Sead 010801

SEAM010801

Operation & Maintenance Manual

KOMNtbU Komatsu America International Company

D375A= BULLDOZER

SERIALNUMBERS

D375A=3

-

17001

and

UP

Operation & Maintenance Manual

SEAM01 0801

D375A= BULLDOZER

SERIALNUMBERS

D375A.3

n

17001

and up

This materialis 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. lt 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. lt is recommended that customers contact their distributor for information on the latest revision.

October 1997

Copyright 1997 Komatsu America International Company

A

UARNINC

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

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

1. FOREWORD

This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor. If you sell the machine, be sure to give this manual to the new owners. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult Komatsu or your Komatsu distributor for those items you may require.

A Improper operation injury or death.

and maintenance

WARNING

of this machine

-I can be hazardous

and could result in serious

Operators and maintenance personnel should read this manual thoroughly before beginning operation or maintenance. Keep this manual in a readily available place near the machine, and have all personnel involved in working on the machine read the manual periodically. Some actions involved in operation and maintenance of the machine if they are not done in a manner described in this manual.

can cause a serious accident,

The procedures and precautions given in this manual apply only to intended uses of the machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual. Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine. The description l-l.

of safety is given in SAFETY INFORMATION

on page O-2 and in SAFETY from page

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents

are known to the State

of California

to cause cancer, birth

defects,

and

other

reproductive

harm.

O-l

2. SAFETY INFORMATION

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

-

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

A WARNING

-

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

A CAUTION

-

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

-

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

g

DANGER

NOTICE

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

o-2

3. INTRODUCTION

3.1

INTENDED

USE

This Komatsu BULLDOZER is designed to be used mainly for the following work. l Dozing e Cutting into hard or frozen ground or ditching l Felling trees, removing stumps l Pushing l Ripping See the section “12.10 WORK POSSIBLE USING BULL DOZER” and “12.12 RIPPER OPERATION” further details.

3.2

l

3.3

for

FEATURES Simple lever operation with directional, steering and gear shift joystick Pressurized, sealed cab with air conditioner for pleasant operations Simple check operations using monitor panel increase in production through use of lock-up torque converter Reduction in fuel costs and undercarriage costs through use of mode selection system High power engine with turbocharger and after cooler A flexible undercarriage mechanism and cab mount with viscous damper are employed to improve the ride for the operator Low noise, high visibility design to ensure simple and safe operations

BREAKING

IN THE MACHINE

NOTICE Before operating the machine for the first time, check that there is coolant in the radiator. machine is delivered with no coolant in the radiator, flush the inside of the radiator thoroughly tap water, then fill the radiator with coolant.

If the with

Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break in the machine for the initial 100 hours (as indicated by the service meter.) During breaking in: l Idle the engine for 5 minutes after starting it up. l Avoid operation with heavy loads or at high speeds. l Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of emergency. The precautions given in this manual for operating, maintenance, and safety procedures are only those that apply when this product is used for the specified purpose. If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of safety in such operations is the responsibility of the user. Operations that are prohibited in this manual must never be carried out under any circumstances.

o-3

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

4.1

Under operator’s

4.2

SERIAL NO. PLATE POSITION

MACHINE the front seat.

ENGINE

of the console

box on the

seen

at the right side of blade back surface.

at the left side surface

of ripper

beam.

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine Engine

serial No.: serial No.:

Distributor

name:

Phone:

Address:

Service

o-4

block, when

RIPPER SERIAL NO. PLATE POSITION This is located

4.5

cylinder

BLADE SERIAL NO. PLATE POSITION This is located

4.4

side of the

SERIAL NO. PLATE POSITION

On the upper left side of the engine from the fan.

4.3

right

personnel

for your machine:

5. CONTENTS

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

1.

Foreword

2.

Safety

3.

Introduction

4.

Location

information

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

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

of plates,

table to enter

serial No. and distributor

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

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

SAFETY 6.

General

7.

.......................................................................................................... Precautions during operation Before starting engine ............................................................................................................. 7.1 Operating machine .................................................................................................................. 7.2

7.3 7.4 7.5

precautions

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

Transportation .......................................................................................................................... Battery ....................................................................................................................................... Towing ......................................................................................................................................

I- 2 I- 9 I- 9

l-11 1-14 1-15 1-16

8.

........................................................................................................... Precautions for maintenance Before carrying out maintenance .......................................................................................... 8.1 ................................................................................................................ During maintenance 8.2

1-17 I-17 1-19

9.

Position for attaching safety labels ................................................................................................ Position for attaching safety labels ....................................................................................... 9.1

1-24 l-24 l-27

9.2

Content and use of warning plates .......................................................................................

OPERATION 10. General view ...................................................................................................................................... 10.1 General view of machine.. ...................................................................................................... 10.2 General view of controls and gauges ................................................................................... ............................................................................................................. of components 11. Explanation 11.1 Front panel ..I . . . . .. . .. . .. . . . . . .. . . . .. . .. . . . . . . . . .. .. . . . . . . .. . . . .. . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . .. ..~.....................

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

Switches .................................................................................................................................... Control levers and pedals ....................................................................................................... Dust indicator ........................................................................................................................... Power source ............................................................................................................................ Fuse box ................................................................................................................................... Door-open lock (machines equipped with cab) ................................................................... Sash glass intermediate lock (machines equipped with cab) ........................................... Door pocket (machines equipped with cab) ......................................................................... Ashtray (machines equipped with cab) ................................................................................. Tool box.. .................................................................................................................................. Using car stereo (machines equipped with cab and car stereo) ...................................... Handling air conditioner (machines equipped with cab) .................................................... Handling heater (machines equipped with cab) .................................................................. Handling accumulator .............................................................................................................

2- 2 2- 2 2- 3 2- 5

2- 5 2-21 2-24 2-31 2-31 2-31 2-33 2-33 2-33 2-33 2-34 2-35 2-40 2-44 2-45

o-5

2-46 . . . . . . . . .. .. .. . . . . .. .. .. . . . . . . .. . . . .. . .. . . . .. . .. . . . . . .. .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . .. . .. . . . . . . . . ._. .. . . . . . .. . .. .. . . . . . . .................. 12. Operation Check before starting engine ................................................................................................. 2-46 12.1 Starting engine.. ....................................................................................................................... 2-61 12.2 Operations and checks after starting engine.. ...................................................................... 2-65 12.3 Moving machine ...................................................................................................................... 2-67 12.4 Shifting gear ............................................................................................................................. 2-69 12.5 Shifting between forward and reverse.. ................................................................................ 2-70 12.6 2-71 Steering machine ..................................................................................................................... 12.7 Stopping machine .................................................................................................................... 2-73 12.8 Precautions for operation ....................................................................................................... 2-74 12.9 2-77 12.10 Work possible using bulldozer ............................................................................................... 2-79 12.11 Ripper operation ...................................................................................................................... 2-82 of work equipment ............................................................................................. 12.12 Adjustment 2-84-l 12.13 Effective use of mode selection system ............................................................................... 2-85 12.14 Parking machine ...................................................................................................................... 2-86 12.15 Check after finishing work.. .................................................................................................... 2-87 12.16 Stopping engine ....................................................................................................................... 2-88 12.17 Check after stopping engine.. ................................................................................................. 2-88 12.18 Locking ...................................................................................................................................... life ................................................................................................ 2-89 12.19 Tips longer undercarriage .. . . . . . . .. . .. . . . . . .. . .. .. . . . . . . .. . . . .. . . . . . .. . .. . . . . . . .. .. . .. . . . . . .. . .. .. . .. . .. .. . . . . . . . . . . . .. .. . . . . . . .. . . . . . . .. .. .. . . . . ........... 13. Transportation Loading, unloading work ........................................................................................................ 13.1 Precautions for loading ........................................................................................................... 13.2 Method of lifting machine ...................................................................................................... 13.3 ................................................................................................ Precautions for transportation 13.4 Removal of cab (machines equipped with cab). .................................................................. 13.5 Installation of cab (machines equipped with cab) ............................................................... 13.6

2-91 2-91 2-92 2-92 2-93 2-93 2-94

.................................................................................................................... 14. Cold weather operation Precautions for low temperature ........................................................................................... 14.1 After completion of work ........................................................................................................ 14.2 After cold weather ................................................................................................................... 14.3

2-95

15. Long-term storage ............................................................................................................................. 15.1 Before storage .......................................................................................................................... 15.2 During storage ......................................................................................................................... 15.3 After storage .............................................................................................................................

2-98 2-98 2-98 2-99

................................................................................................................................. 16. Troubleshooting 16.1 After running out of fuel ......................................................................................................... 16.2 Method of towing machine .................................................................................................... 16.3 If battery is discharged ........................................................................................................... 16.4 Other trouble ............................................................................................................................ 16.5 If mode selection system flashes ..........................................................................................

O-6

2-95 2-97 2-97

2-100 2-100 2-100 2-100 2-103 2-107

MAINTENANCE 17. Guides

to maintenance

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

3- 2

18. Outlines of service ............................................................................................................................ 18.1 Outline of oil, fuel, coolant.. ................................................................................................... 18.2 Relating to electric system .....................................................................................................

3- 5 3- 5 3- 7

19. Wear

3- 8

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

20. Use of fuel, coolant

and lubricants

according

to ambient

temperature

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

21. Standard tightening torques for bolts and nuts ........................................................................... 21.1 Introduction of necessary tools.. ............................................................................................ 21.2 Torque list ................................................................................................................................. 22. Periodic

replacement

of safety

parts

3-14 3-14 3-15

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

3-16

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

3-21

24. Service Procedure . .. . .. . . . . . . . . .. .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . .. .. . . . . . . . . . .. .. . .. . . . . . .. .. . . . . . . . . . .. . . . . . . . . . .. .. . . . .. .. . .. . . . . . ...... 24.1 Initial 250 hours service . .. . . . . . . . . . .. .. . .. . . . . . . . .. . .. . . . .. . . . . . .. . . . . . . .. . .. . . . . . . . . .. .. . . . . . . . . . . . .. . . . . . . .. . .. . . . . . . . .. . .. . . . . 24.2 When required . . . . .. . . . . . .. . . . . . . . .. . . .. . . . .. . . . . . . .. . .. .. . . . . . . .. . .. . . . . . .. .. . .. . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . .. . . . . . . .. . . . . . . . . .. . 24.3 Check before starting .. . . . . . . .. .. .. . . . . . .. . . .. . . . .. . . . . . . .. .. . .. . . . . . .. . .. .. . . . .. .. . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . .. .. .. . . . . .. .. . .. . 24.4 Every 250 hours service . . .. . . .. .. . . . . . . . .. .. . . . . . . . . . . . .. .. . .. . . . . . .. . .. . . . . . .. . . . .. . . . . . . .. . .. . . . . . . .. . . .. . . . . . . .. . . . . . . .. . . . .. . 24.5 Every 500 hours service . .. . . .. . . . . . . . . . .. . .. . . . . . . . . . . .. . .. . .. . . . . . .. . .. . . . . . .. . . . . . . . . . .. .. . .. . . . . . . . .. . . . . . .. . . .. . . . . . . .. .. .. . . 24.6 Every 1000 hours service . . .. .. . . . . . . . .. . . .. . . . .. . . . . . . .. . . . .. . . . . . .. . . . .. . . . .. . .. . . . . . . . . .. .. . .. . . . . . . . .. . . . . . . . . . . .. . . . . . .. . .. . 24.7 Every 2000 hours service .. .. . . . . . . . . . .. . . . . . .. . . . .. . . .. . . . . . . . .. .. . . . . . . . . .. .. . . . . . . . . .. . .. . . . . . . . .. . . .. . . . . . . .. .. . . . . . . . . .. . .. . 24.8 Every 4000 hours service . . . . . . . .. . .. .. . . . . . . .. .. . .. . . . . . . . . . .. . . .. . .. . . . .. . . . . . .. . . . .. . . . . . . .. .. . .. . . . . . . . . .. . .. . . . .. . .. .. . . . . . .

3-25 3-25 3-26 3-48 3-57 3-65 3-69 3-73 3-78

23. Maintenance

schedule

chart

critical

3-10

SPECIFICATIONS 25. Specifications

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

4- 2

o-7

OPTIONS,

ATiACHMENTS

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

5- 2 5 2

27. Using seat belt .................................................................................................................................. manner.. ................................................... 27.1 Fasten the belt and remove it in the following

5- 3 5- 3

28. Selection of track shoe ..................................................................................................................... 28.1 Selection of track shoe ............................................................................................................

5- 4 5- 4

29. Procedure for selecting ripper point.. .............................................................................................. 29.1 Procedure for selecting ripper point.. ....................................................................................

5- 5 5- 5

30. Handling cap with lock ...................................................................................................................... 30.1 Opening and closing lockable cap.. .......................................................................................

5- 6 5- 6

31. Effective method of operation for dual tilt.. ................................................................................... 31 .I Blade condition ........................................................................................................................ 31.2 Dozing work .............................................................................................................................. 31.3 Leveling (spreading) operations ............................................................................................. 31.4 Ditching operations ................................................................................................................. 31.5 Boulder raising operations ..................................................................................................... 31.6 Side cutting operations ........................................................................................................... 31.7 Horizontal dozing operations from side slope (rough ground). ........................................

5- 7 5- 7 5- 8 5-11 5-11 5-11 5-11 5-12

O-8

SAFETY

a

WARNING

Read and follow all safety precautions. result in serious injury or death. This safety section also contains ment and attachments.

Failure

precautions

to do so may

for optional

equip-

l-l

A E~.M;;wJ~;~ Fo;eeasons

qf safety, y precautions.

6. GENERAL PRECAUTIONS

SAFETY

RULES

l

ONLY trained

l

Follow all safety rules, precautions on the machine.

l

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

SAFETY

always

and authorized

personnel

can operate

and instructions

and maintain when

operating

on worksite

the machine. or performing

maintenance

traffic duty, be sure all personnel

FEATURES

Be sure all guards and covers are in their proper position. damaged. Proper position + See “12.1.1 WALK-AROUND CHECK”. Use safety features

CLOTHING

use of safety features

AND

and covers

repaired

if

such as the safety lock and seat belts properly.

NEVER remove any safety features. ALWAYS keep them Safety lever + See “12.10 PARKING MACHINE”. Seat belts + See “27. USING SEAT BELT”. Improper

Have guards

PERSONAL

could result in serious

PROTECTIVE

in good operating

bodily

condition.

injury or death.

ITEMS

Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts and cause serious injury or death. Also, do not wear oily clothes because they are flammable. Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the machine. Always wear safety goggles, hard hat and heavy gloves if your job involves scattering metal chips or minute materials-this is so particularly when driving pins with a hammer and when cleaning the air cleaner element with compressed air. Check also that there is no one near the machine. Cleaning of air cleaner element + See “24.2 WHEN REQUIRED” in service procedure.

A0055010

1-2

1

g

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


UNAUTHOW l

Any modification

l

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

-I

made without

authorization

from

Komatsu

can create

hazards. will not be responsible

STANDIN-

To avoid hitting unlocked

control

levers, before standing

Move joystick to neutral

and move SAFETY

Lower work position.

to ground

Sudden

equipment

and unwanted

machine

LEVER (located

and move

movement

up from operator’s

SAFETY

left of seat) to LOCK position.

LEVER (located

can cause serious

seat, do the following:

right of seat) to LOCK

injury or death.

1-3


1

NEVER jump on or off the machine. NEVER get on or off a moving machine. When mounting and dismounting, face the machine and use the handholds and steps. Maintain three-point contact to be sure that you do not fall from the machine. Do not hold any control levers when getting on or off the machine. Repair any damaged handhold or step, and tighten any loose bolts. Handholds and steps must be free of oil, grease and excessive dirt. When mounting or dismounting,

use the points marked with arrows in the diagram below.

Use the parts marked by arrow A in the diagram below when getting on or off machine. Never use the parts marked by arrow I3 when getting on or off the machine. Use them only when moving along the top of the track or when checking or carrying out maintenance inside the side cover, or when filling the tank with oil.

AE210270

l-4

nE207660

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


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 a flame away from flammable fluids. Stop the engine and do not smoke when refueling. Tighten all fuel and oil caps securely. Refueling and oiling should be made in well ventilated areas. Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.

-I

BURN HAZARD PREVENTION

1

l

If the coolant, engine oil, power train oil or hydraulic oil is hot, use a heavy cloth, gloves, clothing and safety glasses or goggles before checking or touching.

l

To prevent hot water from spurting out: 1) Turn engine off. 2) Allow water to cool. 3) Slowly loosen cap to relieve pressure

before

removing.

To prevent hot oil from spurting out: 1) Turn engine off. 2) Allow oil to cool. 3) Slowly loosen cap to relieve pressure

before

removing.

l

heavy

A0055050

l-5

a

~~~i~W~e


1

ASBESTOS DUST HAZARD PREVENTION

1

l

Asbestos

l

If you handle materials containing asbestos fibers, follow these guidelines 1) NEVER use compressed air for cleaning. 2) Use water for cleaning to minimize dust cloud. 3) Operate the machine with the wind to your back, whenever possible. 4)

dust can be HAZARDOUS

Fo;eeasons of safety, always y precautrons.

Use an approved

respirator

CRUSHING OR CUlTlNG l

to your health

if it is inhaled. as given below:

if necessary.

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

A0055230

1

FIRE EXTlNGUlSHER

AND FIRST AID KIT

l

Be sure fire extinguishers

l

Know where

l

Know what to do in the event of a fire.

l

Be sure you know the phone

1

have been provided

and know how to use them.

a first aid kit is located.

numbers

of persons

you should

contact

AE104200

l-6

in case of an emergency.

A0055070


Do not operate

machine

with ROPS removed


if equipped.

The ROPS is installed to protect the operator if the machine should overturn. It is designed only to take the load when the machine overturns, but also to absorb the impact energy.

not

The Komatsu ROPS fulfills all worldwide regulations and standards, but if any unauthorized modification is carried out on it, or if it is damaged when the machine overturns, its strength will be reduced and it will not be able to provide its original capacity. It will be able to provide this capacity only if modifications and repairs are carried out in the specified way. When

carrying

out modification

or repairs,

always

consult

your Komatsu

distributor

Even when the ROPS is installed, if you do not fasten your seat belt securely, your properly. Always fasten your seat belt when operating the machine. Seat belts + See “27. USING SEAT BELT.”

,

first.

it cannot

protect

PRECAUTIONS FOR AlTACHMENTS l

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

l

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

l

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

resulting

manual

from the use of unauthorized

for the attachment

attachments

will

l-7

a

;;:.:c;1ze


;;;ereasons cjf safety, always ty precautrons.

MACHINES WITH ACCUMULATOR On machines equipped with an accumulator, for a short time after the engine is stopped, if the work equipment control lever is moved to the LOWER position, the work equipment will move down under its own weight. After stopping the engine, always place the safety lock lever in the LOCK position. When releasing the pressure inside the work equipment circuit on machines equipped accumulator, follow the procedure given in the inspection and maintenance section.

Method of releasing pressure *

with an

See “11.16 HANDLING ACCUMULATOR.”

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

Gas in accumulator + See “11.16 HANDLING ACCUMULATOR.”

l-8

7. PRECAUTIONS OPERATION

7.1

BEFORE STARTING

DURING

e


ENGINE

Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous. Before starting the engine, examine the terrain and soil conditions of the worksite. Determine the best and safest method of operation. If you need to operate on a street, protect pedestrians and cars by designating a person for worksite traffic duty or by installing fences around the worksite. If water lines, gas lines, and high-voltage electrical lines may be buried under the worksite, contact each utility and identify their locations. Be careful not to sever or cut any of these lines. Check the depth and flow of water before operating in water or crossing a river. NEVER be in water which is in excess of the permissible water depth. Permissible water depth --) See “12.9.1 PERMISSIBLE WATER

DEPTH”. FIRE PREVENTION Thoroughly remove wood chips, leaves, paper and other flammable engine compartment. They could cause a fire. Check fuel, lubrication, and hydraulic systems excess oil, fuel or other flammable fluids.

Check point -+ See “12.1.1 WALK-AROUND Be sure a fire extinguisher

is present

things

accumulated

for leaks. Have any leaks repaired.

Wipe

on the

up any

CHECK”.

and working.

I-S

A ~~J~~H’Jize Ps;;ereasons of safety, always ty precautrons.

7. PRECAUTIONS DURING OPERATION

IN OPERATOR’S CAB Do not leave tools or spare parts lying around in the operator’s compartment. or break the control levers on switches. Keep tools in the tool box on the inside at the front of the right fender.

They may damage

Keep the cab floor, controls,

and excess dirt.

steps and handholds

free of oil, grease,

snow,

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 “27. USING SEAT BELT”.

VENTILATION l

1

parts.

FOR ENCLOSED AREAS

If it is necessary to start the engine within fumes from the engine can KILL.

an enclosed

area, provide adequate

ventilation.

Exhaust

A0055060

PRECAUTIONS FOR MIRRORS, WINDOWS all dirt from the surface

AND LIGHTS

l

Remove

of the windows

and lights to ensure that you can see well.

l

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

l

Check that the head lamps and rear lamps are installed also that they light up properly.

PRECAUTIONS FOR SLIDING GLASS INTERMEDIATE

to match the operating

conditions.

keep

Check

LOCK

1

The sliding glass intermediate lock is to prevent rattling of the glass. Even when the lock is used, the glass may move because of the shock when starting or stopping suddenly. Do not put your head or hands out of the window during operations. 7690

-j

CHECK THOROUGHLY Always

I-IO

BEFORE STARTING

carry out all checks before

starting.

1

A ~~f?~Ll~G; Faail;;o

follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATION

7.2

OPERATING

MACHINE

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

anyone

For machines

equipped

PRECAUTIONS

WHE

it, checking

tag has been attached

for people

and objects that

1

to the control.

sound the horn as an alert.

the machine

Do not allow

mounting

only while

seated.

other than the operator with

backup alarm,

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

device operates

body. correctly.

Before moving machine or its attachments: Honk horn to alert people nearby. Be sure no one is around Use spotter

if necessary,

When operating worksite traffic. Prevent Follow

people above

machine, particularly

particularly

if you are moving

in areas that may be hazardous

from entering even if equipped

behind

the line of travel with backup

machine. in reverse.

or have poor visibility,

designate

a person to direct

of the machine.

alarm

and mirrors.

A0055080

I-11


1

TRAVELING

Traveling slipping.

ON SLOPES

1

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

On hills, banks or slopes, carry the work equipment closer to the ground, approximately 20 to 30 cm (8 to 12 in) above the ground. In case of emergency, quickly lower the work equipment to the ground to help the machine stop and prevent it from tipping over. Do not change direction on slopes. Avoid sideways travel whenever possible: rather travel up and down the slopes. 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 downhill, drive slowly and use the engine as a brake. When traveling downhill with the machine being pushed by its own weight, the machine may steer in the opposite direction, so be careful when steering. Reverse steering when traveling downhill + See “12.7.2 TURNING WHILE DESCENDING A SLOPE”. INCORRECT

CORRECT

AD051690

l

Turn ON the head lamps and rear lamp, when working at night or at dark sites. Provide additional lights for the worksite if necessary.

l

If visibility is diminished by fog, snow or rain, stop operation. Wait until there is adequate visibility for safe operation.

l

Snow-covered and frozen ground may allow the machine to slip sideways, even if the grade is not steep. Slow down the machine when traveling on such ground. Avoid rapid starts, stops, and steering.

l

In snow removal work, pay special attention to the edge of the road and to objects under the snow.

1-12

g

;;F!$J;;;;

F~ZI;I~O

follow these safety precautions may lead 7. PRECAUTIONS DURING OPERATION

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 or vibration of your machine. Install the HEAD GUARD dirt.

or FOPS if working

in areas where

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

of falling

there is danger

rocks or danger

under the weight

of falling

rocks and

of the machine

turning

PARKING1 Park on level ground whenever possible. If not possible, ground and thrust the edge of the blade in the ground.

block the tracks, lower the blade to the

Thrust

the edge

AE20770B

When parking on public roads, provide fences and signs, such as flags or lights, on the machine to warn passersby to be careful. Be sure that the machine, flags or lights do not obstruct traffic. Parking procedure + See “12.14 PARKING MACHINE”. Before leaving the machine, lower the work equipment to the ground, move the SAFETY LEVER to LOCK position, stop the engine, and lock all the doors, windows, and covers and remove the key(s). Work equipment posture + See “12.14 Locks + See “12.18 LOCKING”.

PARKING

MACHINE”.

1-13

a 7. PRECAUTIONS DURING OPERATION

7.3 4

~;~;;$iseFc;ereasons of safety, always tv orecautrons.

TRANSPORTATION LOADING AND UNLOADING Loading SHOULD

and unloading BE USED.

1

the

machine

Perform loading and unloading of a road. ALWAYS block the wheels loading and unloading.

always

involves

potential

on firm, level ground only. Maintain

of the hauling

ALWAYS use ramps of adequate a safe loading slope.

strength.

vehicle

and place

hazards.

EXTREME

a safe distance from the edge

blocks

under

both

and fastened,

on the ramps.

block the machine

before

and that the two sides are at the same

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

After loading,

ramps

Be sure the ramps are wide and long enough to provide

Be sure that the ramps are securely positioned level as one another.

NEVER correct your steering again.

CAUTION

If necessary,

Remove dirt from

drive away from the ramps and climb

tracks and secure the machine

with tie-downs.

Loading and unloading + See “13. TANSPORTATION”. Tie-downs + See “13. TRANSPORTATION”. CORRECT

Distance

between

ramps

AD052900

SHIPPING l

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.

l

Determine

1-14

the shipping

route while taking into account the width,

height and weight

the

of the load.

g


7.4


BATTERY Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water. Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately with large quantities of water and see a doctor at once. If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil. Call a doctor or poison prevention center immediately. When working with batteries. ALWAYS wear safety glasses or goggles. Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a small spark or flame. Before working with batteries, stop the engine and turn the starting switch to the OFF position. Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across the terminals. Tighten the battery terminals securely. Loosened terminals can generate sparks and lead to an explosion. Tighten the battery cap.

A0055110

A0055100

1

STARTING ALWAYS When

WITH wear

starting

BOOSTER

CABLES

safety glasses from another

or goggles machine,

when

starting

the machine

do not allow the two machines

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

the batteries

in parallel:

positive

to positive

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

with

booster

of the machine

cables.

to touch.

the booster

and negative

cables + See “16.4 IF BATTERY

with booster

cables.

Disconnect

the

to negative.

to be started,

be sure to connect

IS DISCHARGED”. INCORRECT

A0067320

g 7. PRECAUTIONS DURING OPERATION

7.5

~~y~;~~;e~aa;ereasons of safety, always ty precautrons.

TOWING

_i FIT WIRE TO HOOK WHEN TOWING

1

injury or death could result if a disabled If your machine capacity.

is towed

by another

machine

machine,

is towed

ALWAYS

incorrectly.

use a wire rope with a sufficient

If your machine is towed by another machine, stop the engine contact your Komatsu distributor to have the brake released. NEVER allow

a disabled

machine

Do not use a kinked or frayed Do not straddle

the towing

to be towed

wire

cable or wire rope.

Take up the slack in the wire

connection

enter the area between

of the equipment

being towed

the towing

in a straight

rope and tow the machine.

up, use the towing

hook.

If the machine is stuck in sandy soil, dig out the soil around the towing hook to pull the machine out. Permissible load for towin,g hook: 48500 kg (475623 N)

AE207710

1-16

Please

rope.

Set the towing machine and the towing line when connecting it.

lifting the machine

the brake.

on a slope.

When connecting up a towing machine, do not let anyone machine and the equipment being towed.

When

and release

towing

hook, then use the towing

8. PRECAUTIONS MAINTENANCE

8.1

FOR

BEFORE CARRYING If others start the engine you could suffer serious

g


OUT MAINTENANCE

or operate the controls while you are performing injury or death.

service or lubrication,

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

from your Komatsu

distributor. Part No.

i When

this

N+~~;~

plate IS not being used keep it in the storage compartment.

1

PROPER TOOLS l

Enalish

09963 - 03000

German

09963 - 02000

Spanish

09963 - 01000

French

1

09963 - 05000

Italian

1

09963 - 06000

II\\

\

\\

AE207730

1

Use only tools suited to the task. Using damaged, low quality, cause personal injury. Tools + See “21.1 INTRODUCTION OF NECESSARY TOOLS”.

faulty,

or makeshift

I

tools could

A0055120

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS l

Replace the following Fuel system: Hydraulic system:

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

l

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

l

Replace or repair any such components the time specified.

of whether

or not they appear

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

Replacement of safety critical components

+

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

1-17

a 8. PRECAUTIONS FOR MAINTENANCE

i

E;y;:T;‘f;eE;eeasons of safety, always y precautrons.

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

on firm flat ground

and stop the engine

before carrying

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

out inspection

such as when cleaning the and carry out the operation

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

is carried

should be extremely

out with the work

equipment

raised,

careful

always

not to touch or get caught

support

it securely

with

OFF

ON

-START AD051781

1-18

a

E;P$J;V:s

‘,;;;;no

follow

these safety precautions may lead 8. PRECAUTIONS FOR MAINTENANCE

8.2 l

DURING

MAINTENANCE

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

Keep a safe distance 17A-98.11530

-/

1

ATTACHMENTS l

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

A0055130

WORK

UNDER

THE MACHINE

l

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

l

Always

l

Never work supported.

I I

block the tracks of the machine under

KEEP THE MACHINE

the

machine

if the

to the ground or service or repairs

securely. machine

is poorly A0055140

CLEAN

l

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.

l

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, monitors, controllers, connectors, or the inside of the operator’s compartment.

A00551

50

1-19

a

E;.;;;?e

8. PRECAUTIONS FOR MAINTENANCE

1 RULES TO FOLLOW WHEN ADDING FUEL OR OIL Spilled

fuel and oil may cause you to slip, so always

Always

tighten

Never

1 wipe

it up immediately.

the cap of the fuel and oil fillers securely.

use fuel for washing

any parts.

A0055040

A0055030

A0055020

1

Fc;e reasons cf safety, always ty precautrons.

RADIATOR WATER LEVEL 1 l

When checking the water level, stop the engine and wait for the engine and radiator to cool down first.

l

If removing

l

When checking fuel, oil, coolant, or battery electrolyte, always use lighting specifications. If such lighting equipment is not used, there is danger of explosion.

A

the radiator

USE OF LIGHTING

cap, turn it slowly

to release the internal

pressure.

1 with

antiexplosion

A0055160

I-20


PRECAUTIONS l

WITH


BATTERY

When repairing the electrical system or when carrying out electrical @ terminal of the battery to stop the flow of current.

welding,

remove the negative

A0055170

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

Do not use any bent or cracked

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

Avoid torching, soldering, or welding on pipes, tubes and equipment that contain fuel or oils. If heated, they can generate flammable fumes or mist and could cause a fire or explosion.

PRECAUTIONS Do not forget

WITH that the work equipment

circuits are always

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

under

or inspection

pressure. before completely

releasing

the

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

oil, consult

A0055180

a doctor

immediately

for medical

attention.

A0055190

1-21

a 8. PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE HIGH TEMPERATURE l

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

AT

OR HIGH PRESSURE

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 Check cooling

water

system

+ See “24.2 WHEN

level, lubricating

oil level, hydraulic oil level + See “24.3 CHECK BEFORE STARTING”.

Checking

final drive case + See “24.4 PERIODIC

Changing

oil, replacing

filters

REQUIRED”.

MAINTENANCE”.

+ See “24.5 - 7 PERIODIC

MAINTENANCE”.

PRECAUTIONS WHEN USING HIGH PRESSURE GREASE TO ADJUST TRACK TENSION Grease is pumped into the track tension adjustment system under high pressure. If the specified procedure for maintenance is not followed when making adjustments, grease fitting may fly out and cause damage or personal injury. l When loosening the grease drain plug, never loosen it more than one turn. l

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

-I

ROTATING

track tension

FAN AND

-+ See “24.2 WHEN

BELT

rotating

the plug or

in front of any grease

REQUIRED”.

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.

A0055210

l-22


WASTE Never Aiways


MATERIALS dump waste

1 oil in a sewer

put oil drained

system,

from your machine

rivers, etc. in containers.

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

disposing

Never drain oil directly of harmful

objects

on the ground.

such as oil, fuel,

INCORRECT

A0055220

l-23

9. POSITION FOR ATTACHING

SAFETY LABELS

Always keep these labels clean. If they are lost or damage, attaching 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

Accumula

View

Y View

l-24

2

db1

3

Of

P portion

9. POSITION FOR ATTACHING SAFETY LABELS AND STORAGE OF OPERATION & MAINTENANCE MANUAL

1.

Warnings before operating machine (14X-98-l 1580)

3.

Warnings for leaving operator’s seat (14X-98-l 1541)

g, WARNING Improper tenance

operation

To avoid hitting unlocked operation levers, before standing up from operator’s seat, do the following: Move steering and directional lever neutral and move SAFETY LOCK LEVER (located left of seat) to LOCK position. Lower equipment to ground and move SAFETY LOCK LEVER (located right of seat) to LOCK position.

and main-

can cause serious

injury or death. Read manual operation Follow

and labels before

and maintenance.

instructions

ings in manual

and warn-

and in labels on

machine. Keep manual

in machine

-

cab

near operator. Contact

Komatsu

for a replacement

Sudden and unwanted machine movement can cause serious injury or death.

distributor manual.

.

14X-98-11580 -

2.

Warnings before moving in reverse (14X-98-l 1590)

A

WARNING

4.

14X-98-11541 -

Warnings for hot water hazard (14X-98-11531)

A

_

Hot water

Before moving machine or its attachments: l Honk horn to alert people nearby. l Be sure no one is on machine area. 0 Use spotter if necessary, particularly if you are moving in reverse. Follow above even if equipped with back-up alarm and mirrors. 14X-98-11590

hazard.

To prevent hot water from spurting out: l Turn engine off. l Allow water to cool. 0 Slowly loosen cap to relieve pressure before removing.

*

c

WARNING

L

14X-98-11531 -

-

l-25

9. POSITION

FOR ATTACHING

Cautions for opening (09653-03000)

SAFETY

LABELS

cap of hydraulic

tank

7.

Warning (14X-98-l

for handling 1390)

accumulator

8.

Warning for use of seat belt (195-98-12940)

1. ALWAYS STOP ENGINE WHEN REMOVING CAP. 2. DO NOT LOOSEN CAP WHEN 01 TEMPERATURE IS HIGH. IF LOOSENED, OIL MAY GUSH _I *_ UUI.

3. SLOWLY OPEN HYDRAULIC OIL TANK CAP AND RELEASE INTERNAL PRESSURE COMPLETELY. 4. DO NOT OPEN DRAIN PLUG ;;EN OIL TEMPERATURE IS I

09653-03000J

Warnings for adjusting (195-98-22931)

track tension

CAUTION ALWAYS USE SEAT BELT WHEN OP. ERATING MACHINE. ALWAYS CHECK CONDITION OF THE SEAT BELT, THE CONNECTING BRACKETS AND THE TIGHTENING Compressed spring, plug and grease are under hazardous high pressure and can cause serious injury or death. 1. When adjusting track tension, only turn plug @ ONE TURN. Turning plug further could cause plug and grease to fly off and hurt you. See manual for adjustment instructions. 2. When loosening track shoe, if it does not loosen after turning plug @ ONE TURN, ask Komatsu dealer or distributor to disassemble. 3. Never disassemble bolts @. Idler and yoke @ may suddenly release and hit you. Ask Komatsu dealer or distributor to disassemble.

BOLTS. ADJUST SEAT TO ALLOW FULL BRAKE PEDAL TRAVEL WITH OPERA. TOR’S BACK AGAINST SEAT BACK. AFTER ADJUSTING THE HEIGHT FORE AND AFT POSITIONS OF THE SEAT, TIGHTEN THE TETHER BELl BEFORE SITTING IN THE SEAT. 195-98-12940

l-26

9. POSITION FOR ATTACHING SAFETY LABELS

9.

Warning for ROPS (for America (09620-30201)

and Canada)

ROLL-OVERPROTECTIVESTRUCTURE(ROFS, CERTlFlCATlON THISKOMATSU ROPS.MODEL&type No.lSERIALNo.IWHEN INSTALLED IN ACCORDANCEWIT” THE MANUFACTURES INSTALLATION INSTRUCTlONS ON A -1 FOR MAXIMUM PRIME MOVER MASS NOT GREATERTHAN [ LBS,#9). IS CERTIFIEDTO COMPLY WITH THE FOLLDWING REDUIREMENTS: a, IS0 3471 (ROPS) & IS0 3449 (FOPS, b) SAE J 0 & SAE J -

t

11

* Altering ROPS may weaken it. Consult Komatsu Distributor before altering. * ROPS may provide less protection if it has been structurally damaged or involved in roll-over. * Always wear seat belt when moving.

Komatsu Ltd. Japan

9.

Z-3-6 Akasaka, Minato-ku, Tokyo, Japan

Warning for ROPS (except (09620-30200)

KOMAdbU

America

09620-30201

and Canada)

ROLL-OVERPROTECTlM STRUCTVRE(ROPSI TWEROLL-OVERPROTECTIVESTRUCTUREOF THIS MACHINE COMPLlESWlTH THE FOLLOWINGSTANDARDS OR ,RECOMMENDED PRACTICES) INTERNATIONALSTANDARD: IS0 34771IROPSI & IS0 3449 (FOPS.1 AMERICAN STANDARD: SAE J 0 & SAE J I]

MODEL n

- Altering ROPS may weaken it. Consult Komatsu Distributor before altering. - ROPS may provide less protection if it has been structurally damaged or involved in roll-over. * Always wear seat belt when moving.

Komatsu Ltd. Japan

9.2 1.

Content

Z-3-6 Akasaka, Minato-ku, Tokyo, Japan

and use of warning

09620.30200

plates

Warning to prevent operation during maintenance (09963-03000) Hang this warning plate on the controls in the operator’s partment.

com-

l-27

OPERATION

10. GENERAL VIEW

10.1

GENERAL

If directions diagram below. Machines

VIEW OF MACHINE

are indicated

equipped

in this section,

they

refer to the directions

shown

by the arrows

in the

with cab Blade

lift

Cab

cylinder

Fuel

\

\

Track

tank

frame

Frame

Machines

equipped

with canopy

Track

shoe

AE207758

canooy

Left Front AE20776B

2-2

10.2

GENERAL

Machines

VIEW OF CONTROLS

equipped

with cab

Head Air or

Lock

IamP

conditioner Heater Panel

UD mode

switch

Toraue IockuI) switch

AND GAUGES

converter pilot IamD \

Warning

Rear lamp

lamp

switch Starting

I

switch

panel

rake

\

Dedal

eration

Pedal

Blade

Fuel

control

Cigarette

control

control I ever

lighter

Pin-Duller switch AE210288

Engine

water

Charge

IamD

Engine

oil

oressure

Safety lever _

I Parking lever oil

Transmission temDerature

Wiper

gauge

Service mater drive pilot lamp

switch Fue I

gauge’

Radiator

level

Service

co.olant check lamn

Preheater I amp

.--I Engine check

\Transm~ssron temperature caution

pilot \

oil lame

level

meter

Hydraulic caution

oil Iamp

oil lamp

temDerature AD210298

AE20'779B

2-3

10. GENERALVIEW

Machines equipped with canopy Switch

Preheater Rear Head

Lock

IamD

UD mode

IamD

switch

Ioraue IockuD

\

I

converter D~lot IamD Warning

IamD

switc

Starting

switch

swi Brake

JOvst ick Stee r ing, gear shift

(

Dedal

Deceleration dl rect lever

ional.

Blade

Fuel

control

control

lever Horn

switch

Pin-Duller

AE210308

Engine

Charge

water

IamD

Engine

oii

Dressure

Parking lever

I amD Transmission temDerature

Engine water temDerature caution IamD

oil gauge

Service mater drive pilot lamp Fuel

gauge

Radiator

Service

2-4

Transmission temoerature caution lamD

CO

Engine check

meter

oil IamD

level

Hvdpauiic caution

Oil IamD

Oil

temDeratUre brl,,n,09

11. EXPLANATION

OF COMPONENTS

The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the equipment and the meanings of the displays.

11 .I FRONT PANEL

A

D A021031B

@

CHECK MONITOR GROUP (11.1.1) (Check items before starting) If there is any abnormality, the appropriate monitor lamp will flash. Check the location where the monitor lamp is flashing, and carry out the checks before starting. When the engine is started, these monitor lamps will go off even if there are abnormalities. NOTICE When carrying out checks before starting, do not simply rely on the monitor. Always refer to the periodic maintenance items or “12. OPERATION” to carry out the checks.

2-5

11. EXPLANATION OF COMPONENTS

@I CAUTION MONITOR (Caution items)

GROUP

A If any monitor

lamp flashes,

(11.1.2)

WARNING repair

it immediately.

If the abnormality occurs while the engine is running, the appropriate monitor lamp will flash to indicate the abnormality. Even if the monitor lamp flashes, the machine can operate, but it should be repaired as soon as possible. @

CAUTION MONITOR (Emergency caution

GROUP items) g

If any monitor immediately.

lamp

(11.1.3)

WARNING

flashes,

stop

the

work,

and

repair

it

If any abnormality occurs while the engine is running, the appropriate monitor lamp will flash and the alarm buzzer will sound intermittently at the same time. Even if the monitor lamp flashes, the machine can operate, but it should be repaired as soon as possible. @

METER GROUP (11.1.4) This group consists of engine water temperature train oil temperature gauge, fuel gauge and service SWITCH GROUP (11.1.5) This group consists of starting switch, mode switch and preheating switch.

gauge, meter.

power

@

LAMP GROUP (11.1.6) This group consists of warning up pilot lamp.

lamp switches,

lock up

@

lamp and torque

converter

lock

Functional check of the machine monitor system When the starting switch is turned ON before starting the engine, the monitor lamps flash for 3 seconds, the warning lamp lights for 2 seconds, and the alarm buzzer sounds for 1 second. l If any monitor lamp does not light up, there is probably a broken bulb or disconnection in the monitor, so ask your Komatsu distributor to inspect it. l The monitor system cannot be checked for breakage until 30 seconds after the engine has been stopped.

2-6


11.1.1 A: CHECK MONITOR GROUP (Check items before starting) NOTICE When carrying out checks before starting, do not simply rely on the monitor. Always refer to the periodic maintenance items or “12. OPERATION” to carry out the checks. Park the machine on level ground and check the monitor lamps. Confirm that these monitor lamps light for about 3 seconds after the starting switch is turned to ON. If any monitor lamp does not light, ask your Komatsu distributor to inspect it.

A

A0210328

1.

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.

I

I

I AD207820

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.

m

A0207830

2-7


11 .I.2 B: CAUTION MONITOR (Caution items) a If this monitor

lamp flashes,

GROUP

WARNING repair

it immediately.

NOTICE Park the machine on level ground and check the monitor lamps. Confirm that these monitor lamps light for about 3 seconds after the starting switch is turned to ON. If any monitor lamp does not light, ask your Komatsu distributor to inspect it.

AD21033B

I

1.

CHARGE

MONITOR

This monitor indicates an abnormality in the charging system while the engine is running. If the monitor lamp flashes, stop the engine and check the V-belt tension. If any abnormality is found, see “16. TROUBLESHOOTING.” REMARK

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

2-8

+ I A0207850


11.1.3 C: CAUTION MONITOR GROUP (Emergency caution items) a

WARNING

If any monitor lamp flashes, stop the engine idling speed, and repair it immediately.

or run it at a low

NOTICE Park the machine on level ground and check the monitor lamps. Confirm that these monitor lamps light for about 3 seconds after the starting switch is turned to ON. If any monitor lamp does not light, ask your Komatsu distributor to inspect it.

AD21034E

1.

ENGINE OIL PRESSURE MONITOR This monitor indicates a low engine If the monitor lamp flashes, stop immediately.

oil pressure. the engine and

check

it

REMARK 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.

2-9


2.

RADIATOR COOLANT LEVEL MONITOR This monitor indicates a low radiator coolant level. When the monitor lamp flashes, stop the engine, coolant level and add water as required.

check

the

3.

ENGINE COOLING WATER TEMPERATURE MONITOR This monitor indicates a rise in the cooling water temperature. When the monitor lamp flashes, run the engine at the low idling speed until the green range of the engine water temperature gauge lights.

I 4.

POWER TRAIN OIL TEMPERATURE MONITOR This monitor indicates a rise in the oil temperature of the torque converter outlet. When the monitor lamp flashes, run the engine at the low idling speed until the green range of the power train oil temperature gauge lights.

L

HYDRAULIC OIL TEMPERATURE This monitor indicates a rise in When the monitor lamp flashes, engine at the low idling speed until 5.

2-10

MONITOR the hydraulic oil temperature. stop the machine and run the oil temperature falls.

I

I A0207880


11.1.4 D: METER GROUP NOTICE While the engine is at rest, turn the starting switch ON to see if meter lamps 0, @ and @ and the monitor lamp all come on. If they do not light, ask your Komatsu distributor to inspect them.

d5

b4

\\

I

I

D 1.

ENGINE

COOLING

WATER

TEMPERATURE

GAUGE

This gauge indicates the temperature of the cooling water. If the temperature is normal during operation, the green range will light. If the red range lights up during operation, move the fuel control lever to lower the engine speed to approx. 3/4 of the full speed, and run until the water temperature enters the green range. If the engine cooling water temperature enters the red range, and the engine water temperature monitor flashes and the alarm buzzer sounds, stop the machine and run at low idling until the water temperature enters the green range. NOTICE If the water temperature gauge check the radiator for clogging.

often

enters

the

H Green

White

A

C

red range,

2-11


2.

POWER TRAIN OIL TEMPERATURE GAUGE This gauge indicates the oil temperature of the torque converter outlet. If the temperature is normal during operation, the green range will light. If the red range lights up during operation, move the fuel control lever to lower the engine speed to approx. 3/4 of the full speed, reduce the load and run until the oil temperature enters the green range. If the power train oil temperature enters the red range, and the power train oil temperature monitor flashes and the alarm buzzer sounds, stop the machine and run at low idling until the oil temperature enters the green range.

Red

Green AD207938

NOTICE If the power train oil temperature gauge often enters the red range, we recommend you to lower the travel speed one range (for example, F2 + Fl) to reduce the load on the power train when operating. 3.

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 150 e(39.6 US gal, 33 UK gal) of fuel in the tank. When the red range lights, add fuel.

REMARK The display amount of fuel.

is not

directly

proportional

with

the

remaining

4.

SERVICE METER This meter shows the total operation hours of the machine. The service meter advances while the engine is running - even if the machine is not traveling. Set the periodic maintenance intervals using this display. When the engine is running, the green pilot lamp at the top of the meters flashes to indicate that the meter is advancing. Meter will advance by 1 for each hour of operation regardless of the engine speed. 5. ENGINE PREHEATING PILOT LAMP This lamp indicators the engine preheating time when starting the engine by operating APS (Automatic Priming System). When the starting switch key is placed in ON, this lamp lights and goes out after approx. 12 seconds, indicating that the preheating of the engine has been completed.

2-12

AD104460


11.1.5 E: SWITCHES

(MACHINES

EQUIPPED WITH CAB)

AE210360 I I.

STARTING SWITCH This switch

OFF

is used to start the engine.

I OFF Key insertion-withdrawal activate.

position.

None

of electrical

circuits -

ON Charging and electric after starting.

START AD051780

device

circuits

activate.

Keep key at ON

START At this key position, the starting motor will crank the engine. Immediately after starting the engine, release the key which will automatically return to the ON position.

2-13

1I. EXPLANATION OF COMPONENTS

2.

FRONT LAMP, WORKING LAMP SWITCH This lights up the front lamps, working lamps at the front of the left and right fenders, and the panel lamp.

OFF position: ON position:

OFF

ON

LJ

Lamps are out Lamps light up AD051790

3.

REAR LAMP SWITCH This lights up the rear lamps.


OFF

ON

LJ

Lamps are out Lamps light up

AD051790

4.

PREHEATING SWITCH This lights up the rear lamps.

OFF position: ON position: I, II position:

Preheating is not actuated Automatic preheating is actuated Preheating is not actuated. Normally do not turn the key to these positions. AE208940

g

CAUTION

When not using the APS, do not turn the switch to the ON position. For details, see 12.2.2 STARTING IN COLD AREAS. This is used when using the APS to start the engine in cold areas. When the switch is turned to the ON position, electricity flows to the glow plug and the intake air is heated. The preheating monitor on the monitor panel lights up when the switch is turned ON. Do not turn the switch to the ON position when not using the APS. A

I

2-14

I

,

A0207950


5.

LOCKUP MODE SWITCH

This is used when greater power is needed rather than larger production (such as when dozing loose soil). The system is switched between torque converter drive and direct drive to match the load. When the switch is turned ON, the torque converter lock-up pilot lamp lights up. OFF position: ON position:

Torque converter drive Used when greater power is needed, rather than larger production (such as when dozing loose soil). The system is switched between torque converter drive and direct drive to match the load.

OFF

ON

d/

ADO51790

2-l 5

11. EXPLANATION

OF COMPONENTS

11 .I.5 E: SWITCHES

(MACHINES

EQUIPPED WITH CANOPY)

AE210450

L

1.

STARTING SWITCH This switch

OFF

is used to start the engine. I

OFF Key insertion-withdrawal activate.

position.

None

of electrical

circuits

ON Charging and electric after starting.

device

circuits

activate.

Keep key at ON

START At this key position, the starting motor will crank the engine, Immediately after starting the engine, release the key which will automatically return to the ON position.

2-16


2.

FRONT LAMP, WORKING LAMP SWITCH

This lights up the front lamps, working lamps at the front of the left and right fenders, and the panel lamp.

OFF

ON

lJ



A0051790

3.

REAR LAMP SWITCH This lights up the rear lamps.


OFF

ON

lJ


A0051790

4.

1

PREHEATING SWITCH This lights up the rear lamps.

OFF position: ON position: I, II position:

Preheating is not actuated Automatic preheating is actuated Preheating is not actuated. Normally key to these positions.

ll

do not turn the

PIE208940 a

CAUTION

When not using the APS, do not turn the switch to the ON position. For details, see 12.2.2 STARTING IN COLD AREAS. This is used when using the APS to start the engine in cold areas. When the switch is turned to the ON position, electricity flows to the glow plug and the intake air is heated. The preheating monitor on the monitor panel lights up when the switch is turned ON. Do not turn the switch to the ON position when not using the APS.

A0207950

2-17

11. EXPLANATION

5.

OF COMPONENTS

LOCKUP MODE SWITCH

This is used when greater power is needed rather than larger production (such as when dozing loose soil). The system is switched between torque converter drive and direct drive to match the load. When the switch is turned ON, the torque converter lock-up pilot lamp lights up. OFF position: ON position:

2-18

Torque converter drive Used when greater power is needed, rather than larger production (such as when dozing loose soil). The system is switched between torque converter drive and direct drive to match the load.

OFF

ON

LJ

AD051790


11 .I.6 F: LAMPS (MACHINES

EQUIPPED WITH CAB)

AE210370

1.

WARNING

LAMP

NOTICE If the alarm buzzer sounds, stop work immediately and carry out inspection and maintenance of the appropriate point. When the monitor for the B CAUTION and C CAUTION groups on the machine monitor system flashes, the warning lamp also flashes at the same time. If the lamp flashes, check the monitor panel to locate the problem. When the monitor inside the C CAUTION group flashes, the alarm buzzer also sounds continuously.

2.

TORQUE CONVERTER LOCKUP PILOT LAMP When the lockup switch of the switch panel is switched ON, this lamp lights up automatically after the torque converter is locked up (when it changes to direct drive). When the torque converter drive is being used, this lamp remains OFF.

2-19

11. EXPLANATION

OF COMPONENTS

11.1.6 F: LAMPS (MACHINES

EQUIPPED WITH CANOPY)

AE210460

1.

WARNING

LAMP

NOTICE If the alarm buzzer sounds, out inspection and maintenance

stop work immediately and carry of the appropriate point.

When the monitor for the B CAUTION and C CAUTION groups on the machine monitor system flashes, the warning lamp also flashes at the same time. If the lamp flashes, check the monitor panel to locate the problem. When the monitor inside the C CAUTION group flashes, the alarm buzzer also sounds continuously.

2.

TORQUE CONVERTER LOCKUP PILOT LAMP

When the lockup switch of the switch panel is switched ON, this lamp lights up automatically after the torque converter is locked up (when it changes to direct drive). When the torque converter drive is being used, this lamp remains OFF.

2-20

11. EXPLANATION

OF COMPONENTS

11.1.6 G: MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL) l l

l l

Press each mode switch to turn it ON or OFF and to select the mode. For details of the setting of the mode to use, see “12.13 Effective use of mode selection system”. It is impossible to use any combination of the lock-up mode and any other mode. The economy mode, reverse slow mode, and shoe slip control mode can be used independently or in combination.

AW22524B

Selecting the mode to match the type of work and quality of rock or soil makes it possible to carry out operations effectively. Dozing

Ripping Reverse slow mode

Sfcr(o=es[P

X

X

X

0

A

0

Lock up mode

Ec;“o”d~~

0 X

1.

LOCK UP MODE SWITCH This is used when large power is needed rather than high production (such as when dozing loose soil). The drive is switched between torque converter drive and direct drive according to the load. When it is ON, the lamp lights up.

I

AW22525B

2-20-l

11. EXPLANATION

OF COMPONENTS

ECONOMY MODE SWITCH This is used for hauling work after ripping or for dozing blasted rock. When the system is OFF, if the switch is pressed once, mode [I] lights up, and if it is pressed again, mode 121 lights up. Select the mode according to the type of rock.

2.

AW22526B

3.

SHOE SLIP CONTROL SWITCH This is used for ripping operations. When it is switched ON, the lamp lights up. NOTICE If the shoe slip control is switched is automatically set to 131, so switch match the type of rock.

ON, the rock selection mode the rock selection mode to

4.

ROCK SELECTION MODE SELECTOR SWITCH When carrying out ripping work, turn the slip control select mode [II - 151 according to the shoe slip ratio. The lamp for the selected mode lights up.

ON and

1 SOFTO

2 0

3 0

4 0

5 OHARD

AW2252BB

5.

REVERSE SLOW MODE SELECTOR SWITCH Use this after ripping and when dozing rock. When it is turned ON, the lamp lights up..

06

SLOW REVERSE MODE

ON

0

ON

0

2-20-2

Il.

EXPLANATION OF COMPONENTS

SWITCHES

AE208070

1.

HORN SWITCH The horn sounds when the button at the rear of the blade control lever at the right side of the operator’s seat is pressed.

I 2.

ROOM LAMP SWITCH (MACHINES This lights up the room lamp. ON position: Lamp lights up OFF position: Lamp is out

\

AE208080

EQUIPPED WITH CAB)

I

AD051820

2-21


3.

WIPER SWITCH (MACHINES

EQUIPPED WITH CAB)

This activates the wipers. The wiper switches are as follows. @ Left door @ Front window @ Right door @ Rear window

This is also used as the window washer The switch is operated as follows.

l

switch.

Window washer only Keep the switch pressed to the OFF position to spray out water.

I 0

Wiper only If this is switched

on, the wiper

AD051850 J

will start.

AD051860

l

Wiper and window washer If this is kept pressed to the ON position working, water will be sprayed out.

while

the wiper

is

ADO51870

2-22


REMARK When installing the cab, check the colors of the washer tank and window washer hoses, and be sure to connect correctly.

For right door(red),

For front (color,less)

window

(black)

Red-Right door Blue-Left door Black Rear window Colorless-front window

View

4.

ClGARElTE

LIGHTER (MACHINES

Y

From fuse box Red( back uo Doewr source)

AEZoBloB

EQUIPPED WITH CAB)

This is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its original position after a few seconds, so take it out to light your cigarette. Cigarette lighter capacity: 120 W NOTICE This cigarette

lighter is 24V. Do not use it as the power source

AD051830

for 12 V equipment.

2-23


11.3

CONTROL

LEVERS AND PEDALS

ADO55346

1.

FUEL CONTROL LEVER

0 0

This lever is used to control the engine speed and output. Engine stop position: Push the lever forward fully. Low idling position: Pull the lever from engine stop position until you feel the operating force falls

0

High idling position:

@I Off.

2-24

Pull the lever fully from tion.

low idling posi-

I

AE206120


2.

JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER) This is used to select the direction of travel, to carry out steering, and to carry out counterrotation turns.

Forward-reverse shifting 0: FORWARD 0: REVERSE N: NEUTRAL Push the lever forward, the machine will move off forward. Pull the lever backward, the machine will move off in reverse. Steering 0: LEFT TURN 8: RIGHT TURN

AE208130

Lever

guide

Move the joystick to the FRONT to travel FORWARD Move the joystick to the REAR to travel in REVERSE If the joystick is operated to travel forward or in reverse, and is then moved partially in the direction of turn, the machine will turn gradually. If the joystick is moved further in the direction of turn, the machine will turn more sharply. REMARK If the lever is released when steering the machine, the lever will return to the @ position or the @ position and the machine will be returned to straight movement. If you support the lever guide with your hand when steering, the turning operation will be easier.

AE20814B

Gear shifting Rotate the joystick 30” to carry out gear shifting operation. Position @: 1st Position @: 2nd Position 0: 3rd For details of the maximum speed at each speed range, see “25. SPECIFICATIONS”. REMARK When gear shifting the rear of the joystick 1st: iiJis displayed on 2nd: qis displayed on 3rd: flis displayed on

operation is carried out, the display panel at will display the speed range. the display panel the display panel the display panel

2-25


3.

BRAKE PEDAL

A

WARNING

Do not place your foot on this pedal unnecessarily. Depress

4.

the pedal to apply the right and left brakes.

DECELERATION

I-

AD051970

PEDAL A

l l

WARNING,

Do not place your foot on this pedal unnecessarily. When passing over the top of a hill or when a load is dumped over a cliff, the load is suddenly reduced, so there is danger that the travel speed will also increase suddenly. To prevent this, depress the decelerator pedal to reduce the travel speed.

This pedal is used when reducing the engine speed or stopping the machine. When switching between forward and reverse, or when stopping the machine, use this pedal to reduce speed.

5.

PARKING

LEVER

A When the machine LOCK position.

WARNING

is parked, always

set the parking lever to the

This lever is used to apply the parking

brake.

REMARK l If the parking lever is set to the LOCK position when the directional and steering lever is at the forward or reverse position, the directional and steering lever is automatically returned to the N position. l When starting the engine, if the parking lever is not at the LOCK position, the limit switch is actuated and the engine cannot be started.

2-26

AD451665


6.

SAFETY LEVER TROL LEVER)

l

l

l

(FOR BLADE

CONTROL

LEVER,

RIPPER CON-

WARNING g When standing up from the operator’s seat, always set the safety lever securely to the LOCK position. If the blade control and ripper control levers are not locked and are touched by accident, it may lead to serious injury or damage. If the safety lever is not set securely to the LOCK position, the lock may not be applied. Check that it is in the position shown in the diagram. When parking the machine or when carrying out maintenance, always lower the blade and ripper to the ground, then set the safety lever to the LOCK position.

L

This safety lever is a device to lock the blade control and ripper control levers. When it is set to the LOCK position, the TILT, RAISE, LOWER, and FLOAT operations are locked. If the blade control lever is at the FLOAT position and the safety lever is set to the LOCK position, the blade control lever is automatically returned to the HOLD position. REMARK When starting the engine, to ensure safety, always set the safety lever to the LOCK position.

2-27


7.

BLADE CONTROL LEVER (POWER TILTDOZER) This lever is used to raise or tilt the blade.

Lifting control @ RAISE : t k, @ HOLD 3x1 @

@

Blade is stopped and held in this position. LOWER : ( * ) FLOAT :(_I% Blade will move freely according to external

force.

REMARK When released from FLOAT position, this lever will not return to HOLD position, so it must be moved back by hand. Lower AD20816B

Tilting control @ LEFT TILT : ( 1& 1 @ RIGHT TILT: (&)

Right

tilt

1 _.---

.._

Left

tilt AD209178 J

7.

BLADE CONTROL LEVER (FOR DUAL TILT DOZER) This carries out the blade lift, tilt, dual tilt, and pitch operations.

Liiing control @ RAISE : (& @ HOLD : ( -b @ @

1 1

Blade is StoDDed and held in this position. LOWER : ( & 1 FLOAT : (a 1 Blade will move freely according to external

force. Ra

REMARK When released from FLOAT position, this lever will not return to HOLD position, so it must be moved back by hand.

i

1

Lower

Tilting control @

@

LEFT TILT RIGHT TILT

A0208168

: (1& : (&

1 ) Right

tilt

AO20817B

2-28


l DUAL TILT OPERATION @ + @: Left dual tilt (keep

0

+ @:

button 0 pressed and operate in direction @.) R$ht tilt (keep button 0 pressed and operate in direction B.

If the tilt operation is carried out with button @ at the top center of the knob kept pressed, a larger tilting force can be obtained than in normal tilt operations. l PITCH OPERATION @ + @: Rear pitch: Smaller

cutting edge angle (keep button @ pressed and operate in direction @.I @ + @I: Forward pitch: Larger cutting edge angle (keep button @I pressed and operate in direction @.I Return the lever to the neutral position, then keep button @ at the front center of the knob pressed, and operate the tilt to change the angle of the cutting edging of the blade.

PRECAUTIONS WHEN USING DUAL TILT, PITCH l

l

If the tilt operation is carried out with buttons @ and @ both pressed at the same time, the blade will be pitched. (The pitch operation is the priority circuit.) To make effect use of the dual tiltdozer, see OPTIONS, ATTACHMENTS.

REMARK l

l

@ @ l

l

@ @ l

For the dual tilt and pitch operations, keep the button pressed and move the lever to the left or right to start the actuation. The pitch operation is the priority circuit, so if both buttons are pressed at the same time, the pitch will be operated. + @ Left dual tilt (+@I + @ Right dual tilt C’&*) The dual tilt operation can be carried out at any of the RAISE, HOLD, or LOWER positions. If the dual button is not pressed, the normal tilt operation can be carried out. + @ Rear pitch (&.. + @ Forward pitch (k) The pitch operation can be carried out at any of the RAISE, HOLD, or LOWER positions.

2-29


RIPPER CONTROL LEVER (FOR VARIABLE RIPPER) This is used to operate the ripper. RAISE (e 1 HOLD ( 9 1: Ripper is stopped LOWER( 78 1 Digging smaller. Digging larger.

angle

reduced

angle increased

( 9& ( y2

and held in the same position.

) : Cutting

angle

(CL) becomes

1: Cutting

angle

(4

1

k--2-21

becomes

AEZOBEIB

r

OigsinQ decrease

9.

angle *

OigginQ cs

angle increase AE208228

PIN PULLER CONTROL SWITCH (FOR GIANT RIPPER) This is used to operate

@ @

the pin puller.

PULL OUT: Pin is pulled out. PUSH IN: Pin is pushed in.

43 Front of the machine

AC052080

2-30


11.4

DUST INDICATOR

This device indicates clogging of the air cleaner element. When the red piston appears in transparent part @ of this indicator, the element is clogged. Clean the element immediately. After cleaning, push indicator button @to return the red piston to its original position. The dust indicator is on the air cleaner bracket inside the engine room. AK069991

11.5 POWER SOURCE The cigarette

lighter socket can be use as a power

source.

NOTICE The power from the cigarette lighter socket is 24V. Do not use this as the power source for any 12V equipment. The capacity of the cigarette lighter power source is 120W (24V x 5AL

11.6

FUSE BOX

NOTICE Before replacing

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

The fuses protect burning out. If the fuse becomes the fuse is loose in the Replace a fuse with l

l

the

electrical

equipment

and wiring

from

corroded, or white powder can be seen, or fuse holder, replace the fuse. another of the same capacity.

Chassis Fuse box I is installed

inside the cover (left).

Cab (machines equipped with cab) Fuse box II is installed at the bottom

of the overhead

panel.

2-31

11. EXPLANATION

OF COMPONENTS

11.6.1 FUSE CAPACITY

AND CIRCUIT NAME

FUSe

DOX

I

Fuse box I No.

Fuse capacity

Circuit

0

20 A

Starting

0

20 A

Car stereo,

switch

0

-

@I

-

I

@I

-

I

@I a I

-

I

-

20 A

I

-

@I @I a3 I

20 A

Backup

0

15A

Horn

0

20 A

-

I

Rear lamp 20~ I---~

@

I

20 A

Head

IO A

Monitor,

Fuse box II (Machines

-0 I

lamp,

work

pin-puller

equipped

with

1 Radio

20 A

Radio,

10 A

Rear wiper

@

10 A

Right door wiper

0

10 A

Front wiper

@

10 A

@

2-32

I

I

lamp switch,

air conditioner

cab) Circuit

10 A

0

AE20019B

alarm

-0

capacity

lamp

I

10 A

IFuse

room

-

Lock up

No.

lighter,

1

10 A

0

cigarette

-

I Left

memory lamp,

cigarette

door wiper

lighter

Fuse box II

/


11.7

DOOR-OPEN LOCK (MACHINES EQUIPPED

WITH CAB)

Use this when your want to keep the door held open. 1. Push the door against door catch 0. The door will be held by the door catch. 2.

To release the door, move lever @ inside the cab to the front of the cab. This will release the catch.

NOTICE When keeping l Always close tions. Leaving l Keep the door The door may l

the door open, fix it securely to the catch. the door when traveling or carrying out operathe door open will cause the door to break. locked open securely. swing closed because of the vibration. AD052160

11.8

SASH GLASS INTERMEDIATE LOCK (MACHINES EQUIPPED WITH CAB)

When carrying out operations with the cab sash glass open, use this block to prevent the glass from moving. l When the lever is at the FREE position, the glass can be opened or closed. l When the lever is moved to the LOCK (up or down) position, the glass is fixed in position. l If the glass is not held securely, set the lever in the FREE position and rotate clockwise to strengthen the holding power. l To reduce the holding power, turn counterclockwise. ti NOTICE Always close the window when traveling or carrying tions. Leaving the window open will cause the window

out operato break.

_ Tighten

11.9

DOOR POCKET (MACHINES EQUIPPED

Lock 0

WITH CAB)

These are on the inside of the left and right doors, and can be used for keeping things. However, do not put tools or other heavy objects in the pocket. If the pocket becomes dirty, turn three clips 0, remove the pocket and wash it.

11. IO ASHTRAY (MACHINES

EQUIPPED

WITH CAB)

This is on the left side of the operator’s seat. Always make sure that you extinguish the cigarette closing the lid.

before

2-33


‘ll.l’l

TOOL BOX

This is inside the front of the right fender. It is used for storing tools.

2-34


11 .I2 USING CAR STEREO (MACHINES EQUIPPED 11.12.1

EXPLANATION

WITH CAB AND CAR STEREO)

OF PARTS

ADO54320

Symbol

@

Control function

Name

1 ON/BAL/VOL

Radio power

Control method

Explanation

PUSH

Each time the button between

ON/OFF

is pressed,

the radio is switched

ON and OFF. This switch

does not work when

the tape is being used. Volume

balance

PULL

Pull the knob and turn clockwise >

from the right speaker;

PULL

the sound 3

return the knob to its original

Turn to adjust the volume. Low 0

Sleep timer

Automatic

power

High

Radio power

ON

OFF

the volume

/

This switch

position.

has no effect on

of the alarm.

If the radio power ACC-OFF,

the sound to emphasize

from the left speaker.

After adjusting,

Volume

to emphasize

turn counterclockwise

is turned

ON when

the switch

the radio or tape starts and the power

is at goes OFF

after 1 hour. Control

of low

Release

push lock

sounds

Control sounds

From the center: Turn

CLOCKWISE

Turn

COUNTERCLOCKWISE

to BOOST to CUT

0

of high -

+

2-35


Symbol

Name

Control method

Recall Channel

1

@

Control function 1

Explanation

Push the button

Frequency

set in Channel

1 is called

up

for less than 2.0 seconds Save Channel

1

(memory)

Push the button

The frequency

for more than 2.0

(saved to memory)

in the display

is set to Channel

1

seconds See 1

2, 3. 5

0 @

When

4KlB

using

radio: Channel When

See 1

See 1 (only channel

See 1

See 1

4

using tape:

PUSH

Each time button

Dolby ON/OFF When

5APC

0

When

it is switched

between

is pressed,

it is switched

between

ON

See 1

See 1

PUSH

Each time

button

and OFF.

When

5

using tape:

APC ON/OFF

possible Manual

is pressed,

and OFF.

using

radio: Channel

is different)

down

Push the button

it is ON, APC (finding

ON

beginning)

is

in FWREW.

Frequency

goes down

one step (AM 9 kHz, FM 100 kHz)

for less than 0.5 seconds Seek down

Push the button

When

for more than

Seeks down

0.5

button

is being

pressed,

from frequency

changes

where

to fast forward.

button

is released.

seconds Manual

up

Push the button

Frequency

goes up one step (AM 9 kHz, FM 100 kHz)

for less than 0.5 seconds Seek up

Push the button

I

I

1 for more than

1 EJECT

1 EJECT

1PUSH

0.5

When

button

is being

pressed,

1Seeks

up from frequency

1When

using tape (PLAY/FF/REW),

changes

where

to fast forward.

button

is released.

seconds @

This can also be used when 0

REW

0

PRO

Rewind Changes

PUSH between

A side and B side

I

Rewinds

tape during

Push the button

Changes

between

during

direction

of the tape.

PLAY

tape

press to eject cassette.

switch

is at ACC-OFF.

PLAY or FF

A side and B side and changes

PLAY from

Push the button

FWREW

during

FF

Fast forward

PUSH

Push this button to fast forward

PS/AS

PS

Push the button

Receives

(Preset Scan)

for less than 0.5

However,

seconds

sensing.

AS

Push the button

When

(Auto Store)

for more than 0.5

band and stores frequencies

seconds

starting

Push this button to play tape during

the

FF/REW

FWREW

preset channels it skips channels Display

flashes

AS is turned

tape during

for 5 seconds which

during

do not yet have stop

PS.

ON, it searches

from Channel

from

in memory

1. When

PLAY/REW

each.

bottom (preset

of memory)

doing this, it searches

during the 1st cycle at LO and during the 2nd cycle at DX. However, so there twice.

it skips any frequencies

When

is also carried

2-36

that are already

is no case of the same frequency the illumination out at LO.

is lighted

stored,

being stored

up, the 2nd cycle


Symbo

Name

ARM

Control

Control

function

method

Alarm

ON/OFF

PUSH

Explanation Alarm when

Alarm/wake-up

PUSH

selection

can be turned

ON/OFF

time or frequency

If button

is pushed

it switches

when

between

by pushing

alarm time is being displayed,

alarm

and wake-up.

being

used, “A” is displayed

When

the time set for the alarm

is ON, the alarm

sound

This also works When

when

the wake-up

LCD channel the same

When

the alarm

on the LCD channel is reached

is

display.

and the alarm

from the PS on the right side. switch

is being

display.

button

is being displayed.

is at ACC-OFF. used, “U” is displayed

When

on the

the time set for the wake-up

as the actual time and the alarm

is

is ON, the radio

or tape starts to play. This also works when Stop alarm

The alarm

sound

stop the alarm,

switch

is at ACC-OFF.

stops after 3 minutes,

push any button

With wake-up,

the radio or tape stops after 1 hour, but if

you wish to stop the tape or radio,

II)),) (HI WAY)

Highway

traffic

information ON/OFF

(HW)

‘USH

push the radio power

button

(when

using the radio) or push the EJECT button

(when

using the tape) to turn the power

This key turns the highway This system

works

when

but returns to original

traffic

If the key is pressed setting

model

when

and released

OFF. The frequencies

Method

setting

is 1620 kHz.

2 seconds,

if the key is pressed is displayed.

the

for more The.

t I I)))

reception.

of canceling

1. Push HW 2. Turn

within

the other frequency

mark lights up during

ON/OFF.

using tape or radio (AM/FM),

is displayed;

than 2 seconds,

OFF.

information

are 1620 kHz and 1629 kHz; the default

present

but if you wish to

or turn the tape to IN.

( 1I I))) ).

radio OFF.

3. Insert cassette. 4. If HW is selected PRO/FF/REW/EJECT

when

playing

buttons

tape,

to cancel

push any of HW.

2-37


Symbol

0

Name

DISP

Control

Control

function

method

Display

selection

PUSH

Explanation Each time

it is turned

ON, display

changes

as follows.

Frequency IWhen using radio) \

I( Alarm time

-j

Present time

If the key is released, seconds,

the frequency

then the alarm

time

If no other key is operated, the present

is displayed

is displayed

the display

for 5

for 15 seconds.

then

returns

to

time.

To distinguish

between

time, the alarm

the present

mark f&j) flashes

time and the alarm

when

the alarm time is

being displayed. This key cannot Resetting

Setting

time

time,

alarm

present

be

used

WAkeys

(Alarm/present) Keep the DISP key pressed hour and theAkey

Resetting

minute

and second

DISP key and ARM

display,

time

display

ON/OFF

PUSH

Changing reception

band

time

the display

Each time the button

is less than 30 min., the

will advance

is pushed,

When

it is ON, “LD” is displayed

When

it is ON, the soft sounds

Push the button

AM 1 switches

to FM 1

for less than 2.0

FM 1 switches

to AM 1

seconds

AM 2 switches

to AM

FM 2 switches

to FM 1

Push the button

AM 1 switches

to AM 2

FM 1 switches

to FM 2

seconds

AM 2 switches

to AM

FM 2 switches

to FM 1

Only the memory

1 and 2 are switched

on the LCD. are boosted.

1

for AM

is

it will switch the loudness

1

for more than 2.0

time.

time

to the next hour.

ON and OFF.

FM 2 differs; the reception

2-38

and turn ARM ON.

will return to 00 set; with the minute

if the displayed

between

BAND

key to set the

will return to 00 min., and if the displayed

30 min. or more, Loudness

and use the v

to set the minute.

Keep the DISP key pressed The second

for

display

LOUD

auto tuning.

Use the DISP key to display the item to be set.

time

present

during

Use DISP key and

1 and AM 2 and for FM 1 and frequency

is the same.

for both AM and FM at the same


11 .12.2

PRECAUTIONS

WHEN USING

l

If the head is dirty, clean it with a head cleaning

0

Never touch the head with a magnet, hard object.

0

Use a pencil to wind the tape to the outside to remove any slack.

0

When

l

Put the tape in its case. Do not keep the tape in any of the following places. On top of the instrument panel Any place where it is exposed to direct sunlight Any place that is excessively humid Any place that is excessively dusty Any place where there is a strong magnetic field (near a speaker, etc.) Any place where there is high temperature (near the car heater, etc.)

0 0 0 0 0 0

not listening

to the cassette

screwdriver,

tape, always

tape. or any other

remove

it.

0

Use a C-60 (60 minute) tape. Avoid using longer tapes as far as possible. In particular, do not use C-120 (120 minute) tapes. These tapes easily get caught up in the machine.

0

When

0

Do not put anything port.

0

When cleaning, wipe off the dirt with a dry cloth. Never use any organic solvent such as thinner of benzene.

replacing

the fuse, always

use a 5A fuse.

except a cassette tape in the tape insertion

2-39


11.13 HANDLING AIR CONDITIONER (MACHINES EQUIPPED WITH CAB) 11.13.1

COOLING OPERATION

When the cooling is cooled.

operation

is carried out, the inside of the cab

Cooling (RECIRC) When the control switch and lever are operated as shown in the diagram, a cool breeze is sent out. Use this position when strong cooling is needed. l Press switch 0. e Place levers @ and @ in the position shown in the diagram. l Set switch @ to the desired position.

AD051626

Cooling (FRESH) If the air inside the cab is no longer fresh, set FRESH/RECIRC selector lever @ to FRESH to bring in fresh air. Keep the other switches at the same positions as for cooling (RECIRC). In this position, the inside of the cab is pressurized to prevent the entry of dust.

REMARK l

e l

If the cooling effect is reduced, set FRESH/RECIRC selector lever @ to RECIRC again. This increases the cooling effect. New Freon R134a is used as the refrigerant. The tightening torque for the air conditioner gas piping thread is as follows. Thread Discharge

size 22 x 1.5

Liquid 16 x 1.5 Suction

2-40

24 x 1.5

Tightening

torque

Nm (kgm)

19.6 - 24.5 (2 - 2.5) 11.8 - 14.7 (1.2 - 1.5) 29.4 - 24.3 (3 - 3.5)


11.13.2

HEATING OPERATION

When the heating is heated.

operation

is carried out, the inside of the cab

AD051628

Heating (RECIRCI When the control switch and lever are operated as shown in the diagram, warm air is sent out. Use this position when strong cooling is needed. l Place levers @ and @ in the position shown in the diagram. l Set switch @ to the desired position.

AD051629

I

Heating (FRESH) If the air inside the cab is no longer fresh, set FRESH/RECIRC selector lever @ to FRESH to bring in fresh air. Keep the other switches at the same positions as for heating (RECIRC). In this position, the inside of the cab is pressurized to prevent the entry of dust.

I

AD05162A

REMARK If the cab is not heated up sufficiently, turn FRESH/RECIRC selector lever @ back to RECIRC. This increases the heating effect.

Dehumidifying and heating Push switch 0. When temperature control lever @ is placed at the central position, dry warm air blows out. Keep the other switches at the same positions as for heating (FRESH). REMARK If this is used in spring and fall on rainy days when the air inside the cab is damp, there is no problem of the windows misting up, and the cab be warmed up to a comfortable temperature.

2-41

1


11.13.3

PRECAUTIONS WHEN USING AIR CONDITIONER

Carry out ventilation from time to time when using the cooler. l If you smoke when the cooler is on, the smoke may start to hurt your eyes, so turn the lever to FRESH to remove the smoke while continuing the cooling. l When running the air conditioner for a long time, turn the lever to the FRESH position once an hour to carry out ventilation and cooling. Be careful not to make the temperature in the cab too low. When the cooler is on, set the temperature so that it feels slightly cool when entering the cab (5 - 6°C lower than the outside temperature). This temperature difference is considered to the most suitable for your health, so always be careful to adjust the temperature properly.

l

Direction of vents when cooling l If the vents (left and right) in the middle of the dashboard are turned so that cold air plays directly on the cab door glass, moisture may condense on the outside of the cab door glass and reduce the visibility. (This occurs particularly in high temperatures.) If this happens, turn the vent fully to the rear and raise the air conditioner temperature setting slightly.

11.13.4

INSPECTION DURING OFF-SEASON

Even during the off-season, run the compressor at low speed for several minutes once a week to prevent the loss of the oil film at the lubricated parts of the compressor. (Run the engine at low speed and set the temperature control lever at the central position.) REMARK When the ambient temperature is low, if the compressor is suddenly run at high speed, it may cause failure of the compressor. Note that the system is set so that the compressor will not run when the cooler switch is turned on if the ambient temperature is less than 2 - 6.5”C.

2-42


11.13.5

PROCEDURE FOR REPLACING

RECEIVER

Replace the receiver once every two years. After replacing the receiver, add compressor oil. Turn the receiver at an angle and measure the oil remaining inside the receiver, then add the same amount of oil (Denso Oil 6) to fill the receiver. REMARK Depending be shorter.

on the condition

of use, the replacement

interval may

REMARK If the receiver is used when the desiccant has exceeded the water absorption limit, the refrigerant circuit may become clogged and cause failure of the compressor. Precautions when replacing receiver If the receiver is left for more than 15 minutes with the blind cover removed, the moisture in the air will be absorbed, and this will reduce the life of the desiccant. If you remove the blind cover, connect the piping quickly, evacuate the system and fill with refrigerant. l When removing the refrigerant from the refrigerant circuit, release it gradually from the low pressure side to prevent oil from flowing out.

l

11.13.6

CLEANING

AIR FILTER

If the air filter for the FRESH or RECIRC air intake becomes clogged, the cooling or heating capacity will drop. To prevent this, clean the air filter with compressed air once a week. For details of the cleaning method, see “24.2 WHEN REQUIRED”.

11.13.7

CHECK COMPRESSOR BELT TENSION REFRIGERANT (GAS) LEVEL

If the compressor belt is loose, or the refrigerant cooling is not carried out efficiently. For details, see “24.2 WHEN REQUIRED”.

AND level is low,

2-43


11 .I4 HANDLING HEATER (MACHINES EQUIPPED 11.14.1

METHOD

WITH CAB)

OF OPERATION

To heat quickly Set the switches to the position shown in the diagram right to carry out heating quickly. l Set FRESH/RECK selector lever 0 and temperature lever @ to the position in the diagram on the right. l Set blower switch @ to position 3 (HIGH).

on the control

NOTICE If heating is carried out continuously for a long period with the lever at the RECIRC position, the air inside the cab will become stale, so when the cab is warmed up, always set the FRESH/RECIRC selector lever @ to the FRESH position. In this position, the inside of the cab is pressurized to prevent the entry of dust. Normal use Set each switch to the desired

11.14.2

CLEANING

position.

AIR FILTER

If the air filter for the FRESH or RECIRC air intake becomes clogged, the heating capacity will drop. To prevent this, clean the air filter with compressed air once a week. For details of the cleaning method, see “24.2 WHEN REQUIRED”.

2-44


11.15 HANDLING

ACCUMULATOR

for a short time after the engine is stopped, if the work equipment control lever is moved to the LOWER position, the work equipment will move down under its own weight. After stopping the engine, always place the safety lever in the LOCK position. The accumulator is filled with high-pressure nitrogen gas, and it is extremely dangerous if it is handled in the wrong way. Always observe the following precautions. l Never make any hole in the accumulator or expose it to flame or fire. l Do not weld any boss to the accumulator. l When disposing of the accumulator, it is necessary to release the gas from the accumulator, so please contact your Komatsu distributor.

I The accumulator is a device to store the pressure in the control circuit, and when it is installed, the control circuit can be operated for a short time even after the engine is stopped. Therefore, if the control lever is moved in the direction to lower the work equipment, it is possible for the work equipment to move under its own weight. The accumulator is installed to the position shown in the diagram on the right. 11.15.1

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

1.

Lower the work equipment

and stop the engine.

2.

After stopping the engine, operate the control lever fully to the front, rear, left, and right to release the pressure inside the work equipment circuit. However, the pressure cannot be completely removed, so when removing the work equipment circuit, loosen the screw slowly, and never stand in the direction where the oil spurts out.

2-45

12. OPERATION

12.1

CHECK BEFORE STARTING

12.1.1 WALK-AROUND

ENGINE

CHECK Ah WARNING

I

I

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. Do not get on or off the machine from the rear. Using this position is dangerous because it is easy to slip and you cannot be seen from the operator’s compartment. Always use the handrail and step at the side when getting on or off the machine. When horizontal

inspecting, if the machine is at an angle, place to carry out the check.

move

it to a

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

in this section

before

starting

This handrail getting on or

1

6

the

must not be useu off the machine

6----k

This handrail getting on or

7 2-46

for

1 5

must not be used off the machine

for

AE208326

12. OPERATION

1.

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

2.

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

3.

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

4.

Check for oil leakage of oil from power train case, final drive case, hydraulic tank, hose, joints Check that there is no oil leakage. If any abnormality is found, repair the place where the oil is leaking. Check for leakage of oil from the undercover. Check the ground for traces of oil leakage.

5.

Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from rollers If any damage, wear, or oil leakage is found, repair the problem and tighten the bolts.

6.

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

7.

Check for damage to gauges, lamps on instrument panel, loose bolts Check that there is no damage to the panel, gauges and lamps. If any abnormality is found, replace the parts. Clean off any dirt on the surface.

8.

Check for damage to seat belt and mounting clamps Check that there is no abnormality in the seat belt or mounting clamps. If there is any damage, replace with new parts.

2-47

12. OPERATION

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

in this section

before

starting

Machines

the

eauiooed

with

Cab

CHECK MACHINE MONITOR 1. Turn starting switch @ to the ON position. 2.

Check that all monitor lamps and gauges light up for 3 seconds and the alarm buzzer sounds for about 2 seconds.

AE208338

Machtnes

REMARK If the lamps do not light up, there may be a failure or disconnection in the monitor, so please contact your Komatsu distributor.

eauitmed

with

CanODY

NOTICE When carrying out the checks before starting, do not relay only on the monitor. Always carry out all the items listed for the following check and maintenance. OFF

-

CHECK COOLANT

LEVEL, ADD WATER

I-

g

WARNING

START AD052290

-I

Do not remove cap 0, @ while cooling water is hot. Hot water may spout out. When removing cap @I, @ wait until the water temperature goes down and release radiator pressure little by little by loosening caps slowly, then remove the cap. 1. Remove radiator cap 0 and check that coolant is above the bottom of the strainer as shown in the diagram. If necessary, add water through filler of radiator cap 0. 2.

Check that there

is no abnormality,

such as oil in the coolant.

3.

If the water level is low, add water through fillers of both radiator cap @ and subtank cap 0. Add into the subtank up to the level above the bottom of strainer through filler of cap @ as shown in the diagram.

4.

To refill the radiator, first stop the engine and pour in water until the water overflows the filler opening. Then, start the engine, check the water level again after a five-minute idling, and add water if necessary.

5.

After adding

6.

If the volume of coolant possible water leakage.

2-48

water,

tighten

the cap 0,

added

Radiator

1

7ta?

AE20092B

Subtank

@ securely.

is more than

usual, check for

AE200938

I

12. OPERATION

CHECK FUEL LEVEL, ADD FUEL

-A When adding a fire. 1.

2.

AND 3.

WARNING fuel, never let the fuel overflow.

This may cause

Turn the engine starting switch to the ON position and check the fuel level with fuel level gauge @ on the monitor panel. After checking, turn the switch back to the OFF position.

428

After completing work, fill the fuel tank through fuel filler port 0. Check the fuel level with the fuel gauge at the fuel filler port. For details of the fuel to use, see “20. USE OF FUEL, COOLANT LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. After adding fuel, tighten the cap securely. Fuel capacity: 1050 1 (277 US gal, 231 UK gal)

REMARK l When dozing on a grade, make sure there is plenty of fuel in the tank so that the engine fuel line does not becomes aerated. l If breather hole @I on the cap is clogged, the pressure in the tank will drop and fuel will not flow. Clean the hole from time to time. AD054210

2-49

12. OPERATION

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the engine side cover on the right side of the chassis. 2.

Remove

dipstick @ and wipe the oil off with a cloth.

3.

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

4.

The oil level should

be between

the H and L marks on dipstick

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

AL116000

5.

If the oil is above the H mark, remove drain plug 0, loosen drain valve @ to drain the excess oil, then check the oil level again.

6.

If the oil level is correct, tighten close the engine side cover.

the oil filler cap securely

and

AL116450

REMARK l Check the oil level with the engine stopped. l When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking. l If the machine is at an angle, make it horizontal before checking. l When adding oil, remove the dipstick from the holder to release the air inside the crankcase.

2-50

12. OPERATION

CHECK OIL LEVEL IN POWER TRAIN CASE (INCL. TRANSMISSION, TORQUE CONVERTER AND BEVEL GEAR CASES), ADD OIL Start the engine and run at idling for 5 minutes, then check the oil level with the COLD side of dipstick 0. Remove

dipstick 0,

and wipe the oil off with a cloth.

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

be between



oil filler

0.

AND

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

5.

If the oil is above the H mark, pull out hose 0, and loosen drain plug @ to drain the excess oil, then check the oil level again.

6.

If the oil level is correct,

tighten

the oil filler cap securely.

REMARKS l If the machine is at an angle, make it horizontal before checking. l When the engine is stopped, the oil level will rise, so it is impossible to check the oil level correctly. When checking while the engine is running, run the engine at idling and check with the HOT side of dipstick 0. l When working on a slop of more than 20”, check that the oil is up to the H level.

---_w---

AE20WOE

2-51

12. OPERATION

CHECK DAMPER CASE OIL LEVEL, ADD OIL 1. Remove dipstick 0, and wipe the oil off with a cloth. 2.

Insert dipstick again.

@ fully into the dipstick

3.


be between

holder,

4.

,I

I II 11111/I

\-

then pull it out


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

AND

I

n the dipstick

For details of the oil to use, see “20. USE OF FUEL, COOLANT LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. If the oil is above the H mark, drain the excess oil from plug. After draining the oil, check the oil level again.

drain

REMARKS l Check the oil level with the engine stopped. l When checking the oil level, if the machine is at an angle, move it to a horizontal position before carrying out the check.

CHECK BRAKE PEDAL TRAVEL 1. Depress the brake pedal all the way until it stops. 2.

The distance of travel at the center of the pedal (position in the diagram on the right) should be 65 - 85 mm (2.56 - 3.35 in).

3.

When this value exceeds the specified range, or the brake fails to work, please contact your Komatsu distributor for adjustment.

2-52

65-65m

AW53630

CHECK OIL LEVEL IN HYDRAULIC

A

TANK,

ADD OIL

WARNING

When removing the oil filler cap, 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. NOTICE Do not add oil if the level is above the H line. This will damage the hydraulic equipment and cause the oil to spurt out. 1.

Lower the blade to the ground, about 5 minutes before checking H and L in sight gauge 0.

stop the engine and wait for oil level. If oil level is between

Proper range L

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

2.

c

oil filler

AD053410

0.

AND


REMARK When horizontal


A

move

it to a

WARNING

If oil has been added to above the H mark, stop the engine and wait for the hydraulic oil to cool down. Then remove drain plug 8, loosen drain valve 0, and drain the excess oil.

2-53

12. OPERATION

CHECK DUST 1. Open the check that portion of

INDICATOR engine side cover on the right side of the chassis, the red piston has not appeared in the transparent dust indicator 0.

2.

If the red piston has appeared, clean or replace the element immediately. For details of the method of cleaning the element, see “24.2 WHEN REQUIRED”.

3.

After checking, cleaning, and replacing, press the knob of dust indicator @ to return the red piston to its original position.

AD052091

CHECK ELECTRIC WIRINGS

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. e Battery 0 Starting motor l Alternator Please contact your Komatsu distributor for investigation and correction of the cause.

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

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

2-54

CHECK THAT LAMPS LIGHT UP 1. Turn the key of starting switch to the ON position.

I

OFF

-START AD052290

2.

Turn the front lamp and working lamp switch to the ON position and check that the front lamps and working lamp light up.

AD051790

I 3.

Turn the rear lamp switch to the ON position and check that the rear lamps on the left and right fenders light up. OFF

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

ON

lJ

AD051790

CHECK HORN SOUND 1. Turn the key of starting

switch to the ON position.

OFF

-START AD052290

2.

Press the horn switch

and check that the horn sounds.

2-55

12. OPERATION

CHECK BACKUP ALARM SOUND 1. Turn the key of starting switch to the ON position.

OFF

-

START AD052290

2.

Set the joystick to the REVERSE position. The buzzer must sound immediately. The buzzer will continue to sound until the joystick is moved to the NEUTRAL or FORWARD position.

CHECK SEAT BELT FOR WEAR OR DAMAGE Check the belt and mounting clamps, and if they are worn damaged, replace the seat belt.

2-56

or

12. OPERATION

12.1.3 ADJUST

OPERATOR’S

A l

l

SEAT

WARNING

Adjust the seat position at the beginning of each shift or when operators change. Adjust the seat so that the brake pedal can be depressed all the way with the operator’s back against the backrest. Fore-aft Pull up release Fore-aft

adjustment of seat handle 0, set the seat to the desired position, the handle. adjustment: 160 mm (6.3 in) (12 stages)

Weight adjustment of seat Turn knob @ so that the indicator of the weight inside knob @ shows your own weight. Turn the knob to adjust the weight as follows. To make LIGHTER, turn COUNTERCLOCKWISE To make HEAVIER, turn CLOCKWISE The weight - 117.8 lb) @

Adjusting

can be adjusted

reclining

within

then

display

(kg)

a range of 50 - 120 kg (110.3

angle

NOTICE When reclining the seat back to the behind, and adjust to a suitable position. Pull lever 0, set the seatback operate, then release the lever.

ADO53670

rear,

to a position

check

where

the

space

it is easy to

2-57

@ 1.

SEAT ANGLE When lever @ is pulled up, the seat front. (5 stages) 1. To raise the seat front, your weight to the seat 2. To lower the seat front, your weight to the seat

it is possible

to adjust the angle of

keep the lever pulled up and apply backrest. keep the lever pulled up and apply front.

2.

When lever @ is pulled up, it is possible to adjust the angle of the seat back. (5 stages) 1. To raise the seat back, keep the lever pulled up and stand up slightly. 2. To lower the seat back, keep the lever pulled up and apply your weight to the seat back.

@

ADJUSTING VERTICAL HEIGHT OF SEAT Pull up levers @ and @ in turn and adjust the angle. adjusting, release the levers and lock them. (Vertical adjustment amount: 5 stages, 60 mm (2.4 in))

@

l

2-58

After

SEAT ADJUSTING DIRECTION Move lever @ back to release the lock, then turn the seat to the right by hand. It is possible to change the direction of the seat to the 15” position. After changing the angle of the seat, return the lever securely and lock it in position. Adjusting the seat angle to the right is done to make it easier to carry out ripper operations or scraper towing operations.

12.1.4 OPERATIONS ENGINE

AND CHECKS BEFORE STARTING

A

WARNING

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

1.

Check that parking lever @ is LOCK position, the engine will If parking lever @ is placed at returned to neutral even if it position.

2.

Check that joystick

3.

Check that the blade is lowered to the ground and that blade control lever @ is at the HOLD position. If it is at the FLOAT position, the engine will not start.

Machines

wuiD

Machines

eauimed

with

CanODY

locked. If this lever is not at the not start. the LOCK position, joystick @ is is at the FORWARD (REVERSE)

ACM51665

@ is at the 1st position.

2-59

12. OPERATION

5.

Check that the ripper is lowered

6.

Check that safety lever @ is locked. If safety lever @ is locked, the blade control lever is returned the HOLD position even if it is at the FLOAT position.

2-60

to the ground.

to

12.2 STARTING ENGINE

Machines

eouimed

with

cab

Machines

eauitmed

with

CanODY

12.2.1 NORMAL STARTING 4h 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.

Pull fuel control position.

lever @ a little toward

you from the low idling

AE208508

2.

Turn the key of starting

switch @ to the START

position.

OFF

START AD052391

3.

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

OFF I

START ADO52291

2-61

12. OPERATION

12.2.2

STARTING IN COLD WEATHER (Starting with APS (Automatic Priming

When

starting

in low temperatures, a

System))

do as follows.

WARNING

Never use starting aid fluids as they may cause explosions.

NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds. If the engine fails to start, repeat steps 3 and 4 after waiting for about 2 minutes.

Machines

eauioped

with

Cab

B51B

Machines

eauiDDed

with

CanODY

1. Open fuel valve @ for the APS.

2.

Turn the key of starting switch @to the engine for IO seconds.

the START position

and run

OFF

START AD052391

3.


switch @ to the OFF position.

OFF

START AE20853B

4.

Pull fuel control position.

lever @ a little toward

you from the low idling

AE20854B

2-62

12. OPERATION

5.


switch

@ to the ON position. OFF

-

START AD052290

6.

When preheating switch @ is turned @ will also light up, and preheating

ON, preheating pilot lamp will automatically start.

AD051790

7.

Keep in this condition until preheating pilot lamp @ goes out. (Preheating is completed after approx. 12 seconds, and the lamp goes out.)

0 _ Ins

A0207950

8.

When preheating pilot lamp @ goes off, turn the starting switch key to the START position and start the engine.

OFF

START

9.

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

OFF I

START ADO52291

10. When the engine becomes normal,

runs smoothly put preheating

and the color of exhaust gas switch @ in the OFF position.

2-63

12. OPERATION

REMARK l

The time which should elapse before turning the preheating switch off varies with the ambient temperature. Confirm the time to the table below. Ambient

Time from the starting of engine until turning off the preheater switch

temperature

1 - 2 minutes

15 - 0°C Below 0°C

I

3 - 5 minutes

REMARK l l

l

l

When the air temperature is below 15X, leave the valve open. If Step 6 to 8 are carried out without performing Step 1, it may shorten the nozzle life. Be sure to carry out Step 1. If the engine does not start through the steps specified above, return the fuel control lever to the engine stop position and repeat Steps 2 to 8 at an interval of approx. 2 minutes. If the switch is moved to START while the preheating pilot lamp is on in Step 8, glow plugs will get wet, making firing impossible. This will make it difficult to start the engine.

12.2.3 SPECIAL STARTING FUEL)

(AFTER RUNNING

OUT OF

When starting the engine after it has run out of fuel, first add fuel, then bleed the air from the fuel system before starting. For details on how to bleed the air, see “24.5 500 HOURS SERVICE.”

2-64

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 Avoid abrupt acceleration until warm-up run is completed. l Do not run the engine at low idling or high idling for more than 20 minutes. If it is necessary to run the engine at idling, apply a load or run at a medium speed from time to time. l If engine oil pressure monitor @ flashes or the buzzer sounds intermittently, stop the engine and check for the cause. l

AD208578

12.3.1 NORMAL OPERATION 1. Pull fuel control lever @ to the center position between LOW IDLING and HIGH IDLING and run the engine at medium speed for about 5 minutes with no load (warm-up run). 2.

3.

After warm-up run is completed, check gauges and caution lamps for proper operation. If any abnormality is found, repair it. Continue to run the engine at light load until engine water temperature gauge indicator @ falls within the green range. Check that there is no abnormal exhaust gas color, vibration. If any abnormality is found, repair it.

noise,

AE20854B

or

2-65

12. OPERATION

12.3.2 IN COLD AREAS Pull fuel control lever @ to the center position between LOW IDLING and HIGH IDLING and run the engine at medium speed for about 10 minutes with no load (warm-up run).

AE208546

Operate blade control lever @ to the RAISE position, then keep the blade raised to the maximum height and continue to relieve the circuit for IO minutes. Finally, operate blade control lever @ and ripper control lever @ to operate all the blade and ripper cylinders several times. If the oil temperature in the work equipment is not properly raised, there will be a time lag in the response of the work equipment and steering. After warm-up run is completed, check gauges and caution lamps for proper operation. If any abnormality is found, repair it. Continue to run the engine at light load until engine water temperature gauge indicator @ falls within the green range. REMARK If the oil temperature in the power train is not raised properly, it will take longer to accelerate to the maximum speed. 5.

2-66

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

noise,

or

Right tilt

72.4 MOVING MACHINE a

WARNING

When moving machine, check that the area around the machine is safe, and sound the horn before moving. Clear all personnel from the machine and the area. Clear all obstacles from the path of the machine. Use extreme care when reversing the machine. Note there is an blind spot behind the machine. When starting on slopes, always keep brake pedal @ depressed even after releasing parking lever 0. When starting to travel up a steep hill, pull fuel control lever 0 fully to run the engine at full throttle, and keep brake pedal @ depressed. Use joystick @ to select Ist, then move it in the direction of travel and slowly release brake pedal @ to allow the machine to move off gradually. When the machine has started moving, release the brake pedal completely. Machines

1.

Set parking

eauimed

with

CanODv

I

lever @ to the FREE position.

A0051668 2.

Set joystick

@ to the desired

position.

3.

Set safety lever @ for blade control lever @ to the FREE position.

lever @ and ripper control

2-67

12. OPERATION

4.

Operate blade control lever @ and ripper control lever @ to the RAISE position, raise the blade 40 - 50 cm (15.8 - 19.7 in) from the ground, and raise the ripper to the maximum height.

5.

Pull fuel control lever 0, raise the depress decelerator pedal @.

6.

Move joystick @ to the F (FORWARD) or R (REVERSE) position, gradually release decelerator pedal @ and allow the machine to move off.

2-68

engine

speed,

and fully

Hold

I

Raise

12.5

SHIFTING

GEAR

It is possible to change the speed range when traveling, is no need to stop the machine 1.

Move joystick

0

when

to the desired

shifting

Machines

eouiooed

with

cab

Machines

esuiooed

with

canooy

so there

gear.

gear position

to shift gears.

Gear shifting Rotate the joystick 30” to carry out gear shifting operation. Position @: 1st Position @: 2nd Position 0: 3rd For details of the maximum speed at each speed range, see “25. SPECIFICATIONS”.

REMARK When gear shifting the rear of the joystick 1st: qis displayed on 2nd: [z3is displayed on 3rd: His displayed on

operation is will display the display the display the display

carried out, the display panel at the speed range. panel panel panel

2-69

12. OPERATION

12.6

;;;F;Ni

BETWEEN

FORWARD

When switching between FORWARD that the direction of travel is safe.

IA

AND

and REVERSE,

check first

WARN’NG

A

CAUTION

Machines

eouimed

with

Canopy

There is no need to stop the machine even when switching between FORWARD and REVERSE. To increase safety, operator comfort, and the life of the transmission, leave the engine running at full speed, and always depress the decelerator pedal to lower the engine speed.

1.

Depress

decelerator

pedal @ and reduce the engine

speed.

I 2.

Return joystick @to the neutral position, reduce the speed, then depress brake pedal @ and stop the machine.

3.

After depressing desired position.

4.

Release

decelerator

decelerator

pedal 0,

move joystick

pedal @ to raise the engine

REMARK When the gear shift lever is placed warning buzzer will sound.

in REVERSE,

AD052400

N

J-P

Forward

@ to the

speed.

the REVERSE

AD052401

2-70

12.7

STEERING

MACHINE turning

1

l

Avoid

as much as possible

the machine

l

Never

make a pivot turn at high speed.

l

while

traveling,

incline

eouiooed

Machines

eauiDDed

with

Catl

on a slope.

12.7.1 NORMAL TURNING To turn the machine direction to turn.

Machines

joystick

with

CanODY

@ in the

Turning gradually to left while traveling forward If the joystick is pushed forward and moved partially to the left (L), the steering clutch is disengaged and the machine turns gradually to the left.

I

L

REMARK When turning gradually to the right, push the joystick forward, and move it partially to the right. Do the same when traveling in reverse.

u l

Making sharp turns to left while traveling forward If the joystick is pushed forward and moved fully to the left (L), the steering clutch is disengaged, the brake is applied, and the machine turns sharply to the left.

AE2086ao

I

REMARK When making sharp turns to the right, push the joystick forward, and move it fully to the right. Do the same when traveling in reverse.

AE208690

2-71

12. OPERATION

12.7.2 TURNING WHILE DESCENDING A SLOPE On steep downhill slopes where the machine may travel under its own weight, or on downhill slopes where it is being pushed by a towed machine, the machine will steer in the opposite direction, so do as follows.

l

Turning gradually to left while traveling forward If the joystick is pushed forward and moved partially to the right (RI, the machine turns gradually to the left. (Becomes reverse steering)

REMARK When turning gradually to the right, push the joystick forward, and move it partially to the left. (Becomes reverse steering) Do the same when traveling in reverse.

l

Making sharp turns to left while traveling forward If the joystick is pushed forward and moved fully to the left (L), the machine turns sharply to the left. (Does not become reverse steering)

REMARK When making sharp turns to the right, push the joystick forward, and move it fully to the right. (Does not become reverse steering) Do the same when traveling in reverse.

AE208710

2-72

/

12.8

STOPPING

MACHINE

a

Machines

eQuitmed

with

cab

WARNING

Avoid stopping suddenly. Give yourself ample room when stopping. When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, place the parking lever in the LOCK position and insert blocks underneath the track shoes. As an additional safety measure, thrust the blade into the ground. If the work equipment control lever is touched by accident, the work equipment may move suddenly, and this may lead to a serious accident. Before leaving the operator’s seat, always operate the safety lever to place it securely at the LOCK position.

1.

Depress

brake pedal @I to stop the machine.

NOTICE If the brake is depressed when the engine speed or travel speed is high, the brake disc may make a slipping sound. Normally, depress decelerator pedal @ to reduce the engine speed and travel speed before depressing the brake. AD053830

2.

Place joystick @ at the neutral to 1st.

position

and set the speed range

ME08750

2-73

12. OPERATION

12.9

PRECAUTIONS

12.9.1 PAY ATTENTION When the red range gauge while operating, temperature.

12.9.2 METHOD

FOR OPERATION TO GAUGES lights on the power train oil temperature reduce load and wait for lowering of

OF USING STEERING CLUTCH

If the steering clutch one side is used frequently or if many gradual turns are made with steering clutch half-engaged, the steering clutch will wear out in a short time. Design the travel road well and steer the machine properly.

12.9.3 PERMISSIBLE

WATER DEPTH

When operating in water, always keep top surface @ of the track frame above the surface of the water. Also, be careful that the engine cooling fan will not come in contact with water. The fan can be damaged.

12.9.4 PRECAUTIONS

WHEN TRAVELING

UP OR DOWN

HILLS Method of using decelerator pedal When stepping on the decelerator pedal while going uphill, climbing ability will be reduced and the machine will stop. Furthermore, the engine sometimes will stall. Use engine as brake When going downhill, shift gear shift lever into low speed to run engine at slow speed and travel down slope using the engine as a brake. Do not move the joystick to the N position. When traveling down hills of more than 15”, shift down to 1st speed (RI or Fl). Braking when traveling downhill While descending a slope using the engine as a brake, also apply the brakes. Failure to brake may result in overrunning, causing engine trouble.

2-74

12.9.5 PRECAUTIONS

ON SLOPES

Be careful of fuel level If the fuel level in the slopes, the engine may machine or the swaying stop, so be careful not to too low.

fuel tank becomes low when working on suck in air because of the angle of the of the machine. If this makes the engine let the fuel level in the fuel tank become

Be careful of oil level When operating machine on sloped areas of more than 20”, fill every place with oil to H level. Precautions when engine stops on slopes If the engine stops while working or traveling on a hill, immediately depress the brake pedal to bring the machine to a complete stop.

12.9.6 METHOD

OF USING BRAKES

The following actions cause premature damage to the brakes, so avoid such operations. o Using emergency brake at full speed o Using brake with engine running at full speed in first gear (Fl, RI) (Machine stall condition) REMARK Always depress the decelerator before actuating the brakes.

pedal to lower the engine speed

2-75

12.9.7 IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS (MACHINES EQUIPPED WITH CAB) Always keep the door closed when traveling operations. If the door is left open, there is danger obstacles or strong vibration.

or carrying out of damage from

12.9.8 IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW (MACHINES EQUIPPED WITH CAB) l l

For safety reasons, do not install anything to the cab glass that will obstruct the view. Always keep the glass clean to ensure safety during operations.

12.9.9 PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY AND ROPS STAY &b WARNING The cab stay and ROPS stay cause blind spots. When operating, always be sure to check carefully that there is no obstacle or worker in the surrounding area.

2-76

12. OPERATION

12.10 WORK POSSIBLE

USING

BULLDOZER

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

increase the

12.10.1 DOZING A bulldozer digs and transports dirt in a forward direction. Slope excavation can always be most effectively carried out by proceeding from the top downward. With the dual tiltdozer, the angle of the blade cutting edge can be changed, so the angle of the cutting edge can be adjusted during the digging operation to improve the efficiency of the work.

12.10.2

INTO HARD OR FROZEN GROUND OR DITCHING

CUlTlNG

For digging and ditch excavation of hard or frozen ground, tilt the blade. Even hard ground can be dug effectively by a tilted or angled blade. If the ground is harder, use a ripper attachment for better efficiency.

I 12.10.3

FELLING TREES, REMOVING

AE208780

STUMPS

NOTICE Do not up root trees or stumps or fell trees by angling or tilting the blade. For trees with a diameter of 10 - 30 cm (3.9 - 11.8 in), raise the blade high and push 2 or 3 times to fell the tree. Next, travel in reverse, and dig the corner of the blade into the ground to cut and dig up the roots. When doing this, never hit the tree at high speed or apply shock to fell the tree.

12.10.4 l

l

PUSHER OPERATIONS

When carrying out pusher operations, always install a pusher plate. When approaching the other machine, depress the decelerator pedal to reduce the engine speed and approach slowly. After coming into contact, raise the travel speed slowly and push with full power. AE208EOO

2-77

1

12. OPERATION

12.10.5

SMOOTHING

NOTICE Avoid smoothing blade.

on rocky or stony ground.

It can damage

the

When finishing the ground surface to a smooth finish after digging or filling operations, keep a full load of soil in the blade and operate the blade up or down in small movements while traveling forward. When leveling windrows or ruts left by the tracks, set the blade to the FLOAT position, travel at low speed in reverse and drag the blade over the ground surface.

2-78

12. OPERATION

12.11 RIPPER OPERATION 12.11.1

EFFECTIVE METHOD

The optimum perpendicular

OF USE

K+P5’

1

digging angle for the shank is when the shank is to the ground (ripping angle: 45”- 50”).

In comparatively soft rock (seismic velocity: 1500 m/s or below), it is also possible to carry out ripping with the shank tilted to the rear.

AE105480

On comparatively hard rock, if ripping is carried out with the shank tilted to the rear, there will be excessive wear of the point of tip 0, and the self-sharpening ability will be lost. During ripping operations, if the shoes slip because of boulders or resistance from the bedrock, use the tilt cylinder. When picking up a stone, advance the machine at a fixed gear speed (Fl or F2).

AE105490

REMARK When raising boulders or digging up rockbed, do not put the transmission in neutral. If the transmission is in neutral, the reaction of the tilt cylinder will push the machine back. Always operate the machine with the transmission in FORWARD. REMARK Choosing a suitable ripper point to match the type of rock is one of the most important elements in using the ripper effectively. Ripper points are available for different types of rock, so select the most suitable ripper point from the list. For details, see “30. PROCEDURE FOR SELECTING RIPPER POINT.”

2-79

12. OPERATION

12.11.2

DIGGING

UP BOULDERS OR ROCKBED

During ripper operations, if stubborn boulders or rockbed cause the travel speed to become slower, operate the tilt cylinder to dig up the boulder/rockbed.

12.11.3

OPERATING

ON SLOPES

When using the variable ripper, cylinder to select dimension L.

adjust

the

length

of the tilt

I

12.11.4

TANDEM

i_'

AE208840

OPERATION

When it is impossible for one machine to carry out ripping under its own power, ripping can be carried out in tandem.

AE208860

2-80

12.11.5 1.

2.

METHOD

OF OPERATING

PIN PULLER

This is used only on machines equipped with a giant ripper. Stop the machine in a safe place and lower the shank to the ground. Operate the pin puller controller switch to the PULL OUT position and remove the mounting pin.

I 3.

Move the ripper up or down to set to the desired shank position.

AE20d218

Top surface De pth

Align with surface of

4.

Operate the pin puller control switch to insert the mounting pin. If the pin does not match the position of the hole in the shank, set the pin puller control switch to the PUSH IN position and slowly move the ripper up or down.

REMARK When raising the pin position to increase the digging a long protector to prevent wear of the shank.

.“,,/&, Push

depth, use

I

in

AE20094B

2-81

12. OPERATION

12.12 ADJUSTMENT

OF WORK EQUIPMENT a

WARNING

When adjusting, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a safe condition, then stop the engine and lock the work equipment securely with the safety lock. 12.12.1 TILTING

BLADE ADJUSTMENT THE TILTDOZER

NOTICE The maximum amount of tilt is 1065 mm (3.5 f-t). (When semi-U blade is used.) Be sure not to exceed 1065 mm (3.5 ft) for the tilt.

the

The tiltdozer can be tilted by manipulating the blade control lever as indicated below. Tilting adjustment to the right: 650 mm (2.1 ft) or more Tilting adjustment to the left: 650 mm (2.1 it) or more (When the semi-U blade is used.) When a larger tilting adjustment is required, proceed as follows: By turning brace @I with handle bar @ secured to the L.H. brace, the blade can be tilted up to the max. adjustment of 1065 mm (3.5 ft) by changing the length of the brace (!I). Standard distance (!J) between joints is 1552 mm (5.1 ft).

ADJUSTING

SHIM

IN BLADE CYLINDER

CAP

Set the standard shim adjustment in the blade cylinder cap to 4 mm (0.16 in). Remove shims to balance the wear of the cap and the ball at the end of the piston rod. The proper clearance to be maintained with the shims is 0.2 to 0.5 mm (0.008 to 0.02 in). PIE200378

2-82

ADJUSTING

BRACE

A

WARNING

If maintenance is carried out with the engine running, always have one worker sitting in the operator’s seat while another worker carries out the maintenance. Both workers must mutually confirm the safety during the operation. Start the engine and use inching control to tilt to the left and right. Adjustment can be carried out easily by rotating the brace handle while raising and lowering. l When extending the brace Set the blade at FLOAT and rotate the brace handle to adjust.

REMARK When operated in this way, the blade is tilted, so the handle gradually becomes heavier. When this happens, return the blade from the tilt position to the horizontal position and turn the handle again according to the procedure given above.

SHIM ADJUSTMENT Adjust the thickness of shim so that the ball joint play (7 points) in the axial direction (shown by the arrow) does not exceed 1 mm (0.04 in).

Remove

shim @ and tighten

bolts @ to eliminate

the ball joint

play. Measure

clearance

“A” and remove

bolts 0.

Install shim @ having its thickness of “A” mm to “A + 1” mm (“A” in. to “A + 0.04” in) in place with bolts 0. Confirm that ball joint can move smoothly

after tightening

bolts.

AE20928C 1

2-83

12. OPERATION

12.12.2

ADJUSTING

ADJUSTING Mounting according to bottom hole, top hole.

RIPPER

DIGGING DEPTH pin holes are provided in the shank and these are used the desired digging depth. For normal use, use the and when particularly deep digging is needed, use the

To change the digging depth, do as follows. 1. Place a pointed object on the tip of pin 0, then hit with a hammer to remove from the opposite side. 2.

Remove

pin @ and change

the position

of the shank hole.

3.

Insert pin @ partially

a

The pin is made of one piece, so insert it partially by hand then knock it in with a hammer. When a giant ripper is installed, use the pin puller. For details, see “12.15.4 METHOD OF OPERATING PIN PULLER”.

by hand then knock it in with a hammer. AD052740

0

REPLACING POINT AND PROTECTOR To protect the shank, if the protector and point installed to the tip are worn, replace them. Place a pin remover on the pin marked by the arrow, then hit with a hammer to remove from the opposite side. REMARK The pin is a unitized type, so insert the pin partially knock it in fully with a hammer.

2-84

by hand, then

w

AL116090

12. OPERATION

12.13 EFFECTIVE SYSTEM

USE OF MODE SELECTION

Lock UD mode switch

Economy selector

mode switch

Slow reverse mode selector switch

Shoe mode

slip se\ switch

Rock

selection

mode

Selector

switch

Selecting the mode to match the type of work and quality of rock or soil makes it possible to carry out operations effectively. When all the mode selection switches are OFF, the selection is suitable for conventional digging and dozing of bedrock. When carrying out special rock-crushing operations, it is possible to turn all the mode switches ON when the starting switch is turned ON, so please contact your Komatsu distributor for advice. It is impossible to use any combination of the lock-up mode and any other mode. The economy mode, reverse slow mode, and shoe slip control mode can be used independently or in combination.

2-84-l

12. OPERATION

12.13.1

SELECTION

OF MODE

1. DOZING OPERATIONS LOCK UP MODE l l

Speed ranges that can be used: All speed Applicable operations: Dozing loose soil

ranges

When the lock up mode is turned ON, direct drive or torque converter drive are automatically selected according to the load.

AW22525B

ECONOMY MODE l l

ON

Speed ranges that can be used: Fl Applicable operations: Hauling after ripping, dozing blasted rock When the economy

mode is turned ON, it is automatically

set to

0 ECONCW MODE

1 2 0 0

[Il. Carry out dozing operations in this condition, then set to 121 and carry out operations. From this test, select the matching that gives power and low shoe slip ratio (frequency of deceleration operation). Mode [II is set to approx. 90% of full power and mode [21 is set to approx. 70%.

ON

0

AW22526E

2. RIPPING OPERATIONS SHOE SLIP CONTROL Speed ranges that can be used: Fl Applicable operations: Ripping When the shoe slip control switch is turned ON, the rock selection mode is automatically set to [31. Carry out operations in this condition, and if the shoe slip ratio is too high, press a switch in the hard direction to set the mode to [41 or 151. If the shoe slip ratio is low and there seems to be lack of power, press the switch in the soft direction to set the mode to [21 or [Il. l l

REMARK With the shoe slip control, after the gearshift lever is shifted to Fl, the machine will start to move when the ripper lever is operated to LOWER or TILT, so there is no need to turn the switch ON/OFF when carrying out dozing and ripping operations in turn.

2-84-2

SHOE SLIP CONTROL 12345 00000 AW225270

3. l l

I

SLOW REVERSE MODE Speed ranges that can be used: RI, 2, 3 Applicable operations: Traveling on bedrock

This is used when dozing bedrock.

traveling

in reverse

after

ripping

II

!

or when

The travel speed in reverse slow mode is set to approx. 80% of the full travel speed. When using the economy mode and shoe slip control mode together, the travel speed differs according to each mode. With shoe slip control, the travel speed in modes [I] - [5] is set to approx. 85 - 65% of the full travel speed.

,

I

I=

I II

SLOW REVERSE MOOE

ON

0

/I/

2-84-3

12.13.2

PROCEDURE FOR SELECTING WORK

Use the table

I

below

to select

the

mode

Nature and needs of operation

MODE ACCORDING

that

I

matches

Operation

the

nature

TO NATURE OR NEEDS OF

or needs

of the operation. Name of mode to select

of system and effect

By locking up the torque converter and using direct drive, the effective transmission of power is increased and the oroduction oer unit of fuel is further 1imoroved.

I

needed even if the type of rock or soil changes

The engine output is set specially for dozing (modes 1 or 2) to give both power and fuel saving. With this mode, the following can be achieved: @ Reduction in frequency of deceleration operations _ - @ Reduction in shoe slip @ Reduction in fuel consumption

,

L Both power and _ good fuel consumption are needed ~ No operator fatigue even when operating for long hours ~

Economy mode (~1 [Two modes are available to match the type of rock or soil]

The reverse speed is lowered when -traveling on bedrock to improve the ride for the operator.

The reverse speed is lowered when traveling on bedrock to improve the ride for the operator.

-

The following items are always detected: (1) Engine output _ (2) Drawbar pull (3) Shoe slio ratio If any of these values goes too high, the Easy to operate engine output is automatically controlled I I to the optimum for the actual operation. As a result, the following are achieved: @ No need for deceleration operations Both power and reduced fuel @ No need for the operator to watch consumption are desired for shoe slippage @ Reduction in shoe slippage In addition, a selection of five modes is available to cover a wide range of rock Low repair costs for underconditions (hardness). The power can be carriage selected to match the type of rock, so it is possible to achieve both power and reduction in fuel consumption.

H Ripping

No operator fatigue even when operating for long hours

-

Shoe slip control (%)

mode

(~4: The dozing economy mode, reverse slow mode, and ripping shoe slip control mode can all be selected independently or in combination. In addition, it is possible to select and correct as needed, so it is possible to achieve precise matching for various types of operation.

2-84-4

12.14 PARKING

MACHINE

a

Machines

Depress

with

CatI

WARNING

Avoid stopping suddenly. Give yourself ample room when stopping. When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, place the parking lever in the LOCK position and insert blocks underneath the track shoes. As an additional safety measure, thrust the blade into the ground. If the work equipment control lever is touched by accident, the work equipment may move suddenly, and this may lead to a serious accident. Before leaving the operator’s seat, always operate the safety lever to place it securely at the LOCK position.

1.

eauimed

Machines

eouimed

with

CanODY

brake pedal Q) to stop the machine.

NOTICE If the brake is depressed when the engine speed or travel speed is high, the brake disc may make a slipping sound. Normally, depress decelerator pedal @ to reduce the engine speed and travel speed before depressing the brake. ADO53830

2.

Place joystick @ at the neutral to 1st.

position

and set the speed range

AE208750

2-85

12.

OPERATION

3.

Operate

parking

lever

@ to lock the brakes.

AD051665

4.

Operate blade control lever LOWER position, and lower

5.

Set blade position.

6.

Lock blade control lever 0.

control

@ and ripper control the blade and ripper

lever @ and ripper control lever @ to the HOLD

lever @ and ripper

12.15 CHECK AFTER FINISHING 1.

lever @ to the to the ground.

control

lever @ with safety

WORK

Use the meters and caution lamps to check the engine water temperature, engine oil pressure, fuel level and power train oil temperature.

2-86

p

o

0

12.16 STOPPING

ENGINE

Machines

eauiDDed

with

Cab

Machines

eauimed

with

CanoDY

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 low speed to allow it to cool gradually, then stop it.

1.

Place fuel control lever @ in the low idling position and run the engine at low idling speed for about 5 minutes to allow it to gradually cool down.

AE20983E

2.

Push fuel control the engine.

lever @ in the engine

stop position

and stop

3.

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

OFF

A0051781

2-87

12. OPERATION

12.17 CHECK AFTER STOPPING

ENGINE

1. Walk around the machine and check the work equipment, paintwork, and undercarriage, and check also for leakage of oil or water. If any abnormalities are found, repair them. 2.

Fill the fuel tank.

3.

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

4.

Remove

any mud stuck to the undercarriage.

12.18 LOCKING To prevent vandalism, there are locks at the following places. Places that can be locked with the starting switch key. l Right and left engine side cover 0 (left side: 3 places, right side: 2 places) l Electrical component box inspection cover (left) @ l Cab door opener @ l Cap with lock @ l Radiator cap l Fuel tank cap l Hydraulic oil tank cap 0 Power train oil filler cap l Battery inspection cover @ l Tool box inspection cover @ Commercially places. l

2-88

available

Power train centralized inspection cover 0

locks can

pressure

be fitted

detection,

to the

following

power train oil level

AE209260

12. OPERATION

12.19 TIPS FOR LONGER

UNDERCARRIAGE

LIFE

Undercarriage life greatly varies depending on operation method, inspection and maintenance. For most efficient operation, keep the following point in mind.

12.19.1

OPERATION

METHOD

Select the track shoe that best suits the type of soil to be encountered in service. Please consult your Komatsu distributor when selecting track shoes. Do not allow shoe slipping to occur during operation. slipping occurs, reduce load to the blade until slipping Avoid sudden starts, acceleration speeds and sharp turns.

If shoe stops.

or stops, unnecessarily

high

Always operate machine in a straight line whenever possible. When making turns, be careful not to allow the machine to stay to one side, so operation in both turning directions can be done properly. Make turns with the largest possible radius. Prior to operation, clear boulders and obstacles machine from riding over them while operating.

to

prevent

On a slope, operate the machine parallel to the inclination of the slope. Do not operate across the slope. Also when stopping the machine on a slope, the machine should face toward the top of the slope.

When ground inclines to left or right during digging operation, do not continue to dig with machine inclined. Move machine back to level ground and start to dig again. Do not force the machine to carry out work that exceeds its working capability. Such work includes cases where the idler or sprocket come off the ground when the machine meets obstacles that resist the power of the machine during dozing or ripping operations.

2-89

12.

OPERATION

12.19.2

INSPECTION

AND ADJUSTMENT

Clearance

1

A

Properly adjust track tension. Tension should be measured at clearance @ shown in the diagram - usually 20 to 30 mm (0.8 to 1.2 in) at this point. For rocky terrain, tighten tracks slightly. In clay or sandy areas, slightly loosen them. (For inspection and adjustment procedures, refer to “24.2 WHEN REQUIRED”). AE200958

Check idler rollers for oil leakage as well as for loose bolts and nuts. If any trouble is detected, repair immediately.

1

Check the clearance between the idler guide plate and the track frame. If clearance @ increases, idler may develop side motion and tracks may come off. (For inspection and adjustment procedures, refer to “24.2 WHEN REQUIRED”.)

I 12.19.3

INSPECTION

ADO52850

AND REPAIR

Frequent inspection and prompt repair will reduce repair costs. The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Perform periodical inspection and contact the Komatsu distributor in your area when machine has approached repairable limits and reversing limits.

MEASURING HEIGHT OF GROUSER After taking up slack in track shoes, measure shoe as shown below. Standard height (h): 93 mm (3.7 in) Repair limits-30 mm (1.2 in)

height at center of

e

r

h L

I

\I

7 AE105710

MEASURING OUTSIDE DIAMETER OF TRACK ROLLER 1. Measure height (size C) of link tread as shown. 2. Stop machine at position where link tread, whose size C has been measured completely, contacts roller tread. Then measure size B. 3. Calculate outside diameter of tread (size A): A=(B-C)x2 Standard size (A): 270 mm (IO.6 in) Repair limits: 234 mm (9.2 in)

1

AE105720

2-90

13. TRANSPORTATION

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

all related

laws and

13.1 LOADING, UNLOADING WORK

A

WARNING

Make sure the ramp has sufficient width, length and thickness to enable the machine to be safely loaded and unloaded. If the ramp sags appreciably, reinforce it with blocks, etc. When loading and unloading the machine, park the trailer on a flat firm roadbed. Keep a fairly long distance between the road shoulder and the machine. Remove the mud from the undercarriage to prevent the machine from slipping to the side on slopes. Be sure the ramp surface is clean and free of grease, oil, ice and loose materials. Never change the direction of travel when on the ramps. If it is necessary to change direction, drive off the ramps and correct the direction, then drive on to the ramps again. Do not use the counterrotation turn. When loading or unloading, always use ramps or a platform and carry out the operations as follows. Properly apply the brakes on the trailer and insert blocks beneath the tires to ensure that it does not move. Then fix the ramps in line with the centers of the trailer and the machine.

CORRECT

Blocks Distance

between

ramps

Set the machine in line with the ramps, then load or unload the machine at slow travel. Load the trailer.

machine

correctly

in the

specified

position

on the

2-91

13.2

PRECAUTIONS

FOR LOADING

After loading to the specified follows. 1. Lower the blade slowly.

position,

secure the machine

as

2.

Lock all the control

3.

Set the parking

4.

Move the fuel control lever to the low idling position and turn the starting switch key to the OFF position to stop the engine. Remove the key.

5.

Lock the cab door, left and right engine battery inspection cover.

6.

Put blocks under the front and rear of both tracks and secure the machine in position with chains or wire rope of appropriate strength to prevent the machine from moving during transportation. Be particularly careful to tie the machine down securely so that it does not slip to the side.

13.3

METHOD

levers securely

with the safety lever.

lever to the LOCK position.

OF LIFTING

a

side covers,

and the

MACHINE

WARNING

Never raise the machine with any worker on it. Always make sure that the wire rope used for lifting the machine is of ample strength for the weight of the machine. Never try to lift the machine in any posture other than the posture given in the procedure below. There is danger that the machine may lose its balance. When lifting the chassis, pay attention to the center of gravity and be careful to maintain the balance. When lifting the machine, flat ground.

carry out the operation

as follows

or

1.

Stop the engine and be sure to set the parking lever to the LOCk position.

2.

Set the lifting position for the machine on the right.

as shown

AE105730

in the diagran

NOTICE This description of the method for lifting the chassis applies tc standard specification machines. Depending on the attachments and options installed, the methoc of lifting will differ. In such cases, please contact your Komatsi distributor for advice. For details

2-92

of the weight,

see “25. SPECIFICATIONS”.

AE10-5740

13. TRANSPORTATION

13.4

PRECAUTIONS

FOR TRANSPORTATION Blo lck

account

the width,

height

and weight

Block

of the machine.

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

AE20043B

I 13.5

REMOVAL OF CAB (MACHINES WITH CAB)

AEl05760

EQUIPPED

If it is necessary to remove the cab for transportation, disconnect the washer hoses, cab wiring, and washer motor wiring before removing the cab. 1. Push the grommet portion from the hole in the machine cover towards the cab, then remove. 2.

Disconnect 4 washer pin plug x I).

hoses and the wiring

(single wires x 2, 4-

REMARK l After removing, cover the washer hoses with a vinyl bag to prevent any dirt or dust from entering. l Before removing the cab, measure the clearance between the cab and each lever (joystick and blade control lever, etc.). Note the measurements to use as a standard when installing the cab again.

Red-Right Blue-Left Black Rear Colorless-Front

View

From Y ‘Red(back ooewr

fuse

door

door window window

box UD

source)

AE20810B

2-93

13. TRANSPORTATION

13.6

INSTALLATION

I

OF CAB

I

install the cab parts in the opposite order to removal. Connect all parts that were disconnected.

1.

Install the cab mounting bolts as follows. Lower the cab slowly on top of the floor frame.

2.

Align the cab with the floor frame, then install bolts and washers in holes @ - 0. Do not screw the bolts in fully. Screw them in 3 or 4 turns.

3.

Tighten Tighten

the bolts in holes Q - @ fully. in the order 0, 0, 0, 8, @, 0,

Tighten

bolts @ - @ fully.

4.

@, @

I

2-94

AE209290

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 WARNING

-A

-,

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

use methanol,

ethanol

or propanol

Never smoke

based antifreeze.

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. Absolutely avoid using any water leak preventing agent irrespective of whether it is used independently or mixed with an antifreeze. Do not mix one antifreeze with a different brand. For details of the antifreeze mixture when changing the coolant, see “24.2 WHEN REQUIRED”. Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the standard requirements as shown below. With permanent antifreeze, no change of coolant is required for a year. If it is doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for information. Standard requirements for permanent antifreeze. l SAE . .. . .. . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . .. .. . .. . . . .. . . . . . . .. .. . . . . . . .. . . . . . .. . .. . . . . . . . . .. . J1034 l FEDERAL STANDARD . . .. . .. . . . . . . .. . . . . . .. . .. . . . . . .. . . . . . . .. . .. . . . . . .. O-A-548D

2-95


14.1.3

BATTERY g

WARNING

l

To avoid gas explosions,

do not bring fire or sparks near the

l

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

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

100%

90% 80% 75%

1.28 1.26 1.24 1.23

1.29 1.27 1.25 1.24

1.30 1.28 1.26 1.25

the rate of charge

1.31 1.29 1.27 1.26

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

2-96


14.2

AFTER COMPLETION

OF WORK

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions. Mud and water on the machine body should be completely removed. This is to prevent damage to the seal caused by mud or dirt getting inside the seal with frozen drops of water. Park the machine on concrete or hard ground. If this is impossible, park the machine on wooden boards. 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 foliows. Replace the fuel and oil for all parts with oil of the viscosity specified. For details, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. If for any reason permanent antifreeze cannot be used, and an ethyl glycol base antifreeze (winter, one season type) is used instead, or if no antifreeze is used, drain the cooling system completely, then clean out the inside of the cooling system I, thoroughly, and fill with fresh water. When it is unnecessary to use the automatic starting aid (APS) (when the ambient temperature is above 15”C), always keep the fuel valve closed.

2-97

15. LONG-TERM

15.1

STORAGE

BEFORE STORAGE

When putting the machine in storage for more than one month, do as follows. After washing and drying each part, store the machine indoors. If it has to be left outdoors, choose a flat place where the machine will be safe from flooding or other problems, and cover the machine. Completely storage.

fill the fuel tank, lubricate

and change the oil before

Apply a thin coat of grease to metal surface piston rods and the idler adjusting rods.

of the hydraulic

Disconnect the negative terminals of the battery and cover it, or remove it from the machine and store it separately. If the ambient temperature is expected to drop always add antifreeze to the cooling water.

below

OT,

Place all control levers at the neutral position, set the safety lever and parking brake lever to the LOCK position, and set the fuel control lever to the low idling position.

15.2

DURING

STORAGE dk

WARNING

If it is unavoidably necessary to carry out the rustpreventive operation while the machine is indoors, open the doors and windows to improve ventilation and prevent gas poisoning. l

Operate the engine and move the machine for a short distance once a month so that a new film of oil will be coated over movable parts and component surfaces. At the same time, also charge the battery.

l

Before operating the work equipment, hydraulic piston rod.

2-98

wipe off the grease on the

15. LONG-TERM STORAGE

15.3

AFTER STORAGE

NOTICE If the machine is stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service. Carry out the following of long-term storage. l l

procedure

when taking the machine

Wipe off the grease from the hydraulic Add oil and grease to all places.

cylinder

out

rods.

2-99

16. TROUBLESHOOTING

16.1

AFTER RUNNING

OUT OF FUEL

When starting after running out of fuel, fill with fuel and bleed the air from the fuel system before starting. For details of bleeding the air, see “24.5 EVERY 500 HOURS SERVICE”.

16.2

METHOD

OF TOWING a

l

l l

l

MACHINE

WARNING

When towing the machine, use a wire rope that has ample strength for the weight of the machine being towed. A shackle must always be used when using a towing hook. The wire rope should be horizontal and at a right angle to the track frame. Move the machine slowly.

AE207710

If the machine sinks in mud and cannot get out under its own power, or if being used to tow a heavy object, fit the wire to the towing hook as shown in the diagram on the right, or in the case of machines with a drawbar, fit the wire to the drawbar pin when towing. Permissible load for towing hook: 48500 kg (475623 N) Always carry out towing operations within the specified range for the permissible load.

A

WARNING

When checking or handling the battery, stop the engine and turn the starting key to the OFF position before starting. The battery generates hydrogen gas, so there is danger of explosion. Do not bring lighted cigarettes near the battery, or do anything that will cause sparks. Battery electrolyte is dilute sulphuric acid, and it will attack your clothes and skin. If it gets on your clothes or on your skin, wash it immediately off with large amounts of water. If it gets in your eyes, wash it out with fresh water, and consult a doctor. When removing 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.

2-100

disconnect the cable from the

16. TROUBLESHOOTING

16.3.1 STARTING When

starting

ENGINE WITH BOOSTER CABLE the engine

with a booster

cable, do as follows:

REMOVAL, INSTALLATION OF BATTERY CABLE 1. Open battery cover 0. 2. Before removing the battery, remove the ground cable (normally connected to the negative @ terminal). If any tool touches between the positive terminal and the chassis, there is danger of sparks being generated. Loosen the nut of the terminal and remove the wires from the battery. 3. When installing the battery, connect the ground cable last. Insert the hole of the terminal on the battery and tighten the nut. Tightening torque: 5.9 - 9.8 Nm (0.6 - 1.0 kgm, 4.3 - 7.2 Ibft) 4. Close battery cover 0.

PRECAUTIONS WHEN BOOSTER CABLE

CONNECTING

A

AND

DISCONNECTING

WARNING

When starting the engine from another machine, connect the batteries in parallel. When connecting the cables, never contact the positive @ and negative @ terminals. When starting the engine with a booster cable, always wear safety glasses. Be careful not to let the normal machine and problem machine contact each other. This prevents sparks from generating near the battery which could ignite the hydrogen gas given off by the battery. If hydrogen gas explodes. It could cause serious injury. Make sure that there is no mistake in the booster cable connections. The final connection is to the 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 battery size.

cable and clip should be suitable

AD052960

for the

l

The battery of the normal machine must be the same capacity as that of the engine to be started.

l

Check the cables and clips for damage

l

Make

or corrosion.

sure that the cables and clips are firmly

connected.

2-101

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. Engine block the Drobiem

2.

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

3.

Connect terminal

4.

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

5.

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

the other clip of booster of the normal machine.

cable

@ to the positive

of macnine

AE20460B

@

0 terminal

block of

STARTING THE ENGINE 1.

Make sure the clips are firmly connected

2.

Start the engine of the normal idling speed.

3.

Turn the starting switch of the problem machine to the START position and start the engine. Refer to “12.2 STARTING ENGINE”.

DISCONNECTING

machine

to the battery terminals. and keep it to run at high

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 terminal

3.

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

4.

Remove terminal

2-102

the other clip of booster cable @I from the negative of the normal machine.

@

the positive @terminal

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

@

Engine block tne DrOblem

of machIne

PiE204BlB

16. TROUBLESHOOTING

16.4

OTHER TROUBLE

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

(

. l

16.4.1 ELECTRICAL SYSTEM Problem

Main causes

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

Remedy

l

Defective

wiring

l

Defective tension

adjustment

Charge lamp does not go out even when engine is running

l l

Defective Defective

alternator wiring

(0 Replace) (o Check, repair)

Abnormal alternator

l

Defective

alternator

(o Replace)

l

Defective

wiring

l

lnsufticient

battery

charge

l

l

Insufficient

battery

charge

l

a

Insufficient

charge

l

l

Defective

l

a

Defective wiring Insufficient battery

a a

Defective Defective

l

Defective monitor lamp Disconnection in glow plug

to Replace) to Replace)

Blown fuse Low battery

l

Lamp flickers while

Starting starting

is running

noise is generated

motor switch

motor

motor turns

Starting motor engine starts Preheating light up

keeps going

engine

disengages

monitor

sluggishly

before

lamp does not

(When the temperature cooling water exceeds condition is normal) Air conditioner

from

does not turn when is turned to ON

Pinion of starting in and out Starting

engine

of the engine 20X, this

operation

of fan belt

is defective

a

l l l

Blade does not pitch when pitch operation is carried out (dual tilt specification machine only)

battery starting

(e Check, repair loose terminals, disconnections) l Adjust fan belt tension For details, see EVERY 250 HOURS SERVICE

(o Check, repair) Charge Charge

Charge to Replace)

motor

l l

charge

wiring timer

(Check, Charge

repair)

(o Check, repair) to Replace)

(a Check, charge

a

Defective Defective

air conditioner blower switch

l

Defective

compressor

a a

Defective Defective

wiring switch

l

Defective

solenoid

valve

switch

repair)

Charge

(o Replace

air conditioner

(o Replace blower (o Replace)

switch)

switch)

(o Check, repair) (o Replace) (a Replace)

2-103

16.4.2 CHASSIS Problem Oil pressure fails to rise

in torque

Main causes

converter

Remedy

Improper tightening of oil pipe, pipe joint, air leaking in or oil leaking out because of damage Wear, scuffing of gear pump Insufficient oil in transmission

Clogged oil filter element transmission case Torque

converter

is overheats

Torque gauge

converter

oil temperature

does not work

Lacks drawbar (machine

l

0

Oil pressure

l

Lack of flow of lubricant caused wear of power train gear pump

l

Defective Defective

l

pull

Machine will not move off when joystick is placed at FORWARD or REVERSE

Machine doesn’t stop when pedal are depressed Track comes

Sprocket

steering

brake

off

develops

abnormal

Brake rises too slowly

wear

or does not

l

is high

too low by

oil temperature gauge contact in wiring connection

moves

Insufficient

2-104

too slowly

force of ripper

fan belt

(o Replace oil temperature (o Check, repair)

gauge)

l

Lack of oil in steering

l

Transmission oil pressure does not rise Steering clutch slips 0 Wear, scuffing of gear pump o Clogged oil strainer element in steering clutch case

l

l

Brake is not applied pulled

(o Adjust linkage) (o Check brake pressure)

l

Defective

l

Track is too loose

l

Adjust track tension. For details, see WHEN REQUIRED.

l

Track is too loose or too tight

l

Adjust track tension. For details, see WHEN REQUIRED.

l

Lack of hydraulic

l

Add oil to specified

l

is too

See Engine related parts Go to “Oil pressure in torque verter fails to rise”

l

is

brake adjustment

oil

Add oil to the specified level. For details, see CHECK BEFORE STARTING Go to “Oil pressure verter fails to rise” (0 Check, replace)

in torque

l

Work equipment position

lock lever is at LOCK

l

Lack of hydraulic position

oil

l

Work equipment position

lock lever is at LOCK

l

Leakage

piping

con-

o Clean. For details, see EVERY 1000 HOURS SERVICE

(o Adjust linkage) (o Check brake pressure)

level. For

details, see EVERY 250 HOURS SERVICE

from

con-

(o Check, repair)

clutch case

on side which

l

rise at all (or blade tilts too slowly)

Ripper

Replace

See Engine related parts (0 Clean or replace) l Go to “Oil pressure in torque converter fails to rise” (o Replace gear pump) l

l

0

l

Does not steer even when is operated

in

Lack of engine horsepower Oil pressure in torque converter low Steering clutch is slipping

l

does not pick up speed)

strainer

repair

Check, replace) Add oil to the specified level. For details, see CHECK BEFORE STARTING Clean. For details, see EVERY 1000 HOURS SERVICE

case

Loose fan belt Engine water temperature Clogged oil cooler

l l

Check,

l

Set to FREE position

l

Add oil to specified

l

details, see EVERY 250 HOURS SERVICE Set to FREE position

10 Tighten)

level. For

16.4.3 ENGINE Problem

Main

Engine oil pressure monitor flashes when engine speed is raised after completion of warm-

l

Engine

l

(sucking Clogged

causes

Remedy

oil pan oil level is low in air) oil filter cartridge

l

Add oil to specified BEFORE STARTING

l

Replace cartridge, SERVICE

up. l

l

Steam

is emitted

of radiator

from top part

(pressure

Defective tightening of oil pipe joint, oil leakage from damaged part Defective Cooling

valve)

caution water

lamp

level low, water

cooling system Clogged radiator fin

Engine does not start when starting motor is turned

in

cooling system, Clean or repair,

Exhaust

gas occasionally

turns

black

Abnormal noise generated (combustion or mechanical)

see CHECK

clean inside of

see WHEN see WHEN

REQUIRED REQUIRED

Lack of fuel

Add fuel, see CHECK BEFORE STARTING

motor

cranks

pump

packing

Replace)

Repair place where air is sucked Replace pump or nozzle)

or

engine

See ELECTRICAL

Adjust

in

SYSTEM

valve clearance)

l

Too much oil in oil pan

l

Add oil to specified BEFORE STARTING

level, see CHECK

0

Improper

l

Change

fuel

l

Clogged

l

l

Defective Defective Defective

nozzle compression turbocharger

l Clean or replace, see WHEN REQUIRED (o Replace nozzle) (e Adjust valve clearance) 10 Clean or replace turbocharger)

l

Defective

nozzle

(o Replace

l

Combustion noise occasionally makes breathing sound

repair,

Replace thermostat) Tighten cap or replace

sluggishly Defective compression o Defective valve clearance or blue

water,

BEFORE STARTING Replace fan belt Change cooling water,

Defective thermostat Loose radiator filler cap (high altitude operation) Defective water temperature monitor

nozzle Starting

gas is white

lamp)

Add cooling

fin or damaged

Air in fuel system Defective fuel injection

Exhaust

see EVERY 250 HOURS

repair)

(e Replace

leakage Loose fan belt Dirt or scale accumulated

Engine water temperature monitor remains alight

(o Check,

level, see CHECK

fuel air cleaner

l

Low grade

l

Overheating

element

fuel being

used

l l

to specified

nozzle)

Change to specified See item “Indicator

fuel of water

temperature

gauge is in red range on right side of gauge”. l l

Damage inside muffler Excessive valve clearance

(o Replace (o Adjust

muffler) valve clearance)

2-105

16.

TROUBLESHOOTING

16.4.4 APS (Automatic Priming System) Main causes

Problem Engine

does not start at all.

Nozzle clogging (dust, paraffin precipitation, defective nozzle) Defective glow plug Fuel pipe collapse, fuel leak, clogging Defective wiring Fuse breaking Defective

Burner monitor

is ignited

APS controller

l

Defective sensor

to Replace temperature

l

Deposited point

APS water heater

temperature

relay contact

fuel,

10 Check, repair) (0 Replace) (0 Replace)

(0

Clean, change to specified replace nozzle) Replace) Replace)

(0 (0 (0

Check, repair

(0

Replace temperature

(0

Replace)

10 Replace

heater

fuel,

or replace) sensor)

sensor)

relay)

and preheating

lamp remaining

lighted.

Preheating monitor lamp does not become bright (when the temperature of the engine cooling water exceeds ZO”C, the engine preheating system is in normal condition)

l

Disconnection

l l

air heater and glow plug Defective wiring Defective timer

Burner

l

Glow

l

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

is not ignited

o

Z-106

10 Clean, change to specified replace nozzle) (0 Replace) 10 Check, repair)

Nozzle clogging (dust, paraffin precipitation, defective nozzle) Defective glow plug Fuse breaking Alternator functional defect (Alternator output shortage) Defective APS water temperature sensor Defective APS controller

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

When loaded, the engine will emit black smoke and stop.

Remedy

in electrical

plug is not heated

Defective

intake

to Replace) to Check, repair) (o Replace)

red.

APS controller

a

See item “Preheating monitor does not become bright”

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

lamp

fuel,

16.5

IF MODE SELECTION

SYSTEM

FLASHES

If the [Electronic system] caution lamp lights up and the caution lamp flashes, or if it becomes impossible to control the engine speed with the throttle lever and decelerator pedal, stop operations immediately and check the LED display on the controller. Then contact your Komatsu distributor to ask for repairs. In addition to the above, if any of the problems in the table below occur, there is probably some abnormality in the work equipment lever switch or transmission speed range sensor, so please contact your Komatsu distributor for repairs. Mode

Problem

Operation l l l l

Shoe slip control

Ripping

l l l

l

l

Dozing

Economy

Reverse

slow

Reverse

All operations

Lock-up

-

Traveling under own power

l

l l l l

l

Power is not restricted when shoe slip occurs Not possible to control even when shoe slip occurs Power is slow to recover when slippage stops Difficult to rip rock by operating lever TILT and RAISE Travel speed increases when shank penetrates Travel speed is slow and there is lack of drawbar pull No feeling of control, engine remains at full throttle or partial speed When ripping starts, machine moves suddenly Engine speed changes, difficult to carry out operation No feeling of control, engine remains at full throttle or partial speed Ripper RAISE speed is slow Travel speed increases in reverse slow Lock-up is not actuated Transmission shock increases Engine drops to partial own power

speed when

traveling

under

2-107

2 II m 2 P 2 c) m

3 2

17. GUIDES TO MAINTENANCE

Do not carry out any inspection Perform

maintenance

and maintenance

operation

that is not given in this manual.

work on hard, flat ground.

Check service meter Check the service meter to be carried out.

reading

Komatsu genuine replacement Use Komatsu

genuine

every day to see if the time has come for any necessary

maintenance

parts:

parts specified

in the parts list as replacement

parts.

Komatsu genuine oils: Use Komatsu genuine ambient temperature.

oils and grease.

Choose

oils and grease

with

proper

viscosities

specified

for

Always use clean washer fluid: Use automobile

window

washer

fluid and be careful

not to let any dirt get into it.

Clean oil and grease: Use clean oil and grease. Also, keep containers from oil and grease.

of the oil and grease clean. Keep foreign

materials

away

Keeping the machine clean: Always keep the machine grease fittings, breathers

clean. This makes is easier to find parts causing problems. Keep in particular and oil level gauges clean and avoid foreign matters from getting in them.

Be careful of hot water and oil: Draining hot oils and coolants and removing hazardous. Allow the engine to cool. If the oil has to be drained when it is cold, warm before draining it.

their

filters

immediately

after

the

up the oil to a suitable temperature

engine (approx.

stops

are

20 - 40°C)

Checking foreign materials in drained oil: After oil is changed or filters are replaced, materials. If large quantities distributor.

of metallic

check the oil and filters for metallic particles and foreign particles or foreign materials are found, consult your Komatsu

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 is not aware of the circumstances from starting the engine.

control

lever to avoid someone

Obey precautions: During the operation,

3-2

always

obey the precautions

on the safety label stuck to the machine.

who


Welding instructions: l Turn off the engine starting switch. e Do not apply more than 200 V continuously. e Connect grounding the cable within 1 m from the area to be welded. l Avoid seals or bearings from being between the area to be welded and the position point. Fire prevention: Use nonflammable oil.

cleaner

or light oil for cleaning

parts. Keep flame

or cigarette

of grounding

light away from light

Clamp faces: When O-rings or gaskets are removed, clean the clamp faces and replace the O-rings new ones. Be sure to fit O-rings and gaskets when assembling. Objects in your pockets: Keep your pockets free of loose objects which can fall out and drop into the machinery; you work on the machinery while bending over it.

and gaskets with

especially

when

Checking undercarriage: When working in rocky areas, check for damage to the undercarriage and for looseness, flaws, wear and damage in bolts and nuts. Loosen the track tension a little when working in such areas. Cleaning machine: l Do not direct a high-pressure jet directly at the radiator. l Do not splash water over the electrical equipment. l Never spray steam or water directly at the radiator or oil cooler portions. Controller: The machine monitor controller may malfunction if affected by electrical interference from an outside source, so when installing any radio system to the machine, please contact your Komatsu distributor for advice. Checking lubricating oil level: The lubricating oil level should be neither too high nor too low. When that the oil at the proper level.

checking

and adding

oil, check

Pre- and post-work checks: Before starting work in mud, rain, snow or at seashore, check plugs and valves for tightness. Wash the machine immediately after the work to protect components from rusting. Lubricate components more frequently than usual. Be sure to lubricate work equipment pins daily if they are submerged in water. Dusty worksites: When working at dusty worksites, do as follows: o Check the air cleaner for clogging more frequently. 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.

3-3


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. Bleeding

air:

After changing the oil, or replacing or cleaning the filter element or strainer, bleed the air from inside the circuit. If the oil in the hydraulic tank has been changed, or the element replaced, or the hydraulic cylinders or work equipment piping have been removed, run the engine at low idling after completion of the operation to bleed the air as follows. 1. Operate each cylinder 4 - 5 times to a point approx. 100 mm before the end of its stroke.

2.

Next, perate each cylinder to the end of its stroke 3 - 4 times.

If, at first, the engine is run at high speed or the cylinder is operated to the end of its stroke, the air inside the cylinder may cause damage to the piston packing or other parts. Precautions l

l

when

opening

and closing

engine

side cover:

When standing on the track to open the engine side cover, adopt a standing position, hold the side cover with both thumbs, and open it slowly with your other fingers. When the engine side cover is open, do not open or close the cab. Before opening or closing the cab, always close the engine side cover first.

*II209790

3-4

AE209800

18. OUTLINES OF SERVICE

l

Use Komatsu

genuine

l

When

l

Unless otherwise specified, shown in the table below.

changing

Item Engine

oil pan

Power train oil pan (incl. transmission, torque converter and bevel gear cases) Damper case Final drive case

Hydraulic

tank

parts for replacement.

or adding

oil, do not use a different the oil and coolant

SAE 15W-40 API classification

CD

SAE 30 API classification

CD

SAE IOW API classification

CD

Fuel tank

Radiator

Komatsu (AF-ACL)

OUTLINE

used at the time of shipment

from the factory are as

Kind of fluid

I

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

18.1

type of oil.

Super Coolant 41% added to water

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 any impurities (water, metal particles, dirt, etc.) from getting in. The majority of problems with machine are caused by the entry of such impurities. Take particular care not to let any impurities get in when storing or adding oil. Never mix oils of different grades or brands. Always add the specified amount of oil. Having too much oil or too little oil are both causes of problems. If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases, please contact your Komatsu distributor. When changing the oil, always replace the related filters at the same time. We recommend you to have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor.

3-5


18.1.2 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 10 minutes have passed after adding fuel, drain the sediment and water from the fuel tank. If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.

18.1.3 COOLANT River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the engine and radiator, and this will cause defective heat exchange and overheating. Do not use water that is not suitable for drinking. When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual. Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system. The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as it is even in hot areas. Anti-freeze is inflammable, so be extremely careful not to expose it to flame or fire. The proportion of anti-freeze to water differs according to the ambient temperature. For details of the mixing proportions, see “24.2.1 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.

18.1.4 GREASE a

WARNING

Do not carry out greasing when the engine is running. o l

l

3-6

Grease is used to prevent twisting and noise at the joints. The nipples not included in the maintenance section are nipples for overhaul, so they do not need grease. If any part becomes stiff after being used for a long time, add grease. 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 l l

l

OIL AND FUEL

Keep indoors to prevent any water, dirt, or other impurities from getting in. When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at the side. (To prevent moisture from being sucked in) If drum cans have to be stored outside, cover them with a waterproof sheet or take other measures to protect them. To prevent any change in quality during long-term storage, be sure to use in the order of first in _ first out (use the oldest oil or fuel first).

18.1.6 FILTERS l

l

o l l

Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering important equipment and causing problems. Replace all filters periodically. For details, see the Operation and Maintenance Manual. However, when working in severe conditions, it is necessary to consider replacing the filters at shorter intervals according to the oil and fuel (sulfur content) being used. Never try to clean the filters (cartridge type) and use them again. Always replace with new filters. When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found, please contact your Komatsu distributor. Do not open packs of spare filters until just before they are to be used. Always use Komatsu genuine filters.

18.2

RELATING

TO ELECTRIC SYSTEM

l

If the wiring gets wet or the insulation is damaged, in hazardous malfunction of the machine.

l

Services relating to the electric system are (I) check of fan belt tension, in the fan belt and (3) check of battery fluid level.

e

Never

remove

l

Never

install any electric

l

Be careful to keep the electric

l

When

l

Never connect

working

or disassemble

any electric

components

on the seashore, any optional

system

components

system

installed

free of water

when

clean the electric

(2) check of damage

or wear

by Komatsu.

washing system

source to the fuse, starting

leaks and this could result

in the machine.

other than these specified

carefully

power

the electric

the machine to prevent

switch,

battery

or when

it rains.

corrosion. relay, etc.

3-7

19. WEAR PARTS LIST

Wear parts such as the filter element, cutting edge, 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. The parts in parentheses

Item

are to be replaced

Part No.

at the same time.

Part Name

Neight (kg)

Q’ty

Engine oil filter

600-211-1231

Cartridge

Transmission filter

07063-o 1142 (07000-05 175)

Element (O-ring)

Torque converter filter

07063-01142 (07000-05 175)

Element (O-ring)

(1)

Fuel filter

600-31 I-8293

Cartridge

2

Corrosion resistor

600-41 l-l 170

Cartridge

-

2

Hydraulic oil filter

07063-o 1142 (07000-05180) (07000-05195)

Element (O-ring) (O-ring)

-

(I) (1)

Air conditioner filter

17M-91 I-3530 195-211-6691

Element Filter

-

2 1

195-71-61550 198-72-11181 (198-71-21710) (198-71-I 1230) (195-71-61950) 195-71-61930 195-71-61940 (198-71-21720) (198-71-11230) (195-71-61950)

Cutting edge Cutting edge (Bolt) (Washer) (Nut) End bit (left) End bit (right) (Bolt) (Washer) (Nut)

198-72-11181 198-71-11181 (198-71-21710) (198-71-I 1230) (195-71-61950) 195-71-61930 195-71-61940 (198-71-21720) (198-71-I 1230) (195-71-61950)

Cutting edge Cutting edge (Bolt) (Washer)

Semi U-dozer

U-dozer

3-8

(Nut) End bit (left) End bit (right) (Bolt) (Washer) (Nut)

4

Replacement frequency Every 250 hours service

1 -

(I) 1

1

93.2 99.6 113.0 113.0 99.6 125.2 113.0 113.0 -

2 2 (22) (22) (22) 1 1 (16) (16) (16) 2 2 (26) (26) (26) 1 1 (16) (16) (16)

Every 500 hours sevice

Every 1000 hours service

Every 2000 hours sevice

-

19. WEAR PARTS LIST

Item

Part No.

Multi

Replacement frequency

Part Name

195-78-7 1111 195-78-71320 (195-78-71360)

Protector Point (Pin)

195-78-7 1111 195-78-7 1320 (195-78-71360)

Protector Point (Pin)

-

3 3

26.0 -

(9)

26.0

1 1

-

Ripper Giant

NOTICE When handling parts that weight and take the necessary care.

more than 25 kg (55 lb), remember

-

(3)

that they are heavy objects,

3-9

20. USE OF FUEL COOLANT AND LUBRICAF ACCORDING t0 AMBIENT TEMPERATUF

PROPER SELECTION OF FUEL, COOLANT

RESERVOIR

KIND OF FLUID

AMBIENT -4 -20

14 -10

32 0

AND LUBRICANTS TEMPERATURE 50 10

68 20

86 30

Engine oil pan

Power train oil pan (incl. transmission, torque converter and bevel gear cases)

Hydraulic system

Cooling system

104Ol 40°C

CAPACITY Specified amount

Refill caDacitv

58 Q 15.31 US gal 12.76 UK gal

51 Q 13.46 US gal 11.22 UK gal

250 Q 66 US gal 55 UK gal

150 e 39.6 US gal 33 UK gal

2.1 Q 0.55 US gal 0.46 UK gal

2.1 Q 0.55 US gal 0.46 UK gal

270 Q 71.28 US gal 59.4 UK gal

120 Q 31.68 US gal 26.4 UK gal

65 Q 17.16 US gal 14.3 UK gal

65 Q 17.16 US gal 14.3 UK gal

Diesel fuel

1050 e 277.2 US gal 231 UK gal

Water

165 Q 43.56 US gal 36.3 UK gal

% ASTM D975 No. 1

3-10

T

Engine oil

Damper case

Fuel tank

‘ES

-

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

REMARK l

When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%.

Fuel sulphur

Above

Change interval of oil in engine oil pan

content

0.5 to 1.0% 1.0%

1

l/2 of regular

interval

l/4 of regular

interval

l

When starting the engine in an atmospheric oil of SAEIOW, SAEIOW-30 and SAE15W-40, IO’C more or less in the day time.

e

Use API classification interval to half.

l

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 in engine and hydraulic work equipment applications.

CD as engine

temperature of lower than O-C, be sure to use engine even though an atmospheric temperature goes up to

oil and if API classification

Specified capacity: Total amount of oil including oil for components Refill capacity: Amount of oil needed to refill system during normal ASTM: SAE: API:

maintenance

CC, reduce the engine

formulated

oil change

15W-401,

and approved

but be

for use

and oil in piping. inspection and maintenance.

American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute

3-11

20. USE OF FUEL, COOLANT

AND

Engine

LUBRICANTS

ACCORDING

TO AMBIENT

TEMPERATURE

Oil

[CD or CEI ti0.

Supplier

SAEIOW,

30, 40

1ow30, 15w40 (The 15W40 oil marked * is CE.)

Gear Oil

Grease [Lithium-Base]

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

NLGI No. 2

EOIO-CD 1

2

KOMATSU

AGIP

[Ethylene Glycol Base] Permanent

Type

AF-ACL

EOSO-CD EOIO-30CD E015-40CD Diesel sigma S Super dieselmultigrade *Sigma

turbo 300

GO90 GO140

G2-LI GS-LI-S

Rotra MP

GR MU/EP

Multi-purpose

3

AMOCO

*Amoco

4

ARC0

*Arcofleet

5

BP

Vanellus

6

CALTEX

*RPM delo 400 RPM delo 450

7

CASTROL

*Turbomax *RX super CRD

8

CHEVRON

*Del0 400

9

CONOCO

*Fleet motor oil

IO

ELF

Multiperformance Performance 3C

”

EXXON (ESSO)

Essolube D3 *Essolube XD-3 *Essolube XD-3 Extra *ESSO heavy duty Exxon heavy duty

12

GULF

13

MOBIL

3-12

Anti-freeze Coolant

S3 plus

C3

gear oil

AF-PTL AF-PT (Winter, one season typr

RYKON prenium grease

Arco HD gear oil

Litholine HEP 2 Arco EP moly D

Gear oil EP Hypogear EP

Energrease

Universal Universal

thuban thuban

LS-EP2

Marfak all purpose 2 EP Ultra-duty grease 2

EP EPX

MS3 Spheerol

HYP~Y HYP~Y B HYP~Y C

EPL2

Antifreeze

AF engine coolant

Anti-freeze

Universal

gear

Ultra-duty

grease 2

-

Universal

gear lubricant

Super-sta

grease

-

3C

Tranself EP Tranself EP type 2

Glacelf

Gear oil GP Gear oil GX

Beacon EP2

All season coolant

Super duty motor oil *Super duty plus

Multi-purpose gear lubricant

Gulfcrown Gulfcrown

Antifreeze

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

Mobilube Mobilube

Mobilux EP2 Mobilgrease 77 Mobilgrease special

GX HD

EP2 EP special

and coolani

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

No.

Supplier

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

Anti-freeze Coolant [Ethylene Glycol Base1 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 tamidor

14

PENNZOIL

*Supreme duty fleet motor oil

15

PETROFINA

FINA kappa TD

FINA potonic N FINA potonic NE

FINA marson EPLP

16

SHELL

Rimula X

Spirax EP Spirax heavy duty

Alvania EP grease

17

SUN

Sunoco GL5 gear oil

Sunoco ultra prestige 2EP Sun prestige 742

Sunoco antifreeze and summer coolant

18

TEXACO

*Ursa super plus Ursa premium

Multigear

Multifak EP2 Starplex 2

Code 2055 startex antifreeze coolant

19

TOTAL

Rubia S *Rubia X

Total EP Total transmission TM

Multis EP2

Antigel/antifreeze

20

UNION

*Guardol

MP gear lube LS

Unoba EP

21

VEEDOL

*Turbostar *Diesel star MDC

Multigear Multigear B Multigear C

Antifreeze

3-13

21. ;&+lDARD

21.1

INTRODUCTION

The following No.

TIGHTENING

OF NECESSARY

tools are needed

Name of tool Wrench set

TORQUES FOR BOLTS AND

when

carrying

TOOLS out maintenance.

Part No. 09000-30006

Remarks Applicable width across flats (S, - S,) 8 mm - 10 mm, 12 mm - 14 mm 13 mm - 17 mm, 19 mm - 22 mm

s2

24 mm - 27 mm, 30 mm - 32 mm

3

Screwdriver

09033-00190

Interchangeable flat-head and cross-head type

Socket wrench set

09020-10284

Applicable width across flats

AC453370

10 mm, 13 mm 14 mm, 17 mm 19 mm, 22 mm, 24 mm, 27 mm, 30 mm, 32 mm, 36 mm Extension, Handle, Joint 4

Wrench

09002-03641

36mm-41

mm

5

Wrench

0900 I-04600

Applicable wide across flats 46 mm

6

Plier

09036-00 150

7

Hammer

09039-00150 09055-10390

8 9

Filter wrench

0901 g-08035

For filter cartridges

10

Grease pump

07952-80002

For greasing work

11

Nozzle

07951-11400

For grease pump

12

Grease cartridge

07950-90403

(Lithium base grease, 400 g)

13

Gauge

09054-00009

If any of the above tools are broken, please order them from your Komatsu distributor. When not using the tools, always put them in the tool box on the inside of the fender cover on the right side of the machine.

3-14

21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

21.2

TORQUE

LIST

Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table. The tightening torque is determined by the width across the fiats 0J of the nut and bolt. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced. Nm (newton meter): 1Nm \ 0.1 kgm

Thread diameter of bolt (mm)

Width across flat (mm)

(a)

(b)

6 8 10

10

13.2 + 1.4

1.35 k 0.15

,9.73 k 1.03

13

31.4 f 2.9

3.2 + 0.3

23.2 zi2.1

17

65.7 2 6.8

6.7 2 0.7

48.5 + 5.0

12

19

112 + 9.8

11.5 -c 1.0

82.6 2 7.2

14

22

177 + 19

18.0 = 2.0

131 2 14

16

24

279 2 29

28.5 + 3

206 2 21

18

27

383 * 39

39 * 3

282 + 29

20

30

549 f 58

56 sz6

405 2 43

22

32

745 k 78

76 + 8

549 2 58

24

36

927 k 98

94.5 + 10

684 + 72

b

k I--

Nm

AM)54300

km

Ibft

27

41

1320 r 140

135 A 15

973 f 100

30

46

1720 r 190

175 k 20

1270 2 140

33

50

2210 k 240

225 + 25

1630 2 180

36

55

2750 * 290

280 2 30

2030 + 210

39

60

3280 * 340

335 f 35

2420 + 250

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

3-15

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 critical parts.

3-16

22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

SAFETY CRITICAL PARTS No.

Safety critical parts for periodic

1 1 Fuel hose (between 2

1 Turbocharger

replacement

nozzles)

lubricating

Replacement

QW

interval

5

hose

I

1

3

Fuel hose (nozzle - fuel return hose)

1

4

Fuel hose for APS

3

5

Fuel hose (fuel filter - injection

I

pump)

Fuel hose (feed pump - fuel return hose)

Hose (blade valve - blade cylinder) 9

Inspection

hose assembly

10

Fuel hose (fuel tank - fuel strainer)

Hose (torque

converter

Fuel hose (fuel strainer

for power

train pressure

outlet - torque

3

converter

- feed pump)

14

Hose (ripper

low valve - ripper high valve)

15

Hose (ripper

high valve - work equipment

16

Hose (ripper

high valve - tank)

17

Hose (ripper

high valve - ripper

Hose (ripper

high valve - ripper tilt cylinder)

Hose (PPC charge

1

I pump)

4

I

1 1

lift cylinder)

valve - PPC lock valve)

Hose (PPC lock valve - PPC valve for blade) 21

Hose (PPC lock valve - PPC valve for ripper)

22

Hose (PPC pump - PPC charge valve) Hose (hydraulic

oil cooler - relay block)

Hose (relay block - PPC charge

valve)

Hose (relay block - suction tube) 26

Hose (PPC valve for blade - main valve)

4

3-17

22.

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

No. 27

Safety critical

parts for periodic

replacement

Replacement

Q’ty

Hose (PPC valve for blade - PPC drain relay block)

interval

1

Hose (PPC valve for ripper - main valve)

Hose (PPC charge

valve - PPC drain relay block)

31

Hose (PPC drain relay block - suction tube)

32

Hose (work equipment

pump - blade lift valve)

1

33

Hose (work equipment

pump - ripper low valve)

1

34

Hose (blade valve - blade lift divider

35

Hose (blade

36

Hose (relay tube - blade lift cylinder)

4

37

Hose (ripper

2

38

Seat belt

lift divider

I

block)

block - relay tube)

low valve - blade tilt relay tube)

1

I Every 2 years or 4000 hours, whichever comes sooner

1

I

2

1

I

Every 3 years

AE210090

3-18

AL116130

3-19

22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

AE206970

3-20

23. MAINTENANCE

23.1

MAINTENANCE

SCHEDULE CHART

SCHEDULE

CHART

SERVICE ITEM INITIAL 250 HOURS SERVICE (only after the first 250 hours) Replace

fuel filter cartridge

Replace

transmission

3-65

filter element

and torque

Change oil in power train case, clean strainer converter case and bevel gear case) Change

oil in hydraulic

Change

oil in final drive case

Check engine

tank, replace

converter

oil filter element

(incl. transmission

hydraulic

case, torque

3-66 3-69 3-73

oil filter element

3-74

valve clearance,

3-77

adjust

WHEN REQUIRED Clean inside of cooling

3-26

system

Check, clean and replace

air cleaner

3-30

element

3-32

Check track tension Check and tighten Check electrical Adjust Reverse

3-34

track shoe bolts

3-34

intake air heater

3-35

idler clearance and replace the end bits and cutting

Check and clean radiator

3-36

edges

3-38

fin

3-38

Clean fuel tank strainer Drain water Replace

and sediment

air conditioner

Clean, check hydraulic

3-38

in fuel tank

3-39

belt

3-39

cooler fins

3-40

Check undercarriage

oil

Clean air conditioner

air filter (fresh/recirc

Check, adjust air conditioner Grease

(machines

door hinge (machines

equipped

Check door lock striker (machines Replace

door damper

(machines

filter)

equipped

equipped equipped

with cab)

3-42 3-42 3-43

with cab)

fluid level, add fluid (machines

Bleed air from

head end of right pitch cylinder

Replace

blade (machines

(power

with cab)

3-41 3-42

with cab)

with cab)

washer

equipped

equipped

with cab)

Check window

wiper

(machines

equipped tilt, power

with cab) pitch dozer only)

3-43 3-43 3-44

3-21

23. MAINTENANCE SCHEDULE CHART

SERVICE ITEM

PAGE

(WHEN REQUIRED) Check APS (Automatic

Priming

System)

3-45

Lubricating

3-46

l

Fuel control

l

Steering

0

Universal

lever shaft (4 places)

brake control

3-46


3-46

joint (2 places)

3-47

CHECK BEFORE STARTING Check machine Check coolant

monitor

3-46

level, add water

3-46 3-49

Check fuel level, add fuel Check oil level in engine

Check damper

3-50

oil pan, add oil

Check oil level in power train case (incl. transmission and bevel gear case), add oil

case, torque

case oil level, add oil

Check brake pedal tavel

converter

case

3-51 3-52 3-52

Check oil level in hydraulic

tank, add oil

3-53

Check dust indicator

3-54

Check electric wirings

3-54

Check that lamps

3-55

light up

3-55

Check horn sound Check backup alarm

sound

Check seat belt for wear

3-56

or damage

3-56

EVERY 250 HOURS SERVICE 3-57

Lubricating

3-57

shaft (2 places)

3-57

Blade left cylinder

l

Blade lift cylinder

l

Blade arm ball joint (3 places)

l

Brace screw (2 places)

l

Ripper tilt cylinder

bottom

pin (2 places)

3-57

l

Ripper

bottom

pin (2 places)

3-57

l

Ripper tilt cylinder

rod end pin (2 places)

3-57

l

Ripper lift cylinder

rod end pin (2 places)

3-57

3-22

lift cylinder

support

yoke (4 places)

l

support

3-57

23.

MAINTENANCE SCHEDULE CHART

SERVICE ITEM

PAGE

(EVERY 250 HOURS SERVICE) l

Ripper arm pin (front)

l

Ripper arm pin (rear) (2 places)

3-57

l

Equalizer

3-58

l

Suspension

l

Fan pulley

Change

(2

Places)

3-57

bar side shaft (2 places) (Equalizer

bar center shaft) (I place)

3-58

(I place)

oil in engine

3-58

oil pan, replace

Check oil level in hydraulic Check, adjust alternator Check level of battery

engine

oil filter cartridge

3-59

tank, add oil

3-61

drive belt tension

3-62

electrolyte

3-63

Check brake performance

3-64

EVERY 500 HOURS SERVICE 3-65

Replace fuel filter cartridge Replace

transmission

filter element

and torque

converter

oil filter element

3-66

Check oil level in final drive case, add oil

3-67

Check fan belt, replace

3-68

EVERY 1000 HOURS SERVICE Change oil in power train case, clean strainers converter case and bevel gear case)

(incl. transmission

case, torque

3-69

Check, clean fuel strainer

3-70

Clean steering

3-71

clutch case breather

Check oil level in recoil spring and assist cylinder Grease tension

corrosion

bolts

resistor cartridge

Check all tightening

3-71 3-71

pulley assembly

Check for loose ROPS mount Replace

case, add oil

3-72

parts of turbocharger

3-72

EVERY 2000 HOURS SERVICE Change

oil in hydraulic

Change

oil in final drive case

3-74

Change

oil in damper

3-75

Check pivot bearing Clean engine

tank, replace

hydraulic

oil filter element

case, clean air hole and breather oil level, add oil

breather

element

3-73

3-76 3-76

3-23

23. MAINTENANCE SCHEDULE CHART

SERVICE

ITEM

(EVERY 2000 HOURS

SERVICE)

Clean, check turbocharger

3-77

Check play of turbocharger Check alternator, Check engine

starting

rotor

3-77

motor

valve clearance,

3-77

adjust

3-77

EVERY 4000 HOURS Check water

pump

Check vibration

Check fan pully and tension

3-24

SERVICE 3-78

damper

Check main frame,

PAGE

3-78 pulley

work equipment

3-78 (blade,

ripper)

3-79

24. SERVICE PROCEDURE

24.1

INITIAL 250 HOURS

Carry out the following hours. l l l

l

l l

SERVICE

maintenance

only after the first 250

REPLACE FUEL FILTER CARTRIDGE REPLACE TRANSMISSION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINER (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE) CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT CHANGE OIL IN FINAL DRIVE CASE CHECK ENGINE VALVE CLEARANCE, ADJUST

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

see the HOURS

3-25


24.2

WHEN

REQUIRED

24.2.1 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. Never be under the machine with the engine running. To avoid serious injury, always stop the engine before being under the machine to open the drain valve. Never remove the radiator cap when the engine is at operating temperature. At operating temperature, the coolant is under pressure. Steam blowing up from the radiator could cause personal injury. Allow the engine to cool until the radiator filler cap is cool enough to touch with your hand. Remove the filler cap slowly to relieve pressure. When removing drain plug, avoid pouring coolant on yourself. Antifreeze is flammable, so keep it away from any flame. l

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

Kind of coolant

Cleaning inside of cooling system and changing coolant

Permanent type antifreeze (All season type)

Every year (autumn) or every 2000 hours whichever comes first

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

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

When

Every 6 months or every 1000 hours whichever comes first

3-26

not using antifreeze

Replacing corrosion resistor

Every when of the when

1000 hours and cleaning the inside cooling system and changing coolant


Use a permanent type of antifreeze. If, for some reason, it is impossible to use permanent antifreeze, use an antifreeze containing ethylene glycol. Stop the machine the coolant.

on level ground

when

cleaning

type

or changing

When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing rate table given below. It is actually better to estimate a temperature about 10°C (50°F) lower when deciding the mixing rate. Mixing

rate of water

and antifreeze

l

We recommend use of an antifreeze mixing proportions.

density gauge to control the

l

Use city water for the cooling water. If river water, well water or other such water used, contact your Komatsu distributor.

supply

must be

3-27

24. SERVICE

PROCEDURE

1.

Stop the engine

2.

Turn radiator

3.

Set a container to catch the coolant, open drain valve @ at the bottom of the radiator and drain valve @ at the bottom of oil cooler and drain plugs @ at the both sides of cylinder block, and drain off the cooling water.

and tighten

cap @ slowly

valve @ of the corrosion and remove

resistor.

it.

4.

After draining, close up drain valve 0, @ and plugs @ and pour in clean water (ex. city water) up to the vicinity of the water filler.

5.

When the water reaches the vicinity of the water filler, put the engine at low idling, open drain valve 0, @ and plugs 0, then pass water through the cooling system for 10 minutes. When doing this, keep the radiator filled up to the filler with water. When filling with water, be careful to check that the hose supplying the water does not come out of the water filler port at the radiator cap.

6

After washing the cooling system, stop the engine. and close drain valve 0, @ and plugs 0.

7.

After draining the water, flush the system with a flushing agent. For details of the flushing method, see the instructions on the flushing agent.

8.

After flushing, open drain valve 0, @ and drain plugs 0, completely drain all the water, then close the drain valve and drain plug, and fill with city water up to near the filler port.

9.

When the tank is filled to near the water filler port, open drain valve 0, @ and drain plugs 0, start the engine, run at low idling, and continue the flushing operation until clean water comes out.

Drain water

While flushing the radiator, adjust the incoming flow of water to match the drain flow so that the radiator is always kept full during the flushing operation. Be sure that the water supply hose does not slip out of the radiator water filler when flushing. 10. When clean water comes out, stop the engine valve 0, @I and drain plug 0.

and close drain

11. Replace the corrosion resistor and open valve 0. For details on the corrosion resistor replacement “24.6 EVERY 1000 HOURS SERVICE”. 12. Add city water port.

until the water

overflows

from

method,

the water

see

filler

13. To remove the air in the cooling water, run for five minutes low idling, then for another five minutes at high idling. (When doing this, leave the radiator cap off.)

3-28

at

AE20898C


14. Stop the engine, wait for 3 minutes, add city water until the water level reaches near the water filler port, then tighten the cap 0. 15. Open the cap of subtank @ and add water into the subtank referring to the section “24.3 CHECK BEFORE STARTING”.

3-29


24.2.2 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT

Never clean or replace the air cleaner element with the engine When using pressure air to clean the element wear safety glasses or goggles to protect the eyes.

l

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

portion of dust

CLEAN, REPLACE OUTER ELEMENT 1. Loosen wing nut 0, then remove the outer element 0. 2.

Clean the air cleaner body interior.

3.

Direct dry compressed air (less then 700 kPa (7 kg/cm*, 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. The number of times the outer element has been cleaned can be seen by the number of removed seals. 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. 3) Replace the element when the air cleaner clogged warning lamp lights up soon after installing the cleaned element even though it has not been cleaned 6 times. 4) Check inner element mounting nuts for looseness and, if necessary, retighten. 5) Replace seal washer @I or wing nut @with new parts if they are broken.

NOTICE If small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning and drying, replace the element. Do not use an element whose folds or gasket or seal are damaged. When cleaning the element, do not hit it or beat it against something.

AE083070

AE083060

AE083080

4.

Set the cleaned element.

3-30


REPLACING INNER ELEMENT 1. First remove element.

the

outer

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 a inner element.

5.

Install the outer element.

6.

After replacing the element, press button of the dust indicator to return the red piston to its original position.

body

interior,

then

remove

the

cover

it with nuts.

3-31

24. SERVICE

PROCEDURE

24.2.3 CHECK TRACK TENSION The wear of pins and bushings on the undercarriage will vary with the working conditions and soil properties. It is thus necessary to continually inspect the track tension so as to maintain the standard tension. Carry out the check and adjustment under the same conditions as when operating (on jobsites where the track becomes clogged with mud, measure with the track clogged with mud). INSPECTION Stop the machine on level ground (stop with the transmission in FORWARD without applying the brake). Then place a straight bar on the track shoes between the carrier roller and the idler as shown in the figure, and measure the clearance between the bar and the grouser at the midpoint. If the clearance is 20 - 30 mm (0.8 - 1.2 in), the tension is standard. If the track tension is not at the standard value, adjust it in the following manner. ADJUSTMENT

A

WARNING

Grease inside the adjusting mechanism is under high pressure. Grease coming from plug @ under pressure can penetrate the body causing injury or death. For this reason, do not loosen plug @I more than one turn. Do not loosen any part other than plug 0. Furthermore, do not bring your face in front of the grease fitting. If the track tension is not relieved by this procedure, please contact your Komatsu distributor.

l

1.

When increasing tension First remove the bolt 0,

and then remove

the cover 0.

NOTICE When

removing

Pump

in grease

cover 0,

be careful

through

the grease

not to let soil get in. fitting

@ with

a grease

pump. To check that the correct tension has been achieved, machine backwards and forwards. Check the track tension adjust it again.

again, and if the tension

move the

is not correct,

Continue to pump in grease until S becomes 560 mm (22.1 in). If the tension is still loose, the pin and bushing are excessively worn, so they must be either turned or replaced. Please contact your Komatsu distributor.

3-32

L


l

When

loosening

It is extremely relieved

tension

dangerous

to release the grease by any method

by this procedure,

please

contact

your

Komatsu

1.

Loosen

2.

Turn plug @ a maximum

3.

If the grease does not come out smoothly, backwards and forwards a short distance.

4.

Tighten

5.

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

6.

Check the track tension adjust it again.

l

When

plug @ gradually

dis-

to release the grease. of one turn. move the machine

plug 0.

removing

again,

and if the tension

move the

is not correct,

track

A

WARNING

Depending on the situation, the operation to remove the track may be extremely dangerous. Before removing the track, if the procedure above “When loosening tension” does not loosen the track tension, please contact your Komatsu distributor for repair.

3-33


24.2.4 CHECK AND TIGHTEN

TRACK SHOE BOLTS

If the machine is used with track shoe bolts loose, they will break, so tighten any loose bolts immediately. Method for tightening (shoe bolt) First tighten to a tightening torque of 686 + 69 Nm (70 f 7 kgm, 506 f 51 Ibft)) then check that the nut and shoe are in close contact with the link contact surface.

l

1.

2.

After checking,

tighten

e 1.

Method for tightening (master link connecting bolt) First tighten to a tightening torque of 490 +. 49 Nm (50 f 5 kgm, 362 f 36 lbft) then check that the link contact surfaces are in close contact.

2.

After checking,

tighten

a further

a further

120” + 10”.

180” 2 10”.

Order for tightening Tighten the bolts in the order shown in the diagram

on the right. /

I 24.2.5 CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections.

3-34

AD053090


24.2.6 ADJUST

IDLER CLEARANCE

The idler moves forward and backward under external pressure. When this happens, side guide 0 and guide plate @ become worn. As they become worn, there is side play in the idler, or the idler turns at an angle, causing the track to come off or resulting in uneven wear, so adjust as follows.

Adjustment 1. Drive the machine for 1 - 2 m (3 - 7 ft) on flat ground, then measure clearance A (4 places: left, right, inside, outside) between the track frame and side guide 0. 2.

If clearance A is more than 3 mm (0.1 in), remove bolt 0, then take out shim 0, and adjust so that the clearance on one side is less than 0.5 mm (0.02 in).

REMARK There are two types of shim (thickness: mm (0.04 in).

0.5 mm (0.02 in) and 1.0

t.J AL116270

3-35


24.2.7

REVERSE

CUlTlNG

AND REPLACE THE END BITS AND EDGES &h WARNING

It is dangerous if the work equipment moves by mistake when the cutting edges and end bits are being reversed or replaced. Set the work equipment in a stable condition, then stop the engine and lock the blade control lever securely with the safety lever. Reverse or replace the end bits and cutting edges before it is worn out to the blade end. 1. Raise the blade to a proper height and apply a block to the frame so as to prevent fall of the blade. 2.

Operate

the safety lever to the LOCK position.

If the cutting edge and the end bit on both sides are worn replace with new one. If it has been worn out up to the fitting surface, surface and then reverse or replace.

out,

repair the fitting

3.

Loosen nut @ and remove bolt 0. Then remove the cutting edge and the end bit and clean the mounting surface.

4.

Reverse or replace the cutting edge and the end bit when worn out.

If bolt @) and nut @ are damaged, at the same time.

5.

Install the edge to the blade, then tighten partially. Drop the blade three to five times on to the ground or rock to remove any play in bolt 0, then tighten it to the correct tightening torque. When installing end bit 0, put top surface @ of the end bit in close contact with stopper 0, then tighten with the bolts. Tightening

3-36

replace them with new ones

torque: 2226 f 275 Nm (227 & 28 kgm, 1642 + 203 Ibft)

6.

After several

hours of running,

retighten

the nuts.

REMARK The tightening operation been supplied is used.

When the nut is both sides @ of the Be careful not to If it is damaged, mounting surface.

is easier if the power wrench

rusted and is removed by gas cutting, nut as shown in the diagram. damage seat surface 0. repair it. Be careful not to get spatter

that has

cut on a on the

7 / =.455

/

AE200610

3-37


24.2.8 CHECK AND CLEAN RADIATOR g

I

FIN

WARNING

I

When carrying out cleaning or inspection, always engine and check that the fan is not rotating before When the radiator follows. bolts 0

stop the starting.

fin block with mud, dirt or leaves, clean it as

1.

Loosen

and open radiator

grille 0.

2.

Clean the radiator fins clogged with mud, dust and leaves with compressed air. Steam or water may be used instead of compressed air.

REMARK Check the rubber hose. If the hose is found to have cracks to be hardened by ageing, replace such hose with new one. Further, loosen hose clamp should also be checked.

24.2.9 CLEAN FUEL TANK STRAINER Clean the strainer if there is any dirt collected in it. Remove the filler cap of the fuel tank and take out strainer If the strainer is dirty, clean it with diesel fuel.

0.

24.2.10 DRAIN WATER AND SEDIMENT IN FUEL TANK Carry out this procedure after the machine has been at rest for a long time and after a long spell of rainy days. Loosen valve 0 at the bottom of the tank and drain sediment accumulated on the bottom together with mixed water and fuel.

3-38


24.2.11

REPLACE AIR CONDITIONER

1.

Loosen 4 bolts @ and jack bolt 0, the side.

2.

Replace

BELT

then move compressor

@ to

the V-belt.

REMARK When adjusting the V-belt, with a bar. Use jack bolt 0.

3.

do not push the compressor

directly

Tighten jack bolt @ and bolts 0, and apply tension to the V-belt. The standard deflection for the V-belt is approx. 15 - 18 mm (0.6 - 0.7 in) when the belt is pushed by thumb (approx. 10 kg (22 lb)) at a point midway between the air compressor pulley and fan pulley.

24.2.12

CLEAN, CHECK HYDRAULIC

If the hydraulic cooler fins are clogged the fins, clean and check the fins.

COOLER FINS or there is dirt caught

in

1.

Open the inspection

cover on the left.

2.

Use compressed air to remove the mud, dirt, and leaves clogging the hydraulic cooler fins. Steam or water may be used instead of compressed air.

REMARK Inspect the rubber hoses, and replace them or brittle. Check also for loose hose clamps.

if they are cracked

3-39


24.2.13

CHECK UNDERCARRIAGE

OIL

Stop the machine on level ground, and check for any reduction in the oil at the idler (portion P), track roller (portion Q), bogie shaft (portion Q), and carrier roller (portion R). 1.

Loosen seal bolt @ slowly and check if oil oozes out from the thread. If oil oozes out, the oil level has not gone down, so tighten the bolt.

2.

If no oil comes out even when seal bolt @ is removed, the oil level is low, so please contact your Komatsu distributor for repair.

REMARK There outside.

is one bogie

shaft seal bolt @ each on the inside

and

IL---+-

3-40

AD053230


24.2.14

CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (MACHINES EQUIPPED WITH CAB)

If the air conditioner in it, clean the filter. inspection

air filter is clogged

1.

Open

2.

Open inspection cover @ under the front recirculation air filter @ to remove it.

3.

Clean filters @ and @ with compressed air. If there is oil stuck to the filter, or it is extremely dirty, wash it in a neutral agent. After washing it, dry it completely before installing it again.

REMARK If the clogging using compressed

cover @ and remove

or there is dirt or dust

fresh air filter 0. panel

and pull up

of the filter cannot be removed by washing air, replace the filter with a new part.

or

3-41


24.2.15

CHECK, ADJUST AIR CONDITIONER (MACHINES EQUIPPED WITH CAB)

comDressor

CHECKING TENSION OF COMPRESSOR BELT If the belt is loose, it will slip and the cooling effect will be reduced. From time to time, press a point midway between the drive pulley and compressor pulley with your finger (approx. 10 kg (22 lb)) and check that the tension is 15 - 18 mm (0.6 - 0.7 in). When the belt is new, there will be initial elongation, so always adjust again after 2 or 3 days. CHECK LEVEL OF REFRIGERANT

The refrigerant

Drive

pulley

Dulley

AE20915E

(GAS)

used in the cooler is colorless

and odorless

and

eyes or on your hands, it may cause loss of sight or frostbite, so never loosen any part of the refrigerant circuit. If the level of the refrigerant (gas) is low, the cooling effect will be reduced. Run the engine at high idling, and check the flow of the refrigerant in the refrigerant circuit through the sight glass of the receiver when the cooler is running at high speed. l No bubbles in refrigerant flow: Correct l Bubbles in refrigerant flow (bubbles continuously pass through): Refrigerant level low l Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low, so contact your refrigerant dealer to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor. New Freon R-134a is used as refrigerant. AC053280

24.2.16

GREASE DOOR HINGE (MACHINES EQUIPPED WITH CAB)

If the door makes a squeaking noise when it is opened or closed, spray lubricant in through the split in the hinge bushing. If the bushing is worn, replace the hinge.

24.2.17

CHECK DOOR LOCK STRIKER (MACHINES EQUIPPED WITH CAB)

If the wear of the doors lock striker exceeds 0.5 mm (0.02 in), replace the striker. If it is used at it is, the play will increase and this may result in breakage of the hinge or door lock.

3-42


24.2.18 If the (0.08 in), There and right

24.2.19

REPLACE DOOR DAMPER (MACHINES EQUIPPED WITH CAB) depth of the door damper rubber groove is less than 2 mm replace the damper. are two dampers each at the top and bottom on the left doors.

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (MACHINES EQUIPPED WITH CAB)

If there is air in the window washer fluid, check the level and add fluid. Open the battery cover, check the level of the fluid in window washer tank 0, and if it is low, add automobile window washer fluid. When adding fluid, be careful not to let dirt or dust get in.

24.2.20

BLEED AIR FROM HEAD END OF RIGHT PITCH CYLINDER (POWER TILT, POWER PITCH DOZER ONLY)

Bleed the air if the work equipment has been removed or repaired. 1. Raise the blade and run the engine at low idling. 2. Operate the left and right tilt 5 - 10 times to bleed the air from the tilt circuit. 3. Operate the forward and rear pitch 5 - IO times to bleed the air from the bottom end of the right cylinder. 4. Set the left and right cylinders at the neutral position, then carry out the following operations 5 - 10 times to bleed the air from the head end of the right pitch cylinder. @ Forward pitch 1 @ Left tilt L @ RigFt tilt @I Rear pitch i

3-43

24. SERVICE

24.2.21

PROCEDURE

REPLACE WIPER BLADE (MACHINES EQUIPPED WITH CAB)

If the blade is damaged, replace the blade.

it will not wipe the window

Method of replacement l Front, rear wiper 1. Remove screw 0, then remove 2.

Install a new blade, then tighten

clean,

so

the blade. screw @I securely.

AD053340

I

I 1.

Door wiper It is hooked at portion @, so move the blade in the direction the arrow to remove it.

2.

Install the new blade and hook it securely.

l

Rear wiper

I

I

AW53350

of

AD053360

3-44


24.2.22

CHECK APS (Automatic

Priming System)

Check the APS in autumn (ambient temperature below 15‘C, engine cooling water temperature below 13°C). If it is necessary to inspect the APS when the engine cooling water is above 13”C, so please contact your Komatsu distributor. 1. Open fuel valve @ of the APS and remove inlet.

hoses @ of the nozzle

2.

Move feed pump @ up and down to bleed air until no air bubbles comes out of the hose connecting port. At the same time, check for fuel leakage and clogging of fuel pipe.

3.

Place the fuel control lever in the “engine stop” position. Turn the starting switch to ON position. Turn on the preheater switch. Then, confirm the following. l Confirm that the preheater monitor lamp stays on for about 80 seconds. l Confirm that when the preheater monitor lamp goes off, the two glow plugs are red hot. l With preheater monitor lamp off, turn the starting switch key to START position (do not keep the key in this position for more than 20 seconds), and checkfor properfuel combustion inside the intake manifold. When

checking

the glow

If any abnormality SHOOTING”.

plug, remove

is assumed,

refer

plug. to the

“16.

TROUBLE

3-45

24. SERVICE

24.2.23

PROCEDURE

LUBRICATING

1.


2.

Using a grease pump, pump fittings shown by arrows.

3.

After greasing,

1.

Fuel control

2.

Steering

3-46

wipe

to the ground, in grease

then stop the engine. through

off any old grease that was pushed


brake control

the


grease

out.


3.

Universal joint Apply grease to the grease fittings

(2 places) shown

by arrows.

The undercoy is heavy? wARN’NG-pi Never try to open or close the cover when directly beneath it When removmg bolts 0, carry out the work from the rear below the cover so that you can easily get out of the way.

Remove inspection cover @ of the undercover of the chassis as follows.

AE209210

at the rear bottom

(I) Remove 2 bolts @ at the front of the machine. (2) Support the cover with your elbow while gradually bolts @ at the rear of the machine. (3) Lower the cover gradually to open it.

removing

2

Fr m

AD054002

3-47

24. SERVICE

PROCEDURE

24.3 CHECK BEFORE STARTING

Machines

eWiPDed

24.3.1 CHECK MACHINE MONITOR 1. Turn starting switch @ to the ON position. 2.

with

Cab

E-I-3

Check that all monitor lamps and gauges light up for 3 seconds and the alarm buzzer sounds for about 2 seconds.

/

REMARK If the lamps do not light up, there may be a failure or disconnection in the monitor, so please contact your Komatsu distributor.

Machines

yzz-y’ eauimed

AE203338

with

CanODY

NOTICE When carrying out the checks before starting, do not relay only on the monitor. Always carry out all the items listed for the following check and maintenance.

I

OFF

-

24.3.2 CHECK COOLANT

Do not remove

cap 0,

LEVEL, ADD WATER

@ while

cooling water

by little

by

Remove radiator cap @ and check that coolant is above the bottom of the strainer as shown in the diagram. If necessary, add water through filler of radiator cap 0.

2.

Check that threre

3.

If the water level is low, add water through fillers of both radiator cap @ and subtank cap 0. Add into the subtank up to the level above the bottom of strainer through filler of cap @ as shown in the diagram.

is no abnormality,

To refill the radiator, first stop the engine and pour in water until the water overflows the filler opening. Then, start the engine, check the water level again after a five-minute idling, and add water if necessary.

5.

After adding

6.

If the volume of coolant possible water leakage.

3-48

tighten

the cap 0,

added

I-

I

*E20,1

Racliatof

such as oil in the coolant.

4.

water,

AD052290

is hot. Hot water

goes down and release radiator pressure little loosening caps slowly, then remove the cap. 1.

I

START

I

AE20092E

Sulstank

@ securely.

is more

than

usual, check for

AE200939

24.3.3 CHECK FUEL LEVEL, ADD FUEL a When adding a fire. 1.

2.

WARNING

fuel, never let the fuel overflow.

Turn the engine starting switch to the ON position and check the fuel level with fuel level gauge 0 on the monitor panel. After checking, turn the switch back to the OFF position.

After completing work, fill the Check the fuel level with the For details of the fuel to use, AND LUBRICANTS ACCORDING 3.

This may cause

fuel tank through fuel filler port 0. fuel gauge at the fuel filler port. see “20. USE OF FUEL, COOLANT TO AMBIENT TEMPERATURE”.

After adding fuel, tighten the cap securely. Fuel capacity: 1050 & (277 US gal, 231 UK gal)

REMARK o When dozing on a grade, make sure there is plenty of fuel in the tank so that the engine fuel line does not becomes aerated. l If breather hole @ on the cap is clogged, the pressure in the tank will drop and fuel will not flow. Clean the hole from time to time. AD054210

3-49

24. SERVICE

PROCEDURE

24.3.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the engine side cover on the right side of the chassis. 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.


be between



oil filler

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

AL116000

5.

If the oil is above the H mark, remove drain plug 0, loosen drain valve @ to drain the excess oil, then check the oil level again.

6.

If the oil level is correct, tighten close the engine side cover.

the oil filler cap securely

and

REMARK l Check the oil level with the engine stopped. l When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking. l If the machine is at an angle, make it horizontal before checking. l When adding oil, remove the dipstick from the holder to release the air inside the crankcase.

3-50

-

AL116450

24.3.5 CHECK OIL LEVEL IN POWER TRAIN CASE (INCL. TRANSMISSION, TORQUE CONVERTER AND BEVEL GEAR CASES), ADD OIL Start the engine and run at idling for 5 minutes, oil level with the COLD side of dipstick 0. Remove

dipstick 0,

then check the

and wipe the oil off with a cloth.

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

be between

0. If the oil level is belowthe


L mark, add engine oil through

oil filler

0.

AND


5.

If the oil is above the H mark, pull out hose 0, and loosen drain plug @ to drain the excess oil, then check the oil level again.

6.

If the oil level is correct, tighten

the oil filler cap securely.

REMARK l If the machine is at an angle, make it horizontal before checking. l When the engine is stopped, the oil level will rise, so it is impossible to check the oil level correctly. When checking while the engine is running, run the engine at idling and check with the HOT side of dipstick 0. l When working on a slop of more than 20”, check that the oil is up to the H level.

=W-

AE208408

3-51


24.3.6 CHECK DAMPER CASE OIL LEVEL, ADD OIL 1. Remove dipstick 0, and wipe the oil off with a cloth. 2.

Insert dipstick again.

0

fully

3.


into the dipstick

be between

holder,

then pull it out


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

AND 4.

the dipstick

For details of the oil to use, see “20. USE OF FUEL, COOLANT LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. If the oil is above the H mark, drain the excess oil from plug. After draining the oil, check the oil level again.

drain

REMARKS l l

Check the oil level with the engine stopped. When checking the oil level, if the machine is at an angle, move it to a horizontal position before carrying out the check.

24.3.7 CHECK BRAKE PEDAL TRAVEL 1.

Depress

2.

The distance of travel at the center of the pedal (position in the diagram on the right) should be 65 - 85 mm (2.56 - 3.35 in).

3.

When this value exceeds the specified range, or the brake fails to work, please contact your Komatsu distributor for adjustment.

3-52

the brake pedal all the way until it stops.

AD053630

24. SERVICE

24.3.8 CHECK OIL LEVEL IN HYDRAULIC

PROCEDURE

TANK, ADD OIL

When removing

the oil filler cap, oil may spurt out, so stop the to go down, then turn the cap slowly to release the internal pressure before removing

NOTICE Do not add oil if the level is above the H line. This will damage the hydraulic equipment and cause the oil to spurt out. 1. Lower the blade to the ground, about 5 minutes before checking H and L in sight gauge 0.

H

0

stop the engine and wait for oil level. If oil level is between

@

Proper range L

ADO53410

2.

If the level is below the L mark, add engine

oil through

oil filler

I

0.

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


a

move

it to a

WARNING

If oil has been added to above the H mark, stop the engine and wait for the hydraulic oil to cool down. Then remove drain plug @, loosen drain valve 0, and drain the excess oil.

3-53


DUST INDICATOR 24 .3.9 CHECK 1. Open the engine side cover on the right side of the chassis, check that the red piston has not appeared in the transparent portion of dust indicator 0. 2.

If the red piston has appeared, clean immediately. For details of the method of cleaning WHEN REQUIRED”.

or replace

the element

the element,

see “24.2

After checking, cleaning, and replacing, press the knob of dust indicator @I to return the red piston to its original position.

3.

AD052091

24.3.10

CHECK

ELECTRIC a

WIRINGS WARNING

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

3-54

24.

24.3.11 1.

CHECK THAT LAMPS LIGHT UP



SERVICE

PROCEDURE

OFF

-

START ADO52290

2.

Turn the front lamp and working lamp switch to the ON position and check that the front lamps and working lamp light up.

AD051790

3.

Turn the rear lamp switch to the ON position and check that the rear lamps on the left and right fenders light up.

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

24.3.12 CHECK HORN SOUND 1. Turn the key of starting switch to the ON position.

OFF

ON

LJ

”,

f (3

AD051790

OFF

-

START AD052290

2.

Press the horn switch

and check that the horn sounds.

3-55

24. SERVICE

24.3.13 1.

PROCEDURE

CHECK BACKUP ALARM SOUND


OFF


-

START AD052290

2.

Set the joystick to the REVERSE position. The buzzer must sound immediately. The buzzer will continue to sound until the iovstick is moved to the NEUTRAL or FORWARD position. _ .

24.3.14

CHECK SEAT BELT FOR WEAR OR DAMAGE

Check the belt and mounting damaged, replace the seat belt.

3-56

clamps,

and if they are worn

or

Q

24.4

EVERY 250 HOURS

SERVICE

24.4.1 LUBRICATING 1.


2.

Using a grease pump, pump fittings shown by arrows.

3.

After greasing,

1. 2.

Blade lift cylinder Blade lift cylinder

3. 4.

Blade arm ball joint (3 places) Brace screw (2 places)

5. 6. 7. 8. 9. 10.

Ripper Ripper Ripper Ripper Ripper Ripper

wipe

to the ground, in grease

then stop the engine. through

the

off any old grease that was pushed

support support

grease

out.

yoke (4 places) shaft (2 places)

tilt cylinder bottom pin (2 places) lift cylinder bottom pin (2 places) tilt cylinder rod end pin (2 places) lift cylinder rod end pin (2 places) arm pin (front) (2 places) arm pin (rear) (2 places)

The ripper on the upper side is a multishank on the lower side is a giant ripper.

ripper, and the one I

1

_

--'

I

y

.

AL116400

3-57

1


11. Equalizer bar side shaft (2 places)

12. Suspension (Equalizer bar center shaft) (1 place) Grease the suspension through the grease fittings marked by arrow. Pump the greasing lever up and down 3 - 5 times.

13. Fan pulley (I place)

3-58


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

The oil is at high temperature after the engine has been operated so never change the 011 immediately after finishing operations. Wait for the oil to cool down before 1* wARN’NG/changing it.

I

Preoare the followina. ‘Container to catch drained oil: Min 51 L?capacity 0 Refill capacity: 51 e (13.46 US gal, 11.22 UK gal) 0 Socket wrench, filter wrench. 0

1.

Open cover on the under the chassis. Set a container oil under the drain valve.

2.

Remove drain plug @ and loosen drain valve @ slowly to avoid getting oil on yourself, and drain the oil. Take care not to loosen drain valve @ so much that the stopper pin in the valve is distorted. Tightening torque drain valve 0: 69 i 10 Nm (7 f 1 kgm, 51 2 7 Ibft) Tightening torque drain valve 0: 64 + 15 Nm (6.5 + 1.5 kgm, 47 + 11 Ibft)

3.

Check the drained oil, and if there are excessive metal particles of foreign material, please contact your Komatsu distributor.

4.

Tighten

5.

Using a filter wrench, remove full-flow filter cartridge @ by turning it counterclockwise. When doing this, to prevent getting oil on yourself, do not carry out this operation from immediately under the cartridge. In particular, if this operation is carried out immediately after stopping the engine, a large amount of oil will come out, so wait for 10 minutes before starting the operation.

6.

Clean the filter holder, fill a new cartridge with clean engine oil and coat the packing surface and thread of the new filter cartridge with engine oil (a thin coat of grease is also possible), then install the cartridge.

to catch the

drain valve 0.

3-59

24. SERVICE

PROCEDURE

7.

When installing the filter cartridge, bring the packing surface into contact with the filter holder, then tighten a further 3/4 - 1 turn.

8.

After replacing the filter cartridge, add engine oil through oil filler @ until the oil level is between the H and L marks on the dipstick. For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

9.

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”.

NOTICE 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.

3-60


24.4.3 CHECK OIL LEVEL IN HYDRAULIC

TANK, ADD OIL

&k WARNING l

l

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

1.

Lower the blade to the ground in horizontal position, lower the ripper shankvertically and put the tip of the shank in contact with the ground.

2.

Stop the engine and wait for about 5 minutes before checking oil level. If oil level is between top and bottom of red circle sight gauge 0, it is normal.

NOTICE Do not add oil if the level is above the H line. This will damage the hydraulic equipment and cause the oil to spurt out. 3.

If the level is below the L mark, add engine

oil through

oil filler

0.

AND


3-61

24.

SERVICE

PROCEDURE

24.4.4 CHECK, ADJUST TENSION

ALTERNATOR

DRIVE BELT

CHECK The standard deflection for the drive belt is approx. 15 mm (0.59 in) when pressed by thumb (approx. 6 kg (13.23 lb)) at a point midway between the drive pulley and alternator pulley.

ADJUSTING 1. Loosen

bolts and nuts 0,

Alternator

@ and 0.

pulley

I 2.

3.

Turn nut @ clockwise, then move alternator @ to adjust the belt tension so that the deflection is approx. 15 mm (0.59 in) when pushed with a force of 6 kg. Tighten the bolts and nuts 0, position.

@ and @ to fix alternator

I About 15mm

@ in

Drive pulley

A0053430

I

4.

Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove.

5.

If any belt has stretched and there is no allowance for adjustment, or if there are cuts or cracks on any belt, replace the belt.

6.

When the new belt is set, readjust

AE20937B

3-62

it after operation

for an hour.


24.4.5 CHECK LEVEL OF BAlTERY Carry out this check before a l

l

operating

ELECTROLYTE the machine.

WARNING

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.

1.

Open the battery

cover.

2.

Remove cap @ and check that the battery electrolyte is up to the UPPER LEVEL line. If the level is low, add distilled water. Do not add water above the UPPER LEVEL line. This may cause leakage of the electrolyte, which may cause fire. If the battery electrolyte has spilled, have dilute sulphuric acid added.

3.

When adding distilled water to any cell at cap 0, water also to the other cells.

4.

Clean the air hole in the battery cap, then tighten the cap securely. Wipe the top surface of the battery with a damp cloth to keep it clean.

add distilled

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

3-63


24.4.6 CHECK BRAKE PERFORMANCE

contact

your Komatsu

distributor

for repairs

Before starting the engine, check machine is safe, then do as follows.

that

immediately.

the

area

around

the

1. Start the engine. 2.

Set safety lever @ to the FREE position then operate blade control lever and ripper control lever @ to raise the blade and ripper. Leave the safety lever to the FREE position.

3.

Set parking

4.

Depress brake pedal @ and move joystick @ to the FORWARD 2nd position.

lever @ to the FREE position.

NOTICE Do not place the gear shift lever in the 1st speed Otherwise, it will cause damage to the machine.

position. Machines

5.

Operate fuel control lever @ to raise the engine speed gradually to full throttle.

6.

Check that the machine does not move. This indicates that brake performance is normal.

3-64

eauimed

with CanoPY

24. SERVICE

24.5

EVERY 500 HOURS

PROCEDURE

SERVICE

Maintenance for every 250 hours service should be carried out at the same time. 24.5.1

REPLACE

FUEL

FILTER

A l

l l

CARTRIDGE

WARNING

Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing the filter. Do not bring fire or sparks near the fuel. When bleeding the air, be carefull not to let the fuel overflow. It may cause a fire.

Prepare

a filter wrench

1. Set the container

and a container

to catch the fuel.

to catch the fuel under the filter cartridge.

2.

Close valve 0.

3.

Remove drain plug @ at the bottom of the filter, and drain the oil. After draining the oil, tighten drain plug @ again.

4.

Using a filter wrench, remove it.

turn filter cartridge

@ counterclockwise

to

I

5.

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.

6.

When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it up 3/4 to 1 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.

7.

Open valve @ and loosen

8.

Loosen the knob of feed pump @I and move the pump up and down to draw off fuel until air ceases to come out of plug 0.

air bleeding

plug 0.

3-65

24. SERVICE

9.

PROCEDURE

Tighten air bleed plug 0, @ and tighten it.

then push in the knob of feed pump

10. After replacing the filter cartridge, start the engine and check that there is no leakage of oil from the filter seal surface. REMARK When only replacing the filter cartridge, it is enough to bleed the air from the air bleeding plug at the filter head. However, if the fuel piping is removed, bleed the air also from the air bleeding valve of the injection pump.

24.5.2 REPLACE TRANSMISSION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT 7

A

WARNING

1

Before opening the filter case, depress the brake pedal several times to release the pressure, then lock the brake pedal. If there is still pressure inside the filter, the oil may spurt out. 1. 2.

Remove

the floor cover on right side fender.

Remove

bolts @ and cover @ is lifted up, then take out element

0. Clean the inside of the case and the removed new elements. Replace the O-ring at the same time.

parts, and install

AL116560

3-66


:

24.5.3 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL Ah WARNING There is danger that the oil may spurt out under internal pressure, so to the side, and gradually turn the plug to release the internal pressure before removing the plug completely.

1.

Place the machine

on a horizontal

place.

2.

Remove oil level plug @ and check whether the final drive case is filled with oil to lower edge of the plug hole.

AE209410

3.

AND

If the oil level is still too low, add gear oil through oil level plug hole @$ until the oil overflows. Before removing oil level plug 0, remove all the mud and dirt from around oil oil level plug 0. Be careful not to let any dirt or sand get in when adding oil. For details of the oil to use, see “20. USE OF FUEL, COOLANT LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.

3-67

24. SERVICE

PROCEDURE

24.5.4 CHECK, REPLACE FAN BELT Check the V-belt, and replace the V-belt if the condition l l

l

is as follows.

If the V-belt is in contact with the bottom of the pulley groove. If the V-belt is worn and has sunk below the outside diameter of the pulley. If the V-belt is cracked or peeling

Replacement When replacing

the V-belt,

do as follows.

1.

Insert bar @ (length approx. 50 cm) into hole @ (o/18) tension pulley bracket, then pull strongly.

of the

2.

The spring will extend and the tension pulley will move to the inside, so remove the old belt and install the new one.

Always replace the V-belts as a set (3 belts). An autotensioner is installed, so there is no need to adjust the belt tension until the belt is replaced.

I

3-68

AE209420

24.6

EVERY 1000 HOURS

SERVICE

Maintenance for every 250 and 500 hours carried out at the same time.

service

should

be

24.6.1 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE) g

WARNING

The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. Prepare the following. Container to catch drained oil: Min 150 fi capacity l Refill capacity: 150 e (39.6 US gal, 33.0 UK gal) l

1. Remove

the cover on the bottom

of the rear body.

2.

Pull out hose @I slowly to avoid getting loosen drain plug @ to drain the oil.

3.

After draining,

4.

Insert hose @ inside the cover, then install the cover.

tighten

oil on yourself,

and

drain plug 0.

-(z/l= 5.

Remove

the cover on left fender,

remove

AL116590

bolts @ and case 0.

I

\\

AE209430

3-69


6.

Take out strainer @ and magnet 8. If any damage to strainer @ or magnet a new one.

@ is found,

replace with

7.

Loosen bolt 0, then divide into strainer @ and magnet 8. Tightening torque of bolt 0: 46 - 59 Nm (4.7 - 5.9 kgm, 34 - 43 Ibft)

8.

Remove all dirt from strainer, then wash in clean diesel oil or flushing oil. Clean the case interior and the removed parts.

9.

Install the strainers

to their original

position.

10. After installing, replace the element in the power train oil filter. For details, see “24.5 EVERY 500 HOURS SERVICE”.

L-J 11. Refill the specified

AND

quantity

of engine

oil through

oil filler 0.


12. Check that the oil is at the specified level. For details, see “24.2 CHECK BEFORE STARTING”.

24.6.2 CHECK, CLEAN FUEL STRAINER 1.

Tighten

2.

Remove cap 0, and wash the strainer and strainer The strainer forms one unit with the cap.

3.

After checking tighten cap 0.

4.

After installing,

3-70

valve 0.

and cleaning,

open valve 0.

set the strainer

case.

in the case, then

AE209440


A

24.6.3 CLEAN STEERING CLUTCH CASE BREATHER 1.

Remove

bolts 0,

then remove

cover 0.

2.

Remove breather @ on steering clutch case, and wash out dust remaining inside with diesel fuel or flushing oil.

24.6.4 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL 1. Remove bolts (iJ, then remove cover 0. When in.

removing

the cover, be careful

not to let dirt or sand get

2.

Insert a scale and check that the oil level is 70 - 80 mm (2.6 - 3.2 in) from the bottom edge of the inspection port.

3.

If the oil level is low, add engine oil so that the oil. Use Class CD SAEIO engine oil regardless of the ambient perature.

tern-

AE20947B

24 8.6.5 GREASE TENSION

PULLEY ASSEMBLY

1.

Using a grease pump, pump in grease through shown by arrow.

2.

After

greasing,

wipe

off any old grease

that

the grease fitting

was

pushed

out.

3-71

24. SERVICE

24.6.6

PROCEDURE

CHECK FOR LOOSE ROPS MOUNT

BOLTS

Check for loose and damaged bolts. If any loose bolt is found, tighten to a torque of 1520 - 1912 Nm (155 - 195 kgm, 1121 - 1410 Ibft). If any damaged bolt is found, replace the bolt with a genuine Komatsu bolt.

24.6.7

REPLACE CORROSION a

RESISTOR CARTRIDGE

WARNING

If the engine has been operated, all parts will be at a high temperature, so never try to replace the cartridge immediately after stopping the engine. Always wait for the engine and other parts to cool down. Prepare the following. Container to catch drained l Filter wrench l

coolant

1.

Close valves @ (2 places).

2.

Set a container

3.

Using a filter wrench,

4.

Clean the filter holder, coat the packing surface and thread of the new cartridge 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 up 2/3 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of coolant. If the filter cartridge is too loose, coolant will also leak from the packing, so always tighten to the correct amount.

6.

Open valves

7.

After replacing the cartridge, start the engine and check for any leakage of water from the filter seal surface. If there is any water leakage, check if the cartridge is tightened properly.

24.6.8

to catch the coolant

cartridge

0.

AN167100

@ (2 places).

CHECK ALL TIGHTENING TURBOCHARGER

Contact your Komatsu

3-72

remove

under the cartridge.

distributor

PARTS OF

for inspection

or adjustment.


24.7

EVERY 2000 HOURS SERVICE

Maintenance for every 250, 500 and 1000 hours service should be carried out at the same time.

24.7.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT

The oil is at high temperature oil. When

removing

immediately

the oil filler cap 0,

after the machine

has

turn it slowly to release

Prepare the following. Container to catch drained oil: Min. 120 f? capacity l Refill capacity: 120 e (31.68 US gal, 26.4 UK gal) 0

1.

Lower the blade and ripper on the ground securely, stop the engine and slowly turn the cap of oil filler @ to release the internal pressure. Then, remove the cap.

2.

Remove drain plug @ at the bottom of the tank and loosen drain valve 0. After draining the oil, tighten drain plug @ and drain valve 0. When loosening drain valve 0, be careful not to get oil on yourself.

3.

Remove bolts 0, lift up cover 0, valve together with the cover.

4.

Remove nut @ which is tightening element removed parts and install new element. Replace O-ring at the same time.

5.

Add engine

AND


6.

oil through

and take out element

I

I

@ and

@ and clean the

oil filler port @ to the specified

After adding oil, check that the oil is at the specified details, see “25.4 EVERY 250 HOURS SERVICE”.

level.

level. For

AL116710

3-73

24.

SERVICE

PROCEDURE

24.7.2 CHANGE OIL IN FINAL DRIVE CASE

A l

l

WARNING

The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. There is danger that the internal pressure will cause the oil to spurt out, so when removing the plug, stand to the side and turn the plug slowly to release the internal pressure, then remove the plug carefully.

Prepare the following. l Container to catch drained oil: Min. 65 e capacity l Refill capacity: each 65 e (17.16 US gal, 14.3 UK gal) 1.

Remove oil filler plug 0, then remove drain plugs (iJ, and drain the oil. Remove all the mud and dirt from around oil filler plug @ before removing it. Be careful not to let any dirt or sand get in when adding oil.

2.

After draining

3.

Refill the engine oil until oil overflows and tighten the plugs.

AND

3-74

the oil, tighten

the drain plug 0. from filler plug hole 0,



24.7.3 CHANGE OIL IN DAMPER CASE, CLEAN AIR HOLE AND BREATHER Prepare the following. Container to catch drained oil: Min. 2.1 .@capacity Refill capacity: 2.1 .rZ(0.55 US gal, 0.46 UK gal) Remove

breather

@ at the top of the damper.

Wash out dust remaining flushing oil.

inside of breather

@ to the original

with diesel oil and

3.

Install breather

position.

4.

Remove cover.

air hole plate @ (4 places) from the top of the damper

5.

Remove flushing

any dirt or dust, then oil.

6.

Open the inspection

7.

Remove drain plug @ slowly to avoid getting oil on yourself, drain the oil. After draining the oil, tighten plug 0.

8.

Pull out dipstick 0, through oil filler.

wash

it in clean

diesel

oil or

cover under the chassis. and

AL116760

AND 9.

and add engine

oil to the specified

level

For details of the oil to use, see “20. USE OF FUEL, COOLANT LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. Check that the oil level is between the H and L marks on dipstick (iJ For details, see “24.3 CHECK BEFORE STARTING”.

10. Close the inspection

cover.

3-75

24. SERVICE

PROCEDURE

24.7.4 CHECK PIVOT BEARING OIL LEVEL, ADD OIL 1.

2.

Remove plug 0. When removing plug 0,

be careful

not to let dirt or dust get it.

Check that the oil is at the level shown in the diagram. If the oil level is low, add engine oil through the hole of plug 0.

Use Class temperature.

CD SAE

30 engine

oil regardless

of the

ambient

A-A

Section

AE20099B

24.7.5 CLEAN ENGINE BREATHER ELEMENT r 1. Loosen clamp

0,

bolt 0,

then remove then remove

the hose.

2.

Remove

breather

0.

3.

Wash the whole breather in diesel oil or flushing it dry with compressed air.

4.

Replace the breather and install it.

5.

Check the bleather hose, and if there inside, replace it with a new hose.

oil, then blow

O-ring with a new part, coat with engine oil,

is any oil sludge

on the

AL116800

3-76


24.7.6 CLEAN, CHECK TURBOCHARGER Contact your Komatsu

distributor

for cleaning

24.7.7 CHECK PLAY OF TURBOCHARGER Contact your Komatsu

distributor

24.7.8 CHECK ALTERNATOR,

or inspection.

ROTOR

to have the play checked.

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.

24.7.9 CHECK ENGINE VALVE CLEARANCE,

ADJUST

As special tool is required for removing and adjusting you shall request Komatsu distributor for service.

the parts,

3-77

24. SERVICE

24.8

PROCEDURE

EVERY 4000 HOURS SERVICE

Maintenance for every 250, 500, 1000 and 2000 should be carried out at the same time.

hours service

24.8.1 CHECK WATER PUMP Check that there is oil leakage, water leakage, or clogging of drain hole 0. If any abnormality is found, contact your Komatsu distributor for disassembly and repair or replacement.

24.8.2 CHECK VIBRATION DAMPER Check decrease of damper @ fluid, dent or out-of-flat. any abnormality, contact Komatsu distributor for repair.

If there is

24.8.3 CHECK FAN PULLEY AND TENSION PULLEY Check the pulley for play and leakage of grease. If there is any abnormality, please contact your Komatsu distributor for disassembly and repair or replacement.

3-78


24.8.4 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)

Main frame

Check after the first 4000 hours, and every 1000 hours after that. 1.

Preparation Wipe off all the mud that is stuck around portions @ - @ of the work equipment and frame to make it easier to carry out the check.

2.

Visual check Carefully check the base material of the steel casting and welding at portions @ - 0, and check that there is no damage. If any cracks or other damage are found, carry out repairs.

i 0A

Please contact your Komatsu procedure.

distributor

for details of the repair

Blade

Ripper

AE209610

3-79

0

c)

m

w

cn

25. SPECIFICATIONS

OPERATING

WEIGHT

(with semi-U

(without

dozer, variable

operator) multi

67500

kg (148838

lb)

ripper, 610 mm (24 in) shoe, ROPS cab, and air conditioner)

PERFORMANCE Forward

1st

3.8 km/h (2.4 MPH)

2nd

6.8 km/h (4.2 MPH)

I l

Travel

speed Reverse

3rd

11.8 km/h (7.3 MPH)

1st

5.1 km/h (3.2 MPH)

2nd

9.2 km/h (5.7 MPH)

I

3rd BLADE (semi-U

blade)

l

Weight of attachment and cylinder support)

l

Max. tilt

Weight

l

Digging

(incl. tilt cylinder

10540 kg (23241

lb)

1065 mm (3 ft 6 in)

I

RIPPER (variable l

15.8 km/h (9.8 MPH)

giant ripper)

of attachment angle

6720 kg (14818 Standard 45” (possible 32.5” and 55.5”)

lb)

to adjust steplessly

TOWING l

Towing

force

48500

kg (475623

N)

ENGINE l

Model

l

Flywheel

l

Maximum

0 Starting l

Alternator

l

Battery

4-2

Komatsu horsepower torque motor

SAGD170E-2

diesel engine

386 kW (525 HP)/1800

rpm

2648 Nm (270 kgm)/l300

rpm

24 V 7.5 kW x 2 pieces 24 V 12 V

50 A

170 Ah x 2 pieces

between

25. SPECIFICATIONS

Semi-U

tilt dozer + variable

U tilt dozer + variable

multi

multi

ripper

ripper

*;/ 3815(12'6* r

Overall

length

) 10405(3411')

3160(

10' 4' )"

__

“, -

? A0209638

4-3

25. SPECIFICATIONS

3815(12'6" Overall

length

)

5770(18'11') 10209646

4-4

OPTIONS, ATTACHMENTS


26.1

PRECAUTIONS

RELATED TO SAFETY

If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, please contact your Komatsu distributor first. If you do not contact Komatsu, we cannot accept any responsibility for any accident or failure.

WARNING

A

Precautions for removal and installation operations When removing or installing attachments, obey the following safety during the operation.

l

e Carry out the removal

and installation

operations

precautions

and take care to ensure

on a flat, firm ground

l

When the operation is carried during the operation.

out by two

l

When

(more than 25 kg (55 lb)), use a crane.

l

When removing heavy parts, always support the part before removing it. When lifting such heavy parts with a crane, always pay careful attention to the position center of gravity.

carrying

heavy objects

or more workers,

l

It is dangerous to carry out operations stand, and check that it is safe.

l

When removing not fall over.

l

Never go under a load suspended front a crane. Always stand in a position that is safe even if the load should

or installing

Qualifications are unqualified person. For details

5-2

required

of the removal

with

determine

surface.

attachments,

to operate

and installation

the load kept suspended.

signals and follow

Always

Never

operations,

allow

of the

set the load on a

make sure that they are in a stable condition

a crane.

these

and will

fall.

the

please contact

crane

to be operated

your Komatsu

by an

distributor.

27. USING SEAT BELT

When operating the seat belt.

l

l l l

a machine

equipped

A

WARNING

with ROPS, be sure to use

Before fastening the seat belt, inspect the securing brackets and belt for abnormal conditions. Replace any worn or damaged seat belt or the securing brackets. Adjust and fasten the seat belt before operating the machine. Always use seat belt when operating the machine. Fit the seat belt across your lap without twisting.

27.1

FASTEN THE BELT AND REMOVE FOLLOWING MANNER

IT IN THE

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

all the

After positioning the seat, adjust the tether belt 0. With the seat unoccupied, tense the belt slightly across the seat and install. Sit in the seat, hold tongue @ of reel 0, and pull the belt out slowly to a length which fully covers your lap. Insert tongue @ into buckle @ and push until there is a click. Pull back reel @ until the belt fits securely across your lap. In this condition, the lock is applied to prevent the belt from extending any further. Fit the seat belt across your lap without twisting. REMARK If the lock is applied before the tongue is installed into the buckle, return the belt to the reel, then carry out the operation again from the beginning. 5.

Tense the belt and check that the lock is applied.

6.

To remove the belt, press the red button on buckle 0. will automatically wind in.

I

The belt

Inspect bolts and fittings on the chassis for tightness. Retighten any loose bolts to 19.6 to 29.4 Nm (2 to 3 kgm, 14.5 to 21.7 Ibft) torque. If the seat is scratched or frayed or if any of the fittings are broken or deformed from long service, replace the seat belt immediately.

5-3

28. SELECTION OF TRACK SHOE

28.1 SELECTION Select suitable

OF TRACK SHOES track shoes to match the operating

conditions.

METHOD OF SELECTING SHOES If a wider shoe than necessary is used, the load on the track will increase, and this will cause the shoes to bend, links to crack, pins to break,~shoe bolts to come loose, and various other problems. Category

A

Use

Bedrock, normal soil

Precautions

5-4

Normal

C

Soft soil

soil

using

Track shoe width

This shoe can be used for a wide range of work from crushed rock to general civil engineering work such as reclamation of residential land. There is no particular limit to its use. Use this shoe for general

0

when

soil, such as where

610 mm (24 in)

the

main work is scraper work and pusher work, reclaiming land for golf courses, or stripping the overburden for coal mines. This shoe cannot be used on bedrock. On jobsites where there are rocks in the soil, be careful to avoid letting the machine mount the rocks. Use this shoe on soft ground where the shoe in category B sinks into the ground. Do not use this shoe on jobsites where there are rocks in the soil.

610 mm (24 in)

710 mm (28 in) 810 mm (32 in)

@

Procedure

@

Suitable point

Typical rock

Check

Procedure

v

Features

Part No.

Shape

Point @ Non-symmetrical shape 0 Yellow a Short

195-78-71420

ALl16620

+@J~~~+$ZJ~~

l

Features

195-78-71320

ALIl6620

-

Hard

Point @ Non-symmetrica shape 0 Yellow l Short l

?

No

195-78-71370

Medium

195-78-71340

AL116650

Point @ Non-symmetrica shape 0 Yellow 0 Long l

v

v

granite,

Soft e

Yes

chest

Hard

v Does it penetrate ? (Can it be used to end ?)

No v

1

195-78-71350

AL116650

195-78-71330

AL116620

Point @ Non-symmetrica shape a Red l Short l

195-78-71390

AL116640

Point @ l Symmetrical shape a Red l Short

Proportion of quartz is not so high (40% - 70%) Rock is not in layers or seams, so heat is generated at point, point wear rapidly, ripping is difficult

Point @ Non-symmetrica shape a Red 0 Long l

l

l

Basalt, andesite,

No

1

Install point 0

Install point @

v Do impact force cause breakage ?

No (Less than 70%)

v Does impact force cause breakage ?

0 Proportion of quartz is high (70% - 95%), point wears rapidly

Sandstone

Soft -

No

v

1 Install point @ 1

Yes (Over 70%) (Whole point is worn evenly)

Dose rock have high quartz contents ?

Install standard point @

AL116640

Point @ Symmetrical shape 0 Yellow l Short l

rock

v Does it penetrate ? (Can it be used to end ?)

No

cracks produced

No v

All type of general

Soft p

v

<

point Q 1

1Is wear fast ?

[ Install standard

Yes

0 Little quartz, little wear l Deposited in layers, so ripping is easy

Type of rock Shale, limestone

Hardness

penetration

@

Check for cracks or breakage

Procedure

Check wear

@

Procedure

30. HANDLING

30.1

OPENING

CAP WITH LOCK

AND CLOSING

LOCKABLE CAP

Lock-type caps are available for the radiator water filler cap, fuel tank filler cap, power train case oil filler cap, hydraulic tank oil filler cap, and hydraulic tank breather cap. The cap opening and closing method is as follows.

WHEN OPENING CAP 1. Insert the key. Make sure that you have inserted the key fully before turning it. If the key is turned when only partially inserted, it may break. 2.

Turn the key counterclockwise to align the match mark on the cap with the rotor groove, then turn the cap slowly. When a click is heard, the lock is released, enabling the cap to be opened.

-

180”

houlder

AD053810

TO LOCK THE CAP 1. Turn the cap into place. 2.

Turn the key clockwise

REMARK When open.

5-6

the cap is locked,

and take the key out.

it can be turned

freely,

but it will not

I

AD053820

31. E6oFZEECRT’VE METHOD OF OPERATION

31 .I

FOR DUAL TILT

BLADE CONDITION Operating

Single tilt l Normal

method

Applicable l

Normal

operation

Blade position

operations

tilt operation

AE209650

Dual tilt Turn the dual button ON and carry out tilt operation

l

l l

l

l

Digging up boulders Side cutting operations (high places) Horizontal dozing operations from side slope (rough ground) Ditching operations

Hauling Dozing soft soil (filling) Leveling operations (spreading) Side-cutting operations

R pitch (pitch back) Turn the pitch button ON and carry out left tilt operations

l

AE209670

S pitch (standard)

l

Normal

F pitch (pitch dump) Turn the pitch button ON and carry out right tilt operations

l

Digging natural ground and bedrock (digging hard soil) Pushing soil over cliffs Pushing-up soil (Reduces spillage of soil over the top surface of the blade, and reduces amount of soil carried back)

l

l l

operations

AE209690

5-7

31. EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER

31.2

DOZING

WORK

31.2.1 DOZING ON LEVEL GROUND Natural

ground,

OR DOWNHILL

bedrock

Forward

Ditch

2. Haul

ing

I

3. OumDing

AE20970B

a

WARNING

If you feel that the situation is dangerous when dumping the soil, for safety reasons, use two movements to push the soil over the edge. Dig with the F (Forward) pitch, and when the load on the blade is approx. 80%, return to S (Straight) pitch and continue digging. Set to R (Rear) pitch which gives a larger load, and haul the soil. Adjust the cutting angle to the most effective angle for rolling the soil. Use F pitch to dump

5-8

the soil.


Filling, soft soil Carry out digging

in R pitch or S pitch, and haul in R pitch.

REMARK If the digging is carried out in R pitch, there is no sudden digging into the soil, and the operation can be carried out smoothly.

Hard soil (hard clay, shale, etc.) If digging is carried out in F pitch, and the chassis is raised and the blade is tilted, the end bit will dig in better.

5-9

31. EFFECTIVE

METHOD

OF OPERATION

FOR DUAL TILT DOZER

31.2.2 PUSHING-UP SOIL

r

Forward

Rear

Ditch

L

1.

Dig with S pitch When digging gradually, use R pitch. If the ground is hard, use F pitch.

2.

Haul with R pitch. If there is any spillage to S pitch.

3.

5-10

of soil over the top of the blade, change

Dump the soil with F pitch. This dumps the soil more effectively, after dumping.

and less soil is carried back

pitch


31.3

LEVELING

(SPREADING)

OPERATIONS

Carry out this operation with R pitch. When carry out this operation with R pitch, the end bit does not dig in, and the ground can be leveled (or the soil can be spread) smoothly. REMARK If the tilt cylinder is moved completely to the end of its stroke, the tilt operation cannot be carried out on one side, so move the cylinder back slightly from the end of its stroke to the S pitch position.

31.4

DITCHING

OPERATIONS

If the dual tilt is used, the digging width becomes smaller a deeper ditch can be dug. If R pitch is used, the digging can be carried out gradually, this reduces the unevenness.

31.5

BOULDER

RAISING

and and

OPERATIONS

Because the dual tilt greatly increases the amount of tilt, the blade can dig in deep and hook under the boulder. In addition, the operating stroke is large, so operations to raise boulders can be carried out effectively.

t

t

i

It_

---J&

AE20974B

31.6

SIDE-CUTTING

OPERATIONS

Carry out this operation in R pitch, and set the end face of the end bit in contact with the rock face to carry out cutting.

AE209750

REMARK With the dual tilt it is possible to increase the amount to carry out side-cutting operations on higher walls.

of tilt and

AE209760

5-11


31.7

HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND)

The ! dual tilt can give a larger amount of tilt, so when dozing from a side slope, this is effective because the chassis becomes horizontal after a short digging distance.

AE209770

5-12

D375A-3 Form No.

BULLDOZER SEAM010801

’ 1997 KOHAlkU

All Rights 09-97

(01-l)

Reserved

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:

Sead 010801

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