Operation & Maintenance Manual: Compact Track Loader

CEAM017102
Operation & Maintenance

Manual
CK30-1
COMPACT TRACK LOADER
SERIAL NUMBERS CK30-1 A30001 and up

ENGINE 4D98E-2
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2010 Komatsu

Printed in U.S.A.
Komatsu America Corp.
March 2010
0INTRODUCTION
CK30-1 0-1
INTRODUCTION
FOREWORD
This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the
operator and maintenance personnel achieve peak performance through effective, economical and safe machine operation and
maintenance.
Keep this manual handy and have all personnel read it periodically. If this manual is lost, damaged or becomes dirty and
cannot be read, request a replacement manual from your local distributor.
If you sell the machine, be sure to give this manual to the new owner.
Continuing improvements in the design of this machine can lead to changes, which may not be reflected in this manual.
Consult your local distributor or for the latest available information on your machine or for questions
regarding information in this manual.
This manual may contain attachments and optional equipment that are not available in your area. Consult your
local distributor for those items that you may require.
Improper operation and maintenance of this machine can be hazardous and could result in serious injury
or death.
Operators and maintenance personnel must read this manual thoroughly before operating or maintaining
this machine. This manual should be kept near or with the machine for reference and periodically reviewed
by all personnel who operate it.
Some actions involved in operation and maintenance can cause a serious accident, if they are not
performed in the manner described in this manual.
The procedures and precautions given in this manual apply only to the intended uses of this machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that
it is safe for you and others. In no event should you or others engage in prohibited uses or actions as
described in this manual.
KOMATSU delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety features and specifications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult your local distributor or KOMATSU before operating
the machine.
The safety description is given in SAFETY INFORMATION and in the SAFETY section 1.
0-2 CK30-1
INTRODUCTION
SAFETY INFORMATION
Most accidents are caused by failure to follow fundamental safety rules for the operation and maintenance of the machine. To
avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before
performing maintenance and machine operations.
To identify safety messages in this manual and on machine product graphics, the following signal words are used:
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury. This signal word is to be limited to the most extreme situations.
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe practices.
Other signal words

In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the
machine or to give information that is are useful to know.
Remark
This word is used for precautions that must be taken to avoid actions, which could shorten the life or damage
the machine.
The safety precautions are described in SAFETY section 1.
KOMATSU cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore
the safety message in this manual and on the machine may not include all possible safety precautions. If any procedures or
actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such
procedures and actions safely and without damaging the machine or causing injury. If you are unsure about the safety of some
procedures, contact your local distributor.
Before starting any maintenance operation, position the machine on a firm and level surface, lower the equipment to
the ground, engage the safety locks of the equipment and of the controls and stop the engine.
To make the information clearer, some illustrations in this manual represent the machine without safety guards. Do not
use the machine without guards and do not start the engine when the engine hood is open, unless this is expressly
prescribed for some specific maintenance operations.
CK30-1 0-3
INTRODUCTION
It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu cannot be held liable for
any damage to people, property, or the machine, if this has been tampered with by modifying the standard setting of
the hydraulic system.
Before carrying out any electrical welding, disconnect the battery and the alternator (See “Precautions Concerning
The Battery And Alternator” on page 1-43).
Install only available additional attachments (“Characteristics Of The Optional (Factory Supplied) Equipment For The
Machine With High Flow And Super-flow Hydraulic Systems” on page 5-4).
Travel on roads is allowed only if the machine is provided with appropriate lighting, signalling and safety devices and
properly authorized by the relevant permits.
Before travelling on roads, make sure that the equipment installed on the machine is approved and the safety locks are
correctly engaged.
It is absolutely forbidden to operate the machine while standing on the ground.

Every single maneuver must be carried out by the operator, correctly seated in the driving position.
0-4 CK30-1
INTRODUCTION
APPROVED AND NON APPROVED USES

Approved
The Komatsu MACHINES described in this manual have been designed and constructed to be used by duly trained personnel
mainly for EXCAVATION and EARTH-MOVING OPERATIONS.
If provided with suitable safety devices, they can be used with available optional attachments having the characteristics
illustrated in, See “AVAILABLE OPTIONAL ATTACHMENTS” on page 1-2.
Non Approved
• The instructions regarding the available optional attachments are given in the relevant operation and
maintenance manuals; if the equipment is supplied by Komatsu, these publications are attached to this manual.
• The instructions regarding the assembly of the available optional attachments, the controls requiring special arrangements
on the machine, and the hydraulic couplings necessary for the operation of the attachment are shown in the final section of
this manual.
Komatsu MACHINES are constructed exclusively for the handling, excavation and treatment of inert materials; therefore, the
following uses are absolutely forbidden:
• USE OF THE MACHINE BY MINORS OR INEXPERIENCED PEOPLE.
• USE OF THE MACHINE FOR LIFTING PEOPLE OR OBJECTS.
• TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.
• USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.
• USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.
CK30-1 0-5
INTRODUCTION
PRODUCT INFORMATION
Listed are features and machine identification locations. Komatsu skid steer loader and main components are identified by
serial numbers stamped on identification plates or decals attached to the machine or component.
Main Features
• Simple and easy operation.
• Hydrostatic transmission obtained through a double variable displacement pump and axial piston motors operating
epicyclic reduction gears.
• Two driving tracks always engaged through oil-immersed roller chains.
• Main equipment and travel control through servo levers ensuring combination movements that can be modulated
proportionally and continually.
• Foot control for the optional equipment (if installed).
• Foot accelerator.
• Lever accelerator.
• Parking brake control.
• Complete series of instruments visible from the operating position.
• Easy maintenance with simplified intervals.
• Road travel (on request).
Break In Period
Every new machine is properly adjusted and tested before delivery. A new machine must be operated carefully for the first 100
hours to ensure proper run-in time for the various components. It the machine is subjected to excessive or severe work loads at
the beginning of it’s operation, it’s functions will be greatly reduced or damaged. Every new machine must be used carefully,
paying special attention to the following indications:
• After start up, let the engine idle at a low RPM for 5 minutes, to warm up the machine gradually before beginning actual
operation.
• Operate the machine with limited loads. Avoid abrupt starts, accelerations, sudden decelerations, abrupt reversals or
sudden stops.
• After the first 50 hours, perform the following maintenance, in addition to normal maintenance performed at 50 hours:
• Check the drive chain tension.

• Check the rubber track tension.
• After the first 250 hours, perform the following maintenance, in addition to normal maintenance performed at 250 hours
perform:
• Change the hydraulic system filter.

Synthetic Biodegradable Oil Types
On machines in which synthetic biodegradable oil type HEES is used, the following operations are to be performed, besides
the standard maintenance operations:
• After the first 50 hours of operation, change the hydraulic system filter.
• After the first 500 hours of operation, change the hydraulic system oil and filter.
0-6 CK30-1
INTRODUCTION
PRODUCT IDENTIFICATION
The serial numbers and model numbers on the components are the
only numbers that your distributor will need when requiring assistance
or ordering replacement parts. It is a good idea to record this
information in this manual on page 0-9 (Serial Number and distributor
information). All views indicated below are viewed from the operators
position.
Machine Serial Number

The machine serial number is stamped on the inner wall of the right
rear pillar.
Machine Identification Plate And Product Identifi-

cation Number (Pin)
The PIN plate is located on the inner wall of the right rear pillar.
CK30-1 0-7
INTRODUCTION
Engine Serial Number And Emission Plate

The plate (1) indicating the engine serial number and the exhaust gas
emission plate (2) are positioned on the top of the valve cover.
Travel Reduction Gear Serial Number

The serial number of the travel reduction gear is stamped on the plate
positioned on the hydraulic motor cover.
Cab Serial Number

The cab serial number is stamped on the plate positioned on the right
side of the base cross member.
0-8 CK30-1
INTRODUCTION
SERIAL NUMBERS AND DISTRIBUTOR INFORMATION

Model: CK30-1
Machine #
Product identifica-
tion # (PIN)
Engine #
Travel reduction
gear #
Cab #
Excavator #
(if installed)
Distributor:
Address:
Phone #
Contacts:
NOTES:
CK30-1 0-9
INTRODUCTION
TABLE OF CONTENTS
INTRODUCTION
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
APPROVED AND NON APPROVED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
Non Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
PRODUCT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
Main Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
Break In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
Synthetic Biodegradable Oil Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
Machine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
Machine Identification Plate And Product Identification Number (Pin) . . . . . . . . . . . . . . . . . . . . . 0-7
Engine Serial Number And Emission Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
Travel Reduction Gear Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
Cab Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
SERIAL NUMBERS AND DISTRIBUTOR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
Model: CK30-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10
SAFETY
SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Example Of Safety Label Using Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Example Of Safety Label Using Pictogram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Location Of The Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Decals Defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Leaving The Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Mounting And Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Checking The Rear-view Mirrors (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Fire Prevention For Fuel And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Preventing Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Asbestos Dust Hazard Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Preventing Accidents Caused By Improper Operation Of The Work Equipment . . . . . . . . . . . . . 1-25
Fire Extinguisher And First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Precautions Concerning The Cab Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Precautions When Using ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Precautions Concerning The Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
PRECAUTIONS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Safety On The Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
0-10 CK30-1
INTRODUCTION
Precautions To Be Taken For The Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Room Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Precautions To Be Taken For The Lights (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Cleaning The Windows And The Rear-view Mirrors - Checking The Windshield Wiper Blades 1-28
PRECAUTIONS TO BE TAKEN WHEN WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Rules For Traveling In Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Moving The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Working On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Preventing Electrocution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Working On Icy Or Snow-covered Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Preventing Accidents Caused By The Improper Operation Of The Work Equipment . . . . . . . . . 1-33
Working On Loose Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Loading And Unloading The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
The Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Safety Precautions For Work On Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Starting With Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
Precautions For Emergency Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
PRECAUTIONS DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Warning Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Equipment Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Working Under The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Keeping The Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Engine Operation During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
Critical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
Stop The Engine Before Carrying Out Any Maintenance Operation Or Inspection . . . . . . . . . . . 1-41
Rules For Refueling The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Cooling System Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Using Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Precautions Concerning The Battery And Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
Precautions Concerning The Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
Precautions Concerning High Pressure Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
Precautions For Working On High Pressure Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
Precautions For Maintenance Work Involving High Temperatures And Pressures . . . . . . . . . . . 1-45
Rotating Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
Precautions To Be Taken When Using High-pressure Grease To Adjust The Rubber Track
Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
Do Not Remove The Shock Absorbing Spring From The Shock Absorber Unit . . . . . . . . . . . . . 1-46
Hydraulic Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46
Disposal Of Waste Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
Hydraulic Environmental Ester Synthetic (HEES) Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
OPERATION
CK30-1 0-11
INTRODUCTION
SAFETY LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Loader Arm Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
GENERAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Front View Of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Rear View Of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Inside View Of Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Engine Coolant Temperature Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Fuel Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Alternator Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Preheating Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Engine Oil Pressure Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Air Cleaner Clogging Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Hydraulic Oil Filter Clogging Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Parking Brake Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Speed Increase Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Float Switch Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Direction Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Working Light Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Safety Device Functionality Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Switches And Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Parking Brake Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Rotating Beacon Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Left Stabilizer Button (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Right Stabilizer Button (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Working Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Emergency (Hazard) Switch (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Parking Light And Low Beam Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Direction Indicator Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Front Equipment High Flow Hydraulic System Momentary Switch (3 Lines) . . . . . . . . . . . . 2-19
Front Equipment Super Flow Hydraulic System Continuous Switch (5 Lines) . . . . . . . . . . . 2-19
Speed Increase Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Floating Device Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Seat Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Available For Other Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Electrical Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Electric Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Master Electrical Disconnect Switch (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Safety Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
ISO Pattern Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Left PPC Control Joystick (Travel And Steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Right PPC Control Joystick (Loader Arm And Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
0-12 CK30-1
INTRODUCTION
Optional Pattern Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Left PPC Control Joystick (Left Track Travel, Steering, And Loader Arm Control) . . . . . . . 2-30
Right PPC Control Joystick (Right Track Travel, Steering, And Bucket Control) . . . . . . . . . 2-32
Auxiliary Hydraulic Kit Control Pedal (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Foot Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Hand Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Standard Flow Hydraulic System Control (2 or 3 Lines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Super Flow Hydraulic System Control (5 Lines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Speed Increase Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Floating Position Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Pattern Shifting Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Right Stabilizer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Left Stabilizer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Optional Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Fuses And Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Machine Function Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Standard Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Version With Optional Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
GUARDS AND OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Tilting The Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Standard Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Technical Documentation Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Checks Before Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Starting A Warm Engine Or In Temperate Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Starting A Cold Engine Or In Cold Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Warming The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Heating The Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Moving The Machine (Iso Pattern Control System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Steering (Changing Direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
How To Move The Machine (Optional Pattern Control System) . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
CK30-1 0-13
INTRODUCTION
Hand And Foot Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Travel And Steering Control Joysticks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Work Equipment Control Pedals (Loader Arm And Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Auxiliary Hydraulic Control Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
How To Move The Machine (Hand & Foot Control System) . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Moving On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Maximum Immersion Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
Parking On Level Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
Parking On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
HOW TO LIFT THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
COLD WEATHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
Fuel And Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
Other Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
Precautions To Be Taken At The End Of Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
WARM WEATHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
OPERATING THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Lowering The Equipment In Case Of Machine Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Organizing The Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
Loading Heaped And Level Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
Loading Operations On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Digging Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
Changing The Bucket Or Attachment With Standard Quick Coupler . . . . . . . . . . . . . . . . . . . . . . 2-95
Removing The Bucket Or Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
Installing The Bucket Or Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
Checking The Position Of The Locking Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Adjusting The Locking Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
Using The Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
Optimal Use Of The Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
Rubber Track Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
Precautions To Be Taken When Using The Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
Precautions For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Long Periods Of Inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Before The Period Of Inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
During The Period Of Inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
After The Period Of Inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
How To Move The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
If The Fuel Has Been Completely Depleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
Battery Is Exhausted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
Starting With Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
0-14 CK30-1
INTRODUCTION
Other Troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108
Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
Hydrostatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
MAINTENANCE
GUIDE TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

MAINTENANCE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Notes Regarding The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Notes Regarding The Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Notes Regarding The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Notes Regarding Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Parts Subject To Wear That Periodically Need Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Selection According To The Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES . . . . . . . . . . . . . . . . 3-9
LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Critical Parts For Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Standard Flow Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Super Flow Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Operator’s Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Standard Torque For Bolts And Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Specific Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
When Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Checks Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
After The First 50 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Every 50 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Maintenance After The First 250 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Every 250 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
After The First 500 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Every 1000 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Every 2000 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
When Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Air Cleaner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Releasing The Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Checking The Battery Charge Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
CK30-1 0-15
INTRODUCTION
Checking The Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Checking And Adjusting The Rubber Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Changing The Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Checks Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Various Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Checking The Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Hydraulic System Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Draining Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Checking The Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Maintenance After The First 50 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Maintenance Every 50 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Checking The Rubber Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Checking The Coolant Level In The Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Checking The Oil Level In The Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
First 250 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Fan Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Cleaning The Outside Of The Radiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Lubricating The Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Changing The Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Changing The Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Checking The Torque Of The Bolts And Nuts That Fasten The Carriages To The Machine
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Maintenance After The First 500 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Maintenance Every 500 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Changing The Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Changing The Hydraulic Oil Drain Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Changing The Oil In The Travel Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Cleaning The Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Draining Condensate From The Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Maintenance Every 1000 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Changing The Hydraulic System Oil And Cleaning The Suction Filter . . . . . . . . . . . . . . . . . 3-53
Checking And Adjusting The Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Maintenance Every 2000 Hours Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Changing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Changing The Suction Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Checking The Alternator And The Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
SPECIFICATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Standard Machine Overall Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
OPTIONS, ATTACHMENTS
AVAILABLE OPTIONAL ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Basic Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
0-16 CK30-1
INTRODUCTION
Precautions Regarding The Installation Of Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Characteristics Of The Standard Machine With Optional (Factory Supplied) Equipment . . . . . . . 5-3
Characteristics Of The Optional (Factory Supplied) Equipment For The Machine With High Flow
And Super-flow Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Changing The Available Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Connecting The Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Connecting The Return Circuit With Direct Drainage Into The Tank . . . . . . . . . . . . . . . . . . . . . . 5-8
Preparing The Machine For Use With The Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Using The Machine With The Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Pallet Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
CK30-1 0-17
INTRODUCTION
MEMORANDUM
0-18 CK30-1
0SAFETY
Please read and make sure that you fully understand the precautions described in this manual and the safety labels on
the machine. Read and follow all safety precautions. Failure to do so may result in serious injury or death.
CK30-1
SAFETY
SAFETY LABELS
Safety labels are affixed to the machine to inform the operator or maintenance worker when operation or
maintenance of the machine may involve a hazard.
This machine uses safety labels using words and safety labels using pictograms to indicate safety procedures.
Example Of Safety Label Using Words
Example Of Safety Label Using Pictogram

Safety pictograms use a picture to express a level of hazardous condi-
tion equivalent to the single word. These safety
pictograms use pictures in order to let the operator or
maintenance worker understand the level and type of
hazardous condition at all times. Safety pictograms show the type of
hazardous condition at the top or left side, and the
method of avoiding the hazardous condition at the bottom or right
side. In addition, the type of hazardous condition is
displayed inside a triangle and the method of avoiding the
hazardous condition is shown inside the circle.
Komatsu cannot predict every circumstance that might involve a po-

tential hazard in operation and maintenance. Therefore, the safety
messages in this manual and on the machine may not include all possible safety precautions. If any
procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility to take the
necessary steps to ensure safety.
Never engage in prohibited uses or actions described in this manual.
The explanations, values and illustrations in this manual were prepared on the latest information available at that time.
Continuing improvements in the design of this machine can lead to changes in detail which may not be
reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information for your machine or
for any questions regarding information in this manual.
1-2 CK30-1
SAFETY
SAFETY AND WARNING DECALS

Location Of The Safety Decals
★ The safety decals must always be legible and in good condition. If they are dirty with dust, oil, or grease, clean them with
a solution of water and detergent. Do not use fuel, petroleum based products, or solvents.
★ If the decals are damaged they must be replaced before operating the machine.
★ When a component provided with a safety decal is replaced, make sure the decal is also applied to the replacement
component.
★ The machine may be provided with other decals, in addition to those shown below, which must be followed for safe
operation.
CK30-1 1-3
SAFETY
1-4 CK30-1
SAFETY
CK30-1 1-5
SAFETY
The warning and danger decals applied to the machine are accompanied or represented by pictograms. The personnel charged
with the operation and maintenance of the machine must know the symbols contained in the pictograms perfectly; the
following descriptions illustrate what they look like and their respective meanings.
1. Hydraulic oil (37A-98-12210)
2. Hydraulic oil level (37A-98-12290)
3. Hydraulic oil filter (37A-98-12310)
4. Engine air filter (37A-98-12260)
5. Fuel filter (37A-98-12250)
1-6 CK30-1
SAFETY
6. Engine oil filter (37A-98-12230)
7. Radiator cap (37A-98-12270)
8. Electrical socket (37A-98-12320)
9. Diesel fuel filter (37A-98-12240)
10. Emergency exit (22L-98-18270)
11. Do not open engine hood (37A-98-12350)
CK30-1 1-7
SAFETY
12. Safety bar
(37A-98-11261)
13. WARNING -
Safety lock
(37A-98-11370)
• Lift the hood

until the safety
lock is engaged
• Remove
the safety lock
before closing the hood
14. Door lock/unlock

(37A-98-11361)
1-8 CK30-1
SAFETY
15. WARNING - Accumulator (360-52-1685)
HIGH PRESSURE AND BURN HAZARD
1. When breakdown or trouble develops in the accumulator, do not

attempt to disassembler repair. Always contact your nearest
authorized service station.
2. Do not attempt to fill or re-fill with gas. Authorized servicemen,

or persons licensed to handle high pressure gases, are the only
persons allowed.
3. Never hammer a gas filled accumulator, or place one close to a

fire.
4. Never attempt to attach a part to or bore a hole in the accumula-

tor’s wall.
5. Always completely exhaust the accumulator of all contaminated

gas when disassembling or discarding the accumulator.
6. To exhaust the gas, use the air relief valve mounted on the accu-
mulator. When there is no such valve, remove the accumulator
gas filling valve cap and release the gas by depressing the valve
core (pin) with a suitable tool (screw driver).
(1) Type of gas - Nitrogen
(2) Maximum Working Pressure - 210 bar (3,046 psi)
(3) Testing Pressure - 315 bar (4,569 psi)
Do not risk serious injury or death.
16. WARNING - Coupling pins (37A-98-11232)

BEFORE OPERATING MACHINE
• Do not operate machine without confirmation that coupling pins are fully engaged and levers are in horizontal position.
• Do not use your fingers to center the pins.
• Read operation manual before removing or installing bucket or attachment.
• Failure to follow these instructions may cause serious injury or death.
CK30-1 1-9
SAFETY
17. WARNING - loader arm safety support (37A-98-11172)
ALWAYS INSTALL LOADER ARM SAFETY SUPPORT WHEN WORKING UNDER RAISED ARM.
ALWAYS HAVE TWO PEOPLE PRESENT WHEN INSTALLING OR REMOVE LOADER ARM SAFETY
SUPPORT.
To install loader arm safety support
1. Park machine on level ground, slowly raise loader arm to maximum height and stop engine.
2. Have second person remove split pin from loader arm support retaining pin: then remove retaining pin.
3. Lower loader arm safety support onto cylinder rod.
4. Slowly lower loader arm until safety support engages cylinder and stops arm movement.
5. Install retaining pin inside loader arm safety support lock hole and secure it with split-pin.
To remove loader arm safety support
1. Start engine, raise loader arm to maximum height.
2. Have second person remove split pin and retaining pin from inside loader arm safety support locking hole.
3 Place loader arm support in its rest position and secure it with retaining pin. Secure retaining pin with split pin.
4 Slowly lower arm.
DO NOT RISK SERIOUS INJURY OR DEATH.
1-10 CK30-1
SAFETY
Decals Defined
When Tilting The Cab (37A-98-11342)
Remove the split pin from its slot and put it in the hole indicated by the arrow.
WARNING - Arm Safety Bar (37A-98-11271)
To remove arm safety bar check operator manual.
WARNING - Battery (37A-98-12180)
EXPLOSIVE GASES
• When attaching booster cables, always make last connection on

machine frame away from battery to avoid sparks at the battery.
• Keep cigarettes, flames and sparks away from battery to avoid

explosion.
• Always shield eyes and face from battery.
• Do not charge, use booster cables, or adjust post connection without

proper instruction and training.
POISON CAUSES SEVERE BURNS
CONTAINS SULFURIC ACID
• Avoid contact with skin, eyes, or clothing.
• In the event of contact, flush affected area with water and call a
physician immediately.
DO NOT RISK SERIOUS INJURY.
CK30-1 1-11
SAFETY
DANGER - Crush Hazard (37A-98-12120)
CRUSH HAZARD; KEEP CLEAR
• Operate machine from operator’s seat only.
WARNING - Engine (37A-98-12170)
WHILE ENGINE IS RUNNING
1. Do not open cover.
2. Keep away from fan and fan belt.
IMPORTANT - Air Filter (37A-98-12160)
• Element must be kept free of cracks and oil.
• For cleaning and replacement of elements, refer to the Operator’s

Manual.
• Do not put oil into this cleaner.
1-12 CK30-1
SAFETY
DANGER - No Ether (37A-98-12150)
Engine equipped with electric heater.
Using ether as a starting aid may cause explosion.
DONOT RISK SERIOUS INJURY.
WARNING - Hydraulic Oil (37A-98-12140)
Hot oil hazard.
To prevent the sudden release of hot oil:
• Turn off engine.
• Allow oil to cool.
• Slowly loosen cap to relieve pressure before removing.
FUEL - Diesel Fuel Only (37A-98-12130)
Refer to your Operation and Maintenance Manual for instructions on

draining fuel tank.
WARNING - California Proposition 65 (37A-98-12220)
Battery posts, terminals and related accessories contain lead and lead
compounds, chemicals know to the State of California to cause cancer,
birth defects and other reproductive harm.
Wash hands after handling.
CK30-1 1-13
SAFETY
WARNING - California Proposition 65 (37A-98-12330)
Diesel engine exhaust and some of its constituents are known to the State
of California to cause cancer, birth defects, and other reproductive harm.
WARNING - Hot Water Hazard (37A-98-12370)
HOT WATER HAZARD
To prevent the sudden release of hot water;
• Turn off engine
• Allow water to cool
• Slowly loosen cap to relieve pressure before removing.
Hand Accumulator (42N-93-11190)
Pattern Change (37A-98-11281)
Change between Komatsu control pattern and optional control pattern.
1-14 CK30-1
SAFETY
Floating Device Control Button (37A-98-11931)
(Right Joystick)
Controls the loader arm floating function (if installed).
Machine Speed Increase Button (37A-98-11211)
(Left Joystick)
Controls the increase of the machine travel (if equipped).
WARNING - Grease High Pressure

(37B-98-11551)
Grease under high pressure, it could cause severe

injury.
• Do not remove safety lock
• Do not unscrew grease valve more than five.

turns.
• See manual for adjustment instruction.
Danger In The Work Area
(Only for machines with the excavator)
Do not approach or stand near the work equipment operating radius

when the boom and the bucket of the excavator are raised.
CK30-1 1-15
SAFETY
Consult The Manual
Carefully read the contents of the manual before using the machine or
performing maintenance operations.
Do Not Loosen The Bolts (37A-98-11390)
Do not loosen or remove the fastening bolts of the rear damping

supports of the cab.
Fill The System With Hees Type Oil
HEES is a synthetic, biodegradeable type oil that is used only in the

hydraulic oil tank.
Engine Coolant Level (37A-98-12340)
1-16 CK30-1
SAFETY
Anchor Point (21D-98-11860)
Lifting Point (22L-09-R4160)
Jump Start Prohibited (09842-A0481)
CAUTION - Windshield wiper switch (37A-98-12410)
Located on the wiper motor cover inside of cab.
CAUTION Switch off the windshield wiper before opening the door.
CK30-1 1-17
SAFETY
Lever Controls (37A-98-A1251)
1-18 CK30-1
SAFETY
Lubrication Chart (37B-98-11530)
CK30-1 1-19
SAFETY
Equipment Fuse Decal (37A-98-11162)
Standard Version Optional Version
POS COLOR AMP INVOLVED CIRCUIT POS COLOR AMP INVOLVED CIRCUIT
1 Violet 3A Left side lights 1 Violet 3A Left side lights, plate light
2 Violet 3A Control panel lights 2 Violet 3A Control panel lights, right side
lights
3 Blue 15A Horn, low beam, or front work light 3 Blue 15A Horn, low beam, or front work light
4 Brown 7.5A Switch lights 4 Red 10A Switch lights, direction lights
5 Blue 15A Rear work light 5 Blue 15A Rear work light, Stop lights
6 Red 10A Lever switch power supply, 6 Red 10A Lever switch power supply,
Float, Pattern change Float, Pattern change
7 Red 10A Current intake 12V, 7 Red 10A Current intake 12V, hazard,
Beacon light Beacon light
8 Red 10A Control panel, safety box, fuel 8 Red 10A Control panel, safety box, fuel
shut off, safety bar proximity, shut off, safety bar proximity
safety seat switch, Brake switch safety seat switch, Brake switch
9 Brown 7.5A Back-up alarm 9 Red 10A Back-up alarm, Attachment 3-way
HI-FLOW, Stabilizer ENPI valve
10 Brown 7.5A Fuel pump, safety engine relay, 10 Brown 7.5A Fuel pump, safety engine relay,
generator generator
11 Green 30A Pull engine solenoid 11 Green 30A Pull engine solenoid
PPC safety pressure switch PPC safety pressure switch
1-20 CK30-1
SAFETY
SAFETY RULES AND PRECAUTIONS

General Safety Rules
Only trained and authorized personnel are allowed to operate and service this machine.
Before operating this machine it is important to study the operator’s manual thoroughly and become familiar with all controls
and safety decals. Keep this manual with your machine at all times for easy reference.
Safety must always be the operator’s most important concern. Never operate a machine that is unsafe or in poor operating
condition. Always perform a pre-operational check on your machine before operating it.
If the machine is equipped with a seat belt and rollover protective structure, The operator must remain within the confines of
the rollover protective structure, with the seat belt fastened snugly around their waist before operating the machine.
If your equipment is designed for operation by one person, and for one person only. Never allow other personnel to ride on
your machine.
Never leave your machine running and unattended. Always park the machine in a level area, lower any work equipment to the
ground, set the parking brake, lock the controls and turn the engine off before exiting the operator’s compartment.
Be sure that all personnel are outside of the operating radius of the machine before moving or operating the machine. Never
allow anyone to stand near the machine while it’s operating. Remember, the larger the machine the more restricted your
visibility will be.
If pedestrians are in the area proceed slowly and sound your horn. Keep in mind, pedestrians have the right of way, and a
loaded or smaller machine has the right of way over an unloaded machine.
Never use your machine for tasks it was not designed for, damage to the machine or injury to the operator may result.
Follow all safety rules, precautions, and instructions when operating or performing maintenance on the machine.
It is the owner and/or operator’s responsibility to replace any safety or warning decals if they are defaced or removed from the
machine.
Think before you act, study the job carefully. Careful operator and service personnel are the best insurance against accidents.
The operator of this machine must be alert, physically fit, and free from the influences of alcohol, drugs, or medications that
might affect his/her eyesight, hearing, or reactions.
When working with another person on a work site, or during traffic control, be sure all personnel involved understand all hand
signals that are to be used. When leaving a job site for long periods of time always lower all work equipment to the ground,
neutralize work equipment controls and lock and secure your machine properly to avoid tampering by other personnel.
Never drive up to anyone standing in your path of travel. Always be sure all personnel are standing to the side when you
approach them and acknowledge your approach. Follow all rules relating to safety as outlined in this manual and by your
company, never get involved in horseplay.
Safety Features
Be sure all guards and covers are in place, especially after servicing the machine. Have guards or covers repaired immediately
if they are damaged. See “PRECAUTIONS BEFORE STARTING THE ENGINE” on page 1-27.
Use safety equipment such as safety locks and seat belt properly. Never remove any safety features, always keep them in good
operating condition.
Always secure the machine in a safe position: See “Parking The Machine” on page 1-34.
Seat belt: see Seat Belt on page 2-54. Improper use of safety features could result in serious bodily injury or death. Be sure the
machine has the correct equipment required by local rules and regulations.
CK30-1 1-21
SAFETY
Personal Protective Equipment
Avoid loose fitting clothing, jewelry and loose long hair. These can catch
on controls or in moving parts and cause serious injury. Wear a hard hat,
safety glasses, safety shoes, mask or gloves when operating or maintain-
ing the machine.
Always wear safety goggles, hard hat and heavy gloves, if your job
involves driving pins with a hammer or cleaning the air cleaner element
with compressed air.
Check to be sure no one is near your work area. Check to be sure all
personal protective equipment are in good condition before using.
When working for 8 hours with a noise level exceeding 85 dBA, it is

necessary to use headphones or ear plugs and to be particularly careful,
especially towards the end of the work shift. Always check current local
government noise regulations for compliance.
Unauthorized Modifications
Any modification made without authorization can create a hazard. Before making any modifications, consult your local
distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modifications to the
machine.
Leaving The Operator’s Seat

• When leaving the operator’s seat, even if temporarily, make sure
that the machine is in a safe position.
• Before leaving the operator’s seat, carry out the following

operations in the sequence indicated below:
A. Rest the equipment on the ground.
B. Apply the parking brake. see Parking Brake Push Button on

page 2-16
1-22 CK30-1
SAFETY
C. Engage the safety device of the optional equipment

control pedal (if installed).
D. Lock the equipment and travel control by shifting the safety

bars to the lock position. (see Safety Bars on page 2-25)
E. Stop the engine (see STOPPING THE ENGINE on page 2-

83)
F. If you have to go so far away that you will not be able to see
the machine, remove the ignition key.
Mounting And Dismounting

• Do not jump on or off the machine, either when it is at rest or
when it is moving.
• When getting on or off the machine, always use the appropriate

handles and footrests; get on and off the machine very carefully.
• Never hold or rest on the control levers.
• Either when getting on or when getting off the machine, always

maintain three points of contact (holding or resting points), to
avoid losing your balance and falling down.
• Clean the handles and footboards if they are dirty with oil or
grease. Carefully clean the cab floor if it is dirty with oil, grease,
mud or rubble.
CK30-1 1-23
SAFETY
Checking The Rear-view Mirrors (If Installed)
• Make sure that the rear-view mirrors are clean and correctly
aimed; the operator must be able to check the area behind the
machine with no need to twist his trunk with respect to his normal
operating position.
• If the rear-view mirrors should move or break during operations,

stop the machine immediately and fix or change them.
• Working without checking the area behind the machine involves

the risk of running over people who have carelessly approached
the machine or colliding with fixed obstacles or maneuvering
vehicles.
Fire Prevention For Fuel And Oil

Fuel, oil, and some types of antifreeze are flammable. Fuel is
particularly flammable and can be hazardous. Always observe the
following:
• Keep any open flames away from flammable fluids.
• Stop the engine and do not smoke when refueling.
• Refueling or adding oil should be done in well ventilated areas

and only after stopping the engine.
• Keep oil and fuel in its proper place.
• When refuelling, hold the fuel nozzle firmly and keep it

constantly in contact with the filler until you have finished, to
avoid sparks due to static electricity.
• Do not fill the tank completely, to leave room for the fuel to
expand.
• After refueling, tighten the fuel and oil filler caps securely.
• In case some fuel is spilled, wipe it up immediately.
Preventing Burns
Wear gloves and safety goggles when checking any fluid levels:
engine oil, hydraulic oil, engine coolant, transmission fluid.
Before checking the engine coolant, engine oil, or hydraulic oil, stop
the engine and let the fluids cool down. If you don’t, the hot fluids
may spurt out and cause burns. If the coolant level, in the radiator,
needs to be checked due to overheating, slowly loosen the radiator cap
to release the internal pressure or the hot coolant may spurt out and
cause burns.
1-24 CK30-1
SAFETY
Asbestos Dust Hazard Precautions

Asbestos dust can be hazardous to your health, if it is inhaled.
Komatsu does not use asbestos in its products, but if you handle
materials containing asbestos fibers during demolition operations,
always do as follows:
• Never use compressed air for cleaning. Only use an aspirator

and make sure the room in which you are working in is well
ventilated.
• Use water to keep down the dust when cleaning.
• If there is a danger there may be asbestos dust in the air, oper-

ate the machine with the wind to your back whenever possible.
Use an approved respirator.
• Do not allow any other person into the area during operation.
• There may be a danger that non genuine Komatsu parts may

contain asbestos, use only genuine Komatsu parts.
• Always observe rules and regulations related to the job site and
working environment.
Preventing Accidents Caused By Improper Oper-

ation Of The Work Equipment
Never stand under or place any part of your body between the
movable components such as the work equipment and cylinders or
between the machine and work equipment.
Keep in mind, when the work equipment is operated, the clearance

will change, this may lead to serious personal injury or death. Never
drive up to anyone standing in front of a solid object or your path of
travel, the brakes could fail or the machine could slide on a slippery
surface causing injury or even death.
Fire Extinguisher And First Aid Kit

As a precaution, if a fire or an injury should occur, always keep a fire
extinguisher and first aid kit on your machine and do as follows:
• Make sure that fire extinguishers have been provided and note
their position.
• Be sure that the fire extinguisher is in good condition and read

the label on it to ensure you know how to use it.
• Keep a first aid kit in the storage area. Check the kit
periodically and replace any bandages, disinfectants, etc. as
necessary.
• Keep a list of emergency phone numbers in case of an accident.
CK30-1 1-25
SAFETY
Precautions Concerning The Cab Structure
If the cab is inadvertently hit or the machine overturns during work, the cab may be damaged with consequent reduction of its
stiffness and of the safety that must be guaranteed to the operator. Consult your Komatsu distributor to have the cab structure
and strength checked in case of impact or damage.
Precautions When Using ROPS

The ROPS (Roll Over Protective Structure) must never be removed from the machine. The ROPS is installed to protect the
operator if the machine should roll over. It is designed to support the load if the machine should roll over and to absorb the
energy at point of impact. Never drill, cut, weld, repair or modify the ROPS in any way. The ROPS should be replaced if
damaged.
The ROPS fulfills all the regulations and standards for all countries, but if it is modified without authorization or is damaged,
the strength may be reduced and it may not be able to fulfill its function properly.
The ROPS may be recertified if it is slightly damaged. The recertification must be obtained from a qualified individual.
Contact your Komatsu distributor for details.
Precautions Concerning The Equipment

• When installing and using optional equipment, carefully read the relevant instruction manual and operate the machine
accordingly.
• Do not use optional or special equipment without the authorization of your Komatsu distributor. The installation and use
of unauthorized equipment may create safety problems and adversely affect the efficiency and life of the machine.
• Komatsu cannot be held liable for any damage, accident, or product failure resulting from the installation and use of
unauthorized equipment.
1-26 CK30-1
SAFETY
PRECAUTIONS BEFORE STARTING THE ENGINE

Before starting your work operations, it is important to perform several procedures to be sure your equipment is in a safe
operating condition. It is also important to be aware of the hazards involved when operating your machine.
Safety On The Work Site

Before starting your machine and proceeding with any work
operations it is important to be sure your machine is safe to operate.
• Before starting the engine, thoroughly check the area for any
unusual ground conditions that may cause the work to be
dangerous.
• Check the conditions of the work site and, before starting the en-
gine, define the work plan and the best and safest
operating procedure.
• Make the ground surface as level as possible before carrying out
any operation.
• In case of work on the road, protect pedestrians and cars by
designating a person for work site traffic duty and install fences around the work site.
• If water lines, gas lines, and telephone or high-voltage electrical lines are located under the work site, contact the relevant
utility company to find out their exact locations or to make them inoperative until the end of the
operations. Be careful not to sever or damage any of these lines.
• Check the depth and flow of water before operating in water or on river banks.
Fire Prevention
• Completely remove all wood chips, rubbish, paper and other
flammable materials that may have accumulated inside the engine
compartment, since they can cause fires.
• Check the fuel and hydraulic system tubes/hoses for leaks and, if
necessary, repair them. Wipe up any excess oil, fuel or other
flammable fluids.
• Make sure that fire extinguishers are available in the work
area.
Precautions To Be Taken For The Operator’s Cab
• Do not keep objects or tools in the operator’s cab. They may hinder
the operation of the controls and cause serious accidents.
• Keep the cab floor and the controls (pedals and levers) clean, by removing any trace of oil and grease and, as far as the floor
is concerned, remove any excess dirt (dirt, stones, etc.).
• Check the safety belt and change it if it is broken or damaged. Replace any component only with approved parts supplied by
your distributor.
CK30-1 1-27
SAFETY
Room Ventilation
Exhaust gases are deadly. If starting the machine inside a building,
connect a suction duct to the exhaust pipe to vent fumes outside.
Precautions To Be Taken For The Lights (If

Installed)
• Remove any trace of dirt from the lights, to ensure perfect
visibility of the work area.
• Make sure that all the bulbs and the working lights are
functioning properly. If necessary, replace any faulty bulbs with
new ones, making sure that their ratings are correct.
Cleaning The Windows And The Rear-view Mir-

rors - Checking The Windshield Wiper Blades
• Remove any trace of dirt from the cab windows and clean the rear-view mirrors, to ensure unobstructed visibility in the
work area.
• Adjust the rear-view mirrors that may have moved, so that the operator seated in the driving position can clearly see the area
behind the machine. If any glass is damaged, replace it with new.
• Check the condition of the windshield wiper blades; the scraping edge must be smooth, with no indentations and attached to
the rubber back of the blade.
In case of doubts about the efficiency of the edge, change the blade.
1-28 CK30-1
SAFETY
PRECAUTIONS TO BE TAKEN WHEN WORKING

Starting The Engine
• Before operating the machine, walk around it and check for people or objects that might be in the way.
• Do not start the engine if warning tags have been attached to the steering or control levers.
• Sound your horn to warn others in the area before starting the engine or moving the machine.
• Start the engine only when seated and with the seat belt fastened snugly around your waist.
• Do not allow anyone in the cab or on the machine during operations.
Rules For Traveling In Reverse

• When operating in areas that may be hazardous or where visibil-
ity is poor, designate a person to direct the movements of the
machine and the traffic on the work site.
• Make sure that no unauthorized person is standing within the

machine operating radius or in its travel direction. If necessary,
put up appropriate fences.
• Before moving the machine, sound the horn to warn people near
the work area.
• There are blind spots behind the machine, which cannot be seen
by the operator and where someone may be standing. Therefore,
it is necessary to make sure that there is no one behind the
machine before traveling in reverse.
CK30-1 1-29
SAFETY
Moving The Machine
The use of the speed increase button is allowed only for the high
speed transfers of the machine.
• When moving the machine, lower the arm and roll the bucket
back completely; this position makes it possible to evaluate the
space required for movement more precisely and at the same time
ensures the stability of the machine.
• If the equipment control levers must be used during travel, avoid

moving them abruptly; sudden maneuvers change the attitude of
the machine and make driving difficult.
• When traveling on rough ground, keep the speed low and avoid
sudden movements of the bucket arm.
• If possible, avoid moving onto obstacles. If the machine has to

travel over an obstacle, keep the equipment as close to the ground
as possible and travel at low speed. Never move onto obstacles
that may drastically incline the machine (over 10°).
• If one of the rubber tracks goes over an obstacle or gets into a

hole in the ground, the machine may overturn. In these cases,
reduce the speed to a minimum and be very careful of the balance
of the machine.
1-30 CK30-1
SAFETY
Working On Slopes
• Operations on slopes and on river or lake banks with damp
ground may result in the tipping over or sliding of the machine.
• Do not operate the bucket while the machine is on a slope.
• On hills, banks or slopes, keep the arm lowered and the bucket
rolled back, and in case of an emergency, quickly lower it to the
ground to help the machine stop.
• Do not change direction and, if possible, avoid traveling sideways

when working on slopes. It is advisable to go down or up to a flat
surface before performing these maneuvers.
• Travel up or down slopes with the heaviest part of the loader

facing the top of the slope.
• Do not travel on wet grass or thick layers of leaves: if the machine

moves sideways under these conditions, it may slide.
• Before carrying out any operation on a slope, always check the

functionality of the parking brake.
• Do not go down slopes at high speed; you may lose control of the
machine and cause serious damage and even death.
• Do not move on slopes with an inclination exceeding 15°, since

the machine may overturn.
• When the fuel level indicator reaches the red reserve area during
work on a slope, immediately provide for refueling; due to the
inclination of the machine, the engine may suck in air and
suddenly stop, which represents a grave risk for the safety of the
operator and of people in front of the machine.
• If the engine should stop suddenly, immediately lower the bucket

to the ground and apply the parking brake.
CK30-1 1-31
SAFETY
.
Preventing Electrocution
• Digging operations near overhead electric lines are extremely
dangerous and may also cause death due to electrocution; for this
reason, when working near overhead electrical lines, always
respect the minimum safety distances prescribed by competent
authorities and by the accident-prevention rules in force.
• As far as underground long-distance lines are concerned, the

minimum distance depends on the material of the pipes in which
the cables are laid.
• 1 - Wear shoes with thick rubber or leather soles.
• 2 - Request the aid of another person who can warn you if the
machine gets too close to the electric wires.
Voltage Min. Safe Distance
• 3 - Operate at low speed.
6.6 kV 3m 10 ft.
• 4 - Learn what is to be done first in case of electrocution. 66.0 kV 5m 16 ft.
• 5 - Keep the phone number of the electricity company and of 275 kV 10 m 33 ft.
the nearest first aid station at hand.
• If the work equipment accidentally gets entangled in the cables, the operator must remain still and must not leave the cab
until the electricity company has shut off the power.
• When carrying out this kind of operation, warn everyone standing in the work area to keep at the minimum distance
prescribed from the machine and the work equipment.
• Ask the electricity company in advance what are the voltage of the cables and the minimum safety distance are.
1-32 CK30-1
SAFETY
Visibility
• Switch on the working lights as soon as visibility starts decreasing. If visibility decreases due to mist, smoke or heavy
rain, stop the machine in a safe position and wait for the weather to improve until visibility becomes acceptable.
Working On Icy Or Snow-covered Surfaces

• If the ground is icy or covered with snow, even a slight slope may cause the machine to slip sideways, therefore it is
advisable to move at low speed and to avoid abrupt starts, stops or turns.
• When it has snowed heavily, the road shoulders and any obstacles are buried in snow and are not visible, therefore
proceed with care when clearing snow.
Preventing Accidents Caused By The Improper Operation Of The Work Equipment

• When working in tunnels, galleries, under electric cables or other ducts (air, telephone lines) and wherever the height is
limited, proceed with the greatest care to prevent the bucket or the arms from causing any damage.
Working On Loose Ground

• Avoid operating the machine too close to the edge of cliffs, overhangs and deep ditches. These areas may collapse,
making the machine fall down or tip over and this could result in serious injuries or even death. Remember that after
heavy rain or earthquakes these dangerous conditions usually get worse.
• The earth laid near ditches is loose and can easily collapse due to the weight or vibrations of the machine. Be extremely
careful and remember to fasten your safety belt.
CK30-1 1-33
SAFETY
Parking The Machine

• Park the machine on firm and level ground. If this is not possible
and it is necessary to park on a slope, position the machine with
the bucket facing downwards and carry out the following
operations:
• Rotate the bucket forward and rest it on the ground.
• Apply the parking brake.
• Stop the engine.
• Put wedges or safety blocks in front of the rubber tracks.
• Always rest the work equipment on the ground; if it is necessary

to park with the arms raised, make sure that the safety locks are
engaged (see SAFETY LOCKS on page 2-2).
• Always lock the equipment and travel control by shifting the

safety bars to the lock position (see Machine Controls on page 2-
23).
• When leaving the machine, always apply the parking brake and
remove the ignition key.
• If it is necessary to park on public roads, provide for signalling

the presence of the machine according to the local regulations in
force (signalling fires, fences, road work ahead, alternate
directions and direction signs, etc.).
1-34 CK30-1
SAFETY
TRANSPORTING THE MACHINE

Loading And Unloading The Machine
• Loading and unloading the machine on/from another vehicle
always involves potential hazards. Proceed with extreme care.
• Perform loading and unloading on firm, level ground. Maintain a

safe distance from the edges of ditches or road sides.
• If the vehicles used have not been appropriately equipped, put

support blocks under the ramps, to avoid any bending.
• Always lock the wheels of the transporting vehicle with chocks.
• Always use ramps that are sufficiently wide and can support the
weight of the machine. The longitudinal axes of the ramps must be parallel to each other and perpendicular to the loading
board and their distance from each other must be sufficient to accommodate the tread of the machine.
• Make sure the ramps are securely positioned and anchored to the loading board and are the same length.
• Position the ramps with a maximum angle of 15°.
• Make sure that the ramp surface is clean and there is no trace of grease, oil, soil or ice; remove any dirt from the tracks of
the machine before starting to load it on the vehicle. If the bucket is empty or no optional accessories are fitted to the
machine, this end must face the rear.
• Do not reposition the machine while on the ramps. If necessary, go down the ramps and start the operation again.
• After loading the machine, block the tracks with wedges and secure it with tie-downs or chains that prevent any shifting
(see TRANSPORTING THE MACHINE on page 2-84).
The Route
• Define the route to be followed, taking into account the width, height and weight of the transporting vehicle plus the
machine.
Make sure that the overall dimensions of the vehicle and its load are compatible with the roads and any tunnel, underpass,
bridge, power and telephone lines, etc. along the route.
• Adhere to the regulations in force regarding the permissible width, height, weight and speed of heavy vehicles.
CK30-1 1-35
SAFETY
BATTERY
Safety Precautions For Work On Batteries
• Turn the battery disconnect switch (if equipped) to the OFF
position. In the following events, follow the switch-off procedure
as described below.
First turn the starting switch to the OFF position, wait over one
minute, then turn off the battery disconnect switch, and take out
the battery disconnect switch key before:
• Storing the machine for one or more months;
• Repairing electrical systems;
• Performing electric-welding;
• Handling batteries; or
• Replacing fuses or fusible links.
• Electrolytic batteries contain sulfuric acid which can cause burns. It can also corrode clothing and make holes in it. If you
inadvertently splash battery acid on yourself or on someone else, immediately wash the affected part with plenty of water.
• Battery acid may cause blindness if it comes into contact with the eyes.
• If acid accidentally gets into your eyes, wash them immediately with
plenty of water and consult a doctor right away.
• If you accidentally swallow battery acid, drink a large quantity of

water or milk, beaten egg white or vegetable oil and any antacid
substances like magnesia, bicarbonate, etc.; call a doctor or a poison
treatment center immediately.
• Always wear safety goggles when working on batteries.
• Batteries produce hydrogen, which is highly explosive and can be

easily ignited with small sparks or naked flames.
• Before working with batteries, stop the engine and remove the
ignition key.
• Avoid short-circuiting the battery terminals through accidental

contact with metal objects or tools or through the inversion of the terminals.
• Tighten the battery terminals securely. Loose terminals may generate sparks and even cause the explosion of the battery.
• If installed, disable power by turning off the battery disconnect switch.
1-36 CK30-1
SAFETY
Starting With Booster Cables

• When starting the machine with booster cables, always wear safety
goggles.
• When starting the engine by using another machine, avoid any

contact between the two machines.
• Be sure to connect the positive cable (+) first and then the negative
or ground cable (-) when connecting the booster cables. After the
start, disconnect first the negative or ground (-) cable and then the
positive cable (+).
• Connect the batteries in parallel: positive to positive and negative to

negative.
• When connecting the ground cable to the frame of the machine to be started, connect it as far as possible from the battery.
Precautions For Emergency Recovery

• The removal hooks are to be used exclusively for emergency
recovery and not for towing vehicles.
• Before moving the machine, make sure that all the controls are in
neutral.
• Release the parking brake of the travel hydraulic motors (See

“Releasing The Parking Brake” on page 3-25).
• Incorrect maneuvers may result in serious injuries or even death.
• To move the machine, use proper strength steel cables; do not use
worn cables or cables with broken strands (A), twisted cables (B),
or deformed cables (C).
• During the recovery operation, no one is allowed to approach the

machines or the cables.
• Move the machine just far enough to permit the required repairs.
• Do not move the machine in any way other than that indicated in
paragraph (see How To Move The Machine on page 2-105).
CK30-1 1-37
SAFETY
Never stand next to the tow lines when towing the machine. The
cable or chain could break causing injury. Always stay clear of the
towing equipment.
• The maximum pulling force for the emergency recovery is the

following: F = 3,870 kg. (8,333 lb.)
• Use cables of the same length and pull continuously, without

jerks.
• Arrange and connect the machine to be moved by positioning it

on the same axis as the towing vehicle; the force must be parallel to the axis of movement.
1-38 CK30-1
SAFETY
PRECAUTIONS DURING MAINTENANCE

All maintenance performed on this machine must only be performed
by trained and authorized personnel. When performing maintenance it
is important to follow the outlined maintenance procedures and safety
information outlined in this manual and in the Shop Manual for this
machine.
Warning Tags
Before performing any maintenance operations on this machine,
position the machine on a level and firm surface.
Lock the equipment controls, remove the ignition key and tag the
control levers.
Alert all personnel in your area that the machine is down for
maintenance. If necessary, tag the machine at specific points to warn
others that this machine is down for maintenance.
If the machine will be down for maintenance for a long period of time,
be sure to check and see if the warning tags are still in place before
you start your repair procedures the next day.
Tools
• Use only the tools provided with the machine and high-quality
tools suitable for the tasks to be performed.
• Do not use worn, damaged, low-quality tools or tools that are not
suitable for the tasks to be performed, to avoid any personal
injury.
• After use, always put the tools in the appropriate compartment (1)
behind the driver’s seat.
CK30-1 1-39
SAFETY
Personnel
Only authorized and duly trained personnel can service and repair the machine; additional precautions must be taken when
grinding, welding and using a sledge hammer or heavy hammers.
When assembling the equipment or cylinder connection pins, use wooden, plastic or softer tools to check the centering of the
holes.
Do not use your fingers, since you run the risk of cutting them.
Equipment Storage
The normal or special equipment that must be installed on the machine
or that have been removed must be stored in safe places, preventing
them from falling down. If they fall on someone, they can cause
serious bodily harm.
When assembling or removing any equipment, make sure that the

ropes and the lifting hook are in good condition and properly sized for
the load to be lifted.
Working Under The Machine

Always use approved jack stands to support the machine when
performing maintenance under the chassis. Never rely on hydraulic
jacks or the machines work equipment to support the machine when
working under or on the machine.
Always lower the work equipment to the ground or to their lowest

position before performing service or repairs under the machine.
Always lock the machine tracks securely. Do not work under the
machine if it is not sufficiently supported.
Keeping The Machine Clean

Never use flammable liquids to clean your machine. Use only
approved non flammable cleaning solvents to clean parts of the
machine itself.
Avoid using high pressure steam cleaners or caustic soaps to wash the
machine, if possible. Steam cleaning or using caustic soaps may
damage paint, wiring or sensitive electrical components.
Never use high pressure water or flood the inside of the operator’s cab.
Doing so may damage sensitive electrical components.
When pressure washing, keep the jet a minimum of 60 cm (24 in.)

from any surface.
Always grease the machine after cleaning to push any water out of the pivot point connections.
1-40 CK30-1
SAFETY
Engine Operation During Maintenance

If during maintenance the engine must be running, be sure all work
equipment is locked.
Have someone remain in the operator’s seat while the engine is

running to stop the engine quickly, if required.
During maintenance operations with the engine running, never

disengage the safety locks of the controls from the LOCK position.
Service personnel must not move any control lever.
Critical Parts
Periodically some parts must be replaced for safety purposes. Even if
these parts seem to be in good condition and operating properly they may fail at some point causing possible injury to the
operator or a pedestrian. Listed are some of the systems containing these components that may fail under extended use:
• Fuel supply and delivery hoses.
• Hydraulic system: main delivery hoses and tubing.
• Hydraulic hoses: all the hoses that feed and return the hydraulic fluid to and from the work equipment.
For additional information: See “Critical Parts For Safety” on page 3-13.
Stop The Engine Before Carrying Out Any Main-

tenance Operation Or Inspection
• Stop the machine only on firm and level ground and stop the
engine before carrying out any maintenance operation or
inspection.
• If the engine must be running during a maintenance operation,

shift the safety bars to the LOCK position and carry out the
maintenance operation with the help of another person; one oper-
ator must remain on the machine and the words and signs to be
used must be agreed upon in advance.
• The person who carries out the maintenance operations must be

very careful not to touch any moving part of the engine.
CK30-1 1-41
SAFETY
Rules For Refueling The Machine

Keep away from exposed flames while refueling or adding oil.
Spilled fuel or oil makes the ground slippery and may cause accidents;
clean any dirty area immediately and carefully.
Always tighten the fuel tank and the hydraulic circuit oil safety caps
securely.
Do not use fuel to clean any part of the machine that is dirty with oil or
dust.
Always top off the fuel and oil tanks in properly ventilated areas and
refrain from smoking.
When refueling, hold the fuel nozzle firmly and keep it constantly in
contact with the filler tube until you have finished, to avoid sparks due
to static electricity.
Do not fill the tank completely, to leave room for the fuel to expand.
Cooling System Precautions

Never add coolant to a hot or warm engine. Always allow the engine
time to cool down completely before opening the radiator cap.
If it is necessary to remove the cap with the engine still hot, wear
suitable clothes and protection before loosening the cap. Loosen the
cap slowly to relieve pressure gradually.
Never dump used coolant on the ground, in a lake, stream or in a

sewer system. These fluids are to be captured and recycled properly.
Using Lamps
When checking the fuel, oil, coolant or battery electrolyte levels,
always use approved explosion proof lights.
If such lighting equipment is not used, there is a danger of fire and/or

explosion.
1-42 CK30-1
SAFETY
Precautions Concerning The Battery And

Alternator
• Turn the battery disconnect switch (if equipped) to the OFF position.
In the following events, follow the switch-off procedure as described
below.
First turn the starting switch to the OFF position, wait over one
minute, then turn off the battery disconnect switch, and take out the
battery disconnect switch key before:
• When repairing the electrical system, disconnect the battery in order to stop the flow of current, or if installed, disable the
electrical system by turning off the battery disconnect switch.
Remark
Battery disconnect switch (if equipped) - When removing the battery cables, first turn the starting switch to the
OFF position, wait over one minute, then turn off the battery disconnect switch, and take out the battery
disconnect switch key. Then, begin the cable removal at the ground (negative (-)) cable side. When installing
the battery cables, be sure to begin with the positive (+) cable side and finish at the ground cable.
None equipped machines disconnect first the negative ground cable (-) and then the positive cable (+). At the
end of the operation, reconnect first the positive cable (+) and then the negative cable (-).
• If electric welding operations must be carried out on the machine,

disconnect the battery and also the alternator to prevent damage to
them.
CK30-1 1-43
SAFETY
Precautions Concerning The Starter

Do not start the engine by tampering with the terminals of the starter,
since the machine may move.
Sudden or accidental movements of the machine may cause serious

injuries or even death.
Precautions Concerning High Pressure Hoses

Do not use bent, cut or cracked tubing or hoses which have been
previously rejected because of leaks or other defects. Faulty hoses can
burst during operation causing injury or fire.
Repair or replace any loose or faulty fuel or hydraulic lines

immediately. Do not operate the machine with damaged or leaking
hoses or lines.
Precautions For Working On High Pressure Sys-

tems
Remember that working hydraulic systems are always under pressure.
If you have to add or drain hydraulic fluid, service or inspect the
hydraulic system, lower the equipment to the ground and release
system pressure and residual tank pressure before starting any work.
Leaks from pressurized hydraulic lines are extremely dangerous since

the spray from them can penetrate your skin and enter the
bloodstream, or the eyes.
Always wear thick gloves and protective goggles when working on

the hydraulic system. Use a sheet of cardboard or plywood to search
for leaks.
If you are struck by a jet of hydraulic fluid under pressure, or if you are injured even slightly, consult a doctor immediately for
appropriate treatment
1-44 CK30-1
SAFETY
Precautions For Maintenance Work Involving
High Temperatures And Pressures
When you stop the machine at the end of a job, remember the engine
coolant, oil, all engine parts, exhaust stack and the hydraulic system
are still hot and under pressure. If you attempt to drain engine coolant,
hydraulic fluid, or engine oil under these conditions, you expose
yourself to various dangers, including the risk of serious burns.
Carry out maintenance procedures described in this manual only when

the machine has had time to cool down.
Rotating Parts
Take particular care near rotating parts. Keep your body at a safe
distance.
If hands, clothing, or tools become entangled in the fan blades or fan

belt, severe injury may result. Keep well away from all rotating parts.
Precautions To Be Taken When Using High-pres-

sure Grease To Adjust The Rubber Track Tension
The grease contained in the rubber track tension adjustment device is
pressurized. If the adjustment isn't carried out according to the
instructions given in the maintenance section, the grease valve (1)
may be ejected due to the high pressure and may be dangerous for the
operator.
When reducing the tension of the rubber tracks, do not loosen the
valve (1) more than five turns.
Keep face, hands and other body parts away from the valve (1).
CK30-1 1-45
SAFETY
Do Not Remove The Shock Absorbing Spring

From The Shock Absorber Unit
The shock absorber unit is provided with a shock absorbing spring
with high preload, which absorbs impacts on the front idler roller.
Do not attempt to remove the spring, since this may lead to serious
accidents and even death.
For any work to be carried out on the shock absorber unit, contact
your Komatsu distributor.
Hydraulic Accumulator
The hydraulic accumulator contains pressurized nitrogen.
When performing any work on the accumulator, proceed carefully,
since this may cause an explosion and consequent serious injury and
even death. For this reason, follow these instructions:
• Do not remove the accumulator;
• Do not bring the accumulator near sparks or open flames;
• Do not make holes in the accumulator, do not weld or use

oxyhydrogen flames;
• Do not hit or press the accumulator;
• When disposing of the accumulator, take care when releasing the gas it contains. Have this work done only by a Komatsu
distributor.
1-46 CK30-1
SAFETY
Disposal Of Waste Materials
Never dump waste fluids in a sewer system, on the ground, in rivers,
etc. Always drain fluids from your machine into the appropriate
containers. Never drain fluids directly onto the ground.
Obey appropriate laws and regulations when disposing of harmful

objects such as oil, fuel, filters, batteries, coolant, brake fluid and
hydraulic oil.
Hydraulic Environmental Ester Synthetic (HEES) Oil

HEES is a synthetic, biodegradeable oil intended for use in the hydraulic system only.
• Never use HEES in the: engine, transmission, axle, braking system or mix HEES with organic hydraulic oil. Doing so
could clog the hydraulic oil filter.
When switching to HEES for the hydraulic system:
1. Drain the organic oil from the tank completely. Disconnect the hydraulic lines and drain the oil from the lines and the
cylinders.
2. Replace the hydraulic oil filter with a new one. Reconnect the hydraulic oil lines.
3. Fill the hydraulic oil tank with HEES type oil.
4. Start the engine and let it idle until the hydraulic oil reaches 40°C(104°F). Operate all the work equipment to fill the
hydraulic circuits.
5. Stop the engine and check the hydraulic oil level. Add oil as needed.
CK30-1 1-47
SAFETY
MEMORANDUM
1-48 CK30-1
2OPERATION
CK30-1 2-1
OPERATION
SAFETY LOCKS
If it is necessary to stop the machine with the loader arm raised, always engage the mechanical loader arm
support on the loader arm and lock the equipment and travel control by lifting the safety bars (See “Safety
Bars” on page 2-25).
When traveling on roads with a machine approved for this purpose and equipped with a backhoe, roll the
bucket back completely, apply the lock between boom and arm, the anti rotation lock between boom and
sliding plate and the center lock of the sliding plate.
Raise the stabilizer supports completely, assemble the relevant safety chains and finally lock the
equipment controls by shifting the safety device lever to the lock position. If the machine is also equipped
with rear stabilizers, raise the supports and lock them with the relevant safety chains.
When traveling on roads with a machine approved for this purpose and equipped with the cold planer,
apply the lock on the lifting jack to keep the equipment at a given distance from the ground, lower the
loader arm completely, and finally lock the equipment controls by shifting the safety device lever to the
lock position.
Non-compliance with these rules may lead to serious accidents.
Loader Arm Support

The loader arm is provided with a loader arm support (1) to be used to
keep the arm raised when the machine is serviced or routine
operations are carried out.
The engagement of the loader arm support must be carried out by two
people, one seated in the driving position to check the movements of
the machine and the other standing on the ground to engage the
support correctly.
It is important to remember that under operating conditions the loader
arm support (1) must be positioned against the arm and kept in this
position by means of the safety pin (2).
The loader arm support must always rest against the

hydraulic cylinder rod.
The loader arm support must be brought to its final position
by moving the contact surfaces slowly and continuously, in
such a way as not to damage the cylinder head surface.
2-2 CK30-1
OPERATION
After engaging the loader arm support (1), hold it in position

with the safety pin (2).
Do not perform any work under the raised loader arm if the
loader arm support (1) is not in the locked position.
The safety bars (3) located in front of the operator seated in the driving
position make it possible to lock the equipment and travel controls.
For the operation of the safety bars (See “Safety Bars” on page 2-25).
The safety guard (4) locks the optional equipment control pedal in the
neutral position.
CK30-1 2-3
OPERATION
GENERAL VIEWS
Front View Of Machine
1- Bucket 7- Rear idler roller

2- Bucket Cylinder 8- Travel reduction gear
3- Front idler roller 9- Lift cylinder
4- Rubber track 10- Frame
5- Track roller 11- Loader arm
6- Left carriage frame 12- Cab
2-4 CK30-1
OPERATION
Rear View Of Machine
1 - Rear Panel 3 - Muffler

2 - Engine Hood 4 - Right carriage frame
CK30-1 2-5
OPERATION
Inside View Of Cab
1 - Safety bars
2 - Left PPC control joystick
ISO PATTERN SYSTEM
- Travel and steering
OPTIONAL PATTERN SYSTEM
- Left track travel and loader arm control
3 - Right PPC control joystick
ISO PATTERN SYSTEM
- Loader arm and bucket control
OPTIONAL PATTERN SYSTEM
- Right track travel and bucket control
4 - Auxiliary hydraulic control pedal (if installed)
5 - Foot accelerator
6 - Hand accelerator
7 - Parking brake
8 - Dashboard
2-6 CK30-1
OPERATION
10 - Left console switches

11 - Right console switches
CK30-1 2-7
OPERATION
INSTRUMENTS AND CONTROLS
Instruments
1 - Hour Meter
2 - Engine Coolant Temperature Indicator
3 - Fuel Level Indicator
Hour Meter
This instrument indicates the total number of operating hours on the
engine. The count is continuous and the number is increased by 1
when the engine has run for one hour, independently of its speed.
When the engine is running, the LED (A) positioned under the
instrument flashes and counts for every second. The hour meter keeps
functioning even if the machine is not travelling or working. The
reading of the hour meter is to be considered valid for the calculation
of the maintenance intervals.
2-8 CK30-1
OPERATION
Engine Coolant Temperature Indicator
This instrument indicates the temperature of the engine coolant,
which, under normal conditions, should be 80 - 85°C (176 - 185°F).
After starting the engine and before starting work, let it warm up until
the temperature indicator reaches the green range. If the indicator
exceeds the limit values while the engine is running and indicates
overheating, the red range, let the engine idle until the indicator
returns to the normal temperature, the green range.
When the indicator suggests overheating, the red range, the audible
alarm also sounds.
If this problem occurs repeatedly, find out the cause (See
“TROUBLESHOOTING” on page 2-105).
Fuel Level Indicator

This instrument indicates the fuel level in the tank; this information is
available only with the ignition key in position <<I>> (See “Ignition
Switch” on page 2-18).
The green range indicates the normal fuel level, while the red range
indicates a low fuel level (reserve).
If the indicator reaches the reserve, red range, while the machine is
working, stop and add fuel to the correct level.
CK30-1 2-9
OPERATION
Indicator Lights
1- Alternator Warning Light 7- Speed Increase Indicator Light

2- Preheating Indicator Light 8- Floating Device Indicator Light
3- Engine Oil Pressure Warning Light 9- Direction Indicator Light
4- Air Cleaner Clogging Warning Light 10- Working Light Indicator Light
5- Hydraulic Oil Filter Clogging Warning Light 11- Safety Device Functionality Control Unit
6- Parking Brake Warning Light
Alternator Warning Light

This warning light lights when the starting circuit is energized and
goes out when the engine exceeds idle speed; if this warning light
remains on even when the engine is running at the normal operating
speed, it means that the alternator is not charging and the battery is not
charged correctly.
If the warning light remains off when the ignition key is

turned to position “I”, it means that the alternator is faulty or
broken.
2-10 CK30-1
OPERATION
Preheating Warning Light
This warning light lights when the ignition key is turned to position
<< >> to start the engine at low temperatures and goes out
automatically after approximately 13 seconds (See “Starting The
Engine” on page 2-58).
Engine Oil Pressure Warning Light

This warning light lights and activates the audible alarm with the
engine stopped when the starting circuit is energized and goes out as
soon as the engine lubrication circuit is pressurized. If this warning
light remains on or lights with the engine running, stop the machine
immediately and try to locate the trouble.
Air Cleaner Clogging Warning Light

This warning light lights when the engine air filter needs cleaning or
replacing.
Hydraulic Oil Filter Clogging Warning Light

This warning light lights when the hydraulic circuit filter needs
replacing.
CK30-1 2-11
OPERATION
Parking Brake Warning Light
This warning light lights when the park brake circuit is not functioning
properly. If this light lights during normal operation, stop the machine
and try to locate the trouble.
Speed Increase Indicator Light

This light lights when the high speed button on the left joystick is
pressed (See “Speed Increase Button” on page 2-19).
Float Switch Indicator Light

This light lights when the float switch is selected (See “Floating
Device Switch” on page 2-19).
Direction Indicator Light

This warning light lights intermittently when the lever on the left con-
sole is operated (See “Direction Indicator Switch” on page 2-18) or
when the emergency switch is operated (See “Emergency (Hazard)
Switch (If Installed)” on page 2-17).
2-12 CK30-1
OPERATION
Working Light Indicator Light
This light lights when the working lights are turned on with the switch
on the right console (See “Working Light Switch” on page 2-17)
Safety Device Functionality Control Unit

This control unit is positioned on the dashboard and checks the
condition of the safety devices installed on the machine.
The signals are shown on the display by the lighting and extinguishing
of the warning lights.
The functions are as follows:
0A - Red Warning Light

LED off - This indicates that all the safety devices are on and
therefore all the machine functions are normal (the solenoid
valve ensures the lifting of the work equipment and the
machine travel).
LED on - This indicates that at least one safety function is
lacking; in this case the solenoid valve is closed and does not
permit the lifting and therefore the use of the work equipment
and the machine travel.
0B - Green Indicator Light

LED on - This indicates that the operator is correctly seated
in the driving position and that the operator seat switch
sensor is on.
LED off - (With the red warning light coming on at the same
time) This indicates that the operator is standing or that he is
not inside the cab.
The operator presence signal (seat) starts the emergency

procedure after a delay of 1.5 seconds, all hydraulic
functions are locked out and the parking brake is applied. To
resume operation, the operator must sit in the driving
position, lower the safety bars and press the park brake
push button on the left console.
The delay allows the machine to be operated on uneven
ground without signalling repeated emergencies.
CK30-1 2-13
OPERATION
0C - Green Indicator Light

LED on - This indicates that the safety bars are down and the
work equipment and the travel functions can be operated.
LED off - (With the red warning light coming on at the same
time) This indicates that the safety bars are not completely
down and therefore the work equipment and the travel
functions cannot be used.
The sounding of the audible alarm (buzzer) signals that the PPC valve coil is not functioning properly.
This alarm sounds even with the engine stopped and the ignition key removed from the ignition switch.
Take notice of the following conditions:
A) Engine stops and the audible alarm sounds.
Safety bars raised and temporary binding of the PPC solenoid valve.
Lower the work equipment to the ground (See “Machine Controls” on page 2-23), get off the
machine and try to locate the trouble.
B) Audible alarm sounds with the engine off.
PPC solenoid valve binding.
Lower the work equipment to the ground (See “Machine Controls” on page 2-23), get off the
machine and try to locate the trouble.
When troubleshooting for extended periods of time, disconnect the negative cable (-) at the battery, to
avoid discharging it completely.
The green LED’s (seat and safety bar) light only if the operator has engaged all the safety locks and
released the parking brake (red LED on). The LED’s go out whenever the safety bar is lifted (PPC controls
off); to reactivate the PPC controls, sit in the driving position, lower the safety bar and press the parking
brake push button (green and red LED’s on).
2-14 CK30-1
OPERATION
Switches And Push Buttons
1 - Parking brake push button
2 - Rotating beacon light switch
3 - Left stabilizer button (if installed)
4 - Right stabilizer button (if installed)
5 - Working light switch
6 - Emergency (HAZARD) light switch
7 - Parking light and low beam switch
8 - Direction indicator switch
9 - Ignition switch
10 - Horn
11 - High Flow hydraulic system switch (3 lines) for front
equipment (if installed)
CK30-1 2-15
OPERATION
12 - Super Flow (momentary reverse) hydraulic push button for
optional attachments (if installed)
13 - Speed increase button
14 - Floating device button (if installed)
15 - Operates electro-hydraulic functions of optional attachments
(if installed)
16 - Seat Override switch
Parking Brake Push Button

If pressed, this switch engages the parking brake.
If pressed again, it disengages the brake, thus releasing the machine.
The parking brake is automatically engaged whenever the

engine stops; this is due to the lack of pressure in the
hydraulic circuit.
The push button releases the brake only when the engine is
running and all the safety devices are engaged (warning
lights off).
Rotating Beacon Light Switch

This switch turns on the rotating beacon and must be operated when
necessary to travel on roads.
2-16 CK30-1
OPERATION
Left Stabilizer Button (If Installed)
This is a button with three positions: forward, center and back.
Press the button forward or backward to lower or raise the stabilizer.
The center position turns the left stabilizer off.
For use, See “Left Stabilizer Button (If Installed)” on page 2-17.
Right Stabilizer Button (If Installed)

This is a button with three positions: forward, center and back.
Press the button forward or backward to lower or raise the stabilizer.
The center position turns the left stabilizer off.
For use, See “Right Stabilizer Button (If Installed)” on page 2-17.
Working Light Switch

Turns on the working lights.
Emergency (Hazard) Switch (If Installed)

Operates all the direction lights at the same time and must be used
whenever the machine is temporarily parked on the roadside or in an
abnormal position while traveling on roads.
CK30-1 2-17
OPERATION
Parking Light And Low Beam Switch
This is a two-position switch:
The 1st click turns on the instrument lights and the parking lights.
The 2nd click turns on the low beam or working lights, according to
the position of the switch (2).
Direction Indicator Switch

This is a lever switch with three positions. The neutral position is in
the center.
Shift the switch lever to the right or to the left to indicate the turn
direction.
Ignition Switch
This is a rotary key switch with four positions marked by the
following symbols « » - }(OFF) - I - « »(START).
For further details on the use of this switch, See “Starting The Engine”
on page 2-58.
Horn
This push button is located on the left joystick grip and serves to warn
people in the vicinity of the machine, at the beginning of work, and in
case of danger, after being pushed by the operator.
2-18 CK30-1
OPERATION
Front Equipment High Flow Hydraulic System
Momentary Switch (3 Lines)
This is a momentary switch and allows increased oil delivery from the
hydraulic pump to flow in reverse only when it is pressed.
For use, See “Standard Flow Hydraulic System Control (2 or 3 Lines)”
on page 2-36.
Front Equipment Super Flow Hydraulic System

Continuous Switch (5 Lines)
This is a double-function switch and allows the oil delivery from the
hydraulic pump to constantly flow forward.
For use, See “Super Flow Hydraulic System Control (5 Lines)” on
page 2-37.
Speed Increase Button

This button is positioned on the underside of the left joystick grip and
serves to increase the machine speed when pressed.
For use, See “Speed Increase Control” on page 2-39.
Floating Device Switch

This switch is positioned on the underside of the right joystick grip and,
when pressed, enables the electrohydraulic circuit of the floating device.
For use, See “Floating Position Control” on page 2-39.
CK30-1 2-19
OPERATION
Seat Override Switch
The operator must press this switch when using any attachment that
requires him/her to be out of the normal seated driving position when
operating that attachment.
Available For Other Functions

The operator has the opportunity to use 3 push-button controls for electrohydraulic equipment with more than one function.
For use, See “Optional Electrical Connections” on page 2-42.
2-20 CK30-1
OPERATION
Electrical Accessories
1. Audible alarm
2. Electric outlet
3. Optional Master Electrical Disconnect Switch (if installed)
Audible Alarm
This audible alarm sounds when the circuits are energized with the
ignition key (rotation to position «I») and is automatically disengaged
when the engine is started.
The sounding of the alarm during operation signals:
• insufficient engine oil pressure;
• overheating of the engine cooling circuit;
• malfunction of the PPC control solenoid valve coil.
CK30-1 2-21
OPERATION
Electric Outlet
An electric outlet is positioned on the right rear of the cab inner wall
for the connection of a lighting device for routine and maintenance
operations.
It is a two-pole outlet and is in compliance with the ISO 4165-1979
standard.
Power supply 12 V.
Master Electrical Disconnect Switch (If Installed)

This is a removable lever-type switch positioned near the battery. To
reach it, it is necessary to open the engine hood (See “Engine Hood”
on page 2-48).
The current transmitted by the battery to the electric system of the
machine can be stopped by rotating the switch clockwise (position B).
Always rotate the switch to “position B” if it is necessary to work on
the battery or the electrical system, or if electric welding must be
carried out on the machine.
The electrical connection can be restored by rotating the switch
counterclockwise (position A).
2-22 CK30-1
OPERATION
Machine Controls
1 - Safety bars
2 - Left PPC control joystick
Travel and steering - ISO PATTERN SYSTEM
Left wheel travel and loader arm control - OPTIONAL PATTERN
SYSTEM
3 - Right PPC control joystick
Loader arm and bucket control - ISO PATTERN SYSTEM
Right wheel travel and bucket control - OPTIONAL PATTERN
SYSTEM
Auxiliary hydraulic kit control pedal
5 - Foot accelerator
6 - Hand accelerator
7 - Parking brake
8 - Super Flow hydraulic system control (continuous forward) (if
installed)
9 - Super Flow hydraulic system control (momentary reverse) (if
installed)
10 - Speed increase control
CK30-1 2-23
OPERATION
11 - Float position control
12 - Pattern shifting control
13 - Right stabilizer control (if installed)
14 - Left stabilizer control (if installed)
15 - Optional Attachment Electrical Connection control
2-24 CK30-1
OPERATION
Safety Bars
Before leaving the operator seat, lower the equipment to the

ground and rotate the safety bars to the vertical (unlocked)
position.
The safety devices on this machine are composed of electri-
cal components. Before modifying or replacing any wiring or
electrical components, which may result in malfunctions of
the devices, contact your Komatsu distributor.
The locking of the PPC control safety device is performed by lifting

the safety bars (1) to a vertical position.
The safety device can be released by lowering the safety bars to the
horizontal position and pressing the parking brake push button (warn-
ing light off).
Equipment movement and machine travel cannot be

performed with the safety bars (1) in the locked, or vertical
position.
CK30-1 2-25
OPERATION
ISO Pattern Control System
Left PPC Control Joystick (Travel And Steering)
Before carrying out any maneuver with this joystick, the operator must be seated in the work position with
the seat belt fastened; before any maneuver the operator must take all the precautions indicated in “How
To Move The Machine (Optional Pattern Control System)” on page 2-64.
Before moving, make sure that the safety bars are in the horizontal (unlocked) position and the parking
brake is disengaged.
When traveling on roads, make sure that all the safety devices have been engaged.
Failure to comply with these rules may lead to serious accidents.
The left PPC control joystick (2) controls the forward/reverse

movements and the steering of the machine as indicated in the
diagram below.
N - Neutral
A - Forward gear
B - Counter rotation to the right
C - Reverse gear
D - Counter rotation to the left
2-26 CK30-1
OPERATION
If the joystick is operated in directions that are inclined with respect to the machine axis, simultaneous steering movements
proportional to the angle of inclination are obtained, since the two hydraulic pumps corresponding to each single function are
engaged at the same time.
N - Neutral
A - Forward left steering
B - Forward right steering
C - Reverse left steering
D - Reverse right steering
Always travel at moderate speed to obtain maximum

accuracy and efficiency while working.
While working, the movement of the joystick must be
proportional to the required effort to maintain constant
engine speed.
Maneuver the joystick smoothly, without abrupt movements,
and avoid counter rotations as much as possible, since
these maneuvers result in rapid track wear.
The joystick grip is provided with the horn, which must be
used to warn people in the vicinity of the machine at the
beginning of work and in case of danger.
All movement is cancelled by rotating the safety bars to the
locked (vertical) position (See “Safety Bars” on page 2-25).
CK30-1 2-27
OPERATION
Right PPC Control Joystick (Loader Arm And Bucket)
the seat belt fastened and the safety bars in the unlocked (horizontal) position; before any maneuver
perform the operations described in “OPERATING THE WORK EQUIPMENT” on page 2-89.
Before leaving the operating position, lower the equipment to the ground and rotate the safety bars to the
locked (vertical) position, then stop the engine.
Failure to comply with these instructions may lead to serious accidents.
The loader self-leveling system is operated automatically only when the loader arm is lifted with a loaded
bucket. When the loader arm is in the lowering phase the system cannot be operated.
At maximum height, the self-leveling system keeps the bucket partially rolled back to prevent material
from falling out of the bucket.
The right PPC control joystick (3) controls the loader arm and bucket
functions of the machine as indicated in the diagram below.
The bucket should never be rolled back more than 45° with
the arm in the dump position.
The following diagrams show the basic maneuvers and the possible
combined maneuvers.
BASIC MANEUVERS
N - Neutral
A - Arm lowering
B - Bucket dumping
C - Arm lifting
D - Bucket roll back
2-28 CK30-1
OPERATION
If the joystick is operated in directions that are inclined with respect to
the machine axes, simultaneous movements proportional to the angle
of inclination are obtained, since the two hydraulic valves correspond-
ing to each single function are engaged at the same time.
N - Neutral
A - Arm Lower - Bucket Roll Back
B - Arm Lower - Bucket Dump
C - Arm Raise - Bucket Dump
D - Arm Raise - Bucket Roll Back
All movements are cancelled by shifting the safety bars to

the locked (vertical) position.
CK30-1 2-29
OPERATION
Optional Pattern Control System
Left PPC Control Joystick (Left Track Travel, Steering, And Loader Arm Control)
the seat belt fastened and the safety bars in the unlocked (horizontal) position; before any maneuver the
operator must take all the precautions indicated, See “Moving The Machine (Iso Pattern Control System)”
on page 2-60 or See “How To Move The Machine (Optional Pattern Control System)” on page 2-64.
Before moving, make sure the safety bars are in the horizontal (unlocked) position and the parking brake is
disengaged.
Before leaving the work position, lower the equipment to the ground and rotate the safety bars to the
Failure to comply with these instructions may lead to serious accidents.
The self-leveling system is operated automatically only when

the loader arm is lifted with a loaded bucket. When the loader
arm is in the lowering phase the system cannot be operated.
At maximum height the self-leveling system keeps the
bucket partially rolled back to prevent the material from
spilling out of the bucket.
The left PPC control joystick (2) serves to control the forward and
reverse movements, the steering of the machine to the right, and the
loader arm raising and lowering functions according to the movements
indicated in the diagram below.
To move the machine forward or backward, move the control

joysticks (2) and (3) at the same time and in the same
direction.
2-30 CK30-1
OPERATION
N - Neutral
A - Forward right steering
B - Arm lowering
C - Reverse right steering
D - Arm lifting
Always travel at moderate speed to obtain maximum accuracy and efficiency while working.
While working, the movement of the joystick must be proportional to the required effort to maintain
constant engine speed.
Maneuver the joystick smoothly, without abrupt movements and avoid counter rotations as much as
possible, since these maneuvers result in rapid track wear.
The joystick grip is provided with the horn, which must be used to warn people in the vicinity of the
machine at the beginning of work and in case of danger.
All movements are cancelled by rotating the safety bars to the locked (vertical) position (See “Safety Bars”
on page 2-25).
CK30-1 2-31
OPERATION
Right PPC Control Joystick (Right Track Travel, Steering, And Bucket Control)
the seat belt fastened; before every maneuver the operator must take all the precautions indicated See
“Moving The Machine (Iso Pattern Control System)” on page 2-60 or See “How To Move The Machine (Op-
tional Pattern Control System)” on page 2-64 and See “OPERATING THE WORK EQUIPMENT” on page 2-
89.
Before moving, make sure that the safety bars are in the horizontal (unlocked) position and the parking
brake is disengaged.
Before leaving the work position, lower the equipment to the ground and lock the safety bars (vertical
position), then stop the engine.
Failure to comply with these rules may lead to serious accidents.
The right PPC control joystick (3) serves to control the forward and
reverse movements, the steering of the machine to the left, the bucket roll
back and dumping function, according to the movements indicated in the
diagram below.
To move the machine forward or backward, shift the control

direction.
2-32 CK30-1
OPERATION
N - Neutral
A - Forward left steering
B - Bucket dumping
C - Reverse left steering
D - Bucket roll back
Always travel at moderate speed, to obtain maximum accuracy and maximum efficiency during work.
During work, the use of the joystick must be proportional to the required effort to maintain constant engine
speed.
Move the joystick smoothly, without abrupt movements, and avoid counter rotations as much as possible,
since these maneuvers result in rapid track wear.
All movements are cancelled by rotating the safety bars to the locked (vertical) position (See “Safety Bars”
on page 2-25).
CK30-1 2-33
OPERATION
Auxiliary Hydraulic Kit Control Pedal (If Installed)
Always engage the safety guard (2) when use of the control is not required, during travel and when parking
the machine.
When connecting a hydraulic attachment, make sure the control pedal (1) is always in the neutral or
horizontal position and covered with the safety guard.
Never set the control pedal to the maximum flow position unless the machine is stopped, the safety bar
is in the lowered position, and the operator is seated with the seat belt fastened.
The pedal (1) controls the starting and stopping of the oil flow to the
attachment and has three fixed positions ( applied, neutral, and
applied).
To apply the pedal (1), lift the safety guard (2).
1. Neutral or horizontal position (HYDRAULIC CIRCUIT

CLOSED).
No flow provided to the attachment.
2. applied position (HYDRAULIC CIRCUIT OPEN).

In the applied position, oil flow is supplied to the
attachment (excavator, demolition hammer, asphalt cutter,
etc.) and is obtained by pressing the pedal with the left part of
the foot pedal. To provide continuous oil flow, lock foot
pedal in position with lever (3).
To release pedal (1) to the neutral, or horizontal position,
push locking lever (3) forward to agree with illustration .
2-34 CK30-1
OPERATION
3. Two direction variable flow position.
The pedal is also used to control the oil flow to attachments
with two hydraulic circuits (multipurpose buckets, drills,
asphalt cutters, etc.). Shift locking lever (3) to the unlocked
(forward) position and press pedal (1) to position or to
control the flow of oil to the attachment. The amount of flow
in each direction is proportional to the distance the pedal is
moved.
Foot Accelerator
The accelerator pedal (1) is positioned on the operator’s right and
serves to control the engine speed and power.
Use the accelerator pedal with care, especially when the machine is
under load or is working under difficult conditions.
Avoid useless acceleration, to reduce fuel consumption and extend the
life of both the engine and the machine.
Hand Accelerator
The use of the hand accelerator is allowed only under the

indicated conditions; its use in other conditions may lead to
accidents.
The hand accelerator must be used during the warming up of the

engine and successively when operations with the optional equipment
are to be carried out; it can also be used for some maintenance
operations.
• Idle position :
Lever pushed completely forward.
• Maximum speed position :

Lever pulled completely backward.
CK30-1 2-35
OPERATION
Parking Brake
The parking brake must be applied whenever the operator

leaves the driving position, even if for a short time.
The machine must be positioned with the tracks resting
firmly on the ground. If one of the tracks is unstable or is
resting on a small obstacle, the machine may move.
Periodically check the functionality of the parking brake.
Failure to comply with these instructions may lead to serious
accidents or even death.
In case of failure of the hydraulic system, before the
recovery of the machine, release the negative brake installed
on the travel hydraulic motors (See “Releasing The Parking
Brake” on page 3-25).
The braking action is obtained by pressing the switch (1) (LED ON); the release is obtained by pressing the switch again (LED
OFF).
The parking brake is automatically engaged whenever the engine stops; this is due to the lack of pressure
in the hydraulic system.
Every time the engine is started or restarted, it is necessary to release the parking brake before moving the
machine.
Standard Flow Hydraulic System Control (2 or 3

Lines)
Never connect an attachment to the hydraulic lines before

the attachment is mechanically installed and locked to the
machine front coupler.
Controls must be in neutral and deactivated prior to connect-
ing hydraulic lines to an attachment.
Connect hydraulic lines only with the engine off and the
parking brake engaged.
Do not risk serious injury. Always operate the attachment
from the operator’s seat. Do not allow other people close to
the machine or attachment.
Read and understand the attachment Operator’s Manual re-
garding attachment control functions and operation.
The oil flow, which is bidirectional, to the attachment is controlled

by the pedal See “Auxiliary Hydraulic Kit Control Pedal (If Installed)” on page 2-34
and is proportional to the distance the pedal is moved in either direction.
The hydraulic lines are located on the left arm.
2-36 CK30-1
OPERATION
Super Flow Hydraulic System Control (5 Lines)
Never connect an attachment to the hydraulic lines before

the attachment is mechanically installed and locked to the
machine front coupler.
Controls must be in neutral and deactivated prior to
connecting hydraulic lines to an attachment.
Connect hydraulic lines only with the engine off and the
parking brake engaged.
Do not risk serious injury. Always operate the attachment
from the operator’s seat. Do not allow other people close to
the machine or attachment.
Read and understand the attachment Operator’s Manual
regarding attachment control functions and operation.
If the Super Flow button, (1) or (2), is pressed ON, be aware

that the hydraulic flow will operate the attachment if the
button is pressed.
The Super Flow hydraulic controls can be used when the operator
needs increased oil delivery in the attachments hydraulic system. With
the “Super Flow” hydraulic system it is possible to use equipment that
requires a high-flow hydraulic line (left) and, at the same time, a
standard-flow hydraulic line (right) with limited oil flow for
secondary functions (auxiliary hydraulic kit control pedal).
CK30-1 2-37
OPERATION
With the Super Flow hydraulic controls, the operator can utilize two
independent hydraulic circuits (located on the right and left arms).
With the Super Flow system, the standard flow lines are moved to the
right arm. The amount of oil flow in the right hydraulic lines and the
flow reversal are managed by means of the pedal (See “Auxiliary
Hydraulic Kit Control Pedal (If Installed)” on page 2-34).
Left side hydraulic lines are used only for the equipment requiring
Super Flow rates and controlled by push button (1) and push button
(2) on the left joystick.
To provide oil flow to the attachment, press and release push button
(2) (red LED above the button on); press the button again to
completely stop the oil flow (red LED off) through the hydraulic lines.
To provide the oil flow and at the same time reverse it, press and hold
push button (1). Release push button (1) to restore normal operation.
2-38 CK30-1
OPERATION
Speed Increase Control
The button (1) that increases the machine travel speed is positioned on
the underside of the left joystick grip.
When the button is pressed, the speed increases; push the button again
to return to normal speed.
The speed increase function should be used only for the

high speed repositioning of the machine; in any other case,
it is advisable to use the normal speed.
Do not use the speed increase control when performing
steering or counter rotation maneuvers.
Floating Position Control

The right joystick grip is provided with a switch (1) that, when
pressed, (INDICATING LIGHT ON) (See “Float Switch Indicator
Light” on page 2-12) frees the loader arm (floating position), that is,
allows it to automatically follow the undulations of the ground.
Press the switch again to restore the standard operating conditions
(INDICATING LIGHT OFF) (See “Float Switch Indicator Light” on
page 2-12).
CK30-1 2-39
OPERATION
Pattern Shifting Control
Before using the pattern shifting control, lower the equip-

ment to the ground, engage the safety devices and stop the
engine.
Failure to comply with these instructions may lead to serious
injuries or even death.
The pattern shifting control is located in the engine compartment on

the rear wall of the cab and can be reached after opening the engine
hood (See “Engine Hood” on page 2-48).
The lever (1) of the pattern shifting control has two positions:
• ISO CONTROL SYSTEM
Lever in position A
• OPTIONAL CONTROL SYSTEM

Lever in position B
2-40 CK30-1
OPERATION
The control system selection lever (1) is held in the correct position by
means of a safety screw (2).
When it is necessary to modify the control system, loosen the safety
screw (2) until lever (1) can be moved. Use a 13 mm wrench or the
factory supplied ring.
Select the desired control system and lock the lever in place by
tightening the safety screw (2).
Before moving the machine, the operator must make sure

that the selected control system is the one that is required.
The control panels (3) located on the sides of the central

dashboard are lit from behind. The backlighting of the panels
is helpful to the operator in identifying the type of control
system selected (ISO PATTERN control or OPTION control).
CK30-1 2-41
OPERATION
Right Stabilizer Control
Before moving the machine in any way, make sure that the
stabilizer feet are completely raised.
Before traveling on roads, make sure that the safety locks of
the stabilizer feet have been applied.
The right stabilizer is operated by means of the button (1) installed on

the left console and according to the indicated positions.
1. Press the button forward to lower the stabilizer foot.
2. Press the button backward to raise the stabilizer foot.
Left Stabilizer Control
Before moving the machine in any way, make sure that the
stabilizer feet are completely raised.
Before traveling on roads, make sure that the safety locks of
the stabilizer feet have been applied.
The left stabilizer is operated by means of the button (1) installed on

the left console and according to the indicated positions.
1. Press the button forward to lower the stabilizer foot.
2. Press the button backward to raise the stabilizer foot.
Optional Electrical Connections

The right three-button joystick is used when the operator needs to
connect electro-hydraulic equipment with several functions.
Each push button corresponds to an electric line activated by a pulse
control: press the push button to activate the electric contact; release
the push button to deactivate the contact.
This feature is only available with the Super Flow Auxiliary
Hydraulics.
2-42 CK30-1
OPERATION
Battery Disconnect Switch

(If equipped)
• Keep the battery disconnect switch in the ON position, EXCEPT when:

• When switching off the battery disconnect switch, wait more than one minute after shutting off the engine. Never turn off
the switch while the engine is running. Otherwise, electrical systems may be damaged.
• When the battery gets switched off, power supply to all the electrical systems is disconnected, and stored data for clock
time settings or radio channel selection may be lost.
• The battery disconnect switch is used for switching on or off power supply from the battery to the electrical systems of the
machine. The switch is located in the battery compartment.
(O): OFF position

The flow of electricity is shut OFF. At this position the switch
key can be pulled out.
(I): ON position
The flow of electricity is carried to electric circuits. Be sure that
the switch is set in this position before starting the machine
engine.
CK30-1 2-43
OPERATION
Fuses And Relays
If equipped with battery disconnect switch, turn the ignition switch OFF, wait one minute, then turn the
battery disconnect switch off and remove the battery disconnect switch key before working with fuses and
relays.
When changing a fuse, make sure that the ignition switch is in the OFF position. If the fuses are oxidized,
corroded, or do not fit perfectly in their seat, replace them only with new fuses having the same capacity.
If the engine does not run when the ignition switch is brought to “START” position, check that the battery
disconnect switch key is inserted and turned ON, then, check the main fuse and if necessary change it.
Machine Function Fuses

The fuses relevant to the machine functions are grouped on a single base positioned on the dashboard behind the seat.
Standard Version
POSITION COLOR CAPACITY A CIRCUIT
1 Violet 3 Left parking lights
2 Violet 3 Control panel lights, right parking lights
3 Light Blue 15 Horn, low beam, or front working lights
4 Brown 7.5 Switch lights
5 Light blue 15 Rear working lights
6 Red 10 Power supply for joystick switches, floating device, pattern shifting
7 Red 10 12V electrical outlet, revolving light
8 Red 10 Power supply for control panel, safety unit, solenoid valve stop, control
bar sensor, seat sensor, brake switch
9 Brown 7.5 Back-up alarm
10 Brown 7.5 Fuel pump, safety relay (against repeated starting), alternator
11 Green 30 Solenoid pull relay, servo control safety pressure switch
2-44 CK30-1
OPERATION
Version With Optional Connections
POSITION COLOR CAPACITY A CIRCUIT
1 Violet 3 Left parking light, number plate light
2 Violet 3 Control panel lights, right parking lights
3 Light blue 15 Horn, low beam, or front working lights
4 Red 10 Switch lights, direction indicator lights
5 Light blue 15 Rear working lights, stop lights
6 Red 10 Power supply for joystick switches, floating device, pattern shifting
7 Red 10 12V electrical outlet, revolving light, emergency lights (HAZARD)
8 Red 10 Power supply for control panel, safety unit, solenoid valve stop, control bar
sensor, seat sensor, brake switch
9 Brown 7.5 Back-up alarm, power supply for Super-flow 3-way equipment hydraulic
system, stabilizers, safety valves
10 Brown 7.5 Fuel pump, safety relay (against repeated starting), alternator
11 Green 30 Solenoid pull relay, servo control safety pressure switch
Main Fuse
The main fuse (1) is positioned near the battery and can be reached by
tilting the cab (See “Tilting The Cab” on page 2-51).
POSITION COLOR CAPACITY (A) CIRCUIT
1 Red 50 System general circuit
CK30-1 2-45
OPERATION
Relays
The relays are positioned inside the engine compartment and can be
reached by tilting the cab (See “Tilting The Cab” on page 2-51).
Some relays are grouped inside the box attached to the right side of the
machine frame and can be reached by removing the cover (A).
POSITION DESCRIPTION
1 Engine stop relay
2 Safety relay (against repeated cranking)
Other relays are contained inside the base installed on panel (B)
behind the seat and can be reached by removing panel (B).
2-46 CK30-1
OPERATION
3 Safety Unit
Relay board:
A - Stop lights
B - 1 way
C - 3 way
4
D - Momentary high-low
E - 2 way
F - Blinking
G - Detent high-flow
5 Stoplight relay
6 Floating device control relay
7 Parking brake relay
CK30-1 2-47
OPERATION
GUARDS AND OPERATOR’S SEAT
Engine Hood
Do not open the engine hood when the engine is running. Do

not use the machine without engine hood and do not start
the engine when the hood is open, unless this is expressly
prescribed for certain maintenance operations. Failure to
follow these rules may result in serious accidents.
OPENING THE HOOD

After releasing the lock, press the push button (1) and raise the engine
hood (2).
The maximum opening position is maintained by the lifting piston (3),
which is locked in position by the safety retainer (4).
CLOSING THE HOOD
Press the safety retainer (4) of the lifting piston (3) and at the same
time lower the hood.
Push it downwards until the lock engages.
Lock the hood.
Make sure that the safety retainer (4) is engaged every time
you open the hood.
2-48 CK30-1
OPERATION
Rear Panel
Do not open the rear panel when the engine is running.

Do not use the machine without the rear panel and do not
start the engine with the panel open, if this is not expressly
prescribed for certain maintenance operations.
Failure to follow these rules may lead to serious accidents.
The rear panel can be opened only after opening the engine
hood.
When inspecting or carrying out a maintenance operation
inside the rear panel, always engage the panel in the safety
retainer to keep it open.
To reach the release lever (2) for the rear panel (1), raise the engine
To open the rear cover (1), lift the lever (2) positioned on the inner left
side of the machine, at the same time rotate the cover to the maximum
opening position and hold it open with retainer (3), by proceeding as
follows:
1. Lift retainer (3) and rotate it clockwise until it rests against the
rear cover (1).
2. Release retainer (3) and make sure that it has been engaged
correctly.
To close the rear cover (1), release retainer (3), rotate it counter
clockwise and make it rest against the rear cover (1).
CK30-1 2-49
OPERATION
Cab
The cab is a combined ROPS-FOPS; if it is subjected to an

impact for any reason, or if the machine overturns, contact
your distributor, who will make sure the operator’s safety is
ensured.
For maintenance or routine operations, the cab must be
tilted; carry out this operation according to the procedure
described in section (See “Tilting The Cab” on page 2-51)
and adhere to all safety precautions indicated therein.
The cab is of the semi-closed type.

The windows are positioned on the rear and upper part and the rear window can be removed.
In a special version of the machine, available on request, the cab can be completely closed through the addition of side
windows and front door.
2-50 CK30-1
OPERATION
Tilting The Cab
Tilt the cab only with the machine parked on a firm and level surface and with the loader arm lowered to the
ground complete with bucket or any other optional equipment.
Make sure that the surface on which the machine is parked is not slippery.
Before tilting the cab, make sure that the engine hood is open.
When lifting the cab, avoid removing the fastening screws (A) of the rear dampening supports of the cab it-
self.
The cab must be raised or lowered by two people, one per side and it is important to make sure that the
handles and hold points are not dirty with oil or grease.
After tilting the cab, always engage the safety split pin of the cab overturning protection lock.
Do not carry out any operation on the machine if the hitch pin clip of the cab overturning protection lock is
not engaged.
Always tighten the cab fastening screws to the torque indicated in (See “Specific Torques” on page 3-19).
To carry out some maintenance or routine operations it is necessary to

tilt the cab, an operation that must be carried out by two people
according to the following procedure:
1. Stop the machine on firm and level ground.
2. Lower the equipment to the ground.
3. Apply the parking brake and lock the controls by rotating the
safety bars to the lock (vertical) position.
4. Stop the engine as indicated in (See “STOPPING THE ENGINE”
on page 2-83).
5. Open the engine hood (See “Engine Hood” on page 2-48) and
remove the rear screws (1) that fasten the cab to the frame.
Use a 19 mm hexagon wrench.
6. With the help of another person, raise the rear part of the cab
using the appropriate handles and pull it forward until it stops.
7. Engage the hitch pin clip (2) of the cab overturning protection
lock (3).
CK30-1 2-51
OPERATION
When lowering the cab, be careful of the hold points and

carry out the operation with the help of another person.
1. Remove the hitch pin clip (2) of the cab overturning protection
lock (3) and put it in the appropriate seat (4).
2. Lower the rear of the cab until it touches the support surface.
3. Reassemble the fastening screws (1) and tighten them to the
torque indicated in paragraph (See “Specific Torques” on page 3-
19) and close the engine hood (See “Engine Hood” on page 2-48).
2-52 CK30-1
OPERATION
Standard Seat
The seat can be adjusted longitudinally and the operator can choose
the driving position that is most suitable for his physique.
The longitudinal adjustment of the seat is obtained by operating the
lever (1) and making the seat slide on the guides; once the desired
position has been found, release the lever and carry out slight
movements, in order to make sure that the lock pin is engaged in its
seat.
Suspension Seat
This seat is extremely comfortable, offering four adjustment options:
a - longitudinal adjustment;
b - back inclination adjustment;
c - adjustment of the suspension, aimed at dampening the inevita-
ble vibrations and jerks as much as possible;
d - seat cushion inclination adjustment.
The operator can choose the driving position that is most suitable for
his physique.
The longitudinal adjustment of the seat is obtained by operating the
lever (1) and making the seat slide on the guides; once the desired
position has been found, release the lever and carry out slight
movements, to make sure that the lock pin is engaged in its seat.
The back adjustment is achieved by operating the lever (2); operate
the lever and find the position that is most suitable for the operator’s physical structure. Three different degrees of inclination
are possible.
The adjustment of the suspension is carried out with the lever (3), according to the operator’s weight. The suspension can be
stiffened or lightened according to the operator’s needs; adjust the seat suspension by positioning the lever (3) in one of the
five seats available for this purpose. Shift the lever to the left to stiffen the suspension or to the right to lighten it.
The inclination of the seat cushion is obtained by operating the lever (4) and positioning the front part of the cushion at the
same time; it is possible to select 2 different positions.
CK30-1 2-53
OPERATION
Seat Belt
Before starting the engine, fasten the seat belt.

The seat belt must be changed when it is frayed, damaged or
worn and in any case every 4 years.
The seat belt (1) is of the type with two coupling points and adjustable
length (2); it must be well tightened and hold the operator’s hips,
while leaving the upper part of his body completely free.
Emergency Exit
The machine is provided with an emergency exit located in the rear
window (1).
In case of emergency, pull the plate (2) positioned on the upper side of
the window and remove the weather strip completely.
Push the window toward the outside.
2-54 CK30-1
OPERATION
Technical Documentation Case
The Operation and Maintenance Manual and the Parts Book

are integral parts of the machine and must accompany it
even in case of resale.
The Operation and Maintenance Manual must be handled with care

and kept aboard the machine, so it can be easily consulted at any time.
Put the manual in the technical documentation case located inside the
cab on the left side, where the ownership documents and the logbook
are usually kept.
Fire Extinguisher
The machine’s owner must provide for installing and

mounting the fire extinguisher where prescribed.
Periodically make sure that the fire extinguisher is full.
The fire extinguisher (1) must be installed by the owner of the

machine and positioned inside the cab on the left side behind the left
console.
First Aid Kit
Periodically make sure that the first aid kit contains the
necessary disinfectants, bandages, medicine, etc. and check
their condition and expiration dates. Replace as necessary.
The first aid kit must be installed by the owner of the machine and
positioned inside the cab on the right side behind the right console.
CK30-1 2-55
OPERATION
OPERATING THE MACHINE
Checks Before Starting The Engine

Visual Checks
Dirt, oil, and fuel in the engine compartment near hot parts may damage the machine and even cause fires.
Check frequently and eliminate any leakage; if leakages occur repeatedly, contact your distributor.
Before starting the engine, check around and under the machine to verify:
1. If there are loose screws or nuts.
2. If there are oil, fuel, or coolant leaks.
3. The wear of the work equipment.
4. The fastening of the electrical connections.
5. The fastening of the engine exhaust pipe and manifold.
6. The conditions and the wear of the rubber tracks.
7. If the safety and warning plates are sufficiently clean.
8. If the ladders and the handles for access to the operator’s seat are clean.
Any leak or abnormality must immediately be repaired and any trace of oil or grease must be removed. Further visual
checks concern:
9. The correct torque of the rear fastening screw of the cab.
10. The condition of the seat belt.
11. The efficiency of the instruments and of the dashboard.
12. The condition of the cab windows and the efficiency of the lights, working lights and direction indicators.
Daily Checks
Do not smoke during fuel and oil topping off and do not use open flames or non-approved lighting to
check the fuel and oil levels, to not cause fires. If fuel, oil, or lubricants are spilled while filling the tanks,
clean the dirty areas immediately.
Before starting any operation, check the engine coolant, engine oil, and hydraulic circuit oil levels. At the end of work, refuel
to avoid the formation of condensation, always checking the fuel level on the indicator provided on the dashboard.
Avoid filling the tank completely, to leave room for the fuel to expand. After filling the tank, put back the
filler cap, making sure that the bleed hole is completely open. Check the engine oil level with the machine
level and the hydraulic circuit oil level with the front bucket resting on the ground.
2-56 CK30-1
OPERATION
Operational Checks
All the checks must be carried out by the operator while seated, with the seat belt fastened. When the
machine is at rest after use or maintenance, some safety locks may not be engaged; when the operator
gets into the cab, he must make sure that all the mechanical safety locks are engaged and that the
equipment cannot move suddenly and create dangerous situations.
The checks concern:

1. The locking of the safety bars.
2. The hand accelerator idle position.
3. The neutral position of the controls.
4. The application of the parking brake.
The following check is carried out by turning the ignition key to

position <<I>> to apply voltage to the control panel and check the
functionality of the audible alarm, of the fuel level indicator, and of
the engine oil pressure, alternator, and preheating warning lights.
CK30-1 2-57
OPERATION
Starting The Engine
Before starting the engine, carefully read the instructions and information regarding safety given in this
manual and make sure that you know the controls.
From the moment in which the engine is started, the operator is directly responsible for any damage that
may be caused by wrong maneuvers and non compliance with the safety regulations and the rules of the
road.
Before starting the engine, make sure that there is no one within the operating radius of the machine and
sound the horn.
Starting A Warm Engine Or In Temperate Cli-

mates
1. Turn the ignition key directly to position « » (START).
2. As soon as the engine starts, release the ignition key, which will
automatically return to position «I».
Starting The Engine
If the engine does not start within 15 seconds, release the

key, which will automatically return to position I and wait for
30 seconds before trying again.
2-58 CK30-1
OPERATION
Starting A Cold Engine Or In Cold Climates
Do not use any starting fluids or ether to assist in starting an

an engine in cold weather. These products may cause an
explosion, damaging the engine or causing injury.
1. Pull the accelerator lever until reaching half of its stroke and turn
the ignition key to the preheating position « » for a maximum of
13 seconds in the coldest weather.
Preheating is indicated by the warning light located on the
dashboard.
2. Turn the ignition key to position « » (START) until the engine
starts or for a maximum of 15 seconds.
3. As soon as the engine starts, release the ignition key, which will
automatically return to position «I» and reduce the engine speed
to idle.
If the engine does not start on the first attempt, repeat steps
1 and 2 after waiting for at least 1 minute, to not overload the
battery.
CK30-1 2-59
OPERATION
Warming The Engine
1. After starting the engine, let it warm up before starting work.
2. The ideal warming up of the engine is achieved with a constant speed obtained with the hand accelerator
Do not use full throttle or accelerate abruptly until the coolant temperature has reached at least 60°C
(140°F).
3. To reduce the time necessary to warm up the engine, move the hand accelerator lever now and then to the midpoint of its
travel.
4. During the warming up of the engine, check the color of the exhaust gases and verify if abnormal noises or vibrations can
be noticed; any problem must be verified and its cause must be eliminated.
Heating The Hydraulic Oil

When warming up the engine, especially in cold weather, it is advisable to also heat the hydraulic system oil. For this reason,
when the coolant temperature has reached approximately 60°C (140°F), proceed as follows:
1. Release the safety device of the controls by rotating the safety bars down and releasing the park brake. (See “Safety Bars”
on page 2-25 and See “Parking Brake” on page 2-36).
2. Slowly extend and retract the lift and bucket cylinders completely several times.
3. Lower the bucket to the ground and lock the safety device again by rotating the safety bars up(See “Safety Bars” on
page 2-25).
Moving The Machine (Iso Pattern Control System)
Before moving the machine, make sure that you are completely familiar with all control functions and all
relevant safety regulations.
The operator must be seated in the driving position with seat belt fastened.
Before moving the machine, check the position of the rear-view mirrors and make sure that there is no one
within the operating radius of the machine and that there are no obstacles in the surrounding area.
Be extremely careful when engaging reverse and make sure there are no people, working means, or
obstacles in the way.
Avoid maneuvers or changes of direction when travelling at full speed, since the maneuvers carried out
under these conditions cause abrupt machine movements.
Do not use the speed increase function when changing direction or carrying out a counter-rotation.
The use of the speed increase function is allowed only for fast transfers of the machine.
Before moving the machine, check the instruments, warm up the engine and the hydraulic system oil, make sure that the safety
device for the controls is released (safety bars down) and the bucket is rolled back; the equipment control joystick must be in
neutral position.
Release the parking brake.
2-60 CK30-1
OPERATION
1. Pull the hand accelerator lever and set the engine to the desired
travel speed.
2. Operate the joystick (1), shifting it forward to make the machine

advance or backward to make it move in reverse.
CK30-1 2-61
OPERATION
Steering (Changing Direction)
If possible, avoid any abrupt change of direction. Counter rotations should be carried out with the machine
running at moderate speed.
When traveling on roads, avoid carrying out counter rotations, since they may create dangerous
situations; carry out counter rotations only during work cycles.
Changing Direction When The Machine Is Not Moving
To turn to the LEFT, operate the travel joystick as indicated in the

diagram. To move FORWARD, push the joystick to the left with 45°
inclination. To move BACKWARD, pull the joystick to the right with
45° inclination.
To turn to the RIGHT, operate the travel joystick as indicated in the

diagram. To move FORWARD, push the joystick to the right with 45°
inclination. To move BACKWARD, pull the joystick to the left with
45° inclination.
2-62 CK30-1
OPERATION
Changing Direction When The Machine Is Moving
To turn to the LEFT, rotate the travel joystick counterclockwise by

approximately 45°.
To turn to the RIGHT, rotate the travel joystick clockwise by

approximately 45°.
How To Carry Out A Counter Rotation

(with the machine not moving)
To turn to the LEFT, shift the travel joystick to the left with an angle of
90° with respect to the longitudinal axis.
To turn to the RIGHT, shift the travel joystick to the right with an
angle of 90° with respect to the longitudinal axis.
CK30-1 2-63
OPERATION
How To Move The Machine (Optional Pattern Control System)
Before moving the machine, make sure that you know the control functions and all the relevant safety
regulations perfectly.
The operator must be seated in the driving position with seat belt fastened and the safety bars lowered.
Before moving the machine, check the position of the rear-view mirrors and make sure that there is no one
within the operating radius of the machine and that there are no obstacles in the surrounding area.
Be extremely careful when engaging reverse and make sure that there are no people, working means, or
obstacles in the way.
Avoid maneuvers or changes of direction when travelling at full speed, since the maneuvers carried out
under these conditions cause abrupt machine movements.
The use of the speed increase function is allowed only for fast transfers of the machine.
Before moving the machine, check the instruments, warm up the engine and the hydraulic system oil, make sure that the safety
device for the controls is released (safety bars down) and the bucket is rolled back; the equipment control joysticks must be in
neutral position.
1. Release the parking brake.
2. Pull the hand accelerator lever and set the engine at the desired
travel speed.
3. Operate the joysticks (1) and (2) at the same time, shifting them
forward or backward to move the machine.
2-64 CK30-1
OPERATION
If possible, avoid any abrupt change of direction. Counter rotations should be carried out with the machine
running at moderate speed.
When traveling on roads, avoid carrying out counter rotations, since they may create dangerous
situations; carry out counter rotations only during work cycles.
Changing Direction When The Machine Is Not Moving
To turn to the LEFT, operate the right joystick by proceeding as

follows: to move FORWARD, push the joystick; to move
BACKWARD, pull the joystick.
To turn to the RIGHT, operate the left joystick by proceeding as

follows: to move FORWARD, push the joystick; to move
BACKWARD, pull the joystick.
CK30-1 2-65
OPERATION
Changing Direction When The Machine Is Moving (The Two

Joysticks Are In The Same Position)
To turn to the LEFT, shift the left joystick to the NEUTRAL position
(N): the machine will turn to the LEFT.
To turn to the RIGHT, shift the right joystick to the NEUTRAL posi-
tion (N): the machine will turn to the RIGHT.
How To Carry Out A Counter Rotation (With The Machine

Not Moving)
To turn to the LEFT, pull the left joystick backward and push the right
joystick forward.
To turn to the RIGHT, pull the right joystick backward and push the
left joystick forward.
2-66 CK30-1
OPERATION
Hand And Foot Control System
Machine Controls
The controls represented in the figures and not described in this section remain unchanged and are the
same present on the standard version. For details on how to use them, See “Machine Controls” on page 2-
23
1. Left PPC control joystick

HAND & FOOT CONTROL SYSTEM
(Left wheel travel)
2. Right PPC control joystick
(Right wheel travel and auxiliary hydraulic control)
3. Left foot operated hydraulic control
(Loader arm raising and lowering control)
4. Right foot operated hydraulic control
(Bucket dumping and roll back control)
CK30-1 2-67
OPERATION
Travel And Steering Control Joysticks
Before carrying out any machine movements with these joysticks, the operator must be seated in the work
position with seat belt fastened and the safety bars in the unlocked (horizontal) position; before any
machine movement the operator must take all the precautions indicated in see How To Move The Machine
(Hand & Foot Control System) on page 2-76..
Before moving, make sure the safety bars are in the horizontal (unlocked) position and the parking brake is
disengaged.
When traveling on roads, always make sure all safety devices have been engaged.
Before leaving the work position, lower the equipment to the ground and rotate the safety bars to the
The travel control joysticks (1) and (2) are positioned on the operator's
left and right side, respectively, and control the forward and reverse
travel of the machine according to the movements shown in the
diagram.
To move the machine forward or in reverse, shift the

direction.
For further details on the use of the joysticks, see How To
Move The Machine (Hand & Foot Control System) on page 2-
76.
2-68 CK30-1
OPERATION
N - Neutral
A - Forward
B - Reverse
The right PPC control joystick (2) is used to control the right track and
also to control the auxiliary hydraulic circuit according to the
movements indicated in the following diagram:
N - Neutral
A - Right track forward travel
B - Right track reverse travel
C - Oil delivery from the male coupling of the auxiliary
hydraulic circuit
D - Oil delivery from the female coupling of the auxiliary
hydraulic circuit
For details on the use of the auxiliary hydraulic control,.See “Auxil-

iary Hydraulic Kit Control Pedal (If Installed)” on page 2-34
Always travel with the engine running at moderate speed to

obtain maximum accuracy and productivity while working.
While working, use of the joysticks must be proportional to
the effort required to maintain a constant engine speed.
Operate the joysticks smoothly, without abrupt movements
and avoid counter-rotations as much as possible, since this
type of machine movement causes rapid track wear.
Remark
The horn (3) is positioned on the grip of the left joystick (1)
and must be used to warn all the people in the vicinity before starting work and in case of danger.
All movements can be stopped by rotating the safety bars to the vertical (locked) position. (See “Safety Bars”
on page 2-25.
CK30-1 2-69
OPERATION
Work Equipment Control Pedals (Loader Arm And Bucket)
Before carrying out any machine movement with these pedals, the operator must be seated in the work
position with seat belt fastened and the safety bars in the unlocked (horizontal) position; before any
machine movement the operator must take all the precautions indicated in see How To Move The Machine
(Hand & Foot Control System) on page 2-76.
Before leaving the work position, lower the equipment to the ground and rotate the safety bars to the lock
(vertical) position, then stop the engine.
The self-leveling system is automatically operated only when the loader arm is lifted with a full bucket.
When the arm is being lowered, the self-leveling system does not engage.
At maximum height, the self-leveling system keeps the bucket partially rolled back to prevent material
from being spilled.
The control pedals (1) and (2) are positioned on the floorboard in front
of the operator seat and control the movements of the loader arm and
the bucket.
The pedal (1), positioned on the operator's left, controls the raising and
lowering of the loader arm, as indicated in the following diagram:
2-70 CK30-1
OPERATION
N - Neutral
A - Loader arm raise
B - Loader arm lower
On machines provided with a floating device, press the pedal

to position B (lower loader arm) and press the switch
positioned under the right joystick. See “Machine Controls”
on page 2-23.
CK30-1 2-71
OPERATION
The pedal (2), positioned on the operator's right, controls the roll back
and dumping of the bucket, as indicated in the following diagram:
N - Neutral
A - Bucket roll back
B - Bucket dumping
2-72 CK30-1
OPERATION
Auxiliary Hydraulic Control Joystick
Before carrying out any machine movements with this

joystick, the operator must be seated in the work position
with seat belt fastened and the safety bars in the unlocked
(horizontal) position.
The control joystick (1) is positioned on the operator's right and

controls the movement of the right track and the auxiliary hydraulic
circuit, according to the movements indicated on the plate (2) and in
the following diagram:
N - Neutral
A - Right wheel forward travel
B - Right wheel reverse travel
C - Oil delivery from the male coupling (3) of the auxiliary
hydraulic circuit
D - Oil delivery from the female coupling (4) of the auxiliary
hydraulic circuit
CK30-1 2-73
OPERATION
The auxiliary hydraulic control starts and stops the oil flow to any
optional equipment and has four positions (neutral, left, right and
detent position).
1. Neutral position (N)

(CLOSED HYDRAULIC CIRCUIT)
No oil flow to the optional equipment.
2. Positions (C) and (D)

(OPEN HYDRAULIC CIRCUIT).
These positions are used to control optional equipment with bidi-
rectional oil flow (multi-purpose bucket, drill, asphalt cutter, etc.).
Move the joystick (1) to position (C) to deliver oil from the male
coupling (3) positioned on the left side of the loader arm, or to
position (D) to deliver oil from the female coupling (4).
2-74 CK30-1
OPERATION
3. Detent position (E)
(OPEN HYDRAULIC CIRCUIT).
This position is used to obtain a continuous unidirectional
oil flow for the operation of equipment such as excavator,
demolition hammer, sweeper, etc. To hold the joystick (1) in
the detent position (E), move the joystick further to the left.
The joystick (1) remains in detent position (E) only with a

pressurized hydraulic system.
When the joystick (1) is in position (E), pressurized oil is
delivered from the male coupling (3), with return thru the
female coupling (4).
CK30-1 2-75
OPERATION
How To Move The Machine (Hand & Foot Control System)
Before moving the machine, make sure that you are completely familiar with the control functions and all
relevant safety regulations.
The operator must be seated in the work position with seat belt fastened and the safety bars in the
unlocked (horizontal) position.
Before moving the machine, check the position of the rear-view mirrors (if installed) and make sure there is
no one within the operating radius of the machine and that there are no obstacles in the surrounding area.
Be extremely careful when shifting into reverse and make sure that there are no people, other equipment,
or obstacles in the way.
Avoid any travel maneuver or change of direction with the accelerator at maximum speed, since
maneuvers carried out under these conditions may cause dangerous machine movements.
Do not use the speed increase function when changing direction or carrying out a counter-rotation. The
speed increase function must be used only for traveling at high speed.
Check the instruments and warm up the engine and the hydraulic system oil before moving the machine. Make sure that the
safety bars are lowered to the horizontal (unlocked) position and that the bucket is rolled back; the equipment control pedals
must be in neutral position. At this point, release the parking brake.
1. Set the manual accelerator lever to the desired travel speed.
2. Move the joysticks (1) and (2) forward or backward at the same
time to move the machine.
2-76 CK30-1
OPERATION
Avoid abrupt changes of direction as much as possible. Carry out counter-rotations at moderate speed.
Avoid carrying out counter-rotations when traveling on roads, since these maneuvers may cause danger-
ous situations; make counter-rotations only during work.
Changing Direction With Machine At Rest
To turn to the LEFT, use the right joystick as follows: to move

FORWARD, push the joystick. To move BACKWARD, pull the
joystick.
To turn to the RIGHT, use the left joystick as follows: to move

FORWARD, push the joystick. To move BACKWARD, pull the
joystick.
CK30-1 2-77
OPERATION
Changing Direction With Machine In Motion (The Two Joy-

sticks Are Shifted To The Same Position)
To turn to the LEFT, shift the left joystick to the NEUTRAL position
(N) and the machine will turn to the LEFT.
To turn to the RIGHT, shift the right joystick to the NEUTRAL

position (N) and the machine will turn to the RIGHT
.
How To Perform A Counter-rotation (with machine at rest)
To perform a counter-rotation to the LEFT, pull the left joystick

backward and push the right joystick forward.
To perform a counter-rotation to the RIGHT, pull the right joystick

backward and push the left joystick forward.
2-78 CK30-1
OPERATION
Moving On Slopes
Before working on slopes, always check the functionality of

the parking brake.
Always go up or down slopes at moderate speed and with
the heavier end of the loader always directed towards the top
of the slope.
When going up or down slopes, keep the equipment
lowered; movements with the arm raised may cause the
machine to overturn.
Do not use the speed increase function when the machine
travels on slopes.
When working on slopes the following precautions should be taken to

avoid risks for the operator and anyone in the vicinity; the checks
and operations to be carried out are the following:
1. Always check the work area for snow, landslides, gravel, loose
ground and anything that may suddenly modify the work conditions
and the stability of the machine.
2. When it is necessary to travel downhill, the front bucket must
always be directed downward, in transport position.
3. When loading or traveling uphill, the front bucket must always be
directed upward.
4. When moving the machine during work cycles, always lower the
bucket.
5. Carry out any lateral movement on a flat surface at the beginning
or at the end of the slope; if this is not possible, move at an angle,
keeping the machine axis as parallel to the slope direction as
possible. Do not move at too great an angle or, even worse, with
the machine axis rotated by 90° with respect to the slope
direction.
CK30-1 2-79
OPERATION
Maximum Immersion Depth
If it is necessary to work with the machine immersed in water on river banks or sea shores, always check
the water depth and the current flow. Make sure that the surface on which you are working is sufficiently
firm.
If it is necessary to work with the machine immersed in water, make sure that the maximum depth does not exceed 24 cm and
in any case that the engine cooling fan does not touch the water, since it may get damaged or even break.
When working in water or on muddy ground, lubricate the articulated joints more frequently than usual.
After work, remove any dirt or mud and lubricate the articulated joints.
2-80 CK30-1
OPERATION
PARKING THE MACHINE
Parking On Level Ground
Park the machine on firm and flat ground, in a sufficiently

wide space, so that the checks, daily lubrication, and
refueling can be carried out without problems. Lower the
work equipment to the ground. Engage all safety locks and
apply parking brake. Keep to all the safety rules, to avoid any
movement of the machine when the operator is absent.
When leaving the machine, remove the ignition key.
1. Park the machine on firm and flat ground, in a sufficiently wide

space.
2. Lower the bucket to the ground.
3. Lock the equipment and travel hydraulic control by shifting the
safety bars to the lock position (vertical) (See “Safety Bars” on
page 2-25).
4. Engage the safety guard to lock the optional equipment control
pedal.
5. Apply the parking brake.
6. Stop the engine following the procedure indicated in paragraph (See
“STOPPING THE ENGINE” on page 2-83).
7. Remove the ignition key.
8. Leave the cab using the handles and the footboards.
9. Refuel taking the necessary precautions.
CK30-1 2-81
OPERATION
Parking On Slopes
The movement of the machine when the operator is not on

board may cause serious accidents or even death; to
prevent this, carry out the operations described below. Park
on slopes only when it is absolutely necessary. Park only
with the front bucket directed downwards.
1. Park the machine with the bucket directed downwards and resting
against an obstacle. If this is not possible due to the absence of natu-
ral obstacles, rotate the bucket to the dump position and thrust the
teeth into the ground.
2. Lock the equipment and travel hydraulic controls by rotating the
safety bars to the lock (vertical) position (See “Safety Bars” on
page 2-25).
3. Engage the safety guard to lock the optional equipment control
pedal.
5. Stop the engine following the procedure indicated, (See “STOP-
PING THE ENGINE” on page 2-83).
6. Remove the ignition key.
7. Leave the cab using the handles and footboards.
8. Put wedges under the tracks.
9. Refuel taking the necessary precautions.
2-82 CK30-1
OPERATION
STOPPING THE ENGINE
The sudden stop of the engine while it is running shortens

its life. Do not stop it suddenly, except in case of emergency.
It is likewise recommended not to stop the engine suddenly
if it has been running for a long period and is still hot; in this
case, let the engine idle at a min. speed of 1200 rpm for
about 5 minutes, to allow it to cool down gradually before
stopping.
Before stopping the engine, proceed as follows:

1. Rest the work equipment on the ground.
2. Shift the joysticks to the neutral position and engage the safety
devices.
3. Move the hand accelerator lever to the idle position.
Stop the engine by turning the ignition key to position «O» (OFF).
CK30-1 2-83
OPERATION
TRANSPORTING THE MACHINE
Loading And Unloading
The loading and unloading of the machine on-off the means

of transport must be carried out on a flat surface and at a
safe distance from the edges of ditches or from the road
side. Block the means of transport by positioning wedges in
front of and behind each track. Make sure that the ramps are
sufficiently strong; if necessary, reinforce them with blocks
to prevent any dangerous bending. Make sure the ramps are
the same length, firmly anchored to the motor vehicle, paral-
lel to each other and perpendicular to the loading board; the
distance between the ramps must be suitable for the
machine gauge. Position the ramps with a maximum inclina-
tion of 15°. Remove any trace of oil, grease or ice from the
ramps and the loading board. Do not change direction when
the machine is already on the ramps; if necessary, go down
and find the correct direction.
1. The machine, with empty bucket or without optional accessories,

must move on the ramps with the bucket (1) at the back and
raised above the ground.
2. Once the machine has been loaded, lower the work equipment to the bed and rotate the safety bars to the lock (vertical)
position.
4. Stop the engine and remove the ignition key.
5. Keep the machine in position also by putting wedges (2) in front of and behind each track.
6. Attach the machine with tie downs or chains (3) in the tie down hooks(5) and (6).
7. Cover the end of the exhaust pipe (4).
2-84 CK30-1
OPERATION
Transport
1. Check the overall dimensions; the height, width and weight of the means of transport - machine included. It must be
compatible with the road and any tunnel, subway, bridge, electric or telephone line that may be found on the way.
2. Observe all regulations regarding signals, speed limits, road traffic, permits, etc.
CK30-1 2-85
OPERATION
HOW TO LIFT THE MACHINE
To lift the machine use cables of adequate strength; do not use worn cables or cables with broken strands.
Do not lift the machine with the operator on board and make sure that no one is approaching the machine
before lifting it. Before lifting the machine, make sure the eye bolts are correctly attached to the cab roof.
The owner of the machine is responsible for installing the eyebolts correctly on the cab roof.
Torque to 80 N•m (59 lbf-ft)
Use only eyebolts approved by Komatsu for this specific type of machine.
Approved eyebolts must be requested from your Komatsu Distributor, specifying the machine model and
serial number.
To lift the machine, proceed as follows:

1. Lower the loader arm to the ground and roll the bucket completely
back.
2. Rotate the safety bars to the lock (vertical) position and stop the
engine.
3. Insert chains or nylon ropes in the two front eye bolts on the cab roof
and attach with the appropriate retainers or safety pins.
4. Assemble the chains or nylon ropes in the two couplings on the rear
shoulders of the frame, near the arm fulcrum.
5. Connect the ropes or chains to the spreader bar as indicated in the

figure.
Always use the four attaching points provided for the lifting of the machine.
6. Lift slowly until the ropes or chains are tensioned and make sure that the machine is hooked correctly before lifting it off
the ground.
During the lift, avoid jerks and abrupt changes of direction.
When lifting the machine, make sure that it is correctly balanced and that it can be lifted level.
Do not lift the machine with optional equipment installed on it.
2-86 CK30-1
OPERATION
COLD WEATHER PRECAUTIONS
During cold weather or in areas where the temperature is particularly low, especially during the night, it is necessary to take
some countermeasures meant to limit the damage resulting from low temperatures.
Fuel And Lubricants

1. Change the fuel and use winter fuel ASTM D975N.1 when the ambient temperature is below -10°C.
2. Change the engine oil for an oil of suitable viscosity. For the relevant specifications, See “FUEL, COOLANT AND
LUBRICANTS” on page 3-6.
Coolant
The coolant containing antifreeze is flammable; do not smoke and do not use open flames when checking
and preparing the mixture. Do not use methanol-, ethanol- or propane-based antifreezes.
Komatsu Supercoolant (AF-NAC)
1. Coolant has the important function of anticorrosion as well as antifreeze.

Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant AF-NAC. Komatsu Supercoolant AF-NAC has excellent
anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant AF-NAC is strongly recommended wherever available.
2. CK30-1 S/N A30001 and up are serviced with Komatsu Supercoolant AF-NAC from the factory.
3. DO NOT mix all season type coolant with Super Coolant.
4. For details of the ratio when diluting super coolant with water. Supercoolant AF-NAC may be supplied in premix. In this
case, always top off with premix solution. (never dilute with water)
5. To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30%
and 68%
6. Do not use plugging additives, either alone or added to the antifreeze, to eliminate leakage.
7. Do not mix antifreezes of different brands.
CK30-1 2-87
OPERATION
Battery
To avoid explosions due to the presence of gas, do not provoke sparks and do not use open flames near
the battery. The battery electrolyte is dangerous. If it comes in contact with the eyes or skin, immediately
rinse with plenty of water and consult a doctor without delay.
1. When the ambient temperature decreases, the battery capacity decreases accordingly and, if the battery charge is low, the
electrolyte may freeze. Keep the battery completely charged and insulate it to protect it from low temperatures, so the
machine can be started without problems the following day.
2. Measure the specific gravity of the fluid and check the battery charge percentage in comparison to the following table:
FLUID TEMPERATURE
CHARGE%
20°C (68°F) 0°C (32°F) -10°C (14°F) -20°C (-4°F)
100% 1.28 1.29 1.30 1.31
90% 1.26 1.27 1.28 1.29
80% 1.24 1.25 1.26 1.27
75% 1.23 1.24 1.25 1.26
3. To prevent the fluid from freezing, add distilled water in the morning, before starting work.
Other Precautions
Before using the machine in normal operating conditions, carry out some slow movements either forward or in reverse, and
operate all the work equipment cylinders slowly more than once. These operations serve to warm up and decrease the viscosity
of the oil in the hydraulic circuit and the transmission.
Precautions To Be Taken At The End Of Work

1. Completely remove mud and water from the machine body. Park the machine on firm ground; if the machine must be
parked near banks or ditches, park it on wooden boards to distribute the weight of the machine over a larger area.
2. Be careful of water drops forming on the hydraulic cylinder rods: these drops must be completely removed, since if they
freeze the cylinder seals may be damaged. After removing the water drops, protect the rods with oil.
3. Drain any condensate that may have formed in the fuel tank, to prevent the water from freezing overnight.
4. Since the battery capacity may decrease considerably at low temperatures, after work cover the battery or remove it and
store it at a suitable temperature.
2-88 CK30-1
OPERATION
WARM WEATHER PRECAUTIONS
The engine coolant must be changed only if it is not permanent, See “FUEL, COOLANT AND LUBRI-
CANTS” on page 3-6
1. At the end of the cold weather, change the lubricants, the coolant, and the fuel.
2. Make sure the cooling fan belt is in good condition.
3. Make sure that the fins of the radiator and of the heat exchanger are clean.
4. Check the radiator cap gasket and spring; in case of doubt regarding tightness and setting, change the cap.
OPERATING THE WORK EQUIPMENT
Always fasten the seat belt. Before moving the equipment, make sure that there is no one standing in the
work area. Carry out all the possible movements and make sure that the control joysticks operate
correctly. If visibility is insufficient or there are ducts of any kind, proceed at low speed and ask the
assistance of another person. Always warn the people present in the work site, even if they are authorized,
by means of the horn. The basic illustrations shown are those necessary for the proper use and utilization
of the machine; the operator must get to know the controls, the prescribed operating method, and learn
how to organize work in an open area, while seated in the driving position.
Lowering The Equipment In Case Of Machine Failure
Carry out the operations while seated in the work position with the seat belt fastened.
After lowering the equipment to the ground, move the control joysticks more than once to release any
residual pressure.
If the machine should suddenly stop with the work equipment raised due to a mechanical or hydraulic failure, the operator
must lower the equipment to the ground before leaving the machine to locate the trouble. Make sure that the safety bars are
lowered (open hydraulic circuit), turn the ignition key to position «I» and lower the bucket to the ground by shifting the
equipment control joystick; only limited movements are possible.
CK30-1 2-89
OPERATION
Organizing The Work Area
If, after a first inspection, the area appears to be uneven, encumbered
with big obstacles or characterized by considerable height differences, it
is advisable to level the ground as much as possible, before starting work,
for the benefit of the loader and the vehicles to be loaded.
This preliminary operation will make work quicker, ensure better results,
and at the same time reduce the operator’s stress and the straining of the
machine components; furthermore, this will considerably reduce the time
necessary to load the trucks destined for the transport of the material.
To obtain the best performance from the machine it is necessary to
synchronize the movements of the equipment with the traveling
movements, by operating the joysticks smoothly and without jerks. The
changes of direction must be carried out correctly with ample
steering radii. Short steering radii or counter rotations involve useless
efforts of the machine and rapid track wear.
2-90 CK30-1
OPERATION
Loading Heaped And Level Material
The efficiency of the bucket depends on how the operator starts loading;
proceed as follows:
1. Start moving with the arm completely lowered and direct the bucket
towards the base of the pile.
2. While the upper material falls down filling the bucket, raise the arms
gradually and at the same time roll the bucket to the end of its stroke.
3. Reverse the motion of the machine and dump the bucket into the
truck.
Start loading the truck from the cab side and, if the material
is sufficiently mixed, dump from the maximum height to
increase the compaction of the material and its distribution
on the loading platform.
4. After removing the pile completely, incline the bucket forward,

lower the arm until the rubber tracks are slightly raised and, moving
in reverse, level the ground distributing the material uniformly.
Repeat the operation reducing the inclination of the bucket for the
finishing work.
CK30-1 2-91
OPERATION
Loading Operations On Slopes
Travel uphill with the bucket directed forward; the same rule must be followed when loading. Travel
downhill in reverse with the loader directed forward and bucket lowered. Move, changing direction very
slowly, with the bucket as low as possible. Avoid any transverse position with respect to the slope
direction. Sudden movements of the bucket and dangerous positions may cause the machine to overturn
and lead to serious accidents or even death.
2-92 CK30-1
OPERATION
Digging Method
1. At the beginning of work, keep the bucket at the correct penetration

angle.
2. Once the desired digging depth has been reached, position the bucket
with its back parallel to bottom of the excavation and then start
filling.
3. During the collection phase, move the bucket and arm

simultaneously. Combined movements facilitate the filling of the
bucket and therefore increase productivity.
4. The removal depth must be correct and suitable for the type of
ground; an excessive digging depth may cause the locking of the
movements due to the overloading of the engine and pump, and
therefore slow down the digging operations.
5. To dump material from piles, unload the bucket as soon as it gets

near the dumping area; the inertia resulting from the movement will
ensure the compaction of the material with no need to use the bucket
for this purpose, which avoids impacts and vibrations that facilitate
the wear of pins and bushings.
6. The correct method is illustrated in pictures ①, ✍, and ③.
CK30-1 2-93
OPERATION
CORRECT
The bucket starts digging with a slight penetration angle.
INCORRECT
If the penetration angle is too wide, the bucket is thrust

downwards, slowing the digging work.
2-94 CK30-1
OPERATION
Changing The Bucket Or Attachment With Standard Quick Coupler
• Stop the machine on a firm and level surface and lower the bucket or attachment to the ground.
• Before leaving the machine, stop the engine, release the residual hydraulic pressures by operating the
equipment control joystick more than once in all directions and raise the safety bars to the locked
position.
• Clean the upper and lower mounting areas of the bucket or attachment of all dirt and debris before
mounting or releasing it to or from the quick coupler.
• Before starting work, make sure the quick coupler locking pins are completely engaged in, and protrud-
ing from, the retaining tabs (slots) provided on the bucket or attachment and that the coupler levers are
pushed down to a horizontal (locking) position.
• After locking the equipment and before starting work, make sure that the locking pins are correctly
engaged and the length of the protruding portion of the pins is in compliance with the prescribed safety
values (see Installing The Bucket Or Attachment on page 2-97.).
Keep the levers lubricated and free of dirt and debris. Lubricate the coupling pins and keep the area
around the pins free of dirt and debris.
Do not use your fingers to align the holes, since your fingers
may be injured or cut in the event of the loader bucket or
attachment suddenly moving.
The loader is designed in such a way as to permit the installation of

various types of buckets or attachments.
To ensure their quick and comfortable change, a special, universal
coupler is provided with the machine, which permits the release or
installation of the bucket or attachment via a spring loaded over-center
lever and pin latching system that secures the machine coupler to an
attachment or bucket.
LOCKING THE BUCKET OR ATTACHMENT
Rotate the levers (1) down to a horizontal position facing the center of the
bucket or attachment (2).
UNLOCKING THE BUCKET OR ATTACHMENT
Rotate the levers (1) completely upward to a vertical position.
For Non-Komatsu attachments, read the manufacturer’s

instruction manual before installing any attachment.
Refer to the Komatsu Skid Steer Attachment Directory for a single source
of work site application choices of attachments.
CK30-1 2-95
OPERATION
Removing The Bucket Or Attachment
AVOID INJURY.
Perform all operations with the bucket or attachment at
ground level.
1. Lower the arm completely and rest the bucket on the ground in a
horizontal position.
2. Stop the engine, release any residual hydraulic pressures, raise the
safety bars to the locked position and leave the operator’s seat.
3. Pull both lock levers (1) completely upward to a vertical position to

disengage coupling pins (2).
4. Return to the operator’s seat, fasten the seat belt, lower the safety
bar, start the engine and release the brake.
5. Rotate the coupler (3) forward allowing the bucket or attachment

retaining lip (4) to slide off the top edge of the coupler.
2-96 CK30-1
OPERATION
Installing The Bucket Or Attachment
Do not use your fingers to align the holes, since they may
become stuck or even cut in case of sudden or uncontrolled
movements.
1. Make sure that levers (1) are in a vertical position and that coupling
pins (2) are completely retracted.
2. Incline the top of coupler (3) forward and slowly approach the
bucket (4) or attachment until the top edge of the coupler is
completely under the top flange of the bucket (4) or attachment.
Make sure you center the coupler with the bucket or attachment.
3. Tilt the coupler backward until the cutting edge of the bucket or
attachment is slightly off the ground.
4. Roll back the bucket or attachment completely.
5. Stop the engine, release the residual hydraulic pressures, raise the
safety bars to the locked position and leave the operator’s seat.
6. Lock the bucket or attachment to the coupler by rotating levers (1)

toward the center of the bucket or attachment to a horizontal
position.
7. Before moving the machine, make sure that the locking pins (2) are
completely engaged in the tabs provided on the bucket or
attachment.
8. To confirm engagement, tilt the bucket or attachment down and

apply downward pressure. Back up the machine to make sure
there is no movement between the bucket or attachment and the
coupler.
CK30-1 2-97
OPERATION
Checking The Position Of The Locking Pins
The position of the coupler locking pins (1) must be checked with the levers in the locked or horizontal position. The length of
the protruding part of the pins must be in compliance with the specified values, as indicated in the figure.
To check the locking pin protrusion:
1. Slowly raise the arm.
2. Roll the bucket or attachment forward until the pin protrusion can be seen from the operator’s seat.
3. If the length (1) does not appear within the specified range, adjust
it by proceeding as indicated in. See “Adjusting The Locking
Pins” on page 2-99.
Coupler locking pins must extend through the holes in the

bucket or attachment. Levers must be fully down and locked.
Failure to secure the locking pins can allow the bucket or
attachment to come off and may cause serious injury or
death.
2-98 CK30-1
OPERATION
Adjusting The Locking Pins
The pin adjustment must be carried out with the bucket flat on the
ground and the levers (1) of the quick coupler in a horizontal or locked
position and proceeding as indicated below:
1. Check the protrusion of the locking pins per. See “Checking The
Position Of The Locking Pins” on page 2-98.
2. Loosen lock nut (3).
3. Adjust nut (2) until the specified dimension is reached.
4. Tighten lock nut (3) against adjusting nut (2) to maintain the
specified dimension.
CK30-1 2-99
OPERATION
Using The Rubber Tracks

Optimal Use Of The Rubber Tracks
The materials used for the construction of the rubber tracks offer many advantages that improve the performance of the
machine, but at the same time have some problems regarding resistance. For this reason, it is important to know the
characteristics of the rubber tracks, to take the precautions suggested, and to avoid performing operations that are not allowed.
In this way, the rubber tracks will last longer and it will be possible to take full advantage of their pluses. Before using the
rubber tracks, read paragraph (See “Precautions For Use” on page 2-101).
Rubber Track Warranty

It is important to carry out checks and routine maintenance to ensure that the tension of the rubber tracks is always correct.
These must not be used on work sites where they may be cut due to the presence of steel plates, U-shaped grooves, pointed
stones or rocks, steel rods or iron scraps. Komatsu takes no responsibility for any damage to the rubber tracks due to incorrect
use by operators who carry out unauthorized operations or fail to take the precautions indicated.
This type of damage is not covered by the warranty.
Precautions To Be Taken When Using The Rubber Tracks

UNAUTHORIZED USES
For correct use of the rubber tracks, bear in mind the following:
1. Rotations or other operations on hard rocky surfaces, rocky surfaces with protrusions, steel bars or scraps, or near the
edges of steel plates may damage the rubber tracks.
2. In places where there are many small and large stones, like river beds, the stones may get stuck in the rubber tracks, which
may come off or be damaged. Using the machine to carry out leveling operations when the tracks slide on the ground may
damage the tracks and reduce their service life.
3. Do not dirty the rubber tracks with oil, fuel or chemical solvents. If one of these substances gets on the tracks, clean them
immediately. Do not use the machine on roads where there are traces of oil.
4. When the machine is going to remain unused for a long period (3 months or more), keep it indoors, away from direct
sunlight and protected from the rain.
5. Avoid using the machine in areas where the temperature is particularly high, for example near burning wood, hot steel
plates or roads being asphalted.
2-100 CK30-1
OPERATION
Precautions For Use
During work, always adhere to the following rules and take the precautions indicated:
1. Avoid abrupt steering or counter rotations on concrete surfaces.
2. Do not carry out abrupt changes of direction that may damage or cause the untimely wear of the rubber tracks.
3. Do not move or steer on surfaces distinguished by considerable differences in height. When there is a difference in height,
move perpendicularly. This will prevent the track from coming off.
4. If the machine has been raised from the ground by means of the work equipment, lower it slowly.
5. Avoid using the machine to handle materials or substances that once crushed produce oil (like soy, maize or other
vegetables from which oil is derived), or wash the machine soon after use.
6. Avoid using the machine in the presence of materials that may affect the adhesion of the steel core, like salt, ammonium
sulfate, potassium chloride, potassium sulfate or calcium super phosphate, or wash the machine after use.
7. Since salt affects the adhesion of the steel core, avoid using the machine in coastal areas.
8. When handling salt, sugar, flour or soy seeds, the presence of deep cuts in the tracks may cause the infiltration of these
products into the tracks or the dispersion of rubber pieces into the products. Therefore, it is advisable to repair the tracks
before use.
9. Avoid using the machine when the rubber tracks may rub against concrete walls.
10. Rubber tracks slip very easily on snow or ice. Be careful not to slip when travelling or working on slopes.
11. If the machine works in very low temperatures, the properties of the rubber tracks may change and their service life may
be reduced.
12. Considering the particular properties of rubber, it is advisable to use tracks made with the same material at temperatures
between -25°C (-13°F) and +55°C (131°F).
13. Make sure that the track tension is always correct, to prevent the tracks from coming off. If the tracks are slack, they may
come off in the situations indicated on the following page. When carrying out the maneuvers on the following page,
proceed with the utmost care even if the track tension is correct.
CK30-1 2-101
OPERATION
1. Do not change direction when travelling on curbs, rocks or
surfaces with great differences in height. If this cannot be
avoided, always proceed perpendicularly to the obstacles.
2. When travelling up slopes in reverse, avoid steering at the

beginning of the slope. If it is necessary to steer on the slope,
carry out this maneuver gradually.
3. Do not proceed along the edge of a slope or on uneven ground

keeping one track in horizontal position and the other inclined or
partially raised. To avoid damaging the rubber tracks, always
proceed with both tracks resting on the same horizontal plane.
4. In the situations described in points from 1 to 3, avoid changing

direction when the rubber track does not conform exactly to the
ground, as shown in the figure.
2-102 CK30-1
OPERATION
Long Periods Of Inactivity
Before The Period Of Inactivity
When draining the fuel, do not smoke or bring exposed

flames near the machine. Place a container under the
machine to gather the fuel and prevent it from spreading
around. If some fuel is spilled, clean the dirty surface imme-
diately. To protect the cylinder rods when the machine is not
used, position the work equipment as shown. This serves to
prevent the cylinder rods from rusting.
If the machine must be stored for a long period of inactivity, it is

advisable to put it in a sheltered place and to take the following
precautions, to keep all its components sound and efficient:
1. Clean the machine thoroughly, repainting it where necessary to prevent oxidation.
2. Drain and replace all the hydraulic circuit fluids and the lubricants, axles, reduction gears, converter and engine, keeping
to the rules indicated in the section regarding maintenance.
3. Change all the filtering elements, air cleaner, engine oil filter, hydraulic circuit filters, diesel oil filter.
4. Change the coolant to permanent type coolant.
5. Drain the normal fuel and fill the tank with at least 5 l (1.32 gal) of special cleaning and preservation fuel.
6. Let the engine run for about 10 minutes, to eliminate the remaining regular fuel from the filters, the injection pump and
the entire fuel supply system. This operation avoids the freezing of the injection pump and the injectors. Stop the engine
and refuel with normal diesel oil.
7. Remove the battery, by first turning OFF the battery disconnect switch (if equipped), then, check the electrolyte level and
make sure that the battery charge is sufficient.
Store the battery in a room with suitable temperature and periodically recharge it.
8. Grease the hydraulic cylinder rods and the equipment joints.
9. Seal the end of the exhaust pipe.
10. Move the machine controls to the neutral position and engage all the safety locks.
11. Hang a warning notice on the controls to indicate the condition of the machine.
12. Lock the engine hood.
CK30-1 2-103
OPERATION
During The Period Of Inactivity
If it is necessary to carry out a rust prevention treatment while the machine is kept indoors, open doors
and windows to increase ventilation and avoid poisoning by gas.
Start the engine and move the machine for a short distance once a month, so a new oil film covers all the moving parts and the
surfaces of the components. Provide also for charging the battery.
After The Period Of Inactivity
If the machine is stored without carrying out the monthly rust-prevention treatment, have maintenance
performed by your distributor.
When using the machine after a long period of inactivity, proceed as follows:
1. Remove the seals from the exhaust pipe and the fuel tank.
2. Check all the fluid levels: engine oil, coolant, fuel, hydraulic circuit oil.
3. Make sure that the battery charge is sufficient and install the battery. Then turn the battery disconnect switch (if equipped)
to the ON position.
4. Disconnect the engine stop solenoid.
5. Turn the ignition key directly to the start position and crank the engine until the engine oil pressure warning light goes out.
This operation serves to start the circulation of the lubricating oil and to carry out a first lubrication cycle.
6. Reconnect the stop solenoid valve and start the engine.
7. Run the engine at idle for about 20 minutes.
8. While the engine is warming up, remove the protection grease from the hydraulic cylinder rods.
9. Before moving the machine, make sure that the instruments, the warning lights, and working lights work properly.
10. Warm up the hydraulic cylinders, by slowly moving all the work equipment as soon as possible.
2-104 CK30-1
OPERATION
TROUBLESHOOTING
How To Move The Machine
When moving the machine, use a wire rope suitable for the
weight of the machine to be removed.
If the machine gets stuck in mud and cannot get out using only its
motive power, or in case of breakdown, use a wire rope as shown in
the figure at right.
In case of failure of the hydraulic circuit, before moving the machine release the negative brake installed
on the rear axle (See “Releasing The Parking Brake” on page 3-25).
If The Fuel Has Been Completely Depleted

Before starting the engine, when the fuel has run out and therefore air has entered the fuel supply circuit, it is necessary to
bleed the fuel supply circuit. For the necessary operations, See “Every 500 Hours Of Operation” on page 3-21.
CK30-1 2-105
OPERATION
Battery Is Exhausted
• When checking or carrying out any operation on the

battery, stop the engine and make sure that the ignition
key is in position ´Oª and after one minute turn the battery
disconnect switch (if equipped) to the OFF position and
remove the battery disconnect switch key before working
on batteries.
• The battery produces hydrogen, which may explode. Do
not use open flames and do not smoke near the battery,
and avoid creating sparks. The battery electrolyte is made
of diluted sulfuric acid that may corrode clothes and even
skin; in case of contact with this fluid, immediately rinse
the involved area with plenty of water. If the acid gets into
the eyes, immediately rinse with plenty of water and con-
sult a doctor without delay. When working on the battery,
always wear goggles and gloves.
• When removing the battery, first disconnect the ground
cable (-); when installing the battery, first connect the
positive cable (+). If a tool comes into contact with the
positive terminal and the machine structure at the same
time, this may generate sparks with consequent risk of
explosion.
• Carefully tighten the connection terminals, since false
contacts may generate sparks with consequent risk of
explosion. When starting the engine with the aid of another
machine, connect the batteries in parallel. When connect-
ing the cables, avoid any contact between the positive
cable (+) and the negative cable (-).
• When starting the engine with booster cables, always wear
safety goggles. Take care to avoid any contact between the
machine to be started and the machine used as starting
aid, to avoid sparks and therefore the explosion of the
hydrogen produced by the batteries. The explosion of a
battery may cause serious damage and injuries. Take care
not to reverse the cables and connect the ground cable (-)
last, as far from the battery as possible. Remove the cables
with great care; prevent the cables disconnected from the
battery from touching other parts of the machine, to avoid
the explosion of the hydrogen. The cables and pliers must
be suitable for the current load that must be transferred.
• The battery to be used for the starting must have greater
capacity or at least the same capacity as the battery of the
machine to be started. Make sure that the cables and pliers
are neither corroded, nor damaged. Make sure that the
pliers hold the terminals firmly.
2-106 CK30-1
OPERATION
Starting With Booster Cables
Remark
Before connecting two machines with booster cables, turn off the troubled machine battery disconnect switch
(if equipped) and take out the battery disconnect switch key in order to prevent damages to the electrical
systems of the machine.
The cables and pliers must be suitable for the current load that must be transferred.
The battery to be used for the starting must have greater capacity or at least the same capacity as the battery
of the machine to be started.
Make sure that the cables and pliers are neither corroded, nor damaged.
Make sure that the pliers hold the terminals firmly.
CONNECTING THE CABLES AND STARTING THE ENGINE
1. Before connecting two machines with booster cables, turn the

troubled machine starting switch and battery disconnect switch (if
equipped) to the OFF position, and then switch off the normal
machine starting switch. Connect booster cables in the numerical
order as shown in the illustration.
2. Connect the clip of booster cable (A) to the positive (+) terminal of
battery (C) on the problem machine.
3. Connect the clip at the other end of booster cable (A) to the positive
(+) terminal of battery (D) on the normal machine.
4. Connect the clip of booster cable (B) to the negative (-) terminal of battery (D) on the normal machine.
5. Turn on the troubled machine battery disconnect switch. Lastly, connect the other clip of the booster cable (B) to the
revolving frame (E) of the troubled machine.
6. Start the engine of the machine that supplies current and increase its speed.
7. Start the engine of the machine that does not work, “Starting The Engine” on page 2-58.
REMOVING THE CABLES
When the engine has started, remove the cables in reverse order of the
connection process.
1. Remove one clip of booster cable (B) from the revolving frame
(E) of the problem machine.
2. Remove the clip of booster cable (B) from the negative (-)
terminal of battery (D) on the normal machine.
3. Remove the clip of booster cable (A) from the positive (+)
terminal of battery (D) on the normal machine.
4. Remove the clip of booster cable (A) from the positive (+)
terminal of battery (C) on the problem machine.
CK30-1 2-107
OPERATION
Other Troubles
✩ Always contact your distributor when you have to carry out this operation.
★ If the problem or its cause are not included in the failures indicated below, contact your distributor for the necessary
repair.
Electrical Circuit
TROUBLE CAUSE REMEDY

Lights do not work satisfactorily even • Faulty cables ★ Check and repair any loose
with engine running at high speed terminal and connection
Lights come on intermittently with • Faulty fan belt tension ✩ Adjust fan tension, see EVERY 250
engine running HOURS.
Alternator charge warning light does • Faulty alternator ★ Change

not go out with engine running and • Faulty cables ★ Check and repair
increasing speed
Alternator emits an abnormal noise • Faulty alternator ★ Change

Starter does not turn with key in • Battery disconnect switch is in the Turn the battery disconnet switch to
START position OFF position. the ON position
• Faulty cables ★ Check and repair
• Battery charge insufficient ✩ Charge battery
• Faulty main fuse ✩ Change
Starter pinion engages and then • Battery charge insufficient ✩ Charge battery
disengages
Starter makes engine crank slowly • Battery charge insufficient ✩ Charge battery
• Faulty starter ★ Change
Starter disengages before engine has • Faulty cables ★ Check and repair
started • Battery charge insufficient ✩ Charge battery
Engine oil pressure warning light does • Faulty bulb ★ Change

not come on when engine is stopped, • Faulty pressure sensor ★ Change
ignition key in <<I>> position
Alternator charge warning light does • Faulty bulb ★ Change

not come on when engine is stopped, • Faulty cables ★ Check and repair
ignition key in <<I>> position
2-108 CK30-1
OPERATION
Hydraulic System
repair.

• No oil in the tank ✩ Top off
• Faulty pump ★ Repair or change
Pump emits an abnormal noise
• Hydraulic oil unsuitable for the ✩ Change oil
temperature
• Faulty pump ★ Repair or change

• Max. pressure valve setting incor- ★ Calibrate or change
Equipment moves only at low speed
rect or not closed due to impurities
• Dirty drain filter ✩ Change
CK30-1 2-109
OPERATION
Engine
repair.

• Oil level in oil pan too low. ✩ Top off.
Oil pressure warning light remains on
• Oil filter clogged. ✩ Change filter.
even with engine at high speed
• Oil unsuitable for the season. ✩ Change.
Steam comes out of radiator breather • Fluid level low, fluid leakage. ✩ Top off, repair.
pipe • Fan belt slackened. ✩ Check and adjust belt tension.
• Mud or limestone accumulated in ✩ Change fluid and clean cooling
cooling system. system.
Engine coolant temperature indicator • Radiator fins damaged or closed. ✩ Repair or clean.
reaches overheating (red) range:
• Faulty thermostat. ★ Change.
• Radiator cap loose or broken. ✩ Tighten or change cap.
(Working at considerable altitude)
Temperature indicator always on the • Faulty temperature indicator. ★ Change.

right end of the scale
Temperature indicator pointer always • Faulty thermostat. ★ Change.

on the left end of the scale • Faulty indicator. ★ Change.
• No fuel. ✩ Refuel.
Engine does not start with starter • Air in fuel system. ✩ Bleed system.
cranking • Compression defect, valves with ★ Adjust valve clearance.
wrong clearance.
• Too much oil in oil pan. ✩ Correct oil level.

Exhaust gases white or light blue
• Unsuitable fuel. ✩ Change with suitable fuel.
• Air cleaner clogged. ✩ Clean or change.

Exhaust gases occasionally tend to be • Faulty injectors. ★ Change.
black
• Faulty compression. ★ Adjust valve clearance.
Combustion noise occasionally makes • Faulty injectors. ★ Change.
a breathing sound
• Fuel with low cetane rating. ✩ Change to fuel compliant with

standards.
Abnormal noises, during combustion • Overheating. ✩ See defects of temperature indica-
or in mechanical parts tor.
• Muffler insides damaged. ★ Change.
• Excessive valve clearance. ★ Adjust valve clearance.
2-110 CK30-1
OPERATION
Hydrostatic Transmission
repair.

• Oil level insufficient. ✩ Top off.
• Suction filter clogged. ✩ Change.
Machine moves neither • Faulty flexible coupling. ★ Change coupling.
forward, nor backward: • Max. pressure valves faulty or dirty. ★ Clean or change valves.
• Positioning hydraulic connection interrupted. ★ Restore connection.
• Travel motor faulty. ★ Repair or change.
• Oil level too low. ✩ Top off.
• Presence of foam. ✩ Use the recommended oil.
Machine moves with delay • Suction pipe tightness. ★ Check and eliminate leakage.
abnormal noise • Suction filter clogged. ✩ Change.
• Fuel supply max. pressure valve faulty. ★ Disassemble, clean, or change.
• Travel motor faulty. ★ Repair or change.
• Engine does not reach max. speed. ★ Change diesel oil filter and
check injection pump.
• Auxiliary fuel pump (gear pump) faulty. ★ Repair or change.
• Max. pressure valve setting incorrect. ★ Set.
Traction force in the two travel • Connection to servo control faulty lever angle ★ Restore connection shift lever
directions is insufficient incorrect. to correct position.
• Pressure relief valve setting incorrect. ★ Set.
• Excessive oil temperature. ✩ Check oil level and clean ex-
changer.
• Travel motor faulty.
★ Repair or change.
• Engine strongly overloaded. ✩ Reduce loads due to lifting.
Traction force is insufficient in • Incorrect setting of the max. pressure valve rele- ★ Set valve.
one direction only
vant to that direction.
• Oil level too low ✩ Top off.

• Exchanger clogged or dirty. ★ Check and change if neces-
sary.
• Unsuitable oil. ★ Use the recommended oil.
• Suction pipe tightness. ★ Check and eliminate leakage.
Oil overheating • Setting and operation of the max. pressure valves. ★ Check setting - repair or
change.
• Travel pump faulty.
• Pressure relief valve with high setting.
★ Set valve.
• Travel motor faulty.
CK30-1 2-111
OPERATION
repair.

• Suction filter clogged. ✩ Change
• Engine does not reach max. speed ★ Change diesel oil filter and check
Machine does not reach max. speed • Auxiliary pump (gear pump) faulty. injection pump.
selected • Pilot pressure insufficient. ★ Check delivery, repair or change.
• Pressure relief valve setting incor- ★ Set.
rect. ★ Set to rated value.
• Mechanical connection with servo ★ Check if rotation is smooth.
Machine decelerates intermittently
control lever too hard.
• Engine power drop. ★ Check clogging of diesel oil filter,

injection pump and valves.
Machine accelerates slowly.
• Pressure relief valve setting incor- ★ Set to rated value.
rect.
• Sealing rings faulty. ★ Change.

Oil leakage from engine propeller • Counterpressure in pump casing. ★ Drain pipes clogged or damaged.
shaft and/or pump.
• By-pass valve setting too high. ★ Check and restore.
2-112 CK30-1
3MAINTENANCE
CK30-1 3-1
MAINTENANCE
GUIDE TO MAINTENANCE
• Before opening the engine hood, engage safety locks and stop the engine. If it is necessary to check the hydraulic oil level
in the reservoir, lower the arm and rest the bucket on the ground, See “SAFETY LOCKS” on page 2-2.
• Carry out any operation on firm and level ground, after applying the parking brake.
• Raise the cab taking all the precautions indicated in See “Tilting The Cab” on page 2-51.
• Use genuine Komatsu oils and greases; choose oils suitable for the ambient temperature. Use clean oils and greases. Keep
the oil and grease containers clean. Keep any foreign matter away from oils and greases.
• Always keep the machine clean. This makes it easier to locate any parts causing problems. Keep the grease fittings, the
breathers, and the areas near the openings for the fluid level checks clean and prevent any impurities from getting into/on
them.
• Draining hot oil or coolant immediately after stopping the engine is hazardous. Wait for the engine to cool down to at least
40 to 50°C (104 to 122°F) before draining hot liquids. After changing the oil or the filters, check if metal particles are
present. If you find large quantities of metal particles, contact your distributor. Check and change the oil in clean locations
and prevent any impurities from getting into the tank/container.
• Before carrying out any maintenance operation, hang the warning plates on the ignition switch and control levers to
prevent anyone from starting the engine by mistake. When performing maintenance operations, always take the
precautions indicated on safety decals applied to the machine.
• Instructions for arc welding.
A. Turn ignition key to the OFF position.

B. Wait for over one minute, turn the battery disconnect switch (if equipped) to OFF. Disconnect the battery (first,
negative - pole and then positive + pole).
C. Disconnect the alternator.
D. Do not apply more than 200 V continuously.
E. Connect the ground cable within 1 m of the point on which welding will take place.
F. Avoid placing gaskets and bearings between the welding area and ground cable.
• Do not use flammable fluids to clean machine parts. Keep exposed flames and lit cigarettes away from these fluids. When
o-rings and gaskets are removed, thoroughly clean sealing surfaces and replace all o-rings and gaskets with new ones. Fit
the o-rings and gaskets correctly when reassembling.
• Avoid keeping loose objects or tools in your pockets: they may fall out and drop into the machine, especially when you
open covers and work on the machine while bending over it. When washing the machine, do not direct high pressure
water jet onto the radiator and heat exchanger. When washing the machine, protect electric system connectors and avoid
getting the ignition switch wet.
• Before starting work in mud, in rain, on seashores, or river banks perform general lubrication. Wash the machine immedi-
ately after work to protect components from rust. Lubricate equipment joints more frequently than usual.
• When working at dusty work sites, proceed as follows:
A. Check the air cleaner for any clogging and clean it more frequently than usual.
B. Clean the radiator and the heat exchanger frequently, to avoid any clogging of the fins.
C. Change the diesel oil filter more frequently than usual.
D. Clean the electrical components, especially the starter and alternator, to avoid any accumulation of dust.
• Never mix oils of different brands. Do not top off with any oil different from oil used in the machine. If necessary, drain
all the oil and fill tank with new, different brand oil.
Oils, filters, coolant, and the batteries are considered special waste and must be collected and disposed of
according to the regulations in force. Combustible material of some components may become extremely
dangerous if it burns. For this reason, avoid any contact of burnt material with your skin or eyes and do
not inhale fumes.
3-2 CK30-1
MAINTENANCE
MAINTENANCE NOTES
★ Use only genuine Komatsu replacement parts. Do not mix different types of oil. Unless specified otherwise, oils and
coolant used by Komatsu before delivery of the machine are as follows:
ITEM SPECIFICATIONS
• Engine oil SAE 10W-30 API classification CD
• Hydraulic system oil SAE 10W API classification CD
• Biodegradable hydraulic system oil. Only for machines SHELL NATURELLE HFX-32
in which the synthetic biodegradable oil type HEES
(not of plant origin) is used.
• Chain case oil SAE 10W-30 API classification CD
Ambient temperature above -10° C(14°F):

ASTM D975 no. 2 diesel oil
• Fuel
Ambient temperature below -10° C(14°F):
ASTM D975 no. 1 diesel oil
• Radiator coolant Komatsu Supercoolant (AF-NAC)
Notes Regarding The Engine

Engine Oil
• Engine oil must be selected very carefully, since it lubricates the engine, which is the machine’s heart; the main mainte-
nance operations required for engine oil are as follows:
A. Daily check of the oil level.

B. Check condition of the oil with periodic analysis.
C. Periodic oil changes.
CK30-1 3-3
MAINTENANCE
Coolant
Supercoolant (AF-NAC)
1. Coolant has the important function of anticorrosion as well as antifreeze.

anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant AF-NAC is strongly recommended wherever available.
2. CK30-1 S/N A30001 and up are serviced with Komatsu Supercoolant AF-NAC from the factory.
3. DO NOT mix all season type coolant with Super Coolant.
4. For details of the ratio when diluting super coolant with water. Supercoolant AF-NAC may be supplied in premix. In this
5. To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30%
and 68%.
6. Do not use corrosion inhibitors containing soluble oil, since they damage the rubber hoses.
7. The required standards for permanent antifreeze are the following: SAE-J1034 and FEDERAL STANDARD O-A-548D.
In case of doubt regarding the compliance of the antifreeze used with the standards, contact your Komatsu Utility
distributor and ask for precise information.
Fuel
• Always use fuel suitable for the engine. Other fuels with different specifications may damage the engine or reduce its
power.
• Always refuel at the end of the work day.
• When refueling, make sure that there is no water on the fuel drum cover and take care not to draw condensation from the
drum bottom.
• If fuel runs out, or if the fuel filter has been replaced, it is necessary to bleed the circuit.
Notes Regarding The Hydraulic System

• Be extremely careful when performing maintenance on the hydraulic system, since the oil is very hot. The system is pres-
surized not only during work, but also at the end of work.
• The maintenance operations required for the hydraulic system are the following:
• Daily check the oil level in the tank.
• Periodically change the oil filter.
• Periodically change the oil and clean the suction filter.
• Always bleed the system after changing the oil filter and the oil. When a component is removed from the circuit, check the
gaskets and o-rings and change them if they are damaged. When a cylinder or a component of the hydraulic system is
removed, after reassembly bleed the system by proceeding as follows:
A. Start the engine and let it idle.

B. Make all the cylinders perform 4 to 5 movements, stopping them at about 100 mm from the end of their stroke.
C. Slowly make all the cylinders reach the end of their stroke for 3 to 4 times.
3-4 CK30-1
MAINTENANCE
Notes Regarding The Electrical System
• If the cables are wet or their insulating material is damaged, the electrical system may short, and may result in machine
malfunctions. The maintenance operations required for the electrical system are the following:
A. Check the alternator belt tension.

B. Check the alternator belt for damage or breakage.
C. Check the battery electrolyte level.
• Do not remove or eliminate any electrical component installed on the machine and do not install any electrical component
with characteristics different from those specified and approved by Komatsu.
• Be careful to keep the electric system dry. When working on seashores or river or lake banks, protect the jack plugs from
corrosion. Do not connect any optional device to the fuses, ignition switch, battery, relays, etc. For the installation of any
optional equipment, contact your distributor. If any electric welding needs to be done, disconnect the battery and the
alternator.
Notes Regarding Lubrication

• Lubrication makes the operations carried out with the machine and work equipment smoother, while preventing wear and
the noise that may be produced if the joints are dry.
• Lubrication is to be carried out with grease or oil. The maintenance operations required for the components that need
lubricating are the following:
A. Check the fluid and lubricant levels.

B. Change oil at recommended intervals.
C. Inject grease through the grease fittings.
• Use only the specified lubricants, according to the ambient temperature. Always clean the grease fittings before injecting
grease and remove any excess grease after lubrication; this cleaning operation must be performed with extreme care on
the revolving parts. Keep the lubricants at the correct levels; excessive or insufficient quantities are to be avoided.
Parts Subject To Wear That Periodically Need Changing

• The parts subject to wear such as filters, bucket teeth, etc. must be replaced according to the periodic maintenance
intervals prescribed or when they reach their wear limit. The timely change of these parts ensures economical use of the
machine. Use only genuine Komatsu parts, which alone can guarantee excellent quality and interchangeability.
ITEM DESCRIPTION QTY CHANGE INTERVAL
Hydraulic oil filter Cartridge (drain) 1 500 hours
Engine oil filter Cartridge 1 250 hours
Fuel filter Cartridge 1 500 hours
Main cartridge 1 When required

Air cleaner
Safety cartridge 1 When required
Tooth 6 –
Front bucket Screw 12 –
Nut 12 –
CK30-1 3-5
MAINTENANCE
FUEL, COOLANT AND LUBRICANTS
Selection According To The Ambient Temperature
Ambient Temperature Capacity

Kind of
Reservoir
fluid -30 -20 -10 0 10 20 30 40 50°C1
Specified Refill
-22 -4 14 32 50 68 86 104 22°F
SAE 5W-30
SAE 10W
Engine oil 10 l 10 l
SAE 30
pan (2.64 gal) (2.64 ga)
SAE 40
API CD
Oil
SAE 10W-30
Hydraulic SAE 5W-30

system and
50 l 32 l
hydrostatic
SAE 10W (13.2 gal) (8.4 gal)
transmis-
sion
Hydraulic
See
system 50 l 32 l
page 3-
with biode- (13.2 gal) (8.4 gal)
9
gradable oil
Travel Oil
1.17 l 1.17 l
reduction API SAE 10W-30
(.31 gal) (.31 gal)
gears (ea.) CI-4
ASTM D975
Diesel No. 1 72l
Fuel tank -
fuel (19.0 gal)
ASTM D975 No. 2
Engine Super-
15 l
cooling cool- AF-NAC -
(3.9 gal)
system ant★
★ Supercoolant (AF-NAC)
Coolant has the important function of anticorrosion as well as antifreeze.
anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu
Supercoolant AF-NAC is strongly recommended wherever available.
CK30-1 S/N A30001 and up are serviced with Komatsu Supercoolant AF-NAC from the factory.
DO NOT mix all season type coolant with Super Coolant.
For details of the ratio when diluting super coolant with water. Supercoolant AF-NAC may be supplied in premix. In this
To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30%
and 68%.
3-6 CK30-1
MAINTENANCE
Grease
LUBRICATION POINTS CONSISTENCY TYPE
Joints, grease fittings NLGI 2 (See note 1)
Track tensioner unit NLGI 2 LITHIO EP +MoS2
Note 1:
The recommended lubricating grease is No.2 multi purpose lithium grease with 3% molybdenum disulfide (Lithio EP +
MoS2).
Remark
When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance
hours described in this manual. Change oil according to the following table if fuel sulphur content is above
0.5%.
Fuel sulphur content Change interval of oil in engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
★ When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAE10W,
SAE5W-30 or SAE10W-30, even though atmospheric temperature goes up 10°C more during the day time.
★ Use engine oil with CI-4.
★ Use genuine Komatsu oil which has been specifically formulated and approved for use in the engine, hydraulic work
equipment, in the reduction gears, and in the transmission.
First filling quantity: total quantity of oil, including the oil for the components and pipes.
Oil change quantity: quantity of oil necessary to fill the system or unit during the normal inspection and maintenance opera-
tions.
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
API: American Petroleum Institute
NLGI: National Lubricant Grease Institute
CK30-1 3-7
MAINTENANCE
Transmission Oil Antifreeze Coolant

Engine Oil
No. Supplier GM Dexron® II C4 Grease LI, EP, MoS2 [Ethylene Glycol Base]
API CI-4
Allison C4 Permanent Type
1 KOMATSU Premium multi grade Komatsu PM704 Komatsu Super Grease
Engine Oils PM701 (1902) Dexron® III NLGI 2 Supercoolant
SAE 10W/30 PM706 (AF-NAC)
SAE 15W/40 ASTM D128
2 AMOCO Amoco 300 Dexron II ATF Molylith grease 2 Ready Antifreeze
SAE 15W/40
3 ARCO Arcofleet S3 plus ATF Dexron II Litholine HEP 2 Sincol-Blu (-40°C)
SAE 15W/40 Arco EP moly D
Hy-Vis HD extra S3
plus SAE 15W/40
4 BP Vanellus C3 Autran MBX Grease LTX2-M Sigil Fluid (-40°C)
SAE 15W/40
Vanellus C3 Extra
SAE 15W/40
5 CALTEX RPM Delo 500 ATF-HD Molytex EP2 AF engine coolant
RPM Delo 600 CX engine coolant
RPM Delo SPH
6 CASTROL Turbomax RX super TQ - Dexron II Spheerol LMM Antifreeze (pure)
7 CHEVRON Delo 400 Supreme Automatic Moly grease Flurant
Delo 500 Transmission Fluid
8 CITGO – D-21571 – –
9 CONOCO *Fleet motor oil D21718 Fleet Heavy Duty
–
SAE 15W/40 D21570
10 EXXON Essolube TD ATF Dexron II D MP Grease All-season coolant
(ESSO) SAE 15W/40 D-21849 (East Canada) Moly
Heavy Truck Diesel D-21848 (West Canada)
Motor Oil SAE 15W/40
11 GULF Super duty Gulfcrown EP2 Antifeeze and coolant
SAE 15W/40 Gulfcrown EP special
–
Super duty plus
SAE 15W/40
12 MOBIL ATF 220 Mobilgrease sp.I ó
Delvac 1300 Super
SAE 15W/40
Delvac 1200 Super –
SAE 15W/40
Delvac 1300 Super
SAE 10W/30
13 PENNZOIL Supreme duty fleet Multi-purpose white grease Antifreeze and sum-
Pennzoil ATF 705 mer coolant
SAE 14W/40 707L White-bearing grease
14 SHELL Rimula Super Donag TG (Dexron II) Alvania EP grease Shellzone all season
SAE 15W/40 MP MOS (Can.) antifreeze
Myrina X Retinax AM (Corea)
SAE 15W/40
Rotella T
SAE 10W/30
15 SUN - - Sunoco ultra prestige 2EP Sunoco antifreeze and
Sun prestige 742 summer coolant
16 TEXACO Ursa Super TD Molytex EP2 ó
SAE 15W/40 Havoline ATF
Ursa Super LA Dexron II –
SAE 15W/40 Texamatic 7045
(9226)
17 UNION Guardol D21460 Unoba EP –
3-8 CK30-1
MAINTENANCE
APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE
HEES
Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin, therefore use of oils indi-
cated in the following table is authorized and recommended:
SUPPLIER HEES SYNTHETIC BIODEGRADABLE OIL
KOMATSU BO 46 G4 (KES 07.872)
AGIP –
ARAL –
AVIA –
BP –
CONDAT CONDAT D 46 K
ELF –
ESSO –
FINA BIOHYDRAN SE 46
FUCHS –
KENDALL –
KUWAIT PETROLEUM K8 –
MOBIL EAL SYNDRAULIC
MOBIL (USA) –
PAKELO –
PANOLIN HLP SYNTH 46
SHELL NATURELLE HFE-46
TAMOIL –
TEXACO –
TOTAL HYDROBIO 46
VAVOLINE –
It Is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils, since when
the temperature increases insoluble compounds are generated, which are deposited on the filters and clog
them (the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil). The
synthetic biodegradable oil can be used only in the hydraulic system; it cannot be used in the engine, the
transmission, the braking system, etc. Before introducing the synthetic biodegradable oil in the hydraulic
system, empty the system completely, disconnecting the cylinders and all the parts that may contain ordi-
nary oil, and replace the drain filter with a new one. Start the engine and let it idle without using the work
equipment, wait until the oil reaches a temperature of at least 40°C(104°F), then start moving the
equipment, so all the parts of the system are filled with oil. Stop the engine and check the oil level, (See
“Engine Oil Level” on page 3-36).
CK30-1 3-9
MAINTENANCE
For the lubrication procedures for the single points, See “MAINTENANCE PLAN” on page 3-20.
The type of lubricant to be used is indicated in the lubricant table (See “FUEL, COOLANT AND LUBRICANTS” on page 3-
6).
3-10 CK30-1
MAINTENANCE
LUBRICATION DIAGRAMS
General
CK30-1 3-11
MAINTENANCE
PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY
To ensure safety at all times while driving and using the machine, the operator must carry out all periodic maintenance
operations prescribed. Furthermore, the operator must periodically replace the components indicated in the table on the
following pages, which are especially related to safety and fire prevention rules. These components are subject to wear and
since it is particularly difficult to evaluate their conditions through simple periodic maintenance, after a certain period it is
advisable to change them regardless of their condition, to keep them efficient over time. Repair or replace these components
immediately in case of failures or abnormalities, even if the time interval prescribed for their change has not yet elapsed. If the
hose clamps show signs of deterioration, like deformations or cracks, replace them at the same time as the hoses.
In addition to periodic replacement of the components listed on the following pages, the inspections described below are to be
performed on the hydraulic hoses. In case of abnormalities, perform the necessary adjustments and replacements, or institute
any other required measure.
TYPE OF CHECK CHECK ITEM
Check before starting Leakage from joints, grease fittings, hydraulic hoses, or fuel
lines.
Periodic check (monthly check) Leakage from joints, fittings, hydraulic hoses, or fuel lines.
Damaged hydraulic or fuel lines, cracks, wear and tear.
Periodic check (annual check) Leakage from joints, fittings, hydraulic hoses fuel lines.
Deteriorated, twisted, damaged hydraulic hoses fuel lines,
cracks, wear and tear, or in contact with other parts of the
machine.
3-12 CK30-1
MAINTENANCE
Critical Parts For Safety
Fuel Supply System
NO COMPONENTS RELATED TO SAFETY THAT REQUIRE REPLACING QTY REPLACEMENT INTERVAL
1 Fuel line (Fuel tank - precleaner) 1
2 Fuel line (Precleaner - fuel pump) 1
3 Fuel line (Fuel pump - fuel filter) 1

Every 2 years or 4000 hours,
4 Fuel line (Fuel filter - injection pump) 1
whichever occurs first
5 Fuel line (Fuel filter - fuel tank) 1
6 Fuel recovery line (Injection pump - fuel filter) 1
7 Fuel recovery line (Between the injectors - injection pump) 3
★ For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual
section regarding the components connected with safety and components that must be periodically replaced.
★ When replacing hoses, always change o-rings, gaskets, and associated components.
CK30-1 3-13
MAINTENANCE
Standard Flow Hydraulic System
1 Hydraulic hose (Travel pump supply) 4 Every 2 years or 4000 hours,

2 Hydraulic hose (Machine function pump supply) 1 whichever occurs first
• For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual
• When replacing hoses, always change o-rings, gaskets, and associated components.
3-14 CK30-1
MAINTENANCE
3 Hydraulic hoses (Lift cylinders) 6

4 Hydraulic hoses (Bucket cylinders) 6
5 Hydraulic hoses (Auxiliary hydraulic kit - 2 line) 2
CK30-1 3-15
MAINTENANCE
Super Flow Hydraulic System
1 Hydraulic hose (Travel pump supply) 4

2 Hydraulic hose (Machine function pump supply) 1
3 Hydraulic hose (Flow rate increase pump supply) 1
• For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual
• When replacing hoses, always change o-rings, gaskets, and associated components.
3-16 CK30-1
MAINTENANCE
4 Hydraulic hoses (Lift cylinder) 6

5 Hydraulic hose (Bucket cylinder) 6
6 Hydraulic hose (Auxiliary hydraulic kit - 3 line) 2
CK30-1 3-17
MAINTENANCE
Operator’s Safety
No Components needing replacement Qty Interval
1 Safety belt 1 Every 4 years
3-18 CK30-1
MAINTENANCE
TIGHTENING TORQUE
Standard Torque For Bolts And Nuts
Property class designation

Thread Wrench
Pitch
diameter size 8.8 10.9
(mm)
(mm) (mm)
N•m N•m
6 1 10 9.5 ± 1 13.5 ± 1.5

8 1.25 13 23 ± 2 32.2 ± 3.5
10 1.5 17 45 ± 4.9 63 ± 6.5
12 1.75 19 77 ± 8 108 ± 11
14 2 22 122 ± 13 172 ± 18
16 2 24 191 ± 21 268 ± 29
18 2.5 27 262 ± 28 366 ± 36
20 2.5 30 372 ± 40 524 ± 57
22 2.5 32 511 ± 57 719 ± 80
24 3 36 644 ± 70 905 ± 98
27 3 41 945 ± 100 1329 ± 140

30 3.5 46 1287 ± 140 1810 ± 190
Specific Torques
This torque table is not valid for bolts or nuts that contain nylon parts or spring washers.
Item Description N•m
Cab Rear fastening bolts 98 ± 7.3
Wheels Front 186± 9.8

Rear 186± 9.8
Engine Front support bolt 186 ± 9.8

Rear support bolt 186 ± 9.8
CK30-1 3-19
MAINTENANCE
MAINTENANCE PLAN
When Required
ITEM DESCRIPTION OPERATION PAGE
a. Engine air cleaner Check, clean or change 23
b. Parking brake Release 25
c. Fuel tank Drain condensate 24
d. Rubber tracks Checking for wear 27
e. Battery Check charge level 26
f. Rubber track tension Check and adjust 29
g. Rubber track Changing 32
Checks Before Starting
a. Various checks Check 34
b. Fuel tank Check and top off 35
c. Coolant Check and top off 40
d. Engine oil Check and top off 40
e. Hydraulic oil tank Check and top off 37
f. Water separator Drain water 38
g. Electrical system Check 38
After The First 50 Hours Of Operation
a. Front and rear carriage fasteners Check torque 46
Hydraulic oil drain filter

b. Change cartridge 48
(only for machines filled with biodegradable oil)
Every 50 Hours Of Operation
a. Rubber tracks Check tension 39
b. Radiator Check level 40
c. Reduction gears Checking oil level 40
3-20 CK30-1
MAINTENANCE
Maintenance After The First 250 Hours Of Operation
★ Perform these operations together with those to be initiated every 250 HOURS
.
a. Hydraulic oil drain filter Change 48
a. Fan belt Check condition and tension 41
b. Radiator Clean outside 42
c. Pivot points Lubricate 43
d. Engine oil Change 44
e. Engine oil filter Change 45
f. Front and rear carriage fasteners Check torque 46
After The First 500 Hours Of Operation

★ Only for machines in which synthetic biodegradable oil, type HEES is used. Perform these operations together with those
to be initiated every 500 HOURS.
Hydraulic oil and suction filter

a. Change oil and clean filter 53
a. Fuel filter Change cartridge 47
b. Hydraulic oil drain filter Change cartridge 48
c. Water separator Clean 50
Hydraulic oil tank 51

d. Drain condensate
e. Reduction gears Change oil 49
CK30-1 3-21
MAINTENANCE
a. Hydraulic oil and suction filter Change oil and filter 53
b. Engine valves Check clearance, adjust 55
a. Coolant Change 56
b. Suction filter Change 58
c. Alternator and starter Check 59
3-22 CK30-1
MAINTENANCE
When Required
Air Cleaner Cartridge
Remove the air cleaner only after stopping engine, and do

not start engine after the air cleaner is removed. Always wear
safety goggles during cleaning operations.
★ The air filter system consists of a primary filter element with

considerable capacity and of a secondary cartridge that ensures
additional safety protection. The primary element can be cleaned
with compressed air, while the cartridge must be replaced. The
filter must be cleaned when the clogging warning light A
positioned on the instrument panel comes on or flashes.
The air cleaner can be reached after raising the engine hood and
opening the rear panel. To clean the primary element, proceed as
follows:
1. Release safety locks b, moving them toward the outside and
remove the filter cover c.
2. Remove the main filtering element d.
3. Lightly tap the filter element d on the palm of your hand, in a

manner to remove the dust, and blow compressed air on the inner
surface, keeping the air jet at a distance of approximately 15 cm
(5.9 in.) and taking care to prevent pressure from exceeding 4 to 5
kg/cm² (58-73 psi).
4. Carefully clean the inside of the filter case e, taking care to prevent
foreign debris from getting into the suction duct and reassemble the
unit making sure that the ejector is positioned vertically and at the
bottom.
If the clogging warning light comes on after starting the

engine, it is necessary to replace the primary filter element
and safety cartridge.
Replace the primary filter element after 5 cleaning operations
or after one year. Every time the primary filter element is
replaced, the safety cartridge must also be replaced.
CK30-1 3-23
MAINTENANCE
To change the safety cartridge, after removing the primary element, then
proceed as follows:
5. Remove the safety cartridge f and replace it with a new one.
6. Once the safety cartridge f has been installed inside the filter case
e, make sure that it is perfectly seated in its housing.
7. Reassemble the unit as described above, making sure that all filter
components are perfectly locked.
8. Push the safety locks b toward the housing.
Draining The Fuel Tank
When draining the fuel tank, avoid spilling fuel, since this
may cause fires.
If some fuel is accidentally spilled, clean the dirty area
immediately, to prevent it from getting slippery and to avoid
fires.
This operation serves to let all the impurities and the condensate flow
out of the tank.
Proceed as follows:
1. Raise the engine hood (See “Engine Hood” on page 2-48).
2. Open the valve (1), using the lever (2) supplied with the machine.
3. Turn the lever (2) counterclockwise, until clean fuel flows out.
4. Turn the lever (2) clockwise to stop the fuel flow.
5. Close the engine hood (See “Engine Hood” on page 2-48) and put
the lever (2) in the technical documentation case (See “Technical
Documentation Case” on page 2-55).
The tank must be drained before starting the engine, with

temperatures exceeding 0ºC (32°F); when the temperature is
below 0ºC (32°F), the tank must be drained at the end of work
or in any case with the machine at operating temperature, to
prevent the condensate from freezing.
The condensate and the impurities that may have
accumulated inside the tank must be eliminated before
refueling.
3-24 CK30-1
MAINTENANCE
Releasing The Parking Brake
In case of failure of the hydraulic system and before moving

the machine, release the negative brake installed on the trav-
el motors.
The release of the parking brake is obtained by acting on the negative

brake installed on the travel motors, according to the following proce-
dure.
1. Raise the cab (See “Tilting The Cab” on page 2-51).
2. Disconnect the pipe (1) that supplies pressure to the travel motors.
3. Connect a grease nipple (3) to the union (2).
4. Using a grease pump, inject grease until reaching the minimum

pressure required to release the brake.
5. After releasing the brake, carry out the necessary maintenance

operations.
6. To restore the braking circuit to the standard configuration, remove

the grease nipple (3) from the coupling (2) and put back the pipe
(1).
7. Lower the cab (See “Tilting The Cab” on page 2-51).
After restoring the circuit to the standard configuration, it is

not necessary to make any adjustments.
CK30-1 3-25
MAINTENANCE
Checking The Battery Charge Level
If equipped, turn the battery disconnect switch to OFF and remove the battery disconnect switch key
before working on the batteries.
Check the battery charge level only with the engine at rest.To prevent gas explosions, do not use open
flames, do not smoke, and avoid producing sparks due to short circuits.
The battery electrolyte is dangerous: in case of contact with the eyes or the skin, wash with plenty of
running water and consult a doctor. The battery is maintenance-free.
Make sure that the connection terminals are not oxidized; if necessary, clean them and cover them with
anti-oxidation grease.
Remark
Make sure that the connection terminals are not oxidized; if necessary, clean them and cover them with
anti-oxidation grease.
The battery (1) can be reached after opening the engine hood (See
“Engine Hood” on page 2-48).
The change of color of the indicator shows the battery charge level,
according to the table positioned beside the indicator itself:
• Green: the charge is correct
• Grey: the battery needs recharging
• White: the battery must be changed
If a dry battery is installed, check the electrolyte level, which must be approximately 6 mm above the edge
of the plate; if necessary, top off using distilled water only.
If, on the contrary, the level is low because some electrolyte has been split, add sulphuric acid, dilute as
much as necessary to reach the concentration suitable for the ambient temperature (See “FUEL, COOL-
ANT AND LUBRICANTS” on page 3-6).
It is advisable to add distilled water before starting work, to prevent it from freezing.
Before putting back the cell plugs, make sure that the breather holes are not clogged.
3-26 CK30-1
MAINTENANCE
Checking The Rubber Tracks

Change the rubber tracks upon reaching the indicated wear limits.
1. When the height "A" of the rubber claw is less than 5 mm (3/16
in) the track may slip and its traction force reduced.
1 - Roller
2 - Rubber track
2. When the steel core (3) is visible in two or more points of the
track.
3. When more than half of the steel core cords at the center of the
track are cut.
4. When one or more steel cores (4) have come off the track or are
pushed out due to excessive tension.
CK30-1 3-27
MAINTENANCE
5. If the rubber track cannot be tensioned correctly through the

injection of grease, check the track tensioner seals and if
necessary change them or the track.
”Checking And Adjusting The Rubber Track Tension” on page 3-
29.
Do not exceed the tension indicated in the figure.
6. If the broken area between the rubber track support claws reaches
a length (1) of approximately 60 mm (2-3/8 in), the track must be
repaired.
It must also be immediately repaired when the steel cores are
visible, even if the broken area is very small.
If the length of the broken area (2) is less then 30 mm (1.18

in) or its depth is less than 10 mm (0.39 in), it is not
necessary to repair the track.
For any repair or replacement, contact your Komatsu
Distributor.
3-28 CK30-1
MAINTENANCE
*
Checking And Adjusting The Rubber Track Tension
This operation must be carried out by two people. One operator must be seated in the cab and maneuver
the machine following the signals of the other operator who performs the check and adjustment.
The track tension must be checked with the frame raised from the ground; be careful not to shift any
control lever while the operator is carrying out the check
The wear of the rubber tracks may vary according to the operating conditions and to the type of ground on which the machine
works, therefore it is necessary to check the wear and tension of the tracks frequently. To carry out the check and the
corresponding maintenance operation, stop the machine on firm and level ground.
In particular, on new machines or after the installation of new tracks, it is advisable to carry out a first check after 30 hours of
operation. Adjusting the track tension frequently until the initial slackening doesn't occur repeatedly will prevent the track
from coming off due to insufficient tension.
If the machine works with slackened rubber tracks, they may come off and cause the untimely wear of the steel cores.
CHECK PROCEDURE
1. Stop the machine on a firm and level surface and lower the bucket
to the ground.
2. Raise the front part of the machine, pushing the bucket blade
against the ground until the front idler roller reaches a height of
approximately 75 mm (2.95 in) from the ground.
3. Move the machine slowly forward to create any slack.
4. Stop the engine.
5. Measure the slack between the contact surfaces of the central

track rollers and the track rolling guide. The standard slack must
be between 15 and 20 mm (9/16 and 13/16 in).
6. If the slack is not within the standard values, adjust it accordingly.
Remark
Check both tracks.
Adjust the support "A" at a minimum distance of 5 mm (0.2

in) from the track surface, with the machine resting on the
ground.
When using the machine on SANDY GROUND, mainly on lev-
el surfaces, it is advisable to reduce the tension to a maxi-
mum of 40 mm (1.57 in), to prolong the life of the
components.
If the machine works on slopes exceeding 10°, it is advisable
to adjust the tension to the usual values of 15-20 mm (9/16-
13/16 in).
CK30-1 3-29
MAINTENANCE
*
ADJUSTMENT
The grease contained in the hydraulic cylinder is pressurized.

For this reason, do not give the grease valve (1) more than 5 turns when loosening it; in fact, if the valve is
loosened excessively it may be pushed out due to the grease pressure and this is very dangerous for the
operator. Do not loosen any component apart from the valve (1). If the rubber track tension doesn't
decrease after this operation, contact your Komatsu distributor.
If the resistance met when injecting the grease is excessive, move the track slowly covering a short
distance.
To adjust the rubber tracks, position the machine by proceeding as

described below:
to the ground.
approximately 75 mm (2.95 in) from the ground. Position two
stands or safety blocks under the frame.
3. With the aid of a crane or a lift truck, raise the rear part of the
machine until the rear idler roller reaches a height of
approximately 75 mm (2.95 in) from the ground. Position two
stands or safety blocks under the frame.
4. Slowly lower the machine onto the stands or safety blocks,

making sure that it is in a stable and safe position.
To increase the tension
1. Loosen the screws and remove the cover over the adjusting
device (2). Use a 5 mm Allen wrench.
2. Carefully clean the grease valve (1) and inject grease through the
grease nipple until the tension reaches the correct value. If the
injection of grease doesn't proceed smoothly, move the track
slowly over a short distance.
3-30 CK30-1
MAINTENANCE
To decrease the tension
It is extremely dangerous to let the grease out without following the one indicated below.
If the rubber track tension doesn't decrease after this operation, contact your Komatsu Distributor
1. After removing the cover over the adjusting device (2), gradually
loosen the grease valve (1) to let the grease out; do not give the
valve more than five turns.
Use a 5 mm Allen wrench and a 22 mm hexagon wrench.
2. If the grease doesn't come out smoothly, move the track slowly
over a short distance.
3. Tighten the valve (1) and remove any trace of grease.
4. Move the track forward and backward and, after stopping it,
check that the tension is correct.
5. If the rubber track cannot be tensioned enough by injecting

grease, it is necessary to change the track or the track tensioner
seals.
For any repair or replacement, contact your Komatsu Distributor.
The wear of the rubber tracks may vary according to the

operating conditions and the type of ground on which the
machine works.
Therefore it is necessary to check the track tension
frequently and to adjust it when necessary.
After the installation of new tracks, it is advisable to carry
out a first check after 30 hours of operation.
CK30-1 3-31
MAINTENANCE
Changing The Rubber Tracks
This operation must be carried out by two people. One operator must be seated in the cab and maneuver
the machine following the signals of the other operator who carries out the change and the adjustment.
The track tension must be checked with the frame raised from the ground; be careful not to shift any
control lever while the operator is carrying out the check.
During the change do not remove any component other than the track.
If the rubber track tension doesn't decrease after this operation, contact your Komatsu distributor for the
necessary repairs.
REMOVING THE TRACK
The grease contained in the hydraulic cylinder is

pressurized.
For this reason, do not give the grease valve (1) more than 5
turns when loosening it; in fact, if the valve is loosened
excessively it may be pushed out due to the grease pressure
and this is very dangerous for the operator.
Do not loosen any component other than the valve (1). If the
rubber track tension doesn't decrease after this operation,
contact your Komatsu distributor.
When installing or removing the tracks, make sure that the
grease contained in the cylinder has been removed before
turning the sprocket.
Secure the machine in the correct position by placing
support blocks under the front and rear part of the frame.
Stop the machine on a firm and level surface and lower the equipment to
the ground.
Raise the machine approximately 75 mm (2.95 in) from the ground and
secure it in this position by placing safety blocks under the frame.
Follow the same procedure indicated for the adjustment of the track ten-
sion.
1. Loosen the screws and remove the cover over the adjusting device
(2).
2. Use a 5 mm Allen wrench.
3. Gradually loosen the grease valve (1) to let the grease out; do not
give the valve more than five turns. Use a 22 mm hexagon wrench.
Remove any trace of grease.
4. If the grease doesn't come out smoothly, move the track slowly over
a short distance.
5. Introduce steel tubes (3) in the track, turn the sprocket in reverse
(4), so that the steel tubes move with the track and become engaged
with the front idler roller; slide the track sideways (5), and remove it.
3-32 CK30-1
MAINTENANCE
INSTALLING THE TRACK
1 Before installing the track, make sure the grease contained in the
track tensioner cylinder has been removed.
2. Install the rubber track on the sprocket, fitting the drive blocks,
insert the guides in the seat of the rear idler roller and guide the
track until it is in the correct position on the front idler roller.
3. Slowly turn the sprocket in reverse (1) while pushing the track
towards the machine frame.
4. Using a steel tube (2), position the track guides correctly in the seat
of the front idler roller and turn the sprocket again in reverse (1).
5. Make sure that the track is correctly positioned on the sprocket,

track rollers and idler rollers.
6. Adjust the track tension following the procedure and keeping to the
values indicated in ”Checking And Adjusting The Rubber Track
Tension” on page 3-29.
7. Lower the machine until the tracks rest on the ground.
CK30-1 3-33
MAINTENANCE
Checks Before Starting
Various Checks
Dirt, oil, and fuel spread in the engine compartment near hot areas may cause fires and damage the
machine. Check to see if there are frequent leaks, and perform any necessary repairs immediately. If this
occurs repeatedly, contact your distributor.
Before starting the engine, check the following:

A. Check for loose screws or nuts.
B. Check for oil, fuel or coolant leakage.
C. Check for worn equipment.
D. Check condition of wheel rims, and checks for rubber tracks.
E. Check condition and efficiency of instruments and warning lights on the dashboard, working lights and direction
indicators.
The other general checks concern safety, and functionality:
A. Soundness of the safety belt.
B. Clearness and legibility of the warning decals.
C. Cleanliness of the ladders and hand rails used to reach the drivers seat, cleanliness inside the operator’s compartment.
Checking The Coolant Level
Carry out this check with the machine parked on a level

surface and the equipment resting on the ground.
Do not remove the radiator cap; the coolant level must be
checked in the coolant reservoir with the engine cold.
The coolant reservoir (1) can be reached by raising the engine hood
(See “Engine Hood” on page 2-48) and opening the rear panel (See
“Rear Panel” on page 2-49). The coolant level must fall between the
MIN. and MAX. marks.
If necessary, add coolant and, if a constant and considerable decrease
in the fluid level is noticed, check the tightness of the radiator-engine
unit and of the radiator.
3-34 CK30-1
MAINTENANCE
Checking The Fuel Level
When refueling, avoid spilling fuel to prevent any risk of fire.

If some fuel should inadvertently be spilled, clean the dirty
area immediately.
Fuel is flammable; do not use open flames, or smoke while
refueling.
Place the fuel nozzle into the filler neck when refueling.
To check the fuel level, use the indicator (1) positioned on the
dashboard, after turning the ignition key to position «I».
To refuel, if necessary, open the engine hood (See “Engine Hood” on
page 2-48).
Do not fill the tank completely, in order to leave room for the fuel to
expand.
It is advisable to refuel after work, in order to avoid the

formation of water condensate.
After refueling, tighten the filler cap (2) thoroughly, lower the
engine hood, and lock it.
CK30-1 3-35
MAINTENANCE
Engine Oil Level
After the machine is stopped, the engine is very hot. Let the
engine cool down before performing any check. Hot engines
may cause burns. If it is necessary to check the oil level
during or soon after work, stop the engine and wait for 15
minutes before checking.
The dipstick b can be reached after opening the engine hood. The
check must be performed with a cold engine and the machine located
on level ground.
The oil level can be checked on the graduated dipstick b and must be
between MIN. and MAX. marks. If the level is near the MIN. mark,
top off with oil, through filler tube c, of the same brand, suitable for
the ambient temperature, as prescribed in the lubricant chart (See
“FUEL, COOLANT AND LUBRICANTS” on page 3-6).
3-36 CK30-1
MAINTENANCE
Hydraulic System Oil Level
The oil level in the hydraulic system must be checked with

cold oil and the machine positioned on a level surface and
the bucket resting on the ground. If it is necessary to top off,
stop the engine and then eliminate the residual pressures
present in the work equipment by moving the controls more
than once and in the tank by slowly loosening the filler cap.
When adding oil, do not exceed the MAX level. This would
damage the hydraulic system and cause oil to overflow. If a
constant or abnormal decrease of the oil level is observed,
thoroughly check the hydraulic system, the pistons, and the
pump for leaks. After topping off, tighten the hydraulic tank
cap completely.
To check the oil level in the hydraulic circuit, open the rear panel (See
“Rear Panel” on page 2-49). The oil level must be visible through the
gauge (1) positioned on the tank and must be between the MIN. and
MAX. marks. If the level is near the MIN. mark, top off through the
filler opening (2) with suitable hydraulic oil (See “FUEL, COOLANT
AND LUBRICANTS” on page 3-6), after removing the cap. Reinstall
and tighten the cap after topping off.
CK30-1 3-37
MAINTENANCE
Draining Water Separator
Fuel is flammable; do not use open flames and do not smoke

while draining the water separator. If some fuel is spilled,
wipe it up immediately.
The water separator can be reached after opening the engine hood (See
“ENGINE HOOD” on page 2-48). The check must be carried out by
means of the red ring (1) installed in the filter.When the red ring floats
on the surface of the water contained in the water separator, it is neces-
sary to drain it. Provide a suitable container to catch the drained liquid.
Proceed as follows:
1. Turn the valve (2) to close the fuel flow.
2. Loosen the wing nut (3) and drain the condensate until clear diesel
fuel flows out. Close the wing nut (3).
3. Open the valve (2).
4. Drain the fuel tank as described in paragraph. See “Draining The
Fuel Tank” on page 3-24.
5. Bleed the fuel supply circuit as described in paragraph See “Chang-
ing The Fuel Filter” on page 3-47.
6. Properly dispose of the drained liquid.
If the filtering element is considerably clogged or damaged,

change it.
Checking The Wiring System
If the fuses are corroded, oxidized or they are not perfectly held in their seat, replace them only with fuses
having the same capacity; before changing a fuse, make sure that the ignition key is in position «O».
If there are signs of short circuits on the cables, find the cause and repair them; always contact your
Komatsu distributor for troubleshooting.
Before checking the wiring, take all the necessary precautions to ensure safety.
Make sure that there are no disconnected cables or signs of short circuits in the electrical system. Make sure that all the cables
are well tightened in the corresponding terminals; tighten any loose cables.
3-38 CK30-1
MAINTENANCE
These maintenance operations must be carried out after the first 50 hours of operation, together with those to be carried out.
See “Maintenance Every 50 Hours Of Operation” on page 3-39.
★ Check the tightness of the carriage to frame bolt tightness
★ Change the hydraulic oil drain filter (only for machines filled with biodegradable (HEES) oil)
For details on the various maintenance operations, see sections. See “Every 250 Hours Of Operation” on page 3-21 and See
“Every 500 Hours Of Operation” on page 3-21.
Maintenance Every 50 Hours Of Operation
Checking The Rubber Track Tension
This operation must be carried out by two people. One

operator must be seated in the cab and maneuver the
machine following the signals of the other operator who
carries out the check and adjustment.
The track tension must be checked with the frame raised off
the ground; be careful not to shift any control lever while the
operator is carrying out the check.
The wear of the rubber tracks may vary according to the operating
conditions and the type of ground on which the machine works,
therefore it is necessary to check the tension of the tracks regularly.
To carry out the check, stop the machine on firm and level ground.
In particular, on new machines or after the installation of new tracks, it
is advisable to carry out a first check after 30 hours of operation.
Regular checks will prevent the tracks from coming off and the steel
cores from wearing out due to insufficient tension.
CHECK
to the ground.
approximately 75 mm (2.95 in) from the ground.
3. Move the machine slowly forward to create any slack.
4. Stop the engine.
5. Measure the slack between the contact surfaces of the central track rollers and the track rolling guide. The standard slack
must be between 15 and 20 mm (9/16 and 13/16 in).
6. If the slack is not within the standard values, adjust it accordingly. See “Checking And Adjusting The Rubber Track Ten-
sion” on page 3-29.
CK30-1 3-39
MAINTENANCE
Checking The Coolant Level In The Radiator
Carry out this check with the machine parked on a level

surface and the equipment resting on the ground. Do not re-
move the radiator cap when the fluid is hot, since it may be
sprayed out violently and cause burns. Loosen the cap
slowly in order to release the pressure before removing it.
The radiator cap can be reached after raising the engine hood (See
“ENGINE HOOD” on page 2-48). Remove the cap (1) and make sure
that the fluid level reaches the filling hole.
If the fluid level in the radiator is low and the expansion tank
is full of coolant, check the tightness of the radiator cap and
make sure that there is no air leakage from the radiator to
expansion tank hose. If this cap looseness occurs
repeatedly, contact your distributor.
Checking The Oil Level In The Travel Motor
Carry out the check with the machine parked on a firm and
level surface and the bucket resting on the ground.
Right after the machine is stopped the oil is very hot; allow it
to cool down to 40-45°C (104-113°F) before performing the
check.
This check must be carried out on each travel motor positioned with
the plug (1) at a distance of 20 mm (.79 in) from the horizontal axis, as
shown in the figure. If necessary, move the machine slightly until
reaching the specified position, which is necessary for an accurate
check. Remove plug (1), check for the oil level to be at the bottom of
the hole; if necessary, remove the plug (2) and top off using the
prescribed oil.
See “FUEL, COOLANT AND LUBRICANTS” on page 3-6.
Put back plugs (1) and (2).
Use an 8 mm Allen wrench.
3-40 CK30-1
MAINTENANCE
First 250 Hours Of Operation
Perform the following maintenance after the first 250 hours, together with those to be initiated. See “Maintenance After The
First 250 Hours Of Operation” on page 3-21.
★ HYDRAULIC OIL DRAIN FILTER
These operations must be carried out together with those to be carried out See “Every 50 Hours Of Operation” on page 3-20.
Fan Belt Tension
The fan belt can be reached after opening the engine hood, See
“Engine Hood” on page 2-48
The test is manual: press the belt b with your thumb on the indicated
point with a force equal to about 10 kg (22 lb); the resulting
deflection must be about 10 - 15 mm (0.4 - 0.6 in). If the deflection
exceeds this value, loosen the bolt c that fastens the alternator d and,
with a lever inserted between the engine block and casing, move the
alternator. Lock the bolt and check again. Use a 12 mm wrench.
A. Fan pulley
B. Driving shaft puller
C. Alternator pulley
If the belt is worn, replace it and check the tension again

after a few hours of operation.
CK30-1 3-41
MAINTENANCE
Cleaning The Outside Of The Radiators
If compressed air, steam or water are directed against a

person, they may cause injuries. Always wear an eye shield
and safety shoes.
The radiator/hydraulic oil cooler can be cleaned after opening the rear
panel (See “REAR PANEL” on page 2-49), using a compressed air jet
and, if necessary, carrying out a washing cycle with low pressure
water or steam; the specific detergents available on the market can be
used, provided that the instructions given on the package are followed
and that at the end of the operations the washed parts are rinsed and
dried.
Do not use products containing petroleum products, even if in slight quantities, since these promote the
sticking of dust, which reduces the heat exchange process. Clean the outside of the radiators whenever
the radiator and the hydraulic oil cooler are dirty, even if accidentally, with oil, diesel oil, greasy or oily
substances. If the machine is used in dusty places, clean the radiator/hydraulic oil cooler more frequently,
to avoid the clogging of the fins.
3-42 CK30-1
MAINTENANCE
Lubricating The Joints
Clean the grease nipples before applying the grease pump. After lubrication, remove any excess grease.
If the machine is used in difficult conditions, perform these maintenance operations more frequently.
These maintenance operations must be carried out with the arm completely lowered and the bucket resting on the ground. For
the lubrication, use a grease pump and the recommended grease. (See “FUEL, COOLANT AND LUBRICANTS” on page 3-
6).
As a general rule, consider that each cylinder is provided with two grease nipples positioned on the cou-
plings and that each pin serving as fulcrum for a movement is provided with at least one grease nipple.
EQUIPMENT LUBRICATION POINTS
1 - Bucket coupling pin (2 points)
2 - Tool-holder plate fulcrum pin (2 points)
3 - Bucket cylinder head pin (2 points)
4 - Bucket cylinder base pin (2 points)
5 - Lifting cylinder head pin (2 points)
6 - Arm fulcrum pin (2 points)
7 - Lifting cylinder base pin (2 points)
CK30-1 3-43
MAINTENANCE
Changing The Engine Oil
Immediately after the engine has been shut off the engine oil
is very hot and may cause burns; let the engine cool down
until it reaches a temperature of 40-45°C (104-113°F) before
draining the oil.
The oil that may be spilled during the change makes the
ground slippery, therefore, use anti-slip shoes and
immediately remove any trace of oil from the floor.
Oils, filters, coolants and batteries are considered special
waste and must be collected and disposed of according to
the anti-pollution regulations in force.
Drain the oil after positioning the drain hose outside the en-
gine compartment.
Change the engine oil at the same time as the engine oil filter. See
“Changing The Engine Oil Filter” on page 3-45. This operation must be
carried out with the machine parked on firm and level ground and
performing the following steps:
1. Detach the lower cover (1) after removing the fastening screws (2).
Use a 17 mm wrench.
2. Extract the oil drain flexible hose (3) from the lower opening.
3. Raise the engine hood. See “Engine Hood” on page 2-48.
4. Remove the drain plug (4) from the drain hose (3), gathering the
used oil that flows out into a container with suitable capacity. Use a
27 mm wrench. While the oil flows out, remove the filler cap (5),
so that the oil can flow freely.
5. After the oil has completely drained from the pan, screw the drain
plug (4) back into the drain hose, tuck the drain hose away. Pour the
specified quantity of new oil into the pan, using the dipstick (6) to
make sure that the oil reaches the MAX. level.
6. Replace the filler cap (5), start the engine, let it run for 5 minutes
and then stop it. Check the level again and top off, if necessary.
7. Assemble the lower cover (1).
8. Close the engine hood.
Use oil suitable for the ambient temperature. See “FUEL, COOLANT
AND LUBRICANTS” on page 3-6.
After the oil change and after removing any trace of oil, put
the drain hose back inside the engine compartment.
3-44 CK30-1
MAINTENANCE
Some versions of the machine come with special safety drain plugs.
To change the oil proceed as follows:
Remove the plug (7), apply the special union provided and turn
manually until the oil drains. Carry out the change procedures
described for the standard version. At the end of the operation, remove
the special union and put it in the appropriate tool container.
Reassemble the plug (7).
Changing The Engine Oil Filter
Immediately after the engine has stopped, the engine oil is very hot and may cause burns; let the engine
cool down until it reaches a temperature of 40-45°C (104-113°F) before draining the oil. The oil that may
spill during the change makes the ground slippery, therefore, use anti-slip shoes and immediately remove
any trace of oil from the floor. Oils, filters, coolants and batteries are considered special waste and must
be collected and disposed of according to the anti-pollution regulations in force.
This operation must be carried out during every oil change.

Proceed as follows:
1. Raise the engine hood. See “Engine Hood” on page 2-48.
2. Drain the engine oil into a suitable container. See “Changing The
Engine Oil” on page 3-44.
3. Position a container below the filter to catch any oil. Unscrew the
used filter (1) with the special wrench provided and dispose of it
properly.
4. Clean the contact surface between the seal and the filter base (2).
5. Lubricate the seal of the new filter and screw on until the filter
contacts the base.
6. Give the filter a further half turn by hand.
7. Fill the engine with new oil and complete the operations as described in. See “Changing The Engine Oil” on page 3-44.
Start the engine, make sure that there is no leakage and that the oil pressure warning light goes out.
Close the engine hood.
Do not use the wrench to tighten the filter, since this may cause damage and result in oil leaks.
CK30-1 3-45
MAINTENANCE
Checking The Torque Of The Bolts And Nuts That
Fasten The Carriages To The Machine Frame
On new machines, check the torque after the first 50 hours of

operation and successively every 250 hours of operation.
This operation must be carried out on both sides, with the machine
parked on firm and level ground.
Before carrying out the check, raise the loader arm and secure it with
the safety lock. See “SAFETY LOCKS” on page 2-2.
The check must be carried out using a torque wrench calibrated
according to the value indicated in paragraph and serves to restore the
driving torque of the nuts (1) and screws (2) that fasten the carriage to
the machine frame. See “TIGHTENING TORQUE” on page 3-19.
Use 22 and 24 mm wrenches.
Remark
Do not lubricate the threads when the torque must be
checked.
The check must be carried out on both the front and rear carriages on
each side.
If the entire carriage has been removed, before reassembling

it contact your Komatsu distributor and ask for precise in-
structions regarding the correct procedure for fastening
bolts and nuts.

★ (Only for machines filled with synthetic biodegradable oil type HEES)
★ The following maintenance operation must be carried out after the first 500 hours of operation, together with those to be
carried out EVERY 500 HOURS. See “Every 500 Hours Of Operation” on page 3-21.
• Hydraulic Oil Change And Cleaning Of The Suction Filter
3-46 CK30-1
MAINTENANCE
These operations must be carried out together with those to be carried out EVERY 50 and 250 HOURS.
Changing The Fuel Filter
Change the filter element after work and after the engine has
cooled down to 40-45°C (104-113°F). When this operation is
performed, fuel may spill; clean the spill immediately, to pre-
vent any risk of slipping or fire. Oils, filters, coolants and bat-
teries are considered special waste and must be collected
and disposed of according to the anti-pollution regulations
in force.
The fuel filter and the fuel pump can be reached by opening the engine
FUEL FILTER
1. Clean the outside of the filter and then unscrew the used filter (1) with the special wrench provided and dispose of the
filter properly.
2. Clean the inside of the head (2).
3. Lubricate the new filter seal and screw on until the seal contacts the base.
5. Bleed the fuel supply circuit.
BLEEDING THE CIRCUIT
After filling the tank, turn the ignition key to position «I» and wait for
approximately 15-20 seconds, to bleed the fuel supply circuit.
After bleeding the circuit, turn the ignition key to position

« » for a few seconds and wait at least 2 minutes before
starting the engine. If the engine starts without problems and
then stops or runs irregularly, check if there is air in the
circuit; if so, check the tightness of the fuel filter and of the
fuel pump prefilter.
If the machine has run out fuel, bleed the circuit by
proceeding as described above and repeat the operation at
least 2-3 times after filling the tank.
CK30-1 3-47
MAINTENANCE
Changing The Hydraulic Oil Drain Filter
Immediately after the engine has stopped the hydraulic oil is

very hot; let it cool down until it reaches a temperature of 40-
45°C (104-113°F) before changing the filter. The hydraulic
system is pressurized; loosen the filling cap slowly to
release the residual pressure. Oils, filters, coolants and
batteries are considered special waste and must be
collected and disposed of according to the anti-pollution
regulations in force.
On new machines, change the hydraulic oil filter cartridge

after the first 250 hours of operation and successively every
500 hours. On machines filled with synthetic biodegradable
oil type HEES, the first change must be carried out after the
first 50 hours of operation and the successive changes every
500 hours.
The filter is positioned on the hydraulic system drain outlet and blocks
the metal particles that come off the various components due to their
wear. The filter can be reached after opening the rear panel (See “Rear
Panel” on page 2-49).
To change it, proceed as follows:
1. Slowly loosen the filler cap (1) to release the residual pressure from
the tank and then remove the cap.
2. Unscrew the used filter (2) and discard it.
3. Clean the contact surface between the seal and the filter base (3),
lubricate the seal of the new filter and screw on until the seal
contacts the base.
5. Close the rear panel.
6. Check for oil leaks after running the engine.
Do not use the wrench to tighten the filter, since this may
cause damage and result in oil leakage. If the machine con-
tains synthetic biodegradable oil type HEES, the filter must
be changed after the first 50 hours of operation.
3-48 CK30-1
MAINTENANCE
Changing The Oil In The Travel Motors
Soon after the machine has been stopped the oil is very hot;
allow it to cool down to 40-45°C (104-113°F) before carrying
out the check. Oils, filters, the coolant and the battery are
considered special waste and must be collected and
disposed of according to the regulations in force.
This operation must be carried out on each travel motor with the
machine parked on level ground and at a temperature of 40- 45°C
(104-113°F), so that the oil becomes fluid and can be easily drained,
which facilitates the elimination of any suspended solid particles.
1. Move the machine until the drain and level plug (1) is in its
lowest position and vertically aligned with the filling plug (2).
2. Remove the drain plug (1) and let the used oil flow out
completely, gathering it into a container with suitable capacity.
While the oil flows out, remove the filling plug (2).
3. Use a 8 mm Allen wrench.
4. Once the oil has been drained, move the machine gradually until
the drain and level hole (1) is positioned at a distance of 20 mm
(0.79 in) from the horizontal axis.
5. Fill through the filling hole (2), using oil of the prescribed type,
until reaching the lower edge of the hole (1).
6. Put back the plugs (1) and (2).
Move the machine forward and backward a few times, stop the
machine and check the levels again. Always use oil of the prescribed
type. See “FUEL, COOLANT AND LUBRICANTS” on page 3-6.
CK30-1 3-49
MAINTENANCE
Cleaning The Water Separator
Change the water separator at the end of work and after the
engine has cooled down to 40-45°C (104-113°F). When these
operations are performed, fuel may spill; clean the dirty
areas immediately, to prevent any risk of slipping or fire.
The water separator can be reached after opening the engine hood. See
“Engine Hood” on page 2-48.
CLEANING THE WATER SEPARATOR.

1. Close the valve (1).
2. Loosen the metal ring (2) and remove the cup (3) and the filtering
element, collect the fluid in a container of suitable capacity.
3. Clean the inside of the cup and the filter with diesel oil or oil.
4. Replace the filter and the cup (3), tighten the metal ring (2) and
open the valve (1).
When disassembling the water separator, be careful not to

lose the red ring contained in the cup. If the filtering element
is clogged or damaged, change it.
BLEEDING THE CIRCUIT
After filling the tank, turn the ignition key to position «I» and wait for
approximately 15-20 seconds, to bleed the fuel supply circuit.
After bleeding the circuit, turn the ignition key to position

« » for a few seconds and wait at least 2 minutes before
starting the engine. If the engine starts without problems and
then stops or runs irregularly, check if there is air in the
circuit; if so, check the tightness of the fuel filter and of the
fuel pump prefilter.
If the machine has run out fuel, bleed the circuit by
proceeding as described above and repeat the operation at
least 2-3 times after filling the tank.
3-50 CK30-1
MAINTENANCE
Draining Condensate From The Hydraulic Oil Tank
(Only for machines filled with synthetic biodegradable oil
type HEES)
Lower the loader arm completely, rest the bucket on the

ground and, after stopping the engine, eliminate the residual
pressures that may be present in the equipment by operating
the controls more than once and lock the safety bars (See
“Safety Bars” on page 2-25). Let the oil cool down until it
reaches 40-45°C (104-113°F) before performing any
maintenance operation. Immediately clean any area dirty
with oil.
Stop the machine on a firm and level surface, lower the equipment to
the ground, stop the engine and release the residual pressures that may
be present in the equipment by operating the controls more than once.
Raise the engine hood (See “Engine Hood” on page 2-48) and open the
rear panel (See “Rear Panel” on page 2-49).
the tank and remove the cap.
2. Position a container of suitable capacity under the drain plug.
CK30-1 3-51
MAINTENANCE
3. Loosen the lower plug (2) until the condensate has completely
drained. Use a 12 mm hexagon wrench.
4. Retighten the lower plug (2), check the oil level and top off if
necessary. Install the filler cap (1) and close the rear panel and the
engine hood.
Be careful to only loosen the lower plug enough to allow the

condensate to drain and not lose too much hydraulic oil.
The draining of the tank must be carried out at temperatures

exceeding 0°C (32°F), before starting the engine; when the
temperature is below 0°C (32°F), the hydraulic oil tank must
be drained at the end of work, or in any case when the tem-
perature of the machine is high enough to prevent the
condensate from freezing and to allow it to flow out of the
tank without problems.
3-52 CK30-1
MAINTENANCE
These operations must be carried out together with those to be carried out EVERY 50, 250, 500 HOURS.
Changing The Hydraulic System Oil And Cleaning

The Suction Filter
On machines filled with synthetic biodegradable hydraulic

oil type HEES the oil must be changed after the first 500
hours of operation and successively every 1000 hours, and
in any case at least once a year.
Lower the loader arm completely, lower the bucket to the

ground, stop the engine, release the residual pressures from
the work equipment circuits by operating the controls more
than once and lock the safety bars (See “Safety Bars” on
page 2-25). Let the oil cool down until it reaches 40-45°C
(104-113°F) before carrying out any maintenance operation.
Immediately clean any area dirty with oil. Oils, filters,
coolants and batteries are considered special waste and
must be collected and disposed of according to the
anti-pollution regulations in force.
the ground, stop the engine and release the residual pressures from the
work equipment circuits by operating the controls more than once.
the tank and then remove the cap.
CK30-1 3-53
MAINTENANCE
2. Remove the lower plug (2) and let the used oil flow out completely,
gathering it in a container with suitable capacity. Use a 12 mm
hexagon spanner.
3. Once the oil has been drained, disconnect the suction pipe (3) and
remove the flange (4) after removing the screws (5). Use a 17 mm
hexagon spanner.
4. Clean the filtering element (6).
5. Put back the flange (4), the filter (6), the gasket (7) and the lower
plug (2).
3-54 CK30-1
MAINTENANCE
6. Fill the tank with the specified oil until reaching the correct level
(8). Use only the prescribed type of oil (See “FUEL, COOLANT
AND LUBRICANTS” on page 3-6).
7. Raise the cab (See “Tilting The Cab” on page 2-51) and make sure
that the oil in the hydraulic pump reaches the maximum level. To
do this, remove the upper plug (9) and make sure that the hole is
completely filled with oil. Use a 1/2” square drive wrench.
8. If the oil does not reach the maximum level, top off with the speci-
fied oil (See “FUEL, COOLANT AND LUBRICANTS” on
page 3-6).
9. After the check, lower the cab, install the filler cap (1), close the
rear panel and the engine hood and bleed the system.
10. Make sure that all the control levers are in neutral position and let
the engine idle for 2-3 minutes before operating the work
equipment. Move each piston more than once to bleed the system;
check level again and top off if necessary.
Never start the engine with an empty tank, since this would
certainly damage the pump.
Checking And Adjusting The Engine Valve Clearance

Since the check and adjustment of the engine valve clearance require the use of special tools, have these operations carried out
by your distributor.
CK30-1 3-55
MAINTENANCE
Carry out these operations together with those to be performed EVERY 50, 250, 500 and 1000 HOURS.
Changing The Coolant
The coolant must be replaced every 2000 hours of operation

or every 2 years, whichever occurs first.
Immediately after the engine has stopped the coolant is very

hot and under pressure and it may cause serious burns; let
the engine cool down until it reaches approximately 40-45°C
(104-113°F) before changing the coolant.
Slowly loosen the radiator cap, to release the residual
pressure.
Changing permanent type coolant does not require
de-scaling the system.
1. Raise the engine hood (See “Engine Hood” on page 2-48) and open
the rear panel (See “Rear Panel” on page 2-49).
2. Loosen and remove the filler cap (1) of the radiator.
3. Open the drain cock (2) of the radiator, remove the drain plug (3)
positioned on the engine block and let the fluid flow into a suitable
size container. Use a 17 mm hexagon wrench. While the fluid flows
out, drain the coolant tank (4).
4. Close the drain cock (2) and install the plug (3) on the engine
block. Fill the radiator with new coolant (See “FUEL, COOLANT
AND LUBRICANTS” on page 3-6).
3-56 CK30-1
MAINTENANCE
5. Start the engine and let it idle for a few minutes; check the level
again and if necessary top off before putting back the radiator cap
(1).
6. Fill the tank (4) until the coolant reaches the maximum level.
7. Close the rear panel and the engine hood.
CK30-1 3-57
MAINTENANCE
Changing The Suction Filter
Lower the loader arm completely, rest the bucket on to the

ground, stop the engine, eliminate the residual pressures
that may be present in the equipment by operating the
controls more than once and lock the safety bars (See “Safe-
ty Bars” on page 2-25).
Before carrying out any maintenance operation, let the oil
cool down until it reaches 40-45°C (104-113°F).
Immediately clean any area dirty with oil.
the ground, stop the engine and release the residual pressures from the
equipment by operating the controls more than once.
The suction filter must be changed every two hydraulic oil changes.
1. Slowly loosen the filler cap (1) in order to release the residual
pressure from the tank and then remove it.
3-58 CK30-1
MAINTENANCE
2. Drain the hydraulic oil (See “Changing The Hydraulic System Oil
And Cleaning The Suction Filter” on page 3-53).
3. Once the oil has been drained, disconnect the suction pipe (3) and
remove the flange (4) after removing the screws (5). Use a 17 mm
hexagon spanner.
4. Change the filtering element (6).
5. Put back the flange (4), the filter (6), the gasket (7) and the lower
plug (2).
6. Complete the tank filling operations by proceeding as described in

See “Changing The Hydraulic System Oil And Cleaning The Suc-
tion Filter” on page 3-53.
Never start the engine with an empty tank, since this would
certainly damage the pump.
Checking The Alternator And The Starter

For any inspection and/or repair, contact your distributor.
If the engine is started frequently, the alternator and the starter should be inspected every 1000 hours of operation.
CK30-1 3-59
MAINTENANCE
MEMORANDUM
3-60 CK30-1
4SPECIFICATIONS
CK30-1 4-1
SPECIFICATIONS
SPECIFICATIONS
Standard Machine Overall Dimensions
The weight of the machine increases by 120 kg (264 lb.) when it is equipped with additional rear
counterweights.
If the bucket is provided with teeth, the machine length increases by 100 mm (3.9 in).
With the extended bucket the machine length increases by 130 mm.
Overall Dimensions With Standard Bucket L 2030 mm (6’8”) And 450 mm (1’6”) Rubber Tracks
Unit: mm
Overall Dimensions With Standard Bucket L 1880 mm (6’2”) And 320 mm (1’1”) Rubber Track
Unit: mm
4-2 CK30-1
SPECIFICATIONS
Technical Specifications
TOTAL WEIGHT
Max. with L 2030 standard bucket and 450 mm(1’6”) track 4330 kg (9546 lb)
Max. with L 1880 standard bucket and 320 mm(1’1”) track 4300 kg (9460 lb)
BUCKET CAPACITY
Standard bucket L 20300 (SAE) 0.448 cu.m. (0.586 cu.yd.)
Narrow bucket L 1880 (SAE) 0.415 cu.m. (0.543 cu.yd.)
ENGINE
Komatsu diesel engine model S4D98E-2NFE
Rated power (2500 rpm EEC 80/1269) 64 kW (85.8 HP)
Maximum torque (1600 rpm EEC 80/1269) 286 Nm (211 lb.ft)
ELECTRICAL SYSTEM
Alternator 12 V
Electrical output 40 A
Ground Negative
Battery 100 Ah-12 V
Starter 3.0 kW (4.02 HP)
SPEED
FORWARD REVERSE
GEARS 1 2 1 2
km/h 7.5 12 7.5 12
MPH 4.7 7.5 4.7 7.5
RUBBER TRACKS
SIZE MAKE
STANDARD TRACK WIDTH 450 MM (1’6”)
OPTIONAL TRACK WIDTH 320 MM (1’1”)
CK30-1 4-3
SPECIFICATIONS
MEMORANDUM
4-4 CK30-1
OPTIONS, ATTACHMENTS 5
Komatsu does not assume any responsibility for the performance of any attachments used on the machine that have not been
designed, tested, or manufactured by Komatsu. The attachment manufacturer is solely responsible for any defects or failures,
personal injury, or property damage caused by the equipment or its use.
CK30-1 5-1
AVAILABLE OPTIONAL ATTACHMENTS
Komatsu machines can be supplied with available attachments in addition to the standard equipment. If available attachments
are installed and used on your machine, read and study all operations and safety information instructions relating to the
available attachments you will be using. Failure to do so may result in damage to the equipment or injury to the operator.
Komatsu cannot be held liable for damage, accident or reduction of machinery performance due to the application and use of
unauthorized equipment. Always use available equipment on your machine.
Basic Precautions
The installation of optional accessories or equipment other than those available through Komatsu distributors may shorten the
life of the machine and may also cause problems concerning safety. It is advisable to contact a Komatsu distributor before
installing any accessory not indicated in this operation and maintenance manual. In case of failure to comply with this
recommendation, Komatsu declines any responsibility for accidents or damage.
Install or remove available attachments on a firm level surface.

Be sure the equipment you are installing is in good operating condition.
When operations are performed using two or more personnel, agree to a set communication signals in
advance and stick to them.
Always use an overhead crane when lifting equipment weighing more than 25 kg (55 lb.).
Always support any heavy part before removing it. When heavy parts are lifted, always be mindful of the
center of gravity of the object being handled.
It is very dangerous to carry out any operation with a suspended load; therefore, always position the load
on a support and make sure that it is in a safe position.
When installing or removing any equipment, make sure that it is stable and cannot fall down.
Never stand under loads being lifted by a crane. Take care to choose a safe position, where you do not run
any risk in case the load should fall down.
Cranes must be operated by specialized personnel. Do not allow non-specialized personnel to use cranes.
For further details regarding installation and removal operations, contact your distributor.
5-2 CK30-1
Precautions Regarding The Installation Of Attachments
The use of lengthened work equipment reduces the stability of the machine.
If it is necessary to go up or down a slope, be particularly careful, since the machine may lose its balance
and overturn.
When installing work equipment with dimensions exceeding those of the standard equipment, be aware of
the space necessary for the movements of the equipment and of the machine.
Characteristics Of The Standard Machine With Optional (Factory Supplied)

Equipment
★ Specific weight of the handled material = 1.8 tons/m³
MAX. MAX. DIMENSIONS MAX. SAE MAX. OPERATING MAX. FLOW

EQUIPMENT
WEIGHT CAPACITY PRESSURE RATE
(Factory Supplied) Width Height
(kg) (mm) (mm) (cu m) (bar) (l/min.)
Front bucket 215 2030 520 0.466 — —
Multi-purpose front bucket — 2030 550 — 206 80
Pallet fork 172 1500 710 206 —

1219
Max. tooth length (MM)
CK30-1 5-3
Characteristics Of The Optional (Factory Supplied) Equipment For The
Machine With High Flow And Super-flow Hydraulic Systems
★ Specific weight of the handled material = 1.8 tons/m³
MAX. MAX. DIMENSIONS MAX. SAE MAX. OPERATING MAX. FLOW

EQUIPMENT
WEIGHT CAPACITY PRESSURE RATE
(Factory Supplied) Width Height
(kg) (mm) (mm) (cu m) (bar) (l/min.)
Front bucket 215 2030 520 0.466 — —
Multi-purpose front bucket — 2030 550 — 206 80
Pallet fork 172 1500 710 1219 206 —
Max. tooth length
5-4 CK30-1
Changing The Available Attachments
Stop the machine on a firm and level surface and lower the equipment to the ground.
Before getting off the machine, stop the engine, release the residual pressure by moving the equipment
control levers in all directions repeatedly and lock the safety bars (“Safety Bars” on page 2-25).
Before starting work, make sure the quick coupler locking pins are completely engaged in, and protruding
from, the retaining tabs (slots) provided on the bucket or attachment and that the coupler levers are
pushed down to a horizontal (locking) position.
Do not use your fingers to center the pins, since they may be injured or even cut due to sudden or
uncontrolled movements.
The machine is provided with a special tool-holder, called a universal quick coupler, which is used for the installation of
buckets or optional equipment. Change the optional (factory supplied) equipment using the same procedure adopted to change
the bucket. “Changing The Bucket Or Attachment With Standard Quick Coupler” on page 2-95.
Besides the assembly on the tool-holder, the hydraulic excavator also requires fastening to the machine by means of two
connecting tie-rods and the hydraulic connection for the independent control of the equipment. When changing equipment
with independent hydraulic circuits, stop the oil flow to the equipment with the auxiliary kit pedal and disconnect the quick
disconnects before releasing the equipment from the tool-holder. “Connecting The Hydraulic Circuit” on page 5-6.
CK30-1 5-5
Connecting The Hydraulic Circuit
Before performing any operation on the hydraulic circuit, stop the

engine and eliminate the residual pressure from the equipment
circuits by operating the control levers repeatedly, then lock the
safety bars (see “Safety Bars” on page 2-25).
Before and after any operation on the hydraulic circuit, clean up
any oil.
After the mechanical connection of equipment with the independent

hydraulic circuit, make sure that the auxiliary kit control pedal is in
position A - flow interrupted - and assemble the flexible hoses of the
equipment to quick disconnects (1) and (2). See B, C and D.
The quick disconnect couplings must be in compliance with the ISO
8434-3 standard.
Remark
In case there are questions regarding the connection of the
hydraulic circuit to the equipment, contact your Komatsu
distributor.
5-6 CK30-1
CK30-1 5-7
Connecting The Return Circuit With Direct
Drainage Into The Tank
Before performing any operation on the hydraulic circuit, stop the

engine and eliminate the residual pressure from the equipment
circuits by operating the control levers repeatedly, then lock the
safety bars.
Before and after any operation on the hydraulic circuit, clean up
any oil.
The machine may be fitted for the application of equipment with

separate return circuits directed into the tank.
The return system is positioned on the left side of the loader arm and the
equipment drain pipe must be connected to quick disconnect (1).
Remark
In case there are questions regarding the connection of the
hydraulic circuit to the equipment, contact your Komatsu
distributor.
5-8 CK30-1
Preparing The Machine For Use With The
Excavator
After the installation of the excavator, make sure that the mechanical
and hydraulic connections have been carried out correctly and proceed
as follows:
1. Press the auxiliary kit control pedal to the left with your toe and
pull the lever to the rear to lock the pedal in position (B); this posi-
tion ensures the flow of oil to the equipment.
2. For the use of the excavator, see the specific instruction manual.
3. Before leaving the seat, press the SEAT OVERRIDE SYSTEM

button on the left console.
4. If the machine is equipped with rear stabilizers, lower them until

the rubber tracks are partially raised; this maneuver stabilizes the
machine and avoids any overload on the tracks.
Using The Machine With The Excavator
Before using the excavator, read the relevant operation and maintenance manual carefully and follow the instructions
contained therein.
If the machine is equipped with rear stabilizers, always lower them before using the excavator.
After the digging operation and before moving the machine, bring the stabilizers back to their original position.
If it is necessary to travel on roads, engage all the safety locks provided.
CK30-1 5-9
Pallet Forks
Before using the forks for any operation, the operator must get acquainted with the increased dimensions
of the machine and must also practice the use of the swinging movements.
After engaging the material with the forks and before lifting the load, swing the equipment in such a way as
to lift the tips of the forks and prevent the load from slipping.
Use the lifting, swing and travel controls slowly and smoothly, to avoid jerks that may cause the load to
move.
Use the maximum fork width possible.
The forks must always be resting on the plate and be secured in their positions with the safety pins.
The pallet forks make it possible to use the machine like a normal lift truck and the controls for lifting and swinging the loads
are the same used to control the standard bucket. “Machine Controls” on page 2-23.
The pallet forks may require being set to different widths (distance from each other) according to the load to be handled:
adjustment is made by sliding them on the upper coupling bar; once the desired position has been found, carry out slight
movements to make sure that the upper lock pin is engaged in its seat.
5-10 CK30-1

Operation & Maintenance Manual: Compact Track Loader

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operation & Maintenance Manual: Compact Track Loader

Uploaded by

Copyright:

Available Formats

CEAM017102

Operation & Maintenance

SERIAL NUMBERS CK30-1 A30001 and up

Copyright 2010 Komatsu

Other signal words

The safety precautions are described in SAFETY section 1.

It is absolutely forbidden to operate the machine while standing on the ground.

APPROVED AND NON APPROVED USES

• USE OF THE MACHINE BY MINORS OR INEXPERIENCED PEOPLE.

• USE OF THE MACHINE FOR LIFTING PEOPLE OR OBJECTS.

• TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.

• USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.

• USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.

• Two driving tracks always engaged through oil-immersed roller chains.

• Foot control for the optional equipment (if installed).

• Parking brake control.

• Complete series of instruments visible from the operating position.

• Easy maintenance with simplified intervals.

• Road travel (on request).

• Check the drive chain tension.

• Change the hydraulic system filter.

Machine Serial Number

Machine Identification Plate And Product Identifi-

Engine Serial Number And Emission Plate

Travel Reduction Gear Serial Number

Cab Serial Number

SERIAL NUMBERS AND DISTRIBUTOR INFORMATION

SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

GUIDE TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

AVAILABLE OPTIONAL ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Example Of Safety Label Using Words

Example Of Safety Label Using Pictogram

Komatsu cannot predict every circumstance that might involve a po-

Never engage in prohibited uses or actions described in this manual.

SAFETY AND WARNING DECALS

1. Hydraulic oil (37A-98-12210)

2. Hydraulic oil level (37A-98-12290)

3. Hydraulic oil filter (37A-98-12310)

4. Engine air filter (37A-98-12260)

5. Fuel filter (37A-98-12250)

7. Radiator cap (37A-98-12270)

8. Electrical socket (37A-98-12320)

9. Diesel fuel filter (37A-98-12240)

10. Emergency exit (22L-98-18270)

11. Do not open engine hood (37A-98-12350)

• Lift the hood

14. Door lock/unlock

HIGH PRESSURE AND BURN HAZARD

1. When breakdown or trouble develops in the accumulator, do not

2. Do not attempt to fill or re-fill with gas. Authorized servicemen,

3. Never hammer a gas filled accumulator, or place one close to a

4. Never attempt to attach a part to or bore a hole in the accumula-

5. Always completely exhaust the accumulator of all contaminated

(1) Type of gas - Nitrogen

(2) Maximum Working Pressure - 210 bar (3,046 psi)

(3) Testing Pressure - 315 bar (4,569 psi)

Do not risk serious injury or death.

16. WARNING - Coupling pins (37A-98-11232)

• Do not use your fingers to center the pins.

• Read operation manual before removing or installing bucket or attachment.

• Failure to follow these instructions may cause serious injury or death.

To install loader arm safety support

3. Lower loader arm safety support onto cylinder rod.