

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

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

If any abnormality occurs while the engine is running, the appropriate monitor lamp and the warning lamp will flash to indicate the abnormality at the same time.

Even if any monitor lamp flashes, the machine can operate, but it should be repaired as soon as possible.

1.

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

If the monitor lamp flashes, check the charging circuit.

When the engine is running or when the engine is started, the monitor and the warning lamp may flash. However, if the lamps go out when the engine is accelerated momentarily, there is no abnormality.

-+ I ii&%

1

2.

FUEL LEVEL MONITOR This monitor indicates there is less than 265 liters (70.0 US gal, 58.3 UK gal) of fuel in the tank.

If the monitor lamp flashes, add fuel.

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

2-7

11. EXPLANATION OF COMPONENTS

3.

TRANSMISSION OIL FILTER MONITOR This monitor indicates clogging of the transmission oil filter.

If the monitor lamp flashes, replace the filter element.

C.

EMERGENCY

CAUTION

ITEMS

it at low idling and carry out the following

action.

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

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

If any abnormality occurs while the engine is running, the appropriate monitor lamp and the warning lamp will flash and the alarm buzzer will sound intermittently at the same time.

However, when the emergency steering is being operated, only the monitor will flash. The alarm buzzer will not sound, and the warning lamp will not light up.

If any monitor lamp flashes, stop the work, and repair it immediately.

1.

BRAKE LINE FAILURE MONITOR This monitor indicates a drop in the brake oil pressure when the brakes are operated.

If the lamp flashes, stop the machine immediately and check the brake system.

After checking and repair of brake system, push in the overstroke sensor rod on the brake chamber. If this operation is not done, a buzzer and lamp will continue to warn of brake line trouble.

2.

ENGINE OIL PRESSURE MONITOR This monitor indicates a low engine oil pressure.

If the lamp flashes, the engine oil pressure is below the lower limit. Immediately stop the engine.

This monitor lamp flashes and the alarm buzzer sounds when the starting switch is turned to ON immediately after the engine is started or immediately before the engine is stopped. It does not indicate an abnormality.

3.

COOLANT LEVEL MONITOR This monitor indicates a low radiator coolant level.

Check the coolant level when the monitor lamp flashes, stop engine and add water as required.

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

2-8

11. EXPLANATION OF COMPONENTS

4.

AIR PRESSURE MONITOR

This monitor indicates a drop in the air pressure in the air tank.

If the lamp flashes, increase the engine speed and wait until the i.amp goes out.

5.

COOLANT TEMPERATURE MONITOR

This monitor indicates a rise in the cooling water temperature.

When the monitor lamp flashes, stop the machine and run the engine with no load at midrange speed until the green range of the engine water temperature gauge lights.

6.

TORQUE CONVERTER OIL TEMPERATURE MONITOR

This monitor indicates a rise in the torque converter oil temperature.

When the monitor lamp flashes, stop the machine and run the engine with no load at midrange speed until the green range of the temperature gauge lights.

b Dl

7.

EMERGENCY STEERING OPERATION MONITOR If the engine stops while the machine is traveling or an abnormality occurs in the pump circuit, this flashes to warn the operator that the emergency steering is in operation. When flashing begins, stop the machine immediately.

E.

CENTRALIZED WARNING LAMP

This lamp will flash when the machine is in the following condition. l When an abnormality has occurred in any B. CAUTION item.

If the machine is in the following condition, the lamp will flash, and the alarm buzzer will sound intermittently at the same time. l When an abnormality has occurred in any C. CAUTION item. l When the parking brake is applied but the directional lever is not at neutral.

2-9

11. EXPLANATION OF COMPONENTS

11.12 D: METER DISPLAY PORTION

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

1.

2.

PARKING BRAKE PILOT LAMP This lamp lights up when the parking

PliOT LAMP FOR WORKING LAMP This lamp lights up when the working

2-10.

brake is applied.

lamps are switched

on.

11. EXPLANATION OF COMPONENTS

3.

ENGINE PRE-HEATING MONITOR

When using the electrical intake air heater and when starting, switch on lamp and you will be informed that pre-heating has started.

4.

TRANSMISSION

CUT-OFF SELECTOR PILOT LAMP

This lamp lights up when the transmission cut-off selector switch is turned to ON. If the monitor lamp is ON and the left brake pedal is depressed, the transmission will be returned to neutral.

5.

TURN SIGNAL PILOT LAMP

When the turn signal lamp flashes, the pilot lamp also flashes.

If the wiring of the turn signal lamp is disconnected, the pilot lamp will flash faster.

6.

HIGH BEAM PILOT LAMP This lamp lights up when the head lamp is at high beam.

2-11

11. EXPLANATION OF COMPONENTS

1

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

If the temperature is normal during operation, the green range will light. If the red range lights during operation, stop the machine and run the engine with no load at midrange speed until the green range lights.

If the top lamp in the red range lights up, the alarm buzzer will sound, the warning lamp will light up and the torque converter oil temperature monitor lamp will flash at the same time.

7.

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

If the indicator goes out of the green range, do as follows. l If the engine water temperature is in the red range, release the accelerator pedal slightly and lower the water temperature to the green range. l If the top lamp in the red range lights up, the alarm buzzer will sound, the warning lamp will flash and the coolant temperature monitor lamp will flash at the same time. l If there is frequent overheating, check the radiator for clogging.

Red

Green

8.

9.

AIR PRESSURE GAUGE

This gauge indicates the air pressure in the air tank. The green range should be lighted during normal operation.

If the red range lights up during operations,-the alarm buzzer will sound, the warning lamp will flash, and the air pressure monitor lamp will flash.

If this happens, stop the machine, increase the engine speed and wait until the green range lights up. if the air pressure drops even lower, the parking brake will be automatically applied.

2-12

Red Green White

Red

Green

Red

11. EXPLANATION OF COMPONENTS

10. FUEL GAUGE This gauge indicates the amount of fuel in the fuel tank. If there is enough fuel in the tank while the engine is running, the green range lights. If the red range lights, there is less than 265 liters (70.0 US gal, 58.3 UK gal) of fuel in the tank.

When the red range lights, add fuel.

Green

F

B Red

E

11. SPEEDOMETER This meter indicates

A speedometer

the travel speed

of the machine.

for MPH is also available.

12. SERVICE METER This meter shows the total operation hours of the The service meter advances while the engine is running machine is not traveling.

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

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

machine.

- even if the

/

the service is operated

2-13

11. EXPLANATION OF COMPONENTS

11.2

1.

SWITCHES

STARTING SWITCH This switch

is used to start or stop the engine.

OFF position The key can be inserted and removed at this position. When the key is turned to this position, the electric circuit is turned off and the engine stops.

The hazard lamp, the parking lamp and the room lamp will remain on, however, when the switch is turned OFF. ON position Electric current flows in the charging, lamp and accessary circuits.

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

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

2-14

11. EXPLANATION OF COMPONENTS

2.

LAMP SWITCHES

The monitor Position Position Position

head lamps, side clearance lamps, tail lamps, machine lighting, and parking lamp light up. @ * PE : Parking lamp lights up.

OFF @ -. l : Lamps go off. @ 3.0~ : Clearance lamps, tail lamps and machine monitor lighting light up. : Head lamps light up in addition to the lamps in Position @ 3~. position @ 30.4~ .

REMARK The lamp switch can be operated the lever.

2.

regardless

of the position

of

TURN SIGNAL LEVER

This lever operates the turn signal lamps.

LEFT TURN: Push lever FORWARD. @ RIGHT TURN: Pull lever BACK.

@

REMARK

l

When the lever is operated, the turn signal pilot lamp will also light up.

When the steering wheel is turned to the neutral position, the turn signal lever will return automatically to OFF. If not, return the lever to OFF manually.

2.

DIMMER SWITCH

l

This switches the head lamp between @ Low beam iZ@ High beam

F06, //

high beam and low beam.

2-15

11. EXPLANATION OF COMPONENTS

3.

TRANSMISSION

CUT-OFF

SELECTOR

SWITCH

brake pedal. Then depress the accelerator the left brake pedal to start the machine

pedal while off slowly.

releasing

This switch selects the operation of the left brake pedal. Normally, put this switch in the ON position.

0 OFF: Acts as normai brake (iike right brake pedaij. @ ON: Acts as normal brake, but also switches transmission to NEUTRAL.

, /P’

\

(,

\

@ .&$q%

If the switch is at ON, the transmission will light up.

cut-off selector

“-

a

pilot lamp

\ \

19161 4.

ENGINE LOW IDLING SELECTOR SWITCH The engine low idling speed can be switched between two levels. @ OFF: This sets the engine low idling speed to approx. 650 rpm.

This is used for normal operations at low idling, such as when waiting for dump trucks. @ ON: The engine low idling speed is set to approx. 850 rpm. This is used on busy jobsites where it is necessary to reduce the cycle time.

5.

PREHEATER SWITCH This actuates an electric heater to heat the intake engine.

Normally, put this switch in the AUTO position.

0 OFF position: @ AUTO position:

@ ON position:

air for the

The automatic preheating circuit is not actuated.

When the ambient temperature is bleow approx.

-5”C, preheating is automatically carried out in accordance with the ambient temperature.

If the switch is moved beyond the AUTO position, preheating is carried out.

This is used to carry out preheating when the weather is extremely cold and the engine will not start with normal automatic preheating, and is also used for post-heating after starting the engine.

If the switch is released when at the ON position, it will automatically return to AUTO. Method of using preheater switch, refer to the section “12.2.2 STARTING IN COLD WEATHER”.

2-16

-,$ &&

, ,/ \

0

&,I‘\ Q \

Fpggz

11. EXPLANATION OF COMPONENTS

6.

WORKING

LAMP SWITCH

When the front and rear working lamps are turned ON, the pilot lamp and illumination lamp for monitor panel will also light up.

OFF

Even if the parking brake switch is turned ON, there is danger until the parking brake pilot lamp lights up, so keep the brake

@ @

This switch operates the parking brake.

ON position: The parking brake is applied, brake pilot lamp lights up.

OFF position:The parking brake is released.

and

the

parking

REMARK l If the directional lever is placed in F (FORWARD) or R (REVERSE) with the parking brake applied, the warning lamp will flash and the alarm buzzer will sound. l When the starting switch is turned to OFF, the parking brake is automatically applied.

Before starting the engine, turn the parking brake switch to ON, then turn it to OFF. l The machine does not start when the directional lever is operated with the parking brake applied.

NOTICE l Never use the parking brake switch to apply the brakes when traveling, except in an emergency. Apply the parking brake only after the machine has stopped. l If the parking brake has been used as an emergency brake when traveling at high speed (near the maximum speed), contact your Komatsu distributor to have the parking brake checked for any abnormality.

2-17

11. EXPLANATION OF COMPONENTS

8.

HORN BUTTON When the button in the center of the steering the horn will sound.

9.

HAZARD

wheel

is pressed,

LAMP SWITCH

WARNING g Use the hazard lamps only in emergencies.

Using the hazard lamps when traveling will cause problems for other machines.

This switch is used in emergencies, breaks down.

ON: All turn signal lamps flash.

I

such as when the machine

REMARK When this switch is turned to the ON position, the turn direction indicator lamps and turn indicator pilot lamp flash, and display lamp @ lights up at the same time.

10. ClGARElTE LIGHTER This is used to light cigarettes.

To use, push the lighter in. After the few seconds it will spring back.

At that time, remove the lighter and light your cigarette.

I

11. KICKDOWN SWITCH When the speed control lever is in 2nd, and the switch at the top of the knob of the lift arm control lever is pressed, the gear will shift down to 1st.

This switch operations.

is used to increase

the drawbar

pull in digging

REMARK To cancel the kickdown switch, move the directional lever to REVERSE or NEUTRAL, or move the speed control lever to any position except 2nd. It is also possible to cancel the kickdown switch by operating the parking brake switch or by turning the starting switch OFF.

2-18

J

11. EXPLANATION OF COMPONENTS

12. REAR WIPER SWITCH This actuates the rear wiper.

ON position: Actuated Turned to right: Washer liquid is sprayed

I

.f-

i

out.

‘-

ON

-OFF

13. FRONT WIPER SWITCH This actuates the front wiper.

Position 0: Wiper moves at low speed Position 0: Wiper moves at high speed Turned to right: Washer liquid is sprayed

out.

14. ROOM LAMP SWITCH This lights up the room lamp.

On position: Lights up

I

OFF a

ON

I

__--r$=f==J---

2-19

11. EXPLANATION OF COMPONENTS

11.3

1.

CONTROL

LEVERS, PEDALS

DIRECTIONAL LEVER

This lever is used to change the direction machine.

The engine cannot be started if the directional (neutral).

Position Position Position

@ N @

of travel

lever is not at N

: Forward : Neutral : Reverse

When operating the directional lever, hold the steering and operate the directional lever with your fingers.

2-20

of the

wheel

11. EXPLANATION OF COMPONENTS

REMARK The length of the lever can be adjusted freely within a range of 43 mm (1.69 in) for dimension e. To adjust, pull out knob 0, loosen locknut 0, then turn bolt @ to adjust. After adjusting, tighten locknut 0, then push knob @I in fully.

Set dimension ! to within 43 mm (1.69 in). If it is longer than this, the remaining thread is too short, and there is danger that it may come out.

2.

SPEED CONTROL LEVER

This lever controls the travel speed of machine.

This machine has a 3-FORWARD, 3-REVERSE speed transmission. Place the speed control lever in a suitable position to obtain the desired speed range.

1st and 2nd speeds are used for working.

3rd speed are used for traveling.

However, when the speed control lever stopper is being used, it is impossible to shift to 3rd. Disengage the speed control lever stopper before trying to shift gear.

Position 0: Position 0: Position 0:

1st 2nd 3rd

2-21

11. EXPLANATION OF COMPONENTS

REMARK The length of the lever can be adjusted freely within a range of 43 mm (1.69 in) for dimension !. To adjust, pull out knob 0, loosen locknut 0, then turn bolt @ to adjust. After adjusting, tighten locknut 0, then push knob 0 in fully.

Set dimension I! to within 43 mm (1.69 in). If it is longer than this, the remaining thread is too short, and there is danger that it may come out.

3.

SPEED CONTROL LEVER STOPPER

This stopper prevents the speed control lever from entering 3rd position when working.

Position 0: Stopper actuated.

Position 0: Stopper released.

4. @

@ @

@

2-22

the

LIFT ARM CONTROL LEVER This lever is used to operate the boom.

RAISE ( v 1: When the lift arm control lever is pulled further from the RAISE position, the lever is stopped in this position until the lift arm reaches the preset position of the kick-out, and the lever is returned to the HOLD position.

HOLD ( S ): The lift arm is kept in the same position.

LOWER ( a 1 FLOAT ( & ): The lift arm moves freely under external force.

@

11. EXPLANATION OF COMPONENTS

5.

BUCKET CONTROL This lever operates

@ TILT (

‘a

HOLD ( & DUMP ( L

@ @

LEVER the bucket.

1: When the bucket control

lever is pulled further from the TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, and the lever is returned to the HOLD position. ):The bucket is kept in the same position.

)

Tilt Dump

6.

SAFETY

LOCK LEVER

A l

l

l

WARNING

1

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

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

When parking the machine or carrying out maintenance, always lower the bucket to the ground and apply the lock.

This is used to lock the work equipment levers.

Push the lever forward to set it to the lock position.

7.

ACCELERATOR PEDAL This pedal controls the engine speed and output. The engine speed can be freely controlled between low idling and full speed.

2-23

11. EXPLANATION OF COMPONENTS

8.

BRAKE PEDALS

l

l l

When traveling downhill, use the engine as a brake, and always use the right brake pedal.

Do not use the brake pedals repeatedly unless necessary.

Do not put your foot on this pedal unless necessary.

c Right brake pedal The right brake pedal operates the wheel normal braking.

brakes, and is used for

Left brake pedal The left brake pedal operates the wheel brakes, and if the transmission cut-off selector switch is at ON, it also returns the transmission to neutral.

If the transmission cut-off selector switch is at OFF, the left brake pedal acts in the same way as the right brake pedal.

REMARK When the accelerator is being used for operating the work equipment, always use the left brake pedal to slow or stop the machine after putting the transmission cut-off selector switch to the ON position.

2-24

11. EXPLANATION OF COMPONENTS

11.3.1

ENGINE MECHANICAL

STOP LEVER HANDLES

These stop levers are used to stop the engine if the engine cannot be stopped by the key of the starting switch when an abnormal failure occurs in the electrical circuit. The stop levers shut off the fuel supply at the fuel injection pump.

I 8

OFF: 2 ON:

Fuel is not supplied Fuel is supplied

To pull the lever, first turn the handle in the left or right direction to unlock the handle then, pull the lever.

For normal operation,

Stop Lever at Right Side of Cab Floor

keep the stop levers in the ON position.

When it is necessary to use these stop levers, correct the situation contacting your Komatsu distributor.

L12BVO78

by

If the engine is stopped using these stop levers, bleed the air from the fuel system, before starting the engine again. For details, see “24.7.1 REPLACE FUEL FILTER CARTRIDGE�.

L12BVO79

Stop Lever at Left Side of Rear Frame Center Hinge Area

2-25

11. EXPLANATION

MEMO

2-25A

OF COMPONENTS

11. EXPLANATION OF COMPONENTS

11.4

DUST INDICATOR

This device indicates clogging of the air cleaner element. When red piston 0 appears in the transparent part of this indicator, the element is clogged. Immediately clean the element.

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

The two dust indicators are located on the front side of the engine hood behind the cab.

11.5

CIRCUIT BREAKER (MAIN)

This prevents damage to the electrical components and electric wiring.

When the breaker has been actuated, press the reset button to reset the system. However, if the circuit breaker is actuated again after the button is pressed, or the circuit breaker is frequently actuated, there may be a short circuit in the electrical system. In such cases, contact your Komatsu distributor for repairs.

The circuit breaker is not reset for 45 seconds after the breaker is actuated.

11.6

SAFETY BAR

l

Always

use the safety

l

Always

remove

bar for maintenance

the safety

bar during

or when

normal

travel

transopera-

The safety bar is used during maintenance or when transporting the machine. It locks the front frame and rear frame, and prevents the front and rear frames from bending.

2-25B

11. EXPLANATION OF COMPONENTS

11.7

STEERING

COLUMN

A Stop the machine wheel.

before

I

TILT LEVER

WARNING adjusting

the angle

of the steering

This lever allows the steering column to be tilted forward or backward.

Pull the lever up and move the steering wheel to the desired position. Then push the lever down to lock the steering wheel in position.

Range of adjustment: 100 mm (3.94 in) (stepless)

11.8

DOOR-OPEN

I

LOCK

This can be used to hold the door open.

Open the door so that tip @ of the lever is aligned with groove @ for the lock, then pull down knob @ as shown in the diagram.

When using the door-open lock, be sure to apply the lock securely.

When releasing the lock and closing the door, push up knob @ and insert pin @ securely in the groove.

11.9

CAP WITH LOCK

The hydraulic tank filler port and the fuel tank filler equipped with locks.

Open and close the cap lock as follows.

Use the starting key to open and close the cap.

11.9.1 METHOD LOCK

port are

OF OPENING AND CLOSING CAP WITH

To open the cap (For the hydraulic tank filler port) 1. Insert the key into the cap.

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

2. Turn the key counterclockwise and bring the rotor groove in line with the aligning mark on the cap. Turn the cap slowly unit1 a “clicking” sound is made. This releases the lock and allows the cap to be opened.

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

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

2-26

i\l”i044uo

1

Shoulder

11. EXPLANATION OF COMPONENTS

1

To open the cap. (For the fuel tank filler port) 1. Insert the key into the cap.

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

2. 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

ock Open

and take the key out.

Shoulder

11.10

FUEL STOP LEVER

This is used when there is such abnormality as the engine cannot be stopped even if the starting switch is turned to the OFF position.

For normal operations, please keep it fully open.

If any abnormality occurs, turn fuel stop lever 0 to the front to stop the supply of fuel.

When an abnormality occurs such as to use the fuel stop lever, contact your Komatsu distributor.

If the engine is stopped using the fuel stop lever, bleed the air from the circuit, before starting the engine again. For details, see “24.7 REPLACING FUEL FILTER CARTRIDGE�.

11.11

AIR PICK-UP PORT

Air pick-up port @ is on the floor on the left side of the machine.

It is used for blowing air on to the glass of the cab and for blowing air through the air conditioner filter and engine air cleaner.

2-27

11. EXPLANATION OF COMPONENTS

11.12

FUSE

NOTICE Before replacing a fuse, be sure to turn off the starting

switch.

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

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

Replace

a fuse with another

11.12.1 FUSE CAPACITY Fuse box I (Lower side) Fuse caoacitv

No.

I

of the same capacity.

AND

NAME

Circuit r

0

20A

Spare

0

IOA

Rear working

0

IOA

Monitor

0

IOA

Bucket positioner Boom kick-out, Horn

0

IOA

Rear working

8

IOA

Cab working

20A

Air conditioner

1

20A

1 A’rr conditioner

68 1

10A

1

@a

10A

Cigarette

0

IOA

Rear wipper,

0

IOA

Front wipper,

Front washer

0

IOA

Side working

lamp

0 (8

2-28

OF CIRCUIT

Radio,

lamp

’

lamp

lamp lamp (Fan outside

room)

(Fan inside room)

Room lamo lighter Rear washer

11. EXPLANATION OF COMPONENTS

Fuse box II (Upper No.

side)

Fuse capacity

Circuit

.o

20A

Starting

switch

0

IOA

Hazard

0

IOA

Left head lamp

0

IOA

Right head lamp

0

IOA

Left side clearance

8

IOA

Right side clearance

ci>

20A

Lighting

8

IOA

Turn signal

@

IOA

Brake lamp,

63

IOA

Transmission

0 0

IOA

Parking

10A

Front working

000@@@0@@@0@ lj~~&J$fj[~~~[UUi maw-

lamp

iX596 lamp lamp

lamp Back up lamp control

valve

brake lamp

2-29

11. EXPLANATION OF COMPONENTS

11.13

1.

CAR RADIO

POWER SWITCH/VOLUME

CONTROL (SW/VOL)

Push this knob to turn on the power for the radio; push it once more to turn the power off.

Turn the knob to the right to increase the volume; turn it to the left to reduce the volume.

2.

TONE CONTROLLER (TONE)

Turn this knob to the right from the center position to emphasize the high sounds; turn it to the left to emphasize the low sounds.

3.

TUNING KNOB (TUNING) Use this knob to change the frequency

when selecting a station.

Turn the knob to the left or right to move the pointer and select the desired broadcasting station.

4.

STATION SELECTOR BUTTONS (5 buttons)

If these buttons are set beforehand to the desired broadcasting stations, the station can be selected simply by pressing the desired button.

2-30

11. EXPLANATION OF COMPONENTS

11.13.1 HOW TO SET STATION

SELECTOR BUlTONS

1.

Press power

2.

Pull back button @corresponding

3.

Turn station selector knob @ until the pointer is in front of the desired station. Carefully tune in so that noise disappears and the broadcast is heard plainly.

4.

Carefully push back button @with place.

switch 0.

to the station to be preselected.

the fingertip

until it clicks into

One station can be set for each station selector

11.13.2 PRECAUTIONS

I

button.

WHEN USING RADIO

Retract the antenna when traveling in places with low overhead clearance.

For safety reasons, keep the volume low enough to be able to hear the sound from outside the machine during operations.

If water gets inside the speaker case or car radio (auto tuning), it may lead to an unexpected accident, so be careful not to get water on the equipment.

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

Do not disassemble the radio.

2-31

11. EXPLANATION OF COMPONENTS

11.13.3

TROUBLESHOOTING

GUIDE

Problem

Remedy

No sound

l

Turn the SW/VOL knob to the right and press it two or three times.

Sound quality is poor.

Reception is noisy.

l

Return using the station selector knob. lftftznyroblem disappears, reset the tuning

l

Try lengthening extent.

the antenna to its fullest

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

2-32

11. EXPLANATION

11 .I4

CAB HEATER AND AIR CONDITIONER

11.14.1

LOCATIONS

\

AND FUNCTIONS TEMPERATURE SETTING

AND

OF CONTROL

PANEL

ERROR MESSAGE DISPLAY /

1. “ON/OFF” BUTTON and 2. OPERATING INDICATOR LIGHT Press the “ON/OFF” button (1) and indicator light (2) and the “TEMPERATURE indicate ON mode, press it again and the light will go out to indicate OFF mode.

3.

4.

OF COMPONENTS

TEMPERATURE INCREASE BUTTON and TEMPERATURE DECREASE BUTTON Press temperature increase button (3) to increase the temperature (4) to decrease the temperature setting.

SETTING”

will light up to

setting, press temperature decrease button

5.

6.

“FAN” BUTTON and FAN SPEED BAR GRAPH Press “FAN” button (5) to turn the fan ON and the fan speed bar graph (6) will light up to indicate fan speed, press it again and the light will go out to indicate OFF mode. Fan speed bar graph (6) displays the blower fan speed, ranging from low (30%) to high (lOO%), with an 8-segment bar graph.

7.

8.

FAN SPEED INCREASE BUTTON and FAN SPEED DECREASE BUTTON Press fan speed increase button (7) to increase the fan speed and the light on the bar graph will go up, press fan speed decrease button (8) to decrease the fan speed and the light on the bar graph will go down.

9. DEFROSTER BUTTON and 10. OPERATING INDICATOR LIGHT Press defroster button (9) for defroster mode and indicator light (10) will light up and the fan speed will automatically jump to maximum high, press it again and the light will go out to indicate OFF mode.

This feature causes the controller to cycle every 3 minutes, with the heat valve open, to remove humidity from the cab. The heat valve is cycled normally, during 3 minute intervals, to maintain temperature set point. When

2-33

11. EXPLANATION OF COMPONENTS activated the fan speed automatically increases to the highest position. The fan can then be adjusted down and up. After deactivating defroster. the fan speed will return to the position set before defroster activation.

MISCELLEOUS FEATURES When defroster button (9) temperature increase button (3) and temperature decrease button (4) are pressed simultaneously, it will toggle the temperature units between Fahrenheit and Celsius.

When defroster button (9) and temperature decrease button (4) are pressed simultaneously, it will show whether the evaporator thermostat is open (OP) or closed (CL).

OP Displayed - Clutch not engaged / coil to cold CL Displayed - Clutch is engaged / coil is at temperature set point, (opening temperature).

When temperature increase button (3) and temperature decrease button (4) are pressed simultaneously, it shows the ambient inside cab temperature reading from the thermistor probe.

ERROR MESSAGES Error messages display in the temperature setting window EO - Indicates a loss of power to the electrical condenser fan.

El - Indicates an excessively low or high refrigerant pressure.

If these error messages appear, contact your Komatsu distributor.

II .14.2

AIR INTAKE SELECTOR

LEVER

This lever switches the air intake port when cooling or heating.

FRESH: Move the selector lever forward.

Fresh air is taken in from the outside in addition to the air inside the operators compartment. This position is used for ordinary cooling or heating and when pressurizing the inside of the cab.

RECIRC: Move the selector lever backward.

Only the air inside the operators compartment is used. This position is mainly used for quick cooling or heating.

2-34

11. EXPLANATION

11.15

OF COMPONENTS

USING ACCUMULATOR

A

WARNING

The accumulators are filled with highly pressurized nitrogen. To avoid explosions, observe the following precautions.

If accumulators breakdown or have trouble, immediately ask your Komatsu distributor to make the repairs.

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

Never strike a charged accumulator or expose it to flames.

Never weld piping to or cut an opening in an accumulator.

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

The accumulators are on the right inside the rear frame under the center platform.

Always handle an accumulator with the utmost care!

Have your Komatsu distributor check the gas pressure every 2000 hours or every year.

2-35

11. EXPLANATION

OF COMPONENTS

11.16

OPERATION

11.16.1

FUNCTIONS

OF JOY STICK STEERING SYSTEM

AND STRUCTURE

OF JOY STICK STEERING

Be sure to read the following for safe and efficient use of the joy stick steering.

Electric Hydraulic

circuit

JOY stick

-

circuit iC Steering

valve \

/ Steerino

cylinder

Pi tbt

\ stof3

Pumr3

valve

AE406558

l

The joy stick steering system is used to steer the wheel loader with the joy stick instead of the steering wheel.

Since the joy stick is light in operation and short in stroke, the operator is less fatigued when steering.

l

The joy stick steering system consists of the electrical circuit (Joy stick, controller, and joy stick ON/OFF switch), hydraulic circuit (Electromagnetic proportional valve, stop valve and steering valve), and joy stick console (Position adjustment of joy stick and position adjustment of armrest).

l

If the joy stick steering system is installed, the steering and transmission control methods can be selected with joy stick ON/OFF switch @ as shown below.

The functional difference between steering with the joy stick steering system and that with the steering wheel is as follows:

2-36

11. EXPLANATION

Selection Joy stick steering switch

(4 ON/OFF ON - Steering with joy stick

Steering

OF COMPONENTS

(B) OFF - Steering with steering wheel

l l

Steering with joy stick Steering with steering

l Steering with steering wheel

Transmission

speed

I

switch l Can be shifted with transmission control lever also

Change between 1 * 2 *

0B

3”4

OFF

Work with joy stick and steering wheel.

l

Use the joy stick or steering wheel according

to the type of work.

View

Z D 1

AE40183

1)

Steering with joy stick Joy stick is suitable for continuous loading work in a wide job site with a relatively long cycle time.

Since the stroke of the joy stick is short and the resistance is low, the operator is less fatigued even if he operates the machine continuously.

2)

Steering with steering wheel Since the operator can drive fast on a straight course and can control finely with the steering wheel, he can work efficiently with it when moving among job sites and in load-and-carry operations. The steering wheel is also suitable for works of short cycle time since the operator can hold the upper part of his body when changing the moving direction.

Joy stick steering control has priority over the steering wheel.

I

A CAUT’oN I

To avoid undesirable operation of joy stick steering lever, turn off joy stick steering ON/OFF switch when the steering wheel is used.

l

I

The joy stick console can be slid for the ease of entering or leaving the operator’s seat.

With lever @ the console box can be tilted (C) (+) and the console and arm rest can be slid (D) (9).

A CAUT’oN I

Joy stick console should be moved and locked in rearmost position before entering or leaving operator’s seat.

To prevent unexpected turning of the vehicle by misoperation of the joy stick while the engine is running, be sure to slide the joy stick console to the rearmost position, then lock it securely.

2-37

11. EXPLANATION 11 .I 6.1 .I WARNING

OF COMPONENTS FOR TROUBLE

This vehicle has the centralized warning lamps, regardless of the joy stick steering system. If the vehicle is set under the condition explained in “E” below, the warning lamp and the monitor lamp of the part with trouble start flashing.

If the joy stick steering system is added, the above warning lamp warns of trouble in the electric circuit of the joy stick steering system (Only the warning lamp indicates in this case, however).

“E” Centralized Warning Lamp This lamp flashes when the vehicle is under the following tion. l

When any one of warning

l

When the joy stick steering controller

items of(B) has a trouble.

If the vehicle is under the following intermittently.

When any one of warning

l

senses an electrical circuit problem.

conditions,

items of(C)

the above lamp flashes and the warning

11.16.2 PRECAUTIONS

A

buzzer sounds

has a trouble.

When the parking brake is applied and the forward/reverse

l

condi-

lever is not in the neutral position.

FOR STEERING WITH JOY STICK CAUTION

If the vehicle and transmission cannot be operated normally with the joy stick, or if the warning lamp lights up, stop the vehicle with the brake first. Then, turn off the joy stick ON/OFF switch and move to a safe place by using the steering wheel and forward/reverse control lever.

Before starting the operation of the vehicle again, find out and repair the troubled part and confirm that the function is normal. For the troubleshooting and repair, please contact your Komatsu distributor.

Never operate the vehicle before it is repaired completely.

l

l

l

Do not use the joy stick until the LED of N in the FNR indicator LED unit on the center frame console lights up to indicate that the joy stick is ready.

The joy stick controller senses the neutral position of the joy stick each time the main switch is turned on. If the joy stick is moved before the neutral position is sensed, an error is detected and the caution lamp flashes and the joy stick steering system does not work.

If an error is indicated, turn off the joy stick ON/OFF switch, then turn it on again.

LED

If the vehicle is steered with the steering wheel, its turning angle is fixed when turning of the latter is stopped. If the vehicle is steered with the joy stick and the latter is held turned, however, the vehicle is steered to the articulate end.

Since the feel of steering of the joy stick is different from the steering wheel, take care sufficiently until you are get accustomed to the joy stick.

2-38

11. EXPLANATION

OF COMPONENTS

l

If the F or R button at the joy stick head is pushed and held more than 30 seconds, a short circuit is sensed and an error is indicated. Touch these buttons only when required.

l

If the forward/reverse lever is not at the neutral position or the F or R button at the joy stick head is pushed, when the joy stick ON/OFF switch is turned on or off, the neutral interlock circuit will shift the transmission into a neutral condition.

l

If the electric circuit of the joy stick steering system or transmission control system has trouble, the centralized warning lamp (Red) on the left side of the main monitor flashes to notify the trouble to the operator.

11.16.3 OPERATION ING SYSTEM

METHOD OF JOY STICK STEER-

A

CAUTION

When steering with joy stick @, be sure to adjust the angle of the steering wheel so that the FNR indicator lamp (LED) of the center console frame will be seen.

f

1

1. Sit on the o erator’s seat and pull up lever @ to unlock the ‘oy stick conso e, then slide the console from the rear position o the foremost position, then lock it securely.

Under this condition, safety switch @ is turned on. Adjust joy stick @ to the angle for easy operation with console box adjustment lever 0. See “11.16.4 “ADJUSTMENT OF JOY STICK CONSOLE”.

2.

Fasten the seat belt.

3.

Confirm that joy stick @ o erates normally and the forward/reverse lever of the Pransmission is a the neutral position and the periphery of the vehicle is safe. Then, start the engine.

4.

Turn on joy stick ON/OFF switch 0.

FNR button @ on the head of joy stick @ is set to the neutral position automatically.

A

YUTION

1

1

Joy stick ON/OFF switch settmg should be switched only when the machine is stopped and in neutral.

5.

If joy stick @ is turned to the right the vehicle turns to the right, and if the former is turned to the left, the machine turns to the left. The more the joy stick is turned sharply, the more the vehicle turns quickly.

6.

After the vehicle turns to the desired angle, return the joy stick to the neutral position.

2-39

11. EXPLANATION

OF COMPONENTS

Slowly turn the steering wheel to the right and left to warm up the oil in the steering valve. Repeat this operation for about 10 minutes to warm up the oil.

NOTICE Turn the steering wheel a little and stop there. Then, confirm that the vehicle is steered by the angle equivalent to the turning angle of the steering wheel.

Recommended oil Select the oil depending

l

Reservoir

on the temperature

l

0 I

SAE 5W-20 I API Class@cation I I I

10 I

30°C I

20 I

Classification

CE

I CE I

CD is used in a cold season, replace it with SAE IOW / API Classification

CD

OF JOY STICK CONSOLE

A l

-10 I I

If SAE 5W-20 /API Classification after the cold season.

l

-20

SAE ?OW lAPI

Engine oil

11.16.4 ADJUSTMENT

table.

Ambient Temperature

Type of Oil -30

Hydraulic system

as shown in the following

WARNING I

When adjusting the joy stick console, park the vehicle on a level and safe place.

Adjust before starting operation or when the operator changed.

Before adjusting the console, adjust the operator’s seat so that the operator can press the brake pedal fully with his back touching the seat back.

(A) Adjustment of joy stick Turn lever @ forward and set knob @ to a desired position.

After setting, release the lever.

Forward/Backward adjustment: 130 mm (5.12 in) (At knob top) (B) Adjustment

of height of armrest (Left-hand)

Turn grip 6 to unlock the armrest, then set the armrest to a desired position. After setting, tighten the grip securely.

Vertical adjustment range: 35 mm (1.38 in) (C) Movement of console Console should be moved and locked in foremost position for operation, and moved and locked in rearmost position for steering.

2-39c

11. EXPLANATION

OF COMPONENTS

11.16.5 ADJUSTMENT

OF OPERATOR’S

SEAT

A WARNING l

l

l

Before adjusting the operator’s seat, park the machine on a level and safe place and stop the engine.

Adjust the seat before starting operation or when changing operators.

Before adjusting the console, adjust the operator’s seat so that the operator can press the brake pedal fully with his back touching the seat back.

(A) Forward/Backward

adjustment

Raise lever @I and set the seat to a desired position, then release the lever.

The forward/backward adjustment is 140 mm (5.51 in) (20 mm (0.79 in) x 8 steps).

(B) Adjustment of seat suspension Turn grip @ to adjust the strength of the suspension.

The adjustment range (rough) is 50 kg - 120 kg (110.3 - 264.6 lb).

(C) Adjustment of reclining seat back Pull lever @ toward you and move the seat back forward or backward.

The adjustment range is 64” (2” x 9 steps + 46”) in the forward reclining angle and 36” (2” x 18 steps) in the backward reclining angle.

NOTICE If the seat is reclined too much, the headrest may touch the rear glass. Do not recline it so much.

When taking a rest on the reclined seat, set the latter under the following conditions: l Forward/Backward adjustment: Forward stroke end l Vertical adjustment: Top l Seat angle adjustment: Level or forward angle l Reclining adjustment: Reclining backward, 36” max. (18 steps) (D) Vertical adjustment of seat IMove lever @ up or down to move the seat up or down.

The adjustment range is 50 mm (1.95 in).

(E) Vertical

adjustment of headrest Move the headrest up or down.

The adjustment range is 25 mm (0.99 in).

(0

Adjustment of angle of headrest Turn the headrest forward or backward.

2-3913

Il.

EXPLANATION

OF COMPONENTS

MEMO

2-39E

12. OPERATION

12.1

CHECK BEFORE STARTING

12.1.1 WALK-AROUND

ENGINE

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.

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

Always carry out the items engine each day.

in this section

before

starting

the

ACM26600

2-40.

12. OPERATION

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 tank, Check repair

5.

Check for leakage of oil from brake line Check that there is no leakage of oil. If any abnormality repair it.

I

6.

for leakage of oil from transmission case, axle, hydraulic hoses, joints that there is no leakage of oil. If any abnormality is found, it.

is found,

Check for damage or wear to tires, loose mounting bolts Check for cracks or peeling of the tires and for cracks or wear to the wheels (side rim, rim base, lock ring). Tighten any loose wheel nuts. If any abnormality is found, repair or replace the part.

If any valve caps are missing, install new caps.

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

Check for damage to gauges, monitor, loose bolts Check that there is no damage to the gauges and monitor in the operator’s cab. If any abnormality is found, replace the parts.

Clean off any dirt on the surface.

Check for loose air cleaner mounting bolts Check for any loose mounting bolts, and tighten

if necessary.

2-41

12. OPERATION

10. Check for loose battery terminals Tighten any loose terminal.

11. Check seat belt and equipment

Even if there appears to be no abnormality always replace it once every three years.

with

the seat belt,

REMARK The date of manufacture of the seat belt is marked on the belt at the place indicated by the arrow in the diagram on the right.

Check that there are no loose bolts on the equipment the seat belt to the machine, and tighten if necessary.

Tightening

torque:

mounting

24.5 f 4.9 Nm (2.5 + 0.5 kgm, 18.1 & 3.6 ibft)

If the belt is damaged or fluff is starting to form, or if there is any damage or deformation of the seat belt holders, replace the seat belt with a new part.

12. Check Check found Ibft).

If any bolts.

for loose bolts on ROPS for any loose or damaged bolts. If any loose bolts are tighten them to 2746 & 294 Nm (280 f 30 kgm, 2025 c 217 bolts are damaged,

13. Clean cab window Clean the cab window the machine.

2-42

replace them with genuine

to ensure good visibility

when

Komatsu

operating

12. OPERATION

12.1.2 CHECK BEFORE STARTING Always carry out the items engine each day.

in this section

before

starting

the

CHECK MONITOR PANEL 1. Turn the starting switch to ON. 2.

Check that all the monitor lamps, the gauges and the warning lamp light up for about 3 seconds and the alarm buzzer sounds for about 1 second.

If any monitor lamp does not light up, ask your Komatsu distributor to inspect that monitor lamp.

Do not carry out the checks before starting monitor; always carry out also the items specified maintenance.

CHECK COOLANT

using only the for the periodic

LEVEL, ADD WATER

Do not remove

the cap while

When removing

the radiator

cooling

water

is hot. Hot water

cap, turn the cap slowly to relieve

1.

Remove radiator cap 0 at the rear of the machine and check that the coolant is above the hatched portion marked in the diagram on the right. If the coolant level is low, add more water.

2.

After adding water,

tighten

the cap securely.

If the volume of coolant added is more than possible water leakage.

Confirm that there is no oil in the coolant.

usual, check for AH07310

2-43

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL Open the inspection Remove

window

at the rear left side of the machine.

dipstick @ and wipe the oil off with a cloth.

Inset-t dipstick @ fully in the oil filler pipe, then take it out again.

The oil level should

be between

0.

If the oil level is belowthe

the H and L marks on dipstick

L mark, add engine oil through

oil filler

0.

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

AND

The dipstick has level markings on both sides. One side gives the levels for measuring when the engine is stopped (ENGINE STOPPED) and the other side gives the levels for when the engine is idling (ENGINE IDLING).

When measuring the oil level, measure with the engine stopped and use the side of the dipstick marked ENGINE STOPPED. 5.

If the oil is above the H mark, drain the excess engine drain valve 0, and check the oil level again.

6.

If the oil level is correct, tighten close the inspection window.

oil from

the oil filler cap securely,

then

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

Checking the oil level with the engine idling may be allowed, if the following precautions are thoroughly satisfied: l Check that the engine water temperature gauge shows green range. l Use the side of the dipstick marked ENGINE IDLING. l Remove the oil filler cap.

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

2-44

1

CHECK AND REFILL OF OIL IN BRAKE OIL TANK

A

WARNING

Always use engine oil to refill the brake oil tank.

Check from the ground that the brake oil level in the brake oil tank on the left side of the machine is within sight gauge 0 installed to the side of the brake tank.

IF the oil level is low, open the cover at the top of the platform, then open cap @ and add engine oil.

AND

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

CHECK DUST INDICATOR Check that the red piston of dust indicator 0 (2 points) has not reached the service level.

If the red piston is showing, clean or replace the element immediately.

For details of cleaning the element, see “24.2 WHEN CHECK, CLEAN, OR REPLACE AIR CLEANER”.

REQUIRED,

2-45

CHECK FUEL LEVEL, ADD FUEL a

WARNING

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

1.

Turn the engine starting switch to the ON position, then check the fuel level with fuel gauge 0.

After checking, return the starting switch to the OFF position.

2.

Upon completion of work, remove the mud guard cover and add fuel through filler @ until the fuel tank is full.

For details of the method “11.9 CAP WITH LOCK”.

for opening

and closing the cap, see

AND

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

3.

After adding Fuel capacity:

fuel, tighten

the cap securely.

1430 J?(377.5

US gal, 314.6

UK gal)

DRAIN WATER FROM AIR TANK Upon completion of work, stop the engine, open drain valves 0, @ and @ and drain the water from the tank.

2-46

r

CHECK ELECTRIC WIRING a l

l

l

WARNING

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

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 of the fuse and any sign of disconnection or short circuit in the electric wiring. Check also for loose terminals and tighten any loose parts.

Check the following points carefully. l Battery 0 Starting motor l Alternator Please contact your Komatsu distributor for investigation and correction of the cause.

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.

CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER The water separator separates water mixed in the fuel. If float @ is at or above red line 0, drain the water.

Forthe draining procedure, see section “24.2 WHEN REQUIRED�.

Even if a water separator is installed, be sure to check the fuel tank to remove water and sediment in the fuel.

2-47

CHECK EFFECT OF PARKING BRAKE g WARNING Even if the parking brake switch is turned ON, there is danger until the parking brake pilot lamp lights up, so keep the brake pedal depressed.

Measurement l l l

I

conditions

I

Tire inflation pressure: Specified pressure Road surface: Dry paved surface with l/5 (11”20’ ‘) grade Machine: Operating condition

Method of measurement

a

1.

Start the engine, set the machine facing straight to the front, then drive the machine up a l/5 grade with the bucket empty.

2.

Depress the brake, stop the machine, return the directional to the neutral position, then stop the engine.

3.

Press the parking brake switch to the ON position, brake pedal slowly, and check that the machine position.

lever

release the is held in

1

CHECK EFFECT OF BRAKE Drive the machine at a speed of 20 km/h (12.4 MPH) on a dry flat concrete road surface, than 7.5 m (24.6 ft).

and check that the stopping

distance

is less

CHECK SOUND OF HORN AND BACKUP BUUER CHECK FLASHING OF LAMPS,

CHECK FOR DIRT OR DAMAGE

CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE CHECK ENGINE EXHAUST COLOR AND SOUND CHECK OPERATION OF GAUGES CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING

2-46

AM28450

12.1.3

ADJUSTMENT

OPERATOR’S

BEFORE OPERATION

SEAT

Adjust operator’s seat as described under “I 1.16.5 ADJUSTMENT

RIGHT SIDE ARMREST Height adjustment Loosen bolts @ to move the arm rest to the desired then tighten the bolts.

OF OPERATOR’S

SEAT” on page 2-39D.

position,

Angle adjustment Loosen bolts @ to move the armrest to the desired angle, then tighten the bolts.

2-49

ADJUST SEAT BELT Always install a seat belt on machines

7

A

equipped

with ROPS.

WARNING

Before fitting the seat belt, check that there is no abnormality in the mounting bracket and mounting belt of the belt. If the belt is worn or damaged, replace it.

Always

fasten

Always

use the seat belt during

Do not twist fastening it.

the seat belt before

the

left or right

starting

operations.

operations. side of the

Fastening and removing belt Fasten the belt so that it is tight without

seat

belt

when

being too tight.

Sit on the seat, depress the brake pedal fully, and adjust the seat so that your back is pressed against the backrest.

After adjusting the seat position, adjust teaser belt 0. Tense the teaser belt and install it when there is no one sitting on the seat.

Sit on the seat, take buckle @and tongue @ in your left and right hands, insert tongue @ into buckle 0, and pull the belt to check that it is securely locked.

When belt.

removing

the belt, raise the lever of buckle @ to free the

Adjust the length of the buckle and tongue so that the belt follows your body without twisting, and adjust so that the buckle is 1 in the middle at the front of your body.

2-50

1

Adjust belt length To make belt shorter:

Pull the free end of the belt at the buckle end or tongue end.

To make belt longer:

Set the belt holding the buckle or tongue end at right angles to the buckle or tongue, and pull.

AEO61730

ADJUST REAR VIEW MIRROR Sit in the operator’s seat and adjust you can see properly to the rear.

2-51

12. OPERATION

12.1.4 OPERATIONS ENGINE

AND CHECKS BEFORE STARTING

A

WARNING

l

If the control levers are touched by accident, the work equipment may move suddenly. When leaving the operator’s compartment, always set the safety lever securely to the LOCK position.

l

Before starting the engine, use a damp cloth to wipe off the dust accumulated on the top surface of the battery or on the starting motor and the alternator.

1.

Check that parking

2.

Check that directional lever @ is at the N position.

When starting the engine, if directional lever @ is not at the N position, the engine will not start.

3.

Lower the bucket to the ground, then check that work equipment control lever @ is locked by safety lock 0.

1

brake switch @ is at the ON position.

J

1 4.

2-52

Insert the key in starting switch 0, turn the key to the ON position, and check that the pilot lamp lights up.

m.21

OFF

1

12.2

STARTING

12.2.1

NORMAL

ENGINE

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.

Depress

2.

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

3.

accelerator

pedal @ lightly.

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

OFF

OFF

2-53

12. OPERATION

122.2 STARTING

IN COLD WEATHER

l

Check that there are no persons or obstacles

l

Never

use starting

aid fluids

in the surround-

as they may cause explosions.

NOTICE Do not keep the starting

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

When starting in low temperatures, do as follows. ‘l. Turn the key of starting switch @ to ON. Preheating will start automatically, and preheating will light up.

2.

Depress

accelerator

pilot lamp @

pedal @ halfway.

t723

i 3.

When preheating is finished, the pilot lamp will go out. Turn the key of starting switch 0 to the START position to start the engine.

REMARK When starting, the monitor may flash when the starting motor is being cranked.

If this flashing stops after the engine is started, there is no abnormality.

4.

2-54

When the engine is started, release the key of starting switch 0, and the key will return automatically to ON.

OFF

If the engine does not start after following this procedure, turn preheater switch @ to ON and preheat fully before trying to start.

The table shown below gives a guide to preheating times.

Temnerature

1

Above 0°C

1

Preheatincr time

-

0°C to -10°C

20 seconds

-10°C to -20°C

30 seconds

-20°C to -30°C

40 seconds

A WARNING Never

use starting

aid fluids as they

may cause explosions.

When operating the machine at temperatures below -2O”C, special equipment is needed, Contact your Komatsu distributor for details.

For machines where the air dryer is installed as an option, in cold temperatures below -lO”C, when operating the machine after it has been stopped for several hours, run the engine for at least 10 minutes after starting before moving the machine.

2-55

12. OPERATION

12.3

OPERATIONS AND CHECKS AFTER STARTING ENGINE

After starting the engine, do not immediately start operations.

First, carry out the following operations and checks.

NOTICE Do not suddenly accelerate the engine before the warming-up operation is completed.

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

1. Depress accelerator pedal @ lightly and run the engine with no load at midrange speed for about 5 minutes.

2.

After carrying out the warming-up operation, check that the gauges and caution lamps are normal.

If there is any abnormality, carry out maintenance or repair.

Run the engine under a light load until engine water temperature gauge @ and torque converter oil temperature gauge @ are in the green range.

3.

Check that there is no abnormality in the exhaust or vibration.

If there is any abnormality, carry out repairs.

2-56

color, sound,

12. OPERATION

12.4

MOVING

MACHINE a

l

l

OFF

WARNING

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

Do not allow people near the machine.

There is a blind spot behind the machine, so be particularly careful when traveling in reverse.

When starting the machine on slopes, set transmission cutoff selector switch @ to the OFF position, depress left brake pedal @while depressing accelerator pedal 0, then gradually release left brake pedal @ to allow the machine to start.

1.

Check that caution

pilot lamp 0

is not lighted

up.

2.

Set safety lock Q) of bucket control lever @ to the FREE position.

3.

Operate lift arm control lever @ to set the work equipment travel posture shown in the diagram on the right.

lever @ and lift arm control

I

to the

(24 - 28 in) 4.

Depress right brake pedal @ and turn parking brake switch @to the OFF (RELEASE) position to release the parking brake.

Keep right brake pedal @I depressed.

REMARK If the parking brake is still actuated when parking @ is at the OFF (RELEASE) position, turn the parking ON, then turn it OFF again.

5.

‘%icn

Set speed control

lever @ to the desired

brake switch brake switch

position.

2-57

12. OPERATION

6.

Set directional

lever @I to the desired

position.

Forwa

Reverse ._ Release right brake pedal 8, to move the machine off.

7.

then depress accelerator

pedal @

NOTICE If choosing to use the controls of the joy stick steering system, also see 11 .I6 “OPERATION OF JOY STICK STEERING SYSTEM” on page 2-36.

12.5

CHANGING

GEAR SPEED

A

WARNING

When traveling at high speed, do not change the gear speed suddenly. When shifting gear, use the brakes to reduce the travel speed, then shift gear.

Shift the gear as follows.

Move speed control lever @ to the desired position.

Only 1st or 2nd speeds are used for digging and loading tions, so actuate speed control lever stopper 0.

opera-

1

REMARK This machine is equipped with a kickdown switch that shifts the gear down to 1st if the button at the tip of the lift arm control lever is pushed when the machine is traveling in 2nd gear.

We recommend the use of the kickdown switch when carrying out digging or loading operations in 1st or 2nd gear.

For details of use, see “11. EXPLANATION OF COMPONENTS”.

2-58

1st 2nd 3rd

105R3

12.6

CHANGING

I

DIRECTION a

WARNING

When changing direction between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine, so be particularly careful when changing direction to travel in reverse.

Do not switch between FORWARD and REVERSE when traveling at high speed.

When switching between FORWARD and REVERSE, depress the brake to reduce the travel speed sufficiently, then change the direction of travel. (Max. speed for changing direction: 12 km/h (7.5 MPH)) Forwar There is no need to stop the machine between FORWARD and REVERSE. Place directional lever @ in the desired

even .when

switching

position.

Reverse

NOTICE If using the controls of the joy stick steering system, also see 11.16 “OPERATION OF JOY STICK STEERING SYSTEM” on page 2-36.

12.7

TURNING 4b

WARNING

It is dangerous to turn the machine suddenly at high speed, or to turn on steep hills.

If the engine stops when traveling, the steering cannot be used, so never stop the engine when traveling.

This is particularly dangerous on hills, so never stop the engine when the machine is traveling. lf the engine stops, stop the machine immediately at a safe place.

When the engine stops while the machine, is traveling, the emergency steering will operate. But, since this device is an emergency steering device, never stop the engine while the machine is traveling.

It is especially dangerous on a hill (For machines equipped with emergency steering).

When traveling, use steering wheel @ to turn the machine.

With this machine, the front frame is joined to the rear frame at the center of the machine by the center pin. The front and rear frames bend at this point, and the rear wheels follow in the same track as the front wheels when turning.

Turn the steering wheel lightly to follow the machine as it turns.

When turning the steering wheel fully, do not turn it beyond the end of the stroke.

NOTICE If using the controls of the joy stick steering system, also see II .I 6 “OPERATION OF JOY STICK STEERING SYSTEM” on page 2-36.

2-59

12. OPERATION

12.8

STOPPING

MACHINE

a

WARNING

Avoid stopping suddenly. Give yourself ample room when stopping.

Do not park the machine on slopes.

If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.

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

Even if the parking brake switch is turned ON, there is danger until the parking brake pilot lamp lights up, so keep the brake pedal depressed.

,

NOTICE Never use the parking brake switch to brake the machine when traveling except in an emergency.

Apply the parking brake only after the machine has stopped.

1.

Release accelerator the machine.

2.

Place directional

3.

Turn parking

pedal 0,

and depress brake pedal @to

lever @ in N (neutral).

brake switch @ to ON to apply the parking

REMARK When the parking brake is applied, cally returned to neutral.

2-60

stop

the transmission

brake.

is automati-

Thrust

the bucker

ACd2837E

12.9

OPERATION

OF WORK EQUIPMENT

Lift arm control lever @ and bucket control lever @ can be to operate the lift arm and bucket as follows.

LIFT ARM OPERATION (LEVER 0) @ Raise ( q ) Q Hold ( s 1: The lift arm is kept in the same position. @ Lower ( d ) @ Float ( dz ): The lift arm moves freely under external force.

When the lift arm control lever is pulled further from the raise position, the lever is stopped in this position until the lift arm reaches the preset kick-out position, and the lever is return to the hold position.

NOTICE Do not use the FLOAT position

when

lowering

the bucket.

BUCKET OPERATION (LEVER 0, @ Tilt ( ‘a ) @ Hold ( S 1: The bucket is kept in the same position.

0

Dump (

W

1

When the bucket control lever is pulled further from the tilt position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, and the lever is return to the hold position.

’

Tilt

2-61

12.10 WORK POSSIBLE

USING WHEEL LOADER

In addition to the following, it is possible to further range of applications by using various attachments.

12.10.1

DIGGING

increase the

OPERATIONS

/PWARN’NG/ Always set the machine facing directly to the front when carrymg out dlggmg or scooping operations.

Never carry out these operations with the machine articulated.

NOTICE If the tires slip, the tire life will be reduced, tires to slip during operation. l

1.

so do not allow the

When loading piled soil or blasted rock, drive the machine forward as follows to load. To prevent cutting of the tires caused by the tires slipping, be careful of the following points during the operation. o Always keep the operating jobsite flat, and remove any fallen rocks. c When working with stockpiles, operate the machine in 1st or 2nd; when loading blasted rock operate the machine in 1st.

When driving the machine forward and lowering the bucket, stop the bucket about 30 cm (12 in) from the ground, then lower it slowly.

REMARK If the bucket hits the ground, ground, and the tires will slip.

the front tires will come

off the

2.

Shift down immediately in front of the material to be loaded.

When completing the shift down, depress the accelerator pedal at the same time and thrust the bucket into the load.

3.

When the material is in a stockpile, keep the cutting edge of the bucket horizontal; when loading blasted rock, have the bucket tilting slightly down.

Be careful not to get blasted rock under the bucket. This will make the front tires come off the ground and slip.

Try to keep the load in the center of the bucket; if the load is on one side of the bucket, the load will be unbalanced.

2-62

1

I

u%z

Blasted rock

I

4.

At the same time as thrusting the bucket into the material, raise the lift arm to prevent the bucket from going in too far. By raising the lift arm, ample traction will be produced by the front tires.

,oSQO&J$$J$j

e 5.

c% r.xcx

Check that there is enough material loaded into the bucket, then operate the bucket control lever to tilt the bucket and load the bucket fully.

REMARK If the bucket edge is moved up and down while pushing in the bucket and digging, the front tires will come off the ground and this will cause the tires to slip.

6.

If there is too much material loaded in the bucket, dump and tilt the bucket quickly to remove the excessive load.

This prevents spillage of the load during hauling.

2-63

12. OPERATION

l

When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the machine forward.

Always be careful not to load the bucket on one side and cause an unbalanced load.

This operation should be carried out in 1st gear.

1.

Set the edge of the bucket facing slightly

2.

Drive the machine forward and operate the lift arm control lever forward to cut a thin layer of the surface each time when excavating the soil.

3.

Operate the lift arm control lever slightly up and down to reduce the resistance when driving the machine forward.

down.

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

2-64

the digging force

12.10.2

LEVELING OPERATIONS

NOTICE Always operate the machine in reverse when carrying out leveling operations.

If it is necessary to carry out leveling operations when traveling forward, do not set the bucket dumping angle to more than 20”.

Scoop soil into the bucket. Move the machine spreading soil from the bucket little by little.

backward

Go over the spread soil with the bucket teeth ground and level the ground by back-dragging.

while

touching

the

Scoop some more soil into the bucket, put the lift arm in float, level the bucket at ground level, and smooth the ground by moving backward.

12.10.3

PUSHING OPERATIONS

NOTICE Never set the bucket to the DUMP pushing operation.

1.

position

When carrying out pushing operations, bucket parallel to the ground surface.

12.10.4

when

carrying

set the bottom

out

of the

LOAD AND CARRY OPERATIONS

A

WARNING

When carrying a load, lower the bucket to lower the center of gravity when traveling.

The load and carry method for wheel loaders consists of a cycle of scooping -+ hauling + loading (into a hopper, glory hole, etc.)

Always keep the travel path properly maintained.

When using the load and carry method, see “12.18 HANDLING TIRES”.

2-65

12. OPERATION

12.10.5 LOADING

OPERATIONS

Select the method of operation which will give the minimum amount of turning and travel in order to provide the most efficient method for the jobsite.

l

l

WARNING g Always keep the working area flat. Do not turn suddenly or apply the brake suddenly when traveling with a raised load.

These actions are dangerous.

It is also dangerous to drive the bucket at high speed into a stockpile or pile of rocks.

NOTICE If the tires slip, the tire life will be reduced, tires to slip during operation.

Avoid excessive shaking of the bucket. l l

so do not allow the

CROSS DRIVE LOADING Always set the wheel loader facing at a right angle to the stockpile. After digging in and scooping up the load, drive the machine straight back in reverse, then bring the dump truck in between the stock pile and the wheel loader.

This method requires the least time for loading, and is extremely effective in reducing the cycle time.

V-SHAPE LOADING Position the dump truck so that the direction of approach of the wheel loader is approx. 60� from the direction of approach to the stockpile. After loading the bucket, drive the wheel loader in reverse, then turn it to face the dump truck and travel forward to load the dump truck.

The smaller the turning angle of the wheel loader is, the more efficient the. operation becomes.

When loading a full bucket and raising it to the maximum height, first shake the bucket to stabilize the load before raising the bucket.

This will prevent the load from spilling to the’rear.

Precautions when piling up loads When forming products into a pile, be careful not to let the rear counterweight come into contact with the ground.

Do not set the bucket to the DUMP position when carrying out piling-up operations.

2-66

12.11

PRECAUTIONS

12.11 .I

PERMISSIBLE WATER DEPTH

FOR OPERATION

When working in water or on swampy ground, do not let the water come above the bottom of the axle housing.

After finishing the operation, wash and check the lubricating points.

12.11.2

Axle housing

IF WHEEL BRAKE DOES NOT WORK

If the machine is not stopped by depressing the parking brake to stop the machine.

the brake pedal, use

NOTICE If the parking brake has been used as an emergency brake, contact your Komatsu distributor to have the parking brake checked for any abnormality.

12.11.3

PRECAUTIONS SLOPES

WHEN DRIVING

UP OR DOWN

LOWER THE CENTER OF GRAVITY WHEN TURNING. When turning on slopes, lower the work equipment to lower the center of gravity before turning. It is dangerous to turn the machine with the work equipment raised.

BRAKING ON DOWNHILL SLOPES If the service brake is used too frequently when traveling downhill, the brake may overheat and be damaged. To avoid this problem, shift down to a low range and make full use of the braking force of the engine. When braking, use the right brake pedal.

If the speed control lever is not placed in a proper speed position,’ the torque converter oil may overheat. If it overheats, place the speed control lever in the next lower gear speed to lower the oil temperature.

If the temperature gauge does not indicate the green range of the scale even with the lever in the 1st speed position, stop the machine, place the lever in neutral, and run the engine at medium speed until the gauge indicates the green range.

IF ENGINE STOPS If the engine stops on a slope, depress the right Next, lower the work equipment to the ground and brake. Then put the directional and speed control and start the engine again. (If the directional lever the engine will not start.)

brake pedal fully. apply the parking levers in neutral, is not in neutral,

2-67

12.11.4

PRECAUTIONS

WHEN DRIVING

MACHINE

When the machine travels at high speed for a long distance, the tires become extremely hot. This causes early wear of the tires, so it should be avoided as far as possible. If the machine must be driven for a long distance, take the following precautions. l Follow the regulations related to this machine, and drive carefully. l Before driving the machine, carry out the checks before starting. l The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface. Contact your Komatsu distributor or tire dealer for information. l When traveling with standard tires L-5 on a paved road surface, use the table. as a guide.

Ambient temperature(“C)

Max. travel

20 50

!

25

28 30

25 28

0

Traveling time and breaking time

speed (km/h)

28

1

Travel

Break

/

Repeat

13 km or 40’

(3H)

Travel

Break

Repeat

Travel

Break

Repeat

113!

Travel

(3f-U Break

Repeat

Break

Repeat

Break

Repeat

1

.

13 km or 35’

113* Travel I------y: 15 km or 30’ Travel

I’ .

118 1___;37;;N__(Air pressure: 514.8 kPa (5.25 kg/cm2, 74.6 psi)

L-4 tires are suitable as tires for driving on roads, so contact your Komatsu distributor or tire dealer.

When driving the machine continuously, use the following as a guideline for one day’s travel: Travel distance: within 20 km; travel time: Max. 1 hour When the machine is stopped, check the tires and all other parts for abnormalities, and check the oil and coolant levels.

Check the tire pressure before starting, when the tire is cool.

Always travel with the bucket empty.

Never put calcium chloride or dry ballast in the tires when traveling.

2-68

12.12

ADJUSTING

WORK EQUIPMENT a

l

l l l

POSTURE

WARNING

Stop the machine on flat ground and put blocks in front and behind the wheels. ’ Apply the parking brake.

Secure the front and rear frames with the safety bar.

Do not go under the work equipment when the arm is raised.

The boom kickout makes it possible to set the bucket so that it automatically stops at the desired lifting height (lift arm higher than horizontal) and the bucket positioner makes it possible to set the bucket so that it automatically stops at the desired digging angle.

The setting can be adjusted to match the working conditions.

1212.1

ADJUSTING

BOOM KICKOUT

1.

Raise the bucket to the desired height, set the lift arm control lever at HOLD and lock the lever in position. Then stop the engine and adjust as follows.

2.

Loosen two bolts 0, and adjust plate @ so that the bottom edge is in line with the center of the sensing surface of proximity switch 0. Then tighten the bolts to hold the plate in position.

3.

Loosen two nuts @ to make a clearance of 3 to 5 mm (0.12 to 0.20 in) between plate @ and the sensing surface of proximity switch 0. Then tighten the nuts to hold in position.

Tightening 4.

torque:

17.2 f 2.5 Nm (1.75 k 0.25 kgm, 12.7 + 1.8 Ibft)

After adjusting, start the engine and operate the lift arm control lever. Check that the lever is automatically returned to HOLD when the bucket reaches the desired height.

2-69

1212.2

ADJUSTING

BUCKET POSITIONER

1. Lower the bucket to the ground and adjust the bucket to the desired digging angle. Set the bucket control lever at HOLD, stop the engine and adjust as follows.

2.

Loosen two bolts @) and adjust mounting bracket 0 of the proximity switch so that the rear tip of angle @ is in line with the center of the sensing surface of proximity switch 0. Then tighten the bolts to hold the bracket in position.

3.

Loosen two nuts @ and adjust to make a clearance of 3 to 5 mm (0.12 to 0.20 in) between angle @ and the sensing surface of _ proximity switch 0. Then tighten the nuts to hold in position.

Tightening 4.

torque:

17.2 2 2.5 Nm (1.75 + 0.25 kgm, 12.7 f 1.8 Ibft)

After adjusting, start the engine and raise the lift arm. Operate the bucket control lever to the DUMP position, then operate it to the TILT position and check that the bucket control lever is automatically returned to HOLD when the bucket reaches the desired angle.

12.12.3 BUCKET LEVEL INDICATOR @ and @ at the top rear of the bucket are the level indicators, so the bucket angle can be checked @: Parallel with cutting edge a,: 90� to cutting edge

2-70

during

operations.

12.13

PARKING

MACHINE

A

WARNING

Avoid stopping suddenly. Give yourself ample room when stopping.

Do not park the machine on slopes.

If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.

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

Even if the parking brake switch is turned ON, there is danger until the parking brake pilot lamp lights up, so keep the brake pedal depressed.

11

Thrust

ttle DuCket

AW2837B

NOTICE Never use the parking brake switch to brake the machine when traveling except in an emergency.

Apply the parking brake only after the machine has stopped.

1.

Release accelerator the machine.

pedal 0,

and depress brake pedal @to stop

2.

Place directional

3.

Turn parking brake switch @ to ON to apply the parking

lever @ in N (neutral).

REMARK When the parking brake is applied, the transmission cally returned to neutral.

brake.

is automati-

2-71

1

12. OPERATION

4.

Operate ground.

lift arm

control

5. Lock lift arm control safety lock 0.

12.14

lever

($I to lower

the

lever @ and bucket control

CHECKS AFTER COMPLETION OPERATION

bucket

lever @ with

OF

Check the engine water temperature, engine oil pressure, converter oil temperature, and fuel level with the meter and If the engine has overheated, do not stop it suddenly. Run the at a midrange speed to allow the engine to cool down stopping it.

12.15

STOPPING

to the

torque lamps. engine before

ENGINE

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

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

1.

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

2.

Turn the key in starting the engine.

switch @ to the OFF position

and stop OFF

, 3.

2-72

Remove

the key from starting

switch 0.

12. OPERATION

12.16

CHECK AFTER STOPPING

ENGINE

1.

Walk around the machine and check the work equipment, body work, and undercarriage, and check also for leakage of oil and water. If any leakage or abnormality is found, carry out repairs.

2.

Fill the fuel tank.

3.

Remove any waste paper or dead leaves from inside the engine room. These may cause a fire.

4.

Remove

12.17 @ @ @ @ @ @

any mud stuck to the undercarriage.

LOCKING

Always lock the following places.

Engine side panel (left, right) Cab door Air conditioner filter cover Engine hood at rear of cab (2 points) Fuel tank filler cap Hydraulic tank filler cap

REMARK The starting switch

key is

used also for locks @,a,

@,@I, 0, and

8.

2-73

12. OPERATION

12.18 HANDLING THE TIRES 12.18.1 PRECAUTIONS WHEN HANDLING

TIRES

Breaker (cord

ALCAUTION If a tire has reached any of the following service limits, there is danger that the tire may burst or cause an accident, so to ensure safety, replace it with a new tire.

0 Service limits for wear o When the remaining depth of the groove on construction equipment tires (at a point approx. l/4 of the tread width) is 15% of the groove depth on a new tire. o When the tire shows marked uneven wear, stepped wear or other abnormal wear, or when the cord layer is exposed. l Service limits for damage o When there is external damage extending to the cord or when the cord is broken o When the cord is cut or there is dragging o When the tire is peeling (there is separation) o When the bead is damaged o For tubeless tires, when there is air leakage or improper repair Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care.

12.18.2

TIRE PRESSURE

Measure the tire pressure before starting operations, when the tires are cool.

If the tire inflation pressure is too low, there will be overload; if it is too high, it will cause tire cuts and shock burst. To prevent these problems, adjust.the tire inflation pressure according to the table on the next page. ‘:, H-h ; h +I ( Deflection ratio = x100 _ _ _ __ ; I0 H As a guideline that can be checked visibly, the deflection ratio of the front tire (deflection/free height) is as follows.

When carrying normal load (lift arm horizontal): Approx. 10 - 15% When digging (rear wheels off ground): Approx. 20 - 25% When checking the tire inflation pressure, check also for small scratches or peeling of the tire, for nails or pieces of metal which may cause punctures, and for any abnormal wear.

Clearing fallen stones and rocks from the operating area and maintaining the surface will extend the tire life and give improved economy. l For operations on normal road surfaces, rock digging operations: . ..i....................................

High end of range in air pressure chart l

l

2-74

Stockpile operations on soft ground: .. . . .. .. . . . . .. . . . . . . . . .. . .. . . .. .. . . . .. . Average pressure

in air pressure

chart

Operations on sand (operations not using much digging force) . . .. . . .. .. .. . . . . . .. .. . . . . . . . . . . .. . . . . . . Low end of range in air pressure chart

or belt I aver)

Bead AE407em

If the deflection of the tire is excessive, pressure within the limits given in the table deflection (see deflection ratio).

Stockpile materials.

operations

mean the loading

raise the inflation to give a suitable

of sand and other loose

METHOD OF CHARGING TIRES WITH AIR Connect the supplied pump up the tires.

air charge

hose to air pickup

port @ to

PRECAUTIONS WITH LOAD AND CARRY METHOD When traveling continuously with load and carry operations, choose the correct tires to match the operating conditions, or choose the operating conditions to match the tires. If this is not done, the tires will be damaged, so contact your Komatsu distributor or tire dealer when selecting tires.

2-75

12. OPERATION

12.19

l&MWfIL

AND INSTALLATION a

OF THE

WARNING

Park the machine on level ground, set the safety bar on the frame, ground the bucket, shut down the engine, apply the parking brake and place blocks under the tires.

Remove or install the bucket in the following required for the convenience of transportation.

manner,

if so

REMOVING THE BUCKET 1. Loosen retainer mounting bolts on the bucket link pin part and the bucket pin part, then remove retainer @ and shim 0.

2.

2-76

Loosen

lock bolt @ and remove

cam GJ.

12. OPERATION

3.

Sling the bucket link, then pull out the bucket link pin.

Secure the bucket link to the tilt lever with wires.

4.

Pull out and remove bucket.

5.

Disconnect

bucket hinge

pin @ on both sides of the

lift arm and bucket.

2-77

12. OPERATION

INSTALLING THE BUCKET 1. Set cord ring @ on top of lift arm diagram.

boss @ as shown

in the

After completions of assembly of the bucket and adjustment with shims in step 8, move the cord ring down to the groove.

2.

Coat dust seal lip portion

@ with grease.

3.

Align the left and right bucket pin holes.

Select the number of shims so that clearance A between bucket hinge boss @ and lift arm boss @ are less than 1 .O - 1.5 mm (0.04 - 0.06 in).

Assemble the shims the selected in Step 4, align the pin holes, then insert bucket hinge pin 0.

Coat with grease to prevent damage to the dust seal when inserting the bucket hinge pin.

Use a bucket hinge pin that has a grease

hole.

Put bucket hinge pin stopper plate @ in contact plate block, and secure it with cam 8.

2-78

with the hinge

12. OPERATION

Install retainer 0 to bucket hinge pin &then measure clearance B between the end face of the retainer and the bucket hinge boss.

Select the number of shims so that clearance B is 0.2 mm (0.008 in) or loss, then add one 0.2 mm (0.008 in) shim, and assemble.

9.

Move cord ring @ down to the groove.

10. Use the same procedure pin.

Assemble

as in steps I-

a pin that has no grease

9 to install the bucket link

hole at the bucket link.

11. Coat the bucket hinge pin and bucket link pin with grease. details, see “24.5 EVERY 100 HOURS SERVICE�.

For details of removing your Komatsu distributor.

and installing

For

the bucket, please contact

2-79

13. TRANSPORTATION

When transporting this machine, it is necessary to disassemble it for transportation.

Contact your Komatsu distributor for details of disassembly, transportation and assembly after transportation.

2-80

14. COLD WEATHER OPERATION

14.1

PRECAUTIONS

FOR LOW TEMPERATURE

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

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

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

14.12

COOLANT

Keep antifreeze

fluid away

from

an open flame.

Never

smoke

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

For details of the antifreeze mixture when changing the coolant, see “24.2 WHEN REQUIRED”.

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

Standard requirements for permanent antifreeze l SAE ,........................................................................................

J1034 l FEDERAL STANDARD . . .. . .. . . . .. . .. . . . . .. .. .. . . . . . ... .. . .. .. .. . .. . .. .. . . O-A-548D REMARK Where no permanent antifreeze is available, an ethylene glycol antifreeze without corrosion inhibitor may be used only for the cold season. In this case, clean the cooling system twice a year (in spring and autumn). When refilling the cooling system, add antifreeze in autumn, but do not add any in spring.

2-81

14. COLD WEATHER OPERATION

14.1.3 BATTERY ih WARNING l

To avoid gas explosions, battery.

do not bring fire or sparks near the

l

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

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

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

100% 90% 80% 75%

2-82

the rate of charge

20°C

0°C

-10°C

-20°C

-30°C

1.28 1.26 1.24 1.23

1.29 1.27 1.25 7.24

1.30 1.28 1.26 1.25

1.31 1.29 1.27 1.26

1.32 1.30 1.28 1.27

14. COLD WEATHER OPERATION

14.2

F;RE;lJTIONS

AFTER COMPLETION

OF

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions.

0 Mud and water on the machine body should be completely removed. This is to prevent damage to the seal caused by water in mud or dirt getting inside the seal and freezing.

1

l

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

0

Bleed the air from the tank to prevent inside the tank.

l

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

0

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.

14.3

moisture

from collecting

collected

in the fuel

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.

and an is used system system

2-83

15. LONG-TERM

15.1

STORAGE

BEFORE STORAGE

When putting the machine in storage for a long time, do as follows.

After every part is washed and dried, house the machine in a dry building. Never leave it outdoors.

If the machine must be left outdoors, park it on well-drained concrete and cover it with canvas, etc.

Completely storage.

fill the fuel tank, lubricate,

and change the oil before

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

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

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

below

O�C,

Apply the safety locks to the bucket control lever, lift arm control lever, and directional lever, then apply the parking brake.

Open the drain valve of the air tank to drain condensation. after completely drained.

15.2

DURING

’

STORAGE

a

Close

WARNING

If it is unavoidably necessary to carry out the rust-prevention 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.

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

If the machine is equipped with an airconditioner, operate it for 3 5 minutes once a month to lubricate each portion of its compressor.

Be sure to idle the engine at low speed for this purpose. Also, check the quantity of refrigerant twice a year.

15.3

AFTER STORAGE

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

Carry out the following of long-term storage.

procedure

l

Wipe

l

Add oil and grease to all places.

2-84

when taking the machine

off the grease from the hydraulic

cylinder

rods.

out

16. TROUBLESHOOTING

16.1

WHEN MACHINE 4h

RUNS OUT OF FUEL WARNING

The engine will start, so check carefully that the area around the engine is safe before cranking the engine.

If the machine has run out of fuel, add fuel and then bleed the air from the fuel system before starting the engine.

PROCEDURE FOR BLEEDING AIR 1. Loosen air bleeding plug 0.

2.

Loosen feed pump knob @ and move the pump up and down to draw off fuel until air ceases to come out of air bleeding plug 0.

3.

After bleeding the air, tighten air bleeding plug @I, then push in the knob of feed pump @ and tighten it.

2-85

16. TROUBLESHOOTING

16.2 7

TOWING

THE MACHINE g

l

l

l

WARNING

-1

If the machine that has broken down is towed in the wrong way, it may lead to serious injury or damage.

If there is a failure in the brake line, the brakes cannot be used, so be extremely careful when towing.

When using the drawbar pin on the counterweight for towing, the maximum towing load must be kept to less than 32 tons because of the strength of the pin.

NOTICE Towing is for moving the machine to a place where inspection and maintenance can be carried out, and not for moving it long distances.

The machine must not be towed for long distances. l For details of the procedure for towing a machine when it has broken down, please contact your Komatsu distributor. l

This machine must not be towed except in emergencies. towing the machine, take the following precautions.

When

l

When releasing the brakes, put blocks under the wheels to prevent the machine from moving. If the wheels are not blocked, the machine may suddenly move.

l

When towing a machine, tow it at a low speed of less than 2 km/ h (I -24 MPH), and for a distance of a few meters to a place where repairs can be carried out. The machine should be towed only in emergencies.

If the machine must be moved long distances, use a transporter.

l

Fit a guard plate to the machine being towed operator if the tow rope or bar should break.

l

If the steering and brake of the machine being towed operated, do not let anyone sit on the machine.

l

Check that the tow rope or bar is of ample strength for the weight of the machine being towed. If the machine being towed must travel through mud or up hills, use a tow rope or bar of a strength of at least 1.5 times the weight of the machine being towed.

2-86

to protect

the

cannot be

16. TROUBLESHOOTING

Keep the angle of the tow rope as small as possible. Keep the angle between the center lines of the two machines to within 30�.

If the machine is moved suddenly, an excessive load will be applied to the tow rope or bar, and it may break. Always move the machine slowly at a fixed speed.

The towing machine should normally be of the same class as the machine being towed. Check that the towing machine has ample braking power, weight, and rimpull to allow it to control both machine on slopes or on the tow road.

When towing a machine downhill, use a larger machine for towing to provide ample rimpull and braking power, or connect another machine to the rear of the machine being towed. In this way it is possible to prevent the machine from losing control and turning over.

Towing may be carried out under various differing conditions, so it is impossible to determine beforehand the requirements for towing. Towing on flat horizontal roads will require the minimum rimpull, while towing on slopes or on uneven road surfaces will require the maximum rimpull.

2-87

16. TROUBLESHOOTING

16.2.1 WHEN ENGINE CAN BE USED l

If the transmission and steering wheel can be operated, and the engine is running, it is possible to tow the machine out of mud or to move it for a short distance to the edge of the road.

l

The operator should sit on the machine being towed and operate the steering in the direction that the machine is towed.

16.2.2 WHEN ENGINE CANNOT

BE USED

When towing a machine with the engine stopped, use the following procedure.

If leakage in the air circuit has caused the pressure inside the air tank to drop, the parking brake will be applied. When towing the machine, release the oarkina brake.

1. The transmission oil do& not lubricate the system, so remove the front and rear drive shafts. If necessary, block the tires to prevent the machine from moving.

2.

The steering cannot be operated, so remove the steering cylinder and steering linkage.

Even if the brakes are in good condition, the brakes can only be used a limited number of times. There is no change in the operating force for the brake pedal, but the braking force is reduced each time the pedal is depressed.

3.

Connect the towing equipment securely. When carrying out towing operations, use two machines of at least the same class as the machine being towed. Connect one machine each to the front and rear of the machine being towed, then remove the blocks from the tires and tow the machine.

2-88

’

16. TROUBLESHOOTING

16.2.3 RELEASING PARKING BRAKE g l

l

l

WARNING

Stop the machine on a flat surface when releasing the parking brake, and check that the surroundings are safe. In emergencies or when the parking brake must be released on a hill, block the tires carefully before releasing the brake.

When the parking brake is released, no braking force can be applied, so check carefully that the situation is safe when moving the machine.

If there is a failure in the air circuit, the brakes cannot be used.

This is dangerous, so always tow the machine at low speed.

Keep the engine running so that the steering can be used.

Release the parking brake as follows

1.

Remove air charge socket @ installed left rear frame.

before towing

the machine.

on the front portion of the

Remove parking brake switch @ and adapter @ installed to the outlet side of the parking brake solenoid valve, and install the socket removed in Step 1 in their place.

Install the air charge

hose for the tire to the air charge

socket.

Push the end of the hose on the tire valve, and air will supplied to the brake chamber to release the brake.

be

To chamber I

G?z,

When the parking brake is released, remove the air charge hose.

Tow the machine immediately to a safe place.

2-89

16.3

IF BATTERY

IS DISCHARGED a

WARNING

l

When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position before starting.

l

Before starting the engine, use a damp cloth to wipe off the dust accumulated on the top surface of the battery.

l

The battery generates hydrogen gas, so there is danger explosion. Do not bring lighted cigarettes near the battery, do anything that will cause sparks.

l

Battery electrolyte is dilute sulphuric acid, and it will attack your clothes and skin. If it gets on your clothes or on your skin, wash it immediately off with large amounts of water. If it gets in your eyes, wash it out with fresh water, and consult a doctor.

of or

l

When

l

When removing the battery, first disconnect the cable from the ground (normally, from the negative 0 terminal).

When installing, install the positive @ terminal first. If a tool touches the cable connecting the positive terminal and the chassis, there is danger that it will cause sparks.

l

If the terminals are loose, there is danger that the defective contact may generate sparks that will cause an explosion.

When installing the terminals, install them tightly.

0

When removing or installing, check which terminal and negative 0 terminal.

handling

battery,

always

wear

protective

goggles.

is the positive

@

REMOVAL AND INSTALLATION OF BATTERY When removing battery, first disconnect the cable from the ground (normally, from the negative 0 terminal).

If a tool touches a cable connecting the positive terminal and the chassis, there is danger of sparks being emitted. l When installing battery, the ground cable should be connected to the ground terminal as the last step. l

REMARK There are two batteries each (total: 4) on both sides at the rear of the machine. There is also one battery each for the ground (total: 2) on both sides of the machine.

2-90

When removing, disconnect the cable from the ground terminal first.

When installing, connect the cable to the positive

16. TROUBLESHOOTING

PRECAUTIONS FOR CHARGING BATTERY Charging battery when mounted on machine l Before charging, disconnect the cable from the negative Q terminal of the battery. Otherwise, an unusually high voltage will damage the alternator. l

While charging the battery, remove all battery plugs for satisfactory ventilation.

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

l

If the electrolyte while.

l

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

Overcharging the battery may cause the following: 1) Overheating the battery 2) Decreasing the quantity of electrolyte.

3) Damaging the electrode plate.

l

Do not mix the cables (positive @to negative 0 to positive 01, as it will damage the alternator.

l

When performing any service to the battery besides checking the electrolyte lever or measuring the specific gravity, disconnect cables from the battery.

temperature

exceeds

45�C, stop charging

for a

or negative

@

REMARK The batteries are on both sides at the rear of the machine. The battery used for the ground is on the left side of the machine.

2-91

16. TROUBLESHOOTING

16.3.1 STARTING When

starting

ENGINE WITH BOOSTER CABLE the engine

PRECAUTIONS WHEN BOOSTER CABLE

with a booster

CONNECTING

A

cable, do as follows:

AND

DISCONNECTING

WARNING

When connecting the cables, and negative @ terminals.

When starting the engine with safety glasses.

INCORRECT

never contact

a booster

the positive

cable, always

@

wear

Be careful not to let the normal machine and problem machine contact each other. This prevents sparks from generating near the battery which could ignite the hydrogen gas given off by the battery. If hydrogen gas explodes, it could cause serious injury.

Make sure that there is no mistake in the booster cable connections. The final connection is to the engine block of the problem machine, but sparks will be generated when this is done, so connect to a place as far as possible from the battery.

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 l battery size.

cable and clip should be suitable

for the

l

The battery of the normal machine must be the same capacity as that of the engine to be started.

l

Check the cables and clips for damage

l

Make

or corrosion.

sure that the cables and clips are firmly

connected.

There are two batteries each (total: 4) on both sides at the rear of the machine. There is also one battery each for the ground (total: 2) on both sides of the machine.

If the battery capacity of the normal machine is smaller than the battery capacity of the failed machine, use two normal machines.

Connect the booster cable from one machine to the battery on the right side of the failed machine; connect the booster cable from the other machine to the battery on the left side of the failed machine using the same procedure.

2-92

0 /

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 terminal

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

3.

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

the positive

4.

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

@ terminal

5.

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

the engine

@

L

W

Engine block to be started e

block of

STARTING THE ENGINE 1.

Make sure the clips are firmly connected

to the battery terminals.

2.

Turn the starting switch of the problem machine to the START position and start the engine. If the engine doesn’t start at first, wait for at least 2 minutes before trying again.

DISCONNECTING THE BOOSTER CABLES After the engine has started, disconnect the booster cables in the’ reverse of the order in which they were connected.

Remove one clip of booster cable 0 from the engine block of the problem machine.

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

ich

@

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

Remove the other positive @ terminal

clip of booster of the problem

cable @ and machine.

@ from

the

2-93

16. TROUBLESHOOTING

16.4

OTHER TROUBLE

16.4.1 ELECTRICAL SYSTEM ): Always contact your Komatsu distributor . ( In cases of abnormalities distributor for repairs.

l

or causes

Problem

which

when dealing with these items. are not listed below, please contact

your

Komatsu

Remedy

Main causes l

Defective wiring

(0 Check, repair loose terminals,

l

Defective adjustment of alternator belt tension

l

Charge level monitor does not go out 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

to Replace)

Starting motor does not turn when starting switch is turned to ON

l l

Defective wiring insufficient battery charge

(o Check, repair) l Charge

Pinion of starting motor keeps going in and out

l

Insufficient battery charge

l

Starting motor turns engine sluggishly

l

Insufficient battery charge Defective starting motor

l

Starting motor disengages before engine starts

l

Pre-heating monitor does not light

l

Lamp does not glow brightly even when the engine runs at hight speed Lamp flickers while engine is running

l

l

l l

Engine oil pressure monitor lamp does not light up when engine is stopped (starting switch at ON position) Battery charge monitor lamp does not light up when engine is stopped (starting switch at ON position) Outside of electrical heater is not warm when touched by hand

2-94

l l

l l

Charge

Charge (o Replace)

(o Check, repair) Charge

Defective wiring Insufficient battery charge

l

Defective wiring Defective heater relay Defective monitor

(o Check, repair) (o Replace) (o Replace)

Defective monitor Defective wiring, defective sensor

10 Replace) (o Check, repair, replace)

Defective wiring Defective monitor

(o Check, repair) 10 Replace)

Defective wiring D Disconnection in electrical heater D Defective operation of heater relay switch

l

disconnections) Adjust alternator belt tension For details, see EVERY 250 HOURS SERVICE

(o Check, repair) (o Replace) (D Replace)

16. TROUBLESHOOTING

16.42 CHASSIS 1: Always contact 0 ( l

your Komatsu distributor when dealing with these items.

In cases of abnormalities or causes which are not listed below, please contact distributor for repairs.

Main

Problem

causes

your

Komatsu

Remedy

Transmission

Engine is running does not move

but machine

l

Parking brake is applied Directional lever is not shifted properly Lack of oil in transmission case

l l

Even when engine is run at full throttle, machine only move slowly and lacks power

l

Lack of oil in transmission

l

Transmission

Oil overheats

l

Too much oil or too little oil

strainer

case

is clogged

Machine is not traveling in correct speed range l Torque converter is stalled for I long periods l Engine is overheating l

Noise generated

l l

l

Release parking brake Shift lever properly Add oil to specified level.

See WHEN REQUIRED

Add oil to specified level.

See WHEN REQUIRED (o Disassemble, clean) l

l

Add or drain oil to specified level.

See WHEN REQUIRED Place in correct speed range

l

Reduce stall time

l

(o Check engine)

l

Lack of oil

l

Add oil to specified level.

See WHEN REQUIRED

l

Lack of oil

l

Add oil to specified level.

See WHEN REQUIRED

Axle

Noise generated

2-95

16. TROUBLESHOOTING

CHASSIS continued

(16.42)

Problem

Main

causes

Remedy

Disc brake

Brake has no effect even when pedal is depressed

Low air pressure Disc has reached wear limit Defective in hydraulic system o Lack of oil Air in brake line

Brake drags or remains

Brakes slip Parking

applied

Exhaust hole in treadle valve clogged l Power cluster breather clogged s Defective operation of slack adjuster l

D Worn disc

l l l l

wheel heavy

l

l

2-96

o Add oil to specified level.

See CHECKS BEFORE STARTING l Bleed air.

See WHEN REQUIRED 0

Clean

0 Clean (o Check, repair)

(o Replace)

brake

Braking effect is poor

Steering

Charge air to specified pressure (o Replace disc)

l

Linkage is loose Pad is wet Deteriorated air cylinder Worn pad

Steering gear adjustment tight Linkage is stiff

Adjust 0 Clean (o Replace spring) l Adjust or replace l

spring

is too

(o Adjust) (o Check linkage, necessary)

replace if

16. TROUBLESHOOTING

CHASSIS continued

(16.42)

Problem Hydraulic

Main

l

Lack of oil

Bucket takes time to rise

l

Clogged

Excessive bubbles in oil

l

Movement

Remedy

system

Lack of lifting power for bucket

Hydraulic

causes

pressure is low

of cylinder

is irregular

hydraulic

Add oil to specified level.

See EVERY 100 HOURS SERVICE Replace filter.

See EVERY 2000 HOURS SERVICE

tank filter

Low quality oil being used 0 Oil level is low

l l

Replace with good quality Add oil to specified level.

See EVERY 100 HOURS SERVICE Bleed air. See WHEN REQUIRD

l

Air in oil line

l

l

Oil level is low and pump is sucking in air

l

Add oil to specified level.

See EVERY 100 HOURS SERVICE Then bleed air.

See WHEN REQUIRD

l

Add oil to specified level.

See EVERY 100 HOURS SERVICE

0 Oil level is low

oil

2-97

16. TROUBLESHOOTING

16.4.3 ENGINE ): Always contact 0 (

your Komatsu In cases of abnormalities or causes distributor for repairs.

l

distributor when dealing with these items. which are not listed below, please contact

Problem

Add oil to specified level, see CHECK BEFORE STARTING Replace cartridge, see EVERY 250 HOURS SERVICE Check, repair)

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

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

monitor

Cooling water level low, water leakage Loosen fan belt

Clogged radiator fin or damaged fin Defective thermostat Loose radiator filler cap (high altitude operation) Defective water level sensor

lights

up

Engine does not start when starting motor is turned

Lack of fuel

Defective fuel injection nozzle

Add cooling water, repair, see CHECK BEFORE STARTING Adjust fan belt tension, see WHEN REQUIRED Change cooling water, clean inside of cooling system, see WHEN REQUIRED Clean or repair, see WHEN REQUIRED (e Replace thermostat) l Tighten cap or replace packing (e Replace sensor) Add fuel, see CHECK BEFORE STARTING l Repair place where air is sucked in, see EVERY 500 HOURS SERVICE (e Replace pump or nozzle) l

Air in fuel system

,

Replace sensor)

engine oil pressure

Dirt or scale accumulated in cooling system

Coolant temperature

Komatsu

Remedy

Main causes

Engine oil pressure monitor lights up

your

pump or

, Starting , ,

Exhaust gas is white

or blue

Exhaust gas occasionally black

turns

motor cranks engine sluggishly Preheating monitor does not light up Defective compression o Defective valve clearance

(o Adjust valve clearance)

,l Too much oil in oil pan

l

,D Improper

l

fuel

tD Clogged air cleaner element D Defective Defective

4

4D

nozzle compression

D Defective turbocharger

4

2-98

I-

See ELECTRICAL SYSTEM

Add oil to specified level, see CHECK BEFORE STARTING Change to specified fuel

Clean or replace, see WHEN REQUIRED [e Replace nozzle) [e See defective compression above) (e Clean or replace turbocharger) l

16. TROUBLESHOOTING

ENGINE continued

(16.4.3) Main

Problem

causes

Combustion noise occasionally makes breathing sound

l

Defective

Abnormal noise generated (combustion or mechanical)

l

Low grade fuel being used Overheating

l

l l

nozzle

Damage inside muffler Excessive valve clearance

Remedy

(o Replace nozzle)

Change to specified fuel Refer to “Coolant temperature monitor lights up� as above (0 Replace muffler) (o Adjust valve clearance) l

l

2-99

MEMO

2-100

MAINTENANCE

3-l

17. GUIDES TO MAINTENANCE

Do not carry out any inspection Perform

maintenance

and maintenance

operation

that is not given in this manual.

work on hard, flat ground.

Set to the inspection and maintenance posture.

Always carry out operations with the machine in the following posture unless otherwise specified. l Lower the work equipment to the ground and set in the posture shown in the diagram on the right. l Set all control levers to the neutral or HOLD position. l Set the safety lever to the LOCK position. l Press the parking brake switch to apply the parking brake. l Put blocks in front and behind the tires. l Lock the front and rear frames with the safety bar.

AD429U90

Check service meter: Check the service meter to be carried out.

reading

every day to see if the time has come for any necessary

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

oils and grease

fluid and be careful

Always use clean oil and grease: Use clean oil and grease. Also, keep containers from oil and grease.

with

maintenance

parts.

proper

viscosities

specified

for

not to let any dirt get into it.

of the oil and grease clean. Keep foreign

materials

away

Keeping the machine clean: Always keep the machine clean. This makes is easier to find parts causing problems. In particular, keep grease fittings, breathers and oil level gauges clean and avoid foreign materials from getting in them.

After disconnecting the connector, cover it with a vinyl bag to prevent oil or dust from sticking to its contact section.

Be careful of hot water and oil: Draining hot oils and coolants and removing hazardous. Allow the engine to cool.

If the oil has to be drained when it is cold, warm before draining it.

3-2

their

filters

immediately

up the oil to a suitable

after

the

temperature

engine (approx.

stops

are

20 - 40°C)

17. GUIDES TO MAINTENANCE

Checking foreign materials in drained oil and on filters: 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

Warning tag: Attach the warning tag to the starting switch or other appropriate starting the engine during maintenance.

Obey precautions: During the operation,

always

it while

obey the precautions

on the safety

control

fueling.

materials

away from oils.

lever to prevent anyone from

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 grounding the cable within 1 m (3.28 ft) from the area to be welded. l Avoid seals or bearings from being between the area to be welded and the position of the grounding point. l Never weld any pipe or tube containing fuel or oil.

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 work on the machinery while bending over it.

especially

when

3-3

17. GUIDES TO MAINTENANCE

Checking undercarriage: When working in rocky areas, check for damage damage in bolts and nuts.

to the undercarriage

and for looseness,

flaws, wear and

Precautions when washing machine: l Never spray steam or water directly at the radiator. l Do not allow water to get on any electrical component.

Pre-and post-work checks: Before starting work in mud, rain, snow or at the seashore, check plugs and valves for tightness.

Wash the machine immediately after the work to protect components from rusting.

Lubricate components more frequently than usual. Be sure to lubricate work equipment pins daily if they are submerged in water.

On jobsites where heavy-duty operations are common, reduce the maintenance intervals and carry out greasing more frequently.

<

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 used in the machine, do not add it but replace all the oil.

is a different

brand from the one that is

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

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

Controller: The controller for the machine monitor may be mistakenly actuated by interference from external electric waves. For this reason, when installing a radio or other such device, please consult your Komatsu distributor.

3-4

18. OUTLINES OF SERVICE

genuine

parts for replacement.

l

Use Komatsu

l

When

l

Unless otherwise specified, shown in the table below.

changing

or adding

oil, do not use a different the oil and coolant

type of oil.

used at the time of shipment

Compartment

from the factory are as

Fluid Type

Engine

Engine oil SAE 15W-40 API classification CF-4

Torque converter & Transmission

Engine oil SAE 30W API classification CE

Service brakes

Engine oil SAE 1OW API classification CE

Hydraulic system

Engine oil SAE IOW API classification CE

Drive axles - Front & rear

MOBIL 424

Lubrication fittings

No.2 multi-purpose lithium grease with 3% molybdenum disulfide

Fuel tank

Diesel fuel ASTM D975 Grade No. 2-D or ASTM D975 Grade No. 1 for winter season of October to March

Cooling system

50/50 Mixture of ethylene glycol antifreeze and water

18.1

OUTLINE

18.1.1

OIL

OF OIL, FUEL, COOLANT

Oil is used in the engine and work equipment

under extremely severe conditions (high temperature, high pressure), and it deteriorates with use.

Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual. Even if the oil is not dirty, always replace the oil after the specified interval.

Oil corresponds to blood in the human body, so always be careful when handling it to prevent impurities (water, metal particles, dirt,;etc.) from getting in.

The majority of problems with machine are caused by the entry of such impurities.

Take particular care not to let any impurities get in when storing or adding oil.

Never mix oils of different

grades

any

or brands.

Always add the specified amount of oil.

Having too much oil or too little oil are both causes of problems.

If the oil in the work equipment is not clear, there is probably In such cases, please contact your Komatsu distributor.

When

changing

the oil, always

water

or air getting

into the circuit.

replace the related filters at the same time.

We recommend you to have an analysis made of the oil periodically to check the condition machine.

For those who wish to use this service, please contact your Komatsu distributor.

of the

3-5

18. OUTLINES OF SERVICE

18.1.2 FUEL The fuel pump is a precision properly.

Be extremely

careful

instrument,

not to let impurities

and if fuel containing

get in when

storing

water or dirt is used, it cannot work

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-IX), so it is necessary to change to a fuel that matches the temperature.

To prevent the moisture in the air from condensing fill the fuel tank after completing the day’s work.

Before starting the engine, or when and water from the fuel tank.

10 minutes

and forming

water inside the fuel tank, always

have passed after adding

fuel, drain the sediment

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 Use water which has a low mineral content. Water used in conjunction with antifreeze and conditioners should meet the specific requirements defined under “20.3 COOLANT SPECIFICATIONS” on page 3-13.

When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.

An anti-freeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates.

Anti-freeze concentrations between 68% and 100% actually have a higher freezing point than a 68% antifreeze concentration and should not be used due to reduced heat transfer rates.

All cooling system inhibitors, including those in anti-freeze solutions, become depleted through normal operation. If the inhibitors in anti-freeze are allowed to become depleted, the anti-freeze becomes corrosive and attacks and coats the metallic surfaces of the cooling system which reduces heat transfer. Cooling system conditioners which contain these inhibitors must be added to maintain corrosion protection.

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 “20.3 COOLANT SPECIFICATIONS” on page 3-13.

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.

3-6

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 nipples for overhaul, grease.

If any part becomes stiff after being used for long time, add grease.

l

Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts.

so they do not need

18.1.5 STORING OIL AND FUEL l

Keep indoors to prevent

any water,

dirt, or other impurities

l

When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at the side. (To prevent moisture from being sucked in) If drum cans have to be stored outside, cover them with a waterproof sheet or take other measures to protect them.

l

To prevent any change in quality during first out (use the oldest oil or fuel first).

long-term

storage,

from getting

in.

be sure to use in the order of first in -

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

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

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

Never try to clean the filters (cartridge

type) and use them

again. Always

replace

with new filters.

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

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

Always

use Komatsu

genuine

filters.

3-7

18.2

OUTLINE

OF ELECTRIC SYSTEM

If the wiring gets wet or the insulation is damaged, in hazardous malfunction of the machine.

the electric

system

Services relating to the electric system are (I) check of fan belt tension, in the fan belt and (3) check of battery fluid level.

Never

remove

or disassemble

Never

install any electric

components

Be careful to keep the electric When

working

The optional

3-8

on the seashore, power

any electric components

source

installed

carefully

clean the electric

must never be connected

(2) check of damage

or wear

in the machine.

other than those specified

system free of water when

leaks and this could result

by Komatsu.

washing system

the machine to prevent

to the fuse, starting

or when

it rains.

corrosion.

switch,

or battery

relay.

19. WEAR PARTS LIST

Wear parts such as the filter element, air cleaner element, bucket tooth, etc. are to be replaced the time of periodic maintenance or before their abrasion limits.

The wear parts should be changed correctly in order to use the machine economically.

For part change, Komatsu genuine parts of excellent quality should be used.

When ordering parts, please check the part number in the parts book.

The parts in parentheses

are to be replaced

Item

Part Name

600-21 I-1230

By-pass filter

EVERY 250 HOURS

2

I

EVERY 250 HOURS

I

Cartridge

2

EVERY 500 HOURS

Element (O-ring) (O-ring)

6 (12) (6)

EVERY 500 HOURS

600-411-1170

Cartridge

2

EVERY 1000 HOURS

07063-01142

Element

4

Hydraulic filter (07000-05175)

(O-ring) Element assâ&#x20AC;&#x2122;y

2

600-181-4400

Outer element assâ&#x20AC;&#x2122;y

2 1

Cab air filter

*

Element

Bucket tooth points

*

Tooth point (Locking pin)

EVERY 2000 HOURS

(4)

6128-81-7042 Air cleaner

*-

4

Cartridge

I

Replacement frequency

ag

Cartridge

600-212-1510

I

Corrosion resistor

at the same time.

Part No.

Engine oil filter

at

-

EVERY 2000 HOURS WHEN

REQUIRED

(Z)

For part numbers, refer to parts book.

3-9

20.USE OF FU ZL,COOLANT AND LUBRICANTS ACCORDING TO AMBIEI’ T TEMPERATURE

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

RESERVOIR

I

1

AMBIENT TEMPERATURE

KIND OF FLUID

CAPACITY Specified

Refill

90 e US gal 23.76 US gal 21.56 UK gal 19.80 UK gal 98E

25.87

Engine with filters

Torque converter & transmission

:ngine

oil

1641

140t

gal 36.1 UK gal

37.0 US gal

43.3 US

30.8

UK gal

550 e gal 145.2 US gal 212.1 UK gal 121.0 UK gal 946 J?

Hydra&

249.7 US

system

184 4.75 US gal 3.96 UK gal

Service brakes

Axle oil

See Note 1

All lubrication fittings

Grease

lo.2 multi-purpose lithium grease with 3% molybdenum disulfide

Cooling system

1430 e 377.5US gal 314.6UK gal

Diesel fuel

Coolant

US gal 3.96 UK gal

360 I 360 e 95.0 US gal 95.0 US gal 79.2 UK gal 79.2 UK gal

Drive axles - Front & rear (each)

Fuel tank

18!

4.75

se 20.3 COOLANT SPECIFICATIONS page 3-l 3

When operating the machine at temperatures your Komatsu distributor.

below-20”C,

other equipment

on

301 & 79.5 US gal 66.2 UK gal

-

is needed, so please consult

Note 1: For axle oil, use only recommended oil as follows.

SHELL: DONAX l-l- or TD CALTEX: RPM TRACTOR HYDRAULIC FLUID CHEVRON: TRACTOR HYDRAULIC FLUID A’ TEXACO: TDH OIL , MOBIL 424 MOBIL: .

It is possi,ble to substitute engine oil SAE 30W API classification CD for axle oil. Although Increased brake noise may result, durability should not be affected.

ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute Specified capacity: Total amount of oil including oil for components and oil in piping.

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

3-10

20. USEOF FUEL, COOLANT

AND LUBRICANTS

ACCORDING

TO AMBIENT

TEMPERATURE

20.1 ENGINE OIL SPECIFICATIONS Normal operation Oil performance

recommendations

are as follows:

The use of a quality engine lubricating oil combined with appropriate factors in maintaining engine performance and durability.

oil and filter change intervals are critical

SAE 15W-40 multi-viscosity engine oil meeting the American Petroleum classification of CF-4, CG-4, CF-4/SG or CG-4/SH is recommended.

Institute (API) performance

NOTE: Classification CE or CE/SF oils may be used in areas where CF-4, CG-4, CF-4/SG or CG-4/SH oil is not yet available. If API classification CC is used, reduce the engine oil change interval by half.

A sulfated ash limit of 1 .O mass percent is suggested for optimum valve and piston deposit and oil consumption control. the sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has been placed on all engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage and lead to excessive oil consumption.

The API service symbol displays the following information. The upper half of the symbol displays the appropriate oil categories; the lower half may contain words to describe oil energy conserving features. The center section identifies the SAE oil viscosity grade.

Oil viscosity

recommendations

are as follows:

The use of a multi-graded lubricating engine cranking in cold temperatures While SAE 15W-40 multi-viscosity for oil viscosity recommendations

oil has been found to improve oil consumption control and improve while maintaining lubrication at high operating temperatures.

oil is recommended for most operating for extreme climates.

Single graded oils may be used if multi-graded temperature shown in the table.

oil is not available.

Special “break-in” lubricating oils are not recommended during the “break-in” as specified for normal operation.

climates, refer to the previous table

But be sure to use oil that matches the

for a new or rebuilt engine. Use the same type of oil

Additional information regarding lubricating oil availability throughout the world is available in the “E.M.A. Lubricating Oils Data Book for Automotive and Industrial Engines”. The data book may be ordered from the Engine Manufacturers Association, 401 North Michigan Ave., Chicago, II U.S.A. 60611. The telephone number is (312) 644-6610.

Arctic Operation If an engine is operated in ambient temperatures consistently below -23°C (-10°F) and there are no provisions to keep the engine warm when it is not in operation, use a synthetic API performance classification CF-4 or CF-4/SG engine oil with adequate low temperature properties such as SAE 5W-20 or 5W-30.

The oil supplier must be responsible

for meeting the performance

service SPECIFICATIONS.

NOTICE: The use of a synthetic base oil does not justify extended oil change intervals. intervals can decrease engine life due to factors such as; corrosion, deposits

Extended oil change and wear.

3-11

20. USEOF FUEL, COOLANT

AND LUBRICANTS

ACCORDING

TO AMBIENT

TEMPERATURE

20.2 DIESEL FUEL SPECIFICATIONS WARNING Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.

NOTICE: Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and nozzles.

For normal service above -12°C (+lO”F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number of 40 is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent misfires and excessive smoke.

At operating temperatures reduce fuel economy.

below -12°C (+lO”F),

use ASTM Grade No. I-D diesel fuel. The use of lighter fuels can

Where a winterized blend of Grade No. 2-D and No. I-D fuels is available, it may be substituted for Grade No. I-D fuel. However, it is the supplier’s responsibility to provide the fuel for the anticipated ambient temperature.

Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel temperature. Cloud point is the temperature at which crystals begin to form in the fuel.

The viscosity

3-12

of the fuel must be kept above 1.3 cSt to provide adequate fuel system lubrication.

20. USEOF FUEL, COOLANT

AND LUBRICANTS

ACCORDING

TO AMBIENT

TEMPERATURE

20.3 COOLANT SPECIFICATIONS General Selection and maintenance provides recommendations

of the engine coolant is important to long engine life. The following information for selecting the engine coolant and maintaining the coolant inhibitors.

Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additives. Supplemental coolant additive recommendations are included in the section entitled “Inhibitors/Conditioners”.

The coolant mixture must be drained and replaced at the specified service interval shown in “23. MAINTENANCE SCHEDULED CHART” on page 3-19, or every two years of operation, whichever comes first.

Water Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited water must meet the following standards: Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits.

Water containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount will cause scale deposits to develop in the engine.

Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.

Chlorides Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.

Sulfites Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits, scale deposits, corrosion or a combination of these.

If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water supplies meet these standards, water samples can be tested by water treatment laboratories.

“Softened” water that is prepared using common salt (sodium chloride) contains excessive amounts of chlorides and should not be used.

NOTICE:

Never use water alone in the cooling system because corrosion

will occur.

Antifreeze In climates where the temperature is above -37°C (-34°F) use a coolant mixture that contains 50 percent antifreeze. Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is required. Never use more than 68 percent antifreeze under any condition.

An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates.

Antifreeze concentrations between 68 and 100% actually have a higher freezing point than a 68% antifreeze concentration and should not be used due to reduced heat transfer rates.

Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydrogel). This gel formation can occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive. DO NOT use methanol or alcohol as an antifreeze because of its low boiling point.

Antifreeze may retain its freeze protection for more than one season but coolant conditioners maintain corrosion protection.

Antifreeze

formulated

with methoxy propanol, or propylene

glycol, is not recommended

must be added to

for this system.

NOTICE: Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection against freezing. Antifreeze containing sealer or anti-leak additives should NIT be used in this system. Sealer or anti-leak additives will cause plugging problems in the cooling system.

3-l 3

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING

TO AMBIENT TEMPERATURE

Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient protection against freezing.

The following table shows the approximate percentage of antifreeze solution required for various temperatures.

Approximate Freezing Point

Percentage of Antifreeze Concentration by Volume

Specific Gravity at 16°C (60°F)

0°C (+32”F) -7°C (+2O”F) -12°C (+lO”F) -18°C (0°F) -23°C (-10°F) -29°C (-20°F) -34°C (-30°F) -40°C (-40°F) -46°C (-50°F) -51 “C (-60°F) -57°C (-70°F) -62°C (-80°F) -68°C (-90°F) -69°C (-92°F)

0 15 25 33 40 45 48 53 56 59 62 65 67 68

1.ooo 1.025 1.040 1.053 1.062 1.070 1.074 1.080 1.083 1.088 1.092 1.095 1.097 1.098

In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor/conditioner, to protect the engine cooling system.

Inhibitors/Conditioners 1. All cooling system inhibitors, including those in antifreeze solutions, become depleted through normal

operation. If the inhibitors in antifreeze are allowed to become depleted, the antifreeze becomes corrosive and attacks and coats the metallic surfaces of the cooling system which reduces heat transfer. Cooling system conditioners which contain these inhibitors must be added to maintain corrosion protection.

2.

SOLUBLE OIL IS NOT RECOMMENDED for use in this engine as its use will reduce heat transfer.

3.

There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is still the best coolant.

4.

A corrosion inhibitor/conditioner is recommended to inhibit corrosion in the cooling system for the following reasons:

0

Improved compatibility with high silicate antifreezes to minimize hydro-gel formation if over concentration occurs.

Provides engine protection in the following areas: - Copper corrosion/erosion/stress cracking - Solder corrosion/bloom - Cylinder liner cavitation corrosion - Oil fouling - Aluminum cavitation corrosion - Seal and gasket degradation

0

MAINTENANCE OF COOLING SYSTEM INHIBITORS Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits and corrosion.

New machines are delivered with antifreeze protection. Service at regular scheduled intervals specified in “23.

MAINTENANCE

3-l 3A

SCHEDULE

CHART” on page 3-19.

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

Each time the coolant is drained and replaced, the coolant must be recharged with a corrosion inhibitor/conditioner. New coolant can be correctly charged with supplemental coolant additives by using a concentrate.

If coolant is added between drain intervals, additional corrosion inhibitors/conditioners will be required.

3-l 3B

21. iTAl!DARD

21.1

TIGHTENING

TORQUES FOR BOLTS AND

INTRODUCTION OF NECESSARY TOOLS

The following tools are needed when carrying out maintenance.

No. 1

Name Wrench

of tool

09000-30006

set

Remarks

Part No. Applicable

width

across flats (S,-S,)

8mm - IOmm, 12mm - 14mm 13mm - 17mm m,

S2

19mm - 22mm

set

09020-I

24mm

- 27mm

30mm

- 32mm

0284

2

Socket wrench

3

Screwdriver

09033-00190

4

Wrench

09014-10200

5

Pliers

09036-00150

6

Wrench

09001-03600

36 jaw

7

Filter wrench

0901 g-08035

For filter cartridge

8

Bar

424-98-l

Extension

9

Gauge

09289-I 0000

10

Thickness

11

Grease

12

gauge

1130

Crosshead/flat

head interchangeable

bar

09054-00009 07952-80002

For greasing

Nozzle

07951-I

Hose nozzle for grease

13

Grease cartridge

07950-90403

(Lithium

14

Nipple

424-98-11110

For hydraulic

15

Hose

424-98-l

16

Hose

09288-10011

17

Hammer

09039-00150

18

1 Plate

pump

base grease:

pump 400 g)

oil drain

1120

09963-03000

If any of the above tools are broken,

3-14

1400

work

please

Warning

tag

order them from

your Komatsu distributor.

type

21. STANDARD TIGHTENING TORQUES FOR BOLTS

21.2

TORQUE

(a)

Width across flat (mm) (b)

0

0 Nm

6

NUTS

LIST

Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table.

The tightening torque is determined by the width across the flats @ of the nut and bolt.

If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

Nm (newton meter): INm + 0.1 kgm + 0.74 Ibft Thread diameter of bolt (mm)

AND

10

13.2 + 1.4

0 0

kgm

Ibft

1.35 f 0.15 9.73 f 1.03

8

13

31.4 i 2.9

3.2 2 0.3

23.2 + 2.1

10

17

65.7 + 6.8

6.7 + 0.7

48.5 + 5.0

12

19

112 + 9.8

11.5 + 1.0

82.6 + 7.2

14

22

177 + 19

18.0 + 2.0

131 + 14

16

24

279 + 29

28.5 2 3

206 + 21

18

27

383 f 39

39 + 3

282 + 29

20

30

549 sz58

56 f 6

405 2 43

22

32

745+78

76 f 8

549 * 58

24

36

927 + 98

94.5 + 10

684 2 72

27

41

1320 + 140

135 t 15

973 * 100

30

46

1720 + 190

175 + 20

1270 2 140

225 + 25

1630 2 180

33

50

2210 + 240

36

55

2750 it.

290

39

60

3280 + 340

b)

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.

3-15

22. PERIODIC REPLACEMENT

OF SAFETY CRITICAL PARTS

To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out periodic maintenance.

In addition, to further improve safety, the user should also carry out periodic replacement of the parts given in the table. These parts are particularly closely connected to safety and fire prevention.

With these parts, the material changes as time passed, or they easily wear or deteriorate. However, it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function completely.

However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced immediately.

If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same as the hoses.

When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.

Ask your Komatsu distributor to replace the safety critical parts.

3-16

22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

SAFETY CRITICAL PARTS No.

Part name

1

Fuel hose (Strainer

- L.H. injection

2

1 Fuel hose (Injection

3

1 Fuel hose (L.H. injection

4

Fuel spill hose (Between

5

Turbochager

I

pump - fuel tank)

hose

/

7

1 Fuel hose (Fuel tank - strainer)

- R.H. injection

Pump)

8

Fuel hose (R.H. injection

pump - fuel tank)

9

Front brake hose (Outlet

of slack adjuster)

10

Steering

hose

11

1 Front brake hose (Center

12

)

pin portion)

Hose of main suction tube

13

Outlet

14

Suction

15

Outlet

16

Suction

hoses of steering

pump

hoses of loader pump

and steering

hoses of switch

pump

1 Outlet hoses of switch pump

18

/

Hose (Power

cluster - front brake)

19

Rear brake hose (Slack adjuster

20

Hose (Brake oil tank - power

21

Hose (Power

I

inlet)

cluster)

cluster - rear brake)

22

1 Rear brake hose (Air component

23

1 Front brake hose (Air component

24

Rubber parts for power cluster

25

Packings,

26

Rubber parts for treadle r

Every 4000 hours or every 2 years, whichever comes sooner

pump

hoses of loader pump

17

27

I

.nozzles)

6

cylinder

interval

pump)

pump - adapter)

lubricating

Fuel hose (Strainer

Replacement

seals, O-rings

Rubber parts for parking

box outlet)

of steering

I

box outlet)

cylinder

valve brake spring cylinder

28

Rubber parts for slack adjuster

29

Rubber parts for relay valve

30

Seat belt

Every 3 years

3-l 7

22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

AWOSOBZO

3-18

23. MAINTENANCE

23.1

MAINTENANCE

SCHEDULE CHART

SCHEDULE

CHART

SERVICE ITEM INITIAL 250 HOURS SERVICE (only after the fir& 250 hours) Replace fuel filter cartridge

3-23

Replace transmission

3-23

oil filter element

Check engine valve clearance,

adjust

3-23

WHEN REQUIRED Check, clean, or replace

air cleaner

element

Replace coolant and flush cooling system - Every two years or 2000 hours of service Check transmission

oil level, add oil

3-24 3-26 3-30

Check axle oil level, add oil

3-31

Clean axle case breather

3-32

Clean condenser

3-32

Check window Clean radiator Check electrical Replace

of air conditioner washing

fluid level, add fluid

fins

3-32 3-33 3-33

intake air heater

3-34

bucket teeth

3-35

Lubricating l

Work equipment

l

Accelerator

0

Steering

control valve

pedal linkage

column

linkage

(2 points)

(2 points)

3-35 3-35 3-35

(I point)

Check air conditioner

3-36

Adjust

3-37

parking brake brake hvdraulic

air from

Bleeding

air from PPC circuit

3-38

Bleeding

air from hydraulic

tank

3-39

separator

3-40

Drain water from water

circuit

3-38

Bleedino

Reolace fan belt, adiust auto-tensioner

3-41

CHECK BEFORE STARTING _Check monitor Check coolant

panel level, add water

3-42 3-42 3-19

23. MAINTENANCE

SCHEDULE

CHART

SERVICE ITEM

PAGE

CHECK BEFORE STARTING (continued) Check oil level in engine

3-43

oil pan, add oil

Check brake oil tank level, add oil

3-44

Check dust indicator

3-44

Check fuel level, add fuel

3-45

Drain water

3-45

from air tank

3-46

Check electric wiring Check for water

and sediment

Check effect of parking

in water

separator,

drain water

3-47

brake

3-47

Check effect of brake Check sound

buzzer

3-47

check for dirt or damage

3-47

of horn and backup

Check flashing

of lamps,

Check direction Check engine

of rear view exhaust

Check operation

3-46

mirror,

check for dirt or damage

3-47

color and sound

3-47

of gauges

Check play of steering

3-47

wheel,

check operation

of steering

3-47

EVERY 50 HOURS SERVICE Check tire inflation Drain water,

3-48

pressure

sediment

from fuel tank

3-48

EVERY 100 HOURS SERVICE 3-49

Lubricating l

Bucket pin (2 points)

3-49

l

Bucket link pin (2 points)

3-49

l

Lift arm hinge pin (2 points)

3-49

l

Bucket cylinder

3-49

l

Tilt lever pin (I point)

3-49

l

Lift cylinder

3-50

l

Steering

0

Rear axle pivot pin (3 points)

pin (2 points)

pin (4 points)

cylinder

pin (4 points)

Check oil level in hydraulic

3-20

tank, add oil

3-50

3-51

23. MAINTENANCE SCHEDULE CHART

SERVICE ITEM Clean cab air filter element

PAGE 3-52

EVERY 250 HOURS SERVICE Change

oil in engine

oil pan, replace

Check battery electrolyte Check alternator

Check air conditioner â&#x20AC;&#x2DC;Check frame

oil filter cartridge

level

belt tension,

Check for loose wheel

engine

3-53 3-55

adjust

3-56

hub nuts, tighten compressor

belt tension,

3-57 adjust

and boom

3-57 3-57

EVERY 500 HOURS SERVICE Replace fuel filter cartridge

3-58

Replace transmission

oil filter element

3-60

center drive shaft (3 points)

3-61

Lubricate

Check fan belt

3-61

Check air dryer

3-61

EVERY 1000 HOURS SERVICE Change

oil in transmission

Clean transmission

case, clean strainer

case breather

3-62 3-63

Lubricating

3-64 3-64

l

Center hinge pin (2 points)

l

Drive shaft center support

l

Front drive shaft (3 points)

3-64

l

Rear drive shaft (3 points)

3-65

l

Upper

3-65

l

Parking brake linkage

l

Torque

l

Fan pulley (1 point)

3-65

l

Tension

3-65

(1 point)

drive shaft (3 points)

converter

(6 points)

mount

trunnion

pulley (2 points)

Check tightening

parts of turbocharger

3-64

3-65 (I point)

3-65

3-66

Clean fuel strainer

3-66

Tighten

3-66

ROPS canopy

3-21

23. MAINTENANCE

SCHEDULE CHART

SERVICE ITEM

PAGE

EVERY 1000 HOURS SERVICE (continued) Replace corrosion resistor cartridge

3-67

EVERY 2000 HOURS SERVICE Change oil in hydraulic tank, replace hydraulic filter element

3-68

Clean hydraulic tank strainer

3-71

Replace hydraulic tank breather element

3-72

Change axle oil *

3-73

Replace cab air filter element

3-74

Clean PPC circuit strainer

3-74

Check alternator, starting motor

3-75

Check engine valve clearance, adjust

3-75

Check brake disc wear

3-75

Clean and check turbocharger

3-75

Check play of turbocharger

3-75

rotor

Check accumulator

3-76

Internal part of air dryer

3-76 EVERY 4000 HOURS SERVICE

Check water pump

3-77

Check engine vibration damper

3-77

Check fan pulley and tension pulley

3-77

Check air compressor, adjust

3-77

Check injection pump rack rubber boot, replace

3-77

f

3-22

The interval of 2000 hours for changing the axle oil is for standard operations. If the brake is used frequently or the brakes make a sound, change the oil after a shorter interval.

24. SERVICE PROCEDURE

24.1

INITIAL 250 HOURS SERVICE

Carry out the following hours. l l l

maintenance

only after the first 250

REPLACE FUEL FILTER CARTRIDGE REPLACE TRANSMISSION OIL FILTER ELEMENT CHECK ENGINE VALVE CLEARANCE, ADJUST

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

3-23

24. SERVICE PROCEDURE

24.2

WHEN

REQUIRED

24.2.1 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT I------l

l

WARNING

Never clean or replace the air cleaner element with the engine running.

When using pressure air to clean the element wear safety glasses or goggles to protect the eyes. j

Checking Whenever the red piston in dust indicator air cleaner element.

0

appears,

Cleaning or replacing outer element 1. Remove wing nut @ and take out outer element

clean the

0.

2.

Clean the inside of the air cleaner

3.

Direct dry compressed air (less than 700 kPa (7 kg/cm2, 100 psi)), to the 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 whenever the outer element has been cleaned.

2) Replace the outer element which has been cleaned 6 times repeatedly or used throughout a year. Replace the inner element at the same time. after the outer 3) If the dust indicator displays red immediately element has been cleaned, replace both the inner and outer elements, even if the outer element has not been cleaned 6 times. nuts for looseness and, if 4) Check inner element mounting necessary, retighten.

5) Replace seal washer @ or wing nut @ with new parts if they are broken.

3-24

body.

24. SERVICE PROCEDURE

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

When cleaning the element, do not hit it or beat it against anything.

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

4.

Install the cleaned

element.

5.

Push the dust indicator the original position.

reset button to return the red piston to

Replacing inner element 1. First remove the outer element.

element,

and then

remove

the

inner

2.

To prevent dust from getting in, use a clean cloth or tape to cover the air connector (outlet side).

3.

Clean the air cleaner installed in Step 2.

4.

Fit a new inner element to the connector and tighten Do not clean and reinstall an inner element.

5.

Install the outer element.

body

interior,

then

remove

the

cover

it with nuts.

The following methods require spare parts.

With water Dash city water (less than 294.2 kPa (3 kg/cm2, 42.6 psi) on element from inside along folds, then from outside and again from inside. Dry and check it.

With cleaning agent For removing oils and fats as well as carbon etc. attached on the element, the element may be cleaned in lukewarm solution of mild detergent, then rinsed in clean water and left to drip dry.

Drying can be speeded up by blowing dried compressed air less than 700 kPa (7 kg/cm2, 100 psi) from the inside to the outside of the element.

Never attempt to heat the element.

Using warm water (about 40°C) instead of soapy water may also be effective.

3-25

24. SERVICE PROCEDURE

24.2.2 ya

REPLACE COOLANT AND FLUSH COOLING SYSTEM - Every two years or 2000 hours of service 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 go under the machine as the machine may suddenly start moving. While the engine is running, never go under the machine.

Never remove the radiator cap when the engine is at operating temperature.

At operating temperature, the coolant is under pressure. Boiling water and steam spurting out 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

l

Stop the machine on level ground when cleaning or changing the coolant.

Drain the coolant, flush, clean and refill the cooling system and replace the corrosion resistor cartridge after every two years or 2000 hours of service, whichever comes first.

For coolant specifications, see â&#x20AC;&#x153;20.3 COOLANT SPECIFICATIONSâ&#x20AC;? on page 3-13.

3-26

24. SERVICE

l

When deciding the temperature in the given below.

It is actually better when deciding the

PROCEDURE

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

about

10°C lower

Mixing rate of water and antifreeze Min. atmospheric temperature Amount

of

antifreeze

Amount

of

water

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.

3-27

24. SERVICE

PROCEDURE

1. Stop the engine

2.

Turn radiator

and tighten

corrosion

cap @ slowly to remove

resistor valve 0.

it.

Prepare a container to catch the coolant, then open drain valve @ of the radiator and drain valve @ of the oil cooler to drain the coolant.

After draining the water, close drain valves @ and @ and fill with city water.

When the radiator is full of water, start the engine and run it at low idling.

Open drain valves @ and 0, run the engine at low idling, and flush water through the system for 10 minutes.

When doing this, adjust the speed of filling and draining the water so that the radiator is always full.

While flushing water through the system, watch carefully that the water inlet hose does not come out of the radiator water filler.

6.

After flushing, stop the engine, open drain valves @ and 0, then close it again after all the water has drained out.

7.

After draining the water, clean with a flushing agent.

For details of the cleaning method, see the instructions with the cleaning agent.

8.

3-28

given

After cleaning, open drain valves @ and @ to drain all the cooling water, then close them and fill slowly with clean water.

24. SERVICE PROCEDURE

9.

When the water comes up to near the water filler port, open drain valves @ and 0, run the engine at low idling, and continue to run water through the system until clean colorless water comes out.

When doing this, adjust the speed of filling and draining so that the radiator is always full.

10. When the water is completely valves @ and 0.

the water

clean, stop the engine, close drain

11. Replace the corrosion resistor cartridge and open valve 0.

For details of replacement of the corrosion resistor, see â&#x20AC;&#x153;24.8 EVERY 1000 HOURS SERVICEâ&#x20AC;?.

12. Add cooling water

until it overflows

from the water

filler.

13. To remove the air in the cooling water, run for five minutes low idling, then for another five minutes at high idling.

When doing this, leave radiator cap @ off.

at

14. Stop the engine, wait for about three minutes, add cooling water up to near the radiator water filler port, then tighten the cap.

3-29

24. SERVICE PROCEDURE

24.2.3 CHECK TRANSMISSION a l

l

WARNING

When checking the oil level, apply the parking brake, and lock the front and rear frames with the safety bar and pin.

The oil is at high temperature after the machine has been operated. Always wait for the temperature to go down before starting this operation.

Carry out this procedure transmission case, or if there

1

OIL LEVEL, ADD OIL

if there is any sign of oil on the is oil mixed with the cooling water.

1.

Stop the engine.

2.

Use sight gauge @ to check the oil level.

3.

If the oil level is not within the range at upper area A of the sight gauge, add engine oil through oil filler 0.

For details of the oil to use, see â&#x20AC;&#x153;20. USE OF FUEL, COOLANT LUBRICANTS .ACCORDING TO AMBIENT TEMPERATURE.â&#x20AC;?

4.

5.

AND

If the oil is above the A, remove drain plug 0 and loosen plug @ to drain the excessive engine oil, then check the oil level again.

If the oil level is correct, then tighten

the cap.

Make an oil level check before starting engine or 60 minutes or more after the engine is stopped. If oil remains at various portions, the correct oil level cannot be measured.

The oil level can also be checked at low idling. In this case, the oil should be within the range at bottom area B of the sight gauge.

However, the time taken for the oil level to become steady will differ according to the idling speed and the oil temperature.

3-30

------1

Y c

-+fP /

1

u

I2

/-/

A0036600

24. SERVICE PROCEDURE

24.2.4 CHECK AXLE OIL LEVEL, ADD ,OlL

A l

l

WARNING

When checking the oil level, apply the parking brake, and lock the front and rear frames with the safety bar and pin.

The oil is at high temperature after the machine has been operated. Always wait for the temperature to go down before starting this operation.

Carry out this procedure case.

if there

is any sign of oil on the axle

Carry out the inspection with the machine on a horizontal road surface.

(If the road surface is at an angle, the oil level cannot be checked correctly.)

1.

Stop the enaine

and remove

oil level pluo 0. .

2.

Check that the oil level reaches the bottom

3.

If the oil is not close to the bottom edge, add axle oil through hole of plug 0.

-1

of the plug hole.

For details of the oil to use, see “20. USE OF FUEL, COOLANT LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.” 4.

If the oil level is correct,

Tightening

torque:

the

AND

install plug 0.

152 + 24 Nm (15.5 + 2.5 kgm, 112 2 18 Ibft)

3-31

24. SERVICE PROCEDURE

24.2.5 CHECK AXLE CASE BREATHER

rear frames

with the safety

bar and pin.

Remove any mud or dust that is stuck to the area around the breather.

Then, remove breather, immerse in cleaning fluid and clean.

When cleaning the breather, clean the breathers at two places (front and rear).

Do not let dirt get into the port while breather is removed.

24.2.6 CLEAN CONDENSER

the condenser

OF AIR CONDITIONER

will get hot and may break down.

If there is mud or dust on the air conditioner condenser, clean it with water.

Check the fins for clogging or damage.

If the water pressure is too high, the fins may get deformed.

When washing with a high pressure washing machine, apply the water from a reasonable distance.

Use water to wash off any mud stuck to the condenser.

If necessary, use a soft brush. Do not use a hard brush, as this will damage the fins.

24.2.7 CHECK WINDOW FLUID

WASHING

FLUID LEVEL, ADD

Do this when there is air in the window washing fluid.

Check the washing fluid levels in washer tanks @ and 0. When the fluid has run short, add automotive window washing fluid.

0: Front window washing fluid tank 0: Rear window washing fluid tank To prevent the nozzles from clogging, get into the fluid.

3-32

be careful

not to let dust

24. SERVICE PROCEDURE

24.2.8 CLEAN RADIATOR Carry out this procedure to the radiator.

Loosen

FINS if there is any mud or dirt seen stuck

bolt @ and remove

radiator

grille 0.

Use compressed air to clean the mud dust, and leaves from the radiator fins. Steam or water may be used instead of compressed air.

I

u 11ACd28710

The rubber hose should be checked at the same time. If the hose is found to have cracks or to be hardened by ageing, it should be replaced with a new one. Further, loosen hose clamps should also be tightened.

24.2.9 CHECK ELECTRICAL INTAKE AIR HEATER Check the electrical intake air heater mencing work in the cold season.

once a year before

com-

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 a new one.

Ask your Komatsu distributorto

checkelectrical

intake air herater.

3-33

24. SERVICE

24.2.10

PROCEDURE

REPLACE BUCKET TEETH

glasses, work gloves and safety shoes. In addition, keep unnecessary personnel away from the work area to avoid

NEVER HAMMER ON AN EDGE OR A CORNER OF THE TOOTH POINT OR WEAR CAP. Doing so could produce flying shards of

Replace tooth points before they wear down as far as the adapter.

Tooth Point Removal 1.

Drive out locking pin . The use of a Pin Removal Tool is recommended. Begin pin removal with the short shaft of the tool, then finish with the long shaft. If a removal tool is not available, use a punch or a drift pin.

L17DH021 2.

Remove the point with a counterclockwise quarter turn. It may be necessary to tap the side of the point to loosen impacted material.

Slide off the wear cap if it is to be replaced.

Remove the Point

L17DH022

3-34

24. SERVICE PROCEDURE

3.

Clean the nose of the adapter so the new tooth point will fit in place solidly and completely. If a wear cap is to be installed, make sure the wear slots are clean. Reversible wear caps should be rotated with each tooth point change to balance wear and to keep from becoming wedged on.

L17DH023

Tooth Point Locking Pin Inspection

Excessive End Wear or Bending

The locking pin can be reused unless one of the unacceptable conditions exists as illustrated. Replace pins as necessary.

Maximum Wear Lin,e

Pin is bent more than 0.1~ (3 mm) or obviously defomwd \

Maxihum Wear tine

Missing Lock or Takeup Plug

I

L17DH02!

24. SERVICE

PROCEDURE

Plug does not Extend Fully or is Damaged I

-

/I

Impacted fines cause a gap of more than .06” (1.5 mm)

t;j +

II

.16” (4 mm) minimum except V61 at .12” (3 mm) minimum

Ll7DH02C

Tooth Point Installation 1.

If a wear cap is to be installed, adapter’s upper surface.

NOTE:

2.

Slide on Wear

Specific locking pins can only be used with these tooth points and adapters.

Install the tooth point with a clockwise quarter turn. The bottom of the point cavity must fit solidly against the end of the nose .

NOTE:

3.

slide it in place in the slots on the

Before reusing a locking pin as follows, the pin should be inspected as described in “Tooth Point Locking Pin Inspection”.

I

Install the

Place the locking pin into the nose and point ear opening as shown. Drive the top of the pin flush with the top of the point ear using moderate taps from a 2.5 -5.5 kg (6 - 12 lb) hammer. The lock pin plug will compress as it passes the top of the ear and then snap into the ear lock recess. To best assure proper engagement of the lock plug with the ear lock recess, do not over or under drive the top of the pin.

L17DHOW

lock recess

3-34B

24. SERVICE

24.2.11 LUBRICATING 1. Using a grease pump, fittings 2.

shown

After greasing,

pump

in grease

through

the

PROCEDURE

grease

by arrows. wipe

off any old grease that was pushed

out.

1.

Work equipment control valve linkage (2 points) If the work equipment control lever is heavy or does not move smoothly, apply grease.

2.

Accelerator pedal linkage (2 points) If the accelerator pedal is heavy or does apply grease.

not return

properly,

3.

Steering column (I point) If the play of the steering properly, apply grease.

column

is heavy

or does not return

3-35

24.2.12

CHECK AIR CONDITIONER

Check levels of refrigerant (gas) Check twice a year, in spring and autumn.

If the liquid gets into your eyes or on your hands, it may cause

Operate the cooler of the air conditioner for 5 -,I0 minutes, then touch the high pressure portion and low pressure portion of the compressor (or high pressure hose and low pressure hose joint) by hand. At the same time, inspect the flow of refrigerant gas through the sight glass to check the gas level.

Please contact your Komatsu distributor for this inspection.

The sight glass is installed to the receiver on the right side of the air cleaner.

Cooler condition

Normal

Temp. of high and low pressure pipes.

High pressure pipe is hot.

Low pressure pipe is cold.

Clear difference in temperature

Sight glass

Almost transparent.

Any bubbles disappear if the engine speed is raised or lowered.

0

0

0

Connections pipes

of

General condition of cooler

Properly

connected

Coolant level correct, no abnormalities.

Ready for use.

I

nzcnsa:

Abnormal

High pressure pipe is warm Low pressure pipe is cold.

Little difference in temperature

Almost no difference in temperature between high and low pressure pipes.

Bubbles are always flowing.

Sometimes becomes transparent, or white bubbles appear.

Misty substance is flowing.

_.

-0

=-0 1

---

s* o- -0

-â&#x20AC;&#x2122;

=

-0

-3

May be a leak somewhere.

Call service repair shop for inspection.

>_

_--r=

_-z--_ z

.-0

Some parts dirty with oil.

x

-_

I-_-

_â&#x20AC;&#x153;-

Operating the air conditioner off season To lubricate each portion of the compressor of the airconditioner during the off-season, operate the airconditioner for 3 - 5 minutes once a month.

Be sure to idle the engine at low speed for this purpose.

3-36

ceiver

I

-

_-

<

_-

-

Some parts very dirty with oil.

Almost all coolant has leaked out.

Contact service repair shop immediately.

24. SERVICE PROCEDURE

24.2.13

ADJUST

PARKING BRAKE

A WARNING l l

l

When adjusting the parking brake, be sure to put blocks under the tires to prevent the machine from moving.

Maintain the air pressure at a sufficiently high pressure to prevent the parking brake from operating automatically while adjusting the brake. To prevent a third person from operating the parking brake by mistake, be sure to attach a caution tag to the parking brake switch.

Take care not to get oil or grease on the brake pad and the disc surface.

If the parking

brake fails to work

properly,

adjust as follows.

1. Confirm that the indicator of the air pressure gauge green range and then release the parking brake.

is in the

2.

Turn bolt @ clockwise while pressing bolt retainer @ and let pads @ on both sides come into close contact with disc 0.

3.

Turn back bolt @ a half turn conterclockwise retainer 0.

4.

Restore bolt retainer @ to the original the retainer is in the locking position

position and confirm that for bolt 0.

5.

There are two calipers in the parking caliper in the same way.

brake, so adjust the other

while pressing bolt

Check the lining for wear and replace the pad if the thickness the lining is reduced to less than 3 mm (0.12 in).

Ask your Komatsu distributor for replacement of the pad.

of

3-37

24. SERVICE PROCEDURE

24.2.14

BLEEDING AIR FROM BRAKE HYDRAULIC CIRCUIT

A WARNING Always

use engine

oil to refill the brake oil tank.

After removing the piping of brake hydraulic circuit, bleed the air from inside of the circuit as follows: 1. After assembling are not loose.

the piping, be sure to check that the connectors

2.

Remove

3.

Depress brake pedal, loosen air bleed plug @ about 3/4 of a turn and after closing the plug, release the pedal.

4.

Repeat

5.

After

the cap of air bleed plug 0.

until air bubbles

bleeding

stop coming

out of air bleed

plug 0.

the air, close the plug and fit the cap.

NOTICE Bleed the air at 4 locations.

6.

After bleeding the air, check the oil level in the brake oil tank. For details, see â&#x20AC;&#x153;24.3 CHECK BEFORE STARTINGâ&#x20AC;?.

For details,

24.2.15

contact your Komatsu distributor.

BLEEDING AIR FROM PPC CIRCUIT

When removing piping of PPC circuit, or removing strainer, after assembling, bleed air from inside of the circuit as follows: 1) Put bucket control lever in TILT position and boom control lever in FLOAT position, and after cylinder reaches stroke end, keep in that position for one minute.

2) Put bucket control lever in DUMP position an d boom control lever in RAISE position, and after cylinder reaches stroke end, keep in that position for one minute.

For details, contact your Komatsu distributor.

3-38

24. SERVICE PROCEDURE

24.2.16 l

l

BLEEDING AIR FROM HYDRAULIC

TANK

After replacing oil and filter element or cleaning strainer, bleed the air from the circuit.

When changing the oil in the hydraulic tank, or removing the piston pump, or removing the piping of the piston pump, bleed the air in the following way after assembling.

After bleeding air from piston pump, bleed air from hydraulic circuit.

Bleeding

air from piston pump

NOTICE If the damaged,

air is not bleed completely, the piston pump may be so always carry out the air bleeding operation correctly.

Before bleeding the air from the piston pump, check that the hydraulic oil in the hydraulic tank is filled to the specified level.

Loosen plug 0 on top of the tube at the suction side of the piston pump. There is one plug for each pump, so loosen all plugs (3 places).

Loosen the connector at block @ side of case drain hose @ of the piston pump.

The case drain hoses (x 3) for each pump are connected to block 0, but loosen only the connector of case drain hose @ connected to the top of the block. There is no need to loosen the connectors of the other two case drain hoses.

Turn valve @to the right to open it, and pressurize the oil inside the hydraulic tank.

When pressurizing the tank, the tank cannot be pressurized oil filler cap of the hydraulic tank is not tightened.

if the

4.

Continue until oil flows out from plug @ (3 places) and the connector of hose @. When the air has been completely bled, tighten plug @ (3 places) and the connector of hose 0.

If oil spurts out from plug @ and hose 0, loosen nut @ of the pressurizing valve, and turn rod @ counterclockwise to adjust the pressure, then lock with the nut.

5.

Close valve @ completely.

6.

Check the oil level and add oil if necessary.

For details,

contact your Komatsu

distributor.

3-39

24. SERVICE PROCEDURE

Bleeding air from hydraulic circuit.

1. Check that the oil reaches the specified tank.

\

level in the hydraulic

2.

Run the engine at low idling and operate each hydraulic cylinders (of steering, bucket and lift arm) 4 to 5 times, stopping 100 mm (3.94 in) from stroke end.

3.

Next, operate then stop the hydraulic tank After bleeding

4.

Check the hydraulic oil level and add oil if necessary, “24.5 EVERY 100 HOURS SERVICE”.

5.

Increase the engine speed, and repeat step 3 to bleed the air until no more bubbles come out from plug 0.

If the engine is run at high speed at first, or if the cylinder is moved to the end of its stroke, the air in the cylinder may damage the piston packing, etc.

6.

After bleeding the air, tighten the air bleeding plug 0.

Tightening torque of the plug: 11.28 -c 1.47 Nm (1.15 ? 0.15 kgm, 8.32 f 1.08 Ibft)

7.

Check the oil level in the hydraulic tank, and add oil if necessary.

After adding oil, tighten the oil filler cap securely.

8.

Check the hydraulic oil level and ensure that is correct, “24.5 EVERY 100 HOURS SERVICE”.

each cylinder 3 to 4 times to the end of its stroke, engine and loosen air bleeding plug @ of the to bleed the air. the air, tighten the plug.

Refer to

Refer to

24.2.17 DRAIN WATER FROM WATER SEPARATOR When float @ is at or above red line 0, drain the water according to the following procedure: Loosen drain plug @ and drain the accumulated float reaches the bottom.

Tighten

water until the

drain plug 0.

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

See Fuel Filter Cartridge in “24.7 EVERY 500 HOURS SERVICE” section.

3-40

24. SERVICE PROCEDURE

24.2.18

REPLACE FAN BELT, ADJUST AUTO-TENSIONER

Replace the blet if the V-belt contacts the bottom of the pulley groove, or if the fan belt is lower than the outside edge of the pulley, or if there are any cracks, peeling, or other damage to the V-belt.

Replacement 1. Loosen adjustment bolt 0, then remove yoke @ with locknut @ still installed.

There is danger of losing parts, so do not remove bolt @ from bracket 0.

2.

Insert a bar of a length of approx. 50 cm (20 in) into hole 0 (024) of the tension pulley bracket, and pull forward strongly.

3.

The spring is extended and the tension pulley @ moves inwards, so remove the old belt and replace it with a new one.

Always

replace

Adjustment Install adjustment

the V-belt

as a set (5 belts).

bolt @ and locknut @ to yoke 0.

Tighten adjustment bolt @I until the clearance is 0 mm (0 in) between the end of the oblong hole of yoke @ and pin @ of tension pulley 0, then tighten a further three turns. Tighten locknut @ to hold in position.

Run for one hour, then check the clearance between the end of the oblong hole of yoke @ and pin @ of tension pulley 0.

If there is any clearance, repeat Step 2 to adjust again.

If the fan belt makes any abnormal

noise, adjust in the same way.

3-41

24.3

CHECK BEFORE STARTING

24.3.1 CHECK MONITOR

PANEL

1.

Turn the starting

switch to ON.

2.

Check that all the monitor lamps, the gauges and the warning lamp light up for about 3 seconds and the alarm buzzer sounds for about 1 second.

If any monitor lamp does not light up, ask your Komatsu distributor to inspect that monitor lamp.

Do not carry out the checks before starting monitor; always carry out also the items specified maintenance.

24.3.2 CHECK COOLANT

using only the for the periodic

LEVEL, ADD WATER

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

1.

Remove radiator cap @ at the rear of the machine and check that the coolant is above the hatched portion marked in the diagram on the right. If the coolant level is low, add more water.

2.

After adding

water,

tighten

the cap securely.

If the volume of coolant added is more than possible water leakage.

Confirm that there is no oil in the coolant.

3-42

usual, check for

24. SERVICE PROCEDURE

24.3.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL Open the inspection Remove

window

at the rear left side of the machine.

dipstick @ and wipe the oil off with a cloth.

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

The oil level should

be between

the H and L marks on dipstick

0.

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

oil filler

_ p -r

0.

For details of the oil to use, see â&#x20AC;&#x153;20. USE OF FUEL, COOLANT LUBRICANTS ACCORDING TO AMBIENT TEMPERATUREâ&#x20AC;?.

AND

If the oil is above the H mark, drain the excess engine drain valve 0, and check the oil level again.

6.

If the oil level is correct, tighten close the inspection window.

? p

5 $

*

The dipstick has level markings on both sides. One side gives the levels for measuring when the engine is stopped (ENGINE STOPPED) and the other side gives the levels for when the engine is idling (ENGINE IDLING).

When measuring the oil level, measure with the engine stopped and use the side of the dipstick marked ENGINE STOPPED. 5.

Engine stopped

i

Engine idling

*

,~~

oil from

the oil filler cap securely

and

-

ADO35700

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

Checking the oil level with the engine idling may be allowed, if the following precautions are thoroughly satisfied: l Check that the engine water temperature gauge shows green range. l Use the side of the dipstick marked ENGINE IDLING. l Remove the oil filler cap.

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

3-43

24. SERVICE

24.3.4

PROCEDURE

CHECK BRAKE OIL TANK LEVEL, ADD OIL

/&A-p,.

Always

use engme

011 to refill the brake orl tank.

1.

Check from the ground that the brake oil level in the brake oil tank on the left side of the machine is within sight gauge @ installed to the side of the brake tank.

2.

If the oil level is low, open the cover at the top of the platform, then open cap 0 and add engine oil.

AND

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

A0033900

23.3.5 CHECK DUST INDICATOR Check that the red piston of dust indicator @ (2 points) has not reached the service level.

If the red piston is showing, clean or replace the element immediately.

For details of cleaning the element, see “24.2 WHEN CHECK, CLEAN, OR REPLACE AIR CLEANER”.

3-44

REQUIRED,

24. SERVICE PROCEDURE

24.3.6 CHECK FUEL LEVEL, ADD FUEL a WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If spilling fuel, thoroughly clean up any spillage.

1.

Turn the engine starting switch to the ON position, then check the fuel level with fuel gauge 0.

After checking, return the starting switch to the OFF position.

2.

Upon completion of work, remove the mud guard cover and add fuel through filler @ until the fuel tank is full.

For details of the method “11.9 CAP WITH LOCK”.

for opening

and closing the cap, see

AND

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

3.

After adding fuel, tighten

Fuel capacity:

1430 !?(377.5

the cap securely.

US gal, 314.6 UK gal)

24.3.7 DRAIN WATER FROM AIR TANK Upon completion of work, stop the engine, @ and @ and drain the water from the tank.

open drain valves 0,

3-45

24. SERVICE

PROCEDURE

24.3.8 CHECK ELECTRIC WIRING a WARNING l

l

l

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

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 of the fuse and any sign of disconnection or short circuit in the electric wiring. Check also for loose terminals and tighten any loose parts.

Check the following points carefully. l Battery 0 Starting motor l Alternator Please contact your Komatsu distributor for investigation and correction of the cause.

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.

24.3.9 CHECK FOR WATER AND SEDIMENT SEPARATOR, DRAIN WATER

IN WATER

The water separator separates water mixed in the fuel. If float @ is at or above red line 0, drain the water.

Forthe draining procedure, see section â&#x20AC;&#x153;24.2 WHEN REQUIREDâ&#x20AC;?.

Even if a water separator is installed, be sure to check the fuel tank to remove water and sediment in the fuel.

3-46

24. SERVICE

24.3.10

PROCEDURE

CHECK EFFECT OF PARKING BRAKE

Even if the parking

brake switch

is turned

ON, there

Measurement conditions Tire inflation pressure: Specified pressure l Road surface: Dry paved surface with l/5 (ll”20’) l Machine: Operating condition

is danger

l

grade

t Method of measurement 1. Start the engine, set the machine facing straight to the front, then drive the machine up a l/5 grade with the bucket empty.

2.

Depress the brake, stop the machine, return the directional to the neutral position, then stop the engine.

3.

Press the parking brake switch to the ON position, brake pedal slowly, and check that the machine position.

24.3.11

lever

release the is held in

CHECK EFFECT OF BRAKE

Drive the machine at a speed of 20 km/h (12.4 MPH) on a dry flat concrete road surface, and check that the stopping distance is less than 7.5 m (24.6 ft).

24.3.12

CHECK SOUND BUZZER

OF HORN AND BACKUP

24.3.13

CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE

24.3.14

CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE

24.3.15

CHECK ENGINE EXHAUST SOUND

24.3.16

CHECK OPERATION

24.3.17

CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING

COLOR AND

OF GAUGES

3-47

24. SERVICE PROCEDURE

24.4

EVERY 50 HOURS SERVICE

24.4.1 CHECK TIRE INFLATION

PRESSURE

Measure the inflation pressure before operations when the tires are cool.

Standard tire inflation pressure: 45/65-45-38PR (L5 rock) Front tire: Rear tire:

514.8 (5.25 514.8 (5.25

kPa kg/cm2, 74.6 psi) kPa kg/cm2, 74.6 psi)

NOTICE The appropriate tire inflation pressure differs according type of work, so see “12.18 HANDLING THE TIRES”.

24.4.2 DRAIN WATER, SEDIMENT

to the

FROM FUEL TANK

Loosen valve 0 on the right side of the tank so that the sediment and water will be drained together with fuel.

3-48

24. SERVICE PROCEDURE

24.5

EVERY 100 HOURS SERVICE

Maintenance same time.

for every

50 hours should

be carried

out at the

24.5.1 LUBRICATING g WARNING l

l

Apply the parking brake, and lock the front and rear frames with the safety bar and pin.

Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the work equipment control levers.

1. Using a grease pump, pump fittings marked by the arrows.

2.

After greasing,

1.

2.

Bucket pin (2 points) Bucket link pin (2 points)

3.

4.

5.

Lift arm hinge pin (2 points) Bucket cylinder pin (2 points) Tilt lever pin (1 point)

wipe

in grease

through

the

off any old grease that is pushed

grease

out.

ma353oa

24. SERVICE PROCEDURE

6.

Lift cylinder

7.

Steering

8.

Rear axle pivot pin (3 points)

3-go

pin (4 points)

cylinder

pin (4 points)

24. SERVICE PROCEDURE

24.5.2 CHECK OIL LEVEL IN HYDRAULIC

When the oil filler cap is removed,

TANK, ADD OIL

oil may spurt out, so stop the

the cap slowly to release the internal

pressure

before removmg

I_ B G

1.

Lower the bucket horizontally to the ground -and_ stop .the ... . . engine.

Wait for 5 minutes, then check sight gauge GjI. I he 011 Shoula De visible in sight gauge 0.

2.

If the level is low, open the inspeciton add oil through oil filler 0.

cover above the step and

For details of the &I to use, see “20. USE OF FUEL, COOLANT AND

LUBRICANTS ACCORDING TO AMBIENT

TEMPERATURE”.

3-51

24. SERVICE

PROCEDURE

24.5.3 CLEAN CAB AIR FILTER ELEMENT Clean the cab air filters as follows: Be sure the cab blower cleaning the filters.

*

fan is stopped

before

1. Open the access doors located at the rear of the cab to gain access to the fresh air filter.

2.

Remove holder mounting knobs (I), holder (2) and spacers (3) holding filter (4). Pull out the filter element and clean it.

*

Direct dry compressed air (less than 7 kg/cm* [IO0 psi / 689 kPa]) to the element from the inside along its folds, then direct it from the outside along its folds and again from the inside. Check the element for damage and/or deterioration.

I

+WARN’NG

When usmg compressed an-, wear safety glasses and other things required to maintain safety.

1

3.

After cleaning the filter element, reinstall it with the arrow pointing inward.

4.

Install filter holder (2) spacers (3) and mounting

5.

Close the access doors located at the rear of the cab.

6.

Move the operator’s seat forward, then tilt the seat backrest forward and down.

7.

Loosen the two access panel thumb screws (5) and retainers (6) and remove access panel (7) to gain access to recirculating air filter (8). Remove air filter and clean it.

8.

After cleaning the recirculating

9.

Install access panel (7) retainers (6) and thumb screws (5). Tighten the access panel thumb screws.

knobs (1).

air filter, reinstall air filter (8).

IO. Return the operator’s seat back to its original position.

3-52

24. SERVICE

1.

2.

3.

4.

5.

6.

Holder mounting knob Filter holder Holder mounting spacer Fresh air filter Thumb screw Retainer

7.

8.

9.

10.

11.

PROCEDURE

Outer access panel Recirculating air filter Inner access panel Retainer Filter box

3-52A

24. SERVICE

MEMO

3-52B

PROCEDURE

24. SERVICE PROCEDURE

24.6 EVERY 250 HOURS Maintenance same time.

SERVICE

for every 50 hours should

be carried

out at the

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

A WARNING The oil is at high temperature after the engine has been operated, so never change the oil immediately after finishing operations. Wait for the oil to cool down before changing it.

Prepare the following Container to catch drained oil: Min 90 e capacity l Refill capacity: 90 9 (23.76 US gal, 19.80 UK gal) l Filter wrench l

1.

Open the engine

side cover located

on the left of machine.

2.

Open oil filler @.

3.

Place a container to catch the oil under drain valve @ on the left side of the machine.

4.

Loosen drain valve 0,

_

and drain the oil.

When draining the oil, fit the supplied vinyltube to the drain ports of the drain plug to prevent the oil from spraying out.

Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor.

Install drain valve 0.

Using the filter wrench, turn 4 full-flow filter cartridges @ and 2 bypass filter cartridges @ to the left to remove them.

In particular, if this operation is carried out immediately after stopping the engine, a large amount of oil will come out, so wait for IO minutes before starting the operation.

3-53

24. SERVICE PROCEDURE

8.

Clean the filter holder, fill the new filter cartridge with engine oil, then coat the seal and thread of the filter cartridge with engine oil (or coat thinly with grease) and install.

9.

When installing, bring the seal surface into contact with the filter holder, then tighten a further 3/4 - 1 turns.

10. After replacing the filter cartridge, add engine oil through filler @ until the oil level is between the H and L marks dipstick 0.

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

oil on

AND

11. 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 dipstick. For details, see “24.3 CHECK BEFORE STARTING”.

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.

Use API category CD class oil. If CC class oil must be used, change the oil and replace the oil filter at half the usual interval (125 hours).

3-54

24. SERVICE PROCEDURE

24.6.2 CHECK BATTERY ELECTROLYTE LEVEL &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 â&#x20AC;&#x2DC;of water, and consult a doctor.

Carry out this check before

operating

the machine.

Open the cover of the battery box.

There are two battery boxes: One on each side at the rear of the machine.

Remove cap 0, and check that the electrolyte is at the specified level (IO to 12 mm (0.39 to 0.47 in) above the plate). If the electrolyte level is low, add distilled water to the specified level.

If the battery electrolyte is spilled, have dilute sulphuric acid added.

Clean the air hole securely.

in the

battery

cap, then

tighten

the cap

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

3-55

24.6.3 CHECK ALTERNATOR

BELT TENSION,

ADJUST

Checking The belt should normally deflect by about 20 mm (0.79 in) when pressed with the finger (with a force of approx. 6 kg (13 lb)) at a point midway between the drive pulley and alternator pulley.

Drive pulley

Adjusting 1. Loosen

-

bolt @ and lock nut 0.

2.

Rotate adjusting nut @ so that the deflection (at a force of approx. 6 kg).

3.

After adjustment,

4.

Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove.

5.

Replace the V-belt if it has stretched, leaving no allowance adjustment, or if there is any cut or crack on belt.

for

6.

After operating changed V-belt,

ex-

3-56

tighten

is approx.

lock nut @ and bolt 0

20 mm

securely.

36101

the machine for one hour with test and adjust the V-belt again.

a newly

24. SERVICE PROCEDURE

24.6.4 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN If wheel hub nuts @ are loose, tire wear will be increased accidents may be caused.

1.

Check for loose nuts, and tighten if necessary.

When checking for loose nuts, always turn the direction of tightening to check.

Tightening 2.

torque:

If any wheel

nuts

and

in the

471 + 49 Nm (84 5 9 kgm, 347 2 36 Ibit)

bolt is broken,

replace

24.6.5 CHECK AIR CONDITIONER TENSION, ADJUST

all bolts for that wheel.

COMPRESSOR

BELT

Checking The belt should normally deflect by about IO mm (0.39 in) when pressed with the finger (with a force of approx. 6 kg (13 lb)) at a point midway between the drive pulley and alternator pulley.

Adjusting 7. Loosen bolt @ and lock nut 0.

2.

Rotate adjusting nut @ so that the deflection (at a force of approx. 6 kg).

3.

After adjustment,

4.

Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove.

5.

Replace the V-belt if it has stretched, leaving no allowance adjustment, or if there is any cut or crack on belt.

for

6.

After operating the machine for one hour with changed V-belt, test and adjust the V-belt again.

ex-

tighten

is approx.

10 mm

lock nut @ and bolt @ securely.

a newly

24.6.6 CHECK FRAME AND BOOM 7.

Wash the frame easily.

2.

Check all parts of the frame

1

and boom so that the check can be carried out

and boom for damage.

In particular, check the colored part in the diagram, and repair if any cracks or other damage are found. For details of the method of repair, please contact your Komatsu distributor.

3-57

24.7

EVERY 500 HOURS SERVICE

Maintenance for every 50, 100 and 250 hours should be carried out at the same time.

24.7.1

REPLACE FUEL FILTER CARTRIDGE

l

Engine is at high temperature

l

Do not bring fire or sparks near the fuel.

Prepare

a filter wrench

immediately

and a container

after the machine

to catch the fuel.

1.

Open the side panel located on the right of the machine the open lock.

2.

Set the container

3.

Using a filter wrench, remove it.

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 it l/2 to 3/4 of a 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

7.

Loosen feed pump knob @ and move the pump up and down to draw off fuel until air ceases to come out of air bleed plug 0.

8.

After bleeding air, tighten air bleed plug 0, knob of feed pump @ and tighten it.

3-58

replacing

and lock

to catch the fuel under the filter cartridge. turn filter cartridge

filter cartridge

0,

@ counterclockwise

to

loosen air bleed plug 0.

then

push in the

24. SERVICE PROCEDURE

A WARNING When cranking the engine, confirm gine, as the engine may start.

9.

the safety

around

the en-

After replacing the filter cartridge, turn the key in the starting switch to the START position. When the engine starts, check for any leakage from the filter seal surface. If there is any leakage, check the tightening of the filter cartridge. If there is still any leakage, follow the procedure in Steps 2 and 3 to remove the filter cartridge, and check the packing surface. If there is any damage or any dirt or dust caught in the surface, replace the packing with a new part, then repeat Steps 4 to 9 to install again.

3-59

24. SERVICE

PROCEDURE

24.7.2 REPLACE TRANSMISSION 0

Prepare

1.

Loosen bolt and open the side panel.

2.

Set the container

3.

Remove drain plug @ at the bottom of the filter case, and drain the oil. After draining the oil, tighten the plug.

4.

Hold case @ and loosen center

5.

Remove

6.

Replace the filter gasket and O-rings with new parts. Coat the gasket and O-rings with clean engine oil before installing.

7.

Assemble the new element, set it in the case, then install with center bolt 0.

When tightening center bolt 0, install so that chamfered portion @I of the washer is at the head end of the hexagonal center bolt.

Be careful not to tighten center bolt @ too far.

Tightening 8.

3-60

a container

OIL FILTER ELEMENT oil

to catch the oil under the filter case.

the element,

torque:

to catch the drained

bolt 0,

then remove

case 0.

and clean the inside of the case.

181 + 15 Nm (18.5 * 1.5 kgm, 134 f 11 Ibft)

Run the engine at idling for a short time, then check that the oil is at the correct level. For details, see â&#x20AC;&#x153;24.2 WHEN REQUIREDâ&#x20AC;?.

24. SERVICE PROCEDURE

24.7.3 LUBRICATE CENTER DRIVE SHAFT (3 points) A WARNING l

l

Apply the parking brake, and lock the front and rear frames with the safety bar and pin.

Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the work equipment control levers.

1.

Using a grease pump, pump fittings marked by the arrows.

2.

After greasing,

wipe

in grease

through

the

off any old grease that is pushed

grease

out.

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

For details of the replacement REQUIRED”.

so it is unnecessary procedure,

to adjust the

refer to “24.2 WHEN

24.7.5 CHECK AIR DRYER If the air dryer is installed as an option, carry out the following inspection, and if there is any abnormality, contact your Komatsu distributor. l Open the air tank drain valve and check that nothing is drained.

Note that if the temperature around the tank is lower than 16”C, a small amount of water may be collected in the drain. l Check that there is no abnormal inclusion of oil in the water drain from the exhaust port of the air dryer.

3-61

24. SERVICE PROCEDURE

24.8

EVERY 1000 HOURS SERVICE

Maintenance for every 50, 100, 250 and 500 hours should carried out at the same time.

24.8.1 CHANGE OIL IN TRANSMISSION STRAINER

be

CASE, CLEAN

dh WARNING l l

l

0 l

Apply the parking brake, and lock the front and rear frames with the safety bar and pin.

Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the work equipment control levers.

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. 140 ! capacity Refill capacity: 140 e (37.0 US gal, 30.8 UK gal)

1.

Set a container to catch the oil under drain plugs @ and 0, then remove drain plug @ and loosen plug Q to drain the oil.

To prevent the oil from pouring out suddenly, loosen drain plug @ and remove it gradually.

2.

After draining

3.

Set a container

4.

Re,move transmission filter drain plugs @ (6 pieces), oil, then tighten the plug again.

5.

Remove together

6.

Remove any dirt stuck to strainer 0, then wash it in clean diesel oil or flushing oil. If strainer @ is damaged, replace it with a new part.

3-62

the oil, install drain plugs @ and 0. to catch the oil under the transmission

bolt 0, then remove with spring 8.

filter. drain the

cover @ and take out strainer

0

24. SERVICE PROCEDURE

7.

Install spring @ and strainer @ to cover 0.

Replace the O-ring on the cover with a new part, then install the cover.

8.

Pour in the specified

amount

of engine

oil from

oil filler 0.

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

9.

After filling with oil, check that the oil is at the specified details, see “24.2 WHEN REQUIRED”.

10. Check for oil leakage

from the transmission

AND

level. For

case and filter.

Make an oil level check before starting engine or 60 minutes or more after the engine is stopped.

If oil remains at various portions, the correct oil level cannot be measured.

24.8.2 CtEAN TRANSMISSION

CASE BREATHER

Remove all mud and dirt from around the breather, then remove the breather. Put in cleaning fluid and clean the breather.

Take care not to allow dust and dirt to enter the transmission case through the port while the breather is removed.

L

3-63

24. SERVICE PROCEDURE

24.8.3 LUBRICATING a WARNING l

l

Apply the parking brake, and lock the front and rear frames with the safety bar and pin.

Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the work equipment control levers.

1.

Using a grease pump, pump fittings marked by the arrows.

2.

After greasing,

1.

Center

2.

Drive shaft center support

3.

Front drive shaft (3 points)

wipe

in grease

through

the grease

off any old grease that is pushed out.

hinge pin (2 points)

(1 point)

ADO37800

3-64

24. SERVICE PROCEDURE

4.

Rear drive shaft (3 points)

5.

Upper

6.

Parking

brake linkage

7.

Torque

converter

8.

9.

Fan pulley (I point) Tension pulley (2 points)

drive shaft (3 points)

(6 points)

mount trunnion

(I point)

3-65

24. SERVICE PROCEDURE

24.8.4 CHECK TIGHTENING

PARTS OF TURBOCHARGER

Contact your Komatsu distributor checked.

to have the tightening

portions

24.8.5 CLEAN FUEL STRAINER 1. Remove plug 0, then remove spring together with strainer.

2.

Remove all dirt from the surface of the strainer, then wash in clean light oil. If strainer is damaged, replace with a new part.

3.

Install strainer If O-ring

and spring,

then install plug 0.

of the plug is damaged,

24.8.6 TIGHTEN

replace with a new part.

ROPS CANOPY

1.

Loosen the bolt, then remove

2.

Check that there is no looseness in mounting ROPS canopy. If any bolt is loose, tighten it.

Tightening 3.

torque:

the cover. bolts @ of the

2746 + 294 Nm (280 f 30 kgm, 2025 + 217 Ibft)

Install the cover.

The tightening torque is large, so a power wrench is needed when tightening.

Please request your Komatsu distributor to carry out this work.

3-66

24.8.7 REPLACE CORROSION 1. Open the engine hood.

RESISTOR CARTRIDGE

side cover located

on the right of the engine

2.

Screw

in valve @ at the side of the corrosion

3.

Using the filter wrench it counterclockwise.

4.

Coat the seal surface of the new cartridge install it to the filter holder.

5.

When installing, bring the gasket into contact surface of the filter holder, then tighten approx.

6.

After replacement,

provided,

open valves

resistor.

remove cartridge

@ by turning

with engine

oil, and

with the seal 2/3 turns.

0.

After replacing the cartridge, start the engine and check that there is no leakage of water from the filter seal surface.

3-67

24. SERVICE PROCEDURE

24.9

EVERY 2000 HOURS SERVICE

Maintenance for every 50, 100,250,500 be carried out at the same time.

and 1000 hours should

24.9.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT

The oil is at high temperature

immediately

after the machine

ing the oil. When removing the oil filler cap, turn it slowly release the internai pressure, then remove it carefully.

to

Prepare the following.

Container to catch drained oil: min. 550 e capacity Refill capacity: 550 e (145.2 US gal, 121.0 UK gal) Lower the bucket horizontally to the parking brake, then stop the engine.

Remove

the bolt, then remove

ground

and

apply

the

the cover.

Remove the cap of oil filler 0 and air bleed plug @ on filter case.

4.

Set a container

5.

Remove

6.

Loosen drain valve 0,

7.

After

3-68

drain plug @J.

draining

plug 0.

to catch the oil under drain plug 0.

then gradually

pull it out to drain the oil.

the oil, close drain valve

0,

then tighten

drain

24. SERVICE PROCEDURE

8.

Remove mounting bolts @ of the 4 filter covers @ at the top of the tank, then remove the covers.

When doing this, the cover may fly off because of the force of spring @, so keep the cover pushed down while removing the bolts.

9.

Remove

spring @ and bypass valve 0,

10. Check that there cleaning it.

is no foreign

matter

then remove inside

element

the tank

@I_

before

11. install a new element, then install bypass valve 0, spring @, and cover 0.

If the O-ring of the cover is damaged or deteriorated, replace it with a new part.

12. When installing the cover bolts, push down the cover and tighten the bolts evenly.

13. Add engine oil through oil filler port @ to the specified install cap 0 and air bleed plug @ on filter case.

level, then

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

14. Check that the hydraulic oil is at the standard see “24.5 EVERY 100 HOUR SERVICE”.

AND

level. For details,

15. Loosen plug @ on top of the tube at the suction side of the piston pump. There is one plug for each pump, so loosen all plugs (3 places).

16. Loosen the connector at block @I side of case drain hose @I of the piston pump.

The case drain hoses (x 3) for each pump are connected to block 0, but loosen only the connector of case drain hose @ connected to the top of the block. There is no need to loosen the connectors of the other two case drain hoses.

17‘. Turn valve @ to the left to open it, and pressurize the hydraulic tank.

the oil inside

When pressurizing the tank, the tank cannot be pressurized oil filler cap of the hydraulic tank is not tightened.

if the

18. Continue until oil flows out from plug @ (3 places) and the connector of hose @. When the air has been completely bled, tighten plug @ (3 places) and the connector of hose @I. If oil spurts out from plug ($ and hose @I, loosen nut @I of the pressurizing valve, and turn rod @ counterclockwise to adjust the pressure, then lock with the nut.

19. Close valve @ completely.

3-69

24. SERVICE PROCEDURE

Check the oil level and add oil if necessary.

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

21. Check that the hydraulic oil is at the standard see “24.5 EVERY 100 HOUR SERVICE”.

AND

level. For details,

22. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times. Be careful not to operate the cylinderto the end of its stroke (stop approx. 100 mm (3.94 in) before the end of stroke).

NOTICE 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 will cause damage to the piston packing.

23. Next, operate the steering, bucket, and lift arm cylinders to the end of their stroke 3 - 4 times, then stop the engine and loosen vent plug @ to bleed the air from the hydraulic tank. After bleeding the air, tighten plug @ again.

24. Check the hydraulic oil level and add oil to the specified details, see “24.5 EVERY 100 HOURS SERVICE”.

level. For

25. Next, increase the engine speed and repeat the procedure in Step 23 to bleed the air. Continue this operation until no more air comes out from plug 0.

26. After completing Tightening

torque:

the air bleed operation,

tighten

plug 0.

11.3 f 1.5 Nm (1.15 2 0.15 kgm, 8.3 f 1.1 Ibft)

27. After completing air bleeding, lower the bucket the ground and stop the engine.

28. Check that the hydraulic oil is at the standard see “24.5 EVERY 100 HOUR SERVICE”.

horizontally

to

level. For details,

29. Check that there is no leakage of oil from the filter cover mount.

3-70

24. SERVICE PROCEDURE

24.9.2 CLEAN HYDRAULIC

TANK STRAINER

When changing the oil in the hydraulic the tank and clean the strainer.

1.

Loosen bolts @ and 0,

2.

Loosen bolt 0, remove strainer @ together with spring 0.

3.

Remove flushing

If strainer 4.

then remove

any dirt from strainer oil. @ is broken,

replace

tank, drain the oil from

covers @ and 0.

cover 8,

then remove

strainer

@I, then wash in clean light oil or

it with a new part.

Install spring 0, strainer 8, and cover @. When doing this, look through the mounting hole of cover @I to check that the strainer guide pin is fitted in the guide hole.

When installing cover @, coat the thread of bolt @ with thread tightener (LT-2) to prevent it from coming loose. If bolt @ becomes loose and drops out, it will be sucked into the piston pump and will damage the pump.

Tightening torque of bolt 0:.

88 2 34.3 Nm (9 â&#x20AC;&#x2DC;_ 3.5 kgm, 65 2 25.3 Ibft) 5.

Install covers @ and 0.

Replace the O-rings of the covers with new parts.

u

&--

4 1

I

>

3

\\I

3-7 1

24. SERVICE PROCEDURE

24.9.3 REPLACE HYDRAULIC

TANK BREATHER ELEMENT

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

.

the internal

pressure,

then remove

1.

Remove

2.

Remove the snap ring on breather cap.

3.

Replace the filter element and snap ring.

4.

Tighten

it carefully.

the cap of oil filler 0. (iJ, then remove

the breather

with a new part, then install the cap

the cap of oil filler 0.

REMARK It is possible to replace the element with the breather installed in the tank. However, if the breather is removed, do not wrap the taper thread of the breather with seal tape when assembling again, and be careful not to tighten too much.

3-72

24. SERVICE PROCEDURE

24.9.4 CHANGE AXLE OIL

A WARNING l

l

l

-,

Apply the parking brake, and lock the front and rear frames with the safety bar and pin.

Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the work equipment control levers.

The oil is at high temperature after the machine has been operated. Always wait for the temperature to go down before starting this operation.

Front

Prepare the following.

Container to catch drained oil: min. 720 e capacity a Refill, capacity (front and rear, each): l 360 ! (95.0 US gal, 79.2 UK gal) 1.

Remove front and rear oil filler plugs 0, then remove drain plugs @ to drain the oil.

AI3236600

1

I

Rear

2.

Remove

drain plug @ to drain the oil.

3.

Stop the machine so that drain plug @ of the final drive is at the bottom. Remove oil filler plug @ and drain plug 0, and fit the tube of attached tool in hole of plug @I and drain the oil.

4.

After draining the oil, clean drain plugs 0, @ and 0, then install them.

5.

Add oil to the specified level through the oil filler ports @ and @ of the axle housing and left and right final drives.

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

6.

After adding oil, check that the oil is at the specified details, see “24.2 WHEN REQUIRED”.

REMARK For operations axle oil at shorter

where the brake is used frequently, intervals.

LUBRI-

level. For

change

the 3-73

24. SERVICE

PROCEDURE

24.9.5 REPLACE CAB AIR FILTER ELEMENT Replace the cab air filter as follows: *

Be sure the cab blower replacing the filter.

fan is stopped

before

1. Open the access doors located at the rear of the cab to gain access to the filter element.

2.

Remove holder mounting knobs (I), holder (2) and spacers (3) holding filter (4). Pull out the filter element and discard it.

3.

Install the new filter element with the arrow pointing inward.

4.

Install filter holder (2) knobs (1).

5.

Close the access doors located at the rear of the cab.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

3-74

spacers

Holder mounting knob Filter holder Holder mounting spacer Fresh air filter Thumb screw Retainer Outer access panel Recirculating air filter Inner access panel Retainer Filter box

(3) and mounting

24. SERVICE

PROCEDURE

24.9.6 CLEAN PPC CIRCUIT STRAINER 1.

Remove 3 bolts @) of the PPC circuit strainer.

2.

Remove the strainer case and pull out the strainer, then wash the strainer with clean diesel fuel.

3.

Install the strainer in the strainer case, and install it with bolts 0.

4.

Operate the bucket control lever to the TILT position and the boom control lever to the FLOAT position, and when the cylinder reaches the end of its stroke, hold it there for one minute.

5.

Operate the bucket control lever to the DUMP position and the boom control lever to the RAISE position, and when the cylinder reaches the end of its stroke, hold it there for one minute.

6.

Bleed the air from the hydraulic WHEN REQUIREDâ&#x20AC;?.

circuit. For details, see â&#x20AC;&#x153;24.2

For details of the procedure for bleeding air from the hydraulic circuit, please contact your Komatsu distributor.

3-74A

24. SERVICE

MEMO

3-74B

PROCEDURE

24. SERVICE PROCEDURE

24.9.7 CHECK ALTERNATOR,

STARTING

MOTOR

The brush 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.

24.9.8 CHECK ENGINE VALVE CLEARANCE,

ADJUST

As special tool is required for removing and adjusting request your Komatsu distributor for service.

the parts,

24.9.9 CHECK BRAKE DISC WEAR Ask Komatsu

24.9.10

distributor

to check and repair brake disc.

CLEAN AND CHECK TURBOCHARGER

If there is carbon or oil sludge stuck to the blower impeller, it will lower the performance of the turbocharger or cause it to break, so ask your Komatsu distributor to carry out the cleaning.

24.9.11

CHECK PLAY OF TURBOCHARGER

ROTOR

Ask your Komatsu distributor to check the play of theturbocharger rotor.

3-75

24. SERVICE PROCEDURE

24.9.12

CHECK ACCUMULATOR

Check the gas pressure Checking 1. Stop-the

machine

of the accumulator

on level ground

as follows.

and apply the parking

brake.

2.

Raise the work equipment to the maximum the lift arm control lever at HOLD.

3.

Leave the work equipment

4.

Confirm that it is safe around the machine, then set the lift arm at FLOAT and lower the work equipment to a position 1 m (3.28 ft) from the ground.

5.

When the work equipment reaches a position 1 m (3.28 ft) from the ground, move the lift arm control lever to LOWER, and lower the work equipment slowly to the ground.

in this position,

height, then place

and stop the engine.

If the work equipment stops moving during checking, the gas pressure may be below the service limit (700 kPa (7 kg/cm*, 100 psi)), so contact your Komatsu distributor to have the gas pressure measured or gas charged.

Carry out the checks within five minutes of stopping the engine.

If the machine is left with the engine stopped, the accumulator pressure will drop and it will be impossible to carry out the check.

24.9.13

INTERNAL

PART OF AIR DRYER

If the air dryer is installed as an option, replace the following internal parts of the air dryer: Desiccant, oil filter, filter, and all rubber parts.

Contact your Komatsu distributor to have these parts replaced.

3-76

24. SERVICE PROCEDURE

24.10 EVERY 4000 HOURS

SERVICE

Maintenance for every 50, 100, 250, 500, 1000 and 2000 hours should be carried out at the same time.

24.10.1 CHECK WATER PUMP Check that there is no play in the pulley, oil leakage, water leakage, or clogging of the drain hole. If any abnormality is found, please contact your Komatsu distributor for disassembly and repair or replacement.

24.10.2

CHECK ENGINE VIBRATION

DAMPER

Check decrease of damper fluid, dent or out-of-flat. If there is any abnormality, contact your Komatsu distributor for repair.

24.10.3 CHECK FAN PULLEY AND TENSION PULLEY Check the pulley to see if there is any leaking grease. If any abnormality is found, ask your Komatsu distributor to repair or replace it.

24.10.4 CHECK AIR COMPRESSOR, ADJUST Ask your Komatsu distributor to disassemble and replace.

24.10.5

CHECK INJECTION BOOT, REPLACE

repair

or

PUMP RACK RUBBER

Check the injection pump rack rubber boot for cracks and oil leakage. If any abnormality is found, please contact your Komatsu distributor for replacement.

i Injection pump rack rubber boot

3-77

3-78

SPECIFICATIONS

4-1

25. SPECIFICATIONS

WA8004

I

PERFORMANCE l

Bucket capacity

l

Normal

(Heaped) (Straight edge without teeth)

load

18900 kg (41675

Forward l

Travel

10.5 m3 (13.7 cuyd) lb)

1st

7.0 km/h (4.3 MPH)

2nd

12.3 km/h (7.6 MPH)

3rd

28.0 km/h (17.4 MPH)

1st

7.1 km/h (4.4 MPH)

2nd

12.4 km/h (7.7 MPH)

3rd

28.3 km/h (17.6 MPH)

speed

Reverse

l

Max.

rimpull

l

Min. turning

60000 radius

Outside

N)

10910 mm (35 ft 10 in)

of chassis

Center of outside

kg (588000

9210 mm (30 f-t 3 in)

tire

WEIGHT l

Operating

weight

(including

1 operator:

80 kg.)

89500

kg (197140

lb)

ENGINE

I

l

Model

l

Flywheel

l

Max. torque

0 Starting l

Alternator

l

Battery

4-2

horsepower

motor

Komatsu

SA12V140

diesel engine

588 kW (789 HP)/2000 3727 Nm (380 kgm)/l400 24 V

rpm

7.5 kW x 2 pieces 24 V

12 V

rpm

50 A

200 Ah x 4 pieces (N200)

25. SPECIFICATIONS

.I ,SIiS85b41P!fi I IeJahO ( ,II)Oci&E

-_

( â&#x20AC;&#x153;5 .O& )OLZ6 J

4-3

MEMO

4-4

OPTIONS, ATTACHMENTS

26. OPTIONAL

Description

PARTS AND ATTACHMENTS

Specification

or Use

I

Bucket - For standard boom

Capacity - Straight edge rock

10.5 m3 (13.73 yd)

Bucket - For high-lift boom

Capacity - Straight edge rock or Spade nose rock

9.5 m3 (12.43 yd)

Bucket teeth

Consult your local distributor

High-lift boom

Optimum for loading 120 ton class dump truck

Tire mesh chains

Tire protectors

l l

Auxiliary Tires

steering

These and various other parts and attachments distributor.

5-2

or dealer

are available,

for further information

please contact your Komatsu

27. SELECTING BUCKETS AND TIRES

Select the most suitable bucket and tires for the type of work and the ground conditions on the jobsite.

Type of work

l

Loading materials and blasted rock

Bucket

Ground conditions

Tire

!Straight edge

3eneral ground conditions

45165-45-38 PR (L-5) 45165-45-46 PR (L-5) 4516545-50PR

rock bucket (IO.5 m3)

Hard ground

(L-5) 45/67;_5$3PR

Zieneral ground conditions

45/65-45-46PR (L-5) 45/65-45-50PR (L-5)

Hard ground l

Loading blasted rock

Spade nose Bucket (10.5 m3)

4516545-38PR (L-5) 45165-45-46 PR

Ground with many boulders

(L-5) 45/65;45$0

1

Soft ground with many boulders

Use tire chains as a tire brotector 45/65-45-38PR (L-4 or L5) 45/65-45-46PR (L-4 or L5) 45165-45-50 PR (L-4 or L5)

General ground conditions

l

Loading and carrying blasted

rock

Spade nose bucket (10.5 m3)

Hard ground

t General with many

rocks

Soft ground

.

\Ah many rocks

_L

PR

Soft ground with many rocks

4516545-38PR (L-4 or L5) 45/65-45-46PR (L-4 or L5) 45/65-45-50PR (L-5) Use tire chains as a tire protector

The speed display differs according to the tire size, so when changing to optional tires, please contact your Komatsu distributor.

On jobsites where there are many boulders install tire protectors (mesh chain).

or sharp

Check the chain for cuts or slack before starting Be careful

rocks, please

operations.

not to let the tires or chains slip during

operations.

5-3

5-4

Komatsu America International Company 440 North Fairway Drive I Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186

PROPOSAL

1

FOR MANUAL REVISION

FOR INTERNAL P R 0 P

NAME OF COMPANY:

;

DEPARTMENT:

E R

NAME:

MANUAL

NAME:

MANUAL

NO:

DATE:

PAGE NO:

PROBLEM:

Attach photo or sketch.

If more space is needed, use another sheet.

FOR INTERNAL CORRECTIVE

081696

LOCATION: PHONE NO:

MACHINE MODEL: S/N IF APPLICABLE:

PFMRI

USE ONLY - No. PMR

USE ONLY

ACTION: