Komatsu Wheel Loader WA800-2 Operator & Maintenance Manual - PDF DOWNLOAD

Operation 81Maintenance Manual

SEAM004000

WHEEL LOADER

SERIAL NUMBERS

WA800-2 - 10598

andup

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

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

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

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

April 1996

Copyright 1996 Komatsu America International Company

1. FOREWORD

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

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

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

This manual may contain attachments and optional equipment that are not avaiiable 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

1

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 shoufd 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 I-l.

on page O-2 and in SAFETY from page

O-l

2. SAFETY INFORMATION

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

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

A DANGER

-

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

A WARNING

-

A CAUTION

This word is used on safety messages and safety labels where there is a potentially dangerous situation which could result in serious iirjury 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. .

-

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

-

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

NOTICE

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

Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible.safety’preca&ns.

If any procedures or actions not specific$lly 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 l l

3.2 7.

2.

3.

4.

3.3

INTENDED USE This machine is intended mainly for the following operations.

Digging operations Leveling operations Pushing operations 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.

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 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

MACHINE SERIAL NO. PLATE POSITION

4.1

On the center right of the front frame.

4.2

ENGINE SERIAL NO. PLATE POSITION On the right of the cylinder block, when seen from the fan side.

_

4.3

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

__.

._

Engine serial No.: Distributor name:

Address:

-

Service personnel for your machine:

REMARKS

o-4

Phone:

1

5. CONTENTS

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

1.

Foreword

2.

Safety

3.

Introduction

4.

Location

information

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

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

of plates,

table to enter

serial No. and distributor

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

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

SAFETY 6.

General

7.

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

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

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

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

7.4 Battery.. .......................................................................................................................................

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

8.

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

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

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

8.3 Tires ...........................................................................................................................................

9.

Position

precautions

for attaching

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

safety

labels

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

I- 2 I- 7 l- 7 I- 9 l-l 3 .-l-14 1-15 .:. _I I-16 .I-16 1-18 1-22 l-24

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

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

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

11 Explanation of comaonents 17.1 Machine monitor ......................................................................................................................

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

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

11.4 Dust indicator.. ..........................................................................................................................

11.5 Circuit breaker (Main) ..............................................................................................................

11.6 Safety bar ..................................................................................................................................

11.7 Steering column tilt lever.. ......................................................................................................

11.8 11.9 11.10 11.11 11.12 11.13 11.14 11.15 11.16

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

Cap with lock ............................................................................................................................

Fuel stop lever ..........................................................................................................................

Air. pick-up port .........................................................................................................................

Fuse ............................................................................................................................................

Car radio ....................................................................................................................................

Air conditioner ..........................................................................................................................

Car heater ..................................................................................................................................

Using accumulator ...................................................................................................................

2- 2 2- 2 2- 3 2- 4 4 2-14 2-20 2-25 2-25 2-25 2-26 2-26 2-26 2-27 2-27 2-28 2-30 2-33 2-37 2-39

i-

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

12.12 Adjusting work equipment posture .......................................................................................

12.13 Parking machine .......................................................................................................................

12.14 Checks after completion of operation ...................................................................................

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

....... ?......... . ..........................................................

Xi.;.

.... .l...... l..... .............................

2-40 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 ............................................................................................

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

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

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

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

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

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

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

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

......... .:..... l....... i.. ....I:. ..... Ii.::. ..... .:.. ...........................................................................

16. Troubleshoot&g 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

MAINTENANCE 17. Guides to maintenance .... ... .. .... .. .. ..... ....... .......... ......................... .... . ...... .... .... ... ............... ..... .... .......

3- 2

18. Outlines of service ............................................................................................................................. 3- 5

18.1 18.2

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

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

3- 5 3- 8

19. Wear parts list ..................................................... .............................................................................. 3- 9 20. Use of fuel, coolant and lubricants according to ambient temperature .... ............ ....... ...... .. .....

3-10

21. Standard tightening torques for bolts and nuts ........................................................................... 3-14 3-14 21.1 Introduction of necessary tools ..............................................................................................

21.2

Torque list .................................................................................................................................

22. Periodic replacement of safety critical parts ................. .. ......_.. . . . . . . .. . .. .. . . .. . . .. . . . .. . . .. . .. . . . . . . . . .. . . . . . . .. .. .

3-15 3-16

23. Maintenance schedule chart ............................................................................................................. 3-19 3-19 23.1 Maintenance schedule chart ...................................................................................................

24. Service Procedure .............................................................................................................................. 3-23 3-23 24.1 Initial 250 hours service ..........................................................................................................

3-24 24.2 When required ..........................................................................................................................

3-42 24.3 Check before starting ...............................................................................................................

24.4 24.5 24.6 24.7 24.8 24.9 24.10

Every Every Every Every Every Every Every

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

50 hours se&e 100 hours service ..........................................................................................................

250 hours service ..........................................................................................................

500 hours service ..........................................................................................................

1000 hours service ........................................................................................................

2000 hours service ........................................................................................................

4000 hours service ........................................................................................................

3-48 3-49 3-53 3-58 3-62 3-68 3-77

SPECIFICATIONS 25. Specifications ............................................_......................................................................................... 4- 2

OPTIONS, A-ITACHMENTS 26. Optional part and attachments .........................................................................................................

5- 2

27. Selecting buckets and tires .............................................................................................................. 5- 3

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-

l-l

A ~~V;~~~;e’,C,;ereasons

cf safety, always ty precautions.

6. GENERAL PRECAUTIONS

-f

SAFETY RULES

1

l

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

l

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

l

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

duty, be sure all personnel

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

Proper position

See “12.1.1 WALK-AROUND

1

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 condition.

Safety lock lever - See “12.13 PARKING MACHINE”.

Seat belts - See “12.1.3.ADJUSTMENT BEFORE OPERATION”.

-.

Improper use of safety features could result in serious bodily injury or death. rf

CLOTHING AND PERSONAL PROTECTlVE ITEMS

1

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

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

1-2

See “24.2 WHEN REQUIRED” in service procedure.

J

a

~;;l’$G;F,“c’b$~o

follow these safety precautions may lead

made without

authorization

from

6. &NERAL PRECAUTIONS

l

Any modification

Komatsu

can create

l

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

hazards. will not be responsible

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

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

Always take the key with you.

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

Locks -, See “12.17 LOCKING”.

MOUNTING NEVER jump

AND DISMOUNTING on or off the machine.

When

getting

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

l-3

6. GENERAL PRECAUTIONS

A ‘JW&J:C;‘~;~ Fo-oereasons qf safety, always ty precautions.

FIRE PREVENTION FOR FUEL AND 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.

PRECAUTIONSI, 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 cool. Turn the can slowly to release the internal pressure before removing the cap.

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 the cap.

l-4

A yp4;G;

Fbi;biz$

follow these safety precautions

may lead 6. GENERAL PRECAUTIONS

ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled. you handle materials containing asbestos fibers, follow these guidelines NEVER use compre’&ed air for cleaning.

Use water for cleaning to keep down the dust.

Operate the machine with the wind to your back, whenever possible.

Use an approved respirator if necessary.

CRUSHING OR CUTTING l

as given below:

PREVENTION

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

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

FIRE EXTINGUISH l

Be sure fire extinguishers

have been provided

l

Provide

l

Know what to do in the event

l

Be sure you know the phone

a first aid kit at the storage

and know how to use them.

point.

of a fire. numbers

of persons you should contact

in case of an emergency.

l-5

6. GENERAL PRECAUTIONS

A ~M~~~G_~~;~reasons cf safety, always ty precautrons.

If ROPS is installed, 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 modified 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 does not fasten the seat belt properly. Always fasten the seat belt when operating.

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

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.

Any injuries, accidents, product failures resulting from the use of unauthorized attachments will not be the responsibility of Komatsu.

l-6

7. PRECAUTIONS DURING OPERATION

A WARNING:

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

7.1 BEFORE STARTING ENGINE SAFETY

AT WORKSITE

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

Examine the shape of the ground and the quality of the soil at the jobsite, and determine the optimum method of operation.

When working on public roads, position flagmen and erect barriers to ensure the safety of passing traffic and pedestrians.

In places where there are buried objects, such as water pipes, gas pipes, or pipes for high voltage cables, contact the company in charge to confirm the position of the buried object, and be careful not to damage the object during operations.

When working in water or when crossing sand banks, first check the condition of the ground and the depth and speed of flow of the water. Be sure not to exceed the permitted water depth.

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

FIRE PREVENTION Thoroughly remove wood chips, leaves, paper and other flammable things accumulated in the engine compartment.

They could cause a fire.

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

Check point 4 See “12.1.1 WALK-AROUND Be sure a fire extinguisher Do not operate

the machine

is present

CHECK”.

and working.

near any flame.

IN OPERATOR’S CAB l

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

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

l

Keep the cab floor, controls,

l

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

Seat belts - See “12.1.3 ADJUSTMENT BEFORE OPERATION”.

steps and handrails

free of oil, grease,

snow,

and excess dirt. parts.

l-7

7. PRECAUTIONS DURING OPERATION

VENTILATION l

A $WNN$;eFooereasons of safety, always ty precautions.

FOR ENCLOSED AREAS

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

PRECAUTIONS

FOR MIRRORS, WINDOWS

AND UGHTS

l

Remove all dirt from the surface of the windows and lights to ensure that you can see well.

l

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

l

Check.that thehead.

1-8

lam.ps and working lamps..light up properly.

A E;;M;G;

FaEg;z

follow these safety precautions may lead 7. PRECAUTtONS DURING OPERATION

7.2 OPERATING MACHINE 1 Walk around your machine might be in the way.

NEVER start the engine When

starting

if a warning

the engine,

Start and operate

again just before

CHECK WHEN

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.

TRAVELING

IN REVERSE

Before operating the machine or work equipment, do as follows.

Sound the horn to warn people in the area.

Check that there is no one near the machine. Be particularly careful to check behind the machine.

If necessary, designate a person to check the safety. This is particularly necessary when traveling in reverse.

When operating in areas that may be hazardous or have poor visibility, designate a person to direct worksite traffic.

Do not allow any one to enter the line of travel of the machine. _ . . . . .

This rule must be stnctly observed even on machlnes equipped with a back-up alarm or rear view mirror.

ii

PRECAUTIONS

I LTravel l

l

l

WHEN

TRAVEUNG

I

I

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

When traveiing 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

I

1-9

A

)MlWWe

7. PRECAUTIONS DURING OPERATION

Fo;ereasons of safety, always ty precautions.

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

On hills, banks or slopes, carry the bucket closer to the ground, approximately 20 to 30 cm (8 to 12 in1 above the ground. In case of emergency, quickly lower the bucket to the ground to help the machine stop and prevent it from tipping over.

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

Do not travel up and down on grass, fallen leaves, and wet steel plates. These materials may allow 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 and travel slowly.

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

lower the bucket, and apply the

When carrying a load, travel forward when going uphill and in reverse when going downhill.

INCORRECT

i

CORRECT

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

\

1

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

The following actions are effective in preventing accidents.

1) Wear shoes with rubber or leather soles.

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

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

When carrying out operations machine.

near high voltage cables, do not let anyone come close to the

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

Voltage

l-10

Min. safety distance

6.6 kV

3m

loft

33.0 kV

4m

66.0 kV

5m

14ft 17*

154.0 kV

8m

27ft

275.0 kV

10 m

33ft

A E;R;;EG;

PaiJai;o

follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATION

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.

Be careful

1 soil over a cliff, dump

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 does not drop when it is being loaded.

I

I

1

load

ENSURE

GOOD

VISIBILITY

1

l

When working in dark places, work area if necessary.

l

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

OPERATE

CAREFULLY

install working

lamps and head lamps,

and set up lighting

in the

1

ON SNOW

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.

l

and other

suddenly.

to the type of snow, so reduce the load and be careful

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.

not

under

l-11

7. PRECAUTIONS DURING OPERATION

A ~~A.M$~;eFcvereasons

l

Do not put your foot on the brake pedal unless necessary.

l

Do not depress the brake pedal repeatedly unless necessary.

l

When traveling downhill,

of safety, always ty precautions.

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

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

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

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

When operating..i.n. p1aces.where.ther.e is danger of falling rocks or danger of the.machine turning over, always install ROPS and a seat belt.

Park on level ground whenever possible. If the machine must be stopped on a slope, block the wheels to prevent the machine from moving.

CORRECT

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 L4;RMEG;

Faiai;;:

follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATION

7.3 l

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

the

1-13

A E$RNI;E;

Paa;::

follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATION

7.5 TOWING 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,

1

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�.

I-15

8. PRECAUTIONS FOR MAINTENANCE

A V$!RJPJeG,!%;ereasons

of safety, always

ty precautions.

8.1 BEFORE CARRYING OUT MAINTENANCE WARNING TAG If others start the engine or operate the controls while you are performing service or lubrication, you could suffer serious injury or death.

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

These tags are available from your Komatsu

distributor.

(Part No. 09963-03000)

DO NOT operate

PROPER TOOLS l

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

Tools - See “21.1 INTRODWCTCON OF NECESSARY TOOLS”.

-v 4 0

1-16

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

PERIODIC

REPLACEMENT

Replace the following Fuel system: Hydraulic system:

OF SAFETY

CRITICAL

8. PRECAUTIONS FOR MAINTENANCE

PARTS

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

if any defect is found, even though

Replacement of safety critical components

-

or not they appear

they have not reached

See “22. PERIODIC REPLACEMENT OF SAFETY CRlTlCAL 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 the front and rear frames

j

WORK EQUIPMENT

with the safety bar.

SUPPORT

f

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.

1-17

A $W~,N;~P-J;~Fc;eeascns qf safety, always

8. PRECAUTIONS FOR MAINTENANCE

v precautrons.

8.2 DURING MAINTENANCE j

PERSONNEL

t

l

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

l

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

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

Always block the tires of the machine securely.

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

4

KEEP THE MACHINE

CLEAN

1

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

Always keep your machine clean and tidy.

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.

1-18

A

VV;RN;M;;Fai;z;;

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

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

l

4 l

l

wipe

it up immediately.

the cap of the fuel and oil fillers securely.

use fuel for washing

any parts.

add fuel and oil in a well-ventilated

USE OF LIGHTING

place.

and allow the engine and radiator

1

When checking specifications.If such lighting

fuel, oil, coolant,

or battery

equipment

PRECAUTIONS

WITH

When repairing (-1 terminal of

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

is not used, there

electrolyte, is danger

always

use lighting

with anti-explosion

of expfosion.

BATTERY

1

welding,

remove the negative

a

8. PRECAUTIONS FOR MAINTENANCE

-/

HANDLING

~GJbdY&

cf safety, always ty precautlons.

~;ereasons

HIGH-PRESSURE HOSES

l

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

l

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

PRECAUTIONS WITH HIGH PRESSURE OIL Do not forget that the work equipment circuits are always under pressure.

Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the internal pressure.

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

If you are hit by a jet of high-pressure oil, consult a doctor immediately

*.

,#m!J.

PRECAUTlONS WHEN CARRYING OUT MAINTENANCE HIGH TEMPERATURE OR HIGH PRESSURE l

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 oil level, add oil -

see “24.2 WHEN REQUIRED”.

Check cooling water level, engine oil pan, oil level, brake oil level, add oil or water - see “24.3 CHECK BEFORE STARTING”.

Checking hydraulic oil level, adding oil + see “24.5 PERIODIC MAINTENANCE”.

Changing oil, replacing filters -

l-20

see “24.7 - 9 PERIODIC MAINTENANCE”.

g

E;FIP-J;;G; F,“cJ-e$

follow these safety precautions may lead 8. PRECAUTIONS FOR MAINTENANCE

j

ROTATING

FAN AND BELT rotating

1

l

Keep away from

parts and be careful

not to let anything

get caught

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 CHAS l

l

-j

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 under the 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

f

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

equipment

and skill, so please ask your

L

L

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 of harmful

objects

on the ground.

such as oil, fuel,

INCORRECT

1-21

8. PRECAUTIONSFOR MAINTENANCE

A Efzt;;~;~

z;epasons of safety, always y precautrons.

8.3 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. l inflate the tires to the specified pressure. Abnormal heat is generated particularly when the inflation pressure is too low.

THE TIRES�.

Suitable inflation pressure -+ See “12.18 HANDLING l

Avoid overloading.

Suitable load + Normal load for bucket: 18900 kg (41575 lb) (When 10.5 m3 (13.7 cu.yd) standard bucket is installed)

l 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.

l-22

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

-j

8. PRECAUTIONS FOR MAINTENANCE

STORING TIRES AFTER REMOVAL l

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.

l

Stand the tire on level ground,

l

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.

and block it securely

so that it cannot

roll or fall over. equipment

are

l-23

9. POSITION FOR AlTACHING

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

A /

View

X

BP 9

View Y

View

Z

AVO!iOESO

1-24

9. POSITION FOR AlTACHlNG

1.

Precautions when (09653-03000)

1. ALWAYS

SIOP

REMOVING 2.

3.

Do

NOI

ENGINE

LOOSEN

3.

CAP WHEN

OIL

IS HIGH.

IF LOOSENEO.

OIL MAY GUSH OUl.

SLOWLY

HYDRAULIC

OPEN

PRESSURE

RELEASE

OIL INIER-

COMPLETELY.

DO NOT OPEN ORAIN PLUG WHEN, 01

2.

tank cap

WHEN

TEMPERATURE

NAL

hydraulic

CAP.

T,ANK CAP AND

1.

removing

SAFETY LABELS

TEMPERATURE

15 HIGH.

Precautions when (427-93-l 7 520)

Precautions (09668-03000)

connecting

when

removing

radiator

DO NOT LOOSEN CAP WHEN WATER TEMPERATURE

IS HIGH.

IF LOOSENED. BOILING WATER MAY GUSH OUT BECAUSE OF HIGH INTERNAL

PRESSURE. 09666-03000

or disconnecting

-

cap

battery

4.

cable

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 A-I-I-ACHING SAFETY LABELS

5.

Keep Out (423-93-l 14201

8.

FRONT AND REAR FRAMES CAN PIVOT RAPlDLY-STAY CLEAR OF TIRES AND CENTER HINGE AREA WHILE ENGINE IS RUNNING. DO NOT DEFACE

6.

OR REMOVE

THIS

Precautions for operation or maintenance (362-98-12150)

1. WHEN STARTING THE MACHINE TRAVELING OBSERVE THE FOLLOWING.

OR

WHEN

(1) WHEN WlTH BACK-HOE WITHDRAW OUTRIGGER PERFECTLY. (2) CHECK EACH GAUGE AND PILOT LAMP. (3) RELEASE PARKING BRAKE AND START MACHINE. 14) USE PARKING BRAKE ONLY AFTER MACHINE HAS STOPPED COMPLETELY, EXCEPT IN EMERGENCIES. (5) WHEN DESCENDING A SLOPE TRAVEL AT A SPEED SUFFICIENT TO ASCEND THE SLOPE, AND DO NOT SET THE GEARSHIFT LEVER IN NEUTRAL.

DECAL

Precautions for articulate lock (362-98-12160)

2. WHEN CARRYING OUT MAINTENANCE:

MAKE

SURE OF SE1TIN.G

LOCK

TO FIX

THE FRONT/REAR

IN THE FOLLOWING 1. INSPECTION CENTER

ITS

VICINITY.

2.TRANSPORTlNG 3. HOISTING BEFORE

START

DISCONNECT

FRAMES

CASES. AND

THE

(11 PARKTHE MACHINE ON LEVEL GROUND. 12) LOWER WORK EQUIPMENT ON THE GROUND AND LOCK THE LEVER. (3) DO NOT GO UNDER MACHINE WHEN IT IS RAISED BY THE WORK EQUIPMENT.

THEARTlCUiATI

OF

MAINTENACE THE

VEHICLE

IN AND

362-98-12150

VEHICLE.

9.

VEHICLE. A DRIVE ARTICULATE

MAKE

SURE

OF

Precautions with torque converter oil temperature (419-93-l 1980)

LOCK. 362-98-12160

7.

Precautions when starting engine or leaving machine (421-93-I 1940)

READ THE OPERATION L MAINTENANCE MANUAL FOR SAFETY OPERATlON 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 iNI. 121APPLY THE PARKING BRAKE. (31 LOWER THE BUCKET IOR THE FORKS, ETC.l TO THE GROUND AND APPLY THE CONTROL LEVER LOCK. (4) STOP THE ENGINE. (IDLE THE ENGINE FOR 5 MINUTES PRIOR TO SHUT DOWN) 2. WHEN PARKING AT INCLINED PLACE. ADDING TO THE ABOVE ,DESCRIBED. APPLY THE WHEEL STOPPERS FOR BOTH WHEELS (FRONT OR REAR)

l-26

NORMAL OPERATING CONDITIONS. 1. 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. 1F THE INDICATOR LIGHT REMAINS IN THE RED RANAGE, DmRMlNE THE CAUSE OFTHE PROBLEM. 419-93-11980

I

OPERATION

2-1

IO. GENERAL VIEW 10.1 GENERAL VIEW OF MACHINE If directions diagram below.

are indicated

in this section,

they

refer to the directions

shown

by the arrows

Right

Rear Dump cylinder

Lift cvlinder

Rear wheel

Front wheel -

I2 Front

2-2

523 Left

in the

10. GENERAL VIEW

10.2 GENERAL VIEW OF CONTROLS AND GAUGES Machine

Air conditioner control panel

Parking brake switch Directional lever Transmission

Working lamp switch Preheater switch

selector switch Speed control lever

Dimmer switch

Speed control lever St0 Kickdown switch Lift arm control lever _ Bucket control lever Safety lock lever Cigarette lighter Steering column tilt lever

Brake pedals

Accelerator pedal

Turn signal

Brake line failure Engine cooling water temperature

Radiator coolant level monitor Torque converter oil temperature

Torque converter oil temperature monitor

Transmission c

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.

t t .t

MACHINE MONITOR

The machine monitor system consists of the caution displays (A, 8, C. E) and the meter display ID).

WARNING DISPLAYS (A, B, C, EI (11.1.7) A. 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 (DI (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

11.1.1 WARNING

A.

DISPLAYS

CHECK ITEMS

A

r

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 far 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 COMPONEiTS

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.

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.

3.

B.

CAUTION

ITEMS

a

WARNING

If these monitor lamps flash, carry out the following action as soon as possible.

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

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.

2-7

Il.

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 A WARNING lf these monitor lamps flash, immediately stop the engine or run 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 MONlTOR 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

1 (0) 0 cl

I

I 1

Fal%,

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 lamp 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.

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.

G

E.

CENTRAUZED ‘WARNING LAMP

This lamp will flash when l When an abnormality

the machine is in the following condition. has occurred in any 6. 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

11.1.2 D: METER DISPLAY PORTION

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

1.

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

2.

PILOT LAMP FOR WORKING LAMP This lamp lights up when the working lamps are switched on. L

Z-10

3.

ENGINE PRE-HEATING MONlTOR

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-l 1

11. EXPLANATION OF COMPONENTS

METERS 7.

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.

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’

‘I 1. 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.

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-

ii

0

~q.qqGJj~h

is operated

n SERVICEMETER

2-13

11. EXPLANATION OF COMPONENTS

11.2 SWITCHES

1.

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

17. EXPLANATION OF COMPONENTS

2.

LAMP SWITCHES

The monitor Position Position Position Position

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

OFF @ -- l : Lamps go off. @ 10.0~ : Clearance lamps, tail lamps and machine monitor lighting light up. @ zD- : Head lamps light up in addition to the lamps in position @ ~0.0: .

REMARK The lamp switch the lever.

can be operated

regardless

2.

TURN SIGNAL LEVER

@ @

This lever operates the turn signal lamps.

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

of the position

of

REMARK l When the lever is operated, the turn signal pilot lamp will also light up. l When the steering wheel is turned to the neutral position, the turn signal lever will return automatically to OFF. If not, return the lever to OFF manually.

2.

DIMMER SWITCH This switches the head lamp between @ Low beam @ High beam

high beam and low beam.

2-l 5

11. EXPLANATION OF COMPONENTS

3.

c

TRANSMISSION

CUT-OFF SELECTOR SWITCH

If the machine has to be started on a slope, always turn the transmission cut-off selector swtich to OFF and depress the left brake pedal. Then depress the accelerator pedal while releasing the left brake pedal to start the machine off slowly.

This switch selects the operation of the left brake pedal. Normally, put this switch in the ON position. @ OFF: Acts as normal brake (like right brake pedal). @ ON: Acts as normal brake, but also switches transmission to NEUTRAL. If the switch is at ON, the transmission cut-off selector pilot lamp will light up.

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 SWlTCH This actuates an electric heater to heat the intake air for the engine.

Normally, put this switch in the AUTO position.

The automatic preheating circuit is not actuated. @ OFF position: @ AUTO position: 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 posi@ ON position: tion, 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

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.

Working lamps are ON. ON: 7.

PARKING

BRAKE SWITCH a

Always

apply the parking

WARNING brake when

leaving

the machine

or

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.

@ @

This switch operates the parking brake.

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

OFF position: The parking brake is released.

I 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 aiarm 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.

/

I

/’ 77 ,o, .~

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 lf 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 abnormalii.

2-17

11. EXPLANATION OF COMPONENTS

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

8.

9.

HAZARD LAMP SWITCH AL 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, such as when the machine breaks down.

ON: All turn signal lamps flash.

REMARK When this switch is turned to the ON position, the turn direction indicator lamps and turn indicator pilot lamp flash, and display lamp 0 lights up at the same time.

10. CIGARETTE UGHTER 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.

11. KICKDOWN SWITCH When the speed control lever is in Znd, 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 is used to increase the drawbar pull in digging operations.

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

11. EXPLANATION OF COMPONENTS

12. REAR WIPER SWITCH

This actuates the rear wiper.

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

I

.t-

i

‘-

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.

I-

t-L-Q

IC

-\ t-----Q -

OFF

14. ROOM LAMP SWITCH

This lights up the room lamp.

On position: Lights up

OFF <xON ____<==a_-_

2-19

11. EXPLANATION OF COMPONENTS

11.3 CONTROL LEVERS, PEDALS

1.

DIRECTIONAL LEVER This lever is used to change the direction of travel of the machine.

The engine cannot be started if the directional lever is not at N (neutral).

Position @ : Forward Position N : Neutral Position @ : Reverse When operating the directional lever, hold the steering wheel and operate the directional lever with your fingers.

2-20

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 L 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 P 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 Position Position

0: 1st Q: 2nd 0: 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 1. 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 e to within 43 mm (1.69 in). If it is longer than this, the remaining thread is too short, and there is danger that itâ&#x20AC;&#x2122;may come out.

3.

SPEED CONTROL LEVER STOPPER This stopper prevents the speed control lever from entering the 3rd position when working.

Position 0: Stopper actuated.

Position 0: Stopper released.

4. @

@ @ @

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

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

HOLD ( 4 I: The lift arm is kept in the same position.

LOWER ( J. ) FLOAT ( AT 1: The lift arm moves freely under external force.

-w2 1

Raise w

2-22

I

11. EXPLANATION OF COMPONENTS

5.

BUCKET CONTROL This lever operates

0

TILT (

‘k

HOLD ( & DUMP ( !3’

6.

F

I

SAFETY

LEVER the bucket.

): 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.

1

LOCK LEVER

A

WARNING

1

I

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. EXPIANATION OF COMPONENTS

8.

BRAKE PEDALS

7

A l

l l

WARNING â&#x20AC;&#x2DC;I

Right brake pedal The right brake pedal operates the wheel brakes, and is used for normal braking.

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

1

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.

I

is95

11. EXPLANATION OF COMPONENTS

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

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

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 bar for maintenance

or when trans-

l

Always remove the safety bar during normal travel opera-

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.

2-25

Il.

EXPLANATION OF COMPONENTS

11.7 STEERING COLUMN TILT LEVER

A

WARNING

Stop the machine before adjusting wheel.

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 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 @I securely in the groove.

17.9 CAP WITH LOCK The hydraulic tank filler port and the fuel tank filler port are 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

OF OPENING

AND CLOSING

CAP WITH

~20ve3

1

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.

\llbsho”i&%.J

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

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

Aligning mark

2-26

17. EXPLANATION OF COMPONENTS

To open the cap. (For the fuel tank filler port)

1.

2.

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.

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

Open

To lock the cap

1. Turn the cap into place.

2. Turn the key counterclockwise

ock

*zoiuxo J and take the key out.

Shoulder *zD~am

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 â&#x20AC;&#x153;24.7 REPLACING FUEL FILTER CARTRIDGEâ&#x20AC;?.

11.ll

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 of the same capacity.

11.12.1

FUSE

CAPACITY

Fuse box I (Lower side)

AND

NAME

OF CIRCUIT

0

10A

Bucket positioner Boom kick-out, Horn

0

IOA

Rear working lamp

@

10A

Cab working iamp

0

20A

Air conditioner (Fan outside room)

8

20A

Air conditioner (Fan inside room)

8

10A

Radio, Room lamp

@

10A

Cigarette lighter

0

IOA

Rear wipper, Rear washer

0

1OA

Front wipper, Front washer

43

10A

Side working lamp

2-28

11. EXPLANATION OF COMPONENTS

Fuse box II (Upper _ Fuse No. capacity

side)

Circuit

0

20A

Starting switch

0

IOA

Hazard lamp

0

IOA

Left head lamp

0

IOA

Right head lamp

@ 1

IOA

1 Left side clearance lamp

@ 1

10A

1 Right side clearance lamp

0

20A

1 Lighting

1

8

10A

Turn signal lamp

0

IOA

Brake lamp, Back up lamp

63

10A

Transmission control valve

0i-J

10A

Parkina brake

0

1

IOA

.

1 Front working lamp

2-29

7 1. EXPLANATION OF COMPONENTS

11.13

CAR RADIO

0 POINTER

/

1.

POWER SWITCH/VOLUME CONTROL (SW/VOLl 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.

STATION SELECTOR BUlTONS (5 buttons) If these buttons are set beforehand to the desired broadcasting stations, the station can be selected simply by pressing the desired button.

4.

2-30

I

1

11. EXPLkiNATiON OF COMPONENTS

11.13.1 HOW TO SET STATION 1. Press power switch 0.

2.

Pull back button @corresponding

SELECTOR BUTTONS

to the station to be preselected. @

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 place.

push back button @with

One station

11.132 l

l

l

l

l

the fingertip

until it clicks into

can be set for each station selector

PRECAUTIONS

/

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 Remedy

Problem No sound

l

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

Sound quality is Reception is noisy.

l

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

a Try lengthening the antenna to its fullest extent.

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

2-32

11. EXPtiNATlON

11.14

OF COMPONENTS

AIR CONDITIONER

1.14.1 LOCATIONS AND FUNCTIONS CONTROL PANEL

OF PARTS ON

It is possible to use the air conditioner to good effect in dusty jobsites. The outside air is passed through the filter and is sent to the operatorâ&#x20AC;&#x2122;s cab to increase the pressure inside the cab. In this way, dust is prevented from entering, so comfortable operating conditions are always maintained for the operator.

1.

FAN SWITCH The fan speed can be set to three levels.

This switch is also used as the main switch for the air conditioner.

Turn the switch to the right to set the fan speed to LO (low), ME (medium), or Hi (high). s

FAN

2.

AIR CONDITIONER SWITCH This is used to switch the cooling and dehumidifying functions on or off.

ON: Push the button to carry out dehumidification and cooling.

The blue lamp lights up to indicate that the cooling system is on.

OFF: If the system is ON and the button is pressed again, the switch returns to its original position and the air conditioner is switched off.

Turn the air conditioner

switch on after turning the fan switch on.

2-33

11. EXPLANATION OF COMPONENTS

AIR INTAKE SELECTOR LEVER This switches the air intake port when cooling or heating.

FRESH: Operate the lever to the right.

Fresh air is taken in from outside in addition to the air inside the compartment.

This is used for ordinary cooling or heating, and when pressurizing the inside of the cab.

RECIRC: Operate the lever to the left.

ONly the air inside the compartment is used.

This is mainly used for quick cooling or heating.

3.

4.

TEMPERATURE CONTROL LEVER This is used to control the temperature for cooling or heating The farther the lever is moved to the LEFT, the LOWER the temperature of the air blown out from the vent.

The farther the lever is moved to the RIGHT, the HIGHER the temperature of the air blown out from the vent.

2-34

11. EXPLANATION

11.14.2

METHOD

OF COMPONENTS

OF OPERATION

OPERATION OF CONTROL PANEL Air conditioner switch

IzF ! =n

Quick

HI

Air intake selector lever

Temperature control lever

ON

Move fully to left

Left

I

I

Normal

HI - LO

ON

From left side to near center

Right

Dehumiditying, heating

HI - LO

ON

From center to near right side

Right

HI

OFF

Move fully to near right side

HI - LO

OFF

From center to near right side

Right

HI

ON

From center to near right side (move fully to the right when carrying out quick defrosting or demisting.)

Right

HI - LO

OFF

Move fully to left

Right

0

P ._ ;ir P

Quick Normal

Defrosting Ventilation or pressurizing

Left

If the outside air is extremely dusty, set the fan switch to the HI position. This will pressurize the cab and prevent the dust from entering.

SELECTING

AIR VENT

I

I

Defrosting Ventilation

1

Closed Open

1

) Open or closed Open

Open Open

The effectiveness of the air conditioning system can be increased by selecting the most suitable vent.

Do not turn the fan switch on when all the vents are closed.

2-35

11. EXPLANATION

11.14.3 l

l

o

OF COMPONENTS

PRECAUTIONS

FOR USING AIR CONDITIONER

When cooling, change the air occasionally.

Smoking in the air-conditioned cab will cause your eyes to get sore. While smoking, open the window to let the smoke out of the cab.

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

The cab should feel cool when entering there from outside (5°C or 6°C lower than the outside temperature). It is notgood for the health to have the temperature in the cab too low. Always give careful consideration’to temperature regulation.

HANDLING THE AIR CONDITIONER IN SEASON To use the air conditioner comfortably during its season, ask your Komatsu distributor to check the air conditioner and add the refrigerant if necessary. l The standard cleaning cycle for the fresh air filter is EVERY 100 HOURS, but if it becomes clogged, it will be impossible to pressurize the inside of the cab, and in addition, it may cause failures, so check and clean the filter immediately.

For details of cleaning, see “24.5 EVERY 100 HOURS SERVICE”. l If a large amount of dirt or dust collects on the condenser, the cooling capacity drops, so check and clean when necessary. For details, see “24.2 WHEN REQUIRED”.

HANDUNG THE AIR CONDITIONER IN OFF-SEASONS To lubricate each part of the compressor during the off-seasons, operate the air conditioner for a few minutes two or three times a month.

2-36

-

11. EXPLhNATION

11.15

OF COMPONENTS

CAR HEATER

11 m15.1 LOCATIONS AND FUNCTIONS CONTROL PANEL

OF PARTS ON

it is possible to use the car heaterto good effect in dusty jobsites.

The outside air is passed through the filter and is sent to the operatorâ&#x20AC;&#x2122;s cab to increase the pressure inside the cab. In this way, dust is prevented from entering, so comfortable operating conditions are always maintained for the operator.

1.

FAN SWITCH The fan speed can be set to three levels.

This switch is also used as the main switch for the car heater.

Turn the switch to the right to set the fan speed to LO (low), ME (medium), or HI (high).

LO ME a=F/--tYHl

@ s

2.

FAN

AIR INTAKE SELECTOR LEVER

This switches the air intake port when heating.

Operate the lever to the right.

FRESH: Fresh air is taken in from outside in addition to the air inside the compartment.

This is used for ordinary heating, and when pressurizing the inside of the cab.

Operate the lever to the left.

RECIRC: ONly the air inside the compartment is used.

This is mainly used for quick heating.

2-37

11. EXPLANATION OF COMPONENTS

3.

TEMPERATURE CONTROL LEVER This is used to control the temperature for cooling or heating The farther the lever is moved to the LEFT, the LOWER the temperature of the air blown out from the vent.

The farther the lever is moved to the RIGHT, the HIGHER the temperature of the air blown out from the vent.

11.15.2

METHOD

OPERATION

OF OPERATION

OF CONTROL

PANEL Air intake selector lever

Temperature control lever

P â&#x20AC;&#x2DC;Z % I

Quick Normal

Defrosting

Ventilation or pressurizing

Move fully to near right side

HI HI-LO

HI

HI-LO

Left

From center to near right side

Right

From center to near right side (move fully to the right when carrying out quick defrosting or demisting.)

Right

Move fully to left

Right

If the outside air is extremely dusty, set the fan switch to the HI position. This will pressurize the cab and prevent the dust from entering.

SELECTING

FACE

FOOT

DEF

Open or closed

Open

Open or closed

Defrosting

Closed

Open or closed

Open

Ventilation

Open

Open

Open

Heating

L

AIR VENT

The effectiveness of the heating system can be increased by selecting the most suitable vent.

Do not turn the fan switch on when all the vents are closed.

2-38

11. EXPLANATION OF COMPONENTS

11.16

USING ACCUMULATOR

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.

2-39

12. OPERATION

12.1

CHECK BEFORE STARTING ENGINE

12.1.I WALK-AROUND

CHECK

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

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

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 in this section before starting the engine each day.

!

4

w

fl I,,,

1

2-40

47

4

2, 3

4

-

69

7

5

-9

293

10

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.

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,

6.

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.

7.

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

8.

Check for damage to gauges, monitor, loose bolts Check that there is no damage to the gauges and monitor in the operatorâ&#x20AC;&#x2122;s cab. If any abnormality is found, replace the parts.

Clean off any dirt on the surface.

9.

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

A

WARNING

Even if there appears to be no abnormality with the seat belt, always replace it once every three years.

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 mounting the seat belt to the machine, and tighten if necessary.

Tightening

torque: 24.5 + 4.9 Nm (2.5 f 0.5 kgm, 18.1 2 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 k 294 Nm (280 2 30 kgm, 2025 2 217 bolts are damaged, replace them with genuine Komatsu

13. Clean cab window Clean the cab window to ensure good visibility when operating the machine.

2-42

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 distributor to inspect that monitor lamp.

up,

ask your

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

CHECK COOLANT

Komatsu

using only the for the periodic

LEVEL, ADD WATER

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

AOO33bW

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.

usual,

check for

2-43

12. OPERATION

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the inspection window at the rear left side of the machine.

2.

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

3.

Insert dipstick 0 fully in the oil filler pipe, then take it out again.

4.

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

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

For details of the oil to use, see â&#x20AC;&#x153;20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATUREâ&#x20AC;?.

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 oil from drain valve 0, and check the oil level again.

6.

If the oil level is correct, tighten the oil filler cap securely, then close the inspection window.

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

I

wT7!

CHECK AND REFILL OF OIL IN BRAKE OIL TANK g WARNING Always use engine oil to refill the brake oil tank.

1.

Check that the oil level in brake oil tank at the left side of the machine is in sight gauge 0.

2.

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 @ (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 CHECK, CLEAN, OR REPLACE AIR CLEANER”.

WHEN

REQUIRED,

2-45

12. OPERATION

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 for opening and closing the cap, see “11.9 CAP WITH LOCK”.

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

3.

After adding fuel, tighten the cap securely.

Fuel capacity:

1430 I? (377.5 US gal, 314.6 UK gal1

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

2-46

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

Check for damage of the fuse and any sign of disconnection or short circuit in the 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. a

WARNING

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

When carrying out walk-around checks or checks before starting, always check if there is any accumulation of flammable material around the batten/, 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 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.

2-47

12. OPERATION

CHECK EFFECT OF PARKING BRAKE

Even if the parking brake switch is turned ON, there is danger up, so keep the brake

Measurement conditions l Tire inflation pressure: Specified pressure l Road surface: Dry paved surface with l/5 ~‘ll”20’) grade l Machine: Operating condition 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 lever to the neutral position, then stop the engine.

3.

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

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).

CHECK SOUND OF HORN AND BACKUP BUZZER 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

24%

.

12. OPERATION

12.1.3

ADJUSTMENT

OPERATORS

BEFORE OPERATION

SEAT AL WARNING

l l

l

Park the machine in a safe place and stop the engine when carrying out adjustment of the operatorâ&#x20AC;&#x2122;s seat.

Adjust the seat before starting operations or when changing operators.

Check that you can depress the brake pedal fully with your back against the seat backrest.

A:

Forward-backward adjustment Move lever $I to the right, move the seat to the desired position and release the lever.

Fore-and-aft adjustment: 140 mm (5.51 in) (20 mm (0.79 in) x 7 stages) B:

Seat angle adjustment Move lever @ up, set the seat to the desired angle, and release the lever.

The seat can be tilted up or down about 3â&#x20AC;?.

C:

Seat cushion adjustment Rotate grip @ under the seat to adjust scale @ on the cushion adjustment to your own weight.

The weight can be adjusted within a range of 50 to 120 kg (110.3 to 264.6 lb).

D:

Backrest adjustment Pull lever 0, move the backrest to the desired release the lever.

The backrest can be set to 11 positions.

Seat height adjustment Move lever @ upward, set the seat to the desired release the lever.

The seat can be set within 50 mm (1.95 in).

position

and

height

and

E:

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

Angle adjustment Loosen bolts $I to move the armrest tighten the bolts.

to the desired

position,

angle, then

2-49

_ 12. OPERATION

ADJUST SEAT BELT Always install a seat belt on machines equipped with ROPS.

7

a

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 the seat belt before starting operations.

Always use the seat belt during operations.

c

Do not twist fastening it.

the left or right side of the seat belt when

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

1.

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

2.

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.

3.

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.

4.

When removing the belt, raise the lever of buckle @ to free the belt.

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

2-50

Q

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.

ADJUST REAR VIEW MIRROR Sit in the operatorâ&#x20AC;&#x2122;s seat and adjust the rear view mirror so that you can see properly to the rear.

2-51

12. OPERATION

121.4

OPERATIONS AND CHECKS BEFORE STARTING ENGINE AL WARNING

l

If the control levers are touched by accident, the work equipment may move suddenly. When leaving the operatorâ&#x20AC;&#x2122;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 brake switch 0 is at the ON position.

ON

2.

Check that directional lever @ is at the N position.

I 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.

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

2-52

OFF

12.2

STARTING

12.2.1 NORMAL

ENGINE

STARTING

A

WARNING

Check that there are no persons or obstacles in the surrounding 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 the engine.

3.

accelerator

pedal @ lightly.

1

switch @ to the START position to start

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

OFF

and OFF

::

,,â&#x20AC;&#x2122;O/t -- 29 3

2-53

12.2.2 STARTING

IN COLD WEATHER

l

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

l

Never use starting aid fluids as they may cause explosions.

c 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.

When starting in low temperatures, do as follows.

1. Turn the key of starting switch @ to ON. Preheating will start automatically, and preheating pilot lamp @ will light up.

2.

Depress accelerator pedal @ halfway.

3.

When preheating is finished, the pilot lamp will go out. Turn the key of starting switch @ 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.

/

5%

‘Oily

4.

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

OFF

ia ,I’O%

Q

.I’

cp

EiiLl \\

2-54

__

4

--p

4

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.

-20°C to -3OT

40 seconds

A WARNING Never use starting aid fluids as they may cause explosions.

When operating the machine at temperatures below -2Oâ&#x20AC;?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 -10°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 color, sound, or vibration.

If there is any abnormality, carry out repairs.

I

2-56

vm

12. OPERATION

12.4 MOVING MACHINE OFF WARNING

-a l

l

â&#x20AC;&#x2DC;pl

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 0 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 @ is not lighted

up.

2.

Set safety lock 0 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

to the ;

4.

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

Keep right brake pedal @ 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.

Set speed control

lever @ to the desired

*.

\

brake switch brake switch

position.

3rd

2-57

12. OPERATION

6.

Set directional lever @ to the desired position.

I 7.

Release right brake pedal 0, then depress accelerator pedal @ /I to move the machine off.

12.5 CHANGING GEAR SPEED

Shift the gear as follows.

Move speed control lever @ to the desired position.

Only 1st or 2nd speeds are used for digging and loading operations, so actuate speed control lever stopper @I. 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 â&#x20AC;&#x153;11. EXPLANATION OF COMPONENTSâ&#x20AC;?.

2-58

Reverse

FOIIP!

12.6 CHANGING 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.

There is no need to stop the machine between FORWARD and REVERSE. Place directional lever Q) in the desired

even when

switching

Forwar

position.

Reverse

CO973

12.7 TURNING

A

WARNING

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

2-59

12.8 STOPPING MACHINE Avoid stopping suddenly. Give yourself ample room when stopping.

Do not park the machine on slopes.

If the machine has toAL bewARNâ&#x20AC;&#x2122;NGparked 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 maEhine 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 operatorâ&#x20AC;&#x2122;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.

Thrus>the bucket

I

1

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 pedal 0, and depress brake pedal @to stop )I the machine.

2.

Place directional

3.

Turn parking brake switch @ to ON to apply the parking brake.

lever @ in N (neutral).

REMARK When the parking brake is applied, the transmission is automatically returned to neutrai.

2-60

Block

12.9 OPERATION OF .WORK EQUIPMENT Lift arm control lever 0 and bucket control to operate the lift arm and bucket as follows.

lever @ can be used

LIFT ARM OPERATION (LEVER 01 @ Raise ( af 1 @ Hold ( I 1: The lift arm is kept in the same position. @ Lower ( \L 1 @ 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

BUCKET OPERATION (LEVER 0, @ Tilt ( â&#x20AC;&#x2DC;W 1 @ Hold ( 4 ): The bucket is kept in the same @

Dump (

L

the bucket.

position.

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. OPERATION

12.10 WORK POSSIBLE USING WHEEL LOADER In addition to the following, it is possible to further increase the range of applications by using various attachments.

12.10.1

I-

DIGGING

OPERATIONS A WARNING ‘-1

Always set the machine facing directly to the front when carrying out digging or scooping operations. Never carry out these operations with the machine articulated.

NOTICE lf the tires slip, the tire life will be reduced, so do not allow the tires to slip during operation.

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. o When working with stockpiles, operate the machine in ‘lst or 2nd; when loading blasted rock operate the machine in 1st.

l

1. 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, the front tires will come off the ground, and the tires will slip.

2.

Shift down immediately in front of the material to be loaded. 1 When completing the shift down, depress the accelerator pedal Stockpile 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

I_’ ’

- *

Blasted rock

-

p

I

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.

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 hauiing.

2-63

12. OPERATION

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.

Set the edge of the bucket facing slightly down.

2.

Drive the machine fomard 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.

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

2-64

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”.

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

backward

while

2.

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

3.

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

the

OPERATIONS

NOTlCE Never set the bucket to the DUMP pushing operation.

1.

touching

position

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

when

carrying

out

set the bottom of the

12.10.4 LOAD AND CARRY OPERATIONS

a When carrying a load, lower gravity when traveling.

The load of scooping Always keep When using TIRES”.

I

WARNING the bucket to lower the center

/ of

and carry method for wheel loaders consists of a cycle + hauling + loading (into a hopper, glory hole, etc.) the travel path properly maintained. the load and carry method, see “12.18 HANDLING

I

2-65

X2.10.5 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.

A l

l

WARNING

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

These actions are dangerous. lt 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, so do not allow the tires to slip during operation. l Avoid excessive shaking of the bucket. l

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 oile and the wheel loader.

This method requiies 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. 60â&#x20AC;? 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 countemeight 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 12.11 .l

PRECAUTIONS FOR OPERATION PERMISSIBLE WATER DEPTH

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. OPERATION

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.

Max. travel Ambient temperature(‘C) speed (km/h) 20

50

25 34

Traveling time and breaking time Break

Repeat

Travel -V 13 km or 40 Travel

(3H) Break

Repeat

--.

13 km or 35 Travel

Break

Repeat

1 13 km or 25’ , Travel

(3H) Break

Repeat

-1

L”

25 30 28 0

28

‘13 km or 35’ (3H) Repeat Break Travel -v: 15 km or 30 (3H) Repeat Break Travel Vie: (3H) ’ 18 km or 40’ (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 POSTURE

A WARNING l

l l l

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.

12.12.1 ADJUSTING BOOM KICKOUT 1. Raise the bucket to the desired height, set the lift arm control lever at HOLD and lock the lever engine and adjust as follows.

in position.

Then

stop the

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 @_ Then tighten the nuts to hold in position.

Tightening 4.

torque:

17.2 2 2.5 Nm (1.75 -c 0.25 kgm,

12.7 f 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

12. OPERATlOi

12.122

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 @ 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 1 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 + 2.5 Nm (1.75 2 0.25 kgm, 12.7 & 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 â&#x20AC;&#x2DC;control lever is automatically returned to HOLD when the bucket reaches the desired angle.

12.12.3 BUCKET LEVEL INDICATOR @ and @I at the top rear of the bucket are the level indicators, so the bucket angle can be checked during operations. @: Parallel with cutting edge @: 90â&#x20AC;? to cutting edge

2-70

hY.rIA~~m

12. OPERATION

12.13

PARKING MACHINE

I~

g

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 operatorâ&#x20AC;&#x2122;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.

Thru>

the bucket

-Blocks

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 0

to ON to apply the parking brake.

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

the transmission

is automati-

2-71

12. OPERATION

4.

Operate lift arm control lever @ to lower the bucket to the ground.

5. Lock lift arm control lever @ and bucket control lever @ with safety lock 0.

12.14

21

CHECKS AFTER COMPLETION OF OPERATION

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.

torque lamps. engine before

12.â&#x20AC;&#x2DC;15 STOPPING ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency.

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

1.

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

2.

Turn the key in starting switch 0 to the OFF position and stop the engine.

3.

2-72

Remove the key from starting switch 0.

OFF

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 anywaste 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

REMARK The starting

switch key is used also for locks

0,

Q. 0,

@, and

0.

2-73

12. OPERATION

12.18

HANDLING THE TIRES

12.18.1

PRECAUTIONS

WHEN HANDLING

TIRES

If the following defects are found in tires, for safety reasons the tire should be replaced with a new tire. l Bead wire is broken or bent, or the tire is greatly deformed. l Wear is excessive and the carcass ply (excluding breaker) is exposed for more than l/4 of the circumference. l Damage to the carcass exceeds l/3 of the tire width. l Tire layers are separated. l Radial cracks reach the carcass. l Deformation or damage which makes the tire unsuitable for use.

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 XIOOH I Deflection ratio = H IED ____ 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: ..... . ..... .. ... ....... ..... .. .. . ...... High end of range in air pressure chart l

Stockpile operations on soft ground: ........ .. .. .. .. ....... .. ..... .. .. .... . Average pressure in air pressure chart

l

Operations on sand (operations not using much digging force) ..... ..... .............. ...... .... .. .. . Low end of range in air pressure chart

2-74

Tread

If the deflection of the tire is excessive, pressure within the limits given in the table deflection (see deflection ratio).

Tire size (pattern)

piy ratmg

I

Stockpile materials.

raise the inflation to give a suitable

1

(mm1

operations

1

__

_

mean the loading

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

W&/4/L

AND INSTALLATION OF THE

A

WARNING

Park the machine on lever 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 0.

12. OPERATION

3.

1

Sling the bucket link, then pull out the bucket link pin.

Secire the bucket link to the tilt lever with wires.

\ 4.

Pull out and remove bucket.

5.

Disconnect

bucket

hinge

ml6

pin @ on both sides of the

lift arm and bucket.

. _

2-77

INSTALLING THE BUCKET 1. Set cord ring @ on top of lift arm boss @ as shown in the diagram.

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.

_-

4.

Select the number of shims so that clearance A between bucket hinge boss @ and lift arm boss @ are less than 1.0 - 1.5 mm (0.04 - 0.06 in).

5.

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 â&#x20AC;&#x2DC;the dust seal when inserting the bucket hinge pin.

Use a bucket hinge pin that has a grease hole.

6.

2-78

Put bucket hinge pin stopper plate @ in contact with the hinge plate block, and secure it with cam 8.

7.

install retainer 0 to bucket hinge pin 0, then measure clearance B between the end face of the retainer and the bucket hinge boss.

8.

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.

J

9.

Shim 1:

Move cord ring @ down to the groove.

_-

10. Use the same procedure as in steps 1 - 9 to install the bucket link

pin.

Assemble a pin that has no grease hole at the bucket link.

11. Coat the bucket hinge pin and bucket link pin with grease. For

details, see â&#x20AC;&#x153;24.5 EVERY 100 HOURS SERVICEâ&#x20AC;?.

For details of removing and installing the bucket, please contact your Komatsu distributor.

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”.

14.1.2 COOLANT a

WARNING

Keep antifreeze fluid away from an open flame. Never smoke when using antifreeze.

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

l

antifreeze.

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 J1034 l SAE .... .... ... .. ..._......_...........................................................-..... 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

A WARNING l

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

l

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

I--

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

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

100% 90%

2-82

-

1.28

1.29

1.30

1.31

1.32

1.26

1.27

1.28

1.29

1.30

80%

1.24

1.25

1.26

1.27

1.28

75%

1.23

1.24

1.25

1.26

1.27

14. C-OLDWEATHER OPERATION

14.2 PR’.R;;UTIONS AFTER COMPLETION OF To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions.

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

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

Bleed the air from the tank to prevent moisture from collecting inside the tank.

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

As the battery capacity drops markedly in low temperatures, cover the battery or remove it from the machine, keep it in a warm place, and install it again the next morning.

14.3 AFTER COLD WEATHER When season changes and the weather becomes warmer, do as follows. l Replace the fuel and oil for all parts with oil of the viscosity specified.

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

If for any reason permanent antifreeze cannot be used, ethyl glycol base antifreeze (winter, one season type) instead, or if no antifreeze is used, drain the cooling completely, then clean out the inside of the cooling thoroughly, and fill with fresh water.

__

and an is used system system

2-83

15. LONG-TERM STORAGE

15.1 BEFORE STORAGE When putting the machine in storage for a long time, do as follows. l 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. l

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

l

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

l

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

l

If the ambient temperature is expected to drop below Oâ&#x20AC;?C, always add antifreeze to the cooling water.

l

Apply the safety locks to the bucket control lever, lift arm control lever, and directional lever, then apply the parking brake.

l

Open the drain valve of the air tank to drain condensation. Close after completely drained.

15.2 DURING STORAGE

A

WARNING

If it is unavoidably necessary to carry out the r&-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.

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 procedure when taking the machine out of long-term storage. l

Wipe off the grease from the hydraulic cylinder rods.

l

Add oil and grease to all places.

2-84

16. TROUBLESHOOTING

16.1 WHEN MACHINE RUNS OUT OF FUEL

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 0, then push in the knob of feed pump @ and tighten it.

2-85

16. TROUBLESHOOTING

16.2 TOWING THE MACHINE

A

WARNING

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.

l

l

l

NOTlCE l 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.

This machine must not be towed except in emergencies. When towing the machine, take the following precautions.

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.

When towing a machine, tow it at a low speed of less than 2 km/ h (1.24 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 mustbe moved long distances, use a transporter.

Fit a guard plate to the machine being towed to protect the operator if the tow rope or bar should break.

If the steering and brake of the machine being towed cannot be operated, do not let anyone sit on the machine.

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.

2-66

-

l

Keep the angle of the tow rope as small as possible. Keep the towing machine and the towed machine in a straight line, and keep the angle between the center lines of the two machines to within 30â&#x20AC;?.

l

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.

l

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.

l

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.

l

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.

16. TROUBLESHOOTING

2-87

16. TROUBLESHOOTING

16.2.1 WHEN ENGINE CAN BE USED a 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.

The operator should sit on the machine being towed and operate the steering in the direction that the machine is towed.

l

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 parking brake.

1. The transmission oil does 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 RELEASINGâ&#x20AC;&#x2122; PARKING BRAKE a WARNING l

l

l

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 before towing the machine.

installed on the front portion of the

1.

Remove air charge socket left rear frame.

2.

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.

3.

Install the air charge hose for the tire to the air charge socket.

4.

Push the end of the hose on the tire valve, and air will be supplied to the brake chamber to release the brake.

5.

To cham

--7ZI

When the parking brake is released, remove the air charge hose.

Tow the machine immediately to a safe place.

Z-89

16. TROUBLESHOOTING

16.3

IF BATTERY IS DISCHARGED

A

WARNING

When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position before starting.

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

The battery generates hydrogen gas, so there is danger of explosion. Do not bring lighted cigarettes near the battery, or do anything that will cause sparks.

Battery electrolyte is dilute sulphuric acid, and it will attack your clothes and skin. If it gets on your clothes or on your skin, wash it immediately off with large amounts of water. lf it gets in your eyes, wash it out with fresh water, and consult a doctor.

When handling battery, always wear protective

goggles.

When removing, disconnect the cable from the ground terminal first.

When removing the battery, first disconnect the cable from the ground (normally, from the negative 0 terminal). When installing, install the positive @terminal first. If a tool touches the cable connecting the positive terminal and the chassis, there is danger that it will cause sparks.

If the terminals are loose, there is danger that the defective contact may generate sparks that will cause an explosion.

When installing the terminals, install them tightly.

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

REMOVAL AND INSTALLATION OF BATTERY l 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.

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 installing, connect the cable to the positive % terminal first.

16. TROUBLESHOOTING

PRECAUTIONS

FOR CHARGING

BAlTERY

Charging batterv when mounted on machine Before charging, disconnect the cable from the negative 0 terminal of the battery. OthenGse, an unusually high voltage will damage the alternator.

While charging the battery, remove all battery plugs for satisfactory ventilation.

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

If the electrolyte temperature exceeds 45â&#x20AC;?C, stop charging for a while.

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.

Do not mix the cables (positive @ to ndgative 0 or negative 0 to positive @), as it will damage the alternator.

When performing any service to the battery besides checking the electrolyte lever or measuring the specific gravity, disconnect cables from the battery.

REMARK

The batteries are on both sides at the rear of the machine. The used for the ground is on the left side of the machine.

battery

2-91

16. TROUBLESHOOTING

16.3.1 STARTING

ENGINE WITH BOOSTER CABLE

When starting the engine with a booster cable, do as follows:

PRECAUTIONS WHEN BOOSTER CABLE

CONNECTING

AND

DISCONNECTING

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

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

Be careful not to let the normaf machine and problem machine contact each other. This prevents sparks from generating near the battery which could ignite the hydrogen gas given off by the battery. lf hydrogen gas explodes, it could cause serious injury.

Make sure that there is no mistake in the booster cable connections. The final connection is to the 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 l The size of the booster cable and clip should be suitable for the battery size. 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 or corrosion.

l

Make 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

INCORRECT $3â&#x20AC;&#x2122;

_

16. TROUBLESHOOTING

CONNECTING THE BOOSTER CABLES Keep the starting switch at the OFF position.

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

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

2.

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

3.

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

4.

Connect one clip of booster cable @ to the negative 0 terminal of the normal machine.

5.

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

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 doesnâ&#x20AC;&#x2122;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.

1.

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

2.

Remove the other clip of booster cable @ from the negative 0 terminal of the normal machine.

3.

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

4.

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

2-93

16. TROUBLESHOOTING

16.42 CHASSIS ): Always contact your Komatsu distributor (

0

l

In cases of abnormalities distributor for repairs.

or causes which

Problem

when dealing with these items. are not listed below, please contact your Komatsu

Main causes

Remedy

Transmission Engine is running but machine does not move

l

Parking brake is applied Directional lever is not shifted properly Lack of oil in transmission case

Even when engine is run at full throttle, machine only move slowly and lacks power

l

Lack of oil in transmission case

l

Transmission strainer is clogged

s Add oil to specified level.

See WHEN REQUIRED (o Disassemble, clean)

Oil overheats

l

Too much oil or too little oil

l

l

l

l

Machine is not traveling in correct speed range Torque converter is stalled for long periods Engine is overheating -

l

Lack of oil

l

l

Lack of oil

s Add oil to specified level.

See WHEN REQUIRED

l l

l

Noise generated

l l

l

Release parking brake Shift lever properly Add oil to specified level.

See WHEN REQUIRED

Add or drain oil to specified level.

See WHEN REQUIRED Place in correct speed range

a Reduce stall time (o Check engine) Add oil to specified level.

See WHEN REQUIRED

Axle Noise generated

2-95

16. TROUBLESHOOTING

CHASSIS

continued

(16.42) Main causes

Problem

Remedy

Disc brake Low air pressure

Brake has no effect even when pedal is depressed

Disc has reached wear limit Defective in hydraulic system s Lack of oil Air in brake line

Brake drags or remains applied

l

l l

Brakes slip

Exhaust hole in treadle valve clogged Power cluster breather clogged Defective operation of slack adjuster

e Charge air to specified pressure (e Replace disc) 3 Add oil to specified level.

See CHECKS BEFORE STARTING l Bleed air.

See WHEN REQUIRED l

Clean

0 Clean (e Check, repair)

l

Worn disc

(e Replace)

l

Linkage is loose Pad is wet Deteriorated air cylinder spring Worn pad

l

Steering gear adjustment is too tight Linkage is stiff

(e Adjust)

Parking brake Braking effect is poor

l l l

Adjust Clean (e Replace spring) l Adjust or replace l

Steering Steering wheel heavy

l

l

2-96

(e Check linkage, replace if necessary)

-

r

16. TROUBLESHOOTING

CHASSIS continued (16.4.2) Main causes

Problem

Remedy

Hydraulic system Lack of lifting power for bucket

l

Lack of oil

l

Bucket takes time to rise

l

Clogged hydraulic tank filter

l

Excessive bubbles in oil

l Low quality oil being used 0 Oil level is low

l l

Add oil to specified level.

See EVERY 100 HOURS SERVICE Replace filter.

See EVERY 2000 HOURS SERVICE Replace with good quality oil Add oil to specified level.

See EVERY 100 HOURS SERVICE Bleed air. See WHEN REQUIRD

l

Air in oil line

l

Hydraulic pressure is low

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

Movement of cylinder is irregular

0 Oil level is low

l

Add oil to specified level.

See EVERY 100 HOURS SERVICE

2-97

ENGINE continued

(16.431 Main causes

Problem

Remedy

Combustion noise occasionally makes breathing sound

l

Defective nozzle

(0 Replace nozzle)

Abnormal noise generated (combustion or mechanical)

l

Low grade fuel being used Overheating

l Change to specified fuel 0 Refer to â&#x20AC;&#x153;Coolant temperature monitor lights upâ&#x20AC;? as above (0 Replace muffler) (o Adjust valve clearance)

l

l l

Damage inside muffler Excessive valve ciearance

2-99

MEMO

2-100

2 -I m 2 P 2 c) m

17. GUIDES TO MAINTENANCE

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

Perform maintenance work on hard, fiat 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.

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

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

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

Always use clean washer fluid: Use ,automobile window washer fluid and be careful not to let any dirt get into it.

Always use clean oil and grease: Use clean oil and grease. Also, keep containers of the oil and grease clean. Keep foreign materials away from oil and grease.

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 their filters immediately after the engine stops are hazardous. Allow the engine to cool.

If the oil has to be drained when it is cold, warm up the oil to a suitable temperature (approx. 20 - 40°C) before drairting it.

3-2

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 is equipped with a fuel strainer, do not remove it while fueling.

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

Warning tag: Attach the warning tag to the starting switch or other appropriate control lever to prevent anyone from starting the engine during maintenance.

Obey precautions: During the operation, always obey the precautions on the safety label attached to the machine.

Welding instructions: l Turn off the engine starting switch. l Do not apply more than 200 V continuously. l Connect 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; especially when you work on the machinery while bending over it.

3-3

17. GUIDES TO MAINTENANCE

Checking undercarriage: When working in rocky areas, check for damage to the undercarriage and for looseness, flaws, wear and damage in bolts and nuts.

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

Greasing the rod end: Because the rod end is of the oiiless 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

l

Use Komatsu

genuine

l

When

l

Unless otherwise specified, shown in the table below.

changing

parts for replacement.

or adding

oil, do not use a different the oil and coolant

Item

type of oil.

used at the time of shipment

from the factory

are as

Kind of fluid

Engine oil pan

SAE 15W-40 API classification CD

Transmission case

SAE 30 API classification CD I

Axle (Front and rear)

Ax0

75

Hydraulic tank

SAE 1OW API classification CD

Pins

Lithium base EP grease No. 2

Fuel

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

Radiator

Komatsu Super Coolant (AF-ACL) 30% added to water

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

Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual. Even if the oil is not dirty, always replace 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 Always Having

mix oils of different

grades

or brands.

add the specified amount of oil. 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

any

changing

the oil, always

replace

water

or air getting

into the circuit.

the related filters at the same time.

We recommend you to have an analysis made of the oil periodically to che?k 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 instrument, and if fuel containing water or dirt is used, it cannot work properly.

Be extremely careful not to let impurities get in when storing or adding fuel.’

Always use the fuel specified in the Operation and Maintenance Manual.

Fuel may congeal depending on the temperature when it is used (particularly in low temperature below-15”C), so it is necessary to change to a fuel that matches the temperature.

To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank after completing the day’s work.

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

If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.

18.1.3 COOLANT River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the engine and radiator, and this will cause defective heat exchange and overheating.

Do not use water that is not suitable for drinking.

When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.

Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped.

This anti-freeze is effective in preventing corrosion of the cooling system.

The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as it is even in hot areas.

Anti-freeze

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

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

For details of the mixing proportions, see “24.2.2 CLEAN INSIDE OF COOLING SYSTEM”.

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

If the coolant level is low, it will cause overheating and will also cause problems with corrosion from the air in the coolant.

3-6

18. OUTLINES OF SERVICE

18.1.4 GREASE l

Grease

is used to prevent

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.

18.1.5 STORING

twisting

and noise at the joints. so they do not need

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 Always

use Komatsu

genuine

until just before they are to be used.

filters.

3-7

18. OUTLINES OF SERVICE

18.2 OUTLINE OF ELECTRIC SYSTEM If the wiring gets wet or the insulation is damaged, the electric system [e&s and this could result in hazardous malfunction of the machine.

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

Never remove or disassemble any electric components

installed in the machine.

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

Be careful to keep the electric system free of water when washing the machine or when it rains.

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

The optional power source must never be connected to the fuse, starting switch, or battery relay.

3-8

19. WEAR PARTS LIST

Wear parts such as the filter element,. air cleaner element, bucket tooth, etc. are to be replaced at 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

at the same time.

Part No.

Item

Part Name

Qâ&#x20AC;&#x2122;ty

Replacement frequency

Engine oil filter

600-21 l-1230

Cartridge

4

EVERY 250 HOURS

By-pass filter

600-212-1510

Cartridge

2

EVERY 250 HOURS

Fuel filter

600-31 I-7131

Cartridge

2

EVERY 500 HOURS

424-16-11140 (424-16-11630) (424-16-l 1130)

Element (O-ring) (O-ring)

6 (12) (6)

EVERY 500 HOURS

600-41 l-l 170

Cartridge

2

EVERY 1000 HOURS

Transmission oil filter

Corrosion resistor

(07000-05175)

4

Element

07063-01142 Hydraulic filter

I 1 (O-ring)

EVERY 2000 HOURS

1 (4)

6128-81-7042

Element assâ&#x20AC;&#x2122;y

2

600-181-4400

Outer element ass?

2

Air cleaner

Air conditioner air filter

Soft rock

I

121

-

Tooth (Pin)

IO (IO)

Wide

427-70-13810 (427-70-13790)

Tooth (Pin)

10 (IO)

Semi-long life

427-70-13820 (427-70-13790)

Tooth (Pin)

10 (10)

Sharp

427-70-13731 (427-70-13770)

Tooth (Pin)

(IO)

Sharp

427-842-7210 (427-70-13790)

Tooth (Pin)

IO (IO)

Long life

427-842-l 111 (427-70-13790)

Tooth (Pin)

(IO)

Sharp

427-842-l 120 (427-70-13790)

Tooth (Pin)

(10)

General

Tip toott I

j Element

427-70-13780 (427-70-13790)

Long life

rock

) 421-07-12312

-

IO

10

Limestone 10

3-9

20.USE OF FUEL, COOLANT AND LUBRICANT3 ACCORDING TO AMBIENT TEMPERATURE PROPER SELECTION

OF FUEL, COOLANT

AND LUBRICANTS -r

RESERVOIR

KIND OF FLUID

AMBIENT TEMPERATURE -22 -4 -30 -20

14 -10

32 0

50 10

68 20

CAPACITY 104 122’F 40 5(I’C -I--

86 30

Engine oil pan

Specified

Refill

96 e

90 e

25.87 US gal 23.76 US gal 21.56 UK gal 19.80 UK gal

164 e Transmission case

Engine oil

43.3 US gal 36.1 UK gal 1

Hydraulic system

‘. :-. .‘.

.’

._.

.,

I _;;

Brake

1,‘.

.;,

-

“: SAE

,lOw’

I ‘<_.

; ..::,

550 e 946 .!

249.7 US gal 145.2 US gal 212.1 UK gal 121.0 UK gal

I

‘.

;.‘;.

I

‘.;:,.-: /sA&d, ..y.!.....;. ., ,..,. _ ..._..: 1

Axle (Front and rear) (each) Pins

See Note 1

18P 4.75 us gal 3.96 UKgal

360 e

360 e

79.2 UK gal 79.2 UK gal Grease

Iiesel fuel -L_

Cooling system

Water

1430 P 377.5 US gal .314.6 UK gal 301 E 79.5 US gal 66.2 UK gal

4dd antifreeze

% ASTM

D975

When operating the machine at temperatures below-20°C,

No. 1 other equipment is needed, so please consult

your Komatsu distributor.

Note 1: For axle oil, use only recommended oil as follows.

DONAX IT or TD SHELL: RPM TRACTOR HYDRAULIC FLUID CALTEX: CHEVRON: TRACTOR HYDRAULIC FLUID TEXACO: TDH OIL MOBILAND SUPER UNIVERSAL MOBIL: It is possible to substitute engine oil CLASS-CD SAE30 for axle oil.

If noise comes from the brake, it is no problem of durability.

3-10

18C 4.75 US gal 3.96 UK gal

,95.0 US gal 95.0 US gal

.:

Fuel tank

140e 37.0 US gal 30.8 UK gal

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING t0

AMBIENT TEMPERATURE

REMARK When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance 0 hours described in this manual.

Change oil according to the following table if fuel sulphur content is above 0.5%.

_-

Fuel sulphur content

Change interval of oil in engin oil pan

0.5 to 1.0%

l/2 of regular interval

Above 1.0%

l/4 of regular interval

0

When starting the engine in an atmospheric temperature of lower than Oâ&#x20AC;&#x2122;C, be sure to use engine oil of SAElOW, SAEIOW-30 and SAE15W-40, even though an atmospheric temperature goes up to 10°C more or less in the day time.

0

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

0

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

l

We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.

15W-40), but be

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.

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

3-11

20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENTTEMPERATURE

No.

Engine Oil [CD or CE] SAEIOW, 30, 40 1ow30, 15w40 (The 15W40 oil marked * is CE.)

Supplier

I

Gear Oil [GL-4 or’GL-51 SAE80, SO, 140

Grease [Lithium-Base] NLGI No. 2

t EOlO-CD GO90 GO140

G2-LI GZ-LI-S

Rotra MP

GR MU/EP

2

AGlP

Diesel sigma S Super dieselmultigradt3 *Sigma turbo

3

AMOCO

*Amoco 300

Multi-purpose gear oil

RYKON prenium grease

4

ARC0

*Arcofleet S3 plus

Arco HD gear oil

Litholine HEP 2 Arco EP moly D Energrease LS-EP2

I

I 5

BP

Vanellus C3

Gear oil EP “ypogear EP

6

CALTEX

*RPM delo 400 RPM delo 450

Universal thuban Marfak all purpose 2 Universal thuban EP Ultra-duty grease 2

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

Antifreeze

AF engine coolant

I

I

I 7

Anti-freeze Coolant [Ethylene Glycol Base1 Permanent Type

EP EPX

*Turbomax *RX super CRD

CASTROL

HVP~Y HYP~Y B HYP~Y C

I

MS3 Spheerol EPL2

Anti-freeze

I

1 *Delo 400

Universal gear

Ultra-duty grease 2

Universal gear lubricant

Super-sta grease

8

( CHEVRON

9

CONOCO

*Fleet motor oil

0

ELF

Multiperformance Performance 3C

1

EXXON (ESSO)

Essolube D3 *EssoIube XD-3 “Essoiube XD-3 Extra “Esso heavy duty Exxon heavy duty

Gear oil GP Gear oil GX

Beacon EP2

2

GULF

Super duty motor oil *Super duty plus

Multi-purpose gear lubricant

Gulfcrown EP2 Gulfcrown EP special

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

Mobilube GX Mobilube HD

Mobilux EP2 Mobilgrease 77 Mobilgrease special

Tranself EP Tranself EP type 2

3C

l

3

3-12

MOBIL

Glacelf

Antifreeze and coolant

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

-

10.

Supplier

Engine Oil [CD or CEI SAEIOW, 30, 40 1ow30, 15w40 (The 15W40 oil marked * is CE.)

Anti-freeze Coolant [Ethylene Glycoi Base] Permanent Type

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

Grease [Lithium-Base] NLGI No. 2

Multi-purpose 4092 Multi-purpose 4140

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

Anti-freeze and summer coolant

FINA marson EPLP

FINA tamidor

-

14

PENNZOIL

*Supreme duty fleet motor oil

15 Alvania EP grease

16 17

SUN

Sunoco GL5 gear oil

Sunoco ultra prestige 2EP Sun prestige 742

Sunoco antifreeze and summer coolant

TEXACO

*Ursa super plus Ursa premium

Multigear

Multifak EP2 Starplex 2

Code 2055 startex antifreeze coolant

19

TOTAL

Rubia S *Rubia X

Multis EP2

AntigeVantifreeze

-

r:..,

Total EP Total transmission TM

18 -

20 21

Unoba EP

Antifreeze

-

3-13

21. W&llDARD

21.1

TlGHTENlNG TORQUES FOR BOLTS AND

INTRODUCTION OF NECESSARY TOOLS

The following tools are provided with the machine.

-I-

No. 1

Part No.

Name of tool Wrench set

Remarks

09000-30006

Applicable width across flats (S,-S,) 8mm - IOmm, 12mm - 14mm 13mm - 17mm 19mm - 22mm

SP

24mm - 27mm 30mm - 32mm 2

) Socket wrench set

09020-10284

3

1 Screwdriver

09033-00190

Crosshead/flat head interchangeable type

09014-10200

09036-00 150 6

1 Wrench

0900 I-03600

36 jaw

f

1 t;nch

0901 g-08035

For filter cartridge

424-98-l 1130

Extension bar

-t

09289-10000

10 1 Thickness gauge

09054-00009

11 ) G rease pump

07952-80002

For greasing work

12 1 Nozzle

07951-11400

Hose nozzle for grease pump

13

Grease cartridge

07950-90403

(Lithium base grease: 400 g)

14

Nipple

424-98-l1110

For hydraulic oil drain

15

Hose

424-98-l 1120

16

Hose

09288-10011

427-98- 11110 09039-00150

For engine oil drain :

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

.__.

3-14

21.STANDARDTlGHTENlNGTORQbES

FORBOLTSANDNUTS

21.2 TORQUE LIST Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table.

The tightening torque is determined by the width across the flats @ of the nut and bolt. if it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

Nm (newton meter): â&#x20AC;&#x2DC;lNm + 0.1 kgm + 0.74 Ibft Thread diameter of bolt (mm) (a)

Width

b)

across

flat(mm) (b)

@

@

Nm 6

IO

13.2 + 1.4

8

13

31.4 + 2.9

10

17

12

19

14

kgm

Ibft

1.35 2 0.15 9.73 * 1.03 3.2 t 0.3

23.2 2 2.1

65.7 k 6.8

6.7 + 0.7

48.5 5 5.0

112 2 9.8

11.5 2 1.0

82.6 + 7.2

22

177 r 19

18.0 2 2.0

131 + 14

16

24

279 + 29

28.5 t 3

18

27

383 2 39

39 + 3

282 5 29

20

30

549 r 58

56 2 6

405 t 43

22

32

745 *78

762 8

549 + 58

24

36

927 2 98

94.5 + 10

684 c 72

21

41

1320 2 140

135 r 15

973 * 100

30

46

1720 + 190

175 2 20

1270 * 140

33

50

2210 5 240

225r25

1630+180

36

55

2750 5 290

280 e 30

2030 + 210

39

60

3280 2 340

335 r 35

2420 + 250

'206221

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 0F SAFETY CRITICAL PARTS

SAFETY

CRlTlCAL

PARTS

No. 1

Fuel hose (Strainer - L.H. injection pump)

2

[

3

1 Fuel hose (L-H. injection pump - fuel tank)

Fuel hose (injection pump - adapter)

4

Fuel spill hose (Between nozzles)

5

Turbochager lubricating hose

6

Fuel hose (Strainer - R.H. injection pump)

7

Fuel hose (Fuel tank - strainer)

8

Front brake hose (Outlet of slack adjuster)

10

Steering cylinder hose

11

Front brake hose (Center pin portion)

12

Hose of main suction tube

-utiet

hoses of steering pump

14

Suction hoses of loader pump and steering pump

15

Outlet hoses of loader pump

16

Suction hoses of switch pump

17

Outlet hoses of switch pump

movver

cluster -front

Rear brake hose (Slack adjuster inlet)

20

Hose (Brake oil tank - power cluster)

21

Hose (Power cluster - rear brake)

22

Rear brake hose (Air component box outlet)

23

Front brake hose (Air component box outlet)

24

Rubber oarts for Dower cluster â&#x20AC;&#x2122;

Packings, seals, O-rings of steering cylinder

26

Rubber parts for treadle valve

27

Rubber parts for parking

29

Every 4000 hours or every 2 years, whichever comes sooner

_

brake)

19

28

I

1 Fuel hose (R.H. iniection pump - fuel tank)

9

25

Replacement interval

Part name

brake spring cylinder

Rubber parts for slack adjuster 1 [ Rubber parts for relay valve

-

I

30

Every 3 years

Seat belt ._

3-17

22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

3-18

23. MAINTENANCE SCHEDULE CHART

23.1

-

MAINTENANCE SCHEDULE CHART SERVICE ITEM

PAGE

INITIAL 250 HOURS SERVICE (only after the first 250 hours1 Replace fuel filter cartridge Replace transmission

3-23

oil filter element

-

3-23

Check engine valve clearance, adjust

3-23 WHEN REQUlRED

Check, clean, or replace air cleaner element

3-24

Clean inside of cooling system

3-26

Check transmission

3-30

oil level, add oil

Check axle oil level, add oil

3-31

Clean axle case breather

3-32

Clean condenser of air conditioner

3-32

Check window washing fluid level, add fluid

3-32

Clean radiator fins

3-33

Check electrical intake air heater

3-33

Replace bucket teeth

3-34

lubricating

3-35

l

Work equipment

l

Accelerator pedal linkage (2 points)

3-35

control valve linkage (2 points)

3-35

0 Steering column (1 point)

3-35

Check air conditioner

3-36

Adjust parking brake

3-37

Bleeding air from brake hydraulic circuit

3-38

Bleeding air from PPC circuit

3-38

Bleeding air from hydraulic tank

3-39

Drain water from water separator

3-40

Replace fan belt, adjust auto-tensioner

3-41

CHECK BEFORE STARTING _..

Check monitor panel

3-42

Check coolant level, add water

3-42 3-19

23. MAINTENANCE

SCHEDULE CHART

SERVICE ITEM

PAGE

CHECK BEFORE STARTING (continued) Check oil level in engine oil pan, add oil

3-43

Check brake oil tank level, add oil

3-44

Check dust indicator

3-44

Check fuel level, add fuel

3-45

Drain water from air tank

3-45

Check electric wiring

3-46

Check for water and sediment in water separator, drain water

3-46

Check effect of parking brake Check effect of brake Check sound of horn and backup buzzer

3-47

Check flashing of lamps, check for dirt or damage

3-47

Check direction of rear view mirror, check for dirt or damage

3-47

Check engine exhaust color and sound

3-47

Check operation of gauges

3-47

Check play of steering wheel, check operation of steering

3-47

EVERY 50 HOURS SERVICE Check tire inflation pressure

3-49

Drain water, sediment from fuel tank

3-46

EVERY 100 HOURS SERVICE 3-49

Lubricating

3-49

l

Bucket pin (2 points)

l

Bucket link pin (2 points)

l

Lift arm hinge pin (2 points)

3-49

l

Bucket cylinder pin (2 points)

3-49

l

Tilt lever pin (1 point)

3-49

l

Lift cylinder pin (4 Points)

3-50

l

Steering cylinder pin (4 points)

3-50

3-49

_

...

0 Rear axle pivot pin (3 points)

3-50

Check oil level in hydraulic tank, add oil

3-51

3-20

23. MAINTENANCE SCHEDULE CHART

SERVICE I-I-EM

PAGE

Clean air conditioner air filter element.

3-52

EVERY 250 HOURS SERVICE Change oil in engine oil pan, replace engine oil filter cartridge

3-53

Check battery electrolyte level

3-55

Check alternator belt tension, adjust

3-56

Check for loose wheel hub nuts, tighten

3-57

Check air conditioner compressor belt tension, adjust

3-57

EVERY 500 HOURS SERVICE Replace fuel filter cartridge

3-58

Replace transmission

oil filter element

3-60

Lubricate center drive shaft (3 points)

3-61

Check fan belt

3-61

Check air dryer

3-61 EVERY 1000 HOURS SERVICE

Change oil in transmission

3-62

case, clean strainer

Clean transmission case breather

3-63

-

Lubricating l

Center hinge pin (2 points)

3-64

l

Drive shaft center support (I point)

3-64

l

Front drive shaft (3 points)

3-64

l

Rear drive shaft (3 points)

3-65 3-65

o Upper drive shaft (3 points) l

Parking brake linkage (6 points)

3-65

l

Torque converter mount trunnion (1 point)

3-65

l

Fan pulley (1 point)

3-65

a Tension pulley (2 points)

3-65

Check tightening

3-66

parts of turbocharger

3-66

Clean fuel strainer Tighten ROPS canopy Replace corrosion resistor cartridge

...

3-66 3-67 3-21

23. MAINTENANCE SCHEDULE CHART

SERVICE ITEM

PAGE

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 f

3-73

Replace air conditioner filter Clean PPC circuit strainer 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

Ir

Check water Dump

3-77

Check engine vibration damper

3-77

Check fan pulley and tension pulley

3-77

Check air compressor, adjust

3-77

Check iniection oumo rack rubber boot, replace

3-77

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.

3-22

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

Never clean or replace the air cleaner element with the engine

glasses or goggles to protect the eyes.

Checking Whenever the red piston in dust indicator @ appears, clean the air cleaner element.

Cleaning or replacing outer element 1. Remove wing nut @ and take out outer element 0.

2.

Clean the inside of the air cleaner body.

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.

I) 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.

31 If the dust indicator displays red immediately after the outer element has been cleaned, replace both the inner and outer elements, even if the outer element has not been cleaned 6 times.

4) Check inner element mounting nuts for looseness and, if necessary, retighten.

5) Replace seal washer @ or wing nut @ with new parts if they are broken.

3-24

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

5.

Push the dust indicator the original position.

element.

Replacing inner element 1. First remove the outer element.

reset button to return the red piston to

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. water Dash city water (less than 294.2 kPa (3 kg/cm*, 42.6 psi) on element from inside along folds, then from outside and again from inside. Dry and check it.

Wiih

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 CLEAN INSIDE OF COOLING

A

SYSTEM

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.

Stop the machine on level ground when cleaning or changing the coolant.

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

l

l

Kind of coolant

Cleaning inside of cooling system and changing coolant

Permanent type antifreeze (All season type)

Every year (autumn) or every 2000 hours, whichever comw first

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

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

When not using antifreeze

Every 6 months or every 1WO hours, whichever comes first

3-26

Replacing corrosion resistor

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

I

24. SERVICE PROCEDURE

l

When deciding the temperature in the given below.

It is actually better when deciding the

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

about 10°C lower

Mixing rate of water and antifreeze Min. atmospheric temoerature

‘C

-5

-10

-15

-20

-25

-30

“F

23

14

5

-4

-13

-22

Amount of antifreeze

Amount of water

a WARNING Antifreeze is flammable, l

l

so keep it away from any flame.

Use city water for the cooling water.

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

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

3-27

24. SERVICE PROCEDURE

1.

Stop the engine and tighten corrosion resistor valve CiJ.

2.

Turn radiator cap @ slowly to remove it.

3.

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.

4.

After draining the water, close drain valves @and @ and fill with city water.

5.

When the radiator is full of water, start the engine and run it at low idling.

Open drain valves @ and @I, 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 given with the cleaning agent.

8.

After cleaning, open drain valves @ and @ to drain all the cooling water, then close them and fill slowly with clean water.

3-28

9.

When the water comes up to near the water filler port, open drain valves @ and @, 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 the water so that the radiator is always full.

10. When the water is completely clean, stop the engine, close drain valves @ and 0.

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 at low idling, then for another five minutes at high idling.

When doing this, leave radiator cap @ off. â&#x20AC;&#x2DC;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

OIL LEVEL, ADD OIL

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 if there is any sign of oil on the transmission case, or if there 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 “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.”

4.

5.

If the oil is above the A, remove drain plug @ 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.

-7

4

r

/

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

-

I

!J ‘2

4 Arn366ao

24. SERVICE PROCEDURE

24.2.4 CHECK AXLE OIL LEVEL, ADD OIL 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 if there is any sign of oil on the axle case.

Fr

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 engine and remove oil level plug 0.

2.

Check that the oil level reaches the bottom of the plug hole.

3.

If the oil is not close to the bottom edge, add axle oil through the hole of plug 0.

For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.” 4.

If the oil level is correct, install plug 0.

Tightening torque:

152 k 24 Nm (15.5 f 2.5 kgm, 112 + 18 Ibft)

3-31

24. SERVICE PROCEDURE

24.25 CHECK AXLE CASE BREATHER a WARNING When cleaning, apply the parking brake, and lock the front and 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 OF AIR CONDITIONER A

WARNING

Do not wash the condenser with a steam cleaner. Otherwise, the condenser 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 â&#x20AC;&#x2DC;stuck to the condenser. If necessary, use a soft brusâ&#x20AC;&#x2122;h. Do not use a hard brush, as this will damage the fins.

24.2.7

CHECK WiNDOW WASHING FLUID LEVEL, ADD FLUID

Do this when there is air in the window washing fluid.

Check the washing fluid levels in washer tanks 0 and @_ 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, be careful not to let dust get into the fluid.

3-32

- --._

-

24.28

CLEAN RADIATOR

Carry out this procedure to the radiator.

FINS

H

if there is any mud or dirt seen stuck

1.

Loosen

2.

Use compressed air to clean the mud dust, and leaves from the radiator fins. Steam or water may be used instead of compressed air.

3.

24. SERVICE PROCEDURE

bolt @ and remove

radiator

grille 0.

e (I

-Y

1 =a-

0

oa-

,

0, v-00

I-

Ammml

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.

24.29

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 distributor to check electrical intake air herater.

3-33

24.

SERVICEPROCEDURE

24.2.10

REPLACE BUCKET TEETH

It is dangerous condition,

If the bucket

if the work equipment

then stop the engine

equipped

with

moves by mistake

when

and apply the locks securely to

tip tooth.

Replace the-teeth before they wear down as far as the adaptor.

1.

Extract pin @ fitted to the bucket and then remove tooth 0.

When extracting pin 0, strike the part (either the left or right part) with a sharp object. This will enable the pin to be extracted from the opposite side.

2.

insert the new tooth @ into the adaptor 0. and insert pin @ partway as shown in the diagram. Then drive it home by means of a hammer.

3.

After operating the machine for a few hours, check that the pin does not come out.

3-34

.24. SERVICE PROCEDURE

24.2.11

LUBRICATING

1.

Using a grease pump, pump in grease through fittings shown by arrows.

the grease

2.

After greasing, 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.

Accelerator pedal linkage (2 points) If the accelerator pedal is heavy or does not return properly, apply grease.

2.

3.

Steering column (1 point) If the play of the steering column is heavy or does not return properly, apply grease.

3-35

24. SERVICE PROCEdURE

24.2.12

CHECK AIR CONDITIONER

Check twice a year, in spring and autumn.

Check levels of refrigerant (gas)

A WARNING If the liquid gets into your eyes or on your hands, it may cause loss of sight or frostbite, so never loosen any part of the refrigerant circuit.

Sight glass

Operate the cooler of the air conditioner for 5 - 10 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

-I-

0

Receiver

*z_’

Abnormal

Temp. of high and low pressure pipes.

High pressure pipe is hot.

Low pressure pipe is cold.

Clear difference in temperature

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.

Sight glass

Almost transparent.

Any bubbles disappear if the engine speed is raised or lowered.

Bubbles are always flowing.

Sometimes becomes transparent, or white bubbles appear.

Misty substance is flowing.

0 0

0

0

0

-._ 0 3; -’

-0

=

O-o:

-0 --0 _ ‘-0

=-0 1 T -__-_ -_---_ ----_-_ _-_-_ -_ -_ -’ _-

Connections of pipes

Properly connected

Some parts dirty with oil.

Some parts very dirty with oil.

General condition of cooler

Coolant level correct, no abnormalities.

Ready for use.

May be a leak somewhere.

Cal/ service repair shop for inspection.

Almost all coolant has leaked out.

Contact service repair shop immediately.

3-36

-

24.2.13

ADJUST

24. SERVICE PROCEDURE

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.

2.

Turn bolt @ clockwise while pressing bolt retainer pads @ on both sides come into close contact with

3.

Turn back bolt @ a half turn conterclockwise retainer 0.

4.

5.

while

is in the

@ and let disc 0.

pressing

bolt

Restore bolt retainer @ to the original the retainer is in the locking position

position and confirm for bolt 0.

that

There are two calipers in the parking caliper in the same way.

brake, so adjust the other

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

After removing the piping of brake hydraulic circuit, bleed the air from inside of the circuit as follows: 1.

After assembling the piping, be sure to check that the connectors are not loose.

2.

Remove the cap of air bleed plug 0.

3.

Depress brake pedal, loosen air bleed plug @ about 3/4 of a turn and after closing the plug, release the pedal.

4.

Repeat until air bubbles stop coming out of air bleed plug 0.

5.

After bleeding 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, contact your Komatsu distributor.

24.2.15 BLEEDING AIR FROM PPCkIRCUIT When removing piping of PPC circuit, or removing strainer, after assembling, bleed air from inside of the circuit as follows: 1) Put b&&et 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 air is not bleed completely, the piston pump may be damaged, 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.

1. 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).

2.

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 looseh the connectors of the other two case drain hoses.

3.

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 if the oil filler cap of the hydraulic tank is not tightened.

Continue until oil flows out from plug @ (3 places) and the connector of hose 0. 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.

â&#x20AC;&#x2122;

Close valve @ completely.

Check the oil level and add oil if necessary.

For details, contact your Komatsu distributor.

3-39

SERVICE PROCEDURE

24.

Bleeding air from hydraulic circuit.

1. Check that the oil reaches the specified level in the hydraulic tank.

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 each cylinder 3 to 4 times to the end of its stroke, then stop the engine and loosen air bleeding plug ($ of the hydraulic tank to bleed the air.

After bleeding the air, tighten the plug.

4.

Check the hydraulic oil level and add oil if necessary, Refer to “24.5 EVERY 100 HOURS SERVICE”.

5.

tncrease 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 cyiinder 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 2 1.47 Nm (1.15 -I- 0.15 kgm, 8.32 2 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, Refer to “24.5 EVERY 100 HOURS SERVICE”:

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: 1. Loosen drain plug @ and drain the accumulated water until the

float reaches the bottom.

2.

Tighten drain plug 0.

3.

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

See Fuel Filter Cartridge in “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 Q) (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 0

and locknut @ to yoke 0.

Tighten adjustment bolt @ 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 0 and pin @ of tension pulley 3.

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. SERVICE PROCEDURE

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 using only the monitor; always carry out also the items specified for the periodic maintenance.

24.3.2 CHECK COOLANT

LEVEL, ADD WATER

Do not remove the cap while cooling water is hot. Hot water When removing

the radiator cap, lift the lever to relieve the

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 window at the rear left side of the machine.

Remove 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 belowthe L mark, add engine oil through oil filler 1

/,;I

0.

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

The dipstick has level markings on both sides. One side gives the levells 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 oil from drain valve 0, and check the oil level again.

6.

If the oil level is correct, tighten the oil filler cap securely and close the inspection window.

1I

Engine stopped

5

” L!

I

{

Engine idling

.

~~ \

I

2

2’

‘0,744 -

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 thoroughiy 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 PROCEDURE

24.3.4 CHECK BRAKE OIL TANK LEVEL, ADD OIL g WARNING Always use engine oil to refill the brake, oil tank.

1.

Check that the oil level in brake oil tank at the left side of the machine is in sight gauge 0.

2.

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

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

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 REQUIRED, CHECK, CLEAN, OR REPLACE AIR CLEANER”.

3-44

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 capacity:

fuel, tighten

1430 e (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

3-45

24. SERVICE PROCEDURE

24.3.8 CHECK ELECTRIC WIRING 7

gWARNlNG

1

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

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

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

A

WARNING

Accumulation of flammable material (dead leaves, twigs, grass, etc.1 around the battery may cause fire, so always check and remove such material.

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

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.

For the 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 PROCEDURE

24.3.10

CHECK EFFECT OF PARKING

BRAKE

Measurement conditions l l l

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

grade

Method of measurement

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

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

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

24.3.11

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

24.3.13

CHECK FLASHING OF LAMPS, 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

OPERATION

OF HORN AND BACKUP

CHECK FOR

COLOR AND

OF GAUGES

OF STEERING

WHEEL, CHECK

OF STEERING

3-47

24. SERVICEPROCEDURE

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: 514.8 kPa (5.25 kg/cm2, 74.6 psi) Rear tire: 514.8 kPa (5.25 kg/cm2, 74.6 psi) NOTICE The appropriate tire inflation pressure diiers according type of work, so see “12.18 HANDLING THE TIRES”.

to the

24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK Loosen valve @ on the right side of the tank so that the sediment and water will be drained together with fuel.

3-48

-

24.5

EVERY 100 HOURS

Maintenance same time.

24.5.1

for every

SERVICE

50 hours should

be carried

out at the

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.

in grease through

the grease

2.

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

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 (I point)

24. SERVICE PROCEDURE

24. SERVICE

PROCEDURE

6.

Lift cylinder pin (4 points)

7.

Steering cylinder pin (4 points)

I

J

8.

3-50

Rear axle pivot pin (3 points)

1

24. SERVICE PROCEDURE

24.5.2

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

A WARNING When the oil filler cap is removed, oil may spurt out, so stop the engine and wait for the oil temperature to go down, then turn the cap slowly to release the internal pressure before removing the cap.

1.

Lower the bucket horizontally to the ground and stop the engine.

Wait for 5 minutes, then check sight gauge 0. The oil should be visible in sight gauge 0.

2.

If the level is low, open the inspeciton cover above the step and add oil through oil filler 0.

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

3-51

24. SERVICE PROCEDURE

24.5.3 CLEAN AIR CONDITIONER

AIR FILTER ELEMENT

A WARNING When using compressed air, wear safety glasses and other things required to maintain safety.

If the air conditioner has been used, the air filter should be cleaned.

Stop the air conditioner before cleaning the element.

1.

Open the cover at the rear of the cab.

2.

Loosen screw 0 of holder holding the filter element, pull out element @ and clean it.

Direct dry compressed air (less than 700 kPa (7 kg/cm*, 100 psi) to element from inside along its folds, then direct it from outside along its folds and again from inside, and check element.

3.

Align the direction of the arrows and assemble the element.

4.

Move the operatorâ&#x20AC;&#x2122;s seat forward, then push the over down to the front.

5.

Pull the cover at the rear of the ooeratorâ&#x20AC;&#x2122;s seat toward YOU and open the cover.

6.

Remove screw @ and bolt @?holding the filter element, then take out element @ and clean it.

7.

After cleaning the element, assemble it.

3-52

24. SERVICE PROCEDURE

24.6 EVERY 250 HOURS SERVICE Maintenance same time.

24.6.1

for every 50 hours

should be carried out at the

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 e (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 0.

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 @I 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

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 oil filler @ until the oil level is between the H and L marks on dipstick 0.

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

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

-

24.6.2 CHECK BATTERY ELECTROLYTE

24. SERVICE PROCEDURE

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 of water, and consult a doctor.

Carry out this check before

operating

the machine.

1.

Open the cover of the battery box.

There are two battery boxes: One on each side at the rear of the machine.

2.

Remove cap 0, and check that the electrolyte is at the specified level (10 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.

3.

Clean the securely.

air hole

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. SERVICE PROCEDURE

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.

Alernator pulley

Drive pulley Adjusting 1. Loosen bolt @ and lock nut 0.

2.

Rotate adjusting nut @I so that the deflection is approx. 20 mm (at a force of approx. 6 kg).

3.

After adjustment, tighten lock nut @ and bolt Q) securely.

4.

Check each pullev for damaae, wear of the V-groove, and wear of the V-belt. In p&icular, 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 for adjustment, or if there is any cut or crack on belt.

6.

After operating the machine for one hour with a newly exchanged V-belt, test and adjust the V-belt again.

3-56

24. SERVICE

PROCEDURE

24.6.4 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN If wheel hub nuts @ are loose, tire wear will be increased and accidents may be caused.

1.

Check for loose nuts, and tighten if necessary.

When checking for loose nuts, always turn the nuts in the direction of tightening to check.

Tightening torque: 2.

471

-c 49 Nm

(84 k 9 kgm, 347 + 36 Ibft)

If any wheel bolt is broken, replace all bolts for that wheel.

24.6.5 CHECK AIR CONDITIONER TENSION, ADJUST

COMPRESSOR

BELT

Checking

The belt should normally deflect by about 10 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 1. Loosen bolt @ and lock nut 0.

2.

Rotate adjusting nut @ so that the deflection is approx. 10 mm (at a force of approx. 6 kg).

3.

After adjustment, tighten lock nut @ and bolt @I securely.

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 notâ&#x20AC;&#x2122; touching the bottom of the V-groove.

5.

Replace the V-belt if it has stretched, leaving no allowance for adjustment, or if there is any cut or crack on belt.

6.

After operating the machine for one hour with a newly exchanged V-belt, test and adjust the V-belt again.

1

3-57

24. SERVICE PROCEDURE

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

Prepare a filter wrench and a container to catch the fuel.

1.

Open the side panel located on the right of the machine and lock the open lock.

2.

Set the container to catch the fuel under the filter cartridge.

3.

Using a filter wrench, turn filter cartridge @ counterclockwise to 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 replacing filter cartridge 0,

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

loosen air bleed plug 0.

then push in the

24. SERVICE PROCEDURE

/gin..IrthrNG-I When cranking the engine, confirm the safety around the en-

9.

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

OIL FILTER ELEMENT

0

Prepare a container to catch the drained oil

1.

Loosen bolt and open the side panel.

2.

Set the container to catch the oil under the filter case.

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 bolt 0, then remove case 0.

5.

Remove the element, and clean the inside of the case.

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 @_ When tightening center bolt 0, install so that chamfered portion @ of the washer is at the head end of the hexagonal center bolt.

Be careful not to tighten center bolt 0 too far.

Tightening torque: 8.

181 f 15 Nm (18.5 f 1.5 kgm, 134 * 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;?.

3-60

24. SERVICE PROCEDURE

24.7.3 LUBRICATE CENTER DRIVE SHAFT (3 points)

A l

l

WARNING

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

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.

r-

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

A WARNING l

l

l

0

0

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 C capacity Refill capacity: 140 I (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 @ 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.

Remove transmission filter drain 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 0 is damaged, replace it with a new part.

3-62

the oil, install

drain plugs 0

and 0.

to catch the oil under the transmission

bolt 0, then remove with spring 8.

plugs @ (3 pieces),

filter. drain the

cover @ and take out strainer

0

24. SERVICEPROCEDURE

7.

install spring @ and strainer 0 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 AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

9.

After filling with oil, check that the oil is at the specified level. For details, see “24.2 WHEN REQUIRED”.

10. Check for oil leakage from the transmission

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 CLEAN 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.

3-63

24. SERVICE PROCEDURE

24.8.3 LUBRICATING

A WARNING l

l

1.

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.

Using a grease pump, pump fittings

2.

marked

in grease through

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

1. Center hinge pin (2 points)

2.

Drive shaft center support (1 point)

3.

Front drive shaft (3 points)

3-64

the grease

by the arrows.

24.

4.

Rear drive shaft (3 points)

5.

Upper drive shaft (3 points)

6.

Parking brake linkage (6 points)

7.

Torque converter mount trunnion (1 point)

8.

9.

Fan pulley (1 ,point) Tension pulley (2 points)

SERVICEPROCEDURE

3-65

24. SERVICEPROCEDURE

24.8.4 CHECK TIGHTENING

PARTS OF TURBOCHARGER

Contact your Komatsu distributor to have the tightening portions checked.

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 and spring, then install plug 0.

If O-ring of the plug is damaged, replace with a new part.

24.8.6 TIGHTEN

ROPS CANOPY

1.

Loosen the bolt, then remove the cover.

2.

Check that there is no looseness in mounting ROPS canopy. If any bolt is loose, tighten it.

Tightening torque: 3.

bolts @ of the

2746 2 294 Nm (280 2 30 kgm, 2025 2 217 lbft)

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. SERVICE PROCEDURE

24.8.7 REPLACE CORROSION

RESISTOR CARTRIDGE

1. Open the engine side cover located on the right of the engine

hood.

2.

Screw

in valve @ at the side of the corrosion resistor.

3.

Using the filter wrench provided, remove cartridge @ by turning it counterciockwise.

4.

Coat the seal surface of the new cartridge with engine oil, and install it to the filter holder.

5.

When installing, bring the gasket into contact with the seal surface of the filter holder, then tighten approx. 2/3 turns.

6.

After replacement, open valves 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

24.9

PROCEDURE

EVERY 2000 HOURS SERVICE

Maintenance for every 50,100,250,500 be carried out at the same time.

24.9.1

and 1000 hours should

CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT

Prepare the following.

Container to catch drained oil: min. 550 I? capacity 0 Refill capacity: 550 e (145.2 US gal, 121.0 UK gal) 0

1.

Lower the bucket horizontally to the ground parking brake, then stop the engine.

2.

Remove the bolt, then remove the cover.

3.

Remove the cap of oil filler G and air bleed plug 0 on filter case.

4.

Set a container to catch the oil under drain plug 0.

5.

Remove drain plug 3.

6.

Loosen drain valve 0, then gradually pull it out to drain the oil.

7.

After draining the oil, close drain valve 0, plug 0.

3-68

and apply the

then tighten drain

24. SERVICE

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, then remove element 8.

IO. Check that there

PROCEDURE

is no foreign matter inside the tank before

cleaning it.

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 level, then install cap @ and.air bleed plug @ on filter case.

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

14. Check that the hydraulic oil is at the standard level. For details, see “24.5 EVERY 100 HOUR SERVICE”.

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 @ 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 right to open it, and pressurize the oil inside the hydraulic tank.

When pressurizing the tank, the tank cannot be pressurized if the oil filler cap of the hydraulic tank is not tightened.

18. Continue until oil flows out from plug $$ (3 places) and the connector of hose @I. 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 @, loosen nut @ of the pressurizing valve, and turn rod @ counterclockwise to adjust the pressure, then lock with the nut.

19. Close valve a completely.

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24. SERVICEPROCEDURE

NOTICE Never start the engine before the air has been completely bled from the piston pump. If the engine is started without the air being bled from the piston pump, the piston pump may be broken.

20. Check the oil level and add oil if necessary.

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

21. Check that the hydraulic oil is at the standard level. For details, see “24.5 EVERY 100 HOUR SERVICE”.

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 cylinder to 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 level. For details, see “24.5 EVERY 100 HOURS SERVICE”.

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 piug 0.

26. After completing the air bleed operation, tighten plug 0.

Tightening

torque: 11.3 + 1.5 Nm (1.15 4 0.15 kgm, 8.3 * 1.1 Ibft)

27. After completing air bleeding, lower the bucket horizontally to the ground and stop the engine.

28. Check that the hydraulic oil is at the standard level. For details, see “24.5 EVERY 100 HOUR SERVICE”.

29. Check that there is no leakage of oil from the filter cover mount.

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24. SERVICE PROCEDURE

24.9.2 CLEAN HYDRAULIC

TANK STRAINER

When changing the oil in the hydraulic tank, drain the oil from the tank and clean the strainer.

1.

Loosen bolts @ and 0, then remove covers @ and 0.

2.

Loosen bolt 0, remove strainer cover 8, then remove strainer @ together with spring GJ.

3.

Remove any dirt from strainer 8, then wash in clean light oil or flushing oil.

If strainer @I is broken, replace it with a new part.

4.

Install spring 0, strainer 8, and cover 0. When doing this, look through the mounting hole of cover @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 2 3.5 kgm, 65 + 25.3 Ibft) 5.

Install covers @ and 0.

Replace the O-rings of the covers with new parts.

I

3-7 1

24.

SERVICEPROCEDURE

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 chang-

release the internal pressure, then remove it carefully.

1.

Remove the cap of oil filler 0.

2.

Remove the snap ring on breather 0, then remove the breather cap.

3.

Replace the filter element with a new part, then install the cap and snap ring.

4.

Tighten 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

24.9.4 CHANGE AXLE OIL

PROCEDURE

r

g 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.

I

Front

I

Prepare the following.

Container to catch drained oil: min. 720 e capacity l a Refill, capacity (front and rear, each): 360 P (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.

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 0 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 0 and 6 of the axie housing and left and right final drives.

/w

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

6.

After adding oil, check that the oil is at the specified level. For details, see “24.2 WHEN REQUIRED”.

REMARK

For operations where the brake is used frequently, change the axle oil at shorter intervals.

3-73

24. SERVICEPROCEDURE

24.9.5 REPLACE AIR CONDITIONER

FILTER

1.

Open the cover located on the back of the cab.

2.

Loosen nut @ holding the filter element, and pull out element Q.

3.

Align the direction of the arrows and assemble the element.

Install a new element and close the cover.

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 hydrauiic circuit. For details, see â&#x20AC;&#x153;24.2 WHEN REQUIREDâ&#x20AC;?.

For details of the procedure for bleeding air from the hydraulic circuit, piease contact your Komatsu distributor.

3-74

.24. SERVICE PROdEDURE

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 the parts, request your Komatsu distributor for service.

24.9.9 CHECK BRAKE ,DISC WEAR Ask Komatsu distributor to check and repair brake disc.

24.9.10

CLEANâ&#x20AC;&#x2122; 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 of the accumulator as follows.

Checking 1. Stopthe

machine on level ground 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 in this position, and stop the engine.

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.

height, then place

If the work equipment stops moving during checking, the gas pressure may be below the service limit (700 kPa4.7 kg/cm2, 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.

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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 repair or replace.

24.10.5

CHECK INJECTION BOOT, REPLACE

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

MEMO

3-78

SPECIFICATIONS

4-1

25. SPECIFICATIONS

WA800-2

I

PERFORMANCE l

Bucket capacity (Heaped) (Straight edge without teeth)

10.5 m3 (13.7 cu.yd)

l

Normal load

18900 kq (41675 lb)

Forward l

Travel speed Reverse

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 l

Max. rimpull

l

Min. turning radius

60000 kg (588000 N) Outside of chassis

10910 mm (430 in)

I Center of outside tire (

9210 mm (363 in)

WEIGHT l

28.3 km/h (17.6 MPH)

Operating weight (including 1 operator:

I 89100 kg (196430 lb)

80 kg.)

ENGINE l

Model

l

Flvwheel horsepower

l

Max. torque

0 Starting motor l

588 kW (789 HP)/2000 rpm 3727 Nm (380 kgm)/l400 24 V

Alternator

0 Battery

4-2

Komatsu SA12V140 diesel engine

7.5 kW x 2 pieces 24 V

12 V

rPm

50 A

200 Ah x 4 pieces (N200)

25. SPECIFICATIONS

MEMO

4-4

m

0 2

26. OPTIONAL PART AND ATTACHMENTS

Name Bucket Bucket (for high-lift boom)

I

Specification,

use

Capacity (for straight edge rock bucket) Capacity (for spade nose rock bucket, for straight edge rock bucket)

10.5m3 9.5m3

Bucket tooth

l Tip type tooth for rock ! l Tip type tooth for limestone

High-lift boom

Optimum for loading 120-ton class dump I truck

Mesh chain

1Tire orotector

ROPS canopy Emergency steering l Seat belt l Tires These and various other parts and attachments please contact your Komatsu distributor. l l

5-2

are available, so

â&#x20AC;&#x2122;

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

Ground conditions

Bucket

Tire (

l

loading materials and blasted rock

1-

I

General ground conditions

l

Spade nose Bucket (10.5 m3J

Loading blasted rock

Hard ground Ground with many boulders

General ground conditions l

SPac;k;=s

Loading and carrying blasted rock

(10.5 m3)

L

45/65-45-38PR (L-5) 45/65-45-46PR (L-5) 45/65-45-50PR iI -6)

Hard ground

-,

45165-4538PR (L-5) 45/65-45-46PR (L-5) 45165-45-50PR (L-5) 45/65-45-38PR (L-5) 45/65-45-46PR

45/65-45-38PR (L-4 or L5) 45/65-45-46PR (L-4 or L5) 45/65-45-50PR (L-4 or L5)

45/65-4538PR (L-4 or L5) 45/65-45-46PR Soft ground (L-4 or L5) with many rocks 45/65-45-50PR Soft ground (L-5) with many Use tire chains as rocks 1 a tire protector General with many rocks

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 or sharp rocks, please install tire protectors (mesh chain).

Check the chain for cuts or slack before starting operations.

Be careful not to let the tires or chains slip during operations.

5-3

MEMO

5-4

Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186

PROPOSAL

1

FOR MANUAL

REVlslON

FOR INTERNAL USE ONLY -- No. PMR 2

NAME OF COMPANY:

:

PHONE NO:

: S

DEPARTMENT:

E R

NAME:

MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:

PROBLEM:

Attach photo or sketch.

If more space is needed, use another sheet.

1 FOR INTERNAL USE ONLY CORRECTIVE ACTION:

PFMRl 081696

LOCATION:

DATE: