Professional Documents
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. FOREWORD
FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance. Always be sure to read and understand this manual thoroughly before performing operation and maintenance. Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully. Keep this manual at the storage location for the operation and maintenance manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
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If you sell the machine, be sure to give this manual to the new owners together with the machine. 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. Storage location for the Operation and Maintenance Manual: Pocket on right side inside cab
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FOREWORD
FOREWORD
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. FOREWORD
FOREWORD
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FOREWORD
SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations. Signal words The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage. In this manual and on machine labels, the following signal words are used to express the potential level of hazard. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. This word is used also to alert against unsafe practices that may cause property damage.
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Example of safety message using signal word
WARNING
To avoid hitting unlocked operation levers, lower equipment to ground and move SAFETY LOCK LEVER to LOCK position before starting up from operator's seat. Sudden and unwanted machine movement can cause serious injury or death.
Other signal words In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is useful to know. This word is used for precautions that must be taken to avoid actions which could shorten the life of the machine. This word is used for information that is useful to know.
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. SAFETY INFORMATION
FOREWORD
Safety labels Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out operation or maintenance of the machine that may involve hazard. This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures. Example of safety label using words
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Safety labels using pictogram Safety pictograms use a picture to express a level of hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or maintenance worker understand the level and type of hazardous condition at all times. Safety pictograms show the type of hazardous condition at the top or left side, and the method of avoiding the hazardous condition at the bottom or right side. In addition, the type of hazardous condition is displayed inside a triangle and the method of avoiding the hazardous condition is shown inside a circle.
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, it is your responsibility to take the necessary steps to ensure safety. In no event should you engage in prohibited uses or actions described in this manual. The explanations, values, and illustrations in this manual were prepared based on the latest information available at that time. 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. The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))
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FOREWORD
INTENDED USE
INTENDED USE
This Komatsu machine is designed to be used mainly for the following work: Smoothing Repair and maintenance of gravel roads Ditch digging Cutting slope faces Excavating operations Mixed operations Spreading operations Front wheel offset operations See the section "WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER (PAGE 3-78)" for further details.
DIRECTIONS OF MACHINE
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In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the operator's seat in the direction of travel (front) of the machine.
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FOREWORD
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ENGINE SERIAL NO. PLATE POSITION
This is on the left side of engine cylinder block as seen from the fan.
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FOREWORD
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Distributor name Address Service Personnel Phone/Fax
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. CONTENTS
FOREWORD
CONTENTS
FOREWORD FOREWORD SAFETY INFORMATION INTENDED USE DIRECTIONS OF MACHINE LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ENGINE SERIAL NO. PLATE POSITION SERVICE METER POSITION TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SAFETY SAFETY INFORMATION SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS PRECAUTIONS DURING OPERATION STARTING ENGINE OPERATION TRANSPORTATION BATTERY TOWING PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WITH TIRES OPERATION GENERAL VIEW GENERAL VIEW OF MACHINE GENERAL VIEW OF CONTROLS AND GAUGES EXPLANATION OF COMPONENTS MONITOR PANEL METERS AND LAMPS SWITCHES CONTROL LEVERS, PEDALS DUST INDICATOR ARTICULATE LOCK PIN FUSE BOX OPERATOR'S CAB LIFT MECHANISM BACKUP ALARM FRONT GLASS TOOL BAG STORAGE BOX QUICK-FILL FUEL FILLER OPERATION CHECK BEFORE STARTING ENGINE STARTING ENGINE OPERATIONS, CHECKS AFTER STARTING ENGINE STOPPING ENGINE CHECK AFTER STOPPING ENGINE TRAVELING POSTURE FOR MACHINE 11111111112222222222222233333333333333333333333331 2 5 7 7 8 8 8 9 9 1 2 4 5 6 12 20 20 22 26 27 29 30 36 1 2 2 3 6 6 19 20 29 38 38 39 40 40 41 42 42 42 43 43 58 61 63 63 64
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FOREWORD
CONTENTS
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MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING TURNING MACHINE OPERATING WORK EQUIPMENT WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER PRECAUTIONS WHEN OPERATION ADJUSTING WORK EQUIPMENT POSTURE PARKING MACHINE CHECKS AFTER COMPLETION OF OPERATION LOCKING HANDLING THE TIRES HANDLING BLADE ACCUMULATOR HANDLING BLADE FLOAT TRANSPORTATION LOADING, UNLOADING WORK PRECAUTIONS FOR LOADING COLD WEATHER OPERATION PRECAUTIONS FOR LOW TEMPERATURE CAUTIONS AFTER COMPLETION OF WORK AFTER COLD WEATHER LONG-TERM STORAGE BEFORE STORAGE DURING STORAGE AFTER STORAGE TROUBLESHOOTING AFTER RUNNING OUT OF FUEL WHEN LEANING PIPING IS DAMAGED TOWING THE MACHINE IF BATTERY IS DISCHARGED OTHER TROUBLE TRANSMISSION CONTROLLER MAINTENANCE GUIDES TO MAINTENANCE OUTLINES OF SERVICE HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC RELATING TO ELECTRIC SYSTEM WEAR PARTS WEAR PARTS LIST USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS TORQUE LIST PERIODIC REPLACEMENT OF CRITICAL PARTS CRITICAL PARTS MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART SERVICE PROCEDURE INITIAL 250 HOURS SERVICE (only after the first 250 hours) WHEN REQUIRED CHECK BEFORE STARTING EVERY 50 HOURS SERVICE EVERY 250 HOURS SERVICE
3- 65 3- 71 3- 73 3- 78 3-106 3-110 3-111 3-113 3-113 3-114 3-115 3-117 3-119 3-119 3-120 3-121 3-121 3-122 3-122 3-123 3-123 3-123 3-123 3-124 3-124 3-124 3-125 3-128 3-131 3-136 4- 1 4- 2 4- 4 4- 4 4- 6 4- 7 4- 7 4- 8 4- 12 4- 12 4- 13 4- 13 4- 14 4- 14 4- 16 4- 16 4- 17 4- 26 4- 27 4- 28
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. CONTENTS
FOREWORD
EVERY 500 HOURS SERVICE EVERY 1000 HOURS SERVICE EVERY 2000 HOURS SERVICE EVERY 4000 HOURS SERVICE SPECIFICATIONS SPECIFICATIONS ATTACHMENTS, OPTIONS HANDLING EMERGENCY STEERING DEVICE CHECKING AIR CONDITIONER LOCATIONS AND FUNCTIONS OF CONTROL PANEL METHOD OF OPERATION PRECAUTIONS WHEN USING HANDLING AIR-SUSPENSION SEAT ADJUST OPERATOR'S SEAT INDEX
4444556666666667-
41 49 58 62 1 2 1 2 2 3 3 5 5 6 6 1
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. SAFETY INFORMATION
SAFETY
SAFETY INFORMATION
SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS SAFETY RULES IF ABNORMALITIES ARE FOUND CLOTHING AND PERSONAL PROTECTIVE ITEMS FIRE EXTINGUISHER AND FIRST AID KIT SAFETY FEATURES KEEP MACHINE CLEAN INSIDE OPERATOR'S COMPARTMENT ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT HANDRAILS AND STEPS MOUNTING AND DISMOUNTIN DO NOT GET CAUGHT IN ARTICULATED PORTION PREVENTION OF BURNS FIRE PREVENTION ACTION IF FIRE OCCURS WINDOW WASHER LIQUID PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) PRECAUTIONS FOR ATTACHMENTS UNAUTHORIZED MODIFICATION SAFETY AT WORKSITE WORKING ON LOOSE GROUND DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES ENSURE GOOD VISIBILITY VENTILATION FOR ENCLOSED AREAS CHECKING SIGNALMAN'S SIGNALS AND SIGNS EMERGENCY ESCAPE FROM OPERATOR'S CAB ASBESTOS DUST HAZARD PREVENTION 2222222222222222222222222222224 5 6 12 12 12 12 12 12 13 13 13 14 14 15 15 16 16 17 17 17 17 18 18 18 19 19 19 19 19
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SAFETY
SAFETY INFORMATION
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PRECAUTIONS FOR MAINTENANCE WARNING TAG KEEP WORK PLACE CLEAN AND TIDY APPOINT LEADER WHEN WORKING WITH OTHERS STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING PROPER TOOLS ACCUMULATOR PERSONNEL ATTACHMENTS WORK UNDER THE MACHINE NOISE PRECAUTIONS WHEN USING HAMMER REPAIR WELDING REMOVING BATTERY TERMINAL PROHIBITED TO DISASSEMBLE BANK CONTROL LOCK PIN PRECAUTIONS WITH HIGH-PRESSURE OIL HANDLING HIGH-PRESSURE HOSES WASTE MATERIALS MAINTENANCE OF AIR CONDITIONER COMPRESSED AIR PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS PRECAUTIONS WITH TIRES HANDLING TIRES PRECAUTIONS WHEN STORING TIRE 222222222222222222222230 30 30 30 31 32 32 33 33 33 33 33 34 34 34 34 34 35 35 35 35 35
PRECAUTIONS DURING OPERATION STARTING ENGINE CHECKS BEFORE STARTING ENGINE, ADJUST PRECAUTIONS WHEN STARTING PRECAUTIONS IN COLD AREAS OPERATION CHECKS BEFORE STARTING OPERATION PRECAUTIONS BEFORE MOVING OFF PRECAUTIONS WHEN TRAVELING PRECAUTIONS WHEN TRAVELING ON SLOPES PRECAUTIONS WHEN OPERATIONS ON SLOPES PROHIBITED OPERATIONS PRECAUTIONS WHEN OPERATING OPERATE CAREFULLY ON SNOW PARKING MACHINE TRANSPORTATION LOADING AND UNLOADING SHIPPING BATTERY BATTERY HAZARD PREVENTION STARTING WITH BOOSTER CABLES TOWING WHEN TOWING
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20 20 20 20 21 22 22 22 23 24 24 24 24 25 25 26 26 26 27 27 28 29 29
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. SAFETY LABELS
SAFETY
SAFETY LABELS
The following warning signs and safety labels are used on this machine. Be sure that you fully understand the correct position and content of labels. To ensure that the content of labels can be read properly, be sure that they are in the correct place and always keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to peel off. There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same way. If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
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SAFETY
SAFETY LABELS
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. SAFETY LABELS
SAFETY
SAFETY LABELS
(1) Warning before operating machine (09651-A0641)
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(3) Caution when oil is at high temperature (09653-A0481)
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SAFETY
SAFETY LABELS
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(6) Warning of compressed spring (09820-E0481)
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. SAFETY LABELS
SAFETY
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(8) Articulate lock (09161-E0641)
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SAFETY
SAFETY LABELS
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(10) Do not enter (09162-E0641)
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. SAFETY LABELS
SAFETY
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(14) "Do not modify ROPS" sign (09620-A2000)
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SAFETY
SAFETY LABELS
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(18) Warning for battery (This plate is stick on the machine by the battery maker)
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. GENERAL PRECAUTIONS
SAFETY
GENERAL PRECAUTIONS
SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger. When working with another operator or with a person on worksite traffic duty, be sure that all personnel understand all hand signals that are to be used. IF ABNORMALITIES ARE FOUND If you find any problems in the machine during operation or maintenance (noise, vibration, smell, incorrect gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person in charge and have the necessary action taken. Do not operate the machine until the problem has been corrected. CLOTHING AND PERSONAL PROTECTIVE ITEMS Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other protruding parts. If you have long hair and it hangs out from your hard hat, there is a hazard that it may get caught up in the machine, so tie your hair up and be careful not to let it get caught. Always wear a hard hat and safety shoes. If the nature of the work requires it, wear safety glasses, mask, gloves, ear plugs, and safety belt when operating or maintaining the machine. Check that all protective equipment functions properly before using it.
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FIRE EXTINGUISHER AND FIRST AID KIT Always follow the precautions below to prepare for action if any injury or fire should occur. Be sure that fire extinguishers have been provided and read the labels to ensure that you know how to use them in emergencies. Carry out periodic inspection and maintenance to ensure that the fire extinguisher can always be used. Provide a first aid kit at the storage point. Carry out periodic checks and add to the contents if necessary.
SAFETY FEATURES Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. Understand the method of use of safety features and use them properly. Never remove any safety features. Always keep them in good operating condition.
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SAFETY
GENERAL PRECAUTIONS
KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not use water or steam to wash the electrical system (sensors, connectors). If inspection and maintenance is carried out when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes. Always keep the machine clean.
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ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT If the work equipment control levers are touched by mistake, the machine may move suddenly, and this may lead to a serious accident. When leaving the machine, always lower the work equipment completely to the ground, set gearshift lever (1) to the P (Parking) position, then stop the engine. Use the key to lock all the equipment. Always remove the key, take it with you, and keep it in the specified place. To ensure that there is enough space to get on or off the machine, raise the steering column fully when getting off the machine.
INSIDE OPERATOR'S COMPARTMENT When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious accident. Do not leave parts or tools lying around the operator's compartment. Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire. Do not use cellular telephones inside the operator's compartment when driving or operating the machine. Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.
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. GENERAL PRECAUTIONS
SAFETY
HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine.
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To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps to ensure that you support yourself. Do not grip the control levers when getting on or off the machine. Never climb on the engine hood or covers where there are no non-slip pads. Before getting on or off the machine, check the handrails and steps, and if there is any oil, grease, or mud on them, wipe it off immediately. In addition, repair any damage and tighten any loose bolts. Do not get on or off the machine while holding tools in your hand. MOUNTING AND DISMOUNTING Never jump on or off the machine. Never get on or off a moving machine. If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it.
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SAFETY
GENERAL PRECAUTIONS
DO NOT GET CAUGHT IN ARTICULATED PORTION The clearance in the area around the work equipment changes according to the movement of the link. If you get caught, it will lead to serious injury. Do not allow anyone near any of the rotating or telescoping parts.
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PREVENTION OF BURNS High-temperature coolant To prevent burns caused by boiling water or steam spurting out when inspecting or draining the coolant, wait for the temperature to go down to a point where the radiator cap can be touched by hand. When the radiator cap is cool, loosen the cap slowly to release the pressure inside the radiator, then remove the cap. Hot oil To prevent burns from hot oil spurting out when checking or draining the oil, wait for the oil to cool to at temperature where it is possible to touch the cap or plug by hand before starting the operation. Even when the oil has cooled down, loosen the cap or plug slowly to relieve the internal pressure before removing the cap or plug.
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. GENERAL PRECAUTIONS
SAFETY
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Fire caused by accumulation of flammable material. Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed around the engine, exhaust manifold, muffler, or battery, or inside the undercovers. Fire coming from electric wiring Short circuits in the electrical system can cause fire. Always keep electric wiring connections clean and securely tightened. Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair or replace any damaged wiring. Fire coming from hydraulic line Check that all the hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury. Explosion caused by lighting equipment When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with anti-explosion specifications. If such lighting equipment is not used, there is danger of explosion that may cause serious injury. When taking the electrical power for the lighting from the machine itself, follow the instructions in this manual. ACTION IF FIRE OCCURS If a fire occurs, escape from the machine as follows. Turn the start switch OFF to stop the engine. Use the handrails and steps to get off the machine.
FIRE PREVENTION Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particularly flammable and can be hazardous. To prevent fire, always observe the following: Do not smoke or use any flame near fuel or oil. Stop the engine before refueling. Do not leave the machine while adding fuel or oil. Tighten all fuel and oil caps securely. Do not spill fuel on overheated surfaces or on parts of the electrical system. Use well-ventilated areas for adding or storing oil and fuel. Keep oil and fuel in the determined place and do not allow unauthorized persons to enter. After adding fuel or oil, wipe up any spilled fuel or oil. When carrying out grinding or welding work on the chassis, move any flammable materials to a safe place before starting. When washing parts with oil, use a non-flammable oil. Diesel oil and gasoline may catch fire, so do not use them. Put greasy rags and other flammable materials into a safe container to maintain safety at the work place. Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.
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SAFETY
GENERAL PRECAUTIONS
WINDOW WASHER LIQUID Use an ethyl alcohol base washer liquid. Methyl alcohol base washer liquid may irritate your eyes, so do not use it. PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) Install ROPS when working in places where there is danger of falling rocks, such as in mines and quarries, or in places where there is danger of rolling over. If ROPS is installed, do not remove it when operating the machine. ROPS is installed to protect the operator when machine rolls over. When machine rolls over, ROPS supports its weight and absorbs its impact energy. If ROPS is modified, its strength may be reduced. When modifying, consult your Komatsu distributor. If ROPS is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always Komatsu contact your distributor for advice of the method of repair. Even if ROPS is installed, always fasten your seat belt properly when operating the machine. If you do not use your fasten your seat belt properly, it cannot display its effect.
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PRECAUTIONS FOR ATTACHMENTS When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore contact your Komatsu distributor for advice. Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu. When installing and using optional attachments, read the instruction manual for the attachment, and the general information related to attachments in this manual. UNAUTHORIZED MODIFICATION Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.
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. GENERAL PRECAUTIONS
SAFETY
SAFETY AT WORKSITE Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do not carry out operations at places where there is a hazard of landslides or falling rocks. If water lines, gas lines, or high-voltage electrical lines may be buried under the worksite, contact each utility and identify their locations. Be careful not to sever or damage any of these lines. Take action to prevent unauthorized people from approaching the jobsite. When working on public roads, position flagmen and erect barriers to ensure the safety of passing traffic and pedestrians. When traveling or operating in shallow water or on soft ground, check the shape and condition of the bedrock, and the depth and speed of flow of the water before starting operations. In order that travel operations can be carried out safely, always keep the roads on the jobsite properly maintained. WORKING ON LOOSE GROUND Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after earthquakes is weak in these areas. When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling. DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows. Before starting work near electric cables, inform the local power company of the work to be performed, and ask them to take the necessary action.
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Even going close to high-voltage cables can cause electric shock, which may cause serious burns or even death. Always maintain a safe distance (see the table on the right) between the machine and the electric cable. Check with the local power company about safe operating procedure before starting operations. To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on top of the seat, and be careful not to touch the chassis with any exposed part of your body. Use a signalman to give warning if the machine approaches too close to the electric cables. When carrying out operations near high voltage cables, do not let anyone come close to the machine.
Voltage of Cables
100 V - 200 V 6,600 V 22,000 V 66,000 V 154,000 V 187,000 V 275,000 V 500,000 V
Safety Distance
Over 2 m (7 ft) Over 2 m (7 ft) Over 3 m (10 ft) Over 4 m (14 ft) Over 5 m (17 ft) Over 6 m (20 ft) Over 7 m (23 ft) Over 11 m (36 ft)
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SAFETY
GENERAL PRECAUTIONS
If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should not leave the operator's compartment until it has been confirmed that the electricity has been shut off. Also, do not let anyone come close to the machine. ENSURE GOOD VISIBILITY Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to ensure that operations and travel can be carried out safely. Always do as follows. Position a signalman if there are areas at the rear of the machine where the visibility is not good. When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up additional lighting in the work area if necessary. Stop operations if the visibility is poor, such as in mist, snow, rain, or dust. VENTILATION FOR ENCLOSED AREAS Engine exhaust gas includes substances that may harm your health or even kill. Always select a place with good ventilation when starting the engine or operating the machine. If it is necessary to start the engine or run the machine inside a building or underground, where the ventilation is poor, take steps to remove the exhaust gas and bring in ample fresh air.
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CHECKING SIGNALMAN'S SIGNALS AND SIGNS Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman. Only one signalman should give signals. Make sure that all workers understand the meaning of all signals and signs before starting work. EMERGENCY ESCAPE FROM OPERATOR'S CAB Machines equipped with a cab have doors on the left and right sides. If the door on the one side does not open, escape from the door on the other side. ASBESTOS DUST HAZARD PREVENTION Asbestos dust in the air can cause lung cancer if it is inhaled. There is danger of inhaling asbestos when working on jobsites handling demolition work or work handling industrial waste. Always observe the following. Spray water to keep down the dust when cleaning. Do not use compressed air for cleaning. If there is danger that there may be asbestos dust in the air, always operate the machine from an upwind position. All workers should use an approved respirator. Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts.
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SAFETY
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CHECKS BEFORE STARTING ENGINE, ADJUST Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view. Remove all dirt from the surface of the lens of the front lamps, working lamps, and rear combination lamp, and check that they light up correctly. Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and check for damage to the electric wiring. Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake pedal, and check that the pedals work properly. Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no damage or wear to the seat belt or mounting clamps. Check that the gauges work properly, check the angle of the lights and working lamps, and check that the control levers are all at the neutral position. Before starting the engine, check that the gearshift lever is at the P (Parking) position. Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat. Refer to "WALK-AROUND CHECK (PAGE 3-43)". Check that there are no persons or obstacles above, below, or in the area around the machine. PRECAUTIONS WHEN STARTING Start and operate the machine only while seated. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. When starting the engine, sound the horn as a warning. Do not allow anyone apart from the operator to ride on the machine. For machines equipped with a back-up alarm, check that the alarm works properly.
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SAFETY
PRECAUTIONS IN COLD AREAS Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is a hazard that this will ignite the battery. Before charging or starting the engine with a different power source, melt the battery electrolyte and check for frost and leakage of battery electrolyte before starting.
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SAFETY
OPERATION
CHECKS BEFORE STARTING OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check the operation of travel, steering and brake systems, and work equipment control system. Check for any abnormality in the sound of the machine, vibration, heat, smell, or gauges; check also that there is no leakage of oil or fuel. If any abnormality is found, carry out repairs immediately.
When carrying out operations that require the machine to be articulated, insert the articulation lock pin in the stowing position. Before traveling on a road, check that the articulation lock pin is at the LOCK position.
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PRECAUTIONS BEFORE MOVING OFF Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles. Before travelling, sound the horn to warn people in the area. Always operate the machine only when seated. Do not allow anyone apart from the operator to ride on the machine. Check that the back-up alarm (alarm buzzer when machine travels in reverse) works properly. Fix the operator's compartment doors and windows in position securely. If there is an area to the rear of the machine which cannot be seen, position a signal person. Take special care not to hit other machines or people when turning or swinging the machine. Always be sure to carry out the above precautions even when the machine is equipped with mirrors.
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SAFETY
PRECAUTIONS WHEN TRAVELING Never turn the key in the starting switch to the OFF position. It is dangerous if the engine stops when the machine is traveling, because the steering becomes heavy. If the engine stops, depress the brake pedal immediately to stop the machine. When traveling on rough ground, travel at low speed and do not operate the steering suddenly. There is danger that the machine may turn over. The work equipment may hit the ground surface and cause the machine to lose its balance, or may damage the machine or structures in the area. Operate carefully when the wheels are leaning. It is prohibited to travel on roads with the wheels leaning.
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Avoid traveling over obstacles when possible. If the machine has to travel over an obstacle, keep the work equipment close to the ground and travel at low speed. Never travel over obstacles which make the machine tilt strongly to one side. When traveling or carrying out operations, always keep a safe distance from people, structures, or other machines to avoid coming into contact with them. When passing over bridges or structures, check first that the structure is strong enough to support the mass of the machine. When operating in tunnels, under bridges, under electric wires, or other places where the height is limited, operate slowly and be extremely careful not to let the work equipment hit anything. If you drive the machine at high speed continuously for a long time, the tires will overheat and the internal pressure will become abnormally high. This may cause the tires to burst. If a tire bursts, it produces an extremely large destructive force, and this may cause serious injury. When traveling continuously, travel for 2 hours or 80 km, then rest for 30 minutes. Next, travel for 2 hours, then rest for 1 hour, or contact your Komatsu distributor. If you are going to travel continuously, please consult your Komatsu distributor.
Travel at a maximum speed of 10 km/h (6.2 MPH) when using the articulation. If the articulation is used when traveling at a speed of over 10 km/h (6.2 MPH), there is danger that the machine may overturn. Never use the articulation at speeds of over 10 km/h (6.2 MPH).
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SAFETY
PRECAUTIONS WHEN TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. Always travel straight up or down a slope. Traveling at an angle or across the slope is extremely dangerous. Do not turn on slopes or travel across slopes. Always go down to a flat place to change the position of the machine, then travel on to the slope again. Travel on grass, fallen leaves, or wet steel plates with low speed. Even with slight slopes there is a hazard that the machine may slip. If the engine stops, depress the brake pedal immediately, lower the blade, set the gearshift lever to the P (Parking) position, and stop the machine. When traveling downhill, never shift gear or place the transmission at neutral. It is dangerous not to use the braking force of the engine. Always place the transmission in a low gear before starting to travel downhill. When traveling downhill, travel slowly. If necessary, use the braking force of the engine together with the brake pedal to control the travel speed. PRECAUTIONS WHEN OPERATIONS ON SLOPES Do not articulate the machine fully on steep slops. There is danger that the machine may tip over. When working on slopes, control the machine speed with the accelerator pedal.
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PROHIBITED OPERATIONS When operating at the bottom of a cliff, there is danger that the soil may collapse or that rocks may fall. Never operate in such places. The edge of cliffs or road shoulders may easily collapse, and there is danger of falling. Do not go close to such places. Avoid sudden starts, sudden stops, and sudden steering. PRECAUTIONS WHEN OPERATING When operating in tunnels, under bridges, under electric wires, or other places where the height is limited, be extremely careful not to let the work equipment hit anything. To prevent accidents caused by hitting other objects, always operate the machine at a speed which is safe for operation, particular in confined spaces, indoors, and in places where there are other machines. Check that there is no person other than the operator within the range of flying objects caused by the operation.
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SAFETY
OPERATE CAREFULLY ON SNOW Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes. With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the machine to tip over. If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful not to leave the road shoulder or to get trapped in a snow drift. When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations carefully. When traveling on snow-covered roads, always fit tire chains. When traveling on snow-covered slopes, never apply the brakes suddenly. Reduce the speed and use the engine as a brake while appling the foot brake intermittently (depress the brake intermittently several times). If necessary, lower the blade to the ground to stop the machine. PARKING MACHINE Park the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground.
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When leaving the machine, set gearshift lever (1) to the P (Parking) position, then stop the engine. Always close the operator's cab door, and use the key to lock all the equipment in order to prevent any unauthorized person from moving the machine. Always remove the key, take it with you, and leave it in the specified place.
If it is necessary to park the machine on a slope, set blocks under the wheels to prevent the machine from moving.
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SAFETY
TRANSPORTATION
The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary. Always do as follows. Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of the road or cliff. Always use ramps of adequate strength. Be sure that the ramps are wide, long, and thick enough to provide a safe loading slope. Take suitable steps to prevent the ramps from moving out of position or coming off. Be sure the ramp surface is clean and free of grease, oil, ice and loose materials. Remove dirt from machine-tracks. On a rainy day, in particular, be extremely careful since the ramp surface is slippery. Run the engine at low speed and travel slowly. Never correct your steering on the ramps. If necessary, drive off the ramps, correct the direction, then enter the ramps again. When loading or unloading to an embankment or platform, make sure that it has suitable width, strength, and grade. For machines equipped with a cab, always lock the door after boarding the machine. If this is not done, the door may suddenly open during transportation. Refer to "TRANSPORTATION (PAGE 3-119)".
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SHIPPING When shipping the machine on a trailer, do as follows. The weight, transportation height, and overall length of the machine differ according to the work equipment, so be sure to confirm the dimensions. When passing over bridges or structures on private land, check first that the structure is strong enough to support the weight of the machine. When traveling on public roads, check first with the relevant authorities and follow their instructions. Lock the frame with the articulate lock pin to prevent the machine from articulating. For details of the shipping procedure, see "TRANSPORTATION (PAGE 3-119)" in the OPERATION section.
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SAFETY
BATTERY
BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL line. When working with batteries, always wear safety glasses and rubber gloves. Never smoke or use any flame near the battery.
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As there is a hazard that sparks will be generated, always do as follows. Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or other metal objects lying around near the battery. Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the battery, connect the positive (+) terminal first, and connect the ground last. Tighten the battery terminals securely. Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take it to a well-ventilated place, and remove the battery caps before charging it. Tighten the battery caps securely. Install the battery securely to the determined place.
If you spill acid on your clothes or skin, immediately flush the area with large amount of water. If acid gets into your eyes, flush them immediately with large amount of water and seek medical attention. Before working with batteries, turn the starting switch to the OFF position.
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STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery). When starting from another machine, do not allow the two machines to touch. When connecting the booster cables, turn the starting switch OFF for both the normal machine and problem machine. There is a hazard that the machine will move when the power is connected. Be sure to connect the positive (+) cable first when installing the booster cables. Disconnect the negative (-) cable (ground side) first when removing them. When removing the booster cables, be careful not to let the booster cable clips touch each other or to let the clips touch the machine. Always wear safety goggles and rubber gloves when starting the engine with booster cables. When connecting a normal machine to a problem machine with booster cables, always use a normal machine with the same battery voltage as the problem machine. For details of the starting procedure when using booster cables, see "STARTING ENGINE WITH BOOSTER CABLE (PAGE 3-129)" in the OPERATION section.
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SAFETY
TOWING
WHEN TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For towing, see "TOWING THE MACHINE (PAGE 3-125)". Always wear leather gloves when handling wire rope. During the towing operation, never stand between the towing machine and the machine being towed. Never tow a machine on a slope.
Never use a wire rope which has cut strands (A), reduced diameter (B), or kinks (C). There is danger that the rope may break during the towing operation.
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KEEP WORK PLACE CLEAN AND TIDY Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances that will cause you to slip. Always keep the work place clean the tidy to enable you to carry out operations safely. If the work place is not kept claen and tidy, there is the danger that you will trip, slip, or fall over and injure yourself. APPOINT LEADER WHEN WORKING WITH OTHERS When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his instructions during the operation. When working with others, misunderstandings between workers can lead to serious accidents.
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SAFETY
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Stop the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground and stop the engine.
After stopping the engine, operate the left and right blade lift cylinder control levers fully to the RAISE and LOWER positions 2 or 3 times to release the pressure remaining in the hydraulic circuit, then set gearshift lever (1) to the P (Parking) position.
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Put blocks under the front and rear of the tires. Insert the articulation lock pin in the LOCK position to prevent the machine from articulating.
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SAFETY
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows. One worker must always sit in the operator's seat and be ready to stop the engine at any time. All workers must maintain contact with the other workers. Place speed lever (1) at the P (parking) position to prevent the machine from moving. When carrying out operations near the fan, fan belt, or other rotating parts, there is a hazard of being caught in the parts, so be careful not to come close. Do not touch any control levers. If any control lever must be operated, give a signal to the other workers to warn them to move to a safe place.
Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.
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PROPER TOOLS Use only tools suited to the task and be sure to use the tools correctly. Using damaged, low quality, faulty, makeshift tools or improper use of the tools could cause serious personal injury.
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SAFETY
ACCUMULATOR The accumulator is charged with high-pressure nitrogen gas. When handling the accumulator, careless procedure may cause an explosion which could lead to serious injury or property damage. For this reason, always observe the following precautions. Do not disassemble the accumulator. Do not bring it near flame or dispose of it in fire. Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area. If necessary, employ an observer. ATTACHMENTS Appoint a leader before starting removal or installation operations for attachments. Place attachments that have been removed from the machine in a stable condition so that they do not fall. And take steps to prevent unauthorized persons from entering the storage area.
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WORK UNDER THE MACHINE If it is necessary to go under the work equipment or the machine to carry out service and maintenance, support the work equipment and machine securely with blocks and stands strong enough to support the weight of the work equipment and machine.
NOISE If the noise from the machine is too loud, it may cause temporary or permanent hearing problems. When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers or ear plugs while working.
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SAFETY
PRECAUTIONS WHEN USING HAMMER When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury. Always do as follows. If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, there is a hazard that pieces might be scattered and cause injury. Always wear safety goggles and gloves. There is a hazard that the pin hit with strong force may fly out and injure people in the surrounding area.
REPAIR WELDING Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding. REMOVING BATTERY TERMINAL When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of the battery to prevent the flow of current.
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PROHIBITED TO DISASSEMBLE BANK CONTROL LOCK PIN If the bank control pin assembly is disassembled, there is danger that the spring will fly out and cause serious injury. Never disassemble the bank control pin assembly. PRECAUTIONS WITH HIGH-PRESSURE OIL The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to serious injury, so always do as follows. When carrying out inspection and maintenance of the pressure, release the pressure before starting. For details, see "STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE (PAGE 2-31)". Do not carry out inspection or replacement work with the circuit under pressure. If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping and hoses and for swelling in the hoses. When carry out inspection, wear safety glasses and leather gloves. There is a hazard that high-pressure oil leaking from small holes may penetrate your skin or cause blindness if it contacts your eyes directly. If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes, wash the place with clean water, and consult a doctor immediately for medical attention.
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SAFETY
HANDLING HIGH-PRESSURE HOSES If oil or fuel leaks from high-pressure hoses, there is danger that it may cause fire or defective operation, which may lead to serious injury or fire. If there are any loose hoses or piping, or any leakage of oil or fuel from the hose or piping mount, stop operation and tighten to the specified torque. If any hoses or pipes are damaged or deformed, please contact your Komatsu distributor. Replace the hose if any of the following problems are found. Damaged or leaking hydraulic fitting. Frayed or cut covering or exposed reinforcement wire layer. Covering swollen in places. Twisted or crushed movable portion. Foreign material embedded in covering. WASTE MATERIALS To prevent pollution, pay careful attention to the method of disposing of waste materials. Always put oil drained from your machine in containers. Never drain oil directly onto the ground or dump into the sewage system, rivers, the sea, or lakes. Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, and batteries.
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MAINTENANCE OF AIR CONDITIONER If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite. Never touch refrigerant. COMPRESSED AIR When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves, and other protective equipment. PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS In order for the machine to be operated safety for a long time, it is necessary to add oil and to carry out service and maintenance at periodic intervals. In order to further increase safety, components with a strong relationship to safety, such as hoses and seat belts, must be replaced at periodic intervals. Replacement of safety critical parts: See "PERIODIC REPLACEMENT OF CRITICAL PARTS (PAGE 4-13)". The material of these components naturally changes over time, and repeated use causes deterioration, wear, and fatigue. As a result, there is a hazard that these components may fail and cause serious injury or death. It is difficult to judge the remaining life of these components from external inspection or the feeling when operating, so always replace them at the specified interval. Replace or repair safety-critical parts if any defect is found, even when they have not reached the time specified interval.
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3-1
. GENERAL VIEW
OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
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Blade lift cylinder Drawber shift cylinder Cab Ripper Rear wheel
3-2
OPERATION
GENERAL VIEW
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(1) (2) (3) (4) (5) (6) Inching pedal Work equipment control lever Horn button Steering wheel Turn signal lever Yellow rotating lamp switch (if equipped) (7) (8) (9) (10) (11) Brake pedal Gearshift lever Fuel control lever Accelerator pedal Decelerator pedal
3-3
. GENERAL VIEW
OPERATION
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) Central caution lamp Front lamp switch Dimmer switch Transmission caution lamp Turn signal pilot lamp High beam pilot lamp Speedometer Accumlater and brade float switch Service meter Differential lock switch Differential control indicator Accumulator indicator Blade float Parking brake Engine preheating monitor (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) Radiator coolant level monitor Engine oil level monitor Hydraulic oil level monitor Fuel gauge Engine coolant temperature gauge Final drive oil temperature monitor Engine oil pressure monitor Hydraulic oil level Coolant temperature monitor Air pressure monitor Radiator coolant level monitor Charge monitor Hydraulic oil temperature monitor Emergency steering
3-4
OPERATION
GENERAL VIEW
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Starting switch Hazard lamp switch (if equipped) Front wiper switch (top) Front wiper switch (bottom) Air pressure gauge Rear wiper switch (if equipped) Door wiper switch (if equipped) Emergency steering switch (if equipped)
Lift arm lock pilot lamp Bank switch Working lamp switch (cab) Working lamp switch (rear) Front working lamp switch (at rear of blade) Front working lamp switch (in front of blade)
3-5
. EXPLANATION OF COMPONENTS
OPERATION
EXPLANATION OF COMPONENTS
The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays.
MONITOR PANEL
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A: B: C: Check monitor group Caution display portion Emergency caution display portion D: E: Meter group Central caution lamp
Turn the starting switch to the ON position before starting the engine. All the monitors, gauges, and warning lamps light up for approx. 3 seconds and the alarm buzzer sounds for approx. 2 seconds. When this happens, the speedometer displays 188. If the monitor does not light up, there is probably a failure or disconnection, so ask your Komatsu distributor to carry out inspection. When checking the monitor, wait for at least 30 seconds after stopping the engine.
3-6
OPERATION
EXPLANATION OF COMPONENTS
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(1) (2) Hydraulic oil level monitor Engine oil level monitor (3) Radiator coolant level monitor
3-7
. EXPLANATION OF COMPONENTS
OPERATION
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3-8
OPERATION
EXPLANATION OF COMPONENTS
CAUTION
If these monitor lamps flash, inspect and repair the appropriate place as soon as possible.
NOTICE Park the machine on level ground and check the monitor lamps. Confirm that these monitor lamps light for about 3 seconds after turning the starting switch to ON while the engine is at rest. If any monitor lamp does not light, ask your Komatsu distributor to inspect that monitor lamp. This item must be observed carefully when the engine is running. If any abnormality occurs, take the necessary action as soon as possible. If any abnormality occurs, the monitor for the location of the abnormality flashes, and at the same time, the central warning lamp flashes.
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Charge monitor Radiator coolant level monitor Hydraulic oil temperature monitor
(4) (5)
3-9
. EXPLANATION OF COMPONENTS
OPERATION
CHARGE MONITOR This monitor (1) indicates an abnormality in the charging system while the engine is running. If the lamp flashes during operation, stop the engine and check the V-belt tension. If any abnormality is found, see "OTHER TROUBLE (PAGE 3-131)". REMARK The monitor lamps and central warning lamp may flash when the engine is started, but if they go out when the engine speed is increased, there is no abnormality. RADIATOR COOLANT LEVEL MONITOR This monitor (2) indicates a low radiator coolant level. If the monitor lamp flashes, stop the engine, check the coolant level, and add water as required.
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HYDRAULIC OIL TEMPERATURE MONITOR This monitor (3) flashes if the hydraulic oil temperature goes above 108C (226.4 F). If it flashes, stop the engine and ask your Komatsu distributor to carry out an inspection.
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OPERATION
EXPLANATION OF COMPONENTS
EMERGENCY STEERING (If equipped) This monitor (4) lights up when the emergency steering is actuated. When this happens, the alarm buzzer sounds continuously. The emergency steering uses an electric motor pump to provide hydraulic power to the steering system. This prevents any sudden increase in the operating effort of the steering wheel if the engine stops or there is a failure in the hydraulic pump when the machine is traveling.
Action when emergency steering is actuated 1. If the emergency steering is actuated, move the machine quickly to a safe place and stop the machine. 2. After stopping the machine, turn the main switch OFF, stop the emergency steering, then contact your Komatsu distributor for inspection. NOTICE To protect the electric motor pump for the emergency steering, do not run it for more than 30 seconds.
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TRANSMISSION CAUTION LAMP This monitor (5) flashes when there is any abnormal operation or abnormality in the control system, such as trying to start the machine with the transmission in 4th or above, or trying to shift down forcibly. The alarm buzzer also sounds continuously according to the seriousness of the abnormality. A controller is used to carry out control to prevent damage or breakage of the transmission caused by mistaken operation. If the conditions are fulfilled, the warning lamp lights up and the buzzer sounds. However, try to avoid operations that will cause the warning lamp to flash. In addition, if there is any abnormality in the control system, stop the engine, and ask your Komatsu distributor to carry out repairs.
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. EXPLANATION OF COMPONENTS
OPERATION
CAUTION
If these monitor lamps flash, inspect and repair the appropriate place as soon as possible.
NOTICE Park the machine on level ground and check the monitor lamps. Confirm that these monitor lamps light for about 3 seconds after turning the starting switch to ON while the engine is at rest. If any monitor lamp does not light, ask your Komatsu distributor to inspect that monitor lamp. This item must be observed carefully when the engine is running. If any abnormality occurs, take the necessary action as soon as possible. If any abnormality occurs, the alarm buzzer sounds intermittently, the monitor for the location of the abnormality flashes, and at the same time, the central caution lamp flashes.
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Final drive oil temperature monitor Engine oil pressure monitor Hydraulic oil level monitor
(4) (5)
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OPERATION
EXPLANATION OF COMPONENTS
FINAL DRIVE OIL TEMPERATURE MONITOR This monitor (1) flashes if the oil temperature in the final drive becomes abnormally high. If it flashes, stop the machine, turn the differential lock switch to the OFF position, and wait for the monitor to go out.
ENGINE OIL PRESSURE MONITOR This monitor (2) warns the operator that the engine lubricating oil pressure has dropped. If it flashes, stop the engine and look for the cause. 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.
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HYDRAULIC OIL LEVEL MONITOR This monitor (3) flashes if the level of the oil in the hydraulic tank is too low. If it flashes, stop the engine and check the oil level in the oil tank, then add oil.
COOLANT TEMPERATURE MONITOR This monitor (4) indicates a rise in the coolant temperature. When the monitor lamp flashes, stop the machine, run the engine with no load at midrange speed until the green range of the engine water temperature gauge lights.
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. EXPLANATION OF COMPONENTS
OPERATION
AIR PRESSURE MONITOR This monitor (5) indicates a drop in the air pressure in the air tank. If the lamp flashes, stop the machine, increase the engine speed and wait until the lamp goes out.
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OPERATION
EXPLANATION OF COMPONENTS
METER GROUP
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PILOT DISPLAY (1) Differential control indicator (2) Accumulator indicator (3) Blade float (4) Parking brake (5) Engine preheating monitor METERS (6) Engine coolant temperature gauge (7) Fuel gauge (8) Turn signal pilot lamp (9) High beam pilot lamp (10) Speedometer (11) Service meter
PILOT DISPLAY
DIFFERENTIAL CONTROL INDICATOR This monitor (1) lights up when the differential lock is ON. Even when the differential lock switch is at the ON position, if the gear shift lever is at position 5 or above, the differential lock is canceled and this lamp goes out. To engage the differential lock again, shift the gear shift lever down to position 4 or below. The differential lock is then actuated and the lamp lights up again.
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. EXPLANATION OF COMPONENTS
OPERATION
ACCUMULATOR INDICATOR This monitor (2) lights up when the accumulator switch is turned ON.
BLADE FLOAT This monitor (3) lights up when the blade float switch is set to the ON position.
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PARKING BRAKE This monitor (4) lights up to inform the operator that the parking brake has been applied. During operation: Lights up
ENGINE PREHEATING MONITOR This monitor (5) shows the preheating time when starting the engine in temperatures of below 5C (41F). When the starting switch is turned to the HEAT position, it lights up for approx. 36 seconds. After that, it flashes for approx. 16 seconds, and then goes out. When it goes out, it indicates that the preheating is completed.
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OPERATION
EXPLANATION OF COMPONENTS
METERS
ENGINE COOLANT TEMPERATURE GAUGE
CAUTION
If the alarm buzzer sounds, the central warning lamp lights up, or the engine water temperature monitor flashes, stop the machine, run the engine at low idling, and wait for the green range to light up.
This meter (6) shows the temperature of the coolant water. The green range should be lighted up during normal operations. If the top level lights up, the alarm buzzer will sound, the central warning lamp will light up, and the engine water temperature monitor will flash. FUEL GAUGE This meter (7) indicates the amount of fuel in the fuel tank. If there is enough fuel in the tank while the engine is running, the green range lights. If the red range lights, there is less than 70 liters (18.49 US gal) of fuel in the tank. When the red range lights, add fuel.
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TURN SIGNAL PILOT LAMP This monitor (8) flashes together with the turn signal lamp. REMARK If there is a disconnection in the turn signal lamp, the flashing interval becomes shorter.
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. EXPLANATION OF COMPONENTS
OPERATION
HIGH BEAM PILOT LAMP This monitor (9) lights up when the head lamp is at high beam.
SPEEDOMETER This monitor (10) indicates the travel speed of the machine. REMARK A speedmeter for MPH is also available.
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SERVICE METER This meter (11) shows the total operation hours of the machine. The service meter advances while the engine is running - even if the machine is not traveling. While the engine is running, green pilot lamp on the service meter flashes to show the service meter advances. The service meter progresses by 1 when the engine is operated for one hour, regardless of the engine speed.
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OPERATION
EXPLANATION OF COMPONENTS
(1)
(2)
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AIR PRESSURE GAUGE
NOTICE If the warning buzzer frequently sounds, the piping joints may be loose, so check for the cause. This meter (1) indicates the air pressure inside the air tank. It should indicate the green range during normal operations. If it drops to the red range during operations, the warning buzzer will sound, the central warning lamp will flash, and the air pressure monitor will also flash. If this happens, stop the machine, increase the engine speed and wait for the indicator to return to the green range.
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. EXPLANATION OF COMPONENTS
OPERATION
SWITCHES
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Starting switch Bank switch Front working lamp switch (in front of blade) Front working lamp switch (at rear of blade) Working lamp switch (rear) Working lamp switch (cab) (if equipped) Front wiper switch (top) Front wiper switch (bottom) Rear wiper switch (if equipped) Door wiper switch (if equipped) Emergency steering switch (if equipped)
(12) (13) (13) (14) (15) (16) (17) (18) (19) (20)
Differential lock switch Accumulator switch Accumulator and blade float switch (if equipped) Front lamp switch Dimmer switch Turn signal lever Horn button Room lamp switch Hazard lamp switch Yellow rotating lamp switch (if equipped)
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OPERATION
EXPLANATION OF COMPONENTS
STARTING SWITCH
This switch (1) is used to start or stop the engine. OFF The starting key can be inserted and removed at this position. When the key is turned to this position, the electric circuit is turned off and the engine stops. ON Electricity flows to the charging circuit and lamp circuit. START This is the position for starting the engine. Keep the key at this position while cranking the engine. When the engine starts, release the key immediately. The key returns automatically to the ON position. HEAT (preheating) position Use this position when starting in cold weather (ambient temperature below 5C (41 F)). When the key is held at the HEAT position, the electrical heater will be heated and the preheating monitor will light up. When the preheating monitor goes out after flashing, release the key immediately. When the key is released, it returns to the OFF position, so turn it immediately to the START position.
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BANK SWITCH
WARNING
Lower the blade completely to the ground before removing the pin.
This switch (2) is used to pull out the lock pin and set the blade in the bank-cut position. (a) RETRACT: You can pull out the pin securing the lifter guide and frame. (b) LOCK: The pin is locked. (c) INDEX: Select this position to adjust the lifter guide and frame.
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. EXPLANATION OF COMPONENTS
OPERATION
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WORKING LAMP SWITCH (REAR)
This is the switch (5) for the rear working lamp. When the switch is pressed, the lamps will light up and the lamp inside the switch will also light up. Press the switch again to turn the lamps off.
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OPERATION
EXPLANATION OF COMPONENTS
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REAR WIPER SWITCH
(If equipped) This switch (9) actuates the wiper for the door glass. OFF position: Wiper stops Position (1): Wiper is operated
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. EXPLANATION OF COMPONENTS
OPERATION
CAUTION
The emergency steering motor must not be operated continuously for more than 30 seconds.
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Use this switch (11) to actuate the electric motor for the emergency steering. (1) AUTO position: If the hydraulic pressure in the steering circuit goes below 0.69 MPa (7 kgf/cm2, 99.4 PSI), the electric motor is automatically actuated to rotate the hydraulic pump. (2) MANU position: Use this position to check the actuation. This actuates the electric motor regardless of the hydraulic pressure and rotates the hydraulic pump.
When the machine is stopped or is traveling at a speed of less than 1 km/h (0.6 MPH), the emergency steering is not actuated automatically. If it is necessary to release the parking brake, use the procedure given in "HANDLING EMERGENCY STEERING DEVICE (PAGE 6-2)".
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OPERATION
EXPLANATION OF COMPONENTS
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ACCUMULATOR SWITCH This switch (13) is used when actuating the accumulator. ON position: The accumulator is actuated, and the absorber pilot lamp lights up at the same time. OFF position: The accumulator is canceled. For details of handling the accumulator, see "HANDLING BLADE ACCUMULATOR (PAGE 3-115)".
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. EXPLANATION OF COMPONENTS
OPERATION
WARNING
Lower the blade completely to the ground before removing the pin.
This switch (13) is used when actuating the blade float. ON position: The blade moves freely under external force, regardless of the position of the blade control lever. OFF position: The blade is moved by operating the blade control lever. For details of handling the blade float, see "HANDLING BLADE FLOAT (PAGE 3-117)".
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DIMMER SWITCH
This switch (15) the head lamp between high beam and low beam. Position (1): High beam Position (2): Low beam
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OPERATION
EXPLANATION OF COMPONENTS
HORN BUTTON
When the button (17) in the center of the steering wheel is pressed, the horn will sound.
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ROOM LAMP SWITCH
This switch (18) lights up the room lamp. ON position: Lamp lights up. OFF position: Lamp goes out.
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. EXPLANATION OF COMPONENTS
OPERATION
WARNING
Use the hazard lamp only in emergencies. Using the hazard lamp when traveling may cause confusion for other machine operators.
Use this switch (19) only in emergencies, such as when the machine has to be stopped on the road because of a failure. When the switch is pressed, all the turn signal indicator lamps will flash; when the switch is pressed again, the lamps will go out.
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(If equipped) Use this switch (20) to light up and rotate the yellow rotating lamp. (a) ON position: The lamp lights up and rotates. (b) OFF position: The lamp goes off and stops rotating.
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OPERATION
EXPLANATION OF COMPONENTS
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(1) (2) (3) (4) (5) (6) (7) (8) Left blade lift cylinder control lever Ripper lift cylinder control lever (if equipped) Blade side shift control lever Power tilt control lever Blade rotation control lever Drawbar side shift control lever Articulate control lever Leaning control lever (9) (10) (11) (12) (13) (14) (15) (16) Option lever Right blade lift cylinder control lever Fuel control lever Gearshift lever Inching pedal Brake pedal Accelerator pedal Decelerator pedal
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. EXPLANATION OF COMPONENTS
OPERATION
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RIPPER LIFT CYLINDER CONTROL LEVER
(If equipped) This lever (2) operates the ripper. (1) LOWER: The ripper goes down. (2) HOLD: The ripper stops and is held in the same position. (3) RAISE: The ripper goes up.
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OPERATION
EXPLANATION OF COMPONENTS
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POWER TILT CONTROL LEVER
This lever (4) changes the cutting angle of the blade. (1) Max. cutting angle: This makes the blade cutting angle bigger. This is effective when operating on hard ground. Max. cutting angle: 115 (2) HOLD : The blade stops and is held in the same position. (3) Min. cutting angle: This makes the blade cutting angle smaller. This is effective when operating on soft ground. Min. cutting angle: 58 REMARK The distance between the cutting surface and the blade edge can be changed, so it is possible to carry out fine adjustment of the height of the cutting surface.
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. EXPLANATION OF COMPONENTS
OPERATION
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DRAWBAR SIDE SHIFT CONTROL LEVER
This lever (6) shifts the drawbar to the side. (1) LEFT SHIFT: The drawbar is shifted to the left. (2) HOLD: The drawbar stops and is held in the same position. (3) RIGHT SHIFT: The drawbar is shifted to the right.
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OPERATION
EXPLANATION OF COMPONENTS
WARNING
Operate this lever only when traveling at a speed of below 10 km/h (6.2 MPH). If the articulation is operated at a speed of over 10 km/h (6.2 MPH), there is danger that the machine may overturn.
NOTICE To prevent damage to the tires, be careful not to let the blade hit the tires when articulating the machine. This lever (7) is used to operate the articulation. (1) Left articulation: The machine is articulated to the left. (2) HOLD: The articulated condition is maintained. (3) Right articulation: The machine is articulated to the right. Max. articulating angle: 25 to left or right. Min. turning radius (when also using leaning): 7.9 m (25 ft 11 in) when turning to left or right.
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. EXPLANATION OF COMPONENTS
OPERATION
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OPTION LEVER
This lever (9) is used to operate any optional equipment or attachment.
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OPERATION
EXPLANATION OF COMPONENTS
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FUEL CONTROL LEVER
This lever (11) is used to control the engine speed and output. (1) Low idling position: Push the lever forward fully. (2) High idling position: Pull the lever fully back from the low idling position. REMARK The fuel control lever is used only during operations with the work equipment. For general travel, use the accelerator pedal. The fuel control lever is set to a maximum speed of 1500 rpm. This is to prevent any sudden rise in the engine speed if the engine is started with the lever pulled fully and to ensure safety if the lever is pulled during operations.
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. EXPLANATION OF COMPONENTS
OPERATION
GEARSHIFT LEVER
WARNING
When parking the machine, always set the gearshift lever to the P position to apply the parking brake.
This lever (12) is used to shift the travel speed range and to apply or release the parking brake. There are 8 speeds in FORWARD and REVERSE, and the gear can be shifted simply by moving the gearshift lever to the desired position. P position: Parking brake applied. The parking brake is applied. When the gearshift lever is set to the P position, the parking brake is applied and the parking brake indicator lamp on the machine monitor lights up. When applying or releasing the parking brake, press lever button (1) and operate the gearshift lever. N position: Neutral Position 1: 1st Position 2: 2nd Position 3: 3rd Position 4: 4th Position 5: 5th Position 6: 6th Position 7: 7th Position 8: 8th Groove on F side: FORWARD Groove on R side: REVERSE
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A shift lock mechanism is installed to prevent the lever from entering the P (parking) position during normal operations. When shifting from P to N or from N to P, operate lever button (1) as follows: Push -> shift -> release -> shift. REMARK The engine will not start if the speed lever is not at the P (parking) position.
INCHING PEDAL
NOTICE Do not use continuously for more than 10 seconds. This pedal (13) connects and disconnects the motive force from the engine and is used when stopping or starting the machine, or when switching between FORWARD and REVERSE. When the pedal is depressed, the motive force is cut off. In 1st, 2nd, and 3rd speeds, fine control of the machine is possible using this pedal.
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OPERATION
EXPLANATION OF COMPONENTS
BRAKE PEDAL
WARNING
Do not place your foot on this pedal unnecessarily.
ACCELERATOR PEDAL
This pedal (15) is used to control the engine speed and output. This is interconnected with the fuel control lever, and can be operated freely between the speed set by the fuel control lever and the full speed position.
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DECELERATOR PEDAL
This pedal (16) is used to reduce the engine speed. It is possible to adjust the speed freely between the speed set by the fuel control lever and the low idling speed.
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. EXPLANATION OF COMPONENTS
OPERATION
DUST INDICATOR
This device indicates clogging of the air cleaner element. When red piston (1) appears in the transparent part of this indicator, the element is clogged. Immediately clean the element. After cleaning, push indicator button (2) to return the red piston to the original position.
WARNING
When servicing or transporting the machine always use this lock pin. For normal travel, always use the lock pin.
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This pin is used to lock the front frame and rear frame to prevent the machine from bending during normal travel or when servicing or transporting the machine.
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OPERATION
EXPLANATION OF COMPONENTS
FUSE BOX
WARNING
If the fuse blows again immediately after it is replaced, please contact your Komatsu distributor.
NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse. Remove the bolt, open cover (1), and replace the fuse. Replace the fuse with another of the same capacity.
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Fuse I No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fuse capacity 10A 15A 15A 20A 10A 10A 10A 10A 10A 10A 10A 15A 10A 10A 20A Circuit name Bank, Differential, Accumulator Cab mount working lamp Front working lamp Rear working lamp, Air conditioner Horn, Turn signal lamp, Transmission control Air pressure gauge Brake lamp, Air dryer Emergency steering Auto drain Cab (wiper, washer) Cab (wiper) Head lamp Monitor Transmission control, Parking blake Air conditioner, Heater
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. EXPLANATION OF COMPONENTS
OPERATION
WARNING
If the operator's cab is not raised in the correct way, the cab may fall and cause serious injury or even death. Please contact your Komatsu distributor first before using he lift mechanism. Be sure to follow all instructions regarding the method of operation and safety precautions when lifting the cab. Do not use the lift mechanism without receiving guidance from your Komatsu distributor. Komatsu and Komatsu distributors cannot bear any responsibility of any injury or damage is caused due to incorrect use of the lift mechanism.
By using the lift mechanism, it is possible to raise and hold the operator's cab in position without using a crane.
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BACKUP ALARM
The backup alarm sounds immediately when the gear shift lever is placed in reverse. If it does not sound, please contact your Komatsu distributor.
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OPERATION
EXPLANATION OF COMPONENTS
FRONT GLASS
It is possible to open the front glass to the front.
WHEN OPENING
1. Remove lock (1) at the bottom left and right sides of the front glass. 2. Push the bottom of the front glass out and open it to the desired position.
3. Turn left and right lock knobs (2) in the direction of the arrow to fix the glass in position.
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WHEN CLOSING
1. Turn left and right lock knobs (2) in the direction of the arrow to release the glass. 2. Pull the bottom of the front glass to close it.
3. Lock the front glass in position with lock (1) at the bottom left and right sides of the front glass.
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. EXPLANATION OF COMPONENTS
OPERATION
TOOL BAG
CAUTION
Do not leave the tool bag on the floor by your feet. It will get in the way during operations.
A bag is provided to hold the tools supplied with the machine. When not using the tools, put them in the tool bag and put the tool bag behind the operator's seat. REMARK A tool box for holding the tool supplied with the machine is also available as an option. This tool box can be installed to the drawbar. The tool box already installed to the drawbar contains the tools used when lifting the cab.
STORAGE BOX
There is a box for storing small articles at the top right of the cab.
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QUICK-FILL FUEL FILLER
A commercially available mount and relief valve can be installed for use when filling quickly with fuel from a fuel tanker. For details of the method of installing and handling, please see the instruction manual provided with the quick tanker fill device.
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OPERATION
OPERATION
OPERATION
CHECK BEFORE STARTING ENGINE
WALK-AROUND CHECK
Before starting the engine, look around and under the machine to check for loose nuts and bolts, or leakage of oil, fuel, or coolant, and check condition of the work equipment and hydraulic system. Also check for loose wiring, play, and accumulation of dust at places which high temperatures.
WARNING
Remove any flammable materials from around the battery, engine, muffler, turbocharger, or other high temperature engine parts. Leakage of fuel or oil will cause the machine to catch fire. Check carefully, be sure to repair any abnormality, or contact your Komatsu distributor.
Perform the following inspections and cleaning every day before starting engine for the day's work. 1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses Check for cracks, excessive wear, play in wotk equipment, cylinders, linkage, and hoses. If any abnormality is found, repair it.
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2. Remove dirt and debris from around the engine, battery, and radiator. Check for dirt accumulated around the engine and radiator. Also check for flammable material (dry leaves, twigs, etc.) around the battery, engine muffler, turbocharger, or other high temperature engine parts. If any dirt or flammable materials are found, remove them. 3. Check for coolant and oil leakage around the engine Check for oil leakage from the engine and coolant leaks from the cooling system. If any problem is found, repair it. 4. Check for oil leakage of oil from transmission case, final drive case, tandem drive case, hydraulic tank, circle reverse gear case, hose, joints. Check that there is no oil leakage. If any abnormality is found, repair the place where the oil is leaking. 5. Check for leakage of air from brake line Check that there is no leakage of air. If any abnormality is found, repair the place where the air is leaking. 6. Check for damage, wear to tires, wheels, check for loose mounting bolts Check that there is no peeling of the tires or cracking of the wheels (side ring, rim base, lock ring). Tighten any loose wheel nuts. If any abnormality is found, repair or replace. If the valve cap is lost, install a substitute part. 7. Check for problems in handrails, steps, loose bolts. If any problem is found, repair it. Tighten any loose bolts.
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. OPERATION
OPERATION
8. Check for abnormality in gauges, monitor. Check for abnormality in the gauges and monitor in the operator's cab. If any abnormality is found, replace the parts. Clean off any dirt from the surface. 9. Check for damaged mirror, reflector, loose mounting bolts Check that there is no damage to the mirror or reflectors, and replace if there is any abnormality. Tighten any loose bolts. Clean all dirt from the surface of the mirror and reflector. 10. Is door lock normal? Check that there is no damage to the cab door lock. Repair or replace if any abnormality is found. 11. Clean cab window To ensure a good view during operations, always keep the cab windows clean. 12. Check for damage to the seat belt and mounting clamps.
WARNING
Even if there appears to be no abnormality with the seat belt, replace it once every three years.
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REMARK The date of manufacture of the seat belt is marked on the belt at the place indicated by the arrow in the diagram on the right. Check that there are no loose bolts on the equipment mounting the seat belt to the machine, and tighten if necessary. Tightening torque: 24.5 4.9 Nm (2.5 0.5 kgfm, 18.1 3.6 lbft) If the belt is damaged or fluff is starting to form, or if there is any damage or deformation of the seat belt holders, replace the seat belt.
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OPERATION
OPERATION
WARNING
If worn or damaged tires are used, they may burst and cause serious injury or death. To ensure safety, do not use the following tires. Wear: Tires with a tread grooves of less than 15% of that of a new tire Tires with extreme uneven wear or with stepped-type wear Damage: Tires with damage that has reached the cords, or with cracks in the rubber Tires with cut or pulled cords Tires with peeled (separated) surface Tires with damaged bead Leaking or improperly repaired tubeless tires Deteriorated, deformed or abnormally damaged tires, which do not seem usable
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14. Inspect rims.
WARNING
Check the rims (wheels) and rings for deformation, corrosion and cracks. In particular, check the side rings, lock rings and rim flanges thoroughly.
15. Check for loose ROPS mounting bolts. Check that there are no loose or damaged bolts. If any bolts are loose, tighten to a torque of 1520 to 1910 Nm (155 to 195 kgfm, 1121.1 to 1410.4 lbft). If any bolts are damaged, replace them with genuine Komatsu bolts.
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. OPERATION
OPERATION
WARNING
Do not open the radiator cap unless necessary. Wait for the engine to cool down before checking the coolant in the sub-tank. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to check the coolant level in this condition, there is a hazard of burns. Wait for the temperature to go down, then turn the cap slowly to release the pressure before removing it.
NOTICE If the volume of coolant added is more than usual, check for possible water leakage. Confirm that there is no oil in the coolant. 1. Check that the coolant is between the FULL and LOW marks on sub-tank (1). If the water level is low, add water to the FULL level through the water filler port in sub-tank (1). 2. After adding water, tighten the cap securely. 3. If the sub-tank is empty, check for leakage of water and confirm that the radiator main tank is full, then add water to the radiator sub-tank.
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REMARK In summer, the coolant may overflow from the sub-tank drain hose. This is no problem. It occurs because too much coolant has been added.
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OPERATION
OPERATION
WARNING
When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring flames near fuel because it is highly flammable and dangerous.
NOTICE If breather hole (1) in the cap becomes clogged, the pressure inside the tank will go down and the fuel may not flow, so clean the breather hole from time to time.
1. Turn the engine starting switch to the ON position and check the fuel level with fuel level gauge (G). After checking, turn the switch back to the OFF position.
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2. After completing work, fill the fuel tank through fuel filler port (F). 3. After adding fuel, tighten the cap securely. Fuel capacity: 500 liters (132.1 US gal)
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. OPERATION
OPERATION
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation.
1. Open the side cover on the right side at the rear of the chassis. 2. Remove dipstick (G), and wipe the oil off with a cloth. 3. Fully insert dipstick (G) into filler pipe (F), then remove it. 4. The oil level should be between the H and L marks on dipstick (G). If the oil level is below the L mark, add oil through oil filler (F). 5. If the oil is above the H mark, drain the excess engine oil from drain plug (P), and check the oil level again. 6. If the oil level is correct, tighten the oil filler cap securely and close the engine side cover. REMARK When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking. If the machine is at an angle, make it horizontal before checking. When adding oil, remove the dipstick from the guide to release the air inside the crankcase.
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CHECK DUST INDICATOR
1. Check that the red piston has not appeared in the transparent portion of dust indicator (1). 2. If the red piston has appeared, clean or replace the elementimmediately. For details of the method of cleaning the element, see "CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT (PAGE 4-19)". 3. After checking, cleaning, and replacing, press the knob of dust indicator (1) to return the red piston to its original position.
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OPERATION
OPERATION
WARNING
If the fuses frequently blow or if there are traces of short circuits in the electrical wiring, locate the cause and immediately perform repairs, or contact your Komatsu distributor for repairs. Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clean the breather hole.
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Check that there is no damage to the fuses; that fuses of the specified capacity are used; that there is no disconnection or trace of short-circuiting on the electric wiring and no damage to the covering. Check also that there is no loosened terminals. If any, tighten them. Moreover, pay particular attention to the electric wiring when checking the battery, engine starting motor and alternator. Be sure to check that there is no inflammable material accumulated around the battery. If present, remove it as soon as possible. Please contact your Komatsu distributor for investigation and correction of the cause.
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. OPERATION
OPERATION
CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE CHECK THAT ALL ABNORMALITIES FROM PREVIOUS DAY HAVE BEEN REPAIRED CHECK THAT WINDSHIELD WIPER, WINDOW WASHER, AND DEFROSTER WORK PROPERLY, CHECK WASHER FLUID LEVEL DRAIN WATER, SEDIMENT FROM WATER SEPARATOR
The water separator separates water mixed in the fuel. If float (2) is at or above red line (1) , drain the water according to the following procedure. 1. Loosen drain plug (3) and drain the accumulated water until the float reaches the bottom. 2. Tighten drain plug (3). 3. If the air is sucked into fuel line when draining and water, be sure to bleed air in the same manner as for the fuel filter. See "EVERY 500 HOURS SERVICE (PAGE 4-41)".
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Measure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work. Check for damage or wear to the tires and the rims. Check for loose wheel hub nuts (bolts). The proper inflation pressure is shown below. Inflation pressure MPa (kgf/cm2, PSI) 0.25 (2.6, 36.9) Tire size 23.5-25-12PR
WARNING
For general travel, maintenance, and transportation, always keep the articulate lock pin installed.
If the articulation is to be used during travel operations, remove the articulate lock pin and keep it in the place shown by the arrow.
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OPERATION
OPERATION
ADJUSTMENTS
ADJUST OPERATOR'S SEAT
WARNING
Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. 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 down with the operator's back against the backrest.
(A) Adjustment of seat height Turn lever (1) to raise or lower the seat as follows. Turn to RIGHT to LOWER seat Turn to LEFT to RAISE seat (B) Fore-and-aft adjustment of seat Move lever (2) to the left, set the seat in the desired position, then release the lever. (C) Adjust reclining angle Pull lever (3) up, set the backrest to the desired position, the release the lever. Range of adjustment: 87 (17 stages)
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ADJUSTING POSITION OF STEERING CONSOLE, WORK EQUIPMENT CONTROL LEVERS
WARNING
Do not adjust the instrument panel when traveling.
When steering console tilt pedal (1) is depressed, the steering console will move towards you. Adjust to a position that matches your physique and the operating posture. Amount of adjustment: 5 stages
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. OPERATION
OPERATION
WARNING
Do not adjust the instrument panel when traveling.
Turn steering wheel tilt lever (1) to the left to release the lock, then tilt the steering wheel and gauge panel to the desired position, and lock in position with the lever. Amount of adjustment: 20 (stepless)
ADJUSTING MIRROR
Sit in the operator's seat and adjust the mirrors so that you can see the side and rear of the machine.
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OPERATION
OPERATION
WARNING
Before fastening the seat belt, check that there is no problem in the securing brackets or belt. If there is any wear or damage, replace. Even if there appears to be no problem in the seat belt, replace the seat belt once every 3 years. The date of manufacture is woven on the reverse side of the belt. Adjust and fasten the seat belt before operating the machine. Always use the seat belt when operating the machine. Do not use the seat belt with either half of the belt twisted.
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. OPERATION
OPERATION
TO LENGTHEN THE BELT Pull the belt while holding it at a right angle to the buckle or tongue.
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OPERATION
OPERATION
WARNING
When starting the engine, check that the gearshift lever is properly at the P (Parking) position. If the control levers are touched by accident when the engine is started, the work equipment may move suddenly and cause a serious accident. When standing up from the operator's seat, always set the gearshift lever to the P (Parking) position, regardless of whether the engine is running or stopped.
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1. Check that gearshift lever (1) is at the P (Parking) position. When starting the engine, if gearshift lever (1) is not at the P (Parking) position, the engine will not start.
2. Lower the blade and ripper to the ground, and check that work equipment control levers (2) are at the HOLD position.
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. OPERATION
OPERATION
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3. Insert the key in starting switch (3), turn the key to the ON position and check that all monitor lamps and warning lamps light up for 3 seconds, and that the alarm buzzer sounds for 2 seconds. 1) The buzzer will sound for approx. 2 seconds, and the following monitors and gauges will light up for approx. 3 seconds. Central caution lamp Parking brake pilot lamp Blade float pilot lamp Accumulator pilot lamp Differential control indicator pilot lamp Engine coolant temperature gauge Fuel gauge Hydraulic oil level monitor Engine oil level monitor Radiator coolant level monitor Engine preheating monitor pilot lamp Final drive oil temperature monitor Engine oil pressure monitor Coolant temperature monitor Air pressure monitor Charge monitor Hydraulic oil temperature monitor Emergency steering 2) After approx. 3 seconds, the following gauges will remain on and the other monitors will go out. Engine coolant temperature gauge Fuel gauge Engine oil pressure monitor Charge monitor When the engine starts, the engine oil pressure and battery charge lamps go out.
4. Check if parking brake pilot lamp (4) on the machine monitor is lighted up. If it is not lighted up, check if the gearshift lever is at the P position. When starting the engine, if the parking brake is not applied, the engine will not start.
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OPERATION
OPERATION
5. Press horn switch (5) to confirm that the horn will sound.
6. Operate each lamp switch (6) to check that the lamps light up.
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7. Operate each wiper switch (7) and check that the wiper and washer equipment works properly.
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. OPERATION
OPERATION
STARTING ENGINE
NORMAL STARTING
WARNING
Sit down in the operator's seat before starting the engine. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation.
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. Do not start the engine with the fuel control lever and the accelerator pedal depressed to the FULL OPEN position. 1. Set fuel control lever (1) to the low idling position.
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2. Turn the key in starting switch (2) to the START position. The engine will start.
3. When the engine starts, release the key in starting switch (2). The key will return automatically to the ON position.
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OPERATION
OPERATION
WARNING
Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. Never use starting aid fluids as they may cause explosions. Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation.
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. Do not start the engine with the fuel control lever and the accelerator pedal depressed to the FULL OPEN position.
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When starting in low temperatures, do as follows. 1. Set fuel control lever (1) to the low idling position.
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. OPERATION
OPERATION
2. Hold starting key (2) at the HEAT position until preheating monitor (3) flashes. REMARK If the preheating time is too short or too long, the engine will be difficult to start, so always keep to the correct preheating time.
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3. When preheating monitor (3) goes off, turn key (2) to the START position to start the engine. 4. When the engine starts, release the key in starting switch (2). The key will automatically return to the ON position.
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OPERATION
OPERATION
WARNING
Emergency stop If the operation is abnormal or any other trouble occurs, turn the key in the starting switch to the OFF position. If the work equipment is operated without warming up the machine sufficiently, the response of the work equipment to the movement of the control lever will be slow. The work equipment may not move as the operator desires. Follow all warm-up procedures. Particularly in cold areas, make sure to warm up the machine properly.
CAUTION
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 break-in operations, follow the precautions described in this manual.
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NOTICE Before operating the machine for the first time, check that there is coolant in the radiator. If the machine has been delivered without coolant in the radiator, run water through the system to flush the system thoroughly, then fill the radiator with coolant. Idle the engine for 5 minutes after starting it up. Avoid operation with heavy loads or at high speeds. Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops, and sudden changes in direction.
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. OPERATION
OPERATION
NORMAL OPERATION
After starting the engine, do not immediately start operations. First, perform the following operations and checks. NOTICE Do not accelerate the engine suddenly until the warming-up operation has been completed. Do not run the engine at low idling or high idling continuously for more than 20 minutes. If it is necessary to continue to run the engine at idling, apply a load from time to time or run the engine at a mid- range speed.
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1. Pull fuel control lever (1), and run the engine at a mid- range speed for approx. 5 minutes to carry out warming-up. 2. After the 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 coolant temperature gauge indicator (2) falls within the green range. 3. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor. 4. Watch air pressure gauge (3) and check that the air pressure rises normally. If the air pressure rises slowly, check the following. When the pressure inside the air tank is 0, the time taken to fill with air to a point where the indicator of the air pressure gauge enters the green range is as follows. Engine low idling: Approx. 3 min. Engine high idling: Max. 1.5 min. If the rise in pressure is too slow, contact your Komatsu distributor for inspection and repair.
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OPERATION
OPERATION
STOPPING ENGINE
NOTICE If the engine is stopped abruptly, service life of component parts of the engine may be considerably reduced. Hence do not stop the engine abruptly except in an emergency. If the engine has overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually, and then stop it.
1. Place fuel control lever (1) in the low idling position and run the engine at low idling speed for about 5 minutes to allow it to gradually cool down.
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2. Turn the key in starting switch (2) to the OFF position and stop the engine. 3. Remove the key from starting switch (2).
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. OPERATION
OPERATION
WARNING
For general travel, always lock the front frame and rear frame with the articulate lock pin. Before moving any work equipment control lever, check the distance between the blade and tires.
NOTICE Be careful of the clearance between the blade and front wheels. If the blade is at a propulsion angle and the machine is articulated, the blade may bend the steps. If the shank at the center of the ripper body is inserted from above when the ripper is in the central position, it will interfere with the cylinder, so move the ripper away from the center position when installing the shank. 1. During general travel operations, raise the front and rear ends of the blade equally and set so that the blade does not extend outside the machine, as shown in the diagram on the right.
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2. Insert the shank as shown in the diagram on the right.
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OPERATION
OPERATION
WARNING
When moving off, check that the area around the machine is safe, and sound the horn before moving. Clear all personnel from the machine and the area. Use extreme care when reversing the machine. Note there is a blind spot behind the machine. Do not operate the machine when air pressure is abnormal. Before starting operations, check that the seat belt is properly installed.
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2. Set the blade to the travel posture. 3. Depress inching pedal (2).
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OPERATION
4. Operate gear shift lever (3) to the F (FORWARD) or R (REVERSE) position, and set it at 1st speed or 2nd or 3rd speed. NOTICE Do not try to start the machine with the transmission in 4th or above.
5. Depress accelerator pedal (4) while releasing inching pedal (2), and move the machine off.
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OPERATION
OPERATION
WARNING
Avoid sudden shifting of gear when traveling at high speed. When shifting gear, use the brake to reduce speed before shifting gear.
NOTICE When shifting gear, always shift one gear at a time. When shifting gear, do as follows.
INCREASE SPEED
Let back accelerator pedal (1) and shift gearshift lever (2) up to the next speed range.
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REDUCING SPEED
Release accelerator pedal (1) to reduce speed, then shift gearshift lever (2) down one range.
NOTICE If the transmission is shifted down suddenly when traveling at high speed, there is danger that the engine or transmission may be damaged. Use the following table as a guideline for suitable speeds when shifting down.
Gearshift lever 8th -> 7th 7th -> 6th 6th -> 5th 5th -> 4th 4th -> 3rd 3rd -> 2nd 2nd -> 1st
Suitable speed for shifting down km/h (MPH) 35.0 (21.7) 25.0 (15.5) 18.5 (11.5) 12.0 (7.5) 9.0 (5.6) 7.0 (4.3) 4.0 (2.5)
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. OPERATION
OPERATION
WARNING
When shifting between forward and reverse, always check that it is safe to travel in the new direction. Use extreme care when reversing the machine. Note there is an blind spot behind the machine. Do not shift between forward and reverse when traveling at high speed.
When shifting between forward and reverse, always stop the machine first. 1. Depress brake pedal (1) to reduce speed, then depress inching pedal (2) to stop the machine.
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2. Shift gearshift lever (3) to F (FORWARD) or R (REVERSE) and set in 1st or 2nd speed.
3. Let inching pedal (2) back while depressing accelerator pedal (4) to start the machine off.
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OPERATION
OPERATION
STOPPING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
CAUTION
If the fuel control lever is pulled when depressing the brake pedal, there is danger that the stopping distance will increase. In addition, a large heat load is generated in the brake clutch, and this will lead to deformation or damage of the clutch.
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1. Release accelerator pedal (1). 2. Depress brake pedal (2). Before the machine comes to a stop, depress inching pedal (3).
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. OPERATION
OPERATION
4. Check that parking brake pilot lamp (5) on the machine monitor is lighted up.
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OPERATION
OPERATION
TURNING MACHINE
WARNING
It is dangerous to turn the machine suddenly at high speed or to turn the machine on steep slopes. If the engine stops when the machine is traveling, the steering will become heavy, so never stop the engine. This is particularly dangerous on slopes, so never allow the engine to stop while traveling on slopes under any circumstance. If the engine stops, immediately apply the brake and stop the machine in a safe place.
To turn the machine when traveling, turn steering wheel (1) in the direction of the turn.
LEANING OPERATION
Operate leaning control lever (2) to change the angle of the front tires as follows. Pull BACK to lean to RIGHT. Push FORWARD to lean to LEFT. When traveling forward and turning the machine, the radius of the turn becomes smaller if the tires are leaned in the direction of the turn. When traveling in reverse and turning the machine, the radius of the turn becomes smaller if the tires are leaned in the opposite direction to the turn.
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. OPERATION
OPERATION
ARTICULATING OPERATION
WARNING
Do not remove the lock pin for general travel.
NOTICE When turning with the machine articulated, pay particular attention to the clearance between the blade end and the wheel. To carry out articulation operations, remove the lock pin on the left side of the chassis. The machine can be articulated up to a maximum of 25 to the left or right, and the turning radius becomes 7.9 m (25 ft 11 in). 1. Stop the machine, remove pin (1), and insert it in the storage position.
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2. Operate articulate control lever as follows. Pull BACK to articulate to RIGHT. Push FORWARD to articulate to LEFT.
3. When not operating the articulation, set the front frame and rear frame straight, align the pin holes, and fix the front and rear frames in the original position with pin (1).
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OPERATION
OPERATION
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BLADE OPERATION
BLADE LIFT OPERATION
Operate left blade control lever (1) as follows. Pull BACK to RAISE left end of blade Push FORWARD to LOWER left end of blade
Left blade control lever Right blade control lever Blade side-shift control lever Blade rotation control lever
Power tilt control lever Drawbar side-shift control lever Ripper control lever
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. OPERATION
OPERATION
Operate right blade control lever (2) as follows. Pull BACK to RAISE right end of blade Push FORWARD to LOWER right end of blade
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Operate blade side-shift control lever (3) as follows. Pull BACK to shift blade to RIGHT Push FORWARD to shift blade to LEFT
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OPERATION
OPERATION
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OPERATION
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Use a larger cutting angle when cutting hard soil and a smaller cutting angle when cutting soft soil. The distance between the cutting surface and the blade edge can be changed, so it is possible to carry out fine adjustment of the height of the cutting surface
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OPERATION
OPERATION
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OPERATING RIPPER
(If equipped) Operate ripper control lever (7) as follows. Pull BACK to RAISE ripper Push FORWARD to LOWER ripper
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. OPERATION
OPERATION
2. Set the blade so that the earth is discharged outside the rear left wheel.
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3. Operate blade lift cylinder (2) so that the top of blade (1) is at the desired digging position. If only the blade cylinder is extended or retracted, the blade will move slightly to the left or right. If necessary, adjust with drawbar shift cylinder (3).
Example of lift cylinder and drawbar shift cylinder extended a suitable amount and lowered directly.
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OPERATION
OPERATION
When the drawbar shift cylinder is not extended and only the lift cylinder is extended.
4. Lean the front wheels to the left. REMARK Leaning the wheels to the left prevents the machine from being pushed to the right by the load acting on the left side of the machine.
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5. Rotate so that the blade is at the optimum position for the soil. Be careful not to let the rear left wheel run over the windrow (A) discharged from the blade. 6. Operate the power tilt so that the top of the blade (1) is slightly in front of the cutting edge, then start operation. 7. Discharge the soil to the side to prevent any excessive load from bearing on the machine. 8. Spread fine crushed loose soil over the ground surface until it is level. REMARK Generally speaking, carry out operations on flat ground with the frame straight to the blade. Articulate the frame to deal with the force in the side direction caused by the load on the blade. If the tires start to spin, turn the blade to a greater angle to reduce the digging width, thereby reducing the load on the machine. In leveling operations, discharge the soil outside the rear wheels. This makes it easier to steer with the rear wheels.
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. OPERATION
OPERATION
2. Set the blade so that the earth is discharged outside the rear right wheel.
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3. Operate the blade lift cylinder so that the blade is at the desired digging depth, then set it horizontal. 4. Lean the front wheels to the right. 5. Carry out the operation in the same way as when leveling to the right.
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OPERATION
OPERATION
2. Set the cutting angle at approx. 40. Operate the power tilt so that the top of the blade is slightly in front of the cutting edge.
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3. Operate the left blade lift cylinder and raise the left edge of the blade. (The right end of the blade determines the depth of the ditch. The left end of the blade determines the shape of the ditch.) 4. Angle the blade so that a windrow is formed at the center of the chassis.
5. Operate the right blade lift cylinder and dig the right edge of the blade 50 to 100 mm (2.0 to 3.9 in) into the ground.
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. OPERATION
OPERATION
6. Lean the front wheels to the left. 7. Start the digging operation. The first digging pass acts as a guide for the 2nd and later passes. (Cutting the guide groove.)
8. Set the machine with both the front and rear tires on the bottom of the groove formed in the 1st digging pass, then continue the digging operation until the ditch is the desired depth. (Heavy-duty digging) Lean the front wheels so that they are perpendicular. 9. Before the rear wheels start to run over the windrow, move it from the load shoulder and spread it.
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OPERATION
OPERATION
2. Set the cutting angle at approx. 40. Operate the power tilt so that the top of the blade is slightly in front of the cutting edge.
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3. Operate the right blade lift cylinder and raise the right edge of the blade. (The left end of the blade determines the depth of the ditch. The right end of the blade determines the shape of the ditch.) 4. Angle the blade so that a windrow is formed at the center of the chassis.
5. Operate the left blade lift cylinder and dig the left edge of the blade 50 to 100 mm (2.0 to 3.9 in) into the ground.
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. OPERATION
OPERATION
6. Lean the front wheels to the right. 7. Start the digging operation. The first digging pass acts as a guide for the 2nd and later passes. (Cutting the guide groove.)
8. Set the machine with both the front and rear tires on the bottom of the groove formed in the 1st digging pass, then continue the digging operation until the ditch is the desired depth. (Heavy-duty digging) Lean the front wheels so that they are perpendicular. 9. Before the rear wheels start to run over the windrow, move it from the load shoulder and spread it.
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OPERATION
OPERATION
2. Operate the right blade lift cylinder and set the blade to the depth of the ditch.
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3. Be careful not to let the rear left wheel run over windrow (A) formed by the blade.
4. Operate the blade lift cylinder and blade rotation to set so that the windrow is pushed to the outside of the rear left wheel. 5. Lean the front wheels slightly to the left. 6. To push out the soil to the top of the slope face and the road shoulder, a separate pass is needed. Spread the soil, then carry out final finishing with the grader.
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. OPERATION
OPERATION
2. Operate the left blade lift cylinder and set the blade to the depth of the ditch.
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3. Be careful not to let the rear right wheel run over the windrow discharged from the blade. Operate the blade lift cylinder and blade rotation to set the blade in position. 4. Lean the front wheels slightly to the right. 5. To push out the soil to the top of the slope face and the road shoulder, a separate pass is needed. Spread the soil, then carry out final finishing with the grader.
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OPERATION
OPERATION
2. Move the right edge of the blade to the outside of the front right wheel and adjust (reduce) the propulsion angle so that the windrow comes between the rear wheels (chassis).
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3. Adjust the blade height to move the windrow to the center of the road. Set the position of the machine as follows. 1) If the road shoulder is hard, travel with the wheels on either side of the windrow at the road edge to process it. (Spreading posture) 2) If the road shoulder is soft, use the extreme side reach posture to process it. (Shoulder reach posture) Be careful not to let the rear wheels run over the windrow.
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. OPERATION
OPERATION
4. Spread the windrow from the road shoulder to the center of the road. Make the propulsion angle as large as possible to push the windrow to one side. Set the digging angle to the maximum. Be careful not to let the rear wheels run over the windrow. For the finishing operation, travel at a speed of 2 to 6 km/h (1.2 to 3.7 MPH).
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OPERATION
OPERATION
2. Move the left edge of the blade to the outside of the front left wheel and adjust (reduce) the propulsion angle so that the windrow comes between the rear wheels (chassis).
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3. Adjust the blade height to move the windrow to the center of the road. Set the position of the machine as follows. 1) If the road shoulder is hard, travel with the wheels on either side of the windrow at the road edge to process it. (Spreading posture) 2) If the road shoulder is soft, use the extreme side reach posture to process it. (Shoulder reach posture) Be careful not to let the rear wheels run over the windrow.
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. OPERATION
OPERATION
4. Spread the windrow from the road shoulder to the center of the road. Make the propulsion angle as large as possible to push the windrow to one side. Set the digging angle to the maximum. Be careful not to let the rear wheels run over the windrow. For the finishing operation, travel at a speed of 2 to 6 km/h (1.2 to 3.7 MPH).
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OPERATION
OPERATION
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The procedure shown in the diagrams is for one side of the road. Repeat the same operation on the opposite side of the road. When carrying out Steps 4 and 7, articulate the frame. 1. Line of ditch: Light-duty digging Determine the line of the ditch along the measured points. Depth: 30 to 50 mm (1.2 to 2.0 in) Travel speed: 0.5 km/h (0.3 MPH)
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OPERATION
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5. Leveling center 6. Fourth digging pass: Heavy-duty digging
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OPERATION
OPERATION
8. Spreading to center
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10. Finishing bottom of ditch 11. Ditch digging pass (finishing and shaping inside of the slope face)
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OPERATION
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OPERATION
OPERATION
FLAT-BOTTOMED DITCH
When there is no V-ditch, make a V-ditch at the depth of the flat-bottomed ditch. The slope face of the road shoulder must be flatter than normal.
1. Operate the power tilt and angle the blade to the front. 2. Operate the drawbar shift cylinder and set the circle fully to the left of the machine.
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5. Operate the right blade lift cylinder to lower the right end of the blade, and set it to the digging depth. 6. Operate the left blade lift cylinder to raise the right end of the blade, and set it to the desired angle for the slope face of the road shoulder.
3. Place the front right tire in the bottom of the V-ditch. 4. Set the blade so that the right edge of the blade comes to the inside of the front right tire at the width of the flat-bottomed ditch.
7. Lean the front wheels to the left. Dig the No. 2 V-ditch to the same depth or slightly deeper than the No. 1 ditch. 8. Dig the flat bottom. Set the right blade lift cylinder to the desired depth. 9. Operate the left blade lift cylinder as required.
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. OPERATION
OPERATION
10. Set the front right tire at the bottom of the first V-ditch and start the operation. 11. Set the right edge of the blade at the bottom of the slope.
12. Lower the right blade lift cylinder so that the tip of the blade is the set precision for the ditch.
13. Lower the left lift cylinder to the desired digging depth. Lean the front wheels to the left.
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14. Set the blade at an acute angle and push up the soil to the top of the ditch slope. 15. Spread the windrow and finish to the final precision.
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OPERATION
OPERATION
2. Dig the width and depth of the bottom of the ditch with the left ditching method.
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3. Finish the road shoulder.
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OPERATION
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7. Finish the ditch. 8. Finish the slope face on the inside.
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OPERATION
OPERATION
FINISHING WITH GRADER FOR DITCHES WHERE WET ROAD SHOULDER IS LOOSE
This method is used when avoiding hanging trees or protruding rocks which are obstacles when cleaning old ditches. 1. Articulate the machine so that the front wheels and blade remain in the ditch. Steer with the front wheels. 2. Keep the rear wheels on the road shoulder and be careful that the wheels do not slip on the soft weak soil of the ditch.
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LEVELING SLOPE FACE
WARNING
When operating on slopes where the machine may slip to the side, make sure that you understand the operation of the machine completely. Do not articulate the machine fully on steep slopes. On steep slopes, lower the engine speed and operate in 1st gear. When operating on slopes, use the accelerator to control the machine speed.
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. OPERATION
OPERATION
WARNING
Lower the blade to the ground before removing the bank control lock pin.
The procedure given indicates the procedure for the right side. For the left side, operate the blade in the opposite way. 1. The roadbed where the foundation is to be dug must be uniform. 2. If the soil is hard, angle the roadbed slightly towards the bank to prevent the machine from sliding to the side away from the bank.
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5. Rotate the circle and set the end of the blade at the side of the front right wheel. 6. In the position in Step 5, lower the blade so that it is lightly in contact with (touching) the ground.
3. Operate the blade shift cylinder and shift the blade to the right. 4. Operate the drawbar shift cylinder and shift the drawbar to the right.
7. Move the bank switch from the LOCK position to the RETRACT position, then remove the lock pin from the lifter.
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OPERATION
OPERATION
8. Extend the right blade lift cylinder, retract the left blade lift cylinder and drawbar shift cylinder, and rotate the lifter guide counterclockwise enough for the bank control lock pin to come out of the lock hole.
9. When the lifter has rotated, move the bank switch from the RETRACT position to the INDEX position.
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10. Operate the lifter to the specified position (counter mark), then insert the bank control lock pin. 11. When the lifter guide is at the specified position, move the bank switch from the INDEX position to the LOCK position.
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. OPERATION
OPERATION
12. Retract the right lift cylinder and extend the left lift cylinder to set the blade to the bank slope position. 13. Rotate the circle to the right.
14. Rotate the circle and extend or retract the left and right blade lift cylinders to set to the bank slope face posture.
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15. Angle the blade at 3/4 to the front from the high bank position to set to the low bank posture. 16. Extend the left blade lift cylinder, and set the tip of the left cutting edge of the blade in line with the outside of the rear wheels at the bottom of the slope face. 17. The rear right wheel must be in the V at the base of the slope face. 18. Extend the right blade lift cylinder and set the angle to the desired bank slope face. 19. Gradually progress with the cutting. REMARK The wheels should normally be almost perpendicular.
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OPERATION
OPERATION
20. If the digging is comparatively heavy duty, angle the wheels towards the slope face.
21. If the digging is comparatively light duty, angle the wheels away from the slope face. Discharge the soil from the slope face to the outside of the rear wheels.
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. OPERATION
OPERATION
WARNING
Lower the blade to the ground before removing the bank control lock pin.
1. Lower the blade so that it is lightly in contact with the ground. 2. Move the bank switch from the LOCK position to the RETRACT position, then remove the lock pin from the lifter.
3. Extend the right blade lift cylinder, retract the left blade lift cylinder, and rotate the lifter guide to the left.
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4. When the lifter has rotated, move the bank switch from the RETRACT position to the INDEX position.
5. Operate the lifter to the specified position (counter mark), then insert the bank control lock pin.
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OPERATION
OPERATION
6. When the lifter guide is at the specified position, move the bank switch from the INDEX position to the LOCK position.
7. Shift the blade to the side as shown in the diagram. Shift the blade fully to the right. Shift the drawbar fully to the right. Set the blade propulsion angle to approx. 60
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8. Lower the blade to the desired depth, then set the blade at an angle to discharge the soil to the side.
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. OPERATION
OPERATION
WARNING
Do not shift gear or place the transmission in neutral when going downhill. The braking effect of the engine cannot be used, so this is dangerous. Always keep the gear shift lever in a travel position when going downhill. Failure to do this may result in engine overrun and damage to the engine or transmission. To prevent engine overrun, always shift down one gear at a time.
TRAVELING DOWNHILL
When traveling downhill, select the same gear range as when traveling uphill, and make full use of the engine to reduce the travel speed.
IF ENGINE STOPS
CAUTION
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If the engine stops on a slope, immediately depress the brake pedal fully to stop the machine, set the gearshift lever to the P (Parking) position, then start the engine again.
If the engine stops, the brake booster will not work, so the operating effort of the pedal will become heavier and the effect of the brake will become lower even when the pedal is depressed with the same force.
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OPERATION
OPERATION
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. OPERATION
OPERATION
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When the articulation is used to steer the machine, the machine will turn sharply, so at high speed there is a danger that it will turn over. For this reason, only use the articulation at speeds of less than 10 km/h (6.2 MPH).
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OPERATION
OPERATION
CAUTION
When using the ripper, set the frame straight.
For general soil condition, use 3 to 5 shanks. Keep the ripper at a depth where there is no tire slip and where the engine horsepower can be used to its full.
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Travel in a straight line at approx. 2 to 4 km/h (1.2 to 2.5 MPH), and gradually insert the points into the ground. On slopes, carry out ripping downhill to use the weight of the machine. NOTICE To prevent damage, raise the ripper from the ground before turning the machine. Carry out cross ripping only when there is a special purpose. When breaking up a paved surface, raise the ripper after digging up the ground under the surface.
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. OPERATION
OPERATION
BLADE PROTRUSION
The degree of protrusion is controlled by the control lever during operation. If further protrusion is needed, stop the grader for a while and change the installing position of the blade horizontal shifting cylinder piston rod, as follows. 1. Lower the blade to the ground. 2. Loosen the bolt holding the blade to the bracket at the tip of the cylinder rod, then remove the bolt and lock washer. 3. Pull in the cylinder rod. 4. Align the bolt hole in the bracket with a hole in another place on the blade. 5. Install the lock washer and bolt, then tighten the bolt. Protrusion to right: Position (1)
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The angle between the blade and the center line of the machine body is called the blade propulsion angle. Set the blade propulsion angle to about 60 for general cutting work, but set it narrower in the following situations. When the cutting resistance is high. When the soil is hard. When the soil accumulated in front of the blade dose not flow smoothly.
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OPERATION
OPERATION
PARKING MACHINE
WARNING
Avoid stopping suddenly; give yourself ample room when stopping. Do not park the machine on slopes. If the machine has to be parked on a slope, set it at right angles to the slope, put blocks under the tires, and dig the blade into the ground surface to prevent the machine from moving. If the control levers are not locked and they are touched by accident when starting the engine, the work equipment may move unexpectedly, and this may lead to a serious accident. When standing up from the operator's seat, always set the gearshift lever to the P (Parking) position.
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1. Release accelerator pedal (1).
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. OPERATION
OPERATION
2. Depress brake pedal (2). Before the machine comes to a stop, depress inching pedal (3).
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4. Check that parking brake pilot lamp (5) on the machine monitor is lighted up. 5. Operate the work equipment control lever and lower the blade and ripper to the ground.
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OPERATION
OPERATION
LOCKING
Always lock the following parts. (1) Fuel filler cap (2) Engine side cover (3) Cab door (4) Hydraulic oil filler cap (5) Radiator water filler cap
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REMARK The starting switch key is also used for these locks.
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. OPERATION
OPERATION
WARNING
To ensure safety, the defective tires given below must be replaced with new tires. Tires where the bead wire has been cut, broken, or greatly deformed Excessively worn tires where more than 1/4 of the circumference of the carcass ply (excluding the breaker) is exposed Tires where damage to the carcass exceeds 1/3 of the tire width Tires where ply separation has occurred Tires where radial cracks extend to the carcass Tires where there is abnormal deterioration, deformation, and damage, and the tire cannot withstand use.
Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care.
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OPERATION
OPERATION
OPERATION
WARNING
The accumulator is charged with high-pressure nitrogen gas, so it is extremely dangerous if handled incorrectly. Always obey the following rules strictly. Never make a hole in the accumulator or bring it does to any flame or fire. Do not weld any boss to the accumulator. When discarding the accumulator, the gas must be released, so contact your Komatsu distributor.
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In the figure on the right, the left side shows the switches for the machine equipped with an accumulator and blade float, and the right side shows the switches for the machine equipped with an accumulator. 3. Turn off accumulator switch 2, then start the engine. In the figure on the right, the left side shows the switches for the machine equipped with an accumulator and blade float, and the right side shows the switches for the machine equipped with an accumulator.
1. Lower the blade to the ground and stop the engine. 2. Turn starting switch (1) to the ON position to supply power to the electric circuits, then turn on accumulator switch (2). Next, move the right and left blade lift levers forward and backward to release the residual pressure in the accumulator and the hydraulic circuits.
4. Next, extend the right and left blade lift cylinders about 50 mm (2.0 in). At this time, holding pressure is produced at the bottom of the blade lift cylinders.
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. OPERATION
OPERATION
5. Turn on the accumulator switch to operate the accumulator. The oil in the bottom of the right and left blade lift cylinders will flow into the accumulator, both blade lift cylinders will retract, and the front wheels will lower to the ground. In the figure on the right, the left side shows the switches for the machine equipped with an accumulator and blade float, and the right side shows the switches for the machine equipped with an accumulator. REMARK At this time, a pressure is maintained at the bottom of the blade lift cylinders, that is, a pressure acts on the blade. When the machine is operated under this condition, the blade can follow a difference in ground level of about 150 mm (5.9 in), which is the standard operation when an accumulator is in use. In actual operation, the blade lift cylinder levers will move properly so that the blade can follow the required difference in ground level with the proper pressing force. Once the accumulator is set and the machine is started, the blade lift levers do not need to be operated. When stopping the work for a time, the accumulator can be reset to the same condition as before stopping the work by turning off the switch, lifting the blade, lowering it to the ground again, and turning on the switch again.
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The blade accumulator has the following characteristics. EASE OF WORK No need to operate blade This work does not require a lot of skill. SAFETY AND PROTECTION Shocks are reduced. The machine is protected from buried objects. (The machine runs over projecting objects.) The work equipment is protected (the impact load is reduced). IMPROVED STEERING PERFORMANCE Steering performance on curves is improved. Side slips on curves are reduced. Steering performance with the leaning system is improved. Reduction in side slippage when using leaning No pulling of front wheels (floating, safety of front wheels) IMPROVED WORKABILITY Good pushing of blade Good avoidance by blade
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OPERATION
OPERATION
OPERATION
WARNING
If the blade float switch is turned ON when the blade is raised, the pressure will be released from the left cylinder and the blade will fall suddenly. Never allow anyone near the machine when turning the blade float switch ON.
2. Turn starting switch (1) ON (electric current flows through the circuit), then set the blade lift control lever to the HOLD position and turn blade float switch (2) ON. In this condition, the pressure is released from the head and bottom ends of the blade lift cylinder, so the blade is placed in the float condition.
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3. If the blade lift cylinder control lever is operated to the RAISE position when blade float switch (2) is ON, the blade will rise, and if it is operated to the LOWER position, the blade will go down.
4. If the blade lift control lever is returned to the HOLD position when the blade is raised or lowered, the pressure in the lift cylinder will be released and the blade will suddenly drop to the ground. REMARK When the starting switch is ON (current flowing through the circuit), it is possible to switch the float condition at any time by operating the blade float switch ON/OFF.
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. OPERATION
OPERATION
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OPERATION
TRANSPORTATION
TRANSPORTATION
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
WARNING
When loading or unloading the machine, run the engine at low speed, travel at low speed, and operate slowly. When loading or unloading the machine, stop the trailer on firm level ground. In addition, keep well away from the road shoulder. Use ramps of ample width, length, thickness, and strength, and install them securely at an angle of less than 15. When using an embankment, compact the fill soil thoroughly and make sure that the slope face does not collapse. Remove the mud stuck to the undercarriage to prevent the machine from slipping to the side on the ramps. In addition, remove any water, snow, ice, grease, or oil from the ramps. Never change direction on the ramps. There is danger that the machine may tip over. If it is necessary to change direction, return to the ground surface or the trailer platform, correct the direction, and start again. The position of the center of gravity of the machine will change suddenly at the connection of the ramp and trailer, and there is danger of the machine losing its balance. Always drive slowly over this point.
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2. Apply the brakes on the trailer securely and insert blocks under the tires to ensure that the trailer does not move. Then fix the ramps in line with the centers of the trailer and the machine. Be sure that the two sides are at the same height as one another. Make the angle of the ramps a maximum of 15. Set the distance between the ramps to match the center of the tires. 3. Set the machine in line with the ramps, then drive the machine slowly to load or unload it. 4. Load the machine correctly in the specified position on the trailer.
When loading or unloading, always use ramps or a platform and carry out the operations as follows. 1. Insert the shank as shown in the diagram on the right.
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. TRANSPORTATION
OPERATION
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OPERATION
COOLANT
WARNING
Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or on your skin, wash it off with large amounts of fresh water and see a doctor at once. When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface. Antifreeze is flammable. Do not bring any flame close. Do not smoke when handling antifreeze.
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NOTICE Never use methanol, ethanol or propanol based antifreeze. Avoid using any leak-preventing agent, regardless if it is sold separately or in antifreeze. Do not mix one brand of antifreeze with a different brand. For details of the antifreeze mixture when changing the coolant, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-17)". 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 SAE J1034 FEDERAL STANDARD O-A-548D REMARK In areas where permanent antifreeze is not available, it is possible to use antifreeze whose main component is ethylene glycol and does not contain any corrosion inhibitor. (Such antifreeze can be used for the winter season only.) However, in such a case, the coolant must be changed twice a year (spring and autumn), so use permanent antifreeze when possible.
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OPERATION
BATTERY
WARNING
The battery generates flammable gas. 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 a large amount of water and consult a doctor. Battery electrolyte dissolves paint. If it gets on the bodywork, wash it off immediately with water. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is danger that the battery may explode. Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.
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 100%. Insulate it against cold temperature to ensure the machine can be started easily the next morning. Measure the specific gravity and calculate the rate of charge from the following conversion table.
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100 90 80 75 1.28 1.29 1.30 1.31 1.26 1.24 1.23 1.27 1.25 1.24 1.28 1.26 1.25 1.29 1.27 1.26 When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from freezing.
20
-10
-20
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OPERATION
LONG-TERM STORAGE
LONG-TERM STORAGE
BEFORE STORAGE
When putting the machine in storage for a long time, do as follows. After every part is washed and dried, house the machine in a dry building. Never leave it outdoors. In case it is indispensable to leave it outdoors, park the machine on the flat ground and cover it with canvas etc. Completely fill the fuel tank, lubricate and change the oil before storage. Coat the exposed portion of the hydraulic cylinder piston rod with grease. Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately. If the ambient temperature is expected to drop below 0C (32F), always add antifreeze to the cooling water. Komatsu genuine Super Coolant (AF-ACL) is added to the cooling water, so there is no need to change the density for temperatures down to -10C (14F). If the temperature goes below -10C (14F), adjust the density. For details, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-17)". Place gear shift levers at the P (parking) position. Fit a block under the center of the front wheel and the tandem case, jack up the tires from the ground, then put a block under the blade and lower it on top of the block.
DURING STORAGE
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If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors and windows to improve ventilation and prevent gas poisoning. During storage, operate and move the machine for a short distance once a month so that a new film of oil will coat moving parts. At the same time, also charge the battery. When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods. If the machine is equipped with an air conditioner, operate the air conditioner for 3 to 5 minutes once a month to lubricate all parts of the air conditioner compressor. Always run the engine at low idling when doing this. In addition, check the refrigerant level twice a year.
WARNING
AFTER STORAGE
NOTICE If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, do as follows before using it. Wipe off the grease from the hydraulic cylinder rods. Add oil and grease to all places. When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and after starting the engine. If there is water in the oil, change all the oil.
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. TROUBLESHOOTING
OPERATION
TROUBLESHOOTING
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. Always watch the fuel level and be careful not to run out of fuel. If the engine has stopped because of lack of fuel, it is necessary to use the priming pump to bleed the air completely from the fuel circuit.
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WARNING
If the machine is driven with the leaning cylinder piston rod fluctuating or the front wheels leaning on one side because of damaged leaning piping, dangerously unstable steering and excessively worn tires will result. Repair the faulty leaning pipe quickly. If the leaning piping is broken, call your Komatsu distributor for repair.
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OPERATION
TROUBLESHOOTING
WARNING
The brakes will not work if there is a failure in the air system, so be extremely careful. If a mistaken method is used when towing, there is danger of causing death or serious injury. Before releasing the brakes, always put blocks under the tires. When towing, always use a wire rope of ample strength for the load being towed. Avoid applying a sudden load to the wire rope.
NOTICE Towing is for moving the machine to a place where inspection and maintenance can be carried out, and not for moving it long distances. The machine must not be towed for long distances. For details of the procedure for towing a machine when it has broken down, please contact your Komatsu distributor.
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When towing a disabled machine the distance should be within 600 m (1968 ft) at a speed of 8 km/h (5.0 MPH) or less. If the distance is more than the above mentioned, or if more than one day has elapsed since the engine trouble, be sure to use a trailer for transportation. NOTICE If the machine is towed without the engine running, no lubrication oil will be supplied to the transmission. The gears and bearings are rotated, so this may cause them to be damaged. Tow the machine properly according to the instructions given below. The explanation given here is only to be used for a machine that has failed and is to be moved to a safe place for repairs. It must be moved a maximum of 600 m (1968 ft) and at a maximum speed of 8 km/h (5.0 MPH). This procedure is only for emergency purposes. If the machine must be moved a long distance, use a transporter. To protect the operator if the towrope or bar should break, install a protector plate to the machine being towed. If it is impossible to use the steering or brakes on the machine being towed, then do not have anyone sitting in the operator's seat. Before towing, check that the tow rope or bar are in good condition, and that they have ample strength for the towing operation. If the machine being towed may get stuck in mud or may have to be towed uphill, the tow rope or bar must be of a strength of at least 1.5 times greater than the weight of the machine being towed. Keep the angle of the towing line to the minimum. Operate the machine so that the angle does not become greater than 30 from the straight line. If the machine is moved suddenly, the towrope or bar will be subjected to an excessive load, and it may break. Start the machine gradually and travel at a constant speed. Normally, use a towing machine of about the same capacity as the machine being towed. The towing machine must have ample brake capacity, weight, and rimpull. Check that both machines can be controlled on slopes and on the tow road. When moving a failed machine on a downhill slope, a larger towing machine must be used to ensure ample control and braking power. Another method is to use a second towing machine at the rear of the failed machine. In this way, it is possible to prevent the failed machine from going out of control and turning over.
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. TROUBLESHOOTING
OPERATION
It is impossible to determine the drawbar pull needed for various conditions. The minimum drawbar pull may be sufficient on horizontal, flat ground, but the maximum drawbar pull is needed on slopes or on rough roads. When towing a failed machine, please contact your Komatsu distributor.
WARNING
When releasing the parking brake, stop the machine on level ground and check that the surrounding area is safe. If it is necessary to release the brake on a slope in an emergency, block the tires before starting the operation. If the parking brake is released, the brake cannot be used, so check the safety carefully when moving the machine.
If the pressure in the air tank drops below 0.24 MPa (2.4 kgf/cm2, 34.1 PSI), the parking brake is applied automatically. Therefore, when towing the machine, release the parking brake as follows. Turn bolt (1) and the parking brake will be released.
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NOTICE After releasing the parking brake and moving the machine, it is necessary to adjust the parking brake again. Please contact your Komatsu distributor to have the parking brake adjusted.
WARNING
When the engine is stopped, it is impossible to steer the machine, and this may lead to personal injury. If the engine should stop during operations, immediately apply the service brake and stop the machine.
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OPERATION
TROUBLESHOOTING
WARNING
Never operate the electrical motor for the emergency steering for more than 30 seconds. If the machine battery cells are not functioning, the emergency steering cannot display its capacity.
This mechanism works to prevent steering failure caused by a breakdown of the engine or hydraulic pump while the machine is being operated. If the oil pressure in the steering hydraulic circuit drops below 0.69 MPa (7 kgf/cm2, 99.4 PSI), the hydraulic switch is turned on, and the electrical motor is actuated to turn the hydraulic pump and enable steering to be carried out. If the machine is traveling at a speed of less than 1 km/h (0.6 MPH), or if the machine is stopped, the emergency steering device automatically stops. If it is necessary to release the parking brake, use the procedure given in "HANDLING EMERGENCY STEERING DEVICE (PAGE 6-2)".
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. TROUBLESHOOTING
OPERATION
IF BATTERY IS DISCHARGED
WARNING
It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion. Do not bring lighted cigarettes near the battery, or do anything that will cause sparks. Battery electrolyte is dilute sulfuric acid, and it will attack your clothes and skin. If it gets on your clothes or on your skin, immediately wash it off with a large amount of water. If it gets in your eyes, wash it out with fresh water and consult a doctor. When handling batteries, always wear protective goggles and rubber gloves. When removing the battery, first disconnect the cable from the ground (normally the negative (-) terminal). When installing, install the positive (+) terminal first. If a tool touches the positive terminal and the chassis, there is danger that it will cause a spark, so be extremely careful. If the terminals are loose, there is danger that the defective contact may generate sparks that will cause an explosion. When removing or installing the terminals, check which is the positive (+) terminal and which is the negative (-) terminal.
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REMOVAL AND INSTALLATION OF BATTERY
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 a hazard of sparks being generated. When installing the battery, connect the ground cable last.
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OPERATION
TROUBLESHOOTING
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STARTING ENGINE WITH BOOSTER CABLE
When starting the engine with a booster cable, do as follows:
WARNING
When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, wear safety glasses and rubber gloves. 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. 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. When disconnecting the booster cable, take care not to bring the clips in contact with each other or with the machine body.
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. TROUBLESHOOTING
OPERATION
NOTICE The size of the booster cable and clip should be suitable for the battery size. The battery of the normal machine must be the same capacity as that of the engine to be started. Check the cables and clips for damage or corrosion. Make sure that the cables and clips are firmly connected. Check that the work equipment lock levers and parking brake levers of both machines are in the LOCK position. Check that each lever is in the NEUTRAL position.
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STARTING THE ENGINE
CAUTION
Check that the gearshift levers on both the normal machine and problem machine are at the P (Parking) position. Check also that all levers are at neutral.
1. Make sure the clips are firmly connected to the battery terminals. 2. Start engine of the normal machine and run it at high idling speed. 3. Turn the starting switch of the problem machine to the START position and start the engine. If the engine doesn't start at first, try again after 2 minutes or so.
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OPERATION
TROUBLESHOOTING
OTHER TROUBLE
ELECTRICAL SYSTEM
( ): Always contact your Komatsu distributor when dealing with these items. In cases of problem or causes which are not listed below, contact your Komatsu distributor for repairs.
Problem Lamp does not glow brightly even when the engine runs at high speed Lamp flickers while engine is running Charge lamp do not go out even when engine is running Abnormal noise is generated from alternator Starting motor does not turn when starting switch is turned to ON Pinion of starting motor keeps going in and out Starting motor turns engine sluggishly
Main causes Defective wiring Defective adjustment of fan belt tension Defective lamp Defective alternator Defective wiring Defective alternator Defective wiring Insufficient battery charge Defective starting motor Insufficient battery charge
Remedy ( Check, repair loose terminals, disconnection) Check fan belt wear, replace For details, see EVERY 250 HOURS SERVICE ( Replace) ( Replace) ( Check, repair) ( Replace) ( Check, repair) Charge ( Replace) Charge
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Insufficient battery charge Defective starting motor Charge ( Replace) Starting motor disengages before engine starts Preheating monitor does not goes out Charge lamp does not light up while engine is stopped (with starting switch at ON position) Outside of electrical intake air heater is not warm when touched by hand Defective wiring Insufficient battery charge Defective wiring Defective heater relay Defective monitor Defective monitor Defective wiring Defective wiring Disconnection in electrical intake air heater Defective operation of heater relay switch intake air heater ( Check, repair) Charge ( Check, repair) ( Replace) ( Replace) ( Replace) ( Check, repair) ( Check, repair) ( Replace) ( Replace heater relay switch)
3 - 131
. TROUBLESHOOTING
OPERATION
CHASSIS
( ): Always contact your Komatsu distributor when dealing with these items. In cases of problem or causes which are not listed below, contact your Komatsu distributor for repairs.
Main causes Gearshift lever has not been shifted properly Gouging of lever linkage Transmission oil pressure does not rise Lack of oil in transmission case
Remedy Shift lever properly ( Check, repair) ( Check, adjust) Add oil to specified level For details, see EVERY 250 HOURS SERVICE ( Check, replace) ( Check, repair) Clean, replace For details, see EVERY 1000 HOURS SERVICE ( Check, repair) ( Check, repair)
Wear, scuffing of transmission pump Leakage of oil from oil line Clogged transmission filter element Defective operation of transmission, control valve Defective return of parking brake Lack of oil in transmission
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Even when engine is run at full throttle, machine moves slowly, lacks power Clogged transmission oil filter cartridge Defective return of parking brake Improper adjustment of engine More noise than usual is generated from power train Final drive oil temperature lamp on machine monitor flashes Lack of oil in transmission case, tandem case Lack of oil in final drive case Add oil to specified level For details, see EVERY 250 HOURS SERVICE Clean, replace For details, see EVERY 1000 HOURS SERVICE ( Check, repair) ( Check, repair) Add oil to specified level For details, see EVERY 250 HOURS SERVICE Add oil to specified level For details, see EVERY 250 HOURS SERVICE Stop using differential until oil temperature goes down Adjust. For details, see EVERY 1000 HOURS SERVICE Check, adjust ( Check, adjust [adjust bearing preload]) Supply grease Adjust. For details, see EVERY 1000 HOURS SERVICE Inflate tires to same air pressure Install again. For details, see HANDLING TIRES ( Adjust)
Differential has been operated for a long time Abnormal wear of front tires Incorrect adjustment of toe-in
Lack of inflation pressure Heat generated from front wheel hub Front wheels wobble when traveling Loose bearing preload adjustment nut for front wheel Lack of grease Incorrect adjustment of toe-in, loose tie rod Inflation pressure of left and right tires not same Wheel not properly installed Steering wheel is heavy Defective Orbit-roll
3 - 132
OPERATION
TROUBLESHOOTING
Main causes Wear of disc Air leakage in brake piping Seizure of disc Defective piston seal Wear of brake pad Play in lift cylinder ball joint ( ( ( ( (
Remedy Check, replace) Check, repair) Check, repair) Replace) Check, replace) Adjust shim. For details, see EVERY 250 HOURS SERVICE Adjust shim at circle guide connector. For details, see EVERY 500 HOURS SERVICE Replace guide bushing, shim Correct blade rail Adjust position of guide connector. For details, see EVERY 500 HOURS SERVICE Add oil to specified level For details, see EVERY 250 HOURS SERVICE
Poor braking effect of parking brake Blade moves up and down excessively during operation
Excessive clearance between sliding surface of circle and drawbar Worn blade rail guide bushing Rotation of blade during operation is excessive Excessive clearance in circle in radial direction
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Work equipment does not move properly when work equipment control lever is operated
Lack of oil
3 - 133
. TROUBLESHOOTING
OPERATION
ENGINE
( ): Always contact your Komatsu distributor when dealing with these items. In cases of problem or causes which are not listed below, contact your Komatsu distributor for repairs.
Problem After warming-up operation, engine oil pressure monitor lights up even when engine speed is raised
Main causes Oil level in engine oil pan is low (sucking in air) Clogged oil filter element
Remedy Add oil to specified level For details, see CHECK BEFORE STARTING Replace cartridge For details, see EVERY 250 HOURS SERVICE ( Check, repair)
Leakage of oil due to damage, defective tightening of oil pipe, pipe joint Defective monitor Defective oil pressure switch Diluted with fuel, water Defective pressure adjustment valve Steam spurts out from top of radiator (pressure valve) Lack of coolant, leakage of coolant Loose fan belt
( ( ( (
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Dirt or scale accumulated in cooling system Engine water temperature gauge on machine monitor flashes in red range Radiator fins clogged or bent Defective thermostat Loose radiator filler cap (high altitude operations) Defective coolant temperature gauge Engine does not start when starting motor is turned Lack of fuel Air in fuel system Defective fuel injection pump or nozzle Starting motor cranks engine sluggishly Preheating monitor does not light up Defective compression Defective valve clearance
Check, add coolant, repair cooling system. For details, see WHEN REQUIRED Adjust tension For details, see EVERY 250 HOURS SERVICE Change coolant, clean cooling system For details, see WHEN REQUIRED Clean or repair For details, see EVERY 500 HOURS SERVICE ( Replace thermostat) Tighten cap or replace packing ( Replace)
Add fuel. For details, see CHECK BEFORE STARTING ( Repair place where air is sucked in) ( Replace pump or nozzle) See ELECTRICAL SYSTEM See ELECTRICAL SYSTEM ( Adjust clearance)
3 - 134
OPERATION
TROUBLESHOOTING
Remedy Reduce oil to specified level For details, see CHECK BEFORE STARTING Add fuel. For details, see CHECK BEFORE STARTING Change to specified fuel Clean or replace. For details, see WHEN REQUIRED ( Replace nozzle) ( See "Defective compression" above) ( Wash or replace turbocharger) ( Replace nozzle) Change to specified fuel See "Engine coolant temperature gauge is in red range top" Replace muffler ( Adjust clearance)
Lack of fuel
Improper fuel Exhaust gas sometimes turns black Clogged air cleaner element Defective nozzle Defective compression Defective turbocharger Combustion noise occasionally makes breathing sound Abnormal noise generated (fuel system or mechanical system) Defective nozzle Low-grade fuel being used Overheating
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3 - 135
. TROUBLESHOOTING
OPERATION
TRANSMISSION CONTROLLER
If there is a failure in the transmission system, check the failure code on the transmission controller and ask your Komatsu distributor to carry out repairs. Transmission control (1) is installed inside the engine hood at the rear of the cab. Open panel (2) and check the failure code on the controller.
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FAILURE CODE DISPLAY ON TRANSMISSION CONTROLLER
When the starting switch is turned to the ON position, the transmission controller displays the failure codes as follows. 1. Display after starting switch is turned to ON position 1) To make it possible to check the LED, it displays "88" for 5 seconds. 2) To distinguish from the next display, ". " is displayed for 0.5 seconds. 3) CHECK SUM (controller version) is displayed for 3 seconds.
2. Displays past failure history Each failure code that occurred in the past is displayed in turn once.
3 - 136
OPERATION
TROUBLESHOOTING
1) To distinguish from the next display, ". " is displayed for 0.5 seconds. 2) The past failure codes are displayed for 3 seconds. If these failure codes are reset, they will not be displayed in future. Please ask your Komatsu distributor to carry out the resetting.
3. Displays existing failure history The failure codes for existing failures are displayed in turn once. If there is no existing failure, "00" is displayed for 3 seconds. 1) To distinguish from the next display, "E " is displayed for 0.5 seconds. 2) The existing failure codes are displayed for 3 seconds.
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4. Displays number of recorded past abnormal operations 1) To distinguish from the next display, "- " is displayed for 0.5 seconds. 2) Displays abnormal operation codes for 3 seconds. 3) Displays the gear shifting pattern at the time of abnormal operation for 3 seconds. (If the code has no record for each transmission clutch, this is omitted.) 4) Displays number of abnormal operations for 3 seconds.
5. Display after completion of display in Step 4 1) If there is an existing failure, the display in Step 3 is repeated. If there is no existing failure, "0.0." Is displayed.
3 - 137
. TROUBLESHOOTING
OPERATION
CAUTION SYSTEM
If any of the mistaken operations in the table below are carried out, caution lamp (1) or the alarm buzzer are actuated to give a warning.
Content of abnormal operation When shifting down, or when changing direction between F and R, and shifting N -> F (R) when machine is still traveling, shift-down command is issued according to travel speed Caution is issued until it reaches speed range selected by lever position (from 1 sec after lever operation) When shifting N -> F (R) when machine is traveling at more than 4 km/h (2.5 MPH) Caution issued (for 5 sec after lever operation) When transmission is shifted to F4 (R4) or above when engine speed is more than 350 rpm and travel speed is less than 2 km/h (1.2 MPH) Caution issued Inching time (sec) Clutch Category 1 F 2 3 4 1 R 2 3 4 0 1 F 2 3 4 0 1 R 2 3 4
Record
10
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{ {
12
11
Plate calculated temperature ( C (F)) 200 - 230 (392 - 446) 230 - 260 (446 - 500) 260 - 290 (500 - 554) 290 (554) or above 200 - 230 (392 - 446) 230 - 260 (446 - 500) 260 - 290 (500 - 554) 290 (554) or above 200 (392) or below 200 - 230 (392 - 446) 230 - 260 (446 - 500) 260 - 290 (500 - 554) 290 (554) or above 200 (392) or below 200 - 230 (392 - 446) 230 - 260 (446 - 500) 260 - 290 (500 - 554) 290 (554) or above
13
0 - 10
14
10 - 30
3 - 138
OPERATION
TROUBLESHOOTING
Content of abnormal operation 0 1 F 2 3 4 0 1 R 2 3 4 200 (392) or below 200 - 230 (392 - 446) 230 - 260 (446 - 500) 260 - 290 (500 - 554) 290 (554) or above 200 (392) or below 200 - 230 (392 - 446) 230 - 260 (446 - 500) 260 - 290 (500 - 554) 290 (554) or above
Record
15
30 or above
16
Caution issued when engine is running at high speed Caution lamp lights up when engine is operated continuously for 5 sec. at 2525 rpm or more Alarm buzzer sounds when engine is operated continuously for 10 sec. at 2525 rpm or more Acceleration when inching pedal is depressed (exceeding hydraulic control range) Caution lamp if more than max speed for speed range selected by lever position At above danger speed, shift up and caution buzzer Time that lubricating oil temperature is above 120 C (248 F) Caution issued after more than 30 seconds
17
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18
{ {
{
-
{
-
19
Time that lever position is at N and travel speed is more than 4 km/h (2.5 MPH) and engine speed is more than 1400 rpm Recorded as abnormal operation after more than 10 seconds Lever position at F (R) and inching pedal depressed (exceeding hydraulic control range) Time that travel speed is more than 4 km/h (2.5 MPH) and engine speed is more than 1400 rpm Recorded as abnormal operation after more than 10 seconds
1A
3 - 139
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4-1
. GUIDES TO MAINTENANCE
MAINTENANCE
GUIDES TO MAINTENANCE
Do not perform any inspection and maintenance operation that is not found in this manual. Check service meter: Check the service meter reading every day to see if the time has come for any necessary maintenance to be performed. Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu genuine oils: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. Always use clean washer fluid: Use automobile window washer fluid, and be careful not to let any dirt get into it. Clean oil and grease: Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away from oil and grease.
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Checking foreign material in drained oil: After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If large quantity of metal particles or foreign materials are found, always report to the person in charge, and carry out suitable action. Be careful of hot water and oil: If your machine is equipped with a fuel strainer, do not remove it while fueling. Welding instructions: Turn off the engine starting switch. Do not apply more than 200 V continuously. Connect grounding cable within 1 m (3.3 ft) of the area to be welded. If grounding cable is connected near instruments, connectors, etc., the instruments may malfunction. If a seal or bearing happens to come between the part being welded and grounding point, change the grounding point to avoid such parts. Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point. Objects in your pockets: When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop nuts, bolts, or tools inside the machine. If such things are dropped inside the machine, it may cause damage and/or malfunction of the machine, and will lead to failure. If you drop anything inside the machine, always remove it immediately. Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.
4-2
MAINTENANCE
GUIDES TO MAINTENANCE
Dusty worksites: When working at dusty worksites, do as follows: Inspect the air cleaner clogging monitor frequently to see if the dust indicator. Clean the air cleaner element at a shorter interval than specified. Clean the radiator core frequently to avoid clogging. Clean and replace the fuel filter frequently. Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust. When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting into the oil. Avoid mixing oils: If a different brand or grade of oil has to be added, drain the old oil and replace all the oil with the new brand or grade of oil. Never mix different brand or grade of oil. Locking inspection covers: Lock inspection cover securely into position with the lock bar. If inspection or maintenance is performed with inspection cover not locked in position, there is a danger that it may be suddenly blown shut by the wind and cause injury to the worker. Bleeding air from hydraulic circuit: It is necessary to bleed the air from the circuit if the hydraulic equipment has been repaired, replaced, or the hydraulic piping has been removed. Precautions when installing hydraulic hoses: When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and replace with new parts. When doing this, be careful not to forget to assemble the O-rings and gaskets. When installing the hoses, do not twist or bend them into loops with a small radius. This will cause damage to the hose and drastically reduce its service life.
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Checks after inspection and maintenance: If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may lead to serious injury or property damage. Always do the following: Checks after operation (with engine stopped) Have any inspection and maintenance points been forgotten? Have all inspection and maintenance items been performed correctly? Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped inside the machine and get caught in the lever linkage mechanism. Is there any leakage of coolant or oil? Have all nuts and bolts been tightened? Checks when operating engine For details of the checks when operating the engine, see "TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING (PAGE 2-32)" and pay careful attention to safety. Are the inspection and maintenance items working properly? Is there any leakage of oil when the engine speed is raised and load is applied to the oil pressure? Is there any leakage of oil or fuel when the engine speed is raised?
4-3
. OUTLINES OF SERVICE
MAINTENANCE
OUTLINES OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
OIL
Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high pressure), and 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 change 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 the 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 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.
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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 -15C (5 F)). It is necessary to use the fuel that is suitable for 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.
COOLANT
River water contains large amount 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 antifreeze, 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. For details of the anti-freeze, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-17)". Antifreeze is flammable, so be extremely careful not to expose it to flame or fire. The proportion of anti-freeze to water differs according to the ambient temperature. For details of the mixing proportions, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-17)". 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 due to air entering the coolant.
4-4
MAINTENANCE
OUTLINES OF SERVICE
GREASE
Grease is used to prevent seizure and noises at the joints. Grease fittings not listed in the inspection and maintenance section are grease fittings that are used at the time of overhaul, so there is no need to grease these points. When using the machine after it has been in storage for a long time, carry out greasing if there is any stiffness or screeching. 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.
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Measurement of density of metal wear particles This uses an ICP (Inductively Coupled Plasma) analyzer to measure the density of iron, copper, and other metal wear particles in the oil. Measurement of quantity of particles This uses a particle quantifier index measurement machine to measure the quantity of iron particles of 5 or more, enabling early detection of failures.
Others Measurements are made of items such as the ratio of water in the oil, density of the antifreeze coolant, ratio of fuel in the oil, and dynamic viscosity, enabling a highly precise diagnosis of the machine's health.
4-5
. OUTLINES OF SERVICE
MAINTENANCE
OIL SAMPLING
Sampling interval 250 hours: Engine 500 hours: Other components Precautions when sampling Make sure that the oil is well mixed before sampling. Perform sampling at regular fixed intervals. Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor.
FILTERS
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RELATING TO ELECTRIC SYSTEM
It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. This will cause an electrical short circuit and may lead to malfunction of the machine. Do not wash the inside of the operator's cab with water. When washing the machine, be careful not to let water get into the electrical components. Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, so before installing a radio receiver or other wireless equipment, contact your Komatsu distributor. When working at the seashore, carefully clean the electric system to prevent corrosion. When installing an operator's cab cooler or any other electrical equipment, connect it to an independent power source connector. The cables to supply power to the optional equipment must never be connected to the fuse, starting switch, or battery relay.
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, replace 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 affixed to the old filter. If any metal particles are found, contact your Komatsu distributor. Do not open packs of spare filters until just before they are to be used. Always use Komatsu genuine filters.
4-6
MAINTENANCE
WEAR PARTS
WEAR PARTS
Wear parts such as the filter element, air cleaner element, 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. When ordering parts, please check the part number in the parts book.
Item Engine oil filter Fuel filter Corrosion resister Transmission oil filter Hydraulic filter Strainer for emergency steering (if equipped) Air cleaner
Part No. 600-211-1231 600-311-7132 600-411-1151 424-16-11140 (424-16-11130) (424-16-11630) 234-60-31330 205-60-51450
Part Name Cartridge Cartridge Cartridge Element (O-ring) (O-ring) Return filter element Suction strainer
Replacement interval Every 250 hours Every 500 hours Every 1000 hours Every 1000 hours Every 1000 hours Every 1000 hours -
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6128-81-7043 600-181-4401 Element ass'y Outer element ass'y Edge Side edge (Bolt) (Bolt) (Nut) (Washer) Edge Side edge End bit (Bolt) (Bolt) (Bolt) (Nut) (Washer) (Bolt) Point (Pin) Wear plate Wear plate Rail guide Service kit Straight edge Blade 235-70-12320 234-70-32230 (234-70-32260) (234-70-32270) (234-70-32290) (01643-32060) 235-70-12140 234-70-32230 234-70-32240 (234-70-32260) (234-70-32270) (234-70-32280) (234-70-32290) (01643-32060) (235-70-12330) 235-785-1310 (09244-02516) 235-70-41190 235-70-11431 235-70-42210 235-44-11781 2 2 (8) (36) (44) (44) 2 2 2 (2) (34) (2) (44) (44) (6) 3 (3) 6 6 4 1 -
Curved edge
4-7
MAINTENANCE
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4-8
MAINTENANCE
Reservoir Capacity
Specified
Transmission case
Hydraulic system
Fuel tank
Cooling system
38 10.04 34 8.98
35 9.25 25 6.61
63 16.64 57 15.06
10 2.64 8 2.11
500 132.10 -
58 15.32 -
Refill
REMARK When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulfur content is above 0.5%. When starting the engine with an atmospheric temperature of lower than 0C (32F), be sure to use engine oil of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10C (50 F) more or less during the day. Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.
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There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature range in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute
Engine oil change interval 1/2 of regular interval 1/4 of regular interval
4-9
MAINTENANCE
No.
Supplier
Engine Oil [CD or CE] SAE10W, 30, 40 10W30, 15W40 (The 15W40 oil marked * is CE.) EO10-CD EO30-CD EO10-30CD EO15-40CD Diesel sigma S super dieselmultigrade *Sigma turbo *Amoco 300 *Arcofleet S3 pius Vanellus C3 *RPM delo 400 RPM delo 450 *Turbomax *RX super CRD
Anti-freeze Coolant [Ethylene Glycol Base] Permanent Type AF-ACL AF-PTL AF-PT(Winter, one season type) -
KOMATSU
GO90 GO140
G2-LI G2-LI-S
AGIP
Rotra MP Multi-purpose gear oil Arco HD gear oil Gear oil EP Hypogear EP
GR MU/EP PYKON premium grease Litholine HEP 2 Arco EP moly D Energrease LS-EP2
3 4 5 6
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7 CASTROL EP EPX Hypoy Hypoy B Hypoy C MS3 Spheerol EPL2 Anti-freeze 8 9 CHEVRON *Delo 400 CONOCO *Fleet motor oil Multiperformance 3C Performance 3C Essolube D3 *Essolube XD-3 *Essolube XD-3 Extra *Esso heavy duty Exxon heavy duty Super duty motor oil *Super duty plus Delvac 1300 *Delvac super 10W-30, 15W-40 Universal gear Universal gear lubricant Ultra-duty grease 2 Super-sta grease Tranself EP Tranself EP type 2 Glacelf 10 ELF
11
EXXON (ESSO)
Beacon EP2
12 GULF 13 MOBIL
4 - 10
MAINTENANCE
No.
Supplier
Engine Oil [CD or CE] SAE10W, 30, 40 10W30, 15W40 (The 15W40 oil marked * is CE.)
Grease [Lithium-Base] NLGI No.2 Multi-purpose white grease 705 707L White-bearing grease FINA marson EPL2 Albania EP grease Sunoco ultra prestige 2EP Sun prestige 742 Multifak EP2 Starplex 2 Multis EP2 Unoba EP
Anti-freeze Coolant [Ethylene Glycol Base] Permanent Type Anti-freeze and summer coolant FINA tamidor Sunoco antifreeze and summer coolant Coda 2055 startex antifreeze coolant Antigal/antifreeze -
*Superme duty 14 PENNZOIL fleet motor oil 15 PETROFIN FINA kappa TD E Rimura X *Ursa super plus Ursa premium Rubia S *Rubia X *Guardol
Multi-purpose 4092 Multi-purpose 4140 FINA potonic N FINA potonic NE Spirax EP Spirax heavy duty Sunoco GL5 gear oil Multigear Total EP Total Transmission TM MP gear lube LS Multigear Multigear B Multigear C
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20 UNION 21 VEEDOL *Turbostar *Diesel star MDC Antifreeze
4 - 11
MAINTENANCE
CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to the tightened parts, and this will cause failure of the machine or problems with operation. Always pay careful attention when tightening parts.
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. 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.
Tightening torque Target value Nm 13.2 31 66 113 177 kgfm 1.35 3.2 6.7 11.5 18 lbft 9.8 23.1 48.5 83.2 130.2 Nm 11.8-14.7 27-34 59-74 98-123 157-196 Service limit kgfm 1.2-1.5 2.8-3.5 6.0-7.5 10.0-12.5 16.0-20.0 lbft 8.7-10.8 20.3-25.3 43.4-54.2 72.3-90.4 115.7-144.7
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16 18 20 22 24 24 27 30 32 36 279 382 549 745 927 28.5 39 56 76 94.5 206.1 282.1 405.0 549.7 683.5 245-309 343-425 490-608 662-829 824-1030 25.0-31.5 35.0-43.5 50.0-62.0 67.5-84.5 84.0-105.0 180.8-227.8 253.2-314.6 361.7-448.4 488.2-611.2 607.6-759.5 27 30 33 36 39 41 46 50 55 60 1320 1720 2210 2750 3280 135.0 175.0 225.0 280.0 335.0 976.5 1265.8 1627.4 2025.2 2423.1 1180-1470 1520-1910 1960-2450 2450-3040 2890-3630 120.0-150.0 155.0-195.0 200.0-250.0 250.0-310.0 295.0-370.0 868.0-1085.0 1121.1-1410.4 1446.6-1808.3 1808.3-2242.2 2133.7-2676.2
Tightening torque Target value Nm 14.7 29.4 78.5 117.7 147.1 215.7 255.0 kgfm 1.5 3.0 8.0 12.0 15.0 22.0 26.0 lbft 10.8 21.7 57.9 86.6 Nm 12.7 - 16.7 27.5 - 39.2 58.8 - 98.1 88.3 - 137.3 Permissible range kgfm 1.3 - 1.7 2.8 - 4.0 6.0 - 10.0 9.0 - 14.0 lbft 9.4 - 12.3 20.3 - 28.9 43.4 - 72.3 65.1 - 101.3 86.8 - 130.2 130.2 - 180.8 159.1 - 209.8
108.5 117.7 - 176.5 12.0 - 18.0 159.1 176.5 - 245.2 18.0 - 25.0 188.1 215.7 - 284.4 22.0 - 29.0
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MAINTENANCE
CRITICAL PARTS
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No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Safety critical parts for periodic replacement Q'ty 1 2 Replacement interval Fuel hose (fuel tank - fuel injection pump) Fuel hose (fuel injection pump - fuel filter) Spill hose (between nozzles) Fuel spill hose (nozzle - fuel tank) Turbocharger lubricating hose O-ring for brake disc piston O-ring for steering valve Steering circuit hose Brake valve rubber parts Rubber hose for leaning cylinder Brake hose O-ring for steering cylinder Seat belt Fuel return hose (fuel injection pump - fuel tank) 1 2 1 1 8 8 16 16 2 13 7 1 Every 3 years Every 2 years or every 4000 hours, whichever comes sooner
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MAINTENANCE
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44444444444-
17 19 21 21 22 22 22 23 24 24 25
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44444444444444-
28 30 31 32 32 33 33 34 36 36 37 38 39 40
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MAINTENANCE
EVERY 500 HOURS SERVICE REPLACE FUEL FILTER CARTRIDGE CLEAN, CHECK RADIATOR FINS CHECK CIRCLE GUIDE CLEARANCE, ADJUST CHECK PARKING BRAKE LEVEL STROKE, ADJUST CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR EVERY 1000 HOURS SERVICE GREASE DRIVE SHAFT GREASE FAN PULLEY AND TENSION PULLEY REPLACE TRANSMISSION OIL FILTER ELEMENT CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER CHANGE OIL IN FINAL DRIVE CASE, CLEAN STRAINER REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK CHANGE OIL IN HYDRAULIC TANK CHECK LOOSENESS IN DRAWBAR FRONT BALL JOINT AND BALL STUD CHECK TOE-IN, ADJUST CHECK FRONT WHEEL BEARING PLAY, ADJUST REPLACE CORROSION RESISTOR CARTRIDGE CHECK FOR LOOSE ROPS MOUNT BOLTS REPLACING AIR DRYER DESICCANT EVERY 2000 HOURS SERVICE CHANGE OIL IN FRONT WHEEL BEARING CHANGE OIL IN CIRCLE REVERSE GEAR CASE CHANGE OIL IN TANDEM DRIVE CASE CLEAN ENGINE BREATHER ELEMENT CLEAN BREATHER CLEAN AND INSPECT INCHING POTENTIOMETER SENSOR CHECK ALTERNATOR, STARTING MOTOR CHECK ENGINE VALVE CLEARANCE, ADJUST CHECK ALL TIGHTENING PARTS OF TURBOCHARGER CHECK PLAY OF TURBOCHARGER ROTOR CLEAN, CHECK TURBOCHARGER EVERY 4000 HOURS SERVICE CHECK WATER PUMP CHECK VIBRATION DAMPER CHECK FAN PULLEY AND TENSION PULLEY
44444-
41 42 43 46 47
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4444444444458 58 59 59 60 61 61 61 61 61 61
4444444444444-
49 49 50 51 52 53 54 55 55 56 57 57 57
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. SERVICE PROCEDURE
MAINTENANCE
SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE (only after the first 250 hours)
Carry out the following maintenance only after the first 250 hours of operation on new machines. REPLACE FUEL FILTER CARTRIDGE CHANGE OIL IN TRANSMISSION CASE CHANGE OIL IN FINAL DRIVE CASE CHANGE OIL IN CIRCLE REVERSE GEAR CASE CHANGE OIL IN HYDRAULIC TANK REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK CHANGE OIL IN TANDEM DRIVE CASE CHECK CIRCLE GUIDE CLEARANCE, ADJUST CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR CHECK ENGINE VALVE CLEARANCE, ADJUST For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS, 1000 HOURS AND 2000 HOURS SERVICE.
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MAINTENANCE
SERVICE PROCEDURE
WHEN REQUIRED
CLEAN INSIDE OF COOLING SYSTEM
WARNING
Immediately after the engine is stopped, the coolant is at high temperature and the radiator is under internal pressure. If the cap is removed and the coolant trained under these conditions, it will cause burns. Always wait for the temperature to go down, then turn the cap slowly to release the pressure. The washing operation is carried out with the engine running. When standing up or leaving the operator's seat, always place the speed lever at the P (parking) position. For details of starting the engine, see "CHECK BEFORE STARTING ENGINE (PAGE 3-43)" and "STARTING ENGINE (PAGE 3-58)". There is danger of touching the fan if the cover is left removed. When the engine is running, never enter the area at the rear of the machine.
Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the table below. Kind of coolant Permanent type antifreeze (All season type) Cleaning inside of cooling system and changing coolant Every year (autumn) or every 2000 hours, whichever comes first Replacing corrosion resistor
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Non permanent type antifreeze containing ethylene glycol (winter, one season type) When not using antifreeze Every 6 months (spring, autumn) (Drain antifreeze in spring, add antifreeze in autumn) Every 6 months or every 1000 hours, whichever come first Every 1000 hours and when cleaning the inside of the cooling system and when changing coolant Stop the machine on level ground when cleaning or changing the coolant. Use a permanent type of antifreeze. If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol. The proportion of the mixture differs according to the ambient temperature, but to obtain the corrosion resistance effect, a minimum of 30% by volume is necessary. 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 10C (18F) lower when deciding the mixing rate. Mixing rate of water and antifreeze Min. ambient temperature Amount of antifreeze Amount of water C F Liters US gal Liters US gal Above -10 Above 14 17.5 4.62 40.5 10.70 -15 5 21.0 5.55 37.0 9.77 -20 -4 24.0 6.34 34.0 8.98 -25 -13 27.0 7.13 31.0 8.19 -30 -22 29.0 7.66 29.0 7.66
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. SERVICE PROCEDURE
MAINTENANCE
WARNING
Antifreeze is flammable, so keep it away from flame. Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on you. If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.
Use city water for the coolant. If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control the mixing proportions. 1. Stop the engine and turn radiator cap (1) slowly to remove it. 2. Tighten corrosion resistor cartridge (2) of valve (3).
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3. Set a container in position to catch the coolant, then open drain valve (4) at the bottom of the radiator and drain plug (5) at the side face of the cylinder block, and drain the water. 4. After draining the water, close drain valve (4) and drain plug (5), and fill with city water. 5. When the radiator is full, start the engine, and run it at low idle. Keep the engine running at low idle for 10 minutes until the coolant temperature reaches more than 90C (194F). 6. Stop the engine, open drain valve (4) and drain plug (5), and drain the water. 7. After draining the water, clean the cooling system with cleaning agent. For the cleaning method, see the instructions for the cleaning agent. 8. Close drain valve (4) and drain plug (5). 9. Replace corrosion resistor (2), then open valve (3). For details of the procedure for replacing the corrosion resistor, see "REPLACE CORROSION RESISTOR CARTRIDGE (PAGE 4-57)". 10. Add coolant until it overflows from the water filler. Decide the proportions of antifreeze and water according to the table for the mixing rate of water and antifreeze. 11. To remove air in the cooling system, run the engine for 5 minutes at low idle, then for 5 minutes at high idle. (While doing this, leave the radiator cap removed.) 12. Stop the engine. About 3 minutes later, supply city water up to the water filler, then close radiator cap.
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MAINTENANCE
SERVICE PROCEDURE
13. Drain the coolant inside sub-tank (6), clean the inside of the sub-tank, then fill again with cooling water to a point midway between the FULL and LOW marks.
WARNING
If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury. Always use protective glasses, dust mask, and other protective equipment.
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NOTICE Do not clean the air cleaner element before red piston in dust indicator appears. If the element is cleaned frequently before the red piston appears, the air cleaner will not be able to display its performance fully, and the cleaning efficiency will also go down. In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner element.
CHECKING
Whenever the red piston in dust indicator (1) appears, clean the air cleaner element.
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. SERVICE PROCEDURE
MAINTENANCE
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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. When cleaning the element, do not hit it or beat it against something. Do not use an element whose folds or gasket or seal are damaged. 4. Set the cleaned element.
3. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm2, 99.4 PSI)) from the inside of the outer element along its folds. Then direct the compressed air from the outside along the folds, and again from the inside. 1) Remove one seal from the element whenever the element has been cleaned. 2) Replace the outer element if it has been cleaned 6 times repeatedly or used throughout a year. Replace the inner element at the same time. 3) If the dust indicator shows red immediately after the outer element has been cleaned, replace both the inner and outer elements even if the outer element has not been cleaned 6 times. 4) Check inner element mounting nuts for looseness and, if necessary, retighten. 5) Replace seal washer (5) or wing nut (6) with new parts if they are broken.
5. Press the button of dust indicator (1) to return the red piston to its original position.
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MAINTENANCE
SERVICE PROCEDURE
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WARNING
Do not raise the blade unnecessarily high. Be sure not to put any part of your body underneath the blade when blocking it. Replace the cutting edge before it wears to the end face of the blade. If the mounting surface is worn, correct the mounting surface before replacing the cutting edge or side edge. 1. Lift the blade to a suitable height and put a block underneath the blade rail to prevent it from falling. 2. Remove bolts and nuts (1), then remove the cutting edge (2). 3. Clean the mounting face for the cutting edge (2). 4. Turn cutting edge (2) and install to the blade. When turning the edge, turn the left and right edges and interchange them. When both sides are worn, replace with new parts. If the wear has extended to the mounting surface, repair the mounting surface before turning the cutting edge.
5. Tighten bolts and nuts (1) uniformly so that there is no clearance between the blade and cutting edge. Tightening torque for mounting run: 392 to 530 Nm (40 to 54 kgfm, 289.3 to 390.6 lbft) 6. After several hours of running, retighten the nuts.
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. SERVICE PROCEDURE
MAINTENANCE
WARNING
If the pin is hit out with strong force, there is danger that the pin may fly out. Check that there is no one in the surrounding area. There is danger of pieces flying during the replacement operation, so always wear protective clothing, such as safety glasses and gloves.
1. Raise the ripper to suitable height, and put a block under the beam to prevent the ripper from coming down. 2. Using a hammer and bar, remove the pin, then remove the point. 3. Install a new point, and insert the pin. Dimension of point New part: 377 mm (14.9 in) Limit of use: 170 mm (6.7 in)
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CLEAN ELEMENT OF AIR CONDITIONER FRESH AIR FILTER
WARNING
If compressed air is used, there is danger that dirt may fly and cause personal injury. Always wear protective glasses, dust mask, and other protective equipment.
If the air conditioner is being used, clean the air filter element. Stop the air conditioner before cleaning the element. 1. Loosen bolt (1), then remove cover (2). 2. Loosen bolt (3), then remove plate (4). 3. Loosen bolt (5), then take out element (7) and clean it. 4. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm2, 99.4 PSI)) from the inside of the outer element along its folds. Then direct the compressed air from the outside along the folds, and again from the inside.
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MAINTENANCE
SERVICE PROCEDURE
WARNING
If compressed air is used, there is danger that dirt may fly and cause personal injury. Always wear protective glasses, dust mask, and other protective equipment.
NOTICE When bracket (4) is removed using bolt (3), the balance of unit (5) will be lost. Be careful not to let unit (5) fall off or cause damage to the wiring. 1. Loosen bolt (1) and remove cover (2). 2. Loosen bolt (3) and pull out bracket (4). 3. Loosen bolt (6) and remove air conditioner unit (5). 4. Loosen bolt (7) and remove cover (8). 5. Pull filter (9) out to the side and filter (10) out to the top. 6. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm2, 99.4 PSI)) from the inside of the outer element along its folds. Then direct the compressed air from the outside along the folds, and again from the inside. If the filter is extremely dirty, rinse it in water. After rinsing it in water, dry it thoroughly before assembling again.
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4 - 23
. SERVICE PROCEDURE
MAINTENANCE
WARNING
If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit. Do not bring any flame close to any point where the refrigerant gas is leaking.
If the cooling effect is poor, the refrigerant (gas) level may be low. If this is the case, check the sight gauge of the receiver dryer under the right side of the cab. REMARK Run the engine at idling, and if bubbles appear in the sight glass when the air conditioner is set to cooling, the refrigerant level is low, so please contact your Komatsu distributor to have it refilled.
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SELECTION AND INSPECTION OF TIRES
WARNING
If a tire or a rim is handled improperly, the tire may burst or may be damaged and the rim may be broken and scattered, and that can cause serious injury or death. Since maintenance, disassembly, repair and assembly of the tires and rims require special equipment and skill, be sure to ask a tire repair shop to do the work. Do not heat or weld the rim to which the tire is installed. Do not make a fire near the tire.
SELECTION OF TIRES
WARNING
Select the tires according to the conditions of use and the weight of the attachments on the machine. Use only specified tires and inflate them to the specified pressure.
Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the following table. Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor when using optional tires.
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MAINTENANCE
SERVICE PROCEDURE
WARNING
When inflating a tire, check that no one will enter the working area. Use an air chuck which has a clip and which can be fixed to the air valve. While inflating the tire, check the inflation pressure occasionally so that it will not rise too high. If the rim is not fitted normally, it may be broken and scattered while the tire is inflated. To ensure safety, place a guard around the tire and do not work in front of the rim but work on the tread side of the tire. Abnormal drop of inflation pressure and abnormal fitting of the rim indicate trouble in the tire or rim. In this case, be sure to ask a tire repair shop to carry out repairs. Be sure to observe the specified inflation pressure. Do not adjust the inflation pressure of the tires just after high-speed travel or heavy-duty work.
CHECK
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Measure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work.
INFLATION OF TIRES
Adjust the inflation pressure properly. When inflating a tire, use an air chuck which can be fixed to the air valve of the tire as shown in the figure. Do not work in front of the rim but work on the tread side of the tire. The proper inflation pressure is shown below. Inflation pressure MPa (kgf/cm2, PSI) 0.25 (2.6, 36.9)
NOTICE The optimum inflation pressure differs according to the type of work. For details, see "HANDLING THE TIRES (PAGE 3-114)" .
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. SERVICE PROCEDURE
MAINTENANCE
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4 - 26
MAINTENANCE
SERVICE PROCEDURE
WARNING
Set the gearshift lever to the P (Parking) position, and secure the front and rear frame with the articulate lock pin. Set the work equipment in a stable condition, and stop the engine.
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WARNING
Set the gearshift lever to the P (Parking) position, and secure the front and rear frame with the articulate lock pin. Set the work equipment in a stable condition, and stop the engine. 1. Check if distances (wear tolerances) (a1), (a2) and (a3) between the sliding surface of rail guide (1) and guide holder plate (2) have become 0 at any point. (There are 5 rail guides; check all 5 rail guides.) Replace rail guide (1) before there is any interference between rail (3) and guide holder plate (2). 2. Please contact your Komatsu distributor to have the rail guide replaced.
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. SERVICE PROCEDURE
MAINTENANCE
LUBRICATING
WARNING
Set the gearshift lever to the P (Parking) position, and secure the front and rear frame with the articulate lock pin. Set the work equipment in a stable condition, and stop the engine.
CAUTION
Do not insert your finger into any of the holes at the 17 greasing points.
1. Using a grease pump, pump in grease through the grease fittings shown by arrows. 2. After greasing, wipe off any old grease that was pushed out.
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(1) Leaning cylinder pin (1 place) (2) Tie rod (2 places) (3) Steering linkage (2 places) (4) Steering cylinder pin (4 places) (5) Drawbar ball joint (1 place) (6) Front axle center pin (2 places) (7) Front axle king pin (6 places)
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MAINTENANCE
SERVICE PROCEDURE
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(8) Blade lift cylinder yoke (4 places) (9) Blade lift cylinder ball joint (2 places) (10) Drawbar side shift cylinder ball joint (2 places) (11) Bank control guide (2 places) (12) Articulation center pin and articulation cylinder pin (6 places) (13) Blade lifter guide (2 places) (14) Ripper cylinder (3 places) (15) Ripper rod (8 places) (16) Power tilt cylinder (2 places) (17) Bank control lock pin (2 places) With the lifter guide pin removed, grease the bushings starting from the front. For details, see "EXTREME SIDE REACH (PAGE 3-104)". There is no grease nipple and at the lock pin portion. Use a brush or spatula to coat with grease as shown in the diagram on the right.
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. SERVICE PROCEDURE
MAINTENANCE
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Refill capacity: 34 liters (8.98 US gal) Filter wrench 1. Open the engine side cover on the right side of the machine. 2. Open oil filler (F). 3. Set a container to catch the oil immediately under the drain plug (P) at the bottom of the machine. 4. Loosen drain plug (P), and drain the oil. 5. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 6. Install drain plug (P). 7. Using a filter wrench, turn filter cartridge (1) counterclockwise to remove it. 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. 8. Clean the filter holder, fill the new filter cartridge with oil, then coat the seal and thread of the filter cartridge with oil (or coat thinly with grease) and install. 9. When installing, bring the seal surface into contact with the filter holder, then tighten a further 3/4 to 1 turns. 10. After replacing the filter cartridge, add engine oil through oil filler (F) until the oil level is between the H and L marks on the dipstick. 11. Run the engine at idling for a short time, then stop the engine and check that the oil is between the marks on the level gauge. For details, see "CHECK ENGINE OIL PAN LEVEL, ADD OIL (PAGE 3-48)".
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MAINTENANCE
SERVICE PROCEDURE
WARNING
Immediately after the engine is stopped, the parts or oil are at high temperature. Wait for the temperature to go down before starting the operation. Check the oil level with the engine stopped. If the oil level is checked with the engine idling, do as follows. Before checking, to make sure that the machine does not move, place the speed lever at the P (parking) position and check that all levers are at the neutral position. After starting the engine, wait for 5 minutes after the oil level becomes stable before checking.
1. Stop the engine, remove dipstick (G), and leave for at least 5 minutes. 2. Wipe dipstick (G) with a cloth. 3. Fully insert dipstick (G) into filler pipe (F), then remove it. 4. Check that the oil level is between the H and L marks for STOP on dipstick (G). If the oil level is below the L mark, add engine oil through oil filler (F).
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NOTICE The dipstick is marked on one side with the levels for STOP (engine stopped) and RUNNING (engine idling). Always check the level using the STOP marks. 5. If the oil is above the top mark, drain the excess oil from drain plug (P), then check the oil level again. 6. If the oil level is correct, insert dipstick (G) in the oil filler guide, then install the oil filler cap.
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. SERVICE PROCEDURE
MAINTENANCE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
1. Stop the engine, and leave it for 5 minutes. 2. Open the right side cover and lower plate. 3. Remove dipstick (G) and wipe the oil off with a cloth. 4. Fully insert dipstick (G) into filler pipe (F), then remove it. 5. The oil level should be between the H and L marks on dipstick (G). If the oil level is below the L mark, add engine oil through oil filler (F). 6. If the oil level is above the H mark, remove the cover, and drain the excess gear oil from drain plug (P), then check the oil level again. 7. If the oil level is correct insert dipstick (G) the oil filler pipe.
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CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
1. Stop the engine and leave for at least 5 minutes. 2. Remove dipstick (G) and wipe the oil off with a cloth. 3. Fully insert dipstick (G) into filler pipe (F), then remove it. 4. The oil level should be between the H and L marks on dipstick (G). If the oil level is below the L mark, add engine oil through oil filler (F). 5. If the oil is above the H mark, drain the excess engine oil from drain plug (P), and check the oil level again. 6. If the oil level is correct, insert dipstick (G) in the oil filler guide, then install the oil filler cap.
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MAINTENANCE
SERVICE PROCEDURE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
1. Stop the engine and leave for at least 5 minutes. 2. Remove oil filler plug (F), and check that the oil level is up to the top surface of the gear inside. 3. If the oil level is not up to the top surface of the gear, add engine oil through the oil filler port. 4. If the oil level is correct, install oil filler plug (F). REMARK There may be wear particles in the oil, but there is no problem using the oil as it is.
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The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. NOTICE Do not add oil if the level is above the H line. If the oil has been added to above H level, stop the engine and wait for the hydraulic oil to cool down, then drain the excess oil from the drain plug. If the oil is above H level, it will damage the hydraulic circuit or cause the oil to spurt out. 1. Set the machine in position as follows to check the oil level. Return the leaning of the front tires to the upright position and face the wheels straight to the front. Set the front frame and rear frame facing straight (articulated angle = 0). Install the articulate lock pin. Return the blade sideshift to the center of the machine, set the blade at right angles to the chassis and lower it lightly to the ground. Raise the ripper to the maximum height, and put a block under the ripper. 2. Open the side panel. 3. Stop the engine, wait for 5 minutes, then check that the oil level is between the H and L marks on sight gauge (G). 4. If the oil level is below the L mark, add engine oil through oil filler (F). 5. If the oil is above the H mark, drain the excess engine oil from drain plug (P), and check the oil level again.
WARNING
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. SERVICE PROCEDURE
MAINTENANCE
WARNING
Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion. The battery generates flammable gas and there is danger of explosion, so 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 a large amount of water and consult a doctor. When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other parts.
NOTICE When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from freezing. Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.
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If it is possible to check the electrolyte level from the side of the battery, check as follows. 1. Use a wet cloth to clean the area around the electrolyte level lines and check that the electrolyte level is between the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines. If the battery is wiped with a dry cloth, static electricity may cause a fire or explosion.
2. If the electrolyte level is below the midway point between the U.L. and L.L. lines, remove cap (1) and add distilled water to the U.L. line. 3. After adding distilled water, tighten cap (1) securely. REMARK If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker.
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MAINTENANCE
SERVICE PROCEDURE
Use the diagram below for reference, and check if the electrolyte reaches the bottom of the sleeve.
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2. After adding distilled water, tighten cap (1) securely. REMARK If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker.
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. SERVICE PROCEDURE
MAINTENANCE
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1. Carefully check for loose bolts (1). When checking for loose borts (1), always turn the borts (1) in the tightening direction to check. Tightening torque: 1960 to 2450 Nm (200 to 250 kgfm, 1446.6 to 1808.3 lbft) 2. If a hub bolt is broken, replace all the hub bolts.
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MAINTENANCE
SERVICE PROCEDURE
ADJUSTING
1. Loosen nut (1). 2. Use adjust bolt (2) to move tension pulley (3) so that the deflection of the belt is approx. 6 mm (0.315 in) (at a pressure of approx. 59 N (6 kgf)). 3. Tighten nut (1) to fix tension pulley (3). 4. Check for damage to the pulleys, and wear of the V-groove and V-belt. Be particularly careful to check that the V-belt is not in contact with the bottom of the V-groove. 5. If the belt has elongated and there is no more allowance for adjustment, or if the belt is cut or cracked, replace the belt. 6. When the new belt is set, readjust it after operation for an hour.
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. SERVICE PROCEDURE
MAINTENANCE
ADJUSTING
1. Loosen the nuts and bolts in the order (1) to (6), then move alternator (8) to the side to adjust the belt tension. Adjust the tension of the bolt with nut (7) as follows. TIGHTEN nut to INCREASE tension LOOSEN nut to DECREASE tension 2. After adjusting the belt tension, tighten the nuts and bolts in the order (1) to (6). Finally, tighten nut (7). 3. Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom the V-groove. 4. If the V-belt is so lengthened that it cannot be adjusted any more or if it has any cuts or cracks, replace it.
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MAINTENANCE
SERVICE PROCEDURE
ADJUSTING
1. Insert a bar between compressor (1) and the cylinder block, and hold compressor (1) in position. When holding compressor (1) in position, put a wooden block between the bar and compressor (1) to prevent damage to the compressor. 2. Loosen bolts and nuts (2), (3). 3. Use the bar to move compressor (1) so that the deflection of the belt is approx. 12 mm (0.5 in) (at a pressure of approx. 59 N (6 kgf)). 4. Tighten the bolts and nuts (2), (3) to fix compressor (1) in position. 5. 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 the V-groove. 6. If the V-belt is so lengthened that it cannot be adjusted any more or if it has any cuts or cracks, replace it. 7. After the V-belt has been replaced, operate for 1 hour, then adjust again.
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. SERVICE PROCEDURE
MAINTENANCE
WARNING
Since a small amount of oil may come out from inspection plug hole (2), do not peep through the plug wheel when the brake is being applied.
1. Remove only one wheel at the front of the tandem on the left or right side. If the wheel is not worn much, it is not necessary to inspect the three remaining wheels. If it is worn, inspect all the wheels. REMARK Before installing or removing tires, please contact your Komatsu distributor. 2. Remove cage (1) inspection plug (2). 3. Depress the brake pedal and keep the brake applied.
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4. Carry out inspection as illustrated below. If the gap disappears between the inspection hole edge and separator plate (3), ask a Komatsu distributor to replace the disc. 5. Remove the drain plug (P) from the cage (1), and measure the amount of oil leaking into the piston chamber. 6. If there is no leakage, the seal is functioning properly. 7. If the amount of leakage is more than 0.02 liters , please contact your Komatsu distributor for replacement of the seal. 8. Install cage (1) inspection plug (2) and the drain plug (P). 9. Install the tire.
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MAINTENANCE
SERVICE PROCEDURE
WARNING
The oil is at high temperature after the engine has been operated, so never replace the filter immediately after finishing operations. Wait for the parts to cool down before changing the filter. Do not bring fire or sparks near the fuel.
Filter wrench 1. Open the engine side cover on the right side of the chassis. 2. Set the container under the filter cartridge to catch the drained oil. 3. Using a filter wrench, turn filter cartridge (1) counterclockwise to remove it. 4. Clean the filter holder, fill a new filter cartridge with clean fuel, coat the packing surface with engine oil, then install it to the filter holder. 5. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it up 1/2 to 3/4 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten to the correct amount. 6. After replacing filter cartridge (1), loosen air bleed plug (2). 7. Loosen feed pump (3) knob and move the pump knob up and down to draw off fuel until air ceases to come out of air bleed plug (2). 8. Tighten up air bleed plug (2). Push in the knob of feed pump (3) and tighten it. 9. After replacing the filter cartridge, start the engine and check that there is no leakage of fuel from the filter seal surface. If there is any leakage of fuel, check the tightening of the filter cartridge. If there is still leakage of fuel, follow Step 2 and 3 to remove the filter cartridge, then check the packing surface for damage or foreign material. If any damage or foreign material is found in the packing, replace the cartridge with a new part, then repeat Steps 4 to 9 to install the filter cartridge.
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. SERVICE PROCEDURE
MAINTENANCE
WARNING
If compressed air, steam, or water hit your body directly, there is danger of injury. Always wear protective glasses, mask, and safety shoes. When cleaning, use a maximum pressure of less than 0.2 MPa (2.0 kgf/cm2, 28.4 PSI).
Clean the radiator fins if any mud or dirt is stuck to the radiator. 1. Remove bolts (1) to remove panel (2). 2. Clean the radiator fins clogged with mud, dust and leaves with compressed air. Steam or water may be used instead of compressed air. 3. Check the rubber hose. Replace with a new one if the hose is found to have cracks or to be hardened by ageing. Further, check hose clamps for looseness.
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MAINTENANCE
SERVICE PROCEDURE
WARNING
When raising the blade, do not raise it higher than necessary.
NOTICE Before stating the adjustment, confirm that there are gaps between the tooth crest of the circle gear and root of the circle pinion and between the tooth crest of the circle pinion and root of the circle gear. If there is no gap, replace the guide before starting the adjustment. Prepare the following: Feeler gauge Shims (thickness: 1 mm (0.039 in), 0.5 mm (0.020 in); 2 types)
CHECKING
1. Raise the blade from the ground. 2. Measure the clearance at portion P with a feeler gauge. Standard clearance: 1.5 0.5 mm (0.059 0.020 in) (6 places) 3. Measure the clearances at portions F, C, and R. Standard value: F = 0, C = 0.7 mm (0.028 in), R = 1.5 mm (0.059 in) or F = C = R = 1 mm (0.039 in) F is the clearance for the guide at the front. C is the clearance for the guide at the center. R is the clearance for the guide at the rear. 4. If the clearance for portions P, F, C, and R are not the above values, adjust as follows.
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. SERVICE PROCEDURE
MAINTENANCE
ADJUSTING
NOTICE When tightening the locknut after adjusting the clearance between the circle guide and circle, hold the push bolt with a wrench while tightening. If only the locknut is tightened, the push bolt will turn and the adjusted clearance will change. 1. Raise the blade so that the drawbar is parallel to the ground surface, then set dimension E between the ground surface and the end of the blade edge to approx. 30 mm (1.2 in).
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MAINTENANCE
SERVICE PROCEDURE
2. Loosen bolt (1), put portions F, C, and R of circle (5) and circle guide (2), (3), and (4) in contact, then adjust shim (6) so that clearance P between the top face of the circle and bottom face of the drawbar is 1 to 2 mm (0.039 to 0.079 in). 3. Loosen locknut (7), then tighten pushing bolt (8) of rear circle guide (4) to move the whole circle to the rear and adjust to give dimension H of 35.9 to 56.0 mm (1.4 to 2.2 in) between machined surface (9) of the case at the bottom of the pinion gear and the circle and circle guide contact surface (10). REMARK When not using circle guide pusher bolt (8) to carry out the movement, use a lever block. 4. Loosen locknut (12) of front circle guide (2), tighten pusher bolt (13), maintain clearance H between pinion gear (9) and the circle (10), set clearance F between the circle guide (2) and circle (5) to 0 mm, then tighten locknut (12). 5. Check clearance H between machined surface (9) of the case at the bottom of pinion gear and the circle and circle guide contact surface (10) again. Then loosen locknut (14), tighten pusher bolt (15) of center circle guide (3), set clearance C between center circle guide (3) and circle (5) to 0.7 mm (0.028 in), then tighten locknut (14). 6. Adjust pusher bolt (8) so that clearance R between rear circle guide (4) and circle (5) is 1.5 mm (0.059 in), then tighten locknut (7). 7. Tighten bolt (1) and locknuts (7), (12), and (14). 8. Coat the sliding surface of the circle guide with lubricant (LM-P). 9. Check that it rotates 90 to the left and right at high bank.
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REMARK If the following condition is reached, replace the wear plate of the circle guide. When dimension A of wear plate (16) or dimensions B or C of wear plate (17) become 2 mm (0.079 in).
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. SERVICE PROCEDURE
MAINTENANCE
CAUTION
The parking brake effect test applies a large force to the drive system, and also applies excessive force to the transmission, so do not check more than necessary.
1. Place the gear shift lever in "P (Parking)" position, then confirm that slack adjuster move smoothly. 2. Check that the angle of the slack adjuster and push rod (2) of brake chamber (1) is slightly more than 90. 3. When checking the effect of the parking brake, place the gearshift lever at the P (parking) position set the gear at forward 8th, run the engine at full throttle, then slowly release the inching pedal and check that the engine stops within 3 seconds of the power being transmitted.
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ADJUSTING
Adjust the stroke by turning worm shaft (1) with a wrench. When doing this, adjust 1 notch at a time so that ball (2) ships into the ball stop position (hole (3) made to take the ball) of worm shaft (1).
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MAINTENANCE
SERVICE PROCEDURE
CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR
WARNING
When jacking up the front tire, put blocks under the frame at the center of the front axle for safety.
CHECKING
1. Loosen bolt (1) and remove cover (2).
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Method of jacking up front wheels 1) Lower the work equipment, and place the gear shift lever at the P (parking) position. 2) Lower the blade and raise the front tires from the ground. 3) Put a block under the frame at the center of the front axle. 3. Operate the blade rotation lever and check if the clutch slips. Method of checking slip 1) If there is slippage, a sliding noise can be heard, and when the blade turns a little at a time, vertical shaft end holder (4) turns more than the blade. Return the blade rotation control lever to neutral to stop the slippage. (Check the condition at the border point between slippage and no slippage.) 2) In this condition, loosen bolt (3), remove holder (4), then take out one shim (5) (0.2 mm (0.008 in)). 3) Install holder (4), tighten bolt (3), then install cover (2) with bolt (1).
2. Push the blade against the ground to prevent the circle from rotating, and jack up the front wheels or secure the end of the blade.
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. SERVICE PROCEDURE
MAINTENANCE
ADJUSTING
IF CLUTCH DOES NOT SLIP
1. Loosen bolts (3) and remove holder (4), then add one 0.2 mm (0.008 in) shim (5). 2. Tighten holder (4) with mounting bolt (3). 3. Repeat the operation until there is slippage to match with the slip limit. For details, see the section on inspection.
IF CLUTCH SLIPS
1. Loosen bolts (3) and remove holder (4), then take out one 0.2 mm (0.008 in) shim (5). 2. Tighten holder (4) with mounting bolt (3). 3. Repeat the operation until there is no more slippage. For details, see the section on inspection. 4. If there is no more slippage, loosen bolt (3), remove holder (4), add one 0.2 mm (0.008 in) shim (5) to match with the slip limit.
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REMARK If a shim is added, the pushing force of the belleville spring is reduced, so it becomes easier for the clutch to slip. If a shim is removed, the pushing force of the belleville spring is increased, so it becomes more difficult for the clutch to slip.
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MAINTENANCE
SERVICE PROCEDURE
WARNING
Apply the P (parking) position, and secure the front and rear frame with the articulate lock pin. Set the work equipment in a stable condition, and stop the engine.
1. Using a grease pump, pump in grease through the grease fittings shown by arrows. 2. After greasing, wipe off any old grease that was pushed out.
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GREASE FAN PULLEY AND TENSION PULLEY
1. Using a grease pump, pump in grease through the grease fittings shown by arrows. 2. After greasing, wipe off any old grease that was pushed out.
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. SERVICE PROCEDURE
MAINTENANCE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
1. Set the container to catch the oil under the filter case. 2. Remove drain plug (1) at the bottom of the filter case, drain the oil, then tighten the plug again. 3. Hold case (2) and loosen center bolt (3), then remove case (2). 4. Remove the element and clean the inside of the case. 5. Replace the filter gasket and O-ring with new parts. Coat the gasket and O-ring thinly with clean engine oil before installing.
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6. Assemble the new element in the case, then install the case with center bolt (3). When installing center bolt (3), install so that chamfered portion (4) of the washer comes on the same side as the hexagonal head of the center bolt. Be careful not to tighten center bolt (3) too much. Tightening torque: 167 to 196 Nm (17 to 20 kgfm, 123 to 144.7 lbft) 7. Run the engine for a short time at low idling, then stop the engine and check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL (PAGE 4-31)".
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MAINTENANCE
SERVICE PROCEDURE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Refill capacity: 25 liters (6.61 US gal) 1. Set a container under the transmission case to catch the oil. 2. To prevent getting oil on yourself, loosen drain plug (P) and drain the oil. To prevent the oil from spurting out, loosen drain plug (P), then gradually remove it. 3. After draining the oil, install drain plug (P). Tightening torque: 127 to 177 Nm (13 to 18 kgfm, 94.0 to 130.2 lbft) 4. After removing bolts (1), remove tube (2), then remove bolts (4) and cover (3). 5. Remove strainer (5). 6. Remove all the dirt stuck to the strainer, then wash it in clean diesel oil or flushing oil. If the strainer is damaged, replace it with a new part. 7. After washing strainer (5), install it, then install cover (3) with bolts (4), and install tube (2) with bolts (1). 8. Pour in the specified amount of engine oil from oil filler (F). 9. After refilling, check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL (PAGE 4-31)". 10. Check that there is no leakage of oil from the transmission case or oil filter.
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. SERVICE PROCEDURE
MAINTENANCE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Refill capacity: 57 liters (15.06 US gal) 1. Set a container under the final drive case to catch the oil. 2. To prevent getting oil on yourself, loosen drain plug (P) and drain the oil. To prevent the oil from spurting out, loosen drain plug (P), then gradually remove it. 3. After draining the oil, install drain plug (P). Tightening torque: 58.8 to 78.4 Nm (6 to 8 kgfm, 43.4 to 57.9 lbft) 4. Remove 4 bolts (1), then remove cover (2) and take out strainer (3). 5. Remove any dirt stuck to strainer (3), then wash it with clean diesel oil or flushing oil. If the strainer is damaged, replace it with a new part. 6. After washing strainer (3), install it, then install cover (2) with bolts (1). 7. Pour in the specified amount of engine oil from oil filler (F). 8. After refilling, check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL (PAGE 4-32)". 9. Check for oil leakage from the final drive case.
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MAINTENANCE
SERVICE PROCEDURE
REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
1. Remove bolt (1), then remove hose (2) from filter assembly (3). 2. Remove 4 bolts (4), then remove filter assembly (3) from the hydraulic tank. The other bolts are used to install the filter head and case, so do not remove them.
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3. Remove 4 bolts (5), then remove filter head cover (6). 4. Remove the filter element, clean the filter case and the removed parts, then install a new filter element. 5. Install filter head cover (6) with bolts (5). 6. Install filter assembly (3) to the hydraulic tank.
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. SERVICE PROCEDURE
MAINTENANCE
7. Remove bolt (7) of the suction strainer, then remove cover (8). 8. Remove the strainer, wash the strainer and remove parts, then install them to the hydraulic tank again. 9. Install cover (8) with bolt (7).
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
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1. Set the machine in position as follows to check the oil level. Return the leaning of the front tires to the upright position and face the wheels straight to the front. Set the front frame and rear frame facing straight (articulated angle = 0). Install the articulate lock pin. Return the side shift of the drawbar and blade to the center of the machine, set the blade at right angles to the machine, then lower it lightly to the ground. 2. Loosen oil filler port (F) slowly to completely release the air inside the hydraulic tank. 3. Set the container under drain plug (P) to catch the oil. 4. To prevent getting oil on yourself, loosen drain plug (P) and drain the oil. To prevent the oil from spurting out, loosen drain plug (P), then gradually remove it. 5. After draining the oil, install drain plug (P). Tightening torque: 58.8 to 78.5 Nm (6 to 8 kgfm, 43.4 to 57.9 lbft) 6. Pour in the specified amount of engine oil from oil filler (F). 7. After filling with oil, check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL (PAGE 4-33)". 8. Install oil filler (F). 9. Run the engine at low idling, and extend and retract each cylinder 4 to 5 times to a point approx. 100 mm (3.9 in) before the end of its stroke.
NOTICE If the engine is run immediately at high speed or the cylinder is operated to the end of its stroke, the air inside the cylinder will cause damage to the piston packing. 10. Next, operate each cylinder 3 to 4 times to the end of its stroke.
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MAINTENANCE
SERVICE PROCEDURE
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3. Mark the same dimension as measured in step 2 at about the center position of the tire width. Use the same procedure to mark both the left and right tires. 4. Measure the distance between the two marks. This distance is called "A".
5. Next, drive the machine forward slowly to move the marks on the tire to the rear, and stop the machine when the marks come to the same position as the height from the ground to the center of the front axle. Always travel forward when doing this.
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. SERVICE PROCEDURE
MAINTENANCE
6. Measure the distance between the two marks. This distance is called "B". 7. When toe-in (B - A) is adjusted to -5 1 mm (-0.197 0.039 in) of standard range, side slip is decreased to zero. If any value other than the standard range is measured, adjust toe-in using the following procedure.
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CHECK FRONT WHEEL BEARING PLAY, ADJUST
Please ask your Komatsu distributor to inspect and adjust the front wheel bearing.
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MAINTENANCE
SERVICE PROCEDURE
WARNING
All the engine parts are at high temperature after the engine has been operated, so never replace the cartridge immediately after finishing operations. Wait for the oil to cool down before replacing the cartridge.
Filter wrench 1. Turn valve (1) at the top of the corrosion resistor to close it. 2. Set the container to catch the water under the cartridge. 3. Using a filter wrench, remove cartridge (2). 4. Clean the filter holder, coat the steel surface of the new filter cartridge with clean engine oil, then install it.
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5. When installing, tighten until the gasket contacts the seal surface of the filter holder, then tighten a further 2/3 turns. If the filter cartridge is tightened too far, the gasket will be damaged and this will lead to leakage of water. If the filter is too loose, water will also leak from the gap at the gasket, so always tighten the correct amount. 6. Turn valve (1) to open it. 7. After replacing the cartridge, start the engine and check that there is no leakage of water from the filter seal surface. If there is any leakage of water, check the tightening of the filter cartridge.
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. SERVICE PROCEDURE
MAINTENANCE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Refill capacity: 0.9 liters (0.24 US gal) (each) 1. Set the front wheels in the normal position, then apply the P (parking) position securely. 2. Remove plugs (1) from the left and right front axle housings, drain the oil, then tighten the plugs again. 3. Remove plug (2) and add engine oil through the plug hole to the specified level.
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CHANGE OIL IN CIRCLE REVERSE GEAR CASE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Refill capacity: 8 liters (2.11 US gal) 1. Set the container under drain plug (P) to catch the oil. 2. Remove drain plug (P) and drain the oil. 3. After draining the oil, clean drain plug (P) and install it again. 4. Remove oil filler plug (F) and add gear oil to the specified level. 5. After adding the oil, check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL (PAGE 4-33)" 6. Install oil filler plug (F).
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MAINTENANCE
SERVICE PROCEDURE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Refill capacity: 95 liters (25.10 US gal) (each) 1. Put an oil container under drain plug (P) to catch the oil. 2. Remove drain plug (P) and drain the oil. 3. After draining the oil, clean drain plug (P) and install it again. 4. Pour in the specified amount of engine oil from oil filler (F). 5. After refilling the oil, check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL (PAGE 4-32)".
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CLEAN ENGINE BREATHER ELEMENT
WARNING
Immediately after the engine is stopped, the parts or oil are at high temperature and may cause burns. Wait for the temperature to go down before starting the operation. If compressed air is used, there is danger of dirt flying and causing personal injury. Always wear safety glasses, dust mask, and other protective equipment.
1. Before removing the breather, wipe off all the dirt around the breather. 2. Remove breather (1). 3. Wash the whole breather (1) in diesel oil or flushing oil, then blow it dry with compressed air. 4. Replace the breather O-ring with a new part, coat with engine oil, and install it. 5. Install breather (1).
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. SERVICE PROCEDURE
MAINTENANCE
CLEAN BREATHER
Remove the breather and wash out dust remaining inside with diesel oil and flushing oil. (1) Transmission case (1 place)
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(3) Tandem case (2 places)
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MAINTENANCE
SERVICE PROCEDURE
3. Use a cloth to wipe off all the grease stuck to hatched portion (A) of the lever of potentiometer sensor (3), then coat thinly with fresh grease (LM-G). 4. Install cover (2) with bolts (1).
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CHECK ALTERNATOR, STARTING MOTOR
The brushes mat be worn or the bearing may have run out of grease, contact your Komatsu distributor for inspection and repairs. If the engine is started frequently, have this inspection carried out every 1000 hours.
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. SERVICE PROCEDURE
MAINTENANCE
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5-1
. SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS
GD825A-2 Item Operating weight (including operator 55 kg (121 lb)) Engine model Flywheel horsepower A Overall length B Overall height C Overall width Min. ground clearance (to bottom surface of final drive case) Min. turning radius (outermost part of chassis) 1st 2nd 3rd Forward 4th 5th 6th 7th 8th 1st 2nd 3rd Reverse 4th 5th 6th 7th 8th Unit kg (lb) kW (HP)/rpm mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) 29,700 (65,489) Komatsu S6D140E-2 diesel engine 209 (280)/2,100 10,010 (32' 10") 3,550 (11' 8") 3,310 (10' 10") 440 (1' 5") 7,900 (25' 11") 4.0 (2.5) 5.4 (3.4) 8.0 (5.0) 11.5 (7.1) 15.8 (9.8) 21.4 (13.3) 31.3 (19.5) 44.9 (27.9) 4.3 (2.7) 5.8 (3.6) 8.5 (5.3) 12.2 (7.6) 16.9 (10.5) 22.8 (14.2) 33.4 (20.8) 47.9 (29.8)
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Travel speeds
5-2
SPECIFICATIONS
SPECIFICATIONS
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5-3
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6-1
ATTACHMENTS, OPTIONS
This system is installed to ensure that it is always possible to steer the machine. It is automatically actuated if there is a failure in the engine or hydraulic pump during operations. If the hydraulic pressure in the steering circuit goes below 0.69 MPa (7 kgf/cm2, 99.4 PSI), an electric motor is actuated to provide oil pressure to the steering circuit and make it possible to steer the machine. If the travel speed is less than 1 km/h (0.6 MPH) or the machine is stopped, the emergency steering system is not actuated. Action to take when actuated 1. If the emergency steering is actuated, move the machine quickly to a safe place and stop the machine. 2. After stopping the machine, turn the starting switch to the OFF position to stop the emergency steering, then ask your Komatsu distributor to carry out inspection.
CHECKING
EVERY 500 HOURS SERVICE
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1. Check that the emergency steering switch is at the AUTO position (1). 2. Start the engine and lower the blade to jack up the front wheels from the ground. Normally, keep the emergency steering switch at the AUTO position (1). 3. Turn the starting switch to the OFF position and stop the engine. 4. After stopping the engine, turn the starting switch to the ON position. 5. Set the emergency steering switch to the MANUAL position (2). 6. Check that the alarm buzzer sounds continuously and the electric motor for the emergency steering is actuated when this happens. 7. Turn the steering wheel and check that the machine can be steered properly.
NOTICE There is danger of seizure if the electric motor is used continuously, so do not continue the checks in Steps 6 and 7 for more than 30 seconds. 8. Set the emergency steering switch to the AUTO position (1), and check that the monitor and warning lamp go out and that the operation of the electric motor for the emergency steering stops. NOTICE If any abnormality occurs, turn the starting switch to the OFF position to stop the whole system.
6-2
ATTACHMENTS, OPTIONS
AIR CONDITIONER
AIR CONDITIONER
By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it possible to provide a pleasant working environment even on dusty jobsites.
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(1) (2) (3) Fan switch Air conditioner switch FRESH/RECIRC selector switch (4) (A) Temperature control switch The temperature level indicator lamp
FAN SWITCH
This switch (1) can be used to adjust the air flow to 4 stages. This switch also acts as the main switch for the air conditioner. When the switch is pressed, the indicator lamp above the switch lights up to indicate the air flow.
6-3
. AIR CONDITIONER
ATTACHMENTS, OPTIONS
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TEMPERATURE CONTROL SWITCH
This switch (4) is used to adjust the temperature steplessly from low temperature to high temperature. The temperature level indicator lamps (A) light up to display the temperature of the air coming from the vents. The more blue lamps on, the lower the temperature is. The color of the indicator lamp (A) changes while the switch is being pressed. When the temperature reaches the desired level, release the switch to set the temperature. The settings for each mode are retained in memory even when the starting switch is turned OFF. However, in the followig cases, the settings must be made again. When the machine has been out of use for more than 7 days When the battery voltage is extremely low When there has been abnormal interference from outside When the fan switch is turned OFF (the setting is not kept in memory with only the air conditioner switch) If the air conditioner is used at the FRESH position, the inside of the cab will be pressurized and this will prevent the entry of dust. The higher the position of the fan switch, the more effective the pressurizing becomes.
6-4
ATTACHMENTS, OPTIONS
AIR CONDITIONER
METHOD OF OPERATION
Switch Condition of use Cooling High speed Normal High speed Normal Defroster Ventilation or pressurization Fan switch HI HI - LO HI - LO HI HI - LO HI HI - LO Air conditioner switch ON ON ON OFF OFF ON OFF Temperature control FRESH/RECIRC switch selector switch All green More than half green More than half red All red More than half red More than half red All green RECIRC FRESH FRESH RECIRC FRESH FRESH FRESH
When carrying out the defrosting, if the temperature control switch is set so that all lamps are red, this will improve the performance for defrosting and demisting.
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Be careful not to cool the cab too much. For reasons of health, it is recommended that the cab should feel pleasantly cool when you enter it from the outside (5 to 6C (9.0 to 10.8F) lower than the outside temperature). Pay attention to the temperature when carrying out cooling.
6-5
ATTACHMENTS, OPTIONS
WARNING
Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. 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 down with the operator's back against the backrest.
NOTICE When the seat is pushed forward, the available reclining angle becomes greater; when the seat is pushed back, the available reclining angle becomes smaller. When moving the seat back, return the seat back to its original position before moving the seat. (A) Fore-and-aft adjustment Pull lever (1) up, move the seat to the desired position, then release the lever. Fore-and-aft adjustment: 160 mm (6.3 in) (16 stages) (B) Adjusting reclining angle
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Pull lever (2) up, set the seat back to a position where it is easy to carry out operations, then release the lever. When doing this, keep your back pressed against the seat back. If your back is not against the seat back, the seat back may spring back suddenly. (C) Adjusting seat tilt Front tilt Push lever (3) down and adjust the angle of the front of the seat. To raise the front of the seat, keep the lever pushed down and apply your weight to the rear of the seat. To lower the front of the seat, keep the lever pulled up and apply your weight to the front of the seat. Rear tilt Pull lever (3) up and adjust the angle of the rear of the seat. To raise the rear of the seat, keep the lever pulled up and raise yourself slightly from the rear of the seat. To lower the rear of the seat, keep the lever pulled up and apply your weight to the rear of the seat. Amount of tilt: Up 13, down 13 Adjusting seat height It is possible to raise or lower the seat by combining the front tilt and rear tilt. Use the front (rear) tilt operation to set the seat to the desired height, then use the rear (front) tilt to make the seat horizontal. Height adjustment: 60 mm (2.4 in)
6-6
ATTACHMENTS, OPTIONS
(D) Adjusting armrest angle Armrest (4) can be made to spring up by hand approx. 90. In addition, by turning the bottom (5) of the armrest by hand it is possible to make fine vertical adjustments of the armrest angle. Armrest adjustment angle: 25. REMARK Armrest (4) is designed so that it will automatically go up if the seat back is tipped forward without the armrest being raised. (E) Adjusting suspension To select the optimum suspension, turn knob (6) to adjust the dial for the suspension to the operator's weight as follows. Turn CLOCKWISE to make HARDER Turn COUNTERCLOCKWISE to make SOFTER REMARK To adjust to the optimum setting, turn knob (6) so that the indicator in the transparent portion inside the knob indicates the same as the operator's weight (kg).
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6-7
INDEX
INDEX
<A> ADJUSTING WORK EQUIPMENT POSTURE AIR CONDITIONER LOCATIONS AND FUNCTIONS OF CONTROL PANEL METHOD OF OPERATION PRECAUTIONS WHEN USING ARTICULATE LOCK PIN <B> BACKUP ALARM <C> CHECK AFTER STOPPING ENGINE CHECK BEFORE STARTING ENGINE CHECKS AFTER COMPLETION OF OPERATION COLD WEATHER OPERATION AFTER COLD WEATHER CAUTIONS AFTER COMPLETION OF WORK PRECAUTIONS FOR LOW TEMPERATURE CONTROL LEVERS, PEDALS CRITICAL PARTS <D> DUST INDICATOR <E> EXPLANATION OF COMPONENTS <F> FOREWORD FRONT GLASS FUSE BOX <G> GENERAL PRECAUTIONS GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES GENERAL VIEW OF MACHINE GUIDES TO MAINTENANCE <H> HANDLING AIR-SUSPENSION SEAT ADJUST OPERATOR'S SEAT HANDLING BLADE ACCUMULATOR HANDLING BLADE FLOAT HANDLING EMERGENCY STEERING DEVICE CHECKING HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC HANDLING THE TIRES <I> INTENDED USE DIRECTIONS OF MACHINE <L> LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ENGINE SERIAL NO. PLATE POSITION PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE SERVICE METER POSITION TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR LOCKING LONG-TERM STORAGE AFTER STORAGE BEFORE STORAGE DURING STORAGE <M> MAINTENANCE SCHEDULE CHART METERS AND LAMPS MONITOR PANEL MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING <O> OPERATING WORK EQUIPMENT OPERATION OPERATIONS, CHECKS AFTER STARTING ENGINE OPERATOR'S CAB LIFT MECHANISM OUTLINES OF SERVICE 6- 6 6- 6 3-115 3-117 662 2
3-110 6- 3 6- 3 6- 5 6- 5 3- 38
4- 4 3-114
3- 40 117 7
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11118 8 8 9 3- 38 1- 9 3-113 3-123 3-123 3-123 3-123
3-
6 4- 14 3- 19 3- 6
1- 2 3- 41 3- 39
3- 65
2- 12 3- 2 3343 2 2
3- 73 3- 43 3- 61 3- 40 4- 4
7-1
INDEX
<P> PARKING MACHINE PERIODIC REPLACEMENT OF CRITICAL PARTS PRECAUTIONS DURING OPERATION BATTERY OPERATION STARTING ENGINE TOWING TRANSPORTATION PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN OPERATION PRECAUTIONS WITH TIRES <Q> QUICK-FILL FUEL FILLER <R> RELATING TO ELECTRIC SYSTEM <S> SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS SERVICE PROCEDURE CHECK BEFORE STARTING EVERY 1000 HOURS SERVICE EVERY 2000 HOURS SERVICE EVERY 250 HOURS SERVICE EVERY 4000 HOURS SERVICE EVERY 50 HOURS SERVICE EVERY 500 HOURS SERVICE INITIAL 250 HOURS SERVICE (only after the first 250 hours) WHEN REQUIRED SPECIFICATIONS STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS STARTING ENGINE STOPPING ENGINE STORAGE BOX SWITCHES <T> TOOL BAG TORQUE LIST TRANSPORTATION
3-111 4- 13 2- 20 2- 27 2- 22 2- 20 2- 29 2- 26 2- 30 3-106 2- 36
LOADING, UNLOADING WORK PRECAUTIONS FOR LOADING TRAVELING POSTURE FOR MACHINE TROUBLESHOOTING AFTER RUNNING OUT OF FUEL IF BATTERY IS DISCHARGED OTHER TROUBLE TOWING THE MACHINE TRANSMISSION CONTROLLER WHEN LEANING PIPING IS DAMAGED TURNING MACHINE <U> USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE <W> WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER
3- 42
4-
4-
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3- 78 12222444444445 2 4 5 6 16 26 49 58 28 62 27 41
4- 16 4- 17 5- 2 4333312 58 63 42 20
3- 42 4- 12 3-119
7-2
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2004