Operation & Maintenance = ““""" Manual SATAN TT AN RE ES BULLDOZER SERIAL NUMBERS D155A-57285 and up mice | Komatsu has Operation sa tenance Meru tn (Ee ‘ome her language reesary ont youre1, FOREWORD. “This manual provi and guidelines which weil help you use this machine safely and offoutaty. Koop this manus! hangy and have all personnel read It periodically f tis manval has boon Pee, ccoma city and can not be res, request a replacement manual from Komatsu er Your Ti uou sel the machine, be sure to give ths manval to the new overs. Yee si provements inthe desipn of thie machine can lead to changes deal which may nok Oe ne ne manual Goneut Komateu or your Komatsu cistibutor forthe latest avalable Piommation of your machine or for questions regarding Information in this menus manuel may contin attachments and optional equipment thet are not avaliable in Your see. Consult Komateu or your Komatsi distributor for those Rem you may require A warnins: «Improper operation and maintenance ofthis machine can be hazardous and could esut serious injury or death. « Operators and maintenance personnel should read ths manual thoroughy before beglaning ‘peration or maintenance. «6 Some actions involvedin operation and maintenance ofthe machine can cause a serious accident, they are not done in = manner desertbed in thls manval. «The procedures and precautions given inthis manual apply only to Intended uses ofthe machine Tree your machine for any unintended uses that are not specify prohibited, you must rere that safe for you and others. In no event should you or others engage in prohibited tees of actions deserved In this manual «s Komatsu delivers machines that comply with all aplicabe regulations and standards of the Komatet atch # hos Been shipped: this machine has been purchased In another court oF courtelag fom someone mn anotror country, may leck certain safety devices and speciation, hat ae neceasary for use in your county. there Is any question about whether your product rae se ith the applicable standard and regulations of your country, consult Komatsu cr your Komatsu distributor before operating the machine. «The description of safety i given in SAFETY INFORMATION on page 0 and in SAFETY from page He CALIFORNIA CALIFORNIA Proposition 65 Warning | | Proposition 65 Warning, Dien ngnestastandsme ofits | | fled abcmnore con fad onstuemts ae known tthe State | | and load compounds, chemicals Sf calforia to cnine caver, bith | | Known tothe Stato of California aoe ee cevedutive | | t2.eaus@ cancer and br defects (roth reproductive har Ci ‘Wash hands after handling.1. FOREWORD 2 few [ESSN CONTROL WARRANTY EMISSION CONTROL WARRANTY STATEMENT APPLES TO CANADA ONLY) i Tins rey arte age og mc Kom alrsthoe ncaa ee ter tls pepe eg oe Sg femtir i ep aerhl ae ‘Shae inen ana sameeren pe da KOMATSU IS NF RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES ‘TAREE ett i ce comme ai, whe we ware of Kaman THER: ARE NO OTHER WAKKATIES EXPRESS OR IMPLIED, OR OF MERCHANTAMLITY OR Finuas OR cTakeieuae Hebe” ‘CARANTEE SUR LE CONTRLE DES EmSIONS ‘once De Arai SUR CONTROLE DES EMSSIONS (APPLICABLE AU CANADA SEULEMENT ron An ton Cepy. Kate Mig Sy «Kr cr Kon) pi ats See Se mre as nimi enone et ete vend rhs roast pa We er nes WO Ca p ee ne il ch a en en ee einige ameter et tne ee be Vesa ee Ss acme cu Scenes faelnge a ma Ten po pe ‘ent foe pe ct timers Sc rane coated iy Sei Ta mm tree ps pa cn en ‘mma ii ts eae ofan nae se asa ee KOMATSU N'EST FAS RESFONSABLE DES INCIDENTS OU DOMMAGES CONSEOUENTS. Tan am Ai aC 128 021. FoRewoRD2. SAFETY INFORMATION ‘To enable you to use this machine safely, safety precautions and lable are given in this manual and sified to the machine to give explanatione of situations involving potential hazards and ofthe methods Of avolding such stations Signal words “The fllowing signal words are used to inform you that there isa potential hazardous susion that ‘may lead to personal injury or damage. In this manual and on machine labels, the following signal words aroused to express the potenti se AAPANGER — nests ninminenty uae stn wt sel enti Sts ee res ncn AWwarwus ~ ndcaosporntay hazardous shuren whieh Ht weed, coud rst ‘nse swe A.cAUTION. — neater» ptonity hazardous suntn hie na vided ey rest a Miers netre ni Wn cne be mode ae ope aa ee A Warne. To avold hitting unlocked operation lovers, lower equipment to ‘round and move SAFETY LOCK LEVER (located near seat to LOCK positon before starting up trom operstors seat. Sudden and unwanted machine movement ean cause serious Injury or death. ther signal words In adaltion tothe above, the following signal words are sad ta indicate precsutions that should be followed to protect the machine or to give information that seful to know. NOTICE —- This word Is used for precautions that must be taken to avold actions which ‘ould shorten the Ife of the machine, REMARK - Ths gives information that is useful to know. on2. SAFETY INFORMATION Safety labels ‘Safety labels are affixed tothe machine o inform the operator or maintenance worker on the spot when eatryng out operation or maintenance of the machine that may invalve hezard “his machine uses “Safety labels using words” and "Safty labels using pletogram” to indicat safety procedures, ‘Example of safety label using words A WRNNG ‘Safety labels pictogram Safety pitograms use a picure to express a level of hazardous concition equivalent tothe signal word. These safety pitograms ues Dictures In order to let the operator or maintenance worker undor- and the level and typeof hazardous condition at ll times, Safety pictograms show the type of hazardous condition atthe top or lef sid, and the method of avoiding the hazardous condition at the bottom or right side. In adaltion, the type of hazardov Condtion is displayed inside a triangle and the method of avoiding tho hazardous conltion is shown inside 3 ice, PartNo Komatsu cannot predict avery circumstance that might involve a potential hazard in operation and maintenance. Therefor, the safety messages In this manual and on the machine may not inde all possible safety precautions. any procedures or actions not specifically recommended or alowed in this manual ae use, i ie vour responsiblity to take the necossary stops to ensure safety. In'no event should you engage in prohibited uses or actone described in this manual ‘The weplaations, valus, and Hlusraons in this manual were prepared based on the latest Information valable at that timo. Continuing Improvements inthe design of tls machine can Kad 12 changes in detll which may not be reflcted in tls manual Coneut Komateu or your Komatsu slstibutor forthe latest available information of yout machine or for questions regaraing information inthis manual3. INTRODUCTION 3.1. INTENDED USE ‘This Komatsu BULLDOZER fs designed to be used manly forthe following work, 2 boxing Cutting ito hard or frozen ground oF ctehing 1 Feling toes, removing stumpe 3 Pushing 2 Ripping Seo the section "12.18 WORK POSSIBLE USING BULLDOZER* snd “12.16 RIPPER OPERATION" for forthor dota, “Tne precautions given in this manual for perting, malntanence, and salty procedures are only ‘those that apply wen tis products used forthe specfed purpose. the machines used fr» purpose ‘that le at lsted in this manual, Koma cannot bear any responsibilty for safety. All conseration of fey in euch operation i the responsibilty ofthe use, ‘Operation that aa prohibited inthis manual must never be cari out under any circumstances. os4. LOCATION OF PLATES, TABLE TO ENTER ‘SERIAL NO. AND DISTRIBUTOR 4.1 MACHINE SERIAL NO. PLATE POSITION Under the front of the console box on the right side of the operators seat 4.2 ENGINE SERIAL NO. PLATE POSITION (nthe air ntake manifold onthe left side ofthe engine ae seen from the fa, o74 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO, AND DISTRIBUTOR 4.3 BLADE SERIAL NO. PLATE POSITION “hiss located at the right se of blade back surface. 4.4 RIPPER SERIAL NO. PLATE POSITION ‘ni i located at he tet sie eurtace ot ripper beam. 4.5_ SERVICE METER POSITION ‘On the upper of monitor pane. 4.6 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serie! No: Engine serial No Dietrbutor name! address: Phone: Service personnel for your machine 085. CONTENTS: 1 on 2 menor 3s pens 08 44 Location of plates, table to enter serlal No. and distributor veces OT SAFETY ©. General precautions ve 7. Precautions during operation wn 71 Betore starting engin m0 12 Aer starting engine “2 13 Transporation. Me TA Battry nnn “w 15 Towing sno 8 18. Precautions for maintenance ws 420 81 Belore carrying out msintonance +20 82 During maintenance 12 ‘9. Postion for attaching safety labels = 1 8.1 Position for attaching safety labels. a 82 Content and use of warning plates +30 OPERATION 10, General Vie" nnn a 22 101” General viow of machine ssnonnsvnnnnnnn 22 102 General view of contole and gauges etsy) 11 Explanation of components 2 it Meniter pana M2 Lam M13 Switches 14 Control levers, pedals 15 Power source on M18 Fave box: M17. Door-open oak machi MB Boerne - = 118. Ashiray imachines equipped with cab) ‘Vito Toa! box 11 Car rasa machin {1132 Alr conditioner (machines equipped with cab) {1178 Manaling accumulator (f equipped) ann ‘equipped with cab and car radio) 095. CONTENTS: 12, Operation . sev 121 Check before staring engine nnn 322 Stating engine. 323 Operations and shecke ater saring angine.c 240 240 256 256 324 Moving machine... 2.56 125 Shining 9 280 128 Shing betwoon forward and reverse. 260 2a 268 264 287 28 268 20 20 127 Steering machine 128 Stopping machine. 128 Precaution for operation 12:10 Parking machine wen 2 Check aor tnising work 12.12 Stopping ena 12.13 Check ater stopping engine. 1214 Loeking weer 12115 Ripper operation = an 12.18 Wark possible using bulldoze 273 12.17 Adjusting posture of work equipment = SII 23 12.18 Tips for longer undarcariag life. 12.18 Method for releasing when assist brake hs been applied. 13. Teaneportation 7 131 Loading, Unloading work 132 Precautions for loading wn 133. Method of iting machines * 134 Precautions for transportation 135 Removing and instaling cab (machines equipped with cab) pot 14. Cold weather operation a ~ 298 44.1 ‘Precautions for ln temparature 5 296 142 Ator completion of Work 296 143 Aftor cold weather. 298 15. Long-term storage sev 297 181 Belore storage ” 297 152 During storage . 297 183 Aftr storage. = 237 18. Troubleshooting ew : 208 18.1 After running out of fuel 298 182 Method af towing machine 298 183 If batry is dlschorged 2.99 T6A Other TOUBIO nnn en = 208 0-10MAINTENANCE 17, Guides to maintenance on a 16. Outings of serve sven : 18.1 Outline of oi, fuel, coolant nnn = = 182 Relating to olotrie system 19, Wear pats list... sen 20, Use of fuel, coolant and lubricants according to ambient temperature = 21. Standard tightening torques for bolts and nuts oe 2it Torgue tit —————— oo 22, Periodic replacement of safety critical parts a 25. Maintenance schedule chart on se vce Procedure nnn ~ a Tntat 250 houre sonice nnn om Whan roquired —— = m Check before staring ~ : Every 260 hours ceric 265 Every 500 hours series. 246 Every 1000 hours service 247 Every 2000 hours service ~ 248 Every 4000 hours Service nnn nnwnnvnnnn ‘SPECIFICATIONS 25, Spectestons a 29 39 320 3HOPTIONS, ATTACHMENTS 26, General precautions : 25.1" Precttions related safety 27. Introduction of optional parts and attachments... 274. Introduction of optional pats attachments 29, Handing headrest 28.1 Adjusting height of headrest ” 30, Handling reversible fan 3041 Reversing rovrsibie fan 31. Handing eap with tock on S11 Opening and closing lockable cap. 122, Procedure for selecting ripper point 321 Procedure for eolecting npper ont oe oo oe oeSAFETY A warninc: Please be sure that you fully understand this manual and the precautions related to safety forthe machine, When operating frsericng the machine, always follow these precautions st “This safety section also contain precautions for optional equip mont and attachmentsGENERAL PRECAUTIONS i SAFETY RULES: ‘© Only waned and authorized personnel cen operate and msintain the machine. ' Follow all ealety rule, precautions and instructions when operating or performing maintenance fon the machine «# Ifyou are under tho influence of alcohol or medication, your ability to safety operate or realr your ‘machine may bo severely impaired putting yourelf and everyone else on your jobsite in danger. ‘© When working with another operator or witha poreon on worksite waffe duty, be sure that al Dereannel understand all hand signals that are to be Used Ifyou find any abnormalty in the machine during operation or maintenance (noise, vibrate, smell incorrect gauges, smoke, oll leakage, tc, or ny abnormal cleplay on the warning devices of ‘moniton rapt tothe person in chargo and have the necessary action taken. Do not operate the machine unt the abnormality has been corrected. ‘CLOTHING AND PERSONAL PROTECTIVE TEMS ‘= Do not wear loose clthing and aocessores, There es hazard that they may catch on contol levers or other protruding pats «Ifyou have tong hair and ithangs out from your hard hat, there i. hazard that t may get caught up in the machine, so tie Your DY ne hair up and be eareful not to lett get caught ay Always woara hard hat and safety'shoos. tthe nature ofthe — (YG ‘work requires wear safety glasses, mask gloves earplugs, oo _ Rete Senet etetoenneen ey —& ee) using [FRE EXTINGUISHER AND FIRST AID KIT ‘Always follow the precautions below to propare for action if any injury or fire should oceur. 1 'be'cure tet re extinguishers have been provided and read the labels to ensure that you know how to use them in emerge es 1 Carry out periodic inspection and maintenance to ensure that tho fire extinguisher can always be used. 1» Provide a fet aid kit at tho storage point. Carryout periodic chooks and 8d to the contents fnecoesary. '¢ Understand the method of use of sfey festures and use them propety 1 Novor remove any safety features. Alvays keep them In good operating condition, 2Awana 6. GENERAL PRECALTIONS [KEEP MACHINE GLEAN TF water gets into the elctrical system, there Is a hazard that it will cause malfunctions or iisoperstion. Do not use wator or steam to wash the electri! system (sensors, connector), ‘IF inspection and maintenance is carried out whan the machine ie stil diy with mod or el tere Ja hazard that you will slip and fall, or that dirt or mud wil get into your eyes. Always Keep the ‘machine clean. INSIDE OPERATOR'S COMPARTMENT ‘= When entering the opertor's compartment, aways romove ll mud and ol om the soles of your thoes. you operate the pedal with mud or ol afixed to your shows, yout foot may stp andthis nay ceuse 9 serious accident, ‘Do not leave parts oF tool ying around the operator's compartment = Do not fix any suction pd to the window glace, ‘Tho euction pad will at ae 8 lone and may cae a fro ' Do not use eaular telephones Inside the operators compartment when diving or operating the 1 Never bring any dangerous objects such jammable or explosive items int the operator's ab. "ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT ‘© When standing up from the operator's seat (such as when adjusting the operator's seat), lowor the work equipment competay to the ground, st the safety look lovers ight ide of operators seat 3 paces; let side of operators seat: 1 place) securely tothe LOCK pesition, then atop the ‘engine. If you accidentally touch tho lovers whon they are not locked he machine may suddenly ‘move and couse serious injury of damage, ‘+ When leaving the machine, lower the work equipment completely to the ground, set the string lever and dection and speed lover te the neutral position then etal the safety lock levers [t places) eocuoly to the LOCK position and stop the engine Use the key to ock al the equipment Always remave the Key, take it with you, and lave finthe spectied place 2 B1. GENERAL PRECAUTIONS. HANDRAILS AND STEPS ‘Te prevent personal injury caused by alpping or fling off the machine always do as follows. 12'Use tho parts marked by arrow A inthe diagram when gating fn of aff machine. Never use the parts marked by arow B when goting on or off the machine Use thom eniy when moving along the top ofthe tack o when checking or carving aut maintenance inside th side cover, Wen filling th tank with ol. 1» Use the handrails and stops marked by arrows inthe dlagram fn the right when gating on o of the machi To encure efety, sways fe the machine and maintain th polnt contact (bth feet and one hand, or both hans and one oot) withthe handcals and steps to ensure that you suppor ‘yourself 1 Do not grip the contol levers when getting on or off the machine ‘Use only the inspection path fited with non-slip pads whon elimbing on top of the machine. Never climb on the engine hood or covere where there are ao nowalip pada # Botore geting on or off the machine, check the handrails and ‘stops fntuding the tack shoo). 1 oll grease, oF mud on the handrails or steps (including the wack ehoe), wipe itt immeciately. Always hoop these parts clean. Repair any ‘damage and tighten any loose bolt. '¢ Dovnot get on or aff the machine wile holding tools in your somm hand. MOUNTING AND DISMOUNTING ‘= Never jump on oF off the machine. Nover got on or off a moving machine {lf the machine stats to move when there Iso operator on the machine, do not jump an to the machine and try to stop it [NO PERSON ON ATTACHMENTS laver Tot anyone ride onthe attachments. There isa hazard of faling and suffering serous injury. “Wanna: Faare ANS, Sas, follow these eaeyprecawons may led 6. GENERAL PRECAUTIONS PREVENTION OF BURNS ot cootant 1#'To provant burns from hot water or stam spurting out when checking or drating the coolant wait forthe water to caol to ' temperate whore itis poesibie to touch the radiator cap By hhand before starting the operation. Even when the coolant has aoled down, loosen the cap slowly to rellove the pressure Inside the radiator before removing the cap. Hot ot "Toprevent burns when cectngo nog theo wat forthe — i to ool toa temperature whore els pestle ove the sy ‘up by hand batore sarin the operation Even whe te o ‘has cooled down, loosen the plug slowiy to relieve the internal Ww Dresure before femoviog the Blogs f 16aLwannins reasons of ssey, aways 6. GENERAL PRECAUTIONS ati thse Stel tree TRE PREVENTION Fire caused by fue o oil Fel, ol, antitoeze, and window washer liquld ar particularly flammable and can be hazardous To prevent fire, alvays observe the folowing "Do not smake or use any flame near fu! or oft ‘Stop the engine before refueling Do not leave the machine while adding ful or oi ‘Tighten all fol and oll cape securely. Do not spill fol on overheated surfaces or on pars af the eletiel system, ‘Use wallventlatod areas for adding of storing oll]end fue Keep oil and fue in te determined place and do not alow unauthorized persons to enter. ‘Aer adding fue ool, wipe up any spilled fel or ‘When carrying out grinding or welding work on the chassis, move any flammable materials to 2 sate place before staring, + When washing parts with ous ‘200 not use them. + Put greasy rage and other flammable materials into 3 work place + Dovnet weld or use ‘on-tammabie ol. Diesel il and gasoline may catch fre, fe container to maintain safety cuting toreh to cut any pipes or tubes that contain flammable quid, ©O Fire caused by accumulation of flammable materia, Remove any dry leave, chips, paces of paper, dust, oF anyother flammable matrials accom lated or affixed around the engine, exhaust manifold, muti or batery, o inside the undoeavers Fire coming from elettic witing ‘Shor creute In the electra! aystem can cause fr + "always keep elctrie wiring connections clean and securely tightened, {Check the sing everyday for looseness or damage, Tighten any loose connectors or wiring clamps. Repair or replace any damaged wiring. Fite coming from hydraulic tine Chock that al the hove snd tube clamps, guerds, and cushions are securely fixe in postin. It ‘thoy are loose, they may vibrate during operation and rub against othor pars, This may laa 10 ‘damage tothe hoses, and cause high pressure ol to spurt out leading to five damage er serious Explosion caused by lighting equipment + "When checking fue ol,Bttery electrolyte, window washer fluid, or coolant, use explosion: proof lighting. Ifyou do not use explosion proot lighting, there fa Hazard of serous injury Or Samage caused by explosion. + Wen taking th electrical power forthe lighting trom the machine, follow the instructions in thie manu. 16‘A WARING ars fo olow testy recone may lead a cenenns pagcaurions (-(AcTION iF ARE OCCURS Ifa fre occurs, eacape fom the machine as follows Push fuol contrat lever inthe engin stop position and stop the engin {Turn the stating switen OFF and stop the engine 1 Use’ tho handrails and stops to gat off the machine, -Lwinbow wasHER uaUID Use an ethyl alchohol base wesher quid Methy! alchohol baee washer liquid may iritate your eyes, 20 do not uee PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structre) Inatall ROPS when working in places where thee ls danger of {aling rocks, such asin mines and quarries, oF in places where ~~ there is danger of rolling over. ‘TF ROPS fe installed, do not remove ROPS wien operating the machine 1 The ROPS is installed to protect the operator Ifthe machine should roll aver. It is designed net only to support the load i ‘the machine should rll over, but also to abeord the Impact oo ‘energy. + ITMOPS is modifi, is strength may op. Conult your Komatsu ltrioutor before carrying out any modification ‘# IF ROPS is damaged or deformed by fang objects or by cling over, strength wil ba reduced ‘and it will not be able to flit its function properly In euch eaten, aivaye Komatau contact your latributor for aie ofthe method of repair. Even if ROPS is installed, alvays fasten your seatbelt propery when operating the machine. Hf you do not use your fasten your seat belt propery, ht cannot Gaplay ts effect, [PRECAUTIONS FOR ATTACHMENTS ‘# When instaling optional parts or attachments, thore may be problems with safety oF legal restrictions, so contect your Kometeu dstrbutor for advice, ‘Any inure, accidents, or product fallures resulting Irom the use of unauthorized attachments or parts will not be the responsibilty of Komatsu ‘¢ When instaling and using optional stachments, read the Instrution manual for the attachment, and the general information ralated to attachments in this manus 3 the engine is stopped If the work equipment contol aver Is moved tthe LOWER postion, the work equipment wall move down under te own weight After stopping the engino, always plac the safety lock i the LOCK position, \When releasing the pressure inside the work equipment circuit on machines equipped with an sccumblator, follow the procedure ven In the inspection and maintenance section, Method of reloaing proseure ~ See "11.14. HANDLING ACCUMULATOR” {ne sccumulstor i filed with high pressure nitrogen gas, and Ils extremely dangerous if i handled in the wrong way. Always observe the folowing precautions {When caring Sit sisssembly of maltonance ofthe accumulator or when dlaposing ofthe _ccumulator, It's necessary to fleaso the gas from the accumulator spacial air bleed valve ls necessary for this operation, so please contact Your Komatsu ditibutor. 7(UNAUTHORIZED MODIFICATION ‘ny mealfeation mode withovt authorization from Komatsu can crest hazards, Betore making 2 modification, consul your Komatsu distributor. ‘© Komatsu will not be responsible for any injuries, accidents, or product fallures resulting from modifications made without authorization from Komotst [SAFETY AT WORKSITE Before stating operations, thoroughly check the area for any Unusual conltons thet could bo dangerous "Wan carrying out operations near combustable materiale such ‘2s thatched roof, dry leaves or dey geass, there lea hazard of fire, 20 be careful when operating. Chock the torsin and concition ofthe ground st tha worksite, “nd determine the safest method of operation. De not carry out ‘Operations at paces where there is hazard of landslides oF faling rocks, ‘¢Fwater lines, gs lines, or high-voltage electrical lines may be ried under the worksite, contact each uty and deny thet locations Be careful nat to saver or damage any ofthese nes ‘© Take necessary measures to prevent any unauthorized person {com entering the operating area ‘¢ When traveling or operating in shallow water or on soft ground, check the shape and condition ofthe bedrock, and the depth land speed of flow of the water before starting operations ‘© Set and maintain the haul load on the jobstes co thot the ‘machine can always travel safely ‘© Avoid wavaling oF operating your machine to ele tothe edge of eis, overhange, and deep itches. The ground may be weak in such ess. Ifthe ground should collapee under ths weight ‘or vibration of the machine, there isa hazard thatthe machine may fall o ip over, Ranambar that the sol after hoavy rain or basting oF after earthquakes la weak In these areas. ‘When working on embankments or near excavated ditches, thera ea hazard thatthe weight and Vibration ofthe machine wal eauso the sol to collapse. Before starting operations, take stops to lensure thatthe ground is safe and to prevent the machine from roling over or fling.A. WARIING, ly to foow tae eat precaution may eat {Bo NOT Go cLose To WGH VOLTAGE CARLES Do ot wavel or opette the machine reo Rect low hob es hard sects Sat wteh'mey" nus seews aro ope some on obese he ms aiaee [in st ee Ein nays Sows w'duoiccosen saree do as follows. gB__100+ 200 2m Tastee staring work nea dete cates, 22] cama v im io She il power comeny toe — "| —seemey —- Toliotepetannmd sentence gL — 280 3 ‘© Even going close to high-voltage cablescan "154,000 V Bm Ssmelsionie seh ach enece. & Stousbumecrevendanh Atareainan = | 1270000 em tate dames osc elope se ihe ho & [8000 7m Setmonteracineseatescareet, § [- —Be000¥ E Shock win tote power span boat = safe operating procedure before starting eperetions '# To prepare for any possible emorgoncies, woar rubber shoas and gloves. Lay 9 rubber shost on top of the seat, and be earful not to touch the chassis with any exposed part cl your body. Uso a signaiman to glve warning if the machine approaches to0 close tothe alectrc cable, When carrying out operations near high voltage cables, do not let anyone come close to the ‘Ifthe machine should come too close of touch the electric eable, to prevent electric shock, the operetor should not leave the operator's compartment until hae bees confirmed that the locity has been shutoff Also, do nat let anyone come clase to the machine, {ENSURE Goo visiouTY ‘© Check for any persons or obstacles in the area around the machine and check the coeliions of tho Jobsite to ensure that operations an tavel can be carced out eafely. Aways do as follows + Postion a signaimen if ther are areas atthe rear of tho machine where the visibly ls not good * When working in dark places, turn ‘on the working lamp. and front lamps installed to the machine, and sot up adettona igting Inthe work area If necessary. + Stop operations i the Vsbity ie poor, such as In mst, snow, ain, or dust VENTILATION FOR ENCLOSED AREAS | Exhaust fumes from the engine can kil ite nocaseary to star the engine within an enclosed area, or when handling fue, Fushing ol, ‘or paint, open the doors and windows to ensure that you provide adequate ventiltion is provided te prevent ge poisoning 1%8. GENERAL PRECAUTIONS. A Bis the clay peewee [CHECKING SIGNALMAN'S SIGNALS AND SIGNS ‘© Setup sins to inform of road shoulders and soft ground. Ifthe visibility is not good, position @ Signalman if neceseeryOporstors should pay careful attention tothe signe and elow the instructions fromm the sgnaiman, 4 Only ane signatman should give signals. 1 Mako cure that all orders understand the meaning of al signals and signs before starthg work _-[ ASSESTOS DUST HAZARD PREVENTION Asbestos dust inthe air can cause lung cancer if itis inhaled. Thre is dangor of inhaling asbestos tinen working on jobstes handling demolition work or work handing industrial waste Always ‘beerve the following, Spray water fo keep down the dust when cleaning * De not use compressed alr fr cleaning irthore ie danger that there may be aebestos dust Inthe Sn upwind postion. «All workers should use an approved respirator. Do not alow other persons to approach during the operation Always observe the rues end fegultions forthe work site snd environmental stander ‘This machine dose not use asbestos, but thre lee danger that imitation parts may contain asbestos, ‘0 always use genuine Komatsu parts ways operate the machine fromWARNING: For reasons of iy, staays A swe lt eta 7. PRECAUTIONS DURING OPERATION 7.1 BEFORE STARTING ENGINE Ifthore [sa warning tag hanging from work equipment contol lever, do not start the engine of touch the levers (-{_GHEGKS BEFORE STARTING ENGINE, ADJUST Carryout the following checks before starting the engine atthe beginning af tha day's work. 1 Remove all i from the surface of the lens ofthe front lamps, working lamps, and ret lamp, and check that they light up correct ‘Check the coolant leva, fal love, and cl levl In engine oll pan, check for clogging of the lane, and ohack for damage to th electric wiring. ‘# Adjust tne operator's seat to position whore ts eagy to carry out operations, and check that there is no damage or wear to the saat belt of mounting clamps ‘© Chock that the gauges work propery, and check thatthe contol lovers are all atthe nevt postion ‘¢ Aajst the mirrors so thatthe rear ofthe machine can be 1 Check that there 1 leary from tho operator's seat. ‘no persons or obstacoe above, blow, oF In the are around the machine. PRECAUTIONS WHEN STARTING When starting the engine, sound the hom as a warning. ‘Start and operate the machine only while seated ‘Do not allow anyone apart from the operatr fo Fido on the machine. Do not shor clecutthe starting motor creut to start the engine eis not only dangerous, but will also cause damage to the equipment. 1 For machinos equipped with back-up alarm, check thatthe alarm works propery {PRECAUTIONS IN COLD AREAS ‘© Carry out the warming-up operation thoroughly. If the machine is not thoroushly warmed up before the contol vers are operated, the action ofthe machine willbe sow, and ths may ead to unexpected accidents. Ifthe battory oletrolye is frozen, do not charge the batery or start the engine witha diferant ower source, There fea hazard that this wil ignite the battery. Before charging or starting the engine with a ferent power source, melt the battery elacrcyte and chock Tor fost and laskage of battery slocraytebofore stating1 PRECAUTIONS DURING OPERATION 7.2_ AFTER STARTING ENGINE -[_cHecks AFTER sTanTinG ENGI } Wien carrying out the chooks, move the machine to a wide area where there are no obstructions, and operate slowly. Do at alow lanyone neat the machine. "Always fasten your set bet 1 Chock the actuating condition of the work equipment, rave, and brake systems ‘© Check for any abnormality in the sound ofthe machine, vibre tion, heat, sel, or gauges; check a of ello fel Ifany abnormality ie found, carryout repairs immediatly. Lf) Ng [CHECK WHEN CHANGING DIRECTION {Before travling, chook again that there la no one Inthe Sut rounding aea, and that there are no obstaces. Before sound the horn to warn people Inthe are ‘Alviaye operate the machine only when seated 1 Do net allow anyone apart from the operator to ride on the machine '© Chock that the back-up alarm (alarm buzzer when machine travels in reverse) works property. ‘+ Ficthe operator's compartment doors an windows in postion securely ‘Always be sure to carty out the above precautions even when the ‘machine Is equipped with mirrors.WARNING: ature ofl these satay precautions may las A oeteaocs else 1. PRECAUTIONS DURING OPERATION PRECAUTIONS WHEN TRAVEUNG ‘= Never turn the Key inthe stating switch tothe OFF postion. i fe dangerous ifthe angine tone when the mechine fe taveling, because it bacomes impossible to operate the steering. Ht the {engine stops, depress the brake padalimmodiataly to stop the machine. ‘© Whon waveling on fovel ground, pullin the work equipment and keep it ata height of €0 50 cm (16 to 20 in) fom the ground. ‘« When traveling on rough ground, to avoid turning over, travel at low apeed, and avoid sudden Changes in rection. There also danger ofthe work equipment touching the ground and making {the machine ose ts balance, or of hing ether machines or structures Inthe surrounding area ‘¢ Avoid waveling over obstacies as far as possible. Ifthe machine has to travel over an obstacle, {eop the work agulpmant as clos tothe ground as possible and travel alow spond. The machine ‘wil also tend to turn over to the let or right sides, 20 do not tavel over obstacle tht make the ‘achine tit excessively to one side 1 When traveling or carrying out operation, shwaye keep your distance from other persons, machines, or structures to avoid coming into contact with them ‘¢ When passing ever bldges or structure, check first thatthe structure the mass of the machine, When traveling on public roads, check fist with the relevant authorities and follow thelr 1 When operating in tunnels, inside buildings, under bldges, under electe wires, oF other pcos ‘wher the height i imited, operate slowly and be extremely careful not to lt the machine oF Work ‘equipment hit anyaing ‘Be careful not to approsch t0 close tothe eg of ifs. When making embankments or lnc, ‘or whan dropping sol ever a cif, dump one load, then use the next load of sol to push the firs toad 1 The load suddenly becomes lighter when the oll ls pushed aver elif or when the machine passes over the top ofa slope. Whan ths happens, there ls danger thatthe travel spood will Suddenly increas, so be sue to reduce the speed «# Ifthe toad le applied to only one sido of tho Blade, the rear ofthe machine may swing. is strong encugh to surport‘PRECAUTIONS WHEN TRAVELING ON SLOPES ‘To prevent the machine for Epping over or aipping to the side, avays do as follows ‘¢"When traveling on slopes, kaep the work equipment approximately 2030 em (@ 12) above the ground, in case of emergency, quick lower the blade tothe ground to help the machine to stop. ‘Always travel straight up or down a slope. Travaling at an angle or across the slope ie extremely Sangorous. ‘* Domottur on slopes or travel across slopes. Always go down to fat place to change the position ‘of the machine, then travel on tothe slope agoln ‘© Travel on grace, fallen loaves, or wet stot plates with low speed, Even with slight slop 1e'a hazard thatthe machine may sip. ‘When traveling downhill never shift gor or place the transmission at neutral. tis dangerous not 10 .se the braking force ofthe engine. Aivays place the ranemission ins low gear before starting te travel cowl, ‘© When traveling downhill under ts own weight, the machine may steer to the opposite side, so be earful when stoerng. there -{_PRONIBITED OPERATIONS ‘TFs necessary (0 go close toa cif or road shoulder during operations, keep the track aright angles to the cif of road shoulder withthe sprockets the rear and make sure that tis possible {o drive away from the elif or road shoulder quickly in an emergency. ‘© Wen using the machine, do not exceed the stabilty determined from the structure of the ‘machine, maximum using load end other performance values to pravent the tipping of the ‘machine and breakage of the work equipment caused by an overload /-LLMETHODS OF USING BRAKE ‘© Do not rest your foot on the brake pedal if you aro not using the brake. H you travel with your foot on th poda, the brake wil always be applied. This will cause abnormal heating ofthe bake nd the brake wil not work 1 Do not depres the brake pedal rapeatedy if not nacessery Ifthe brake overheats, the blade may have no braking effect when itis needed, ‘© whon traveling downhil, use the braking force ofthe eng necoseary, use tha right brake pedal at the same time.WARIING: Faure to follow tees sey precautions may lead ARTs selon 1. PRECAUTIONS OURING OPERATION _{orERATE caneroiLy on BNOW ‘= Snow covered or frozen surfaces are slippary, so be extrmaly careful when traveling or opersting ‘the machine, and do nat operate the lavors tuddeny. Even alight slope mey cause the mactine to alip. so be particulary careful when working on slopes. ‘With frozen ground surfaces, the ground Becomes sof when the temperature rises, and this nay ‘cause the machino to tip over. 1 Ifthe machine enters deop snow, there Ie hazard tht may tp aver or become buried in the now. Be caeful not to leave the road shoulder orto get trapped in a snow dri ‘¢ When cleoring snow the toad shoulder and objects placed beside the road are burled inthe snow land cannot be seen. Tere Is a hazard of the machine tipping over or hing covered objec, so ftways carry out oparatons carefully ‘© Whon traveling on snow-covered slopes, never apply the bakes suddonly. Reduce the spoed anc tase the engine ac a brake wile appiving the foot brake intermiteniy (depress the rake intermivanty several times). W necessary, lower the blade to the ground to stop the machine. panne MACHINE ark the machine on firm, level ground. Seloct a place where thre is no hazard of falling rocks or landslides, or of flooding if the land is row. 1s Lower the work equipment completa tothe ground. {itt Ts necessary to park the machine ona slope, st blocks under the track o prevent the machine fom moving, then alg the work equipment into the ground ‘After stopping the ongine,operata the blade contro over soveral times tothe RAISE and LOWER positions to release the remaining pressure In the hydraulic cre 4s When parking on public roads, provide fences, signs, Nags, or lights, and put up any ether ‘necessary signs to ensure that passing tafe can see the machine leary, and park the machine noes do not obstruct traf "12.10 PARKING MACHINE”. Parking procedure 5 ‘* Wnon leaving the machine, st tho safety lock lever to the LOCK positon, stop the engine, and ‘use the ey fo lock al tho equipment. Always remove the key and take ¥ with You ‘Werk equipment posture See “1210 PARKING MACHINE” Locks~ ‘See "12.14 LOCKING" ‘6 Aways close the door of the operators compartmentWARNING: For rezone of {2 PRECAUTIONS DURING OPERATION ow thee eset pressor 7.3 TRANSPORTATION LOADING AND UNLOADING \iten loading or unloading the machine, mistaken operation may bring the hazard ofthe machine tipping over or falling, so particular care fe necessary. Alvays do as flows, ' Perform loading and unlosding on frm, level ground only. Maintain a sae distance fromthe edge othe road or elif 1 Aways use ramps of adequate strength. Be sure thatthe ramps are wid, long, and thick enough to provide a safe loading slope. Take suitable stops to prevent the ramps fom movieg out of postion or coming af. ‘+ Be sure the ramp surfceis clean and fee of gress cl ce and loose materials, Remove sit rom «tinesracks. On 8 rainy Gay, tn parila, take extremely carta since the ramp safors slippery. fe Rum the slowly. ‘+ When on the ramps, do not operate any laver excep forthe travel lover (FORWARD, REVERSE) 1 The conte of gravity of the machine will suddenly change when the machine crosses the bordet between the ramps and the trailor platform, and there fe danger that wl love ts sas, 0 ‘operate particulary carefully when passing this point + When loading or unloading to an embankment or platform, make sure that thas suitable width, strongth, and grade ‘¢ For machines equippod with a cab, always lock the doar after loading the machine. If hs fs not ‘done, the door may suddenly open during transportation, ‘Seo 13. TRANSPORTATION. lever ine at low ding, select ILo travel] forthe travel speed, and operate the rave ‘When shipping the machine on tse, do as follows 1 When pasting over bridges or structures on privat in, chock fist thatthe structure i strong ‘enough to support the weight of the machine. When traveling on puble roads, checks frst with the relovant authorities an follow thet insvtions ‘¢ For deals ofthe shipping procedure, see 13. TRANSPORTATION in the OPERATION section {For machine equipped witha ea, always lock the door.A. WAtN Fare oto there ey proctons ny lad 7.4 BATTERY [BATTERY HAZARD PREVENTION ‘ateryelecroyte contains sulphors acid, and batteries generate flammable hydrogen ges, which ‘may explode. Mistaken handling ca lead to serious injuty or lie. For thi reason, aways observe the following precautions. ‘Do not use or charge the battery ifthe beter electrolyte level is below the LOWER LEVEL tne, ‘This may cause an explosion, “Always check the battery slectroyee level periodically and add datiled water to bring the elactroiyalovel tothe UPPER LEVEL Iie. '¢ When working with batteries, always wear safety glasses and rubber gloves. «ald ui your ee, tah hr ned wth ge oo of ter rsa seal anon Vs ‘Before working with batteries, turn the stating ewitch tothe (OFF postin ‘As thro isa hazard that sparks wil be generated, ahvays do as follows. 1'Do not let tools or ether metal objects make any contact betwoen the battery terminals. Do not leave tos or other metal objects lying around near the bata. '# Always disconnect the nogative © termina ground side) fest ‘aon removing th battery: whan insaling the battery, con ect the postive ® termina st and connect the ground as. Tighten the batery torminals sacurely. ‘+ Flammable hydrogen gae i generated when the bater i charged, so remove the battery om the chases tako i to 8 svllventlted place, and remove the Battery cape before charging ‘¢ Tiohten the battory cops securely Install the battery securely to the determined place.‘STARTING WITH BOOSTER CABLES any mistake is made in tho method of connecting the booster cables, may cause the battery to explode, 20 always do ae follows, "When starting witha booster cable, carryout the stating operation with two workers one worker Siting inthe operato’'s seat sn the other working with the battery) ‘= Wen starting from anether mechine, do not alow the two machines to touch, ‘= When connecting the booster cables, tun the strtng switch OFF for both the normal machine ‘and problem machine, Therois a hazard thatthe machine will move when the powers connected. ‘¢ Be sure to connect the positive @ cable First when insaling the booster cables. Dleconnect the ‘round oF negative © cable (ground side) fist when removing thet ‘* When removing the booster cables, be careful not to let the booster cable clips touch eachother forte let the clips touch the machine ‘Always wear safety goggles and rubbor gloves when starting the engine with booster cables, ‘¢ When connecting @ normal machine to a problem machine with booster cable, always use & normal machine with the same batery voltage ae the problem machine, ‘For detals ofthe stating procedure when using booster cable WITH BOOSTER CABLE Inthe OPERATION section, 500 16.4.3 STARTING ENGINEA WARNING: Faire to foiow thet stay precutons may lead 7.8 TOWING WHEN TOWING Serious injury oF death could reult fa disabled machine is towed incorrect or Hf there i in the selection o inspection of the wire rope. ‘When towing, always use the method given in 16.3 TOWING THE MACHINE in the OPERATION = Always wear thor gloves when handling wite rope. + During the towing operation, never stand between the towing machine end the machine being towed, {© Novor tow a machine on a slop.8. PRECAUTIONS FOR MAINTENANCE 8.1_ BEFORE CARRVING OUT MAINTENANCE Lwannne Tas ‘Always attach the “DO NOT OPERATE” warning tag to work fsquipment contol lever in th operator's eab to alert others ‘that you are performing service of maintenance on the me chine, Attach adaltional warning tage around te machine i necoseary. ‘Warning tag Part No. 09963-81640 Keep this warning tag in the tool box while tis not used. i ‘ther is nt the tool box, Keep the tag in the operation manual pocket ‘If othors stat the engine, oF touch or operate the work ‘equipment contol lever while you are perlorming sarvion of maintenance, you could suffer serious injury or property damage. KEEP WORK PLAGE CLEAN AND TOY Do not eave hammers or other tots ving around inthe work pace. Wipe up al ree, olor other substances that wil cause you to lip Aways keep the work place loan the tdy to eneble You to Carry out operations safely Ifthe workplace is not kept clean and tidy, there isthe danger tht you wil rip slip, oral over ‘and injure yoursl. {APPOINT LEADER WHEN WORKING WITH OTHERS \Whan repairing the machine or when removing and inaling the work equipment, appoint a leader land follow his instructions during the operation, When working with others, misunderstandings between workers can le to serious accidents 120‘STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE ‘© Stop the machine on fim, level ground slides, or flooding. «+ Lower the work equipment tothe ground and stop the engine a ca place where tore Ie he hatard of fling rocks, land t wy we, STOP orci ‘After stopping the engine, operate bad tit cylinder control fever 2-3 times fully to the RAISE and LOWER postions to ‘eloase the pressure inside th hydraulic circu, than set safety Took aver to the LOCK positon. 1 Put blocs under the trackto prevent the machine from moving.For teosone of ese, avays 8. PRECAUTIONS FOR MAINTENANCE ton tse sae recov 8.2_ DURING MAINTENANCE [TWO WORKERS FOR MAINTENANCE WHEN ENGINE 16 RUNNING To prevent injury, 60 not carryout maintenance with the engine running. f maintenance must be carried out with the engine running, cary out the operation with at leat two workers sd do a8 follows 1 One worker must sways stn the operator's sest and be eady to stop the engine at any time, All workars must maintain contet withthe ther werkes. ‘© When carrying out operations near the fen, fan bet or other rotting pars, there is @ hazard of being caught in the part, so be extremely caroful ‘Never drop or insert tools or other objets into the fan or fan belt Parts may braak or be sent fing ‘Set safety lock lver to the LOCK position ‘# Do:not touch any contol levers. f any control laver must be operated, aways give 2 signal tothe tether worker to warn them to move fo a sale place, Si, [PROPER TOOLS Use only 01s suited to tho task and be sure to use the tools correctly. Using damaged, low quality, faulty, makeshift toole or improper usa of the tools could aes serious personal injury. 12ARTES Sais, Clow mere stew preswtons may tg. pAecAUTIONS FOR MAINTENANCE (Penson. ‘Only authorized personnel can service and repair the machine, Do not allow unauthorized personnel into the area. if necoscary, employ an observe. -(armacrments ‘© Appoinnta leader before starting removal orintllaton ope tions for attachments 1 Place attachments thet have bean removed from the machine in stable condition so that thay donot fl. And take stops to prevent unaushored prosone from entering the storage of, [WORK UNDER THE MACHINE (9 TF is necessary to. go undar the work equipment or the ‘machine 19 carry ovt service and meintenance, support the ‘work equipment snd machine securely with Blocks and stands “Srong enough te support the welght of the work equipment «iis extremely dangerous to work und shoes are off the ground and the ‘the work oquipment. If the cont {ako, of tore fo a hazard to the hydraule line, the. work favipment oF the machine may suddenly doscond. Ths Is freely dangerous. Never work under the machine i the Iachine fs not propery supported by blocks oF stands. the machine the wack Lowes Fhe noise from the machine Isto loud, t may cause temporary of permenent hearing problems. \When carying aut maintenance ofthe engine nd you are exposed to noise for long periods of Smo, Wear ear covers of ear plugs while working.|. PRECAUTIONS FOR MAINTENANCE IECAUTIONS WHEN USING HAMMER Wien using a harm, pins may fly out or metal panicles may be scattered. This may load to serious injury. Alwaye do 22 ‘owe © ifhard meta parts such a pine, tooth or cutting edges are hit aa wits harman thers dagorthacpaces ightbescatred She couse sion nur. anys weary goggles gloves 2nd Star protective sein Z «wen iting ins Father pas, tare ange tat kan = places might be sont riying ena tjure peopie Inthe euround- ing area. Always check that there fsa one in the surrounding ‘Hf ping ar hit with strong fore, there isa hazard thatthe pin ‘may flyout and injure people in the surrounding area REPAIR WELDING: Wielding operations rust always bo carried out by a qualified welder and ina place equipped with ' proper equipment Thee s a hazard of fie or elecrection when carrying oxt welding, re Never flow any ungualified personnel to carry out welding. [REMOVING BATTERY TERMINAL \Wen repairing the slecical system or when carying out electrical welding, remove the negative © terminal ofthe battery to prevent the flow of current, {SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION. ‘© Groase Ja pumped into the track tension adjustment system tndor high pressure. ifthe specinied procedure fr maintenance isnot followed when ing adjustment, grease drain lug @ may fy out and cause Serious injury or propery damage ‘When loosening grease cain plug @ to loosen the track tonsion, never loosen it more than ane turn, Loosen the grease fin plug slow — «+ Noverputyourtnc, hands, ft oranytherpartotyoursedy at sae aahWARING: Faure to follow these safety precautions may ead As eet ‘2. PRECAUTIONS FOR MAINTENANCE [00 NOT DISASSEMBLE RECON SPRINGS The ert sng eerly hued ea he neat onthe er, conta a pring und high sure 0 If tis disassembled by mistake, the spring wil ly out and cause serious Injury or ven oath, Never desssomble the reco erin. Te hfe sere avayr ender imal press, When repecing or eli pp or roan anya cst hat th rare ne rou creat ho bees awed teckel weaer petra i oad te satus nyo rope Seroe seater oe SWE od et neeion ons BankcntePer ate tin epee bore Saning £0 is sve “STOP ENGINE SetORE CARRYING OUT NSPECTION AND MATE HENCE ‘Bont cry ot pesto o fester os wi he cea ae pret, + there any oskage rom the piping or hoses the surrounding “real be wet, 20 check for evacks Inthe piping and hoses and for swelling n the hoses. \Whan carry out Inspection, wear safety glassas and leathor slaves. 1 Theresa hazord that high-pressure oll leaking from smell holes may penetrate your akin or causa badness fe eontate your eyes dirty. Hf you ae hit by a jet of high-pressure oi! and ‘Suffer injury to Your skin or ayes, wach the place with clean water, and onc a doctor immediately for medical attention. HANDLING HIGH PRESSURE HOSES: «© Tol or fue oaks from high-pressure hose, it may caus fo or defective operation, which may lead to serous injury oF property damage. Hany loose bots are found, stop work and tighten to the specified torque, f any damaged hases are found, stop operations laxmedltaly and contact, ‘your Komatsu distributor Replace the hose if any ofthe following problems are found. ‘Damaged or leaking hydra fiting. ' Frayed or cut covering oF exposed reinforcement layor of wi ' Covering swollen in places. {Twisted of crushed movable portion {Foreign material embedded In covering. To prevent pollution, pay careful attention to the method of poring of waste materiale ‘Always put ol drained from your machine in containers Never drain ell directly onto the ground or dump into the sewage systom, rivers the S63, of lakes. ‘© Oboy appropriate laws and regulations when disposing of ‘armfol objects such ol fuel caolant, solvent ters, end | |_ batteriesreasons of sxfey, aways {PRECAUTIONS FOR MAINTENANCE ety precaufone IT ar conditioner refrigerant gots inte your eyes, may cause blindness; iit touches your skin it ‘may cause frostbite Never touch refrigerant, coMPRESsED Am ‘# When carrying out cleaning wth compressed sir, tare ie hazard of serious injury or property damage caused by fying particles, ‘¢ vunon using compressed air to clean elements or the ratiator, always wear safety goggles, dust mask glove, and other protective equipment. (PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Im order forthe machine to be operated safely for a longtime, it is necessary to add ol and to carry out service and maintenance at periodic intervals. In order to further ineease safely, Components with a strong relationship to safety, euch as hoses and seat bolt, most be replaced at perio intervals. Replacement of safety crcl parts: See 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS. Tho material of these components natutlly changes over time, and repeated use causes Seterioration, wear, and fatigue. Asa recut there isa hazard that these components me fll and ‘cause serious injury or property. damage. Its afeut to judge the remaining ie of theve ‘components from external Inspection or the fealing when oporting, 20 slvays replace them at the specied interval ' Roplace or repicsofety teal pars If any detect is found, even when they have not reached the time specifi interval 1269. POSITION FOR ATTACHING SAFETY LABELS ‘Always ka9p these labels clan. If thoy are lost or damage, attaching them again or replace ther with anew labo. seni ter bl in ation othe ey able eta follows, so han them ne sare Safety abels may be avalible in languages oer tan English To find out what label ja comtact your Komatsu dletrbutor. 9.1 POSITION FOR ATTACHING SAFETY LABELS9. POSITION FOR ATTACHING SAFETY LABELS 1. Warning before operating machine 3. Waring for leaving operators seat (osesr-Ansen) (oaese-B064%) Warning sig, re ey Read the Operation and Maintenance» Manual before operating, main- taining, carving out ds- assembly, assembly or transportation. of this machine. ] } 2. Warning before moving In reverse 4 (ose02"80750) (03653-A0481), A ® tre ison Recs Warning for hot water hazard the angie emt peraing igh) tem rau. Sear 2 Fgh fempersure a owing Up rom te radiator ot Paral, fase powona! ny Seddon. Never ere ter (Bor capo Marie {arco ler wien cot of sat heh teroer5. Waring fads wok enon 2. cauon engine rning (coerce ‘caeraat | org cau 8 fs mune co a sp. tr [sae sl << | BSE track shoe tension and maintenance e y || Ses Sinomen! sores tamus'and cone | See oe causa i Gut th coe net a od when oserng A tact ion stop 6 wanng for bat cable 5. caution fr aproch when machine moving (oso Aone (ene be rr cng tp Br Seen thei De net 98 dose ma Theme ea © Read te opron ad ve. ea et ten hate ta ” Sings wes Corin cat trod en hen, EB9, POSTION FOR ATTACHING SAFETY LABELS 9. Warning for use of eoat bolt (098 9812040) ‘CAUTION, ALWAYS USE SEAT BELT WHEN OP. ERATING MACHINE. ALWAYS CHECK CONDITION OF THE SEAT BELT, THE CONNECTING BRACKETS AND THE TIGHTENING Botts. BRAKE PEDAL TRAVEL WITH OPERA TOR'S BACK AGAINST SEAT BACK. AFTER. ADJUSTING THE HEIGHT, FORE AND AFT POSITIONS OF THE SEAT, TIGHTEN THE TETHER. GELT BEFORE SITTING IN THE SEAT. 10. Warning for ROPS (09620-30200) 9.2 CONTENT AND USE OF WARNING PLATES. 1." Warning te prevent operation during maintenance (0996s-A1640), Hang this warning plate on the controls in the operator's compartment 120OPERATION10. GENERAL VIEW 10.1 GENERAL VIEW OF MACHINE papers lade Blade tit cylinder Blade lit cylinder cab Ripper tt eyinder Ripper shit eytindor 7. Mt 8 Sproctet frame shoe’ 8. Track tt10. GENERA. VW 102 GENERAL VIEW OF CONTROLS AND GAUGES 2. Cigarate lighter (machine equipped with cab) 3. Ashtray 4 Ar coedtioner contro! panel . Fual contol lever 6. Safty lock lever (or directonel and gear shit lever) 7. Stocring lever 18. Working lamp, 3, Brake pedal a mn 11. Blade contol lav 3 blade control lever) 12, Safety lock lever 15. Hoad lamp stitch 1. Working lamp switch 1. Car stereo 1: Stating switch 18. Finpullor contol switch 20. Safety lock lover (or ripper contol lever 21. Hoan ewteh| 22. Safety lock lever (or brake pedal) 25, Reom lamp switch 24 Lamp saith 25. Wiper switch 2a1 7 Engin oil pressure monitor 2 8 Service metor 2 8. Power tain oll temperature monitor 4 Engine cooling water tamperature gauge 10, Preheating monitor 5. Rodistor coolant level monitor 11 ir cleaner clogging caution monitor 5 Charge mentor 12. Engine cooling water temperature monitor 2411. EXPLANATION OF COMPONENTS: Tho folowing is an explanation of the doviees needed for ‘operating the machine, “To cary out suitable operations correctly and safely, itis impor- tant to understand fuly the methods of operating the equipment and the meanings ofthe di 11.1 MONITOR PANEL 25.11. EXPLANATION OF COMPONENTS 11.11 A: CHECK ITEMS BEFORE STARTING Nomice ‘When carrying out checks before starting, donot simpy rely on the monitor. Always refer to the periodic malntanance Kem or “12. OPERATION" to carryout the checks. Park the machine on level ground and check the monitor lamps. Confirm that these monitor amps light for about 3 seconds ater ‘the starting switch is tumed to ON. Hany monitor lamp dose not Hight, ask your Komatsu distributor to inspect I ‘eal tS any abnormality, the appropriate monitor amp wt ‘Chock the location where the monitor lamp is lashing, and carry cout the checks before starting. When the engine started, these monitor lamps wil ‘it thore are abnormales. off even 1. RADIATOR COOLANT LEVEL MONITOR ‘This monitor indicates alow radlator coolant lave. tthe monitor lamp flashes, check the eoolant level nd ade water a8 eequied, 2611.12 B: CAUTION TEMS “a warnune {this monitor lamp lashes, repair It immediatly. ‘norice Park the machine on level round and check the monitor lamps. Confirm that these monitor lamps igh for about s seconds afer the starting switeh is tumed to ON. H any monitor lamp does not IM, ask Your Komatsu dstlbutor to inspect ii the ‘abnormality occurs while the engine is running, the appropriate monitor lamp will flash to ndicte the abmorm Even i the monitor lamp flashes, the machine can operate, but It should be repaired as soon as possible. 1. CHARGE MONITOR “This monitor indicates an abnormality inthe charging system ‘white the engine is running Ifthe monitor lamp flashes, stop the engine and chackthe V-belt tension any abnormality Isfound, e818, TROUBLESHOOTING.” 211. EXPLANATION OF COMPONENTS 11.13 C: EMERGENCY CAUTION ITEMS. “A wanna: any monitor lamp flashes, stop the Idling speed, and repair it immediately. onic Park the machine on level ground and check the monitor lamps. ‘Conti that these monitor lamps ight for about 3 seconds tor te string switch is tured to ON. Hany monitor lamp doesnot has Your Kometa ditibutor to inapect ft “shi any sbnormotty secure wile the engine x running, the spproprite monitor lamp wl ash and the alarm buzzer wil sound intormieonty at the same tine. run tat alow nin 1. ENGINE OIL PRESSURE MONITOR ‘This moritor warns that the engine lubricating oll pressure has ‘ropped. Ifthe monitor lamp Mashes, stop the engine and check the ol REMARK ‘The amp romains lighted up when the stating switch is atthe (ON postion, and goes out when the engine ls started2. RADIATOR COOLANT LEVEL MONITOR This monitor Indietes low radintor colant level. Ifthe monitor lamp flashes, stop the engine, check the coolant level and ada water 2 require. | 3, ENGINE COOLING WATER TEMPERATURE MONITOR ‘This monitor indeates 2 sein the cooing water temperature, = When the monitor lamp flashes, stop the machina and run the engine atthe low ling speed until the green rango ef th engine water temperature gauge lights 4 POWER TRAIN OIL TEMPERATURE MONITOR "This monitor indeste ale inthe ol tamperature ofthe torque ‘When the monitor lamp flashes, sop the machine and run the fengine atthe low dling speed until the green range of the power v train ol temperature gauge lights. 5. AIR CLEANER CLOGGING CAUTION MONITOR IW the ir closner element clogged, the monitor lamp ashes. ‘Stop the engine, chack the air cleaner lament and clean i 2911. EXPLANATION OF COMPONENTS 11.14 D; METER, LAMP Nomice With the engine stopped, turn the starting switch to the ON position and check that the gauge and monitor forthe engine water smperature gauge, power train oll temperature gauge, and fuel ‘gauge fight up. they do not light up, please contact your Komatsu distributor for inspection ‘This group consicts of engine water temperature gauge, power ‘rain ll temperature gauge, fuel gauge and service meter kay = 1. ENGINE COOLING WATER TEMPERATURE GAUGE “This gauge indiestos the temperature ofthe cooling water, ‘tthe temperature is normal during operation, the green range wil ‘ite gine water temperature monitor lamp will sme time. If this occurs, stop the machine and run te engine ata low idling speed unl the green range lights 2. POWER TRAIN OIL TEMPERATURE GAUGE ‘This gauge indicates the ol temperature af the torque converter outer. If the temperature fs normal during operation, the green range will ght the red range lights during operation, the alarm buzzee wal sound and the powar tain oll temperature monitor lamp wil fash tthe same time this occurs, stop the machine andrun the engine ‘18 low fling speed untl the green range lights, Nomice HF the powertrain oll temperature gauge frequently goes into tho red range, shift the wansmission down one postion fo reduce, ‘the load on the power tran during operations 2103. FUEL GAUGE This gauge indicates the amount of ful in the fuel tank. thre |s enough fuel Inthe tank while the engine is runing, the green ‘ange lights the red range lights, thors toss than 802 (21.12 US ‘921, 17.8 UK gall of ful in tho tank ‘When the red range lights, add fk REMARK "The dleplay ie not proportional tothe remsining amount of fu 4. PREHEATING MONITOR ‘This monitor tamp Indieates th pre-heating time required when string the engine at an ambient temperate below 8. monitor lamp lights when th starting switch le turned to EAT (0! postion and fashes tht the reesing fe completed {The monitor lamp wil go off ater about 16 seconds) 5. SERVICE METER ‘This meter shows the total operation hous of the machine. The service meter advances while the engine fs running ~ oven if the machine ls not traveling Set the perile maintonanco intervals using this display. ‘When the engine is running, the green pilot lamp atthe top of the meters flashes to inaioate thatthe meter I advancing. Moter will advance by 1for esch hour of operation regardless of the engine speed, Ww | J“1. EXPLANATION OF COMPONENTS 11.5 E: SWITCHES 1. sraRtING swrTcH ‘This switch ie used to star the engine. OFF) Fa 7 loiontsns postion, Hoe of ac creas | Pg on «) Charging and electric devin circuits activate, Keep key at ON ster starting. start (@) Zt thi ky poston, the stating motor wil rank the engine fleas key mmecistay sar sang position when starting in cold wosthe Ifthe kay is kopt et the HEAT poston, the eoctrical heater wil become hat and the preheating monitor wll light up. ‘When the preheating monitor flashes, release the key immedi sal Reloase the key to alow it to roturn automatically to OFF (() and then, without elay turn it to START (11, EXPLANATION OF COMPONENTS 2. HEAD LaMP SWITCH ‘This switches on the head lamps and the pane! lamp. (ON postion: Lamp lights up (OFF postion: Lamp is out 3. WORKING LAMP/REAR LAMP SWITCH ‘This switches onthe ight nd et fonder lamp and te ear lamp. ON postion: Lamp tahts up (OFF position: Lamp Is ut{1 EXPLANATION OF COMPONENTS 112 LAMP H// HH) | VN [fy 1. WARNING LAMP When the monitor tamps of the 8 CAUTION ITEMS and C EMERGENCY CAUTION ITEMS. on the machine montor system fashos, this warning lamp flashes et the same time the lamp flashes, check the monitor panel Yo locate the problem. ‘Wien the monitor lamp inthe C EMERGENCY CAUTION ITEMS, ut) ‘ash, the alorm buzzer sounds intermiteny esos11. EXPLANATION OF COMPONENTS 113 SWITCHES ™ nen the button atthe rear ofthe blade contol lover atthe right sida ofthe operator’ seat Is pressed 2. ROOM LAMP SWITCH (MACHINES EQUIPPED WITH CAB) “This lights up the room lamp. ‘ON postion: Lamp lights up ‘OFF postion: Lamp i out11. EXPLANATION OF COMPONENTS 3. ADDITONAL WORKING LAMP SWrTCH (MACHINES EQUPPED WITH CAB) (IF EQUIPPED) ‘This Is used to turn on the addtional working lam, [AS ROPS roar lamp and ripper lamp switch 8: ROPS front lamp switch PER SWITCH (MACHINES EQUIPPED WITH CAB) IFEQUIPPED) This activates the wipers The wiper switches areas fellows. Rear window @ Right door © o ‘This is algo used asthe window washer swith, ‘The switch is operated as follows, ‘+ Window washer only Keop tho ewitch pressed tothe OFF position to spray out water. © Wiper only I this ie switched on, the wiper wil start, © Wiper and window washer IW this fe kept pressad to the ON postion while the wiper is working, water wil be sprayed out, a.5. CIGARETTE UGHTER This is used to light eigarotos. When the cigarette lighter fe pushed in, i will return to its ‘original postion ater a few seconds, eo take lt ut to light your aarete "The cigerette ighter can be used ae the power supply fr othe ‘equipment. orice "This cigarette lighter is 24 V.Do not use it a the power source for 12 V equipment. ‘The capacity ofthe cigarette lighter is 120 W (24 V x5 Al. 11, EXPLANATION OF COMPONENTS an11. EXPLANATION OF COMPONENTS 11.4 CONTROL LEVERS, PEDALS 1. FUEL CONTROL LEVER This is used to adjust the engine speed and output. © Engine stop: Push lover fly to font © Low fling! Pull over back rom positon @ to position where ‘fort changes (becomes Iighter) ® back flly from positon Fl hot: Pui o 2, DIRECTIONAL AND GEAR SHIFT LEVER ree reverse ‘use to stor the machine, I the lever ls moved partally in the dection of turn, the machine, the etaering elute Is ‘isengagod and the machine turne grad te applied and the4. BRAKE PEDAL A warnine Bo not place your foot on this pedal unnecessary. Depress the pedal to apply the right and lft brakes, Hw stig lover ule out haeamy andthe take padal | CS onthe some side otha ver Gpresaasthe same time tbe | SV Stacing wil ate plot tan = 5. DECELERATION PEDAL eB A warns: a ‘De met place your foc on this pedal unneonsry. 2 Bhatt ts ct arate tig sah ievciraa eipetatencem eran || 3-7 seta yd Sane cle Sopot A ‘ecalerator pedal. “This pods! is used when reducing the engine speed ond when stopping the machine. When switching between forward and reverse, or when stopping the machine, use this pedal to reduce speed. dal is dopressod fully tothe stopper, the engine 6. SAFETY LOCK LEVER (FOR BRAKE PEDAL) A warning ‘When the machine is parked, slays set the safety lock levers 10 the LOCK positon “Thi lover ls used to lock te brake pedal ‘To lock the brake peda, pul the lock lever, then depress the brake podal strongly and lock it securely in position “Tareloace the brake pada, depress the brake pedol and push the lock over11 EXPLANATION OF COMPONENTS 7. SAFETY LEVER (FOR DIRECTIONAL AND GEAR SHIFT LEVER) “A wannane. When the machine fe parked, slays set the safety lock lovers 10 the LOCK postion. ‘This lover is used to lock the directional and speed lever. Set the directional snd speed lever tothe newtal postion, then lower the lever ta lock in position, 8, SAFETY LEVER (FOR BLADE CONTROL LEVER) A wannina: '* When leaving the operators compartment, set the safety lover securely to the LOCK postion Wthe Blade control and ripper control levers are not locked touched by accident, K may lead to serious injury oF damage. «Ifthe safety aver isnot set securely to the LOCK positio lock may not be spied ‘Check that ts In the position shown in the dagram. ‘© When parking the machine or wen carrying out mainte: nance always lower the blade and ripper te the ground, then ‘et the safety lever to the LOCK postion. This safety lver Isa device to lock the blade control lave, \Whor ti set tothe LOCK postion, the TILT, RAISE, LOWER, and FLOAT cannot be operated, ‘Lower the lever to lack in postion, socal TIM ee11, EXPLANATION OF COMPONENTS | SAFETY LOCK LEVER (FOR RIPPER CONTROL LEVER) “A warwivs: ‘When loving the operator's compartment, ast the safety lock securely tothe LOCK poston the contol lever snot locked, and it Is touched by mistake, this may lead toa serious accident. 1 Ifthe safety lock e not placed securely inthe LOCK position, the contral laver may not be properly locked ‘Check thatthe situation ts as'shown inthe diagram, ‘© When parking or servicing the machine, be sure to lower the Dla and ripper and set the safety lock Inthe LOCK postion. “This devie is used to lock the ripper control lever. \inen itis sett the LOCK postion, the TILT, RAISE, and LOWER cannot be operated, Lower the lever to lack in pli, 10, BLADE CONTROL LEVER This lover fs Used to raise oF tit the blade iting contol tay a Stow AS Sides nhl in ie postin @ tower ge & toe Blade will mave feely ozording to extemal force. REMARK ‘© Whon released from FLOAT poston, this lover will ot rturn to HOLD position, o it must be moved back by hand. '¢ Set the blade contro! laver to the HOLD postion whon starting {he engine. The engine wil not stat Ifthe biade contro le Is at the FLOAT poston. “Titing contr @ LEFT TILT: @ RlGHT TiLT (eg) ‘orice ‘© The lever should bo returned quickly to HOLD postion atthe end of tit evindor str ‘s Dornot operate titing when blade feat top or bottom poston {After etopping the engine, I the blede contr ever operated to the LOWER pston, the work equipment will go down under Ie own weight wm {i t eS Ay 221{1 EXPLANATION OF COMPONENTS 111 RIPPER CONTROL LEVER This is used to operate the ripper. @ PASE (31 © HOLD (5): Ripper is stopped and held in the same positon © Lowen, 5) Keop switch ( In the cantar of the knob pressed down and ‘operate the ripper to change the ripper angle |@ Decrease ripper angle: Ripper angle (a) becornes smaller. |® Increase ripper angie: Ripper angle (a) becomes larger. 12. PIN PULLER CONTROL SWITCH (IF EQUIPPED) ‘This is used to operate the pin puller. @ PULLOUT. Pints pulled out {B PUSHIN: Pin ie pushed in 222118 POWER SOURCE None “The power from the cigarette lighter socket 26 V. Do not use thia'as the power source for any 12 V equipment. “The capacity of the elgartte lighter power source Is 120 W (24V xsal 11.6 FUSE BOX orice Before replacing 2 fuse, be sure to turn off the starting switch “The fuses protect the alectrical equipment and wiing trom burning out ithe fuse becomes corroded, or white powder can be the fuse fe loose in the fuse holder, replace the fuse place a fuse with another of the seme capacity © chassis Fuse box (le Installed inside the cover atthe front of the ‘console box on the right side of the operator's eab where the machine serial number pate is fx. '¢ Cab (machines equipped with cab) Fuse box @ is installed to tho top loft face ofthe operator's compartment inside the cab, 11, EXPLANATION OF COMPONENTS 2a{14 EXPLANATION 0F COMPONENTS 11.6.1 FUSE CAPACITY AND NAME OF CIRCUIT Fase box © Tr] Fons ey Sra Sa aoe Ib @| 16h | Fer amp, Monitor Arenson stl @ | Wea] Wontng ae ss ©) 160 _| pear me a @[ 6a [en @ | 16a | case Craon mp, Gaon baer @ | 168 — [ar onto Fuse box @ {machine equipped with eab) Ra Fas | i O| wa | Fonwnaor oer igananeas @| ma [Rar window vse eaBeGee @] 19a [tt dor wise @[ a ae oor wie oo ol = : @| a [Room ono @| 19a — [awe ior @] wa [ears 22611. EXPLANATION OF COMPONENTS 11.7 DOOR-OPEN Lock (MACHINES EQUIPPED WITH CAB) Use this when your want to keep the door hal 1. Push the door against door cath 0: The door ‘oor catch 2. To relesse the door, push knob @ at upper ofthe catch, This wil release the each, open, Be hald by the orice ‘When keeping the door open. fx it securaly ta the catch ‘Always close the door when traveling or carrying out opera- tions. Leaving the door open wil cause the door to break, ‘© Keep the door locked opan securely The door may swing closed because ofthe vibration. 118 BOX Peace use it ‘Do not us ito store tools or other heavy objects, 119 ASHTRAY, le ofthe operator's that you extingush the cigarette before losing the li 11.10 TOOL BOX '¢ This Ison the stop outside the let door ofthe cab, Use i for storing tools ‘+ The optional too! Box is onthe top surface ofthe engine hood infront of the cab.11, EXPLANATION OF COMPONENTS 11.11 CAR RADIO (MACHINES EQUIPPED WITH CAB AND CAR RADIO) 111.11.1 EXPLANATION OF COMPONENTS: 1. POWER SWITCH/VOLUME CONTROL/BALANCE CONTROL ‘Turn this knob clockwise, The “lick” sound indicates that the power supply leturmed on- Further turning ineeases the speakor Volume 12. BASS CONTROL SUDE-KNOB Slide this knob fo the right to incroaces the bass sound and to the lotto decrease the base. 9. TREBLE CONTROL SLIDE-KNOB. Sidenote ght entance igh equency soundand {o the let to suppress tigh frequency sound.EJECT BUTTON Push this button to ject the cassette tape. ‘casserte Doon Ingen cassette tape with the exposed magnetic tape sie facing to the night. FAST-FORWARD/REWIND /PROGRAM CHANGEOVER KNOB To fast forward the apo, push the button matching the draction of program indieation and to rowind, push the other button. To “top fast forwarding or rewinding ight press the button which it locked to cancel the operation. Tha systor wil then start playing the tape again normally. To change the program, press fhe fost forward and rewind buttone simultaneously, The direc tion of tape food will rovers MEMORY swiTcH Prose this bution to pret the fraquences of desired stations (Me flashes) ‘SEEK \When tho SEEK button is pressed, tho system automatically ‘searches fora receivable station, and automatically tops search- ing once a station is picked up. Loun Burton ‘This wich is used to operate the system at @ lower sound volume but with enhanced bass end treble sound. ("LOUD Ineation appears on display (2) 11, EXPLANATION OF COMPO VENTS1 XPLANATION oF COMPONENTS 10, AUTO-MEMORY When the "MEMO" buton is pressed, the system tunes tei to stations receivable in the area in which the machine I ‘currently located, one after another, and momorzes the froquen- los in Rs preset memory, all automaticaly. 11, FM/MMW/AM BAND SELECT SWITCH Pressing the “BAND® ewiteh changos over between FM, FM2, FMS and MWA) bands. Display 9 inciates the receiving band name and frequency. 12. DISPLAY Tho display Indicates the receiving fraquency when recsiving & ‘dio brondcast or th currant operation mode, 13, TUNE SWITCH (TUNER) Pressing the shaped TUNER button raises the receiving fr- ‘quency by 8 KHz in AM an by 0.1 MHz in FM for each press. Pressing the ¥-shaped TUNER batton lowers the receiving fe (quency similry. Pressing ether af these buttons continuously shifts the receiving frequency continuously. 14 PRESET SWITCH KEYS (One station esch in the FMI, FM2, FMS and MWIAM) bands, respectively, ean be preset foreach ofthese preset key (Refer to the socton “Presetng to selected stavons") 15, METAL SWTICH Prose the "MTL" button before playing @ metalic tape “NITL" indication appears onthe deploy. ™ gages) = 800"s) =D cy11. EXPLANATION OF COMPONENTS 11.112 METHOD OF OPERATION ‘Mathod of setting preset buttons 1. Ifyou aro playing a cassette, press eassate eject buton @ to stop the tape, 2, Select the station tobe proset. Uso FM, MW (AM) band selector button) to select MW (AM), FMT, FM2, or FMB, then use the ‘manual selector button to select the fraquency of the broadeast- ing station {3 Prose auto memory buton ©, 44 Prose proset button @ ofthe number to be peeset while MEMO ieMiaching. ‘The proset channel and frequency are diplayed and the presoting ie complete, 5. Repeat Steps 2 to 4 to prosetothor stations. 10" Use Steps 210 4 aio wien changing the setting of a preset switch to another station REMARK’ ‘© To liston to a prosot station, use FM, MW (AM) bond selector button {to select MW (AN) FM, FN2, of FM, then race the poset switch number to listen to the desired station, Fels possble to preset sk AM stations and 18 FM stations (FMI: 6, FMD: 6, FMS: 6). '© When the power fa disconnected, such as when the battery is ‘replaced, al the setings ae ist, so preset the stations again. ‘© reception of FM stereo ie weak the brosdessting sation i ar “way or you are listening in a mountainous are), te ception changes automatically from stereo to monaural o reduce ita forance. ifthe storeo broadcast becomes strong, the reception automaticaly return to stereo. Selecting stations manually Press the UP button of the mana selector button to move up {9 kHe (AM) or 01 Mr (FM) or the DOWN burton to move down 9 ke (AM) or 0.1 Miz (FM. Ifthe buton is kept presse, tho fe ‘quency will change continuously.Selecting station automatically ‘When the automatic slocion button fs pressed, a search willbe carried our starting from the lower frequencies and! moving up tothe higher feequencies. When station ie found, will sutomatcally stop at that station Listening to cassette tape 1. Sette cassette with the exposed ape on the rah side and push Into cacsete door ©. The tape wil automatically sar playing fF fthe artow Inaicatig tha ration of pay is pointing othe Fight thetop side is being payed, and ifthe arrows poling {0 the [oft tho bottom side fs boing played. © When the tape reachas tho ond it is automaticaly reversed ‘nd the other side starts to psy. 2. When finishing with the tape, press cassette eject button © to ‘automaticaly switch tothe radio broadeest. REMARK {© you insort a cassette when listening to the radio, he tape wil 1 Toswiteh tothe rediowhan listening oa caeotte, pres cassette ‘fect bution @ to stop the tape Reversing tape "When istoning tothe tape, poss both the «and -+» butons of FFIREWIPROG selector button © lightly. The tape will bo re versed, 220Fast ora rein “To fast forward the tape when it ls playing, press the button painting in the same direction as the movement of the tape (©. or-+- button) unt i locks. | © To rewind the tape winon iis playing, press the button in the |” opposite section to the movement ofthe tape (+ @ oF-¥-> B button ue locks Canceling fast forward or rewind ‘the fast forward or wind, press the button thats ot locked. The lock wil be released |e ithe tape ie fact forwarded or rewound fully, the tape wil start to pay aga 11.113 PRECAUTIONS WHEN USING ‘© For atety reasons, when operating keep the sound to @ level where you can enjoy the sousd but ‘tl hear the sound from outide vehicles. ‘¢twater gets insda the speaker case or ar radio (auto tuning) t may cause 2 serious problem, £0 do not lat water got on those pars. ‘* Do not wipe the knobs or buttons or any other parts with any solvent such as benzene or thinner ‘Always wipe with soft ry cloth fn cases of extreme dit, use aleahol on the eat). 2311. EXPLANATION OF COMPONENTS 11.12_AIR CONDITIONER (MACHINES EQUIPPED WITH CAB) @ @ © 11.12.1 CONTROL PANEL 1. INSIDE - OUTSIDE AIR SELECTOR SWITCH Use this ewitch to henge over the intake vente when heating or cooling the cab 2 inide se When this switch is tured tothe postion shown inthe diagram fon the right, the air Inside the cob fe recirculated. Use this position 1o heat or oo! the cab qucky or when the ouside sit fe cin Outside air \hien this switch is tured to the position shown inthe diagram fm the right, ar fs takon in form ouside the ab to cary out poling and heating. This poston Is used to bring in clan ait ‘rom outside or when fomoving the mist from the windows, 222VENT SELECTOR SWITCH Vent postions Air blows out to upper half of body ‘ir blows out to foot, ‘lr blowa to defroster at rear of cab ‘lr blows to detrster at font of exb ‘ic flows to feet cab defroster ‘When this ston s turned tothe postion shown inthe diagram fn the ight, the ow af alr from the alr conditioner le concen trated t0 the feet and the defrostre atthe front and rear of the cab, ‘Thi position is used to send a warm air low during winter. ‘The vent posions are B, ©, and &. ‘lr flows to feet, upper half of body, cab defroster \Whan this switch is turned tothe potion shown nthe diagram ‘onthe right the flow of ir from the si conditioner sant to the {oot, upper haf of body, andthe derostrs atthe font and reor ofthe cab, ‘This postion is used mainly for ventilation. ‘The vont postions are‘) @, (and Air flows to upper half of body ‘When thi ste is turned tothe poston shown inthe dlageam ‘nthe right, the Now ofa feom the ar condtloner Is concen ‘Wated to the upper half of body. This postion is sed to sand @ ‘00 ar flow curing summer. ‘Tho vent postion ie. 11, EXPLANATION OF COMPOVENTS 2a11. EXPLANATION OF COMPONENTS 3. BLOWER swrTcH “This switch Ie sed not only to control the flow of ai in coating {and heating, but also as the maln switch (2° Tho alt ow is contrellad la three ranges, High, Medium, and tow. ‘© When the switch is turned OFF, the power tine is disconnected ‘and the sie conditioner stops. 4. COOLER TEMPERATURE CONTROL SWITCH. ‘This witch control the ai temperature Inthe cooling operation and is siso used ne the cooler eich 12" The farther this switch is turned clockwise, the lower the tem- perature of the air coming out ofthe vot 1 When the switch i OFF the cooler switch wil go off and the cooling function wil stop. 5. HEATER TEMPERATURE CONTROL SWITCH ‘This switch controls the airtomperaturein th heating operation. © The farther this sultch ie tured clocking, the higher the tr perature ofthe air coming out ofthe vont 1 Won the switen isin OFF, the water valve wil be closed andthe heating funetion will stop. r@ HEATER11.122 METHOD OF OPERATING AIR CONDITIONER 1. coun ‘The cooler ie uted to coo! the inside ofthe cab, ‘© Cooling using inside alr When the control switches aro operated to the positions ‘shown in the diagram a refeshing, cool broeze blows oUt. Use this when particulary strong cooling is needed ‘+ Sat switches (, ©, and ( to the positions shown In the alagram. + Setenitches @ and @ to the desired postion. © Cooling using outside air Ifthe at inside the cabs cnt, set ar intake selector switch (to FRESH to take in air rom the outside. The postion of the other switches the seme es for coallng using Inside ae REMARK © Ifthe cooling is not strong enough, return ‘switch © to RECIRC. ‘Now fraon R134a fs used for the refrigerant 5 Tetihtning tors ote a conaons a ining ar as iow intake selector Tse abe “Tpeing ore Gain) Thr 22x18 | WE 2AS Nm = 25 gt 4510 BRT gd 1613 | T8218 in 108 Gicton 268 | 289249 Hn BBB thn, 2.9 23511. EXPLANATION OF COMPONENTS 2. HEATING ‘Tho hoator is used to cool the inside ofthe cab, 1+ Heating using inside a ‘When the control switches are opersted to the positions ‘shown inthe diagram, a warm breeze lowe out. Use this when particularly strong heating Is needed. + Set switches (0, ©, and @ to the postions shown in the siagram. + Sot ewitchos @) and © to the desired postion. © Heating wing outside air the air inside te cable ity, stale itake selector switeh (to FRESH to take in ai from the outside, The poston of ‘tho other switches isthe seme as for heating ving Inside i. REMARK 1 the heating ts not strong enough, return air intake switch © to RECIC. This gives more powertu hesing Sector ‘© Dehumidtying and heating IW eoclar temperature contol switch (is eet to the COOL position, dohumitied warm sis blown out ‘The postion ofthe other slices ie the eame a8 for heating using outside ae REMARK If this ie used in spring oF fll or during rainy weather when the sic inside the cab hur there Is no problem ofthe windows ‘misting up, and a pleasant tomperture can be obtained 29611.123. PRECAUTIONS FOR USING AIR CONDITIONER, ‘When cooling, change the air occasionally '¢ When smoking and using the cooler, the eyes may begin to hurt. Tenis happens, use coating at “OUTSIDE” for a short time to Cloar out srmako In the cab, © Whon using the at conditioner for along period, move the knob to RECIRC. » OUTSIDE once every hour to chenge the si Be careful not to overcool the cab, 2° ‘The cab should feel cool when entering there from outside (5°C or 6°C (FoF 11°F) lower than the outdo temperature. Irie not {900d for the heath to have the tomppature inthe cab to low, ‘Always give careful consideration to temperature regulation. |When using the cooler, make sure the hot water clreult is com- pletely stopped fit hot water is circulating In the heater, it is tike having a hot ‘water bottle Inthe ea [ways make sure the heater temperature knob i atthe OFF 1 Wien not using the heater for # long period, fully cose the hot Water outlet and init velves atthe engine water manifold and the engine oll cooler. 1.12.4 CHECK DURING OFF-SEASON ‘When the air conditioner snot being used, run the compressor at low speed fora few minutes every week to avold loss of ol. (Run the engine at low epeed with the cooler temperature contre knob at Low coo REMARK tn cold weather, do not run the compressor euddonly at high speed. This may eause fallure inthe compeessor. When the temper {Ure ig below 2 to G5°C (36 to 44°F, the low pressure cutoff ewitch functions to stop the compressor from running ven when the cooler tomparature control switch le turned on EXPLANATION oF COMPONENTS11. ExeLAWATION OF COMPONENTS 11.125 PROCEDURE FOR REPLACING RECEIVER Replace the recover every two years. ‘Ato replacing rade ompressor ol. When adding ol place the receiver at measure the amount of ol remaining inside the receiver. Add the same amount of fresh cl [Denso 6) to the receiver, REMARK ‘© Th replacoment interval may become shorter according to the canton of use 1 He receiver is used when the moisture absorption limit of the desiccant has been excseded, the tefrigerant circuit may become blocked and cause the compressor to break down, Precautions when replacing recaiver 1 Ifthe blind cover ofthe receiver I loft off for more than 16 minutes, the moisture in thea wil be Absorbed and the fe ofthe desicant will bo shortaned. If the blind cover is removed, connect the Piping immeciatay, then evacuate the ciruit and fil with refigerant. ‘© When removing the retrigerant from the refrigerant circuit, remave gradually from the low pressure side to prevent the oi from flowing out, 11.126 CLEANING AIR FILTER the air ft forthe FRESH or RECIRC sr intake becomes clogged, the cooling or heating capacity will drop. To prevent this, clean the alr iter with compressed ar ance a week For details of the cleaning method, see "24.2 WHEN REQUIRED" 1.12.7 CLEANING AIR CONDITIONER CONDENSER FIN the air conditioner condenser fins become clogged, the cooling capecty ie reduced. Clean the air conditigner condenser fins with compressed ai. For detalls ofthe cleaning method, soe "242 WHEN REQUIRED” 1.12.8 CHECK TENSION OF COMPRESSOR BELT AND VOLUME OF REFRIGERANT (Gas) tthe compressor bets loose or there slack of cfrigerant, the cooling performance wil be poor. For detlis ofthe maintenance method, see "24.2 WHEN REQUIRED”11.13 HANDLING ACCUMULATOR (IF EQUIPPED) A warn ‘On machines equipped with an accumulator, for a short time after the engine estopped the work equlpment control lever {emoved to the LOWER position, the work equipment will move ‘down under Its own weight. ‘After stopping the engine, always place the safety lever inthe Lock postion. ‘The accumulator i filed with high-pressure nitrogen gas, and it's extremely dangerous I lis handled In the wrong Way. ‘Always observe the following precautions ‘Never make any hole in the aecumulator or expose it to flame ‘tre. Do not wold any boss to the accumulator. 1 Whan daposing ofthe accumulator, ts necessary to release ‘the gas from the accumulator so please contact your Komatsu Setributer. “The aocumulator ie a device to tore the prastute inthe control cireuit ane when iis instal, the contol circuit ean be opersted fora shor ime even after the engine i stopped. Therefor, I the {ontrol lever fe moved inthe direction to ower the work equipment, tie possible forthe work equipment to move under ts own weight ‘Phe accumulator is intalled fo the position shown In the dla- ram onthe right 1.13.1 METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR 1. Lower the work equipment and stp the engin. 2. Aft stopping the engine, operate the contol lever fully to the front, rea lef, and right to release the pressure inside the work squipment cecal However, tha pressure cannot be completely removed, 60 when | ‘work equipment circu, loosen the sor slowly, and 20912. OPERATION 12.1 CHECK BEFORE STARTING ENGINE 12.1.1 WALK-AROUND CHECK A warninc: 1 Leakage of ol or fuel, oF ecumulation of flammable material round high temperature pars, such as the engine muffler oF ‘# Dornot get on of off the machine from the reer. Using this postion ts dangerous because Wtf easy to alip and You cannot be seen from the operators compartment. Always Use the handrall and step a the se when getting on or of the machine, When inspecting if the machin ie at an angle, move it to a horizontal place to carry out the check Before starting the engine, look around the machine and under tho machine to check for loose nut or bots, or leakage of ol us or coolant, and check the condition of the work equipment and hyeraulicaystom, Check ala for loose wiring, play, snd caletion ‘of dust at places which reach high temperatures. ‘Always cary out the items inthis section before stating the fongine each day 1. Check for dama linkage, hoses Check that there are no cracks, excessive wear, or py inthe work equipment, liners linkage, or hoses. I any abnormality Js found, repair play in work equipment, evlinders, 2. Remove dit and dust from around engine, battery radiator (Check theo te any cir or cust sccumulated around the engine ‘or radtor. Check also i there Is any flammable material (dead leaves, twigs, grass ot) accumulated around the battery oF high temperature engine parts, euch ae the engine muffler oF turbocharger. Remove al sch dt or flammable material 3. Check for leakage of water or oil around engine ‘Check that there s no leakage of ol from the engin or leakage ‘of water from the cooling system. H any abnormality ia found, ‘4. Check for oll eakage of oll fom power train case, final drive case, hydraulle tank, bose, joints Check that there is no ol iakage. any abnormality Ie found, repair the place whore the ali leaking, {Ghock tor akage oF ol from the undercover. Check the ground for traces of ol 240(Chock the undercarriage (track, sprocket, alr, guard) for dam- ‘age, west, loose bolts, of leakage of ol fom rollers IFany damage, woar, or ol leakage fs found, repair the problem and tighton the bolts. ‘Check for damage to handral loose bolts Repair any damage and tighten any loose. Chock for dams bolts ‘Chock that thore is no damege tothe pans, gauges and lamps any sbnormality is found place the para: Clean off any a fon the surface 10 gauges, lamps on instrument panel loose (check for damage to seatbelt and mounting clamps Check that tore fs no abnormality inthe seatbelt oF mounting clamps. there is any damage, replace with new parts. 2a12, OPERATION 12.12 CHECK BEFORE STARTING ‘Always crty out the items In thie longing each day tion before starting the (CHECK COOLANT LEVEL, ADD WATER A warn: Do not open the radar cap while cooling water Is ot, Hot water may spout out When removing eap release resator pressure ite by il by loosening cep slowly, thn remove the co. 1. Remove radiator cap (© and check that coolant fe above the bottom of the strainer as chown inthe diagram. ncessary, add water through flr of radiator cap (- 2. Alter adding water, stat the engine, check the water level again ‘ator a five-minute idling, and add ater f necessary, 3. After adding water, tighten cap © securely. Norice ‘Do not rely only onthe radiator water level monitor to check the coolant level (CHECK WITH MACHINE MONITOR 1. Tum staring switeh © to the ON postion, 2. Chock that all monitor lamps light up for 3 seconds, the panel lamp lights up for 4 seconds, the warning lamp lights up for 2 seconds, and the alam buzzer sounds for 1 second, REMARK. ‘Ifthe lamp do not light up there may be a failure or digconnee tion in the monitor, $0 pleace contact your Komatsu dstrbutor. ‘© When carrying aut the checks before starting, do nt ely only ‘om the monitor. Always cary ut al the em listed fr periods ‘maintenance, 2a DQ, oe ~ «< Sip ~ FON Z(CHECK FUEL LEVEL, ADD FUEL A warwne: When adding fuel, never let the ful overtow. This may cause fe. If you spl tel, thoroughly clean up any spillage. 1. Tur the engine starting switch tothe ON position and check the fuel level wit fool level gauge on the monitor panel ‘After checking, turn the sitch back tothe OFF postion, 2. Remove dipstick @ at inside cap © and wipe the ol off with a cloth. 3. Insor dipstick fully inthe ol ior pipe, then take tout again. 44. After competing work, il the fuel tank through ol filer por. 5. After adding We, tighten the cap secualy. | Fuel capacity: 600 # {158.4 US gal, 132 UK gal) REMARK breather hole on the capi clogged, the pressure in the tank vill drop and ful wil not flow. | Shen te ote rom se to tine [DRAIN WATER, SEDIMENT FROM FUEL TANK Loosen drain valve () at tha bottom ofthe ful tank and drain the sediment and water accumulated atthe bottom of the tank {gether withthe fu 2312, oveRATION ‘CHECK OIL. LEVEL IN ENGINE OIL PAN, ADD OIL 1 Opan the engine side cover on th lft ska ofthe chassis, 2 Romove dipstick G and wipe the oi off with a cloth. [3 Incort ciptick & flyin the ol filer pipe, then take ut again 4 The ol ove should be between the Hand L marks on dipstick so. tei os isbolow the L mark, add engine ol through ol fil If the ol is above the H mark, drain the excess engine oil from Grain plug @, and check the ol level again 6. tho oil fvel is coroct,tghten the ol flor cap eacurly and lose the engine side cover 1S Whon checking the oll level ater the engine has been operste, wait for atleast 18 minutes ator stopping the engine before checking ‘+f the machine is at an angle, make it horizontal before checking. When adaling oi remove the dipetick from the holder to release the alr inside the crankcase 2412, oPenarion ‘CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL {Remove dipstick G, and wipe the oil of wth a cloth 2. Insert lpstck fully in the oi filer pipe, then take it out agai, 3. The ail should be between the H and L marks on dipatck 3. Tee otlevel is below the L mar, add engine olthrough ol ler e. 4 ifthe cil is above the H ma fil Alter draining the ol, check the ol level agai. 5. tf the ol lave is correct, tighton the ol filer cap securely REMARK 'Wiien checking the oil ove, the machine satan angle, move ‘toa horizontal postion before carrying cut the chock. then lacsen dain plug © and drain ausCHECK BRAKE PEDAL TRAVEL ‘Drive the machine, depras the brake pedo, and check thatthe machine tops CHECK BRAKE PEDAL STROKE 1. Run the engine at low ling 2. Measure the stance thatthe brake pada travels when it opressed. ‘Standard stroke @: 160 - 170 mm (59-67 in) (operating effort 147 N (15 kg) 3. tthe brake pedal stroke i greater than the specified value othe braking effect is poor, ploaca contact your Komatsu distributor Tor adjustment. (CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL A warning filer cap, oll may spurt out, 60 stop ‘¢ When removing the ‘Fol has been added to above the H mark, stop the engine and walt for the hydraulle ol to cool down. Thon remove ‘rain plug ©, loosen drain valve 0), and drain the excess ol Nonice ‘Do not ad oll the lvel ls above the H ine. This will emoge ‘the hydraulle equipment and cause the oll to spurt out. 1. Lower the blade tothe ground, stop the engine and wait for about 5 minutos before checking ol level ol levels between Hand Ln sight gauge &. 2. th lovel fe Bolo the L ma e REMARK Winer inepecting, ifthe machine i horizontal place to camry out the chock 24d engine oi through ol ilar 246CcHECK ELECTRIC WIRINGS A warns. ‘Hf fuses are frequently Blown or H there are traces of short ‘ret on the electreal wiring, locate the cause and arry out ‘epi. 1 Accumulation of flammable material (dead leaves, twigs, ‘ase, ate) around the battery may eause fire, so. slays heck and remove such materia. ‘Keep the top surface of the battery clean and check the breather hole inthe battery cap. its clogged with dit or dust, wash the battery cap to clean the breather hole, ‘Check for damage and wrong capacity ofthe fuse and any sign of disconnection or short cruit nth otc wiring. Check alba for Foose terminals and tighten any loose pats. ‘Chock the wiring ofthe “battery”, “starting motor” and “alor- ator” carefully in particular \When carving out wa around chocks or checks before stating, ‘aways check I there ie any accumvlation of flammable mata ‘round the battry, and remove such flammable materla Please contac your Komatsu disvibuter for Investigation and correction of the ease.12 OPERATION ‘CHECK THAT LAMPS LIGHT UP 1. Turn the key of stating switeh to the ON poston 2 Turn the tront lamp switch ® tothe ON positon and check thet, the front lamp ight up 3. Tur the working lamp and roar lamp switch @ to the ON position and check that the working lamp and rear lp ight up 248 on &\ 2 oe12 ovtearion | ‘Hex HonN soUND ‘Wi Turm the tay of starting switch © tothe ON postion 2. ross the horn switch and check thatthe horn sounds.(CHECK BACKUP ALARM SOUND 1 Tun the key of stating switch © to the ON position the joystick to the REVERSE postion. The buzrer must sound immediatly. The buzzer wil entinue to sound ntl the joyetick |s' moved tothe NEUTRAL of FORWARD position. (CHECK SEAT BELT FOR WEAR OR DAMAGE ‘Chock the bot and mounting clamps, and if they are worn or \amaged, replace the sat bet ‘CHECK FOR WATER AND SEDIMENT iN WATER ‘SEPARATOR, DRAIN WATER ‘The water separator separates water mixed in the fuel. float Isat or above redline 0), ain the water according to the folowing Procedures 1 Loosen drain plug @) and drain the accumulated water until the float reaches the bottom. ‘rain plug Te sucked int fuel line when draining and water, be sure 1 bleed alr inthe same manor as forthe fut fier. Sea "28 EVERY 800 HOURS SERVICE"12 oPenarion 112.13 ADJUSTING BEFORE STARTING OPERATION ADJUSTING OPERATOR'S SEAT A warnins: ‘+ Adjust the seat postion at the beginning of each shift or when operators change. 1 Aajust the sent so thatthe brake pada can be depressed all ‘the way withthe operators back against the backrest. @ Fore-aft adjustment of soat Shree the seat to a postion where i s easy to jase the lever. Fore-aft adjustment. 160 mn (8.3 ln) (8 stages) ® Weight adjustment of seat ‘Turn knob @ under the seat to match the weight adjustment ale with your own Weight. ‘Tha weight can be adjusted within range of 5 ~ 120 kg (121 ye8 bh REMARK H you want to make the set ster, turn the weight adjustment to. lower welght; you want to make the seat harder, dust to @ higher weight. When operating on uneven surfaces, aust the seat to harder © Adjusting roetining angle Nomice ‘When recining the sest back to the rear, check the space behind, and sous to sultable position Pull up lover @ st the seatback tothe desired position, then release the lever to lock in poston, 26112. OPERATION @ SEAT ANGLE When lever © ie pulled up, I is possible to adjust the ange of the gaat ont. Hane) To rate the soat front, koop the lover pulled up and apply your weight to the seat bockrest. 2, To omar the seat front keop the lever pulled up and apply your woight ro the seat font 2. When lover is pulled up, it ls possible to adjust the ang of the soot back. (5 stage) 1" To raice the soa bac, keep the lever pulled up and stand up stat. 2. To lower the sest back, Keop the lever pulled up and apply Your weight tothe seat beck. © ADJUSTING VERTICAL HEIGHT OF SEAT Pull up levers © and Gin turn and adjust the angle. Atar adjusting, release the levee and lock tham. (Wertial adjustment amount: 5 stages, 60 mam (2.6 in) © SEAT ADJUSTING DIRECTION Move lever ® back to release the lock, then tun the saat tothe Fight by hand. itis possible to change the direction ofthe saat to the 15" position ‘Aftor changing the angle ofthe seat, return the lever eecuraly ‘and Fock tin poston, 1 Adjusting tho Saat angle tothe right i done to make i easier to ‘eazy out ripper operations or seraper towing operations. ADJUSTING MIRROR (Machines equipped with cab) {Looson screw () which is installed on the mirror, and adjust the best postion tee the mieror from th operas est Especaly for soaing behind the machine, adjuet im such a way that you can easily soe persons at the reer LH and RLM comers 26212 oPenamion 12.14 OPERATIONS AND CHECKS BEFORE STARTING ENGINE A warnine 1. Cheek that brake podal i lckad with safety lock lever. 2, Check hat stering levers the (neutral position andis locked swith safety lock lever 2 3. Chock thatthe blads is lowered on the ground and the blade ‘control lover i locked with safety lok lever 44 Check thet the ripper is fowerad on the ground and tho ripper contol lever le locked with safety Tock lover Loa | 28212 OPERATION 122. STARTING ENGINE 122.1 NORMAL STARTING A warn. ‘Check that there are no persons or obstacles in the surrounding ‘area, then sound the horn and start the engine. orice ‘Do not keep the starting mo ‘than 20 seconds. 1 the engine will not start, walt for atleast 2 minutes before ‘eying to start the engine again. ing continuously for more 1 Pull fuel control lover © toa litle postion past the low iting position towerd the fll speed position. 2 Insort the kay into starting switeh @ and turn the key to the START poston. The engine wil start. 3. When the engine stars, release the kay in starting switch @. The kay wil return automaticaly to the ON postion 25612.2.2 STARTING IN COLD WEATHER ‘When starting in low temperatures, do as follows. “A warns: [Never use starting a fluids as they may cause explosions. Nonice Do not keep the starting motor rotating continuously for more ‘than 20 seconds the engine falls to stat repest steps 2 and 3 after waiting for bout 2 minutos. 1. Pll ful control lever @ to postion midway between the low ialing and fll speed postions. 2. Tum thokay instarting switch @ tothe HEAT poston, checkthat| preheating monitor ( lights up, and hold inthis poston. [ter approx. 38 seconds, preheating monitor @) will Mash to ‘ndeate that prebesting is completed. 3. When preheating monitor @ flashes, turn tho key in stating fitch ©) 10 the START postion to start the engin. ‘4 When th engine starts, oleae the key in starting switeh ©. The ey wil return automaticaly to the ON postion.12 OPERATION 123 OPERATIONS AND CHECKS AFTER STARTING ENGINE ‘After starting the engine, do not immedistey start operations. First, cary out the following operations and checks. 123.1 BREAKING IN THE MACHINE Nonice Before operating the machine forthe fst time, check that there 'scoolant in the radiator. tthe machine is delivered with no coolant Ince rector tush the inside ot the racator thoroughly with tap ‘ater, then fl the radiator with coolant. ‘Your Komatsu machine has been thoroughly adjusted antested before shipment However, operating the machine under severe conditions atthe beginning can adversely affoct the performance and shorten the ‘machine Ite Be sure to break i 1 Inaleated by the service me During breaking in fale the engine for § minutes after starting it up ‘Avoid opertion with heavy loads or st high speeds. Avoid sudden stats, suddan aceseration, suden steering and fddan stops except in cases of emergency, 12.32 WARMING-UP OPERATION orice ‘Avold abrupt acceleration until warm-up run is completed, ‘Do not run the engine t lowing or high ling for more than 20 minutos. ‘+ Hit erecessary to run the engine a ing, apply load or run at a medium speed from time to time. '© engine ol pressure monitor © ashes and the buzzer sounds intermittently stop the engine and carry out inepection. ‘machine forthe lil 100 hours (as 1. Pull fue control lever @) to the midway postion between LOW IDLING and HIGH TOLING and run the gin at madlurn speed for about 5 minutes with no load 28612 ovenarion 2. After warm-up run is completed, check gauges and caution lamps for proper operation I any abnormally fs found, repair at light toad nti | _ terre paige as in he ren nae. gine water 3. Check that there is no abnormal exhaust gas color, nolse, oF Vibration. if any abnormality fs found, reps 1233 IN COLD AREAS Nonice 1 Avoid abrupt acceleration until warmup run is completed. ‘Do not run the engine at low iling or high fling for mare than 20 minutes. 1© Hit Te necessary to run the engine at ling, apply load or run [it's medium speed from time to time. ‘+ engine oll pressure monitor ©) flashes and the buzzer sounds intermittently, stop the engine and carry out inspection. 1. Pull fuel control lever ©) to the midway postion betwen the TOWIDLING and HIGH IDLING, and run the engine at medim | Masumepand rane nop “speed, and continue to run under no load for approx. 10 minutes. ES Wa 2. Operate blade control levar @ to the RAISE postion, then keep ‘the blade reise tothe maximum height and continue to relieve ‘the circuit for 10 minvtes. aly, operate blede contr lever @ and ripper contro aver to operate all the blade and ripper cyfinders several times. I the oll temperature In the work equipment Is not properly 4, there will bo a time lag in the response of the work ‘equipment and storing, 4 Ator warmup tun Is completed, check gauges and caution {amps for proper operation. I any abnormally Is found, repair t Continue to run the engine at ight load until engine water temperature gauge © fale within the gran range. 5. Chock that there i¢ no abnormal exhaust gas cole, nol vibration. It any abnormality i found, ropatr i 28712 OPERATION 12.4 MOVING MACHINE A wasnne: ‘¢ When moving machine, check thatthe area round the ma chine Is safe, nd sound the horn before moving. {lear al personnel from the machine and the ares. Coat all obstaces trom the path of the machine, Use extrome care when reversing the machine, Not there is an blind spot behind the machine ‘© When starting on slopes, slays keep brake pedal @) de- [ressed even after releasing safety lock lever. 1 When starting to travel up a steep hil, pull fuel contol lever {Daly to run the engine at fll throttle, and Keep brake pedal @ depressed. Place directional and gear shit lever (in st, ‘then move dlectlonal and gear shift lever Inthe direction ‘of travel and slowly relesse brake pedal to allow the "machine to move off gradually. When the machine has started ‘moving, release the brake pedal completely. 1. Set safety lever © forthe directional and gear sit lever tothe FREE postion. ress brake podal (then push sefety lock over to set ta EE positon. brake pedal @. ‘3 Shift directional and gear hit lever @) to the desired posh 258 tex | “he FSet safety lock © for blade control lover @ and ripper contol lever © tothe FREE position Operate blade contol lever @ and ripper contol aver @ tothe RAISE postion, raise the blade and ripper 40 s0em (15.8~ 19.7 In from the ground Pll fol control lever to increase engin Depress decslerator pedal ©. ‘engine speed. 25912, orenxrion 125. SHIFTING GEAR “There is no need to stop machine to shit gears ‘Set the directional and gear shit lver Inthe desired postion to shit gear 126 SHIFTING BETWEEN FORWARD AND REVERSE A caution. ‘There is no need to stop the machine even when switching ‘between FORWARD and REVERSE, To Increase safety, operator comfort, and the Ife of the trans mission, leave the engine running st full speed, and always, dapross the decelerator pedal to lower the engine speed. 1. Depress docslorator pedal @ to reduce the engine speed. 2. Shift directional and gear shit lever (to the desired position 3. Rolease deceloratr pedal 10 raise the engine speed 26012 OPERATION 12.7 STEERING MACHINE A warnive: ‘Avoid as much as posable tuning the machine on a slope. ‘The machin wl endo lp sideways, Parteler care shou be taken on soft o cy land. « Nover make a pivot tum thigh speed 127.1 NORMAL TURNING ‘Tot the mach se to tur, hile traveling, ul staring lever (Don the ‘© Turning gradually to left while raving forward Pull the LH. steering over halfway (tothe detent. The steering cluteh wil be disengaged, allowing the machine to make gradual fot urn REMARK "To mako 2 gradual right turn, manipulate the RH. storing In the same manner as desribed above. © Making sharp turns to left hile traveling forward Pull the UH. stowring lever all tha way backoard. The storing ‘lutch wll be dcengoged and the stering brake will be appli. REMARK "To make a pivot right turn, manipulate the RA. stering lever In the same manner as described above.12.72 TURNING WHILE DESCENDING A SLOPE “A wanninc: (On steep downhill topes where the machine may travel under its own weight, oF on downhil slopes where fis being pushed bby a towed machine, the machine will ster in the opposite rection, 20 do a follows, ‘© Making gradual turns to left while traveling forward Pall the Ri. steering lover haltway to ts stroke end. The ma- nigel moke a gradual lft turn leomnpensatonstowrng), REMARK TTomake 2 oradusl right turn, manipulate the LH. steering lever inthe samo manner as described above. compensation steering! |¢ Making sharp turns to ltt white traveling forward Pull the ing lover all the way backward, Theo, the machine wil vet lee tun ino compensation staeringh REMARK “To mako a pivot right tur, manipulate the Ri. steering lever in| the samo manner as deseribed above, {no compansstin steering) 202 v oo2. OPERATION 128 STOPPING MACHINE A warnine ‘+ Avoid stopping suddenly. Give yourself ample room when stopping ‘s When stopping the machine, select flat hard ground and tvotd dangerous places it ls unavoldably necessary to park ‘the machine on slope, place th parking lever in the LOCK positon and insert Blocks underneath the track shoes. Asan ‘daltional safety measure, thrust the blade into the ground. «Ifthe directional and gear shift lever and work equipment || * contrtteveris touched accident, the work equipment may ‘move suddenly, and this may lead to serious accident. Betore leaving the operator's seat, always operate safety lock levers ©, © and 2 to place it securely atthe LOCK postion. 1. Lower engine speed by operating fuel conte laver 2 Place directional and goar shift lover @) in the N (neutral), position, IY with safety look lever ©. orice the engine speed and travel speed, 263129 PRECAUTIONS FOR OPERATION 123.1 PERMISSIBLE WATER DEPTH When working in wator, operate the machine only within a depth where bottom surface @) of th carter roller remains above the ater surface. the cooling fan goes into the water, the fan may be broken, 12.92 PAY ATTENTION TO GAUGES ‘Winen the red range lights on the power tain oi! temperature ‘gauge while operating, radiee load and wait for lowering of tom 12.9.3 METHOD OF USING STEERING CLUTCH W tho steering clutch one side ie used frequently or if many gradual turns are made with stesring clutch half-engaged, the Steering clutch wil wear out ina short time. Design the travel rad ‘well ander the machine property. 12.94 PRECAUTIONS WHEN TRAVELING UP OR DOWN HLS [METHOD OF USING DECELERATOR PEDAL IF the deceleratr pedal I depressed when traveling upil the ‘engine speed wil drop and the gradeabiity wil be redueed. Fr thie eason, the machine may stop and the engine may also stl, Ifthe decelerator pedal is dopressed too much and the machine ‘stops, depress the brake pedal before the engine stops in ordor to apply the brake securely and hold the machine, USE ENGINE AS A BRAKE [Never go down hills withthe goar shit aver at Neutral, When traveling downhils of more than 15" shiR down to tet speed (Rt or Fr) BRAKING WHEN TRAVELING DOWNHILL "Whon using the engine as a brake during downhill ravel use the service brake also. Using ony the braking face ofthe engine may {cause the engine to overun, In pantcuar, when traveling downhill towing a scrap ‘transmission is shifted down, the engine wil fond to overtun, not ent dawn wile wavelnig dow12, oFesaTiON 12.95 PRECAUTIONS ON SLOPES Be carol of fuel level ifthe fue level in the ful tank becomes low when working on slopes, the engine may suck in ai because of the angle of the ‘machine or the swaying of the machine. I this mekes the engine ‘top, £0 be careful otf lot the fuel level In the ful tank become t20 Tow. Be careful of ol level ‘When operating machine on sloped ara of more than 20°, fill | every place with al to love. Precautions when engine stops on slopes ifthe engine stope when working 0 traveling on 9 slope, | depress the Brake pedal immediately, lower the work equipment, fand stop the machine, Then pull the Safty lock lever (to lock tho | brake pods Nest, return the gearshift aver to neutral, lock it in positon, then Star the engine again Precautions when stopping temporarily on slopes ‘When stopping the mechine temporary on slope, depross the brake pedal, stop the machine, then lock the brake pedal securaly with the safety Tock lever © evar operate the fuel control lever or ce the machine on slopes. or pedal t stop 26612. OPERATION 12.8.6 METHOD OF USING BRAKES ‘The following actions cause premature damage othe brakes, 20 avoie 1 Using Brako with engine running at ful speed in fst (F1, RI) (Machine stall condition) REMARK ‘Always depress the declerator peda to lower the engine speed botore actuating the brakes. 129.7 IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS (MACHINES EQUIPPED WITH CAB) ‘Always keep the door closed wien traveling or carrying aut ‘operations. There le danger of damage from obstacles OF strong bration. 12.98 IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW (MACHINES EQUIPPED WITH CAB) 1 For safety reasons, do not install anything tothe cab glass that, ‘wll obstruct the view, ‘© Always Keep the glass clean to ensure safety during operations 12.89 PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY AND ROPS STAY A warns: ‘The cab stay and ROPS stay cause blind spots. ‘When operating, always be sure to check carefully that there Is no obstacle or worker in the surrounding ares 26612 orenarion 12.10 PARKING MACHINE A waanin: ‘+ Avold stopping suddenly. Give yourself ample room when topping, ‘¢ When stopping the machine, select Mlat hard ground and void dangerous places. ft fs unavoldably necessary to park ‘the machine on # slope, place the parking lover inthe LOCK. Position and insert blocks underneath the track shoes. Asan ‘daltonal safety measur, thrust the blade Into the ground. ‘© Ihthe directional and gearshift lever and work equipment accident, the work equlpment may ‘move suddenly, and this may lead to a serious accident Before leaving the operators seat always operate safety lock levers @),, and to place lt securaly at the LOCK position 1. Lower engine speed by operating fuel contre! lever weg 2. Place directional and gear shift lover @ in the N (neutral postion fs @ to apply the brake, thon Took securely with brake lock ver nome Cx I the engine seed I igh or he machine travel speod ean, | CUES IS tin trnke may nates stppey sound nenthetate eaepresed | SG ES Mhanaspendetiobrate Sopentieclomorpeddltsveaus |S nal {he engine sent and avl speed _ 26112 OPERATION 4 Lock gear shit lever @ with safety lever @. 5. Put blade control lover @ snd ripper contral lever @ in the LOWER postions to lower the blade and the ripper tO the grou. 1. Lock blade control lever ® and ripper control ever (with ssety lose O. 12.11 CHECK AFTER FINISHING WORK 1. Uso the meters and caution lamps fo check the engine water perature, engine ol pressure, and fut level, 26812, overarion 12.12 STOPPING ENGINE Nonice HE the engin is abrupty stopped before It has cooled down, engine life maybe greatly shortened. Consequenty, donot abruptly ‘op the engine apart from an emergency. ‘in particular, the engine has overated, donot abruptly stop ‘but runt at medium speed tallow ito cool gradually then stop 1. Pace fuel control lever © inthe low ing position and run the {for about 8 minutes t0 allow Ht to 2, Place fuel contol lever @ In the engine stop position and stop te engine {3 Turn the kevin starting snitch @ 10 the OFF poston and remove the oy from sarting ete 2. 26912, oPenaTION 12.13 CHECK AFTER STOPPING ENGINE 1. Walk around the machine snd check the work equipment paint- work, and undercarriage, and check also for leakage of el or water. any abnormalities are foun, repr them. 2 Fl the fuel tank, 3. Chock the engine compartment fr paper and debris Clean out ‘ny paper and debris to avoid a fire hazard. |& Remove any mud stuck tothe undereariage. 12.14 LOCKING ‘To prevent vandalism, thee ar lock at the following places Places that ean be locked with the starting switch key. ‘Cab door opener ©) tmachines equipped with ea) ‘Cap with lock @ tf equipped) Radiator cap Fuel tank cap Hydraule ol tank cap 1 Power tai ol filer eap Commercially avaiable locks can be fitad to the folowing places. Fight and of engine side cover ® if equipped) tery anda contioner iter inspection cover © (f equipped) Inspection cover for fol tank drain valve © i equipped) Too! box © ti equipped a12. oFeRATION 12.15 RIPPER OPERATION 12.15.1_ EFFECTIVE METHOD OF USE 12) The optimum digging angle for tho shank is when the shank is perpendicular tothe ground (ripping angle: 45" ~ 60° ‘+ Incomparatively soft ook (seismic velocity: 120 ms or below), itis also possible to carry out ripping withthe shank tited tothe rear max. ripping ange. © On comparatively herd rock If ripping is carsod out with the Shank ted tothe rea, thro will be excessive wear of the point of tp. and the saifsharpening ality wil be lost ‘© During ripping operations, ifthe shoes slip bacause of boulders for resistance from the bedrock, use the tt cylinder. ‘+ choosing @ suitable ripper pont to match the typeof rocks one ‘of the most Important elements In using the ripper effectively Ripper points are avaliable for ferent types of rook, so select the most suitable ripper point rom the lot. For deal, 509 "32 PROCEDURE FOR SELECTING RIPPER POINT.” 12.152 DIGGING UP BOULDERS OR ROCKBED During ripper operations, If stubbom boulders or ockbed cause the wacks to sip oF the travel speed to bacome slower, operate the Ait einer to aig up the boulderirockbed. 12.153 OPERATING ON SLOPES ‘When using the variable ripper, adjust the length of the tit crlindor to elect dimension L.12 oeRarion. 12.154 METHOD OF OPERATING PIN PULLER This is used only on machinos equipped with» gisn ripper 1. Stop the machine in safe piace and lower the shank tothe ‘ground. 2. Operate tho pin puller controller ewiteh and remove the mount Ing in ‘8. Move the riper up or downto set othe dese shank poston 4 Operate the pin puller contco switch to insert the mounting pin, Iti pin does not maten the poston ofthe ole Inthe shank, fat tho pin puller contol switeh to the PUSH IN postion and lowly move the ripper up ot down. ‘© When raising the pin position to increase the digging depth, use. long protector to prevent wear of the shank12.16 WORK POSSIBLE USING BULLDOZER In ation tothe following itis possible to further inerease the range of applications by using Various attachments. 12161. pozING ‘A bulidzer cigs and transports ditin a forward irecton. Slope ‘excavation can always be mos ffestively carried out by proceeding from the top downward. when dozing toward one side only, operate with angled blade (angledozer ony 12.162 SMOOTHING Nonice ‘Avoid smoothing on rocky or stony ground. ican damage the blade When finishing the ground surface to a smooth finish after . Always take some action to hold the handle {0 provent danger. “This machine s equipped with an asist brake oytinde (tle inetalled othe top ofthe steering case atthe bottom ight side of tho uel tank) "When the engine stops, the brake ie applied to hold the machine ‘and prevent from moving Wits impossible to start the engine aftor the assist brake has been appled, and it is necessary 10 move the machine with the ‘engine stopped, do as follows to release the brat, 2.19.1 METHOD FOR RELEASING ASSIST BRAKE (1) Before rleasing the brake, always measure travel “L* ofthe Fight brake pedal with the engine topped.12 OPERATION [METHOD OF RELEASING 1 Remove cover © on the right side of the operstor's compart 2. Set handle @ to the CLOSED postion, and pump in grease through grease fing @ to release the assist brake "Amount of gtease- 450 ce METHOD OF RESETTING Fit is no longer necessary to have the assist brake released, slay set handle to OPEN and reset the brake 20 that tie applied. ‘# "Incold weather, the viscosy ofthe grease increases, s0 if the ‘arease dose not come out automaticaly when handle © i sot 1 the OPEN position, remove al the graaea ae follows. Set handle @) to OPEN, stan the engine and run a ding unt all the grease is removed. If It ie meveseary to run ating for ‘more than 20 minutes, apply aloud from time to time to F the engine speed to a midrange speed. 2. Stop the engine. (Assit brake spplied) 53. Measure avel "L"of the right broke peda, and check that its tho same dimension 36 peda travel "L” bofoe tha grease via released (pumped In). If wavel“L" fz small, continue Step 2.8612.192 METHOD FOR RELEASING ASSIST BRAKE (2) 1. Loosen locknut & of asist brake cylinder, then sere in out (Band eet so that dimension ‘als 65 mm (28 In. 2. Serew in locknut @ ond tighten #0 that I locks nut ® securely. [METHOD OF RESETTING 1. Looson nuts ® and {tothe postion shown inthe diagram on the right, thon lock nut @® in postion with locknut @. 2. Startthe engine and check that cimension *b* nthe dlagram on the right i265 ~70 mm (28 28 I assay 20713. TRANSPORTATION When transporting the machine, observe I related laws anc regulations, and be careful {0 sssure safety. 13.1 LOADING, UNLOADING WORK A warnine ‘¢ Make sure the ramp has sufciont width, length and thick: ness to enable the machine tobe safely loaded and unloade IW tho ramp sags appreciably, reinforce R with blocks, ete ‘+ When loading and unloeding the machine, park the trailer on 2 flat frm roadbed. Keep a fairly long distance between the ‘oad shoulder and the machine '¢ Remove the mud from the indercsriage to prevent the ‘machine from sipping tothe side on slopes. Be sure the ramp surface ix clean and free of gress, cl, ico ‘and loose materials. '¢ Never change the ection of travel when on the ramps. Mit necessary to change dlrection, drive off the rampe and ‘correct the Wirection, then drive on tothe ramps again, 1 Do not use the counterotation turn. When loading or unloading, always use ramps ora platform and catty out the operations as foliows. 1." Property app tho brakes on the valor anlinget blocks beneath theives to eneure that f dose nat move. Then fix the rampe It line with the’ centers ofthe taller and the machine, 2, Sot the machine In ine with the ramps, set the directional and ‘ear shift lover fo Tet speed, then load or unload the mechine at Slow travel 3 Load the machine corectly in the specified position on the trailer. 13.2, PRECAUTIONS FOR LOADING ‘Ar loading to the specified poston, secure the machine as follows, 1. Lower the blade slowly. 2, Lock brake pedal, dvectional and goar shit lever, bade control lever and ripper contol lever securely with the safety lever, 3. Sot the parking ever tothe LOCK positon ‘4 Turn the staring switch to the OFF postion, stop the engine, thon remove the kay. 5. Lock the cab door, left and right engine side covers, and the battery inspection cover. {6 Put blocs under the front and rar ofboth tracks and secure the ‘machine in postion with chains or wite rope of appropriate Stronath to pravent the machine from moving during tanspor. tation. Be particulary careful tote the machine down securely 50 that it does not slip tothe side 29813.3 METHOD OF LIFTING MACHINE Aa WARNING: + Nover rise the machine with any worker on i. {Always make sure that the wire rope used for Iiting the ‘machine is of ample strength forthe welght of the machine. 1 Nover tr to lift the mechine in any posture other than the pposture gWven In the procedure below, Thre fs danger that {the machine may lose its balance. ‘¢ When iting the chassis, pay attention tothe center of gravity land be careful to maintain the balance ‘When iting the machine, carryout the operation as follows on ft ground 1. Stap the engine and be sure to set the parking lever tothe LOCK 2. Sotthe iting postion forthe machine a shown in the diagram ‘onthe right orice "This description of the method for iting the chassis appliee to standard specication machines Depending onthe attachments and options installed, the method ‘of liting wil fle In such case, please contact your Komatsu ‘strbutor for advice. For details of the weight, soe “25. SPECIFICATIONS". 20914. TRANSPORTATION 18.4 PRECAUTIONS FOR TRANSPORTATION A warnne: Determine the route for transporting the machine by taking into ‘account the width, helght and weight of the machine. ‘Obey all state and local lawe governing length of a load. Observe all reguations gov weight, width and ing wide loads Method of transportation We [i =~ oa ne 290135 REMOVING AND INSTALLING CAB (MACHINES EQUIPPED WITH CAB) self # ROBBER move the ea or wasponaion, do as A warnins Always us iting equipment of ample strength. REMOVING CAB Removing panels inside cab 4" Remove (ull out lf and right knobs © of the car streo, then loosen the nuts, and remove holder plato 2. 2. Remave 10 caps © installed tothe top surface ofthe panel ‘3. Remove 18 pane! mounting serews @ and washers ©, then remove panels @), and ®: Removing left and right door bottom platos "Remove mounting crows @ and washers @ (eft and right 6 places), then romove plates lft and right 2 places) Pate 6 fe the door seal protector plate Removing blind caps for eab mounting bots ‘5. Remove 7 bind cape ® installed at he front under the cab and Under the let and right doors. After removing the cab, install blind caps © again. 12, TRANSPORTATION 20113_TRawsrorTaTion Disconnecting connectors 8. Disconnest wiring haress connectors © and @ (oretrading {rom the ff side of the cab) Hold down protring part B ofthe connector with your finger, then pull up to remove. ‘Connector 3: Alt conditioner power source, 17 pins Connector ‘3: Cab, display power source, 21 pins Disconnecting window washer hoses 7. Daconneet & hoses 1 Ipretruding fom the lft side ofthe ea. Pull hoses © up to remove, Removing cab B. Romove 14 cab mounting bolts @ to. Remove 2 seal rubbors (for blocking clearance) and keep in a safe place for use when installing te cab again (Cab weight: Approx. 450 kg (992.9 fo) 2921a. TRansPoRTATION INSTALLING CAB ‘Connect and install ll parts inthe reverse oF For the following parts, do a8 follows. te removal ‘© tang cab ‘Connecting contrel panel and control cables. Intaling cab AT inatall height adjustment jolt © (Installed to tho ab) so that dimension 5 inthe dageat Is lss than 8 mm (0:32 i) 2. Lower the cab slowly trom above the floor. 3. Align the cab with he floor frame, then inst ova. Do nat tighten the bolt completly, Serew them in 3 or & turns, bots and washers 4. Tighten bots ®t fully A cauTion. ‘Do not use wrench to tighten after the tip ofthe adjustment joint contacts the surfece ofthe floor frame. This wil cause the {ab oF loge fame to deform and will generat initial stress, ‘© When tightening bots to Gt, check thet sdjustment joint © Inetalled to 3) to ie not In contact with the Moor frame ‘mounting surtsce. 5. Tighton adjustment joints © at to uni they contact the floor frame mounting surface 6. After acusting the jolt, tighten eab mounting bots @) 10 ©. 29314. COLD WEATHER OPERATION 14.1, PRECAUTIONS FOR LOW TEMPERATURE the temperature becomes low, It becomes dificult start the lengine, and the coolant may freeze, 20 do follows. 14.1.1 FUEL AND LUBRICANTS Change to fual snd oll with low viscosity fr all components For dotalls of the specified viscosity, see "20. USE OF FUEL, (COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA’ "TORE" 14.12 COOLANT A warnne Keep antifreeze fluid away from an open flame. Never smoke when using antifreeze, Nonice ‘Never use methanol, ethanol or propanol based antireere ‘where no permanent antireee ie available, an ethylene glycol antifreeze without eorosio inhibitor may be used ony Yor the cold season. In this cas, clan the cooling system twice a yea in pring {and autumn). Wihon roiling the coaing eystom, add antireeze In {autumn but do not ad any in pring, ‘Absolutely avoid using any water oak peventing agenttraspec- tive of whether tla used independently or mixed wit an anteece Do not mix one antifeere with» diferent brand For details ofthe antifreeze mbcure when changing the coolant, see "26.2 WHEN REQUIRED" Use a Permanent Antifreeze (ethylene glyco! mixed with coro- son inhibitor, antifosm agont, ot) mesting the standard requle- ‘ments as shown below. With permanent anifeeze, no change of foolant is requled for'a year Wit ie doubtful that an avatable ntfeeze met tho standard requrements, ak te supplier of that fnutfeeze for information. ‘Standard requirements for permanent antitrecz, SAE veo evn SORA FEDERAL” STANDARD. . ‘ease14.1. BATTERY A warns. «To avold gas explosions, do not bring ie or sparks near the battery «Battery slctrolyte is dangerous. It gets in your eyes or on Your skin, wash It off with large amounts’ of water, and Consult a doctor. ‘When the ambient temperature drops the capacty ofthe batary wil also drop. If the batter charge rato is low, the battary electro Fyte may tresze. Mainain the battery charge ae close as possible to 100%, and Insulate against cold tomperature so that the machine can be started easily the next morning. Mossure the specific gravity and ealeulate the rate of charge {om the fllowing conversion table. raw? we | oc | -we | -ave horse oom 7 Tis | oz co ae 1 | ts ee tae te | i iss wm ra | ts COLD WEATHER OPERATION 29814. COLD WEATHER OPERATION. 142. AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage trom trezing and ‘making i impossible for the machine to move on the following ‘morning, always observe the folowing procetions. f° Mud’ and water on the machine body. should be completly removed, This to prevent damage tothe sal caused by mud fr dir gottng inside the coal with frozen drops of wat ‘¢ Park the machine on concreta or hard ground, I this i mpos- ‘ible, park the machine on wooden bosrd, ‘© Opon the drain valve and grain any water collected fn the fusl ‘systom to prevent fom freezing, ‘© AS the batory capacty drops markodly in low temperatures, over the battory or remove it frm the machine, Keep tin & ‘Warm place, and instal t again the next morning. 143. AFTER COLD WEATHER \Whvensoason changes and the weather becomes warm, do a fellows 1 Replace the fuel and oll for all parts with oil ofthe viscosity pected For dotall, 99 *20, USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”, + IV for any reason permanent satieeze cannot be used, and an shy! glycol base antioeze (winter, one eoason type le used Insteed, or if no antifroeze Is used, drain the cooling syetem Completely, thon clean ou the Inside of the cooling system ‘thoroughly, and il with fresh water.15. LONG-TERM STORAGE 15.1 BEFORE STORAGE When putting the machine in storage for more than one month, 0 as follows 1 tar avery part ie washed and dried, the machine shall be housed in dry builng. Never leave it outdoors. In-eao itis indlapensable to leave it outdoors, park the machine ‘on the flat ground and cover Ie with canvas ot. ‘* Completely fil the ful tank, lubricate and change the ol before 's Apply a thin cost of grease to metal surface of the hydraulic piston rods and th idler adjusting rods 1 Disconnect the negative terminals ofthe batory and covert oF Femave it rom the machine and store soparstly. © If the ambiont temperature is expected to drop below OC, ‘wave add antireoze tothe cooling water. © Place all control levers atthe neual postin, oporat the safety ing avert the LOCK position, then move the i ‘control dat the low idling postion. 15.2 DURING STORAGE A wasninc Wit Is unavoidably necessary to carry out the rustpreventive operation while the machine is indoors, open the doors and ‘indows to improve ventilation and prevent gas poisoning. Operate the engine and move the machine fora short distance ‘ones a month so that a new film of of wll be coeted over ‘movable parts and component suriaces, At the seme ime, Charge the battery. ‘© Before operating th work equipment, wipe off the grease on the hnydrauliepston rod 15.3 AFTER STORAGE Nomice I the machine fs stored without carying out the monthly rust prevention operation, request your Komatsu distributor for servic. Carry ou the following procedure when tang the machine out ‘of longiterm storage ‘¢Wipe off the grease from the hydraulic eylinder rods. (Aaa oll and grease to all places. 29716. TROUBLESHOOTING 16.1 AFTER RUNNING OUT OF FUEL ‘Whan starting after running out of fue, fil wth fuel and blood tho air fom the Tuel system before starting. For dotale of bleeding the sr, see "24 EVERY 600 HOURS SERVICE" 16.2, METHOD OF TOWING MACHINE ~ A wanna ‘+ When towing the machine, use @ wire rope that has ample "strength for the weight of the machine being towed. ‘¢ Ashockle must slways be used when using towing hook 1 The wire rope shouldbe horizontal and ata right ange othe track frame, ‘2 Move the machine slowly. Hf the machine sinks in mud and cannot get out under ts own power, ori being used to tow a heavy object, ft the wire tothe {owing hook as shown inthe diagram on the right, on the case oF machines with a deawhor, tthe wire to the drawbar pin who toning, nonce The maximum towing capacity for this machine is 307,908 N (31.400 kg. ‘Always carry out towing operations within the maximum tow: ing capacity.163 IF BATTERY IS DISCHARGED A warnine ‘Its dangrous to charge the battory when itis mounted on the machine, Always remove the battery before charging It. ‘¢ When checking or handling the battery sop the engine and turn the stating key to the OFF position beloe starting. 1 The battery generates hydrogen ges, so there Is danger of ‘explosion. Do not bring lighted cigarettes near the battery, oF {do anything that wll eause sparks. Battery electrolyte is dlute sulphuric acid, and it wil attack Your clothes and skin. ft gets on your clothes or on your “hin, wash sy off with large amount of wate. If Fegetsin your ayes, wash it out with tesh water, and consult 1 When handling batteries, always wo land rubber gloves. ‘© Whon removing the battry irs disconnect the cable from ‘the ground (normally, fom the negative) terminal. When rst. Watool touches the cable connecting the positive terminal and the chasss, ‘there Is danger that lt wil eause sparks. 1 Ifthe terminals are loose, there ls danger thatthe defective ‘contact may genorato sparks that will cause an explosion. When instaling the terminals, Ineal ther tightly. ‘¢ When installing the terminal, install them tightly When removing or installing the terminals, check whichis the Posttive ) terminal and which le the negative © terminal ‘© Greon rust around the terminals i a cause of eat diecharge of the battory. Polish the terminals with sandpaper. After Femoving the rust, cost the terminals thinly with grease Before instaling, protective goggle 163.1 REMOVAL, INSTALLATION OF BATTERY CABLE {© Before removing the batery, move the ground cable (normally connected to the negative © termina). If any tool touches betwoen the postive terminal andthe chassis, hore fs danger of sparks being generated ‘2 Whon inetaling the batiory, connect the ground cable las ‘3 When replacing the Batoy, ic the battery securely with batary ‘mount eam, Tightening torque: 8.8 ~ 1955 Nem (1.0~20 kgm, 7.2- 145 lb) ges ig ~ e ss)1632 BATTERY CHARGES ‘When charging the battery, i the battery ienot handled corracty, there isa hazard that the battery may explode. Always fllow the instructions of "6.3 F BATTERY iS DISCHARGED” and the instuc tion manval accompanying the charger, and do ae follows. ‘© Sotthe voltage ofthe charger to match the voltage ofthe battory te bo charged Ifthe volage isnot selected correty, the charger may overheat and cause tn explosion, 1» Connocrtho postive = charger eip ofthe charger tothe postive @ terminal ofthe batery, then connect the negative © charger lip of the charger tothe negative © ternal ofthe batiory. Bo ture to fc the elips securely. f¢ Sarthe charging curent to 110 ofthe value of the rated battery Capacity: when carrying out rapid charging, eat tt lags than the fated battory capac ifthe chargor current Is too high, th electrolyte wil leak or dry Lup, and this may cause the batary to catch fire and explode. 1 itn battery electrolyte is frozen, do not cherge the battry oF start the engine witha ferent power source, There fs 8 hazard ‘that this wil ignite the battery slctolyee ane cause the battery to explode ‘+ Dornot use or charge the battary ifthe battery electrolyte lvel is below the LOWER LEVEL line. This may cause an explosion, ‘Auaye check the batory eloctolye level periodically and add sted water to bring the electroyt level to the UPPER LEVEL Tine, 2.100 L163.3 STARTING ENGINE WITH BOOSTER CABLE ‘When starting the engine with a booster cable, do as follows PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE A waanina: ‘¢ When starting the engine from another machine, connect the batteries in paral. ‘* When connecting the cables, and negative © terminals. ‘contact the posit + Wien Sarting the gine with a booster cable, atways wa safety glasses 4 Be caret not to let the normal machine and problem ma: Oy thine contact eachother. This prvents sparks from gener gE ing near the batory which could ignite the hydrogen gas oo ‘ven off by the battery hyerogen gee explodes could aan ‘ause serous injury. ‘+ Make sure that there fs no mistake in the booster cable ‘connections. The inal connection ft the engine block ofthe problom machine, but sparks wil be generated whon this is ‘done, so connect to a place as far as possible from the battery 4 Use care when removing the cables from the machine that has bean started. Do nat allow the eable ends to contact each ther of the machine, to avoid hydrogen explosion. Nonice 1 The size of the booster battery size. ‘¢ The battery of the normal machine must be the same capacity as that ofthe engine tobe started. 1¢ Check the cables and clipe for damage or corrosion ‘+ Make cure that the cables and lips ae firmly connected © Chock thatthe safety lok lovers and parking both machines are securely atthe LOCK position. “© Check that al control levers are at the neutral position. 210116. TROUBLESHOOTING ‘CONNECTING THE BOOSTER CABLES. Keop the starting switch st the STOP postion Connect the booster cable as follows in the order ofthe num bers marked inthe diagram. 1" Make sure thatthe starting suliches ofthe normal machine and problem machine are both atthe OFF position. 2. Connect one clip of hoster eable tothe postive @ terminal ofthe problem machine. 3. Connect the other clip of booster cable @) to the postive © ‘erminal ofthe normal machine, 4. Connect one alip of booster cable ( tothe nagatve © terminal of tho normal machine 5. Connect the other clip of booster cable @ to th the problem machine nine block of STARTING THE ENGINE 1. Mako sure the clips ae firmly connected tothe batery terminal, 2. Startthe ongine ofthe normal machine and keep tto run at high Idling speed, 3. Tur the starting ewitch of tho problam machine tothe START position and stat the engine. Refer to."122 STARTING EN- ine”, DISCONNECTING THE BOOSTER CABLES ‘Alter the engine has start, disconnect the booster cablesin the reverse of the order in which they were connected. 1. Romove one clip of booster eabe @ from the engine block of the problem machine. 2. Remove the other clip of booster cable @ from the nogative © terminal of the normal machine 3. Remove one clip of boost fof the normal machine. able from the poskive © terminal 4 Remove the other clip of booster cable @ fom the positive © terminal of the problom machin, 2-02 Sk. 9m.16.4 OTHER TROUBLE ln cases of abnormal ditributor for repair, 16.4.1 ELECTRICAL SYSTEM {Always contact your Komatsu distibutor whan dealing with th which are not listed below, pi 386 contact your Komatsu ened ‘hen the angins reo igh sped fora ane EVERY 250 amp iar wie egies ours sence ‘rg ip doe ra go ot wren |» Bete ahaa ‘s fepaces ‘ion no ening Bec tg fb sn ‘enor ok & pte tom |» else atoms "= Recs ‘rina mater dove vat tur when «atte wing 1s Shak ein Prion of suring motor twpe going « tticot bay charge + chee ‘Sang meter ae nae saphy cage 2 nt bey age (et pa 18m Best Ie fapen, Bee fe iy 1S Rei etupwhor mgaetestgpeed’” | & Dotchecagton tm entch eo (ring sh a ON pon 1 Dose nn (2 hes ‘hg lop das rat gh up bon |» Delactve chews ame is Roo gine opp arog sic | & baecte weg (2 Shs oi ‘ute of sles! wie arbewar |» Dative wig Ve Gos oni ‘Stora nhar touches by ana! |$ Barometer acral te | (2 esos + Ee somo hel (Sh it [A enon doo ot wot ropay16. TROUBLESHOOTING Probie er Ss Eee (cma fee FESS arn as 2 ed So 1 inure tow osu ta warn | fe Repuce per poms “Torque conan tanpetre gage |» eftiv ol mapaaiva guge” | Fel ol erpowtve pipe doe nt won 1 Blo comet ng (2 Chat eet ‘ea hit overs pace in poston “ransmisslon al presre owe ot_| Te Se "Tore ane c= pacman. |" Tas ES eae oooms Te = ese At a Teieseic eye eons Tae waaweati tet maa | er Tatar at re ner Tawra [+H 210816.43 ENGINE — loc rome sigh noe, ‘al sped raat er ‘otiton of worm ‘Sood oi rca Date dering oa ip ere «Reps om EVERY 0 HOURS a poet Sopoes tare omeoes {teen orca on “ite por pie puhing epic hemo bic wer ompertr auge is no sn ‘in feta Sema ttn a ot + Bape EO TO Fair lc tere ae ited in opce sung ono) [menace eon (aut av anc) 2105MEMOMAINTENANCE A wasnina: tt» DANGER, DO NOT17. GUIDES TO MAINTENANCE ‘bo not carry out any inspection and maintenance operation that isnot given i thi manual Perform maintanance work on har, at ground Check service meter (Check the service motor reading avery day toa te be carted out Ifthe time has come for any necessary maintenance Komatsu genuine replacement pats: Use Komatsu genuine parts specfed in the parts it as replacement pars. Komstau genuine ols Use Komatsu genuine ols and gresse, Choose olls and grease with proper viscosities stecifed for lamblent temperature ‘Always use clean washer uid: Uso automobile window washer Nuid and be careful not to lat any drt got into it Clean ol and grease: Use clean cl and grease. Also, keop containers ofthe ol and grease clean Keep foreign materials away from all end grasee. Keoping the machine cles: Always Koop the machine claan. This makes is easier to find parts causing problems. Keep ir particular ‘arbaee fitings, breathors and oil level gauges loan and avoid foreign matters from geting in them. Be careful of hot water and ot Draining het oils nd coolants and removing thelr fers immediately after the engine stops are hazardous. Allow the engine to cool Ite of has to be drained when If old, warm up the ol oa suitable temperature (approx. 20 — 40°C) before raining Checking foreign materias in drained of: After ol is changed or fiers are roplecod, check th oll and fiters for metalic pales ad foreign ‘matorals. I large quanti of meta particle or foreign materials are found, consult you Komatsu itributr. Fuel strainer: It your machine ie equipped with a fuel strainer, do not remove it while fueling. lt change: (Check oF change ols Inthe places where dusts scarce to keep foreign materials away from ails. 32“7. GuIDES To MAINTEVANCE Warning tag Altach the waring ta tothe starting switch or other appropriate controll {snot aware of the ercumstances from starting the engine. 1 t0 avold someare who Obey precautions: ‘During the operation, always obey the precautions on the safety lebel stuck to the machine. Wilding instructions: ‘¢) Turn off the engine stating switch. 12 Do-not apply more than 200 V continuously. ‘2 Connact grounding the cable within m from the area to be welded, ‘2 Avoid setts or besringe from being between the area to be welded and the postion of grounding point Fre prevention: Use nonflammable cleaner or light ol fr cleaning parts. Keep fame or cigarette ight away from ight (lamp faces: ‘When O-rings or gaskets are removed, clean the clamp faces and replace the Ovings and geske's with row ones. Bo eure to Mt Oxinge and gaskets when assembling Objects in your pockets: Keop your pookts fee of loose object which can ‘you work on the machinery while bending over I ‘out and drop into the machinery especialy when Checking undercariage: ‘When working in rocky area, check for damage tothe undercarriage and for looseness aw, Wear and ‘damage in bolts nd nuts. Loosen tho tack tonsion # litle when working in such areas, ator and air conditioner condenser. 1 Do not splash wator over tho electrical equipment 2313. GUDES To MAINTENANCE Pre: and postwork checks: Before starting workin mud ain, snow or at seashore, check plugs and valves for tightness. Wash the ‘machine Immediately after the work to protect components from rusting. LUbricte components more frequently than usual. 8e sure to lubricate work equipment pine ily they are submerged in water. Dusty worksites: When working st dusty worksites, do a8 follows: 1 "Chock the al cleaner for clogging more frequently. Clean the alr cleaner at shorter intarvals than species Clean the radiator core frequently to avoid clogging. {lean and rplace th ful fiter frequently ' Giean eiecrial components, especially the starting motor and alternator, to old accumulation of ust ‘Avoid mixing os: Never mix ols of eiferent brands. Ifyou have only oll which is diferent brand from the one that i used in the machine, do not add ie but replace altho el18. OUTLINES OF SERVICE 18.1, OUTLINE OF OIL, FUEL, COOLANT 781.101 Glia used in the engine and work equipment under extremely severe conditions (high temperature, high pressure), ana it deteriorates with use. ‘Alwaye uso oll that matches the grade and temperature for use given In the Operaticn and ‘Maintenance Manual. Even ithe oi isnot diy, alwaye replace the ol ater the specied irterval ‘© Oil corresponds to blood inthe human body, so always be careful when handing eto prevent any Impurities (water, metal particles, dirt. te) fom getting in ‘The majority of problems with machine ere caused by the entry of such Impurtes Take partclar care att et any puree gen when string aang Never mix olls of eiferent grades or brands. Always add the specified amount of of. Having too much ell oF too Tt ol ae both causes of problems. # lfthe ol inthe work equipment isnot elsr there ie probably water or ar getting into the sri. In such eaaes, please contact your Komatsu distributor 1 Whoa changing the ol, aways replace the rlated fter atthe same time. = Werecommend you to have an analysis made ofthe oll periodically to check the condition of the machine. Fr those who wish fo Use this sevice, plaase contact your Kematau ditibutr 18.12 FUEL © The fuel pump Isa precision Instrument, and if fuel containing water or dit ie wed, icannet work propery. 12 Bo oxtemely careful not to lt impurtios get in whon string or adding fue, 1S Aiways use tho fuel specified in tho Operation and Maintenance Manual. Fuel may congosl depending on the temperature when it fused (particulary in low temparture below “18°C, t0 ite necessary to change toa ful that matches the tomportur. {© To prevent the molsture in the alr om condensing and forming water inide the fuel tank, aways fill ho fuel tank ater completing th day's work © Before starting the engina, oF when 10 minutos have passod after adding ful, 8nd water from the fel tank 12 runs out of fuel, oF the fiters have Been replaced, iis necessary to bleed the ar from ln the sediment the eireut,18.13 COOLANT 1 Fiver water contains large amounts of calcium and other impuritis, soi it used, sal wl stick to the engine and radiator, and this will cause defective heat exchange and overheating. Do not use water that fs not sutable for drinking ‘* When using antifaeze, always observe the precautions given in the Operation and Muintenance Manual ‘¢ Komatsu machines are supplied with Komatsu origina ant-reze in the coolant when the machine is shipped ‘This ant ooze is effective in preventing corrosion ofthe coating system. ‘The antiseeze can be used continuously for two years or 4000 hours. Therefore, It can be used as itis even in hot areas, ‘¢ Antifreeze is infammabo, 0 be extremely careful not to expose i to flame or fre '¢ The proportion of ant-treoz to water efers according tothe embiont temparatue, For detalls ofthe mixing proportions, see "242.1 CLEAN INSIDE OF COOLING SYSTEM", ‘© tne engine overheats, wait for the engine to cool before adding coolant 1 tthe coolant aval love, wll cause overheating and wil also cause problems with corrosion from ‘their inthe coolant. 18.1.4 GREASE A warnina: Bo not cary out greasing when the engine ie running. Grease ie uted to prevent twisting and nolae atthe joints, ‘The nipples not included inthe maintenance section are nipples for overhaul, eo they do not need grease, FFany pare becomes stif ster being used fora long time, add orease ‘© Always wie of all ofthe ola grease thats pushed out when greasing, Be particularly careful to wipe ‘offthe old grease in places where sand or dit stxing in the grease would cause wear of te rotting pans. 18.15 STORING OIL AND FUEL '© Koop indoors to prevent any water, dir, or other impurities fram geting in, ‘Won keeping drum cans fre long perad, put th drum ont side eo thatthe filer pot the drum ‘an ie atthe side. (To provent molsture fom being sucked i) Idrum eans have to be stored outside, cover them with 9 vt te protect ther, ‘© Toprevent any change in quality during long-term storage, be sure to ut in the order ofS ‘out use the oldest a oF fl frst. 18.16 FILTERS. proof sheet or take athe me io fist ‘iter are extremely important safety parts. They provent impure in the fuel and ar ceuts from entering important equipment and easing prot. Replace al fiers periodically. For deals, see the Operation and Maltenance Manu However, whan working In severe conditions, ti neceseary to eonaldar replacing tho fiers at shorter intorvals according tothe oll and fut (sulfur contont being used, ‘¢ Never try to clean the fiers (cartridge type) and use them again. Always replace with raw fers, ‘When replacing o iter, chock i any mtal particles ee tuck to the oa iter Many metal artles fare found, please contact your Komatsu distributor. ‘2 Do not open packs of spare fers unt jst before they a ‘2 Always tee Komatsu genuine fiers, 10 be uted 2618 ourunes oF sevice 182. RELATING TO ELECTRIC SYSTEM. ‘¢fthe wiring gate wet ofthe insuaton In hazardous maifunetion of the mech damaged, the electric eystem losks and this could result 1¢ Services relating tothe electric systom ar 1) check of fan bet te Inthe fan belt and (3) check of battry Mui level Jon, (2 check of damage o- wear ‘2 Never remove or dsassemble any electric components installed inthe machine. ‘¢ Never install any electric components other than these specified by Komatsu, ‘+ Bo careful to keep the electric ayetem fra of water when washing the machine or when isn. When working on the shore, carefully clean the slectrc system to prevent corrosion. ‘+ Never connect any options! power source tothe fuse, starting wltch, battery relay te a719. WEAR PARTS LIST ‘Wear parte such asthe fiter element, cutting edge, et. ‘maintenance or before thelr abrasion inits ‘The wear parts should be changed correctly in ordor to use the machine economically For part change, Komatsu genuine parts of excellont quality should be used, “The pars in parentheses are to be roplaced at the same time, we Sah Foahome [PSR aa, | Rontsonent “ eg) y frequency gine ot er woarraat | cane - [+ [Seer ‘751031800 | Elenent =] | een nanos rower win ter | torowoaatts) | (Ouray 2] a | oy ‘coaweatte | (e-ing) ita ust ar coosnea | cane = | | Bey 50 teu Conoson rxitor | amartst | cxaape = [oa | Bray tenons soortmer | OG8307100 | Elman oY ever 180 Fe ‘yarwatc ol 107000-05180)_| (O-ring) 1) _| service Zar donee 00-15 6100 | lemert seemiy [=| : ‘a [she exave780 | rte = [2 sonal Recire filter! 14x-914-7741 | Fitter = 1 ‘7E028010"| citing spo mas Henan | fou tet ae ertazee | End wt ooh alt Tito | creriaes | fou = hen - Inertia) | toon = | te tment) | ted = | os use ioreaazzs) | Westen = | es ‘ms7oaes10 | extna eae wa] 3 Heranne | Ena fat st revezzee | End oan : ole dco] (revs) | (at) = |) ao : oer) | (eat = fae eres) | ta = fos totes zze) | ashe = |e vws7eata | Point | 2 as | tosreataza | Prtctor Ba - neoer teraonee_| (eon Slo are | sreataae | Petar al - teronee_| ny 2 Le nonce ‘When handing parts thet weigh more than 25 kg, remember that they are heavy abject. and take ‘the necessary care. 38| | 20. USE OF FUEL, COOLANT AND LUBRICANTS | ACCORDING TO AMBIENT TEMPERATURE PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS kino oF | AMBIENT TEMPERATURE ‘caPACITY reservorr | KIND 0 so to SB Slur Srectied | Rot Engine ot pan geieat | azar Boing ute a5 aoe ‘Tranomisoion, Engine ot Ba egal | BT Ue go a nal ve ja 1883 UE ge. oo route sytem at US oat Bis bel ors Disa ul ‘oeste Fting reese S feaingerty | wot || ast anrece : ‘8 ASTM DS75 No. 1270. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE REMARK 1 When fue! sulphur content i fees than 05%, change olin the oil pan every patie maintenance hhoute described inthis manu Change oil according tothe following table Hf fuel sulphur content is above 0.5%, ‘Chango interval of on Fuel sulphur content ha ‘engine ol pan aie 1% 12 of regular Interv Above 10% | V4 of regular interval Above 10%] of regulrioterval_ ‘¢ wmen starting the engine in an atmosphere temperature of lower than 0°, be sure to use engine cil of SAEOW, SAETOW-20 and SAETEW:-40, even hough an atmosphere temperature goes upto $0°C more of less inthe day time © Use API classifestion CO Interval t hat lege oil and if AP classification CC, reduce the engine oil change, ‘© There is no problem i single grade ol ls mixed with muitigrade oll (GAEIOW 20, 15W0), but be sure to ada single grade ol that matches the temperature inthe table. *© We recommend Komatsu genuine oil which has been specifically formulated and approved for use In engine and hydraulic work equipment applications. ‘Specied capacity: Total amount of el including il for component and oi in piping. Refill capacity: Amount of ell needed to rel system during normal inepection and antenance ASTM: American Socety of Testing and Material SAE: Socioty of Automative Engineers APL Amerigan Petroleum Insite 21020. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Tage OF oan oI No} suwoter | Soyo raved | catteeLs | can’t | ‘Aig Great (The 15W40 colt ‘SAEBO, 90, 140 NLGI No. 2 Basel marked * is CE) Permanent Tyee Toros wae prsu | £02882 000 eau see 1 | KOMATSU | Eoro30c0 Goro Gos APPT (Winter, one Estee se en ma a [ace | Seerstini | emne | on ur - *Sigma @ [nose |-amaco a0 ‘aioe a | NON wen 4 | anco | -aronaersa pe | arco no gear ou | oti He 2 - s [ee | voramecs 1 | enomrone.ser2 | Antoze “pov uc s09 | Univ! tan _| Mara pup 2 8 | CALTEX | RPM deo 450, ‘Universsi thuban EP) Uitr-cuty grease 2 | AF engine costent stoma ie 1 > | exsmot | nx apr Wr MS acne | Anite oo ior : ior @ | cxevnon [oe an a ee - 8 | conoco | -Fieeemotoron | UAVS GHE | paca grease - velar | Bape 9 aa Goa Eoctaeo3 axon ua ob " “Echo 303 exe eocon era a eaton cot (ees0) | eahbe X02 bar | oh oon fe a va] ear | sire mtr ot | matures gu | oaown EF? a “*Super duty plus. lubricant | Gutferowm EP special a mot | SDeene super Mite @x | ties 77 . 70WW-30, 15-40 ‘monies HO “Mobilgresse special an21. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE = oe a uo] soppuer | SAE10N, 9,40 08 ‘reas a See | at) lag | tian Set cerae | seksi | meen | Se fees i #5 duty. ‘Mutt 4092 ad 705 wn Antifreace and 4 | PENNZOIL | figet motor oll ‘Multi-purpose 4140 | 707L White ~ bearing | summer coolant. 15 | PETROFINA| FINA kappa TD Na le N FINA marson EPL2_ FINA tarnide oro | Bun ite 16 | SHELL Ri ‘Spirax EP Alvania EP immo X ‘Spirax heavy duty grease 7 a gear ol ‘Sun prestige 742 ‘coolant [rea [rama [mmo [summers | Sasa see i vw} ror | mules Tota nein | ae cra Antostotone san eo oe . Tees wa een [Sacre eS ae Fa21. STANDARD TIGHTENING TORQUES FOR BOLTS AND 21.1 TORQUE LIST Unies otherwise specified, tighten the metric bolts and nuts to the torque shown in the tabi ‘The tightening torques det © of the nut and bate Trtis nocossary to replace any nut o bol ‘genuine par ofthe same size au the port im (newton meter: Nev = 0.1 kgm ozs tbe ine bythe width aross the fats se a Komatsu replaced, ‘w<-| © © a Nm kgf wet Sache sce ance es an22, PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS To ensure safety at all ines when operating or crving the machine the user ofthe machine must _tuays carry out periodic maintenance. In adson, to furtner improve safety, the usorsRould alo cary ‘ut periodic replacement of tho pars given In the table. These pats are particulary closely connected to safety and fre prevention, ‘With these parts, the material changes as time passed, or they easly wear or deteriorate, However, itis iit to judge the condition ofthe parts simply by periodic meintenance, eo they shculd alwys be replaced aftr a fix time has passe, rogadless of thelr conltion, This necessary to ansure thot thoy alwaye maintsin ther funtion completely. However, I these parts show any abnormality before the replacement interval has passed, they should be repaired of roplaced immediately. Ifthe hose clamps show any detarioratlon, such as deformation or cracking, replace the clamps at ‘Wien roplacng the hoses, time ‘Ask your Komatsu distributor to replace the eral part, lays replace the O-rings, gaskets, and ather such part athe same a122, PERODIC REPLACEMENT OF SAFETY CRTICALPARTS SAFETY CRITICAL PARTS. Ne. Sefety etal parts for palodie replacement ‘ary | _ Replacement itera Fuel hose (fuel fer injection purnp) Fuel hose (ful tank - fuel strainer) Fuel hose (ful strainer ~ injection pump) Fuel return habe (injection pum ~ int Fuel roturn hoee joint ~ fue tank) Fuel spill hose (engine — join Fuel epll hose (turbocharger lubrication hose) Fuol spill hose torque convert oi cooler) 7.0. lubrication hose (torque converter - P.O.) 7.0. lubrication hose (wansmission ~ ol cooler Every 2 years or 4000 hour, 1 | wbichevr comes sone 1" P.O. lubrication hose (steering pump ~ fier) 2 7.0. lubrication hose (leering fier ouwet hose) ILO. lubrication hose (vansmission pump ~ fier) « TO. lubrication hse (transmission fier outlet hose) 6 7.0, lubrication hose (bade valve — bade eyllder| 16 PIO, Tubrcation hose {yaraulie tank solactor valve (tipper) "7 18 7.0, lubrication hose (soiecor valve Wipper— ripper lit cylinder, 5.0. lubrication hose (selector valve (ripper ~ ripper tit eyinden 1° Seat bot 1 _| Every 3 youre23. MAINTENANCE SCHEDULE CHART 23.1. MAINTENANCE SCHEDULE CHART ‘SERVICE FTEM PAGE INTIAL 250 HOURS SERVICE (only after the fret 250 hows), Replace fel iter caidas 350 hang of power tain case wash avalos Ging ah, naman, 3 ‘Change oll in final drive ease aa {Change oll in hydoulle tank, replace hydraule ol iter element 355 ‘Check engine valve clearance, aust 300 (WHEN REQUIRED {loan inside of cooling system 0 ‘Check, lean and replacs air cleaner element 3 ‘Check electrical intake air heater 328 ‘Check track tension 326 ‘Chock and tghton track shoe bolts 328 Feverso and replace the end bits and euting edges 39 Replacing ripper poet, protector aa Adjusting brake pada 32. Adjusting deceerstor ped 33 Replace fan belt aa ‘lean, check raditor fins 338 Replace ai conditioner belt 335 {ioan, check air conditioner condenser fins - 335 ‘lean air conditioner ar ftor (FRESHRECIRG tar (Machines equipped with eab) 3368 (Check, adjust air condtioner (Machines equipped with cab) 3a, ‘Adjust idler cleranco 338 ‘Grease door hinge (Machines equipped with ab) Fy ‘Check window washer fd lavl, add flu (Machines equipped with ab) 20 Replace wiper blade (Machinas equipped with cab) 340 2624, MANTENANCE SCHEDULE CHART ‘SERVICE ITEM PAGE ‘CHECK BEFORE STARTING _ ‘Check coolant level adé wator 2a check with machine monitor ——~S=~=~“‘*‘“‘*S*~<“‘s*~*‘“‘*«SCS*S Check fuel level, ad fuel 248 Drain water, sediment from foal tank (Check il evel in power Wain case, add oll 208 (Chock brake pedal travel 246 ‘Check brake pedal stroke 248 ‘Check ot level in Hydaulle ol, eda 248 ‘Check electric wings 2a “Check that lamps light uP ae ‘Check horn sound 240 ‘Check backup alarm sound 250 ‘Check aeat bot for wear or damage 250 (Check for wator and sediment in water separator, drain water 250 EVERY 250 HOURS SERVICE “Lubricating 342 ‘Check oll level in final dive case, add oil 345 ‘Check level of batary elecrohyto 345 ‘Check, egjust alternator dive belt tension 348 Closn sirainer at bottom of fool tank 7 Replace transmission fiter element and stoorng ol fiter element HT ‘Change ail in engine oll pan, replace engine oil fier cartridge 48 (Chock brake performance 48 EVERY 600 HOURS SERVICE Foplaco fue iter carriage E80 ‘lean final drive breather @ places) 251 ‘Chock fan belt 28123, MAINTENANCE ScvEDULE Cuan ‘SERVICE TEM. PAGE [EVERY 1000 HOURS SERVICE ‘Change olin power train oaso, wash strainers atering lich, transmission, torque converter esse) 362 {Change oll n final dive case 38 {Change ll in hydraulle tank replace hydraule ol fiter element 355 Replace corrosion resatorcanridge 356 (Check ll tightening parts of turbocharger 36 {Greate tension pulley assembly (1 place) 356 (Grease diagonal brace 2 paces) 36 {Greate universal joint places) 357 ~ Grosse torque converter eup ring (place) 357 Greate ier adjustment rod (2 places) 357 “Chock undercariageoll —SS~=~“—~*~*~“~sS*S~S~S~S~CSSS ‘Chock for loose ROPS mount bolts (Machines equipped with cab) [EVERY 2000 HOURS SERVICE —Groaso equalzorbershoh —SS™=~<“~*~*~s~sS brake pedal shaft ‘Check play of turbocharger rotor 360 hack turbocharger 360 ‘Gre 31824. SERVICE PROCEDURE. 24.1. INITIAL 250 HOURS SERVICE ‘carry out the following maintenance only after the frst 250 hours. ‘© REPLAG FUEL FILTER CARTRIDGE {CHANGE OILIN POWER TRAIN CASE, WASH STRAINERS (STEER. ING CLUTCH, TRANSMISSION, TORQUE CONVERTER CASE) ‘© CHANGE OI IN FINAL DRIVE CASE {CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OM ALTER ELEMENT. ‘¢ CHECK ENGINE VALVE CLEARANCE, ADJUST For details of the method of replacing or maintaining, se the section on EVERY 500 HOURS, 1000 HOURS AND 2000 HOURS SERVICE.24, SERVICE PROCEDURE 24.2 WHEN REQUIRED 242.1 CLEAN INSIDE OF COOLING SYSTEM Aware ‘+ Soon after the engine has been stopped, the coolant is hot and can cause personal injry. Allow the engine to cool before draining water. ‘© Never be under the machine with the engine running. To void serious injury, always stop the engine before boing Under the machine to open the drain valve. ‘+ Never remove the radiator cap when the engine is at operat- Ing temperature. At operating temperature, the coolant fe lundor pressure. Steam blowing up from the radiator could ‘ause personal Inury. Allow the engine to cool unt the ‘adiator filer cap is cool enough to touch with your hand Remove the filer cap slowly to relieve pressure, ‘¢ When removing drain plug, avold pouring coolant on your- alt 1 Antireeze is flammable, so keep It away trom any flame. ‘© Clean the inside ofthe cooling system, change the coolant and replace the corrosion resistor according to the table below. hana eooa ser teteee conning | evn) "ne OS |e ete© Uso_a permanent type of antifreeze. If for some reason, is Impossible to use permanent type toss, uso an niresze containing ethylne gly. ‘+ Stop the machine on level ground when cleaning or changing the coolant. ‘+ When deciding the ratio of antitesze to water, check the lowest temperate in the past, and decide from tho mixing rate table given below. Iie actualy beter to estimate a tomporature about 10°C (50°F) lower when decicing the ming rate ‘Mixing rato of wator and antiroeze mn [| =] ] 5] | 6] aumoerhe| fnpeswre| = | = | «| 6 | [3 | 2 7 [al] *, a) «| amownt of Os eai| 90 | 792 | ast] 1196] reas] 132i ‘cos | 490 eso | 791] 970 | worn] 1050 7 [mal | «| | «| "gaat tus gsi | 2042] ve00| 169 | vest | 26] razt ‘Uc a| 700] 1620 | 1407] vee | v1.87 | 1090 ‘+ We recommend use of an ante ‘mixing proportions. 1 density gauge to contra the '© Use city water for the cooting wat ‘river mater, well water or ether uch wator supply must be Used, contat your Komatsu distributor. 24 SERVICE PROCEDURE on24, SERVICE PROCEDURE ‘© Prepare a container to catch drained coolant: Min, 100 & (26.42 US gal, 2198 UK gal) capacity. 1. Tighton valve) of the corrosion resistor 2. Turn radiator cap ® slowly and remove it 3. Prepare a container to catch the coolant, then open di Gat the bottom ofthe radiator onthe right sido ofthe mechine ‘and drain the coolant 4 After draining the coolant, close drain valve @ and fill the ‘agiator with tap water. 5. When the radiator filled with wat ‘the engine, and run at low idling Keep the engine running at low ling and flush the radiator for 40 minutes While fushing the racltor, act the incoming flow of wator to match the drain flow so that the radiator fe ahwaye kept fall during the fushing operation. Als, be sure thatthe wet eupply hose dovs not slp our ofthe radiator water filer wien fishing open drain valve @, start 8. Aftor flushing, stop the engine, allow al the water to drain out {rom drain valve), then elote drain valve & 11. After draining the water, fush the eystom with a flushing agent For details ofthe Mushing method, see the instructions onthe flushing agent. {8 Aftor fusing, open drain valve, drain out ll the water, close rain valve) and add tap water so that the water level fo neat the mouth of the water filer 9. When the water reaches the wator filer port, open drain valve G, star the engine, run st low ing and continue to fs the system until clean water comes ou While flushing tho radiator, adjut the incoming flow of water to ‘match the drain flow eo thatthe racator is alway kept ful during ‘the flushing operation. Bo sure thet the water supply hese does Mot flip out ofthe raditor water filer when flushing, 10, When clean water comes out, stop the engine and close drain wave @. 11, Roplace the corosion resistor and open valve For details on the corrosion resistor replacement method, "248 EVERY 1000 HOURS SERVICE” 12 Aa ety water until the water overfiows from the wate file pon. 18, To remove the ai inthe cooling water, run for five minutes at low fang, then for enotherfve minutes et high ing. {When deing this, eave the radiator exp of), Fey14, Stop the engine, wait for3 minutos, add city water until the water level reaches noar the water filo port, then tighten the cap24, SERVICE PROCEDURE 24.22 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT A warns: ‘Always wear protetive glasses, dust mask, or other protee- ‘ve equipment ‘© When removing the air cleaner element frm the air cleaner body, I fe dangerous to pull tout by Toree, ‘When working at high places or where the foothold is poor, be careful not to fll because ofthe rection when pulling cut the outer element. ‘CHECKING Hair cleaner clogging monitor © ofthe mentor pane! fash, clean the sir elesner element, Replacing Replacing elemont, O-ring fone year has paseod since instaling the element or if air lasner logging monitor (D onthe monitor pana ashes immeditey after the element Is cleaned, replace the outer element, nner slant, tnd Oring Nonice Do not clean the air cleaner sloment until the sir cleaner clogging monitor on the monitor pase ashes. I the element is cleaned frequently before the clogging monitor lashes, the ar cleaner wil ot be eb ‘to dleplay Its performance full, and the cleaning sffcioncy wil alse go down. In adtion, during the cleaning operation, more drt stuck to the element vil fall inside the inne ‘loment. ‘CLEANING OF REPLACING OUTER ELEMENT orice’ Before and after cleaning the eloment, do not leave or keep it in direct sunlight 1 Open the engine hood at the front side ofthe machine, remove { hooks ©, then remove cover B: 2. Hold the outer element, rook i lightly up and down and to the loft and right and rotate th elemant tothe left and Hight o pull Norice ‘© Never remove the inner element, twill allow dit to enter and ‘ave fallure ofthe eng ‘© Dornot use a screwdriver or other too 3. After removing the outer slement, cover the air connector Inside ‘the alr clesner body witha clan oth or tape to provent dt or ‘hut trom entering 224| 24, senvice pROCeOURE 4. Wipe off or brush off the det stuck to cover and the inside of ‘the air cleaner body. 5, Direct dry compressed arias than 0.69§Pa (hgten’, 89.4PS) |” the outer element from inside along its folds, then direct from outside along ts folds and again fom Inside 4) Chock that thre Ie no pay inthe Inner element. If any play ts found, push It in propety 2) Roplace beth inner and outer elements when the monitor =P amp (flashed soon ater instaling the clesned outer ele- S| a mont. 16 Remove the cloth oF tape cover installed in Stop 3 7. small holes or thine parte are found on the element when it Jcheckea by shining alight through tafe leaning, replace the < loment orice ‘¢ When loaning the element, donot hit or beat t against anything 1 Donotuse an element whose fldsor gasket or saa are damaged. REPLACING INNER ELEMENT 1. Firetremove th outer element, andthen remove the inner element. 2. Coverthe ai connector side (outa side) with a lean clot or tape, 53 Clean the ai eteaner body intro, then remove the cloth or tape installed in Step 2 44, Fite naw Inner aloment to the connector. Do not clean and reinstall Iner slomert ‘5 Install the outr element and the cover 242.3 CHECK ELECTRICAL INTAKE AIR HEATER ‘tore the stat ofthe cold season (once 2 -——Komatau datributor to have the electrical iake for checked for ct of disconnectons. 33524. SERVICE PROCEDURE 24.2.4 CHECK TRACK TENSION “Tho woar of ping and bushings an the undercartioge will vary withthe working conditions and sol properties. itis thie necessary {0 continually mapoct the tack tension so a8 to maintain the stand fd tension, Carry out the chock and adjustment under the same conditions ‘a when operating (on jobstes where the track becomes clogged With mul, measure withthe track clogged with mod) InsPEcTION ‘Stop the machine on evel ground (stop with the transmission in FORWARD without appiving the brake). Thon place a straight bar on the track shoes butwoon the care rlir and the idler se shown the figure, and measure tho clesrance betwen the bar and the ‘rouser at the midpoint. Ifthe eearance is 20 ~ 30 mm (0-73 4118 in} the tanson fs standard. tthe track tonsion is not at the standard value, adjust it in the foliowing manner ADJUSTMENT A warnnc Grease inside the austing mechanism is under high pressure. Grease coming from lubricator 2) under pressure can penetrate the body causing injury or death. For ths reason, do not loosen lubrieator 2 more than one turn Do not loosen any part other ‘than lubricator ©. Furthermore, do not bring your fase In front of grease fing Ifthe track tension ls not relieved by this procedure, please contact your Komatsu distributor ‘5 When increasing tension 1. Open cover @: None ‘+ There Is a safety label stuck to the rear fabe of cover @, so be careful not to damage the safety label, ‘+ Be’careful not to let art or soll get in whon opening cover, 2. Pump in grease through greace Fiting ©) with 9 grease pump. 3. To check thatthe corract tension has been achieved, move the ‘machine backwards and forwards 44 Check the tack tension again, and i the tension fe not correct, ‘sdjut i again 5. Continue to pump in grease until “S" becomes 0 mm, Ifthe tension i il loose, th pin and bushing are excessively worm, so they must be either turned at replaced, Please contact Your Komatsu disvibutor. 32824, Senvice paoceDURE ‘+ When loosening tension A warnins ‘tis extremely dangerous to release the grease by any method ‘except the procedure given below H the track tension Ts not {elloved by this procedure, pleese contact your Komatsu dx tributor. 1. Open cover @. nonce 1 There i 2 safety label stuck to the rear face of cover @, £0 be careful not to damage the safety label. ‘+ Bo careful not to let dit or sol get In when opening cover 2. Loosen lubricator @ gradually to release the groas 3 Turn lubricator @ a maximum of one turn. nat come out emoathly, move the machine beckwarde and forwards 9 short distance. 5, Tighten lubricator @. {To check thatthe correct tension has been achieved, move the machine bachowerds ana forwards 71. Check the took tension agai, and ifthe tension isnot core adjust again © When removing track A wannnc- Depending on the situation, the operation to remove the track ‘may be extremely dangerous. Before removing the track, i the procedure above “When loos: fning tension” doesnot loosen the track tenson, please contact ‘your Komateu distributor for repale24. SERVICE PROCEDURE 242.5 CHECK AND TIGHTEN TRACK SHOE BOLTS. Ifthe machine Ie used with track shoe bolt lose, they will break, 60 tighton any loose bolts immediately. ‘© Method fr tightening (shoe bot) First tighten toa tightaning torque of 61 = 48 Nom (45 2S kgm, 484 2 4 Toft) than check thatthe nut and shoe ar Contact with the ink contact surface, 2. Aftor checking tighten further 120 20%, {¢ Method fo tightening (master link connecting bolt) 4. Firt tighten ta tightaning torque of 4&1» 49 Nem (452 5 kg, 484 «43 [bt then chock thatthe lnk contact surface ae in close 2. Affor checking, tighten further 120 3. Order for tightening Tighten the bots inthe order shown inthe diagram onthe right, 228242.6 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES A warning: tis dangerous if the work equipment moves by mistake when the cutting edges and and bits are belng reversed of replaced, Set the work equipment in a sable condtion, then stop the ‘engine and lock the blade contol aver securely with the safety liver Reverso or replace the end bits and cutting edges before its ‘worn out tothe blade end 12 "Roige the blado toa proper height and apply «block to the frame 59 a8 to prevent fall ofthe blade 2. Oparate the eafety lever tothe LOCK position, 43 Measure the wear ofthe end bit and cutting ge In accordance ‘with the wear standarda given below. ‘24, sence ppoceouRe 6 ‘Wear standards Unit: oem in 1 | soe poe SES | tomiinn mea | | + [peo oe sete) | ow Hote [pa atei earos — [saga | — a 1 22924, SERVICE PROCEDURE If th cuting edge and the end bit on both sides are worn out replace with new one, tit hae boon worn out upto the fing surface, repair he iting surface and then reverse or raplace 44 Remove the cutting edge andthe end bit and clean the mounting surface, 5. Reverse or replace the cutting edge and the end bit when worn out Nut tightening torque: 735.5 ~ 1000 Nim (75 — 102 kgm, 543 - 799i) It bolt @ and nut Dare damaged, replace thom with new ones a the same time, cutting edge. 1) Install the edge tothe blade and tighten temparaiy. Lower the 7 blade and push it against the ground to remove the playin bol Q ff bo bots @ Z osen nuts GS, remove bolts @, then replace or reverse the Lae Q — rthen tighten to ha caret ightoning Tora. ) a Wen insaling end bit , bring top edge © ofthe end bit into SRiamnarane sisrasie Sot le 6. Alter several hours of running, retighten the nuts242.7 REPLACING RIPPER POINT, PROTECTOR A warn. {tte extremely dangerous Hf the work equipment moves during the replacement operation ‘Set the work equipment ina stable condition, stop the engine, ‘then lock the ripper controller lever securely with the safety Tock Replace the ripper point and protector before they excood the 1 Raise the ripper to a sultable height, then put a block under the Fipper to prevent i from coming down, uh the safety lock to eet to the LOCK postion 2, Measure the wear of the riper polat and protector according to the following wear standards. Wear standards ite ind | Thsaenen sani Trea 3 wase the part fe worn, replace it with @ new per. 3. Using a hammer, remove the polnt or protector mounting pin in the direction shown by the sito, then eloan the mounting ‘4 Install the new point or protector. Ire mounting pin fs damages, replace tat the gam time,24 SERVICE PROCEDURE. 242.8 ADJUSTING BRAKE PEDAL Hf the traval of the brake pedal ie too large, the brake ining is probably worn, 0 adjusts follows, [ADJUSTMENT METHOD "Adjust both the lft and right brakes. 1. lease the assist brake For tals see "12-10 METHOD FOR RELEASING WHEN ASSIST BRAKE HAS BEEN APPLIED" 12. flemove the cover atthe rear of the fender, then remove brake Inspection cover ‘2 Tighten acjustment bolt ® tightening torque: 49 Nm (kgm, {36 Toft) to bring the lining into tight contact withthe drum. 4. Turn adjustment bolt @ back approx. 118 turn, ‘5. Depress the brake pedal and check thatthe brake travel is within the standard value Engine stopped 78 mm (2:96 in) Engine at fling: 180 ~ 170 mm (539 - 6.7 in) Nonice ‘Ast so the travel of the loft and ight pedals isthe same, Whore is 2lferenc, the brakes wil pul to one side, {6 Measure cimonsion A ofthe brake adjustment bot, less than 127 mm (6.0 In, replace the ning. nd He IF the braking effect is still poor aven after adjusting, please contact your Komatsu distibutor for repairs 30224, SERVICE PROCEDURE 242.9 ADJUSTING DECELERATOR PEDAL inseecrIns {1 Set the fusl control lever tothe midway postion, depress the ecelerator pedal (clearance A = 0} and check thatthe engine peed is 800850 rpm. If not within tis range, adjust os follows ‘aDJusTING 1. Remove arommet © and loosen locknut O. 2. Turmcorew (to adjust so thatthe anginespood is 800 ~ 850 rpm when the decelertor pedal I depreseod (coarance A ~ 0) 3, After adjusting, tighten locknut 2. REMARK ‘Atachometor i necessary tos the engi please contact your Komatsu distributor. peed accurately, 23324, SERVICE PROCEDURE. 242.10 REPLACE FAN BELT Fit @ wrench tothe tonsion pulley, push inthe direction of the arrow to remove the V-belt then replace the Vel REMARK ‘# An auto-tonsionor ia inetalled, so there is no need to cary out ‘any adjustment unt the belt ie roplace, '© Replace the Vibote ae 8 set. 242.11 CLEAN, CHECK RADIATOR FINS A warninc. {compressed alr steam, or water hit your body irecty, there is danger of injury. Always wear protective glassex, mask, and safety shows. Ifthe radiator fins ae clogged or aity, loan and inepact them, 1. Remove bots @ (6 bolts Remove radiator gril. 2. Clean the radiator fins clogged with mud, dust and compressed prossed at REMARK Check the rubber hose. Ifthe hose ie found to have cracks to be hardened by ageing, replace such hose with now one. Further, loosen hose clamp should sito be checked.242.12 REPLACE AIR CONDITIONER BELT {Loosen & bolt @ and eck bot then move compressor @ to the side 2. Roplace the V-belt, REMARK When adjusting the V-belt, do not push the compressor dractly with aba. Use jack bolt 3, Tighten jack bolt and bolt, and apply tension tothe V-belt ‘The standard defection forthe V-belt te approx. 10 rm 0.8 nh ‘hen tho belt is pushed by thumb (approx. 58.8 N (6 ka) a point midway between the air compressor pulley snd fan pully. 242.13 CLEAN, CHECK AIR CONDITIONER ‘CONDENSER FINS ‘+ tthe sircondltioner condenser fins are clogged, clean and check the fin, 1s Rirconditionr condenser fine the radiator: 10 Installed at the top rear of 1. Remove engine side cover ©. 2. Use comprassed air to blow off the mud, dit, or leaves clogging the fine 2. Install engine side eover ©. 24, SERvICE PROCEDURE 23824, Senvice PROCEDURE 242.14 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (MACHINES EQUIPPED WITH CAB) I the air condtioner aie iter is clogged or there ie drt or dust in it cloan the tite. 1 “Opon inspection cover © atthe front ofthe fuel tank onthe let sid ofthe machine, remove frame rubber ©, then remove fresh fir fter 2. Open inspection cover (let unde the ooerstors eat and Siow SRE rr 3, loan fers @ and @ with compressed ai. there to the fier, or its extremely dirty, wash It in 2 neues agent ‘Ator washing i dry itcompletely before intaling It again. It the clogging of the fiter cannot be removed by washing or using compressed air, replace the fiter with # new par. oil stuck 39624, senvice pRocEDURE 242.18 CHECK, ADJUST AIR CONDITIONER (MACHINES EQUIPPED WITH CAB) orm ‘CHECKING TENSION OF COMPRESSOR BELT aa if the belt i 10086, wil slip and the cooling effect will be redid. From tima to time, press 3 point midway between the dive pulley sed compressor pulley with your finger (approx. 58.8 N (6 hand chack that te tension ia 10 mm (038 in. oneal "when the belt ¢ nev, there wil be iia elongation, 60 always, ‘adjust agsin after 2 oF 3 ays (CHECK LEVEL OF REFRIGERANT (GAS) A wasninc: “© When handling refrigerant ga, always follow local laws and regulations, «¢ The refrigerant used inthe cooler i colorless and odorless ‘nd docs not harm the atmosphere, but the igud gets nto {your eyes or on your hands, # may cause loss of sight or {rosthite, so never loosen any part ofthe refrigerant cout. Ifthe level ofthe refrigerant (gas) i low, the cooling effect will bb reduced, Run the engine at high cing, and check the low ofthe Feftgerant in the refrigerant circuit through the sight glass of the Feceiver when the cooler fe running a high speed. (F'No bubbles in retrigerant flow: Comeet 13 Bubbles in refrigerant low [bubbles continuously pass through): Refrigerant level tov 4¢ Colorless tranaperent: No rofrigorant REMARK Wien thare are bubbles, the rtrigerant gas level Is low, 30 ‘contact your refrigerant desler to have rofigorant added. I the ait conditioner fe run with the refrigerant gas fvel low, It wll cause Gamage to the compressor New Freon Fe1Sie is used as rofigeant.24. SERVICE PROCEDURE 242.16 ADJUSTING IDLER CLEARANCE The idler moves forward and Backwards under external force. when this happens tho side guide and top and bottom guide plates wil waar these parts are worn too much, the ier wil move to the side ‘or be at an angle, and the track may come off or wear unevenly. To Drevent this, adjust as follows. ‘ADJUSTING IN VERTICAL DIRECTION If the total (B + C) of ciearance B (clearance between support) tana guide plate (2) and clearance © (etarance between fop and bottom guide) and wear plato of track ramos more than Sm (0.20 inl, romove the necessary amount of shim (8 fellows, and ‘84d to shim to adjust clearance ® = C to 2 mm (008 in). ‘When the condition fe normal, © = 0mm (In. 1. To caloulate the amount of adjustment, measure clearance 8, thon subtract 2 mm (0.08 in} fom that value to obtain the adjustment amount Example: Clearance 8 = 5 mm (0:20 in). ‘Adjustment amount = §~2='3 mm (0.12 in) 2. Loosen bolts) (insi, ouside: 4) until there ls no response tthe epring, 3. Loosen bolt ©. When doing this, do not loosen it mare than 3 4 Using a bar, pull up top and bottom guides ©, set clearance C 0.0, then remove the amount of shims measured in Step 1 5. Add removed shims @ on top of shim (ef, ight, inside, and outside: total 8 places) When doing this, check thatthe total shim thcknass for shim @) ‘and shim @ isthe same befor adjustment and ater aclustment at aliplaces, if any hime a function propery, ‘Thate are two thicknesses of shi iscarded or added, the built-in spring will not men (0.08 in, 1m (0.08 in 33824, senvice pROceoURE ADJUSTING IN SIDEWAYS DIRECTIONS. 4 Drive the machine for 1/~ 2 m 0 Mat ground, thon measure Searenee Alef, right, inside, and outside: paces) between the teock frame and guide plates 2, Hf elearance A ie more than 4 mm (0.18 in), loosen bolt © and omove shim @ toadustthe clearanes on one ide to O51 mm {02 ~ 0.04 i, “There ara two thicknesses of shim: 0.5 mm (0.02 in), 1.0mm (0.08 i ‘When loosening bolt, do not loosen it more than 3 turns 242.17 GREASE DOOR HINGE (MACHINES EQUIPPED WITH CAB) Ifthe door makes a equeaking noise when itis opened or closed, spray lubricant in through te spit inthe hinge bushing the bushing fe wom, roplace the hing24. SERVICE PROCEDURE 242.18 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (MACHINES EQUIPPED WITH CAB} Check the window washer fui level f no fluid comes out (Open the inspection cover atthe font ofthe fuel tank onthe left side ofthe machine, and check the level of the lid in window washer tank ©. Add window washer fd f the level i low. ‘When adding fluid, be careful not to lt dirt or dust get in 242.19 REPLACE WIPER BLADE (MACHINES EQUIPPED WITH CAB) Ime blade ss damaged, twill not wipe the window clean, £0 replace the bisde, Method of replacement Front, roar wipor 4. Remove serew ©, thon remove the bad. 2. Install a new blade, thon tighten serow () securaly. 2, Install the new blade and hook it securely. 34024, SERVICE PROCEOURE 243. CHECK BEFORE STARTING For details of the following items, see "12.1.2 CHECK BEFORE STARTING® in the OPERATION section. ‘¢ CHECK COOLANT LEVEL, ADD WATER CHECK WITH MACHINE MONITOR (CHECK FUEL LEVEL, ADD FUEL DRAIN WATER, SEDIMENT FROM FUEL TANK CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OL CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OL CHECK BRAKE PEDAL TRAVEL (CHECK BRAKE PEDAL STROKE 3 GHeck O1L LeveL IN HYDRAULIC OWL, ADD OM CHECK ELECTRICAL WINGS: 3) GHeck THaT LaMps LIGHT UP 3 Heck HonN sound 3 CHECK BACKUP ALARM SOUND CHECK SEAT BELT FOR WEAR OR DAMAGE 3 CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER a24, SenVice PROCEDURE 24.4 EVERY 250 HOURS SERVICE 244.1 LUBRICATING Lower the work equipmont tothe ground, then stop the engin, 2 Using a grease pump, pump in grease through the grease fitings shown by aerowe. 3. After greasing, wipe off any old grease that was pushed out © Grease fan pulley 1 pace) Fight side of radiator quer 2224, SERVICE PROCEOURE + Ti dozer Lit eyindar support yoke (8 places) Lt indo support shaft ace) Blade arm (2 places Ti yd bt on poe) Tit brace ball joint (placa Blade center link (1 place). Tit brace thread (2 plac Lift eyliner ball joint 2 places) Roe24, SERVICE PROCEDURE. erepe pees Angledozer Lit evinder support yoke (4 places) Lift evinder support shaft 2 places) Tit brace thread (2 paces) Lit eying ball joint (2 places) Brace joint (2 places) Fipper Tit eylindr bottom pin 2 places) Lit einer Bottom pin (2 places) Tit evinder rod ond pin (2 places) ‘Aum in (oar 2 places)24, senvice PROCEDURE 24,42 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL. A warnins: “The oll lat high temperature immediately after the machine hs been operated. Wat for the ollto cool down before starting the operation. Remove plug @ and check thatthe oli near the bottom ofthe plug hole Ith oll level Ie low, add engine il CD class SAE20 Fogardess of ambient temperatre) through plug hole take eure thatthe machine i horzontal when carrying out the Inepectin, 24,43 CHECK LEVEL OF BATTERY ELECTROLYTE ‘Cary out thie check before operating the machine. A warninc ‘+ To avold gas explosions, do not bring re or sparks near the battery. 1 Battery electrolyte is dangerous. It gets in your eyes or on {your skin, wash Hoff with large amounts” of water, and onaut a doctor. ‘Open the battery covers © and @: nd chack thatthe battery alectroite fe in. the love is low, oda ete ‘Bo not add water above the UPPER LEVEL line. This may cause kage of tha electrolyte, which may eause fo. the batery ‘lately ie spilled, have lute sulphuric acid ado 3, When adding distilled water to any call at caps @) and @) add ‘stiles water algo tothe ther cells 44. Clean the alr hole in the battery cap, then tighton the cap securely. Nonice When adding distiled water in cold weather, add it before starting operations inthe morning to provent the electrolyte rom freezing 24624, SERVICE PROCEDURE 24.4.4 CHECK, ADJUST ALTERNATOR DRIVE BELT ‘TENSION Alternator sulle Heck The standard defection forthe crive belt is approx. 13-18 mm {0.81 = 0169 in) when pressed by thumb (approx. 98.1 N (10 kg) at ' point midway between the drive pulley and aternator pully apvusTING 4. Loosen 2 cover mounting bolts and remove the cover. 2. Loosen bolts and nuts ©, @, and @, then turn nut @ and adjust the bet tension. 2. After adjusting, ighton bolts and nuts ©, ©, and @ to secure alternator 3 in position, 4 Install the cover and tighten caver mounting bolts @- Check thatthe covers do not contact the rotting portion ofthe sattarator. REMARK 1+ Chock or damage t each pulley, wear ofthe V-groove, and wear ‘ofthe V-belt. Checkin particular that the V-belt does nat contact the bottom of the V.groove, '# ithe Vibote is elongated and thera is no more allowance for fgjustment, o if th bal ia erecked or cut, replace th bel. ‘+ When adjusting the V-bot, do not push the alternator eiacty| ‘wih a bar. inser a wooden Block ena push tha bck with aba ‘© Afor replacing the V-bet, operate the machine for one hou then check and adjust again,| 28, SERVICE PROCEDURE 24,42 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD Ol A wannns: “The oils a high temperature immediately after the machine |__| ints bean operated: Walt fr the of to cool down before starting the operation. Remove plug @ and check thet the oils near the bottom ofthe plug hole I the oft level Is low, add ongine ol (CD class SAE2O egerdess of ambient temperature) through plug hole | 2 Make sure mat the machine is horizontal when carving ou the | Inspection, 24,43 CHECK LEVEL OF BATTERY ELECTROLYTE ‘Cary out thie check before operating the machine. A warnine «To avoid gas explosions, donot bring fre or sparks near the battery |_| «Battery etectrotyte is dangerous. It gets in your eyes or on your akin, wash it off with lage amounts of water, and onault a doctor 1. Open the battery covers @ and @. | 2, Remove cape @ and and chack that tho battery electrolyte is tip to the UPPER LEVEL line, If the level is low, add cstild (Do not add water above the UPPER LEVEL line. This may cause leakage ofthe elecrcyte, which may cause i. If he batery bocroive e spill, have dilute sulphuric sci added. 3. When adding distilled water 1 any coll at caps @ and @, add dated water also tothe other cells. 44. Clean the sir ola’ in the battery cap, then tighten the cap securely. Nonice When adding distiled water i cold westher, ada i before starting operations inthe morning fo prevent the electrolyte from freezing,24. SERVICE PROCEDURE. 24.4.4 CHECK, ADJUST ALTERNATOR DRIVE BELT TENSION Heck “The standard deflection forthe dive bel is approx. 19 — 18 min (0.51 ~0.83 in) when proseed by thumb (approx. 96.1 N (10 kgf st 2 point midway between the drive pulley and aterstor pulley ADJUSTING 1. Loosen 2 cover mounting bolts @ and remove the cove. 2. Loosen bolts and nuts), ®, and then tuen nut @ and aust the belt tension, 3. Aor adjusting, tighten bolts and nite D, @, and (to secu ‘atternator im postion, 4 Install the cover and tighton cover mounting bots @: (Check thatthe covers do not contact the voting potion ofthe sterator. REMARK. '* Check or damage to each pulley west ofthe V-groave, and wer ‘ofthe V-belt. Checkin particular thatthe V-belt dose not contact ‘the bottom of the Vgroove, ‘© ithe V-bet is elongated and thre is no more slowance for adjustment, oi the bel is cracked or cut, replce the bel ‘© Wen acjusting the V-bet, do not push the altemator directly with a bar. Insort @ wooden Block and push the Black with aba ‘© Aer replacing the Vibe, operate the machine for one hour, then check and adjust again, 2462, SERVICE PROCEDURE 24.45 CLEAN STRAINER AT BOTTOM OF FUEL TANK 4. Gpen engine side cover at lft side of machine. 2. Tighten valve @. 3. Remove strainer cap @: ‘Cap (is braved, 20 romove the strainer together with cap ©. 4 Wash the strainer and strainer cas. 5 stall cap @ securay 18 Open valve @, then close engine side cover D. 24.4.6 REPLACE TRANSMISSION FILTER ELEMENT AND ‘STEERING OIL FILTER ELEMENT 4. Open engine side cover at lft side of machine. 2. Remove bolt ® then pull up cover ‘The elomont and valve can be removed together with cover 3. Remove wing aut @ of the valve, than remove alement ©, 4. Clean the inside ofthe case and the removed parts, then install slemont 5. Install engine sie cover ©. a02h, SERVICE PROCEDURE 24.47 CHANGE OIL IN ENGINE OIL PAN, REPLACE | | ENGINE OIL FILTER CARTRIDGE A wasninc: ‘The oll is at high temperature after the engine has been oper- ated, 80 never change the oll immediately aftr finishing opera. 10-cool down before changing ft Prepare the following ‘¢ Container to eateh drained ol: Min 27 & capacity {Refill capacity: 37# (9.77 US gal, 8.14 UK gal) 1. Remove the cover Dat the bottom of the machine and container to estch the oll under the drain plug 2. To prevent gating clon yours, remove drain plug ® slowiy ‘then loosen drain valve 2 through the work hole onthe let side of the undercover, and din the oll Bo not loosen the dain valve too far, otherwise, the stopper pin inside the valve my be ‘forme. 8. Chock tho drained ol, and if there are excessive metal particles ‘oF foreign material, please contat your Komata ditibutr. 4 Install drain plug ® and drain valve ©. Tightening torque Drain plug @: 68.6 = 98 Nem (7 1 kat, 506 + 7.2 lbh) Drain Valve @: 68.7 = 187 Nm (65 «15 haem. #7.0= 108 bt) 5. Using ater wrench, tun fier cartidge @ counterclockwise to remove it. When doing this to provent getting ol on yours do ‘ot earry out this operation from immediately under the car tds. In particular, if this operation is carried out Immediately after stopping the engine, aarge amount of ol will come out s0 wt {or 10 minutes before starting the operation, he now fits careidge with engine of nd tread with engine ol (or cost i ‘thinly with great, then inetall the fier ears 7. When intaling te iter carrie, bring the packing surface into ontect with the fer holder, then tighten further 3/41 turn 34824, sence pROceDURE 8. Attar replacing the fitercaridge, edd engine cil through oil filler until the oi lve! fe betwen the H and L marks onthe sips. 8, Run the engine at ling fora shor time, then stop the engin {and check thatthe oll vel s between the Hand L marks on the Aipstick, For detail, e00 "26:3 CHECK BEFORE STARTING” omice Even i'the machine has not been operated fr 250 hours, the of ‘and fitereartrige must be replaced when the machine has been ‘Operated for 8 months. inthe same way, even f the machine has not been operated for ‘6 months, the oll and iter cartridge must be replaced when the ‘machine has been operated for 250 hours. 24.4.8 CHECK BRAKE PERFORMANCE A waanins. {Wf the machine moves during the fllowing operation, please ‘contact your Komatsu distibutor for repairs immediatly. Nonice ‘Do not place the directional lver Inthe 1st speed position. Otherwise, will eause damage to the machine. Before starting the engine, check that the machine Is safe, thon do as follows. rea around the 1. Start the engine. 2, ‘Se eaety lack lever (tothe FREE position then operate blade tontrllaver and ripper control lover (to alsa the blade and Fipper. Lave the safety look lever (D tothe FREE position. 3. Sot efety lock levers @ and @ to the FREE positon. 44 Deprege brake pada and move directional and gearshift lover @ to the FORWARD 2nd postion 5, Operate fue control aver) to rage the engine speed gradually te ful vote 6. Checkthat tha machine dovs nat move. This indicates that brake perormance ts normal24, SeRvice PROCEDURE 245 EVERY 500 HOURS SERVICE [Maintenance for every 250 hours service shouldbe carried out atthe same time, 245.1 REPLACE FUEL FILTER CARTRIDGE A warns: ‘Engine is at hightemperature immediately after the machine thas been operated. Walt for engine to cool down before replacing the fier, Prepare a fier wronch and a container to catch the Fue. 1. Open engine side cover) a the let side of the machi 2. Set the container to catch the fuel under the filter cartridge 2. Close fuel valve ©, 4. Using after wrench, tun fer cartridge © counterslockwise to remove i 5. Clean the fiterholdor, fila now titer eartridge with clean fl, ‘oat the packing surface with angin ol, then neal othe fer nti the packing surface contacts the seal eurface ofthe fiter holder, then tighten it up V2 to 84 ofa If tho fr corvidge is tightened too far, the packing will be damaged and this wil Tead to leakage of fuel Ifthe iter tartrdge ie too loos, fuel wil leo leak from the packing. 0 aiwaye tighton tothe correct amount. 1 Open fuel valve @; loosen the knob of feed pump ® and operate 180 ~ 60 times up and down. This wl bleed the a 18 Push in the knob of feed pump © and tighten 9. After replacing tho iter cartldge, start the engine and check that ‘there ino leakage of fuel fom the iter sal surface, I there is any leakage of fue, check tha tightening ofthe fier caridge Wmenaver there i leakage of fu, follow Stops 1 end 2 to ‘remove the fit cartidge, then check the packing surface for Samoye or foi Irany damage of foreign materat 's found inthe packing, replace the packing with anew part then repest Steps 3~ 6 to instal the liter cartridge 3024.5.2 CLEAN FINAL DRIVE BREATHER (2 PLACES) Remove covers (D at lo and eight rear side of machine. 2. Remove breather @) and wash out dust remaining inside with Goce’ ofl and ushing ol 3. Alter washing, install brosther ®, thon install covers O. ‘+ Be careful not to let foreign material get in breather hove 245.3 CHECK FAN BELT ‘An auto tensioner i installed to msitsin constant bot tonsion| regardless of any elongation of the V-belt so there is no need (0 tarry out eny adjustment unt the bolts replaced. Chock the V-belt, land replace witha new part I any ofthe following abnormality ars found, neck f# An auto-tensioner (advice to automaticaly adjust the fan belt 20 ts not necessary 10 asus the tension. 24:2, WHEN, tension) fs instal ‘of the replacement procodurs, 24, SERVICE PROCEDURE24, SERVICE PROCEDURE 2 sence noceoune 24.6 EVERY 1000 HOURS SERVICE Maintenance for every 250 and 500 hours service carried out atthe same time. ould be 24.6.1 CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (STEERING CLUTCH, TRANSMISSION, TORQUE CONVERTER CASE} A wasn ‘The oli at high temperature Immediately after operations, 20"walt forthe temperature t go down Betore starting ths peration 1 The undercover Is heavy. Do not go directly under the cover when opening oF closing i When removing bolts ©, carry ‘ut the operation under the cover from the rear to make sure that I le possible to escape at any tim Prepere the following ‘Container to catch drained ol: Min 196 € capacity ‘Refill capacity: 196 # (385 US ga, 28.91 UK gal) 4. Remove drain plug from the steering clutch at the bottom of [— ‘he machine, drain the el, then tighten drain plug ©) again, 2. Remove drain plug @ from the torque convertor case at the bottom ofthe machine, drain the ol then tighten drain plug 38224, SERVICE PROCEDURE 3. Remove the floor cover at the font ofthe operator's compar mont, thea remove Bolt, remove cover (©) and take Out ‘and magnet (from the steering clutch eae. 44. Remove bolts © atthe bottom of the machine, torque converter staines together with cover ©. take ut the 5, Remove the di stuck othe strainer then wash it in clean desl fl or flushing oi Wash the inside ofthe case and anyother parts that wore removed, then install agin Pete strainer or magaet se Broken, replace thom with new 6. Add engine ol through ol filler port 10 the specified level. th oll check thatthe oll eat the specified level. "2.12 CHECK BEFORE STARTING”24. SERVICE PROCEDURE 24.62 CHANGE OIL IN FINAL DRIVE CASE A warninc: ‘The ol is at high temperature Immediately after the machine has been operated, Walt forthe oo coo! down betore starting the operation Prepare the following. ‘# Container to catch drained oil Min. 85 ¢ capacity ‘Refill capacity: each 85 (14.53 US gal, 1209 UK gal). 1. Remove drain plug @ and arain ne oi aster araining the ol, tighten the plugs 2. Add engine oll tothe specified level trough the hoo in oli plug @. 3. Chock thet the ollie atthe specified love For details, see "24.4 EVERY 250 HOURS SERVICE" 35624, SeAvCe PROCEOURE 24.63 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT A wasninc: ‘The oll i at high temperature i thts beon operated. Wat for the olf ing the oil When removing the ol filler cap, turn it slowly 0 ‘lease the Internal pressure, then remove I carefully Propare the following. 2 Container to catch drained ll Min. 108 2 capacity {Refi eapociy: 103 ¢ (2721 US gal, 2265 UK gal) Socket wrench, fter wranch 1. Remove desin plug ® at lower side of hydraulctank then loosen train valve ©, drain tho ol then tighten dain plug ® and dain valve © again 2. Remove bot @ then pull up cove land the valve together withthe cover and remove element 8. Wauh the inside ofthe case with clea diesel olor fusing ol, ‘than itll a new eloment 44. Ate replacing the element, add the specified amount of engine oil through ol flier For details of the cll use, see “20. USE OF FUEL, COOLANT [AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. 5. Cheok that the ols a the specified ove. For deta, see “12.1.2 (CHECK BEFORE STARTING”. 35524, SERVICE PROCEDURE 24.6.4 REPLACE CORROSION RESISTOR CARTRIDGE 4 Serow in valve (Dat the top of the corrosion resistor 2, Using a fer wrench, turn cartidge @ to the le, and remove cs ‘3. Coat the seal surtce ofthe new cartridge with engine oil then install to the iter holder 44 Whom installing, bring the packing surface into contact with the seal surface ofthe fiter holder, then tighten approx. 2 turns, 5. Open valve. ‘Always use & genuine Komatsu artidge, 24.6.5 CHECK ALL TIGHTENING PARTS OF ‘TURBOCHARGER Contact your Komatsu distributor to have the tightening portions checked. 24.6.6 GREASE TENSION PULLEY ASSEMBLY (1 PLACE) ‘Add grease through the grosse iting until grease comes out fom the relief valve 24.6.7 GREASE DIAGONAL BRACE (2 PLACES) ‘Grease the diagonal brace from the ttorn rear ofthe machine,24.68 GREASE UNIVERSAL JOINT (2 PLACES) Carty out the greasing from under the machine. 246.9 GREASE TORQUE CONVERTER CUP RING (1 PLACE) Carty out the greasing from under the machine. 246.10 GREASE IDLER ADJUSTMENT ROD (2 PLACES) ‘open the inspection cover for adjusting the tack tension and ‘greasing the idler acjustment nipple, then carry out the greasing Speation 24, senvice paocrDuRe24 SERVICE PROCEDURE 246.11 CHECK UNDERCARRIAGE OIL o as follows to check I the ol eve in the track ole, carior roller ®, and idler ® has gone down, 11. Stop the machine on level ground. 2. Loosen seal bolt ©) slowly, andi ell oozes out from the thread, the cil level has not gone down, so ughtan the bolt again Irmmediatly, 2. Ino oll comes out oven when seal bol (Dis remove, there is ‘+ tach of oly so please contact Your Komateu disibutor for REMARK '¢ There is ono seal bolt) each onthe inside ofthe cartier roller {orion fi. 246.12 CHECK FOR LOOSE ROPS MOUNT BOLTS (MACHINES EQUIPPED WITH CAB) ‘Chock that there are no loose or damaged bots. Hany bots ae loose, tighten to torque of S27 +109 Nim (845 2 105 kgm) any bol is damaged, replace i with » Komatsu genuine botsvc prez 24,7 EVERY 2000 HOURS SERVICE [Maintenance for every 250, $00 and 1000 hours service should be caried out atthe same tine. 24.7.1 GREASE EQUALIZER BAR SHAFT (PLACE) ‘open the engine side cover atthe left side ofthe machine ana ‘carryout greasing through grease nipple ©) under the Tuo itr. 24.7.2 GREASE BRAKE PEDAL SHAFT (6 PLACES) Carty out the greasing operation from the top of the machine24, SERVICE PROCEDURE 24:7.3 CHECK PLAY OF TURBOCHARGER ROTOR ‘Contact your Komatsu aitributor to have the play checked. 247.4 CLEAN, CHECK TURBOCHARGER {Contact your Komatsu distributor for cleaning or inspection, 247.5 CLEAN ENGINE BREATHER ELEMENT 1. Wipe ofall the dit around breather 2. Remove breather ©, ‘3. Wash the whole breather in dese ol or Musing ol ‘tary with compressed ai 44 Replac the breather O-ring with anew part, cout wth engine ol ‘and instal 24.7.6 CHECK ALTERNATOR, STARTING MOTOR “The brush may be wor, oF the bearing may have run out af ‘reaco, so contact your Kematsu ditributr for inspection o eps. I the engine ie stared frequently, carry out inspection every 1000 hours. 24.7.7 CHECK ENGINE VALVE CLEARANCE, ADJUST Contact your Komatsu distributor for inepaction or adjustmentSERVICE PROCEDURE 24.8 EVERY 4000 HOURS SERVICE [Maintenance for every 250, 00, 1000 and 2000 hours service shouldbe saried out at the same time. 24.8.1 CHECK WATER PUMP ‘Chock that here ls olf laskage, water leakage, or clogging ofthe Grain hole Hany abnormaty Is Young, contact Your Komatsu Sstrbutr for desssembly and repal oF replacomont. 24.82 CHECK FAN PULLEY AND TENSION PULLEY ‘Cheek th pulley for play or leakage of grease. f any abnormality ie found, pleste contact your Komatsu distributor. 24.83 CHECK VIBRATION DAMPER ‘Check that there are no exec ar posting inthe outside surface ‘of the vibration damper ©. any eracks oF peeling tributor to have the parts rep ‘ound, contact your Komatsu dis: 8 361MEMO 302SPECIFICATIONS25. SPECIFICATIONS Tem Tai DIBeaz ‘Operating weight (wthow operat | ig tb) aso 92405) Bae me cam rob) 5810 (12810 oper weight i) 500 (685) Name of engine = [Komatsu SAED 408-2 ssl engine Engine horsepower wtp 735.36 (31612000, A | Overat eng on (i 8560 (26) [Overt hight oi ein 3720.2) € | Overairwith om iin) 150 0377, Trvel speed Forward_| imh MPH | a7 Bayes aavina va) Uiscandbra everss_| kmh MPH | as v8 G.vRa7 Bs) ¢ 8 2OPTIONS, ATTACHMENTS j26. GENERAL PRECAUTIONS 26.1. PRECAUTIONS RELATED TO SAFETY If atschments or options other than those authorized by Komatsu ae int afect the Ife ofthe machine, but wil iz couse probleme with safety. ‘When instaling attachments not listed In this Operation and Maintenance Manual, plsse contact vour Kemateu ditibutor fst. you do not contact Komatsu, we cannot accept any responsibilty for any acident o* flare ‘thi ill not only A wanna. Precautions fr removal and installation operations ‘+ Whrrremoving or netting attachments, obey the following precautions and take caro ensure safety during the operation '¢ Corry out the removal and installation operations on fist, frm ground surface, ‘* When the operation is carried out by two or more workers, determine signals and follow these during the operation. 1 When carrying heavy objects (more than 25 kg (55 Ib), use & crane. When removing heavy parts, alvays support the pert before removing it. When iting such heavy parts witha eran, always pay careful attention to the positon of the center of gravity. ‘+ ttl dangerous to cary out operations with the load kept suspended. Always et the I stand, and check that lt i ste. ‘© When removing or installing attachments, make sure that they rein stable condition and wil not fall over, ‘© Never go under a load suspended front a crane Alwaye stand In position that Is safe even I the load should f Nomice ‘Qualifications are required to operate a crane, Never allow the crane to be operaed by an unqualified person For detis of the removal and instalation operations, please contact your Komatsu distributor 6227. INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS 27.1 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS Speaiicaions, use ‘Wide ehoe width 10 mm Ba") ‘Wide shoe width (650 mm 25") “rack shoes Wide shoe width 710 rom 28") Heavy-duty shoe width 610 mm 26") Heavy-duty shoo width 60 mm 26°) Ripper point Reversibe fan (Cap with tok Various other optional parts are avalable, so please contact your Komatsu distributor. 5828. USING SEAT BELT When operating @ machine equipped with ROPS, be sure to use the soat belt “A wasnins: efore fastening the seatbelt, Inspect the securing brackets and belt for abnormal conditions FReplaco any worn or damaged seat belt or the securing brackets ‘Adjust and faston the seat belt before operating the machine. {Always use seat belt when operating the machine. 1 Fit the seatbelt across your lp without twisting, 28.1 FASTEN THE BELT AND REMOVE IT IN THE FOLLOWING MANNER HANDLING SEAT BELT A warninc ‘Before iting the seat bot check that ther eno abnormality, tn the belt mount bracket or mounting belt. ils worn oF damaged, roplace the seat bet. ‘Even f no abnormality can be seen inthe belt, replace the ‘seat belt every 3 years. The date of manufacture ofthe belt Is shown on the Back of the belt, ‘» Aajust the seat bolt and fit it before starting operation. 1 Always wear the est belt during operation, '¢ Fitthe seat belt so that it fits across your abdomen and le not twisted 1. Aunt sent oat aa pd an ve opr ae ave apo bc pee nee 2. After postoning the seat, adjust the tether belt. With the seat ‘unoccupied, tance the belt sight across the seat and install 23. Sit in the seat, hold tongue @ of reel @, and pull the belt out Slowly 10a length which fly covers your lap. '& ser tongue @ into buckle) and push unt thore ie a click. Pull bck ree @) until the bel is securely serose your lp. In this concition, the lock is applied to prevent the belt rom exionding ‘ny further Fi the seat belt across your lap without twisting. 54ic set REMARK Tine lckis applied before the tongue is installedinto the buckle, I then carey out the operation again from “Tons the batt and chock that the look is applod 6, To remove the bolt, prose the rod button on buckle The belt will automatically wind in Inspect bots and fitings on the chess for tightness. Retighten | any foose bolts to WHS to 2.4 Wim 2to 3 Hg 14 to 217 I) It the seat is seatched or frayed or Hf any of the ftings are ‘broken or deformed from long sorvice, replace the seat bet imme- stay. 5529. HANDLING HEADREST. 29.1 ADJUSTING HEIGHT OF HEADREST ‘To maka it higher Hold the headrt and pull it up, © To mate it owe Keop knob (pushed down, end push the headrest down tothe Height aajustment: 60 mm (2.36 in) (2 stages) [30. HANDLING REVERSIBLE FAN 30.1. REVERSING REVERSIBLE FAN ‘When reversing the reversible fan in cold weather, das follows. 1. Loosen bolt @) then remove cover © on the left side of the ‘adator guard. hole for inserting the tool can bo seen. 2. Open engine sido cover @ onthe left side ofthe machi the reversing operation ean be seen : sothat Insert the tip ofthe tool nto fan blade 44 Push towarde the center of the tn, and tum the nanae ofthe tool to reverse the fan blades, 15 Reverse 8 fan bndes, but rotate the fan as follows. Starting motor to rotate-the fan. he nut ofthe spring which applies tension tothe tension pulley, rede the belt tension, and rotate by hand. Bonet loosen the nit too far or remove it ‘eAfer completely reversing al the fon blados tighten the nut to ‘ts origina poston. REMARK When inserting the too, tho work equipment or anyother part Trinthe way, change the poston of bolt to extend the toot &f | when using — . 1a sed in the suction dration in temperatures below MgC nas te effoct of heating or maintaining the battery | temperature. f 1¢ Uso'pant number 175:9003810 for the tol. etna ear sce | WI) ance | shan sae i - |___setingriy s 5731. HANDLING CAP WITH LOCK 31.1 OPENING AND CLOSING LOCKABLE CAP Locktype caps ae available fr the raator water filer cap, uel tank filer cap, powertrain case il ier cap, hydraull ark al ler ‘9p, and hydraulic tank breather cap. The eap Opening and eloting method ies follows, WHEN OPENING CAP a | 1. Inger the key. Make sure thit yu have inserted the key fully boforeturning ithe keys tured when ony asta need, itmay break a . (ES ew 2. Tu he ay country he math mark on no | (Lb EY on spe ar eg ty et | (SS ts hoard, tho lock is releeseg, enabling the cap to be opened, To Lock THE CAP 1. Tur tho ap inte place. 2. Tum the Koy clockvice and take the key out32. PROCEDURE FOR SELECTING RIPPER POINT 32.1. PROCEDURE FOR SELECTING RIPPER POINT | [ Precaue ® Preeti Proce Ssivioayayefesneeaea [ a : oo |. (Se. SEER 2. Sane | ~|2 || A\BA\B ssDISBA2 BULLDOZER Form No. SEAMO23000P