SEAMO2250602 Operation & Maintenance Manual KOMATSU PC2030-6 HYDRAULIC EXCAVATOR SERIAL NUMBERS PC20-29360 PC30-13022 and upFOREWORD This manual describes procedures for operation, handing, lubrication, maintenance, checking. and aojustmant It wil hap the opertor or anyone realize peak performence through effective, economical and sefe machine See eit @ Please reed this manual carefull BEFORE operetng the machine. & Please continue studying this manual untl proper operation fs completely reinforced into personal habit «This manuel describes the besic techniques. Skil is performed 26 the operator or enyore get the caract knowledge and performance ofthe mrochine «Operation, inspection, and mainionance should be carefully cared out and tho safety gust be given the fst preity, Safety precaution ae i Gieated with gh marks and technical precautions with + rnarks in this manual The eet information conteined inthis manuals intended only {D aupplament softy codes, insurance requement, local laws, ues andregulstons « Some phatogrephs end istration pictures ae diferent from your ma- chine ao toehnizal mproveront is eontinuously rflacted on it Revision to up-to-dte menue's conten is performed inter editions. «This operation & maintenance manual may contain attachments end op- tone! equipment that are rot eveluble In your are, Pleese consult your local Komatou distributor forthose tems you may require. Matera and specticatons are subject to change without note. FOREWORDBREAKING IN YOUR NEW MACHINE BREAKING IN YOUR NEW MACHINE Each machine is carefully adjusted and tested before shipment. However, ‘2 new machine requires careful operation during the first 100 hours to break in the various parts. Ha machine is subjected to unreasonably hard use at the initial operation stage, the potential of performance prematurely deteriorate and the ser- vice life will be reduced. A new machine must be operated with care, partic ularly with regard to the following items. © After starting, let the engine idle for 5 minutes to allow proper engine warm-up prior to actual operation. ‘© Avoid operation with heavy loads or at high speeds. ‘© Sudden starting or acceleration, unnecessarily abrupt braking and sharp turning should be avoided. ‘© At the first 50 hours of operation, ‘the machine should be main- tained in the following manner in addition to usual 50 hours service. 1) Replacement of hydraulic oil filter element 2) Cleaning of hydraulic tank strainer © At the first 250 hours of opera tion, the machine should be main- tained in the following manner in addition to usual 250 hours 1) Checking and adjustment of engine valve clearance 2) Changing of engine oil pan cil final drive case and swing ‘machinery case oil * When replacing oll filter elements (cartridges), check their interiors for dirt and dust. If heavily col- lected, check for possible cause before starting operation. ‘+ Hours of operation are indicated by the service meter.OPERATION GENERAL LOCATIONS AND SPECIFICATIONS ...... INSTRUMENTS AND CONTROLS OIL FILLER AND LEVEL GAUGE POSITIONS CHECK BEFORE STARTING OPERATING YOUR MACHINE REPLACEMENT OF BUCKET COLD WEATHER OPERATION CONTENTS 19 20 24 38 39 MAINTENANCE PERIODIC MAINTENANCE MAINTENANCE TABLE INITIAL 50 HOURS SERVICE EVERY 50 HOURS SERVICE EVERY 100 HOURS SERVICE INITIAL 250 HOURS SERVICE EVERY 250 HOURS SERVICE EVERY 500 HOURS SERVICE EVERY 1000 HOURS SERVICE EVERY 2000 HOURS SERVICE WHEN REQUIRED HANDLING RUBBER SHOES ‘SERVICE METER MACHINE AND ENGINE SERIAL NUMBERS FUEL, COOLANT AND LUBRICANTS 43 44 47 47 49 50 51 87 59 61 63 "1 76 7 78GENERAL LOCATIONS AND SPECIFICATIONS GENERAL LOCATIONS AND SPECIFICATIONS 1. Bucket 2. Bucket cylinder 3. Arm 4. Arm oylinder 8. Boom With cab 6. Boom cylinder 7. Sprocket 8. Track frame 9. Track shoe 10. Front blade PC20-6 ( ):PC30-6 Operating Weight ‘With canopy 2836 kg (3235 kg} With ROPS cab 2936 kg (3335 kg) Performance Bucket capacity (SAE) 0.08 m* (0.10 m*) (CECE) 0.07 m* (0.09 m*) Travel speed 2.4 kmih (High: 3.6 km/h Low: 2.1 km/h} ‘Swing speed 10 rpm (11 pm} Engine Mode! Komatsu 3084-1F Diesel Engine (Komatsu 3084-16 Diesel Engine) Flywheel housepower/Rated rpm 25.6 HP/2600 rpm (29.8 HP/2700 rpm} NOTE: Specifications are subject to change without noticeINSTRUMENTS AND CONTROLS INSTRUMENTS AND CONTROLS METERS AND LAMPS 1. SERVICE METER 2. ENGINE WATER This meter shows the total opera-. --»- TEMPERATURE GAUGE tion hours of the machine. The ser- vice meter advances while the engine is running — even if the ma- chine is not traveling Refer to the section “SERVICE METER” When indicator is in the green range during operation, water tem- perature is normal. After engine start-up, warm up ‘the engine until indicator moves into green range. If indicator moves from green into red range during operation, run the engine at low idling speed until indicator returns green range. ene -5-INSTRUMENTS AND CONTROLS 3. FUEL GAUGE 5. ENGINE OIL PRESSURE WARNING LAMP Os This gauge indicates the amount of fuel in the fuel tank. Normally this lamp is out during operation. If it comes on during operation, the oil pressure has dropped. In such a case, immediately stop the engine and check the cause of the trouble. 4. CHARGING LAMP 4 Normally this lamp comes on when the starting switch is tumed to the ON position and gradually go ‘out as the engine speed increases. 6. THERMOSTART SIGNAL LAMP When the starting switch is turned to HEAT, thermostart signal lamp will come on, thus indicating thermostart is heated. The lamp will 0 off in approx. 18 seconds.SWITCHES 1. LAMP SWITCH With lamp switch in position I, panel lamps wil light. With lamp switch in position II, head lamp and working lamp will also light. INSTRUMENTS AND CONTROLS 2, WIPER SWITCH on This switch is used to turn on the front windshield wiper. ON: For operation * When turning the switch ON, free the wiper blade from the sash + If the wiper does not work when the switch is turned ON, check the wiper motor breaker.INSTRUMENTS AND CONTROLS 3. CAB HEATER SWITCH This switch is used to heat the ‘operator's cab. The flow of warm air can be adjusted in 2 steps H: Strong L: Weak + The cab is heated by means of warm water from the engine. Accordingly, heating can not take place while the engine cool ing water is warming up. 4, STARTING SWITCH < OFF vert OF Sf Las OFF Key insertion-withdrawal_posi- tion. None of electrical circuits activate. ON Charging and lamp circuits acti- vate. Keep key at ON after starting. START ‘At this key position, the starting motor will crank the engine. Release key immediately after starting HEAT Use this position when starting in cold weather. Release the key to allow it to retum automatically to OFF and then, without delay, tum it to START.6. HORN SWITCH When this switch is pressed, the horn will sound 6. ROOM LAMP SWITCH ON 4h OFF ‘When this switch is moved to ON position, room lamp will light. 7. WIPER MOTOR BREAKER gore This prevents excessive currant from flowing in the wiper motor op- eration circuit. INSTRUMENTS AND CONTROLS. (ON: The wiper is actuated when the wiper switch is turned ON. WOFF:The wiper is not actuated even if the wiper switch is turned ON. % The cause of the breaker going OFF is that the wiper switch is left ON with the wiper blade fixed in the sash. ‘* The breaker cannot be switched ON again immediately after it has gone OFF. Wait for approx. 60 seconds before turing it ON againINSTRUMENTS AND CONTROLS LEVERS AND PEDALS 1. SAFETY LEVERS. ‘The safety levers are used to lock (for work equipment levers) the work equipment levers. Aiwien stopping the machine or leaving the machine, be sure to lower the bucket to the ground, ‘then operate the levers to lock the left and right work equip- ment levers. 2, LEFT WORK EQUIPMENT LEVER [arm/swing contro! lever) Bn © & “os Ah ogi’, A ®@ Neutral When the lover in this position, the upper works and the arm wil be retained in the position in which they stop. ‘Arm operation ‘Arm moves out. @ Armmovesin. ‘Swing operation © Upper works swings to the right. ©) Upper works swings to the lettINSTRUMENTS AND CONTROLS 3. RIGHT WORK EQUIPMENT 4, TRAVELING AND STEERING LEVER LEVERS (boom/bucket control lever) Lyle NN A : If the swing/boom swing selector ©) Neutral: ‘The traveling and steering levers lever isin the boom swing position When the lever in this position, reused to operate the left and the boom and the bucket will be right travel motors. Boom operation retained in the position in which) Forward: © Boom swings to the right. they stop. Push the levers forward. © Boom swings to theleft. ® Reverse: Boom operation Pull the levers backward ® Boom raises. ® Neutral: ® Boom lowers. Parking brake is applied and the machine stops. Bucket operation @® Bucket dumps. ® Bucket curls Pow =eINSTRUMENTS AND CONTROLS 5. SWING/BOOM SWING 6. BLADE CONTROL LEVER SELECTOR LEVER Adit the track frame is facing When switching this lever, the Lever position backwards, operate the travel- left work equipment control lever is: LOWER ing and steering levers in the used to swing the boom and the @: RAISE reverse manner to that when upper works. ® : NEUTRAL the track frame is facing — @):Boom swing operation. Blade is stopped and held in this forward. ®: Swing operation. position. Arsetore operating the traveling and steering levers, check whether the track frame is facing forward or backward, Assuming the machine is ina position to advance by means of being the sprocket at the rear. =12-INSTRUMENTS AND CONTROLS 7. FUEL CONTROL LEVER 8. TRAVELING ACCELERATOR PEDAL (Only for PC30) This lever is used to control the _If the pedal is depressed, the ma- engine speed and output. chine speed will increase. ® Lowidling position: Push the lever fully. ® High idling position: Pull the lover fully. oesINSTRUMENTS AND CONTROLS 9. SWING LOCK LEVER When this lever is placed to the lock position, the upper works is locked. + Swing lock lever must be in lock position machine. + This lever must be in the lock po: sition after the upper works is parallel with the track frame. during traveling of Adve not attempt to rotate the per works, whan the sing Sse rong ee us position DUST INDICATOR This device indicates clogging of the air cleaner element. When red piston (1) appears in the transparent part of this indicator, the element is clogged. Immediately clean element, After cleaning, push indicator button (2) to return red piston to original position, Dust indicator is on air cleaner bracket in engine hood. -14— FUSE BOX The fuses protect the electric devices and wiring from burning out. If any fuse is rusted or coated with white powder, replace it. 3 Loosen bolt (1) cover (2). + Replace @ fuse with another of the same capacity, and remove ABetore replacing a fuse, be sure to turn off the starting switch.Fuse arrangement Ciro [| Remaek ae : 204 [tn : 7 " ae ese : ® F zon | Wontr sim 7m o o 208 Engine stop motor 5 = 15 - INSTRUMENTS AND CONTROLS FUSIBLE LINK If the electrical power does not come on when the starting switch is tumed to the ON position, fusible links (1) may be disconnected, so check or replace them. % The following checks can be made from the wiring of the mounting connectors for fusible links (1), SWE (black and white wire): Chargine circuit 5W (white wire): Starting circuit, Machine power sourceINSTRUMENTS AND CONTROLS OPERATOR'S SEAT o 7 @ Forward-backward adjustment Move lever 1) tothe right, move the seat to the best positon and release the lever. The seat can be moved forward or beckwerd over 120 mm in stages ® Backrest adjustment Pull lever (2) in the direction of ‘arrow, move the backrest to the desired position and release the lever. Location of tool kit The tool kit is kept behind the operator's seat OPERATOR'S SEAT (Bucket type reclining seat with armrest) Set the seat in the disired position ‘by moving lever (1) to the direction of arrow; then release the lever. The seat can be adjusted forward or backward 160 mm (in 9 steps). -16- Seat cushion adjustment Move knob (2) until clearance be- tween tip of chain (3) and frame be- comes zero. Seat is now adjusted in the most comfortable condition, Backrest adjustment Set seat in desired position by pulling lever (4) upward, then release lever.DOOR Lock To hold an open door stably, use a door lock. The door will be held positively when pushed against catch (1), In order to release the door, depress the black button (2) in the operator's cab, FRONT WINDOW The upper part of the front window can be opened and closed. To fully close the front window (when washing the machine or during rainfall, close the upper part and insert the center sash between the upper and lower parts. ie INSTRUMENTS ANO CONTROLS CEILING WINDOW Ceiling window is opened by releasing the lock in the direction of the arrow and pushing the ceiling window.INSTRUMENTS AND CONTROLS LOCKING CAP The fuel tank filler port is equipped with a lock. + Use the starting key to open and ‘close the cap. Open and close locking cap as follows: @ To open the cap 1. Insert the key into the cap. “ Insert the key as far as it will go. If the key is turned before it is in- serted all the way, it may break. Shoulder Tur the kay counterclockwise, align the match mark on the cap with the rotor groove, then remove the cap. To lock the cap. ‘Turn the cap into place. Turn the key clockwise and take the key out —18- es(lL FILLER AND LEVEL GAUGE POSITIONS OIL FILLER AND LEVEL GAUGE POSITIONS 1. Swing machinery case level 6. Hydraulic tank oil filler 11. Engine oil pan level gauge gauge and oil filler 7. Engine oil pan oil filer 12. Hydraulic tank level gauge 2. Final drive case drain plug 8. Cooling water inlet 13. Hydraulic tank drain plug 3. Final drive case level plug 9. Cooling water drain valve 14, Fuel tank drain valve 4. Swing machinery case drain 10. Engine oil pan drain plug plug 5. Fuel tank oil filler 14131211109 raw -19-CHECK BEFORE STARTING CHECK BEFORE STARTING Pre-operation checks forestall machi a, WALK-AROUND CHECK Look around the machine and under the machine to check for loose nut or bolts, collection of dirt, or leakage of oil, fuel, or coolant, land check the condition of the work equiment and hydraulic system. Check also for loose wiring, play, and collection of dust at places which reach high temperatures. 1. Check for oil leak at high pressure hose, high pressure hose joints ‘and hydraulic cylinder seal 2. Check swing machinery case for oilleak 3. Check hydraulic tank for oil leak. 4. Check final drive case for oil leaks. Check radiator for water leak. Check around the engine for water and oilleaks. Check tighteness of exhaust pipe ‘mounting bolt. Check tightness of battery terminal Check tightenss of air cleaner ‘mounting bott. —20- e trouble. Never neglect them. b. CHECK AND REFILL COOLANT Check the level of the coolant. The water level must be between the FULL and LOW marks on sub- tank (1). If the level is too low, add water to sub-tank (1).Ao not open the radiator cap unless necessary. When check- ing the coolant, always check ‘when the engine is cold (check ‘the sub-tank) c. CHECK OIL LEVEL IN ENGINE Ol PAN Check the engine oil level. The oil level should be between H and L of gauge (6). ‘%* When checking the oil level, park the machine on a level surface, stop the engine and wait for 15, minutes before checking, ‘* The type of lubricant used depends on the amibient tem- perature. Select according to the tabel "FUEL, COOLANT AND LUBRICANTS”. -21- (CHECK BEFORE STARTING 4. CHECK FUEL LEVEL wena Check the fuel level using sight gauge (G). Upon completion of work, pour in additional fuel from filler until the fuel tank is full % If breather hole in the cap is blocked up, fuel flow to the engine may stop. Accordingly, clean it from time to time. + Foul capacity: 50% * When filling with fuel, do not lot the fuel overflow. This may cause fire.CHECK BEFORE STARTING ¢, CHECK AND REFILL OF OILIN HYDRAULIC TANK UE 969 eos EES 1. Run the engine at low speed, re- 2. Check the oil level in the hydraulic ‘tract the arm and bucket cylinder, system, lower the boom until the tips of __—The oil level should be between teeth touch the ground and then _—top H and bottom L lines of sight stop the engine. gauge (G). * The type of lubricant used FED depends on the ambient tempera- ture. Select according to the table "FUEL, COOLANT AND q Proper range LUBRICANTS”. Sa ae 22 {. CHECK DUST INDICATOR Q a, When air cleaner element is clogged, the red piston of dust in- dicator (1) reaches service level and gets locked. In that case, clean element rofer- ring to the section "WHEN REQUIRED”. ‘After cleaning element, push buttom (2) to return red piston.9g. CHECK FOR SEDIMENT AND WATER IN THE WATER ‘SEPARATOR Check for water with red ring (1) inside the water separator. % If there is water inside the water ‘separator, red ring (1) will float to the surface of the water, so drain the water as follows, Place handle (2) to the CLOSED position. Loosen ring (3), then remove case (4) and throw away the water inside it Install case (4) and tighten ring (3) Drain the water and sediment from the fuel tank. See EVERY 50 HOURS SERVICE, ~23- CHECK BEFORE STARTING h. CHECK ELECTRICAL WIRING Check for any sign of disconnec- tion or short circuit in the electric wiring. Check also for loose termi- nals and tighten any loose parts. Check the following points carefully. @ Battery © Starting motor @ AlternatorOPERATING YOUR MACHINE OPERATING YOUR MACHINE BEFORE STARTING THE ENGINE TO START THE ENGINE 1. Put the traveling and the steering 3. Check that the blade control 1, Pull the fuel control lever a little control levers in the N (neutral) _—_leveris at the neutral position. towards you from the low idling position. position. Neuvat Lowiating 2. Put the left and right work equip- 2. Tur the starting key to the ment levers in neutral and check START position. that the safety levers are locked. he3. When engine is started, release the starting key and the key will return automatically to ON. * If engine will not start, repeat the starting procedure after 2 minutes. + Do not leave the key in START for more than 20 seconds. % If the engine has been warmed Up, itis possible to start it by put- ting the fuel control lever in the low idling position. OPERATING YOUR MACHINE STARTING AT LOW Special starting TEMPERATURE ‘When starting after running out 1. Check the oil level in the termos- of fuel, fill with fuel, then fillthe fuel tart fuel tank. filter cartridge with fuel and bleed 2 the air from the fuel system before starting Refer to FUEL FILTER in EVERY ‘500 HOURS SERVICE. 2. Fully pull the fuel control lever. Lowialng =25-OPERATING YOUR MACHINE 3. Move the key to HEAT position, and thermostart signal lamp will 5. Release the starting key, and the key will return automatically to come on. The preheating will be ON. completed in approx. 18 tts seconds, and the lamp will go off yer atthe same time, 4, Then tum the key in the START position and start up the engine. 6. Put the fuel control lever in the tow idling position. West ofr Low iating Ma High iting = 26 Airever use starting If the engine does not start up under the above procedur repeat steps 3 and 4 after waiting for about 2 minutes. fluids as they may cause explosions.CHEKS AFTER STARTING After starting, make the following checks. 1. Run the engine at low idling speed, and check that the engine oil pressure warming lamp has gone out. +O 2. Pull the fuel contro! lever and run the engine at medium speed. Low iaing Medium speed 3. Free the safety lever of the bucket control lever. 4, Leaving the bucket control lever in either pushing or pulling side, run the engine for about 5 mi- nutes to warm up the hydraulic oil _, Dump —27- OPERATING YOUR MACHINE Avoid abruptly accelerating the engine until the completion of warm-up. After warm-up run is completed, check gauges, warning lamp for proper operation. Check if the exhaust color is normal or whether there is any abnormal noise or vibration Do not run the engine at low idling or high idling for more than 20 minutes. If it is necessary to run the engine at idling, apply a load from time to time or raise the engine speed to @ midrange speed.OPERATING YOUR MACHINE TO MOVE THE MACHINE OFF 1. Put the swing lock lever into the lock position by pushing the lever down. 3. Free the safety levers of left and right work equipment levers, move the work equipment in and raise it to @ height of about 40 to 2. Pull the fuel control lever to in- 4, Pull the blade control lever and crease engine speed. raise the blade. Low iting —28- 5. Slowly incline left and right tabel- ing and the steering levers in the forward (forward moving off) or reverse (revers moving off) direc- tion, and move off. Neutral ee An sk 6. Depress the accelerator pedal (only for PC30) to increase travelAd check whether the track frame is facing forward or backward before operating the traveling and steering levers. Ai Avoid abruptly operating the traveling and steering lovers with the fuel control lever fully open, as this will cause the ma- chine to move off suddenly. TURNING (CHANGING DERECTION) Operating the travel levers to change direction. Operated the two travel levers as follows, * When the sprockets are at the front, the operation of the travel levers is reversed, so before operating the travel levers, check the position of the sprockets. * Avoid sudden changes in direc- tion as far as possible. When car- ing out conterrotation tums ‘pin turns), stop the machine first before tuning it * When changing direction in places where there is large resis- tence to turning, do not use the accelerator pedal. (only for PC30) = 29- OPERATING YOUR MACHINE ‘When changing direction with ma- chine stopped Turing tttwnen ) \y eninstonend Turing left when Na, When tuming left, operate the RIGHT travel lever as follows. When ‘traveling FORWARD, push lever FORWARD. When _ traveling REVERSE, pull lever BACK, * When tuming right, operate the left travel lever in the same way.(OPERATING YOUR MACHINE Changing direction when traveling (when both left and right travel levers are in the same position) WRT al When turing to the left, return the left travel lever to neutral, and the machine will tum to the left (pivot turn), ‘* When tuming right, operate the right travel lever in the same way. When making a counterrotation turn (spin turn) When tuming to the left on the spot, pull the left travel lever back and push the right lever forward, % When making 2 counterrotation ‘tum to the right, pull the right travel lever back and push the left lever forward, — 30 ~ SWING OPERATIONS ‘Always check that the surround- ing area Is safe before swinging the upper works. 1. Before swinging, pull out the ‘swing lock lever and release the lock. Beofre starting swing operations, always check that the lock is released. Use the left work equipment con- trol lever to swing the upper works. Never insert the swing lock lever when swinging,3. When not swinging, align the upper works with the track frame, and insert the swing lock lever to lack the upper works. %* Do not operate the swing lock lever in any other position OPERATION OF THE WORK EQUIPMENT The work equipment is operated using the right and left work equip ment control levers, and blade con- trol levers, ‘The left work equipment control lever controls the arm, the swing ‘and boom swing operation and the fight work equipment control lever controls the boom and the bucket. If you release the lever it returns to the neutral position and the work equipment is held in that position. * When switching swing/boom swing selector lever, the left work equipment control lever is used to swing the boom and the upper works. Aiwnen operating the work tauipment, do not depress the travel accelerator pedal. only forPcs0) -31- OPERATING YOUR MACHINE ARM OPERATION x If the swing/boom swing selector lever isin the (B) position.(OPERATING YOUR MACHINE TO STOP THE MACHINE BOOM OPERATION BOOM SWING OPERATION 1. Put the loft: and right traveling and the steering levers in the neu- tral position. — es ‘ If the swing/boom swing selector 2. Lower the engine speed using lever isin the (A) position, the fuel control lever. KR, Low iting a igh ing BUCKET OPERATION BLADE OPERATION = 32-TO STOP THE ENGINE 3.Lower the bucket horizontally 1 until its underside touches the ‘ground, 4. Lock the work equipment levers 2. with the safety levers., 5. Lower the blade to ground, Awiren stopping the machine, Select flat hard ground. and avoid dangerous places tmuvoidably necessary to par the machine on a slope, insert blocks “underneath the wack * thoes. As an edaltional safety mmoasure,, trust the, bucket Into the ground Run the engine at low idling speed for about 6 minutes to allow it to gradually cool down. Return the starting key to the OFF position, stop the engine and romove key. If the engine is abrupity stopped before it has cooled down, engine life may be greatly short- ened. Consequently, do not ab- rupty stop the engine apart from ‘an emergency. In particular, if the engine has overheated, do not abrupty stop it but run it at medium speed to allow it to cool gradually, then stop it 33 (OPERATING YOUR MACHINE PRECAUTIONS FOR OPERATION © Be careful not to compact the soil or damage earth mounds as 2a results of the swining force. ‘@ When swinging, do not dig the bucket teeth into the soil ‘© Do not move off and excavate with the bucket leaving dug into the ground. ‘© When working with the machine, do not move the cylinder to the end of its stroke but leave a small safety margin ¢ Do not use the dropping force of the bucket as a pickaxe, breaker, or pile driver. ¢ Do not use the dropping force of the machine for digging. ¢@ tis better to excavate hard rocky ground after breaking it up by some other means. This will not only reduce damage to the ma- chine but make for better economy.OPERATING YOUR MACHINE @ Never allow the blade to butt — @ Note that the following phenome- against, or give strong impact. To _naare not faults. do such work will damage the 1) When the arm is pulled back, it blade and the hydraulic cylinder. will sometimes stop when be- ‘© Nover hit the blade by the bucket _ comes more or less vertical because they interfere in lowering 2) The arm may sometimes stop ‘and retracting for moving and when the bucket teeth become transportation. more or less horizontal © Do nt support the machine on 3) At the beginning and end of a telesea cone end of the blade to use it as. swinging, a noise may sometimes. ‘an outrigger. be emitted from the brake valve. @ Do not immerse the machine in © Do not hit the boom cylinder 4) When descending @ steep slope water by more than the permissi- against the blade when digging _—at low speed, a noise may some- _ble depth (under swing circle (1)) the deep ditch in front of the times be emitted from the travel _In addition, properly grease parts blade. Back hoe work should be motor. which have been immersed in carried out after keeping the water for @ long time, until the blade to the opposite position of QMIt it is necessary to use the old grease comes out from the the bucket, equipment control levers when _bearings (vicinity of bucket pins, the machine is traveling, tem- swing circle system, etc.) porarily stop the machine, then the work equipment. =34-When diving the machine aut of 0 nt travel on slopes of over water, if the angle of the machine exceeds 15°, the rear of the upper structure will go under water, and water will be thrown up by the radiator fan. This may ‘cause the fan to break. Be extremely careful when driving the machine out of water. © When traveling down a hill, adjust the speed with the travel lever and fuel control lever. Hf the grade exceeds 15°, set the machine in the posture shown in the diagram below, and reduce the engine speed. ie ‘Y20 — 30cm 30° as there is danger that the machine may overturn. To brake the machine during downhill runs, put the traveling and steering lever in the neutral position. This will cause the brake to be automatically applied. When climbing a hill if the shoes slip or the travel motor relieves, preventing the machine from climbing by means of the tracks alone, it is possible to use the force of the arm as an aid When the engine stops on a slope, move the traveling and steering levers to neutral position and lower the bucket. Thereafter, turn starting key to START, When the engine stops on a slope, the boom will move by it’s ‘own weight if the swing lever is moved, Therefore, do not move the swing lever under any conditions. Se OPERATING YOUR MACHINE HOW TO ESCAPE FROM MUD ‘© Always operate carefully to avoid getting stuck in mud. If the ma- Chine does get stuck in mud, use the following procedures to get the machine out. ¢ When one side is stuck. When only one side is stuck in mud, use the bucket to raise the ‘track, then lay boards or logs and drive the machine out. If neces- sary, put a board under the bucket also. + When using the boom or arm to raise the machine, always have the bottom of the bucket in con- tact with the ground. (Never push with the teeth) The angle b tween the boom and arm should be 90° to 110°(OPERATING YOUR MACHINE ‘© When both sides are stuck. When the tracks on both sides are stuck in mud and the machine will not move, lay boards as ex- plained on the left, and dig the bucket into the ground in front. Then pull in the arm as in normal digging operations and put the travel levers in the FORWARD position to pull the machine out. PRECAUTIONS WHEN USING RUBBER SHOES @ When traveling, avoid traveling over sharp objects or over stones on the road, and avoid using the ‘machine in unstable conditions. © Turning suddenly on road sur- faces with a high friction coeffi- cient (such as concrete) will cause the rubber shoes to break @ Do not go into places where the ‘temperature is high, such as im: mediately after a bonfire, @ In areas where there are large ‘amounts of rocks and stones, the rubber shoes may be damaged or come off because of rocks or stones caught in the rubber shoe, 80 drive extremely carefully in such areas. @ Do not rub along concrete walls when driving. = 36- Be careful not to let oll get stuck fon the rubber shoes. If there is any oil on the shoes, wipe it off immediately When storing for long periods, keep indoors away from direct sunlight and rain The adhesion of the metal core is attacked by salt, so avoid using near the sea. Because of the properties of rubber, use the rubber crawler within’ range of —25°C to +55°C, Always maintain the shoes at a suitable tension. Sudden changes of direction when traveling cause early wear ‘and damage of the rubber shoes, so avoid such operations as far as possible. When turning on the spot (spin turn), stop the ma- chine, and run the engine at mi- drange speed or below when turning(OPERATING YOUR MACHINE ‘@ Rubber shoes are likely to slip on snow or icy roads. When working on snow-covered or icy slopes, avoid using rubber shoes and take full precautions to ensure safety. ‘® When changing from steel shoes to rubber shoes, always remove the stopper plate used to prevent the track from coming off. Plate Aiwnen changing trom steel shoes to rubber shoes, or from rubber shoes to steo! shoes, always contact your Komatsu distributor to have the. work carried out -37-REPLACEMENT OF BUCKET REPLACEMENT OF BUCKET Stop the machine on a firm, flat surface. When performing joint work, ‘make clear signals to each other and work carefully for safety's sake. Ade, Jt a 1. Select a flat surface and stabilize 3. Couple the arm to hole (1), then. the bucket connect the link to hole (2). 2. After removing the stop bolt and 4. After mounting the stop bolt and nut for each pin, extract pins A _nut for each pin, apply grease to and B. ‘ach pin. % After removing the pins, make sure that they do not become contaminated with sand or mud and that the seals of bushing on both sides do not become damaged, -38— omeCOLD WEATHER OPERATION COLD WEATHER OPERATION PREPARATION FOR LOW TEMPERATURE If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, 0 do as follows, FUEL AND LUBRICANTS. Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see the TABLE OF FUEL, COOLANT AND LUBRICANTS. COOLANT ‘After cleaning inside of the cool- ing system, add antifreeze to the coolant to prevent the coolant from freezing when the machine is not being used + For details of the antifreeze mix- ture when changing the coolant, see WHEN REQUIRED. = 39 - Care in using Antifreeze Use a Permanent Antifreeze (ethylene glycol mixed with corro- sion inhibitor, antifoam agent, etc) meeting the standard requirements fs shown below. With permanent antifreeze, no change of coolant is required for a year. If it is doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for information Standard requirements for perma- nent antifreeze © SAE J1034 © FEDERAL STANDARD 0-A-548D(COLD WEATHER OPERATION + Never use methanol, ethanol or propanol based antifreeze. ‘%* Where no permanent antifreeze is available, an ethylene glycol an- tifreeze without corrosion inhibi- tor may be used only for the cold season, In this case, clean the cooling system twice a year (in spring and autumn). When refill ing the cooling system, add an freeze in autumn, but do not add any in spring. + Absolutely avoid using any water leak preventing agent irrespective of whether it is used indepen- dently or mixed with an antifreeze. ‘+ Do not mix one antifreeze with a different brand. Maniitrooze is tlammabie, so keep it away from any flame. BATTERY ‘As ambient temperature drops, bettery capacity will drop, and elec- trolyte may sometimes freeze if bat- tery charge is low. Maintain battery at a charge level of approx. 100% and insulate it against cold tempera- ture so that machine can be readily started the next morning. ‘* Measure specific gravity of fluid and obtain rate of charge from the following conversion table: Tap Lats! ore | orc | -10'e| -20¢ Beal vous Poae [rae va0 [rah sox | 126 |127| 128 | 123 tox | 126 | 125] 126 | 127 rox_| 123 | 120] 126 | 128 -40- ‘* When electrolyte level is low, add distilled water in the morning before work instead of after the day's work. This is to prevent fluid from freezing at night. Ai7o avoid gas explosions, do not bring fire or sparks near the battery. Ait tne ctectrotyte gets on your ‘skin or clothes, immediately wash with plenty of clean water.CAUTIONS AFTER COMPLETION OF WORK 1. Mud and water on the machine body should be completely removed. Park the machine on concrete or hard ground. If this is impossible, park the machine on wooden boards. This will prevent the ac- cessories from freezing or the track and undercarriage from freezing to the ground thereby preventing vehicle movement the next morning. Particular attention should be given to water drops collected on the surface of the hydraulic cylinder piston rods. Such droplets must be fully wiped off because if water is frozen to the rod when the eylin- der is utilized, the cylinder oil seals may be damaged. 2. Drain water collected in fuel system so that such water may be frozen at night. 3. As battery capacity drops at low ambient temperature, cover the battery or remove it from the ma- chine to be kept warm at night. 4a COLD WEATHER OPERATION AFTER COLD WEATHER When weather becomes warm, perform the following without fail: Replace lubricating olls for vari- us units with the ones specified for warm-weather uso. ¢ If for any reason permanent anti- freeze cannot be used, and an ethyl glycol base antifreeze (winter, one season type) is used instead, or if no antifreeze is used, drain the cooling system completely, then clean out the inside of the cooling system thor- oughly, and fill with fresh water.PERIODIC MAINTENANCE Proper lubrication and maintenance assure trouble-free operation and long machine life. Time and money spent for scheduled periodic mainte- nance will be amply compensated by prolonged machine operation and re- duced operating cost Al hourly figures given in the following descriptions are based on service meter readings. In practice, however, itis recommended to rearrange all of them into units of days, weeks and months to make the maintenance schedule more convenient, Under rough job site or operating conditions, itis necessary to somewhat shorten the maintenance intervals stated in this manual —43— PERIODIC MAINTENANCEMAINTENANCE TABLE MAINTENANCE TABLE No vrem SeRvicE [Pace Wo rem Service [Page ‘CHECK BEFORE STARTING EVERY 50 HOURS SERVICE 2 | Wat around check 20a Fulmer atorand b | Coote Check andsuppiy | 20 b| Dumeup Cleon a cc | Engine oil pan ‘Check and supply | 21 © | Lubricating 48 Fuel tank ‘Check and supply. a + | Swing circle pinion Lubricate 1 point al 48 EVERY 100 HOURS SERVICE | Hydraulic tank Chek ond spy + | Oustinsizator Check - 2 | Lubrieatng 0 Water sparator [eves 23 Boom-wing evinder fot pin | Lubricate 1 point | 49 | etectrica wiring Cheek 23 2| Boom evliner foot pin Lricate point | a9 | Boomswingcvlinger rod end | Lubricate t point | 48 : INITIAL 50 HOURS SERVICE -4[ Boom foot pin © [ tubrcate point | 49 a | veroue tier Replace element | 47 | Boomwing bracket pin Lsbrieae 2 points | 48 © | crate tank strainer Clean “5 | Boom evinder ro ene Lubricate 1 point | 49 2| Am eying 10% pin Lricae 1 point | 48 | em cylinder rod end Lirica point | 49 = 44—MAINTENANCE TABLE Ne vem Senvice [PAGE Ne Trem SERVICE [PAGE | Boormarm coupting pin Lubriate point | 49 INITIAL 250 HOURS SERVICE 10| Bucket ylinder foot pin___| Lubricate 1 point | 49 | Fira crv cave Change ait 20 41 | Bucket cylinder rod end Lubricate 1 point | 49 bb | Swing machinery case Change oil 60. -12| Link coupling pin Lubricate 1 point 49 “e Engine valve clearance Check and agjust 50 “713 Bucket tink coupling pin Lubrieatet point | 49 - | - 14] Arm-bucket coupling pin | Lubricate 1 point “| 49 ~ ~ 15) Arm-link coupling pin Lubricate 1 point | 49 | EVERY 250 HOURS SERVICE “16 | Bae cylinder rod ena | Luvrisste point | 60 a nol rive cave [check and supaiy | 81 17| Blade cylinder foot Bin Lubricate point | 60 b| Fan ver Check tension 31 “1e| Bla oot in ‘uoricat 2 points | 60 | Hydraulic iter Reolece element | 62 “| Swing machinery case Check and supply | 60 | Battery electrolyte Check fiuid level | 89 {hou dost mglestor fapiscs semen |S 1 | water separator element ‘ivan | = - ~ a | Engine ot pen and fiter Chenoeovane™™ | se —45—MAINTENANCE TABLE me ire service rua Tem = EVERY 600 HOURS SERVICE WHEN REQUIRED | oe | Rea each Sistine | + | Ruse Geen S oc cin | Labricating 7 se | Tank Greek ond edit | gg ung ov T|ewenwaecm [se Ta lemeen peice a @ | Window washing fluid ‘Check and supply 70 EVERY 1000 HOURS SERVICE 7 - 7 ‘3 | Final drive case Change oil 59 iz 'b| Swing machinery case - Change oi! 59 EVERY 2000 HOURS SERVICE 2 [| Hvcrauttank Sane Tendo «| Averetoranswaring nor” Coe @ Check anseaue | « | Engine vaive clearance =46—INITIAL 50 HOURS SERVICE Perform the following mainte- nance after running the machine for the first 50 hours. ‘a, HYDRAULIC FILTER b, HYDRAULIC TANK STRAINER For details of the method of replacing or maintaining, see the section on EVERY 250 HOURS AND 2000 HOURS SERVICE Simultaneously, maintenance for 50 hours should be carried out. INITIAL SOHOURS SERVICE EVERY 80 HOURS SERVICE EVERY 50 HOURS SERVICE a, FUEL TANK b. AIR CLEANER DUST CUP Loosen valve (1) on the bottom 1. Remove dust cup (1), dispose of the tank so thet the sediment and _the dust int. mixed water will be drained in ac- 2. Clean inside of the cup. companiment with fuel. -47-EVERY 50 HOURS SERVICE ©. LUBRICATING Apply grease to the grease fit- tings shown by arrows. 1. Swing circle pinion (1 point) Turn the chassis little by little and apply grease through the grease fitting. * When applying grease, stop the swing operation. —48—EVERY 100 HOURS SERVICE EVERY 100 HOURS SERVICE * Maintenance for every 50 hours should be car- ried out at the same time. a. LUBRICATING Apply grease to the grease fit- tings shown by arrows. 1. Boom-swing cylinder foot pin (1 point) 2. Boom cylinder foot pin (1 point) 3. Boom-swing cylinder rod end (1 point) Boom foot pin (1 point) Boom-swing bracket pin (2 points) Boom cylinderrod end_(1 point) Arm cylinder foot pin (1 point) Arm cylinderrodend (1 point) Boom-arm coupling pin (1 point) Bucket cylinder foot pin (1 point) Bukcet cylinder rod end (1 point) Link coupling pin (1 point) Bucket-link coupling pin( point) ‘Arm-bucket coupling pin (1 point ‘Arm-link coupling pin (1 point) —49-EVERY 100 HOURS SERVICE INITIAL 250 HOURS SERVICE 16. Blade cylinder rod end (1 point) 17. Blade cylinder foot pin (1 point) 18. Blade foot pin {2 points) b. SWING MACHINERY CASE Check the oil level in the swing machinery case. The oil level should be between H and L of gauge (G) + Check that dipstick (G) is com- pletely inserted in * The type of lubricant used depends on the ambient tempera- ture. Select according to the table "FUEL, COOLANT AND LUBRICANTS’ —50- INITIAL 250 HOURS SERVICE Perform the following mainte nance after running the machine for the first 250 hours. a. FINAL DRIVE CASE b. SWING MACHINERY CASE ¢. ENGINE VALVE CLEARANCE For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS, 1000 HOURS AND 2000 HOURS SERVICE,EVERY 250 HOURS SERVICE EVERY 250 HOURS SERVICE * Maintenance for 50 and 100 hours should be car- ried out at the same time. a. FINAL DRIVE CASE b. FAN BELT 1, Set level plugs (1) (2 places) * The type of. lubricant used de- 1. The belt tension should normally parallel to the ground with drain pends on the ambient tempora- deflect by 10 to 15 mm when plug (2) at the bottom. ture. Select according to the pressed with the finger at a point 2. Remove one of plugs (1). If the table “FUEL, COOLANT AND. midway between the fan pulley oil is not filled up to near the LUBRICANTS" ‘and the crankshaft pulley bottom line of the plug hole, refill (approx. 6 kg) with engine oil through plug hole. Fan pulley sontsm O) oe J Crankshaft pulley Pam -51-EVERY 250 HOURS SERVICE 2. To adjust the belt tension, loosen bolt (1) and nut (2) and shift alter- nator (3) slightly. When adjusting the V-belt, do ot attempt to push alternator (3) directly with a bar or the like, but use a wood pad to prevent damage to the core Check each pulley for damage, and V-grooves and V-belt for ‘wear. Particularly, check whether V-belt is in contact with bottom of V-groove through wear. Replace belt if it has stretched, leaving no allowance for adjust- ment, orif there is a cut or crack on bolt. —52- c. HYDRAULIC FILTER 1. Gradually loosen cap (F) of the oil filler to relieve inner pressure. 2. Remove the bolts (2) and cover @)3. Remove element (1) and replace it with @ new one after cleaning the removed parts and the case interior. Aiwien removing the cover, tndo the bolts (bolt) gradual Iy to prevent the cover flying oi under the fore of "the spring. d. BATTERY ELECTROLYTE ‘~ vor wt Remove cap (1). If the electrolyte level is lower than the prescribed level (10 to 12 mm above the plate), supply distilled water. Should any of the acid be spilt, have it replenished by the nearest battery shop with acid of the cor- rect specific gravity. When inspecting electrolyte level, clean the air hole of the bat- tery cap, 53 - EVERY 250 HOURS SERVICE Ait te electroivte gets on your Res Tasteey amie kenh wach with, plenty of clean oe Bie aveid gas explosions do not bring fie or sparke near the meeeEVERY 250 HOURS SERVICE e. AIR CLEANER ELEMENT (without dust indicator) 1, Remove clip (1) and dust cup (2). 2. Remove wing bolt (3) and ele- ment (4). Clean the element, inside of the ‘case and the dust cup, and install them. Do not clean or replace the A Cover the air inlet port when removing element. Be sure to assemble seal washer (5) when mounting element Install the dust cup holding it's arrow mark upward. Replace the element which has been cleaned 6 times repeatedly or used throughout a year. Replace seal washer (5), wing bolt (3) if they are broken. ‘cleaner element with the engine running. = 64— Cleaning element With compressed air au Direct dry compressed air (loss than 7 kg/cm!) to element from inside along its folds, then direct it from outside along its folds and again from inside, and check element, Arwen using compressed air, voor safety glasses and other things required. to main safetyEVERY 260 HOURS SERVICE f, WATER SEPARATOR 9. ENGINE OIL PAN AND FILTER ELEMENT ae 1. To facilitate filter replacement, % If small holes or thinner parts are 1. Tighten handle (1). stop the engine after turning the found on element when it is 2. Loosen ring (2), then remove upper frame alittle (ebout 30°) checked with an electric bulb _case (3) and the element. 2. Remove the drain plug (P) to after cleaning end drying, replace 3. Clean the inside of the case and drain oil. After draining, tighten- the element. the element with diesel oi, ing the drain plug. % Do not use element whose folds 4. Install the element and case (3), 3. Using a filter wrench, remove car- or gasket or seal are damaged. then tighten ring (2) ‘ridge (1) of the engine oil filter ‘* When cleaning element, do not —* Be careful not to lose the red ring _by turning it counterclockwise hitit or beat it against something. inside the case. + if filter cartridge (1) is removed 5. Open handle (1) immediately after stopping the engine, oil will spill. Wait at least 10 minutes after stopping the engine before replacing the filter cartridge, 55 -Every 250 HOURS SERVICE Engine ol er eartrdge 4, Clean the filter base and apply engine oil to the seal on the new filter cartridge. * To install cartridge, bring its packing surface into contact with sealing surface of filter base and then tighten cartridge 1/2 to 3/4 tum 6. After replacing the cartridge, pour in the specified quantity of engine oil from oil filler (F) 6. Run the engine for a short time at idling, then stop the engine and leave for about five minutes Measure the oil level and check that it is between H and L marks on the gauge. + Refill capacity: 45& * The type of lubricant used depends on the ambient tempera- ture. Select according to the table “FUEL, COOLANT AND LUBRICANTS” —56— Be sure to fit a genuine Komatsu cartridge. Replace once every 6 months, regardless of the number of hours operated. When fitting the cartridge, be careful not to tighten it up excessively Use API category CD class oil. If CC class oll must be used, change the oil and replace the oil filter at half the usual interval.EVERY 500 HOURS SERVICE a. FUEL FILTER, 1. Loosen the ring (1) and take the element out of the filter, using the service tools furnished with the machine. 2. Wash element cup (2) in light oil fr in 2 cleaning oil and install a new element in the filter. + When replacing 2 fuel filter ele- ment, replace the filter O-ring at the same time. 3 4, EVERY 500 HOURS SERVICE * Maintenace for every 50, 100 and 250 should be carried out at the same time. Turn the starting switch key to the ON position. Push air bleed button (3) of the fuel filter, and continue to press it Until no more bubbles come out from the air bleed hose. Push air bleed button (4) of the injection pump inlet port, and continue to press it until no more bubbles come out form the air bleed hose, When no more bubbles come out, turn the starting switch key to the OFF position. When the machine has been out of use for a long time, bleed the air also before starting the engine. -57- b. RADIATOR FINS. Clean the radiator fins clogged with mud, dust and leaves with compressed air. Steam or water may be used instead of compressed air. % The rubber hose should be checked at the same time. If the hose is found to have cracks or to be hardened by ageing, such hose should be replaced by new one. Further, loosened hose ‘clamp should also be checked,EVERY 600 HOURS SERVICE ¢. LUBRICATING Apply grease to the grease fit- tings shown by arrows. 1. Swing circle (2 points) -58-EVERY 1000 HOURS SERVICE a. FINAL DRIVE CASE = ® 1. Set level plugs (1) (2 places) parallel to the ground with drain plug (2) at the bottom. 2, Remove plug (2) to drain the oil After draining, tighten the plug. 3. Then, supply new engine oil through oil filler (1) respectively to the specified level. (Refer to EVERY 250 HOURS SERVICE.) EVERY 1000 HOURS SERVICE * Maintenace for every 50, 100, 250 and 500 hours should be carried out at the same time. % The type of lubricant used de- pends on the ambient tempera- ture. Select according to the table “FUEL, COOLANT AND LUBRICANTS”. % Refillcapacity: 1.2.8(each side) —59- b. SWING MACHINERY CASE 1. Drain off oil from drain plug (P) at the bottom of the machine After draining, tighten the drain plugEVERY 1000 HOURS SERVICE 2. Pour in the specified amount of * Refill capacity: 13.2 engine oil from gauge hole (F). (Refer to EVERY 100 HOURS SERVICE) % The type of lubricant used depends on the ambient tempera- ture. Select according to the table “FUEL COOLANT AND LUBRICANTS” — 60 ~ aseEVERY 2000 HOURS SEAVICE EVERY 2000 HOURS SERVICE + Maintenance for every 50, 100, 250, 500 and 1000 hours should be carried out at the same time. a. HYDRAULIC TANK 1, Retract the arm and bucket cylin- 3. Loosen hose band (1) end bolt After changing oil, put the control der, then lower the boom and put (2). Remove flange (3) and wash —_levers in N (neutral) position and the tips of the teeth in contact _the strainer (4). run the engine at low idling speed with the ground. 4, Pour in the specified amount of _for a few minutes before opera- 2. Remove drain plug (P) to drain engine oil from oil filler. tion of work equipment. off the oil, After draining off the (Refer to CHECK BEFORE oil tighten up drain plug (P) STARTING) ‘* The type of lubricant used de- pends on the ambient tempera- ture. Select according to the table "FUEL COOLANT AND LUBRICANTS”. + Refill capacity: 352EVERY 2000 HOURS SERVICE b. ALTERNATOR AND STARTING motor As the hours of engine employ- ment indicate that the brushes are already worn out, you should re- quest repair from @ Komatsu distributor, * They should be repaired every 1000 hours, if the machine is fre- quently operated at night. c. ENGINE VALVE CLEARANCE ‘Ask Komatsu distributor to check engine valve clearance be- cause special tools should be used —62-WHEN REQUIRED a. CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT (with dust indicator Checking moO Whenever the red piston in dust indicator (1) appears, clean the air cleaner element. Stop the engine when cleaning the element. Cleaning or replacing element 1, Remove clip (1) and dust cup (2) 2. Remove wing bolt (3) and ele- ment (4), Clean the element, inside of the ‘case and the dust cup and install them. 3. Push the dust indicator reset button to return the red piston to the original position. =63— WHEN REQUIRED Cover the air inlet port when removing element. Be sure to assemble seal washer (6) when mounting element. Install the dust cup holding it's arrow mark upward. Replace the element which has been cleaned 6 times repeatedly or used throughout a year.wren REQUIRED % Replace seal washer (6), wing bolt (3) if they are broken, Aico not clean oF replace the ai leaner element with, the engine running. Cleaning element With compressed, Direct dry compressed air (less than 7 kg/em*) to element from inside along its folds, then direct it from outside along its folds and again from inside, and check element. Aiwien using compressed air, wear safety glasses and other things required to maintain safety. a * If small holes or thinner parts are found on element when it is checked with an electric bulb after cleaning and drying, replace the element. Do not use element whose folds or gasket or seal are damaged ‘When cleaning element, do not hit it or beat it against something,b, CLEAN INSIDE OF COOLING SYSTEM Clean the inside of the cooling system, change the coolant, and add the corrosion resistor agent Kl according to the table. ‘* Stop the machine on level ground when cleaning or chang- ing the coolant. * Use a permanent type of antifreeze If, for some reason, it is impossi- ble to use permanent type anti- freeze, use an antifreeze contain- ing ethylene glycol A Always add Komatsu genuine corrosion resistor agent Ki. One packet of corrosion resistor agent contains 100g, The stan- dard density of the mixture should be 79/£. Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. Antifreeze is flammable, so keep it away from any flame. Cleaning inside of Kind of cootent cooling system and ‘changing cook ‘Adding corrosion resistor agent Kr Permanent type antifeeze {Altsecson type) comes ist ‘Non permanent type vary 6 months (pring, | Every 1000 hours and when anttfeeze containing futur. ‘loaning the inside ofthe ‘inylane glyco! {Grain sntitreazein spring, | cooling ystam and whon (Winter: one season type) | ade antifreeze imauturnn!” | changing coolant Every yea autor) or ‘very 2000 houre wnichover Every 6 months or When not using antifrze | every 1000 houre whichever ec wien ReauiReD @ Add antifreeze in the cooling water When deciding the ratio of anti- freeze to water, check the lowest temperature in the past, and decide from the mixing rate table given below. It is actually better to estimate a ‘temperature about 10°C lower ‘when deciding the mixing rate. Mixing rate of water and antifreeze in, atmospheric | _5| _19| 15 |-20 “Amount of aniteere | 12) 18 | 18 | 21 a “Amount of | moter” | ae] 36 | 32 | 20 ‘ah | * We recommend use of an anti- freeze density gauge to control the mixing proportions.WHEN REQUIRED Water filler 1. Stop the engine, turn radiator cap (1) slowly until it comes off. 2. Loosen drain valve (2) at the bottom of radiator and drain plug (3) at the side of cylinder block and drain off the cooling water. Att the water temperature high, do not remove the cap. This is because of the possibili- ty of scalding water spurting out, When removing the cap, turn the cap slowly to allow pres- sure to be relieved Drain valve (radiator) 3. After draining the water, close drain valve (2) and drain plug (3), ‘then pour in water to fill the radia- tor. When the radiator is full, start the engine and run it at low idling, 4. Keep the engine running at low idling, open drain valve (2) and drain plug (3), and flush with run- ning water for 10 minutes. % When flushing, adjust the flow 0 that water is added at the same rate as the water is drained to keep the radiator always ful — 66 — Drain plug (cylinder block) i Woe After washing the cooling system, stop the engine, Open drain valve (2) and plug (3) to drain water and close drain valve (2) and plug (3) After draining off the cooling water, wash out the cooling system using commercially available detergent. Follow the in- structions on the detergent container.‘Sub-tank = 7. After washing the cooling system, drain off all the water, then close up drain valve (2) and plug (3) and pour in clean water (ex. city water) slowly up to the vicinity of the water filler. 8. When the water reaches the vicinity of the water filler, put the engine at low idling, open the drain valve (2) and plug (3), then pass water through the cooling system until clean water comes ‘out from the drain valve and plug, 10. u When flushing, adjust the flow 80 that water is added at the same rate as the water is drained to keep the radiator always full. When the water becomes com- pletely clean, stop the engine and close the drain valve (2) and plug(3) Add the specified amount of the corrosion resistor agent KI to the radiator. Use a genuine Komatsu corro- sion resistor agent. For details of the adding procedure, follow the instructions on the agent. Supply water until it overflows from water filler. We 12, 13, 14, WHEN REQUIRED Run the engine 5 minutes at low idling and then for another 5 minutes at high idling to elimi- nate air trapped in the cooling system (leave radiator cap off during this operation) After draining water in sub-tank (4), wash the sub-tank interior, ‘and supply water so that the water level is between H and L marks. Stop the engine and wait for about 3 minutes. Supply cooling water up to the specified level Tighten the cap.‘WHEN REQUIRED ¢. CHECK TRACK TENSION (STEEL SHOES) ‘The wear of pins and bushings fon the undercarriage will vary with the working conditions and soil properties. It is thus neces- sary to continually inspect the track tension s0 as to maintain ‘the standard tension on it. If the track tension is not at the standard value, adjust it in the fol- lowing manner: Inspection Raise the machine by means of the boom and arm, and measure the clearance between the tread of the 2nd track roller from the sprocket and the roller contact face of the track link. f the clearance is between 30 and 60 mm, the track tension is normal ~68— Adjustment For tightening the _ tension, pressurize grease through lubricator (1). On the other hand, for loosening the tension, extract grease by reversely rotating lubricator (1) ‘graduallyGrease may be pressurized til S dM. Do not loosen the lubricator (1) will be O mm. In case the tension is yet loose after applying pressurized injection of grease till the above- mentioned limit, it indicates that the pin bush is reduced by too much abrasion. So it is necessary either to turn or replace the pins and bush: ings. Consult your Komatsu distribu- tor for repair. over one complete rotation Also, be careful not to loose any part other than the lubrica- tor (1). If the lubricator (1) or any other part should be loosened exces- sively, it will be liable to fly out under the high pressure of jammed grease. If grease does not ooze smoothly, try moving the machine back and forth for a short distance. 69 - WHEN REQUIRED d. REPLACE BUCKET TEETH Replace the teeth before they weardown, gy) 1. Raise the bucket to a suitable height, and fit a block under the bucket to prevent it from coming down, %* Set the bottom of the bucket horizontal 2. Remove nuts and bolts (1) and (2), then remove tooth (3) 3. Install the new tooth to the bucket. 4. Adjust clearance inserting shim (4) when finding much clearance between the teeth and the bucket.Hen REQUIRED e. CHECK AND REFILL WINDOW WASHING FLUID Do this, when there is air in the window washing fluid. % Tightening torque of mounting bolt. 26.5 + 3.5 kgm % After using the bucket for several hours, tighten the mounting bolts Check the washing fluid levels in again. washer tank (1). When the fluid has run short, add automotive window washing fluid + To prevent the nozzles from clog- ging, be careful not to let dust get into the fluild ~70-HANDLING RUBBER SHOES HANDLING RUBBER SHOES INSPECTION OF RUBBER SHOES © Check the contact surface be- @ When width “d” of wire core is Replace the rubber shoes with tween the rubber shoe and the worn to 2/3 of the width of @ new parts if they are in the follow- track roller, and replace the shoe new part. ing condition if more than half of the metal Ai ¢ When dimension “2” is less than core can be seen from the rubber 112.2 mm. shoe. Holes in rubber for machine of sprocket Wear surtoce Track olor LSS TS @ When the wire core has come out because of excessive tension. @ If cracks or deop cuts reach the steel cord inside the rubber shoe, Or if the steel cord is cut, replace the shoes, N=HANDLING RUBBER SHOES REPLACEMENT OF RUBBER SHOE Removal of rubber shoe Installation of rubber shoe 1. Raise the chassis with the boom 3. Fit steel pipes inside the rubber 1. Raise the chassis with the boom and arm, shoe, rotate the sprocket in andarm, reverse so that the steel pipes make the rubber shoe come up from the idler, then slide to the side to remove. Direction of rotation ® 2. Loosen lubricator (1) and drain 7 the grease inside, v Do not loosen the lubricator (1) 2, Loosen lubricator (1) and drain the grease inside. ~ A\.00 not loosen the lubricator (1) cou cover one complete rotation. over one complete rotation. When carrying out the above Also, be careful not to loose Also, be careful not to loose operation, check that the inter- any part other than the lubric: any part other than the lubrica- nal grease has all been re- tor (1). tor (1). moved before rotating the If the lubricator (1) or any other Ifthe lubricator (1) or any other sprocket part should be loosened exces- part should be loosened exces- sively, it will be liable to fly sively, it will be liable to fly out under the high pressure of out under the high pressure of se. jammed grease. mmed gre ==Mesh the rubber shoe with the sprocket and fit it over the idler. Rotate the sprocket in reverse ‘and push in the rubber shoe. Stool pine Using a steel pipe, fit the rubber shoe and rotate the sprocket again. Check that the rubber shoe is fitted securely on the sprocket ‘and idler. Adjust the track tension. (For details, see CHECK TRACK TENSION) Check that the track tension is correct and that the rubber shoe is correctly meshed on the sprocket and idler, then lower the machine to the ground. CHECK TRACK TENSION The wear of the rubber shoe will vary with the working condi- tions and type of soil. Therefore, it is necessary to inspect the wear and track tension frequently. After fitting new parts, be sure to carry out the first inspection after 30 hours of use. == HANDLING RUBBER SHOES Set the connection (M mark) of the rubber shoe at the top midway between the two axles. Then use the arm and boom to raise the ma- chine, and check the clearance be- tween the rolling surface of the track shoe roller and the tread of the ‘3rd track roller from the sprocket. The standard clearance is 10 to 15 mm. If the clesrance is more ‘than 20 mm, the tension must be adjusted,HANDLING RUBBER SHOES Adjustment (A ‘= For tightening the tension, pressurize grease through lubricator (1). On the other hand, for loosening (6 He ® the tension, extract grease by reversely rotating lubricator (1) gradually. oe If the tension is slack even when dimension S is adjusted to 50 mm, it is necessary to replace the rubber shoes. Contact your Komatsu distributor for replacement, -74- Ai.0° not ioosen the tbricator (1) over one complete rotation, isn, be care not to tose any pat other than the lub tor (1). ifthe lubricator (1) or any other part shouldbe loosened exces. Sivetye Tt wl bo Hable to ly cut under the high pressure of iommed gromse. grouse dost nat core bmowthiy, ey mening tho mochl back and forth forSERVICE METER This meter tegrated work hour cording to instructions. indicates the in- the - So, use it ac- following SERVICE METER @ Record the readings at the start and the end of work, this is the work record of the machine. © This record will indicates, when Periodical maintenance is due @ It also indicates the integrated working hours when machine problems are encountered, * How the meter progresses This meter shows the total opera- tion hours of the machine. As long as the starting swichis put in ON po- sition, this meter indicates every 10 hour of operation ragardiess of the engine speed. The lowest figure indicates 6 minutes of operation. Ee[MACHINE AND ENGINE SERIAL NUMBERS MACHINE AND ENGINE SERIAL NUMBERS When calling for a service of mechanic or when — making replacement-parts order, be sure to give Komatsu distributor the ma- chine and engine serial numbers as wall as the service meter reading before mentioned. These numbers are founds an the plates shown in the photos below. Location of the engine serial number mark ¢ Location of the machine serial number mark This is seen on the upper left of the cylinder head, when seen from the fan side. This is seen on the front left of the frame. sae -17-FUEL, COOLANT AND LUBRICANTS FUEL, COOLANT AND LUBRICANTS PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS KINO OF FLUID. ‘AMBIENT TEMPERATURE ee er =10 ee CAPACITY (2) RESERVOIR Specified eit TTSAE3G) Engine oil pan 48 48 ‘Swing machinery case Final drive case (each) Engine oil 12 Hydraulic tank 38 Fue tae Diet fue! Cooling system ‘Ad antifreeze '® ASTM DTS No. 1 —78-NOTE: (1) When fue! sulphur content is less than 0.5% change oil in the oil pan every periodic mainte- ‘nance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%. ee Change interval of oil in Fuel sulphur content Seneclpan 0.5 to 1.0% 1/2 of regular interval Above 1.0% 1/4 of regular interval ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API. American Petroleum Institute (2) 3) FUEL, COOLANT ANO LUBRICANTS. When starting the engine in an atmospheric tem- perature of lower than 0°C, be sure to use engine oil of SAE1OW, even though an atmospheric tem- perature goes up to 10°C more or less in the day time. Use API classification CD as engine oil and if API classification CC, reduce the engine oil change in- terval to hat Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.SAFETY AND OPERATIONCONTENTS SAFETY HINTS: - - A HANDLING OF BATTERY TRANSPORTATION METHOD OF RAISING THE MACHINE PRECAUTIONS FOR MAINTENANCE STORAGE COOLANT AND LUBRICANTS 15 18 19 20 27 28SAFETY HINTS: - - & OPERATION GENERAL '® Accidents or injuries are liable to @ If there should be an accident or ‘occur when the operator is car fire or any other such unexpected less or slack. It is most important mishap, deal with it quickly, to bear safe operation in mind at _using the nearest apparatus. all times. Learn beforehand the locations © Wear well-itting helmet, safety @ Take care of your health. Do not _of the first aid boxes and fire ext- shoes and working clothes. the operate when tired, or after _inguishers and how to use them. nature of the work requires drinking. It is also important to know the safety, wear protective goggles _@ Learn the prohibitions, cautions emergency contact system. or mask, thick gloves, ear plugs and rules about work procedures. @ Learn about the safety devices or other protection. in the work site. fon your own machine and about ‘When there is a leader, fix stan- how to use them. Confirm that dard signals and always follow —_ they are correctly attached in the these signals when operating prescribed position. Such safety devices include Protective-Devices ‘% Seat BeltsBEFORE STARTING OPERATION ¢ Exhaust gas is dangerous. When ® When operating inside a building running the engine for long peri- always be sure of the clearance ods in a poorly ventilated area, of the ceiling, entrances, aisles, there is @ danger of gas poison. _ etc. and the load limit of the floor. @ Examine the lay of the land and ing, so open the windows or @ Never allow other person than the kind of soil at the work site to doors to ensure agood supply of _—the operator to ride on the ma- determine the dangerous points fresh air. chine during operation. and the best method of © Read the Operation and Mainte- operation. nance Menual carefully. Learn Proceed with the work only after how to use the control devices, making safety arrangements gauges and warning devices. Be about the dangerous points. sure you understand the meaning @ Inspect leakages from the fuel, lu- of the caution plates. Remember bricating and hydraulic systems. ‘the check points and checking Check that the shoe bolts are not method for engine cil, fuel, cool- loose, and that no other parts are ing water and hydraulic oil levels. damaged or missing. Machines having such failures should not be operated.@ When getting on or off the ma- chine, use the handrail provided. Do not jump up or down from the machine. Do not leave parts or tools lying around in the vicinity of or on the floor of the operator's cab. Keep everything in its proper place. Wipe off thoroughly any grease, oil or mud on the handrail, floor ‘or control levers. Failure to do this may cause you to slip. Check the level of the fuel, lubri- cants and cooling water. Ext- inguish cigarettes before check- ing or replenishing. Check that the radiator cap and each oil filler caps or plugs ere firmly tightened. Adjust the operator's seat until it is in the most comfortable posi tion for operating. Always sit in the seat while operating. Do not operate the machine from any other position. To ensure the safety of workers rear the machine, always sound the horn to wam them before starting the engine and moving the machine, Be particularly care- ful to check that the rear is clear before backing the machine@ Inspect the inside of the engine room and remove any dead leaves or papers. Dead leaves or Papers are highly inflammable and can cause fires. ‘© Before starting the engine, con- firm that all control levers are in NEUTRAL. AFTER STARTING THE ENGINE © Confirm that all gauges and warning devices are functioning correctly, and that the gauge readings are within the prescribed range. ‘© Check the play and travel of each lever. © Operate the working equipment to confirm that they are function- ing normally nt e » SX sa © Before operating the traveling and steering levers, check wheth- fr the track frame is forward or backwards. If the track frame is facing backwards, operate the traveling and steering levers in the reverse manner to that when the track frame is facing forward. @ Move the machine slowly and listen carefully to the engine or gears to confirm that they are not making any unusual noises, ‘© Choosing a safe place, turn the machine to the left and right to confirm that the traveling nd steering levers are functioning normally @ If these tests reveal anything wrong, however slight is may be, contact the man in charge of the machine and operate the machine only after obtaining his permission.DURING OPERATION @ Maintain the bucket at a height of 40 to 50 cm above the ground 0 that it can be quickly lowered to the ground and the machine stopped in an emergency. @ As far as possible, operate the machine so that it does not tilt (Do not tilt it by more than 35° in either the forward, rear, left or right directions, even under static conditions.) Always operate slowly in crowd- ed places. On haul roads or in narrow places, give way to loaded vehicles. Do not allow unauthorized per- ‘sons into the work area. Before reversing or tuming, ensure that there is nobody in the vicinity. Also, be careful of obstacles. When operating on slopes, as far {as possible, avoid turning the ma- chine on a slope. It may cause the machine to roll over or slip sideways, When operating the machine along a road, retract the working equipment to improve machine stability. As far as possible pro- ceed along a flat road,© The machine should always be * Wherever possible, avoid trav. The machine condition can be operated at a speed where it can cling over large rocks, fallen judged from many _ factors. be correctly controlled. Never do trees, tree stumps and other Changes in the gauges, sound, vi the following: such obstacles. Either use the bration, exhaust gas color or re- 1) Speeding working equipment to remove _sponse of the control levers can 2) Sudden starting, sudden brak- them, or travel round them. indicate the occurrence of some ing, sudden turning When itis impossible to avoid —_— disorder. If any disorder occurs, 3) Snaking traveling over them, reduce park the machine immediately in 4) Coasting speed and mount over the a safe place and take appropriate ‘@ When operating on uneven obstacle. Just before the front action. Be especially cereful in ground or in places where there of -the machine tips down, the case of a fuel leak as there is are obstacles, remember the fol- reduce speed even more to danger of fre. lowing points: make the shock of hitting + Operate at as low a speed as ‘ground as small as possible. Possible and avoid sudden + Never mount over an obstacle changes in direction. at an angle; never disengage ‘one traveling and steering lever to travel over an obstacle.‘¢ When passing through a narrow ‘® The work area should be made © Be careful of thos® around you, space, be careful of the side and fas flat as possible, If the work and always confirm that there is overhead clearances. Take spe- ‘area is flat, operation is made no person or obstacle in the way _cial care not to touch any obsta- much easier and this reduces before moving or turning the cles on either side or overhead. If operator fatigue. machine. necessary, have someone outside @ Always concentrate. It is ex- . the machine call out instructions. ‘tremely dangerous to allow your- i — @ Be careful not to operate the ma. 7 Chine into a bog. In the event that self to be distracted or to think of other things when operating a fy __ the machine goes into a bos, ex- machine. In dangerous places, or =) hey ‘tract it in the following manner; where there is restricted visibility, be 1) If only one track of the ma- chine is in the bog, push the = bucket down against the = ‘ground on the side of the ma- it is important to get down from ‘the machine and confirm whether itis safe before continuing work @ When using the working equip- chine which is stuck so as to ment, be sure to keep your eyes float the track. Then place onit all the time. Failure to do this logs or timber underneath the ‘may result in an accident. track and free the machine.* 2) When raising the undercar- riage by means of the boom or arm, push the bottom of the bucket against the ground (on no account use the teeth) until the angle between the boom and the arm is 80° to 110°. If both tracks of the machine are in the bog and slip, pre- venting the machine from get- ting in, place logs or timber under the tracks in the manner described in 1), then thrust the bucket into the soil in front of the machine and drag it out by bending the arm in the same manner as when ex- cavating and putting the trav- ling and steering lever into the forward position. © After earthquakes, confirm that the ground is stil firm; after blasting, confirm that there are no unexploded charges. remaining % © When working on river embank- ments or other places made of piled soil, there is the danger that the weight of vibration of the ma- chine may cause the machine to sink into the piled soil, so be ex- tremely careful when operating in such places. @ When continuing operations after rain, remember that condi tions will have changed from those before the rain started, so proceed with caution, Be particularly careful when ap- proaching the shoulder of the road of cliffs, as they may have been loosened by the rain.© Check the load limits of bridges before crossing. © When working in water or marshy ground, be careful of the following: * When working on soft ‘ground, place thick boards on the ground to prevent the ma- chine sinking. Place the boards horizontally and ar- range them as neatly as possible. When operating in water or when crossing shallows, first check the bed soil condition and the depth and flow speed of water, then proceed, taking care not to go beyond the permitted depth % First check the water depth, the firmness of the ground and the strength of the cur- rent. Do not enter if the water exceeds the permissible depth (up to the bottom of the swing circle) = 10- When operating in fog, mist or smoke, where visibility is bad, be especially careful to confirm first whether operation is safe, When visibility drops below safety level, stop work and wait for the visibility to improve.‘© When operating at night, remem- ber the following points: + Be sure to arrange an adequate lighting system % At night it is very easy to make mistakes in assuming the dis- tance and height of objects ‘and land. Be very careful not to touch elec- tric wires, always bearing in mind that there is a possibility of re- ceiving an electric shock. Wear rubber or leather soled shoes. Position a full-time watcher at the site to ensure that operator is not exposed to the risk of electric shock =e Depending upon the supply vol- tage itis conceivable that an elec- tric shock may be received by merely coming into the vicinity of an electric feeder wire. Accord- ingly, observe the minimum dis- tances given in the table below, taking into account the inertia of the boom when in motion, Suppi weage urbe tater) (kv (satbaon 320(1 te 3 inet) an 68.016 08 instr) Sm 15401104018 neuter) a0 2750116t020%nauetor) | 10m * Become familiar with the neces- sary measures to be taken in the event that a operator receives an electric shock.‘© Do not perform excavation at the bottom of a precipice as it is dangerous practice, @ If it is unavoidably necessary to operate the working equipment lever when traveling the machine in the vicinity of a precipice, road shoulders, on sloping ground or through @ confined space, stop the machine momentarily before operating the working equipment lever in order to minimize danger. When working on loose, crumbly soil, do not dig deeply and back the machine off smartly. If the ground crumbles, preventing the ‘machine from getting away in time, do not panic and raise the working equipment. It is often better in the interests of stability to leave it down, Do not undercut the machine unless absolutely necessary. lf necessary, always take care to Prevent the machine falling -12- WAL ‘¢ When operating at the edge of a cliff or on the shoulder of a road, remember the following points: % When operating in a place where there is danger of the ‘machine falling over the side, bbe doubly careful. Do not ap- proach the edge of the cliff or road shoulder by mistake.‘@ If you suspect that there are @ Take care not to swing the buried facilities (water or gas bucket against the sides of pipes, etc) at the work site trenches or dump trucks. Load check with the companies re- the truck from the rear. sponsible for looking after such facilities and also try a different method of excavation. Then, after confirming the existence ‘and location of such facilities, carefully carry out excavation work. Peo -13-PARKING ‘© When parking the machine, park @ When parking the machine, @ Before leaving the machine, carry it in @ safe place outside the return the working equipment out the following: working area, or in the specified __levers to neutral, apply the brake Apply the swing lock. place. The following factors lock, lower the bucket to the Lower the bucket to the should be considered when ground, and put all safety levers ground. choosing a parking place: it in the lock position. Switch off | Put the working equipment should be on flat, firm ground _the engine and remove the key. lever in neutral and lock it. where there is no danger of rock- % Stop the engine and remove falls, landslides or floods. If the the key to prevent other machine has to be parked on a people using the machine, slope, it should be parked facing + Lock the cab, directly up or down the slope, ‘and chocks should be placed under the tracks. When the ma- chine is facing downhill, lower the bucket so that it cuts slightly into the ground to further in- crease the safety. 14 oweHANDLING OF BATTERY PRECAUTIONS FOR CHARGING BATTERY 1 Before charging, disconnect the cable from the negative (—) terminal of the _ battery. Otherwise, an unusually high voltage will damage the alternator, While charging the battery. remove all battery plugs for satisfactory ventilation. To avoid gas explosions, do not bring fire or sparks near the battery 3.1f the electrolyte temperature exceeds 45°C, stop charging for awhile. 4, Turn off the charger as soon as the battery is charged. Overcharging the battery may cause followings: 1) Overheating the battery 2) Decreasing the quantity of electrolyte. 3) Damaging the electrode plate. 5. If the electrolyte gets on your skin or clothes, immediately wash with plenty of clean water. 15 = 6 8 HANDUNG OF BATTERY Do not mix up cables (positive (+) to negative (—) or negative (=) to positive (4)), as it will damage the alternator When inspecting or servicing 9 battery, be sure to stop the engine and turn the starting switch key to “OFF” position When performing any service to battery besides checking the electrolyte level or measuring the specific gravity, disconnect cables from the battery.HANDLING OF BATTERY REMOVAL AND INSTALLATION OF BATTERY @ When removing battery, first disconnect the cable from the ground (normally, from the negative (—) terminal. If 2 tool touches a cable connecting the positive terminal and the chassis, there is danger of sparks being emitted. @ When installing battery, the ground cable should be connected to the ground terminal as the last step. STARTING ENGINE WITH A BOOSTER CABLE When starting up the engine with a booster cable, do as follows: 1. Before connecting the booster cable 1) Size of booster cable and clip should be suitable for the battery size. 2) Check cables and clips for breaks, corroded surfaces, etc. 3) Make sure cables and clips are firmly secured. 4) Keep the starting switch in “OFF” position. 5) The battery of the running engine must be the same capacity as that of engine to be started. ~16- 2. Connect the booster cables in the following manner. 1) Connect one clip of booster cable A to the positive (+) terminal of the engine to be started. 2) Connect the other clip to the positive (+) terminal to the engine which is running. 3) Connect one clip of booster cable B to the negative (—) ‘terminal of the engine which is. running, 4) Connect the other clip to the engine block to be started. * Make sure the clips are firmly connected to battery terminals Then, start the engine. engine 10 be started @ Engine block tobe startedArwnen connecting the cables, never contact the positive (++) and negative (—) terminals. Aimake sure that the booster cable connections are correct. Connect the booster cable to the engine block as far as possible from the battery. 3. Starting engine 1) Turn the starting switch to START position and start up the engine. 2)If the engine doesn’t start at first, try again after 2 minutes or so, After the engine has started, the booster cables should be disconnected in the reverse order in which they were connected. 1. Disconnecting the booster cables 1) Disconnect the clip of booster cable B from the engine block which was started. 2) Disconnect the other clip from the negative (—) terminal of the running engine. o Tes HANDLING OF BATTERY 3) Disconnect the clip of booster cable A from the positive (+) terminal of the running engine. 4) Disconnect the other clip from the positive (+) terminal of the engine which was started engine which wos started Engine block which was states -17-“TRANSPORTATION When transpor TRANSPORTATION 19 the machine, observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc, It is a good idea to obtain a special platform for loading and unloading the machine. When it is unavoidably necessary to use a gangplank, however, at the very least observe the following for the sake of safety. 1, Properly apply the brakes on the trailer and insert blocks beneath the tres to ensure that it does rot move. Then fix the gangplank in line with the centers of the trailer and the machine + Make sure the gangplank has suf- ficient width, length and thick- ness to enable the machine to be safely loaded and unloaded. if the gangplenk segs apprecia- bly, reinforce it with blocks, ete Lock the upper works using the swing lock lever. 2, Determine the direction of the gangplank, then slowly load or unload the machine. Adkemove the mud from the un- dorcarriage to prevent the ma- chine from slipping to the side on slope: * Move the machine backward to get on the trailer. Do not on any account change the direction of the machine while it is on the gangplank. To change the direction of the ma- chine, first take it down from the gangplenk. Correctly load the machine onto the specified part of the trailer. After loading the machine, fully extend the bucket and arm cylin ders, then slowly lower the boom. When transporting the ma- chine, place rectangular timber under one end of the bucket cylinder to prevent it touching ‘the ground, thereby saving it from possible damage. eae 4, When transporting the machine, place rectangular timber under- neath the front and rear track shoes to prevent the machine from moving about. Also, hold it down with chains or rope. Be par- ticularly careful to ensure that the machine does not slip sideways. 6. Lock the swing lock lever and apply the lock to the work equip- ment levers, % Determine the route for trans- porting the machine by taking into account the width, height ‘and weight of the machineMETHOD OF RAISING THE MACHINE METHOD OF RAISING THE MACHINE Raise the machine as follows. 1 k fA\s0°—40" Rotate the upper structure so that the blade is at the rear of the ‘machine, then apply the swing lock. Raise the blade fully. Extend the bucket cylinder, arm cylinder, and boom cylinder fully, then set the work equipment con- trol levers at neutral, and apply the safety lever. Center the boom swing, then set the boom swing control lever at neutral, and apply the safety lever. 5, Install shackles to both ends of the blade and to the lifting brack- ets on the boom (¢ places), then fit the wire rope securely. % Always use the brackets at 4 places, 6. Make the angle of the wire rope approx. 30° — 40° when raising, % When raising, pay attention to the center of gravity and be ex- tremely careful to maintain the balance. + Never attempt to raise the ma- chine with the boom swing or Upper structure at an angle. Ado not raise the machine with ‘any worker on the machine. This is extremely dangerous. Aiton rsising ne machin, be of ample. capacity forthe wrelghtat the machine. ~19-PRECAUTION FOR MAINTENANCE PRECAUTION FOR MAINTENANCE SAFETY... © Do not handle electrical equip- ment while wearing wet gloves, or in wet places, as this can cause electric shock ‘© During maintenance do not allow ‘any unauthorized person to J stand near the machine. dost] © Wear wellsitting helmet, safety @ Fuel or oil are dangerous, shoes and working clothes. substances. When drilling, grinding or ham- ‘Never handle fuel, oll, grease or mering, always wear protective _cily clothes in places where there goggles. is any fire or flame. As preparation in case of fire, ‘always know the location and di- rections for use of fire extinguish ers and other fire-fighting equipment. ‘© Exhaust gas is dangerous. When working inside, be particularly careful to have good ventilation. -20- owes& ¢ Unless you have special instruc- tions to the contrary, mainte- nance should always be carried ‘out with the engine stopped. Lock the swing lock lever and also all of the safety levers. If maintenance is carried out with the engine running, there must be two men present: one sitting in the operator's seat and the other one performing the mainte- nance. In such a case, never touch any moving part. PRECAUTION FOR MAINTENANCE When working underneath the ‘machine, place a sign to that effect on the operator's seat and, if necessary, put @ similar signs in the vicinity as well Do not go undemeath the ma- chine after raising it up using the boom and the arm, -a- When working with others, choose a group leader and work according to his instructions. Do not perform any maintenance beyond the agreed work. When maintenance has to be car- ried out with the working equip- ment raised, they must be securely supported by blocks.PRECAUTION FOR MAINTENANCE ‘@ Always remember that the hy- Method of relieving pressure ‘@ Flames should never be used in- draulic oil circuit is under pres- 1) Lower the working equipment to stead. of ‘lamps. Never use @ sure. When feeding or draining the ground and stop the engine _—_—naked flame to check leaks or the the oil or carrying out inspection _ after idling it for two or three mi-_—level_ of ‘oil, fuel, antifreeze or ‘and maintenance, release the nutes. Then operate the various _—_electrolyte. pressure first. operation levers. (working equip- Immediately remove any oil or ment, traveling and steering lever grease on the floor of the opera- through their full stroke in each tor’ compartment, or on the direction) handrail. It is very dangerous if When removing air instruments someone slips while on the or pipings, open the drain valve machine. under the air reservoir to relieve © Be particularly careful when air pressure, removing the radiator cap. If this, 2) Gradually unscrew the cap of the _is done immediately after using hydraulic tank and leave it for a «the machine, there is a danger few minutes. that boiling water may spurt out. PootPRECAUTION FOR MAINTENANCE ‘© Do not check the fan belt tension while the engine is running. Be sure to turn off the engine before inspecting other rotating parts and the vicinity thereof Do not allow anybody other than the necessary workers to go near the machine while it is being it spected or maintained. Also, be careful of people in the vicinity. It is necessary to exercise particular care when performing grinding or welding, or when swinging 2 large hammer. Fa aes Use the too! which is suitable for the maintenance work. — 23- Remove the minus terminal from the battery in maintaining the electrical system, When the tracks are removed, never put your fingers between the shoes. When carrying out other difficult maintenance works, carrying them out carelessly can cause unexpected accidents. If you con- sider the maintenance is too diffi- cult, always request Komatsu dis- tributor to carry out it.PRECAUTIONS FOR MAINTENANCE MISCELLANEOUS © Thoroughly wash the machine, particularly the oiling and greas- ing parts and the vicinity, thereof, in order to prevent the ingress of dust. © Use genuine Komatsu repiace- ment parts specified in the parts list @ Use Komatsu specified oil and ‘grease. Use oil and grease having the recommended viscosity for the particular ambient temperature, @ Use clean oll and grease and keep them in clean containers to avoid the ingress of dust. @ Inspect or replace oll in a dust- free location to prevent the in- gress of dirt © Drain off used oil after heating it to 2 suitable temperature (about 20 t0 40°C). When the strainer is located in the oil filler, the strainer must not be removed while adding oi. When adding oil or checking the oil level, check that the oil is at the correct level After greasing up, always wipe off the old grease that was forced out. When changing the oil or filter, check the drained oll and filter for any signs of excessive metal particles or other foreign materials, When removing parts containing O-rings, gaskets or seals, clean the mounting surface and replace with new sealing parts, —24— When washing the machine, ensure that water does not get onto the alternator. Special measuring apparatus is needed for testing hydraulic pressure, ‘Thoroughly wash the machine. In particular, be careful to clean the filler caps, grease fittings and the area around the dipsticks. Be careful not to let any dirt or dust into the system. When check an open cover there is a risk of dropping things in Before removing the covers to in- spect cover, empty everything from your pockets. Be particularly careful to remove wrenches and nuts.© When working on the sea shore, check that the various plugs and valves, etc, are tightened up properly. After the completion of work, thoroughly wash the ma- chine end carefully clean all electrical equipment to ensure that is does not corrode. © Before working in muddy water, rain or snow, check that the vari- ous plugs, valves, are properly screwed up. Upon completion of work, wash the machine, then check the various parts of the machine for cracking, scratching, loose or missing nuts and bolts Also, oil and grease the verious parts of the machine. © When working in a dusty location, be careful of the following: 11 Inspect the dust indicator to see whether the air cleener is blocked up. Clean the air cleaner as soon as it becomes dirty 2) Clean the radiator core so that it does not become blocked up. 3} Clean or replace the fuel filter as soon as it becomes dirty. 4) Clean the electrical equipment, particularly the starting motor and alternator, to prevent ac- ‘cumulation of dust. ‘© When working on rocky ground, be careful of damage to the undercarriage, loose nuts and bolts, cracks, wear and other damage. Also, adjust the track tension so that itis a little slacker ‘than usual. = 25 — PRECAUTIONS FOR MAINTENANCE When installing car radio and a walkie-talkie or citizen band, con- tact your Komatsu distributor. When washing the machine, take care not to splash water over the electrical equipment. If it is soaked with water, it may not operate normally. After disconnecting the con- nector, cover it with a vinyl bag to prevent oil or dust from stick- ing to its contact section, When welding, be careful of the following 1) Turn OFF the power (starting switch! 2)Do not continuously apply ‘more than 200 V. 3) Install the ground cable at least 1 m from the range to be welded, 4) Take care not to install the seals between the grounded point and the range to be welded,PRECAUTIONS FOR MAINTENANCE ‘¢ After replacing oil iter element or strainer, bleed the air from the circuit. # After replacing hydraulic oll aid Filter element, or replacing the hy- draulic cylinder or the piping system for the machine, the air vvent operation is necessary. Low- idle the engine, and proceed as follows: 1. Extend and contract each cylinder 4 to 5 times, taking care not al- lowing it to reach its stroke end fie. allowing it to return from a point of about 100 mm before the stroke end} 2. Then, extend and contract each cylinder 3 to 4 times up to the stroke fullend + Sudden running of the engine at 2 high speed and allowing of the cylinder to reach the stroke end cause damage to the piston pack- ing, etc. due to the air trapped in the cylinder. — 26- PonBEFORE STORAGE To place the machine in storage for an extended period of time, the following measures must be taken to insure that it can be returned to operation with minimum of service. © After every part is washed and dried, the machine shall be housed in 2 dry building. Never leave it outdoors, In case itis indispensable to leave it outdoors, lay wood plates on the ground, and park the machine fon the wood plates and cover it with canvas etc, ‘© Completely fill fuel tank, lubricate and change oil before storage. © Apply a thin coat of grease to metal surface (hydraulic piston rods and front idler adjusting rods). 1 As to batteries, remove the termi- nals and cover them, or remove them from the machine and store separately. STORAGE © When the ambient temperature is anticipated to drop below 0°C, always add antifreeze in the cool ing water. © The fuel control lever shall be set to STOP position. DURING STORAGE ‘© Operate the engine and move the machine for a short distance ‘once @ month so that new oil film will be coated over movable parts and component surfaces. © Before operating the work equipment, wipe off the grease (on the hydraulic piston rod, AAW ein uravotdabty necessary to cart out runt preventive ope cretion while the: machine is indoors. open up dooreanwin, dows to improve veilaton and provent the gas potsoning. = 27- STORAGE AFTER STORAGE After storage (when it is kept without cover or the rust-preventive operation once @ month is not madel, you shall apply the following treatment before operation ¢¢ Loosen the drain plugs on oil pan and other cases and drain mixed jer head cover and lubricate sufficiently valves and rocker arms. And inspect the valve operation, © After the engine is started, oper- ate it until it is warmed up ‘completely.COOLANT AND LUBRICANTS: COOLANT AND LUBRICANTS magn = rere Coe vo | swernone | sagidiobarso, | Thabane! | (etre yes Bt ‘SAE10W/30, SAE15W/40 iF [Permanent Type} oe 1 [scr Superdiese! Multigrade. cam = 2 [ance dame sto a : an 5 | cacTex RPM Delo 400 Marfak All Purpose ‘AF Engine Coolant | eae . Z cao rs ne ‘Delo 400, ‘Ultra-Duty Grease 2 7 ee Performance 3C_ EPEXA 2, Glace 9 | EXXON (ESSO} | Essolube XD-3 eee - soCOOLANT AND LUBRICANTS Engine O11 Grease Anti-Freeze Coolant fa on (cot (Lithium Basel [Ethylene Giyeo! Basel 'e. | Supplier Name | sae tow, SAE3O, NLGI2 {Pormanent Type! SAETOW/30, SAETSW/40 Gulferon Gresse No.2 | Cruisemanter Antitracze vo | cur super Dury Gulferovin EP Special and Greate No, 2 Summer Caalant Detvee 1300 Mobilorease MP NMopilgreaee 17 a1 | most, DaWvec 1400 beet Permozone Delvse 1400 Super Mobilux EP2 : ‘supreme Duty Fleet IMuit:Purpose No.705 | Anti Freaze & 2a ea Mult-Dury Wheel Bearing No.707L | Summer Coolant 7 peat ‘Avanin Grosse EP | zs 13 | SHELL at ‘Grease EP Sunflet Diesslube XL | Sunfleet HP ‘Sunace Mult Saak0n sae Suntleet Super © ‘Sun Prestige 742 €P ‘Anti-Freeze Ursa Super Plus ‘ Marfok All Purpose Startax AF & 18 | Texaco Uae OHA Marfak Multi Purpose 2 | Summer Coolant Ursa Super LA Rubies i a 16 | ToTAL. Rubie x Multis €P2 Antifreeze 17 | union Gusrdol Unoba €P ~ 29-