SEAMU4170103 WAIBO. WHEEL LOADER seria. nuweens WATBO-10001 anc up KOMATSUFOREWORD This manual describes procedures for operation, handling, lubrication, ‘maintenance, checking, and adjustment. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance. ‘© Please read this manual carefully BEFORE operating the machine. Please continue studying this manual until proper operation is completely reinforced into personal habit. ‘© This manual describes the basic techniques. Skill is performed as the ‘operator or anyone get the correct knowledge and performance of the machine, ‘© Operation, inspection, and maintenance should be carefully carried out, and the safety must be given the first priority. Safety precautions are i dicated with marks and technical precautions with * marks in this manual. The safety information contained in this manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations. ‘© Some photographs and illustration pictures are different from your ma- chine as technical improvement is continuously reflected on it. Revision to up-to-date manual's content is performed in later editions, © This operation & maintenance manual may contain attachments and op- tional equipment that are not available in your area, Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice FOREWORD[BREAKING IN YOUR NEW MACHINE BREAKING IN YOUR NEW MACHINE Each machine is carefully adjusted end tested before shipment. However, ‘@ new machine requires careful operation during the first 100 hours to break in the various parts. Hf a machine is subjected to unreasonably hard use at the initial operation stage, the potential of performance will prematurely deteriorate and the ser- vie life will be reduced. A new machine must be operated with care, partic- ularly with regard to the following items. © After starting, let the engine idle @ At the first 250 hours of opera- for 5 minutes to allow proper tion, the machine should be main- fengine watm-up prior to actual _—_tained in the following manner in operation. addition to usual 260 hours © Avoid operation with heavy loads service: ‘or at high speeds. 1) Replacement of fuel filter car- © Sudden starting or acceleration, _—_tridge and transmission oil filter unnecessarily abrupt braking and _element sharp turning should be avoided. 2) Replacement of engine oil filter cartridge and oil 3)Checking and adjustment of ‘engine valve clearance For replacement procedure and details, see maintenance table in the maintenance section, ‘* When replacing oil filter elements (cartridges), check their interiors for dirt and dust. If heavily col- lected, check for possible cause before starting operation, ‘* Hours of operation are indicated by the service meter.OPERATION GENERAL LOCATIONS AND SPECIFICATIONS INSTRUMENTS AND CONTROLS CHECK BEFORE STARTING OPERATING YOUR MACHINE ADJUSTMENT OF WORK EQUIPMENT... HANDLING THE TIRES ... TOWING : COLD WEATHER OPERATION CONTENTS 4 . 23 27 38 38 a 42 MAINTENANCE PERIODIC MAINTENANCE BLEEDING AIR FROM CIRCUIT .. PERIODICAL REPLACEMENT OF SAFETY PARTS MAINTENANCE TABLE OIL FILLER AND LEVEL GAUGE POSITIONS EVERY 50 HOURS SERVICE EVERY 100 HOURS SERVICE INITIAL 250 HOURS SERVICE .. EVERY 250 HOURS SERVICE EVERY 500 HOURS SERVICE . EVERY 1000 HOURS SERVICE EVERY 2000 HOURS SERVICE ... EVERY 4000 HOURS SERVICE ‘WHEN REQUIRED ADJUSTMENT foo ‘TROUBLE SHOOTING GUIDE ‘SERVICE METER ..... MACHINE AND ENGINE SERIAL NUMBERS FUEL, COOLANT AND LUBRICANTS: 47 48 49 50 53 54. - 85 87 87 63 65 70 73 14 87 89 92 93 94.(GENERAL LOCATIONS AND SPECIFICATIONS. GENERAL LOCATIONS AND SPECIFICATIONS Bucket Lift arm Head lamp Tum signal lamp Rear wheel geen 6. Safety bar 7. Front wheel 8 Lift cylinder 9. Dump cylinder 10. Tilt lever With ROPS cab WA180-1 (Tire size 15.5 — 25) PERFORMANCE 1. Bucket capacity (Heaped) 17m 2. Travel speeds Forward Max. 34.5 km/h (21.4 MPH) Reverse Max. 35.0 km/h (21.7 MPH) OPERATING WEIGHT 9200 kg ENGINE 1. Model Komatsu S6D95L-1 diesel engine 2, Flywheel horsepower (at 2500 rpm) 110 HP WA180-1 (Tire size 17.6 — 25) PERFORMANCE 1. Bucket capacity (Heaped) 17m! 2. Travel speeds Forward Max. 36.1 km/h (22.4 MPH) Reverse Max. 36.6 km/h (22.7 MPH) OPERATING WEIGHT 9400 kg ENGINE 1. Model Komatsu S6D95L-1 diesel engine 2. Flywheo! horsepower {at 2500 rpm) 110 HP NOTE: Specifications are subject to change without notice,INSTRUMENTS ANO CONTROLS. INSTRUMENTS AND CONTROLS CLUSTER GAUGE 1. TORQUE CONVERTER OIL ‘TEMPERATURE GAUGE GP Ga This gauge indicates the tem- perature of the torque converter oil If the temperature is normal during operation, the needle indicates the green range. If the needle indicates red range during operation, stop the machine and run the engine with no load at midrange speed until the needle returns to the green range.INSTRUMENTS AND CONTROLS 2. ENGINE COOLING WATER ‘TEMPERATURE GAUGE & This gauge indicates the tem- perature of the cooling water. If the temperature is normal during operation, the needle indicates the green range. If the needle indicates ‘the red range during operation, stop ‘the machine and run the engine with no load at midrange speed until the needle returns to the green range. 3. FUEL GAUGE This gauge indicates the available fuel supply in the fuel tank, and indicates the empty condition of the fuel, while “F” indicates the full condition, ‘* Fuel tank should always be filled at the end of each day's work. 4. VOLTMETER This meter indicates the voltage of battery. If voltage is normal during operation, the needle indi- cates the green range. If the needle indicates the red range, stop the engine and inspect the electrical system, % Before starting the engine, turn ON the starting switch and check the gauge. If needle indicates left range, check the battery immediately.INSTRUMENTS AND CONTROLS PILOT LAMPS, METERS 1, BRAKE OILLEVELPILOTLAMP — 2. PARKING BRAKE PILOT LAMP @) @®) This lamp indicates a low brake This lamp lights up when the oillevel parking brake is applied. If the lamp lights, check the oil level and add brake oil as requiredINSTRUMENTS AND CONTROLS. ‘3. EMERGENCY STEERING NORMAL PILOT LAMP wv When the machine is traveling, this lamp is on to show that the emergency steering system pump is operating normally ‘4, EMERGENCY STEERING PILOT LAMP. If the engine stops when the ma- cchine is traveling, or if the oil pres- sure in the steering pump drops, the lamp will light up, If the lamp lights up, move the ‘machine immediately to a safe place and stop the machine. 5. TURN SIGNAL PILOT LAMP When the turn signal lamp flashes, the pilot lamp also flashes. 6. HEATER SIGNAL This signal is red-heated after the starting switch is turned to HEAT, thus indicating the electrical intake air heater is heated, 7. SPEEDOMETER This meter indicates the running speed of the machine.8. WORKING PILOT LAMP This lamp lights up when the ‘working lamps are switches on. 9. HIGH BEAM PILOT LAMP a This lamp lights up when the head lamp is at high beam, 10. SERVICE METER This meter shows the total ‘operation hours of the machine, The service meter advances while the engine is running - even if the machine is not traveling, Refer to the section “SERVICE METER”. % The indicator under the service meter rotates when the engine running to show that the meter is. running, INSTRUMENTS AND CONTROLS SWITCHES |. PARKING LAMP AND ‘TRANSMISSION CUT-OFF ‘SELECTOR SWITCH This has the function of tuning on the front and rear parking lamps and switching the function of the left brake pedal,INSTRUMENTS AND CONTROLS Position | Parking | Transmission of switch | ‘lamp cut-off o ON ‘OFF @ | oF OFF, @_| or ‘ON Parking lamp Position @ : Lamps light Transmission cut-off selector Select the operation of the left brake pedal.) Position © , @ + Depressing the left brake pedal ‘operates the wheel brakes (like right brake pedal) Position @ : Depressing the left brake pedal operates the wheel brakes, and also returns the transmission to neutral * Normally, put this switch in ON position. Aiietne machine has tobe started ‘on a slope, always turn the transmission cutoff selector switch to OFF and depress the left brake pedal. Then depress the accelerator pedal while releasing the left brake pedal tostart the macine off slowly. ~10- 2. WORKING LAMP AND CLUSTER GAUGE CHECK ‘SWITCH Position) Front and rear working lamps and pilot lamp light. Position @ : It is possible to check the lamps of the cluster gauge for blown- ut bulbs. If the lamps light when the switch is in this position, the bulbs are normal Artur off working tamps when raveling on public roads.When this switch is pulled, head lamps light. Position Position @) ‘When this switch is operated, the clearance lamps, the tail lamps and panel lamp will also light up. Low beam High beam 4, STARTING SWITCH es OF This switch is used to start or stop the engine. OFF Key insertion-withdrawal tion. None of electrical activate. The parking lamp will remain on, however, when the switch is turned OFF. To stop the engine, turn the switch to OFF. ON Charging, lamp, and accessary circuits activate, posi- circuits -ue INSTRUMENTS AND CONTROLS START ‘At this key position, the starting motor will crank the engine, Release the key immediately after starting, and the key will return automatically t0 ON. HEAT Use this position when starting in cold weather. Release the key to allow it to return automatically to OFF and then, without delay, tum it to START. 5. HORN BUTTON e When the button in the center of the steering wheel is pressed, the horn will sound.INSTRUMENTS AND CONTROLS, PEDALS AND LEVERS 1. DIRECTIONAL LEVER, This lever is used to change the direction of travel of the machine. ® Forward @ Reverse ® Neutral * The engine cannot be started if the directional lever is not at N (neutral, 2, SPEED CONTROL LEVER This lever controls the travel speed of machine. This machine has a 3- FORWARD, 3-REVERSE speed transmission. Place the speed con- trol lever in a suitable position to obtain the desired speed range. % 1st and 2nd speeds are used for working. 3rd speed is used for travling,SAFETY LOCK (for direction lever) \\ roe ¥ ee G40 Safety lock prevents the directional lever from entering FORWARD and REVERSE positions. Dirvways apply the direction lever Safety lock when leaving or servicing machine. ‘4, SPEED CONTROL LEVER STOPPER INSTRUMENTS AND CONTROLS 5. TURN SIGNAL LEVER This stopper prevents the speed control lever from entering the 3rd position, when working. Position @) ‘Stopper actuated. Position @) ‘Stopper released. -13— This lever operates the turn signal lamps. @ LEFT TURN: Push lever up. @ RIGHT TURN: Pull lever down, ‘* When the lever is operated, the turn signal pilot lamp will also light up. * Return the switch lever manually to the NEUTRAL position after the steering wheel is returned to the NEUTRAL position from right or left turning,INSTRUMENTS AND CONTROLS. ACCELERATOR PEDAL This pedal controls the engine speed and output. The engine speed can be freely controlled between ow idling and full speed. 7. BRAKE PEDALS Right brake pedal ‘The right brake pedal operates the wheel brakes, and is used for normal braking, Bon bills, use the right brake pedal or use the left pedal with the transmission cut-off selec- tor switch put in OFF. Left brake pedal The left brake pedal operates the wheel brakes, and if the transmis- sion cut-off selector switch is at ON, it also returns the transmission to neutral If the transmission cut-off selec- tor switch is at OFF, the left brake Pedal acts in the same way as the right brake pedal. -14- Addo not use the brake pedals repeatedly unless necessary, Aico not use the brake pedals as footrests. Use them only when applying the bra * When the accelerator is being used for operating the work equipment, always use the left brake pedal to slow or stop the machine after putting the trans- ion cut-off selector switch in ON. AXFor machines with a booster, when the engine is stopped, the operating force of the brake pedal becomes 3.6 times than normal.INSTRUMENTS AND CONTROLS. 8. WORK EQUIPMENT CONTROL LEVER This lever is used to operate the @) Tilt“) lift arm and the bucket. ® Dump ( # ) @Raise( w ) @dold( = ): The lift arm and the bucket are a kept in the same position. @Lower( “ ) @Float( a ): The lift arm moves freely under external force. ‘* When the work equipment con- trol lever is pulled further from © position, the lever is stopped in this position until lift arm reaches the preset position of kick-out, and the lever is backed to hold position. wanes -158-INSTRUMENTS AND CONTROLS. 9. SAFETY LOCK 10. PARKING BRAKE LEVER {for work equipment control a lever) Lock @ ‘ ceed on Dump % When the work equipment con- This is used to lock the work This lever operates the parking ttol lever is pulled further from equipment control lever. brake, The brake is applied by puling @ positon, the lever is stopped this lever, and the parking. brake inthis position until bucket pilot lamp lights up. Push the button reaches the preset position of or when the perform- on the tip ofthe lover to release the bucket positioner, and the lever ing maintenance, always lower parking brake is backed to hold postion, the bucket to the ground, put the work equipment levers in AM Always apply the parking hold position and check that safety lock lever s locked. it. * The machine does not start when the, directional lever is operated with parking brake applied. — 16 - woesDUST INDICATOR Q a, This device indicates clogging of the air cleaner element. When red piston (1) appears in the transparent part of this indicator, the element is clogged. immediately clean element. After cleaning, push indicator button (2) to return red piston to original position. The dust indicator is on the engine intake manifold inside the right side panel SAFETY BAR The safety bar is used during maintenance or when transporting ‘the machine. It locks the front frame and rear frame, and prevents the front and rear frames from bending. Biaiways use the safety bar for ‘maintenance or when trans- porting the machine. Ai Aiways remove the safety bar during normal travel oper: tions. -1W7- INSTRUMENTS AND CONTROLS. DRAWBARPIN 1. Align protrusion @ of drawbar pin © with groove ® of the counterweight, then insert and rotate 180°, 2. To prevent the drawbar pin from rotating, fold the knob of the drawbar and set in positionINSTRUMENTS AND CONTROLS. %* When removing, remove in the ‘opposite order. Adit step 1. and 2. are not carried ‘out properly, the pin may come out and be lost. FUSE BOX The fuses protect the electric devices and wiring from burning out. If any fuse is rusted or coated with white powder, replace it. Replace a fuse with another of the same capacity. Arseiore replacing 2 fuse, be ‘sure to turn off the starting switch Fuse arrangement and circuit Fuse box I @ > HETEATE 2 DVO 9O0E SR Fuse box II =18-Fuse box I Fuse box I Fuse 7 Fuse ‘ wo ue, | Cea a Greve D150 | string switch = = @]_ 108 | reine stop motor @| 100 = @| 100 | Satz psrtane O00 | water | __ ct] 2 . Bucket pestoner 10A | Boomerkout @|_108 | Rotatng ome 208 | Mainiamp circuit @| 20a | Cigereto lighter ‘15A | Hom Working lamp DJ] 108 | Front wiper a Clesrance ome @| TOA | Rear wiper D | 10% | Sota 2 D ‘ircondivoner D[_10A_ | Heastamp Wow beam) @|_ 204 | Condenser on @ [_1A_| Heodamp High bear Air condivoner @] 208 | aninade room) Go -19- INSTRUMENTS AND CONTROLSINSTRUMENTS AND CONTROLS. OPERATOR'S SEAT The seat adjustment should be checked at the beginning of each shift and when operators change. A:Forward-backward adjustment Move lever (1) to the right, move the seat to the best position and release the lever. The seat can be moved forward or backward within arange of 140 mm in8 stages. t height adjustment Move lever (2) upward, set the seat to the desired height and release the lever. The seat can be set within 50 mm. in stages. c: jackrest adjustment Move lever (3) upward, move the backrest to the best position and release the lever. The backrest can be set to 12 steps. -20- Arran the machine in a sate lace and stop. the. engine Wien carving tut adjustrent Stine opertors see.OPERATOR'S SEAT BUCKET TYPE The seat adjustment should be checked at the beginning of each shift and when operators change. to, (KB Boll ‘A: Forward-backward adjustment Move lever (1) to the right, move the seat to the best position and release the lever. The seat can be moved forward or backward within a range of 140 mm in7 stages. B: Seat angle adjustment Move lever (2) up, set the seat to the desired angle, and release the lever. The seat can be tilted up or down about 3°, C: Seat cushion adjustment Rotate grip (3) under the seat to adjust scale (4) on the cushion ad- justment to your own weight. (60 to 120 kg) -2- INSTRUMENTS AND CONTROLS D: Backrest adjustment Pull lever (5), move the backrest to the best position and release the lever. The backrest can be set to 11 steps, E: Seat height adjustment Move lever (6) upward, set the seat to the desired height and release the lever. The seat can be set within 50 mm, Arpark the machine in a sate place and stop the engine when carrying out adjustment of the operator's seaINSTRUMENTS AND CONTROLS SEAT BELT Arpetore fastening the seat belt, inspect the securing brackets and belt for abnormal conditions. Fasten the belt and remove it in the following manner. 1. Adjust the seat so that the brake pedal can be depressed all the way with the operator's back ‘against the backrest. 2. After positioning the seat, install the tether belt (1), With the seat ‘unoccupied, tense the belt slight- ly across the seat and install. Check that there are no kinks in the belt. Sit in the seat. Hold buckle (2) and insert (3) into the buckle (2) Check that the belt has locked by pling it When removing the belt, raise the tip of the buckle lever to release it. When leaving the operator's seat, release the seat belt and hang it over the arm rest. Fasten belt along your body with- out kinking it. Adjust the lengths of the belt on both the buckle and the insert sides so that the buckle is located at the mid-point of your body front. Adjust the belt length in the fol lowing manner. To shorten the belt, pull the free end of the belt on either ‘the buckle body or insert side. =22- i) To lengthen, pull the bett while holding it at a right angle to buckle or insert. = When operating a machine equipped with ROPS, be sure to use the seat bet. Inspect bolts and fittings on the chassis for tightness. Retighten any loose bolts to 2 to 3 kgm torque. If the seat is scratched or frayed or if any of the fittings are broken or deformed from long service, replace the seat belt immediately.(CHECK BEFORE STARTING CHECK BEFORE STARTING Pre-operation checks forestall machine trouble. Never neglect them. a. WALK-AROUND CHECK b. CHECK AND REFILL COOLANT 1. Check wear of bucket. 2. Check tightness of wheel hub IN nut. 3. Check around the axle and trans- mission case joints for ol leak. 4. Check hydraulic tank joint for oil leak. 5. Check around the engine for water and oil leaks. 6. Check radiator for water leak. 7. Check tightness of battery terminal 1. Open left engine side cover. 3. If the level is too low, add water 8. Check tightness of air cleaner 2. Check the level of the coolant. to sub-tank (1), ‘mounting bolt. The water level must be between 8. Check for illeak at high pressure the FULL andLOW marks on sub- AMDo not open the radiator cap hhose, high pressure hose joints tank (1). unless necessary. Check and hydraulic cylinder seal always the coolant level of the sub-tank when engine is cold. ID + the vole of cola dedi ie more than usual, check for poss ble water leakage. wooo ~ 23 —(CHECK BEFORE STARTING ¢. CHECK OIL LEVEL AND REFILL d. CHECK FUEL LEVEL AND IN ENGINE OIL PAN REFILL FUEL 1. Open the engine side cover at the * Do not fill above the H mark. 1. Check the fuel level using fuel rear left side of the machine, * When adding oil, pull the dipstick gauge (G) 2. Use dipstick (G) to check the oil out from the guide to bleed the 2. Upon completion of work, pour level. air from inside the case in addition fuel from filler (F) until 3. The oil level should be between * When checking the oil level, park —_the fue! tank is full. mark L and H, if necessary, add the machine on @ level surface, oilat oil filler (F). stop the engine and wait for 18 % The type of lubricant used de- _minutes before checking, pends on the ambient tempera- ture. Select according to the table “FUEL, COOLANT AND LUBRICANTS”. ~24—Fuel capacity: 140 £ * When adding fuel, never let the fuel overflow. This may cause a fire e. CHECK DUST INDICATOR 1 element is 1 When air clogged, the red piston of dust in- dicator (1) reaches service level and cleaner gets locked In that case, clean element refer- 2. ting to the section “WHEN REQUIRED”. * After cleaning element, push button to return red piston. 25 — CHECK BEFORE STARTING CHECK AND REFILL OF OIL IN BRAKE OIL TANK Check that the oil level in tank (1) at the right side of the operator's seat is between the MAX and MIN marks. Open cap (2) and refill engine cil, if necessary. The type of lubricant used de- pends on the ambient tempera- ture. Select according to the table "FUEL, COOLANT AND LUBRICANTS”. When refilling the brake oil tank, be sure to use the engine oll.CHECK BEFORE STARTING 9. CHECK THAT PARKING in, CHECK STEERING PLAY; q. CHECK FOR SEDIMENT AND BRAKE WORKS PROPERLY. CHECK THAT STEERING WATER IN THE WATER WORKS PROPERLY. SEPARATOR h, CHECK THAT BRAKES WORK PROPERLY. 0. CHECK THAT BACK-UP BUZZER SOUNDS PROPERLY. |. CHECK THAT HORN SOUNDS. PROPERLY. p. CHECK ELECTRICAL WIRING Check for any sign of disconnec- |. CHECK THATLAMPS FLASH tion or short circuit in the electric PROPERLY; CHECK FOR DIRT wiring. Check also for loose termi- OR DAMAGE. nals and tighten any loose parts. Check the following points carefully. k. CHECK DIRECTION OF REAR Battery VIEW MIRROR; CHECK FOR @ Starting motor The water separator separates DIRT OR DAMAGE. @ Alternator water mixed in the fuel. If float (2) is at or above red line (1), drain the 1. CHECK THAT ENGINE water. For the draining procedure, EXHAUST GAS COLOR AND see section "WHEN REQUIRED”. SOUND ARE NORMAL. % Even if a water separator is in- stalled, be sure to check the fuel m.CHECK THAT GAUGES AND tank to remove water and sedi- INSTRUMENTS WORK ‘ment in the fuel PROPERLY. erBEFORE STARTING THE ENGINE 1. Carry out an initial inspection. (For details of the inspection, see CHECK BEFORE STARTING) 2. With your back against the back- rest of the operator's seat, adjust the seat position so that the brake pedal can be easily depressed. 3. Is parking brake lever (1) in lock position? -27- OPERATING YOUR MACHINE OPERATING YOUR MACHINE 4. Is directional lever (2) in N (neu- tral) position? Forwara (3 a o Noutrat fX)— * The engine will not start while directional lever (2) is in any posi- tion other than N (neutral) 5. Is work equipment control lever (3) locked by safety lock (4)? Lock 6. Turn the starting switch ON and check that the pilot lamp lights up.OPERATING YOUR MACHINE TO START THE ENGINE 1. Depress accelerator pedal (1) lighty. 2. Turn the key of starting switch (2) to the START position to start engine. we 3. When engine is started, release the key of starting switch (2) and the key will return automatically to ON. * If engine will not start, repeat the starting procedure after about 2 minutes, + Do not leave the key in START for more than 20 seconds. + To start engine in cold weather, refer to COLD WEATHER OPERATION. 28 - Special starting When starting after running out of fuel, fill with fuel, then fill the fuel filter cartridge with fuel and bleed the air from the fuel system before starting, Refer to FUEL FILTER in every 500 hours services.OPERATING YOUR MACHINE CHECKS AFTER STARTING TO MOVE THE MACHINE OFF After starting make the following checks. 1. Depress accelerator pedal (1) 3. Check if the exhaust color is lightly and run the engine withno normal or whether there is any load at midrange speed for about —_—_abnormal noise or vibration, 5 minutes, * Avoid abruptly accelerating the 2. After warm-up run is completed, engine until the completion of check gauges and caution lamps warm-up. for proper operation % Do not run for more than 20 mi- % Continue to run the engine at nutes at low idling or at high light load until the green ranges _idling, 1. Check that the caution lamps are Of the engine water temperature not lighted, gauge and torque converter oll 2. Free the safety lock for work gauge are indicated. equipment control lever. Bring the work equipment in the traveling posture. ooOPERATING YOUR MACHINE CHANGING GEAR SPEED 4. Set speed control lever (3) and directional lever (4) to the desired position iw ani 3. Depress right brake pedal (1), 5. Release right brake pedal (1), Move speed control lever (1) to ‘and release the parking brake then depress accelerator pedal the desired positon using parking brake lever (2). (5) to move the machine off. —— os ‘on a slope, always turn the transmission cut-off selector ‘switch to OFF and depress the left brake pedal. Then depress ree @ ‘the accelerator pedal while * To use 1st or 2nd speeds for dig- ing the left brake pedal ging and. loading operations, to start the machine off slowly. actuate speed control lever stopper. -30-CHANGING DIRECTION There is no need to stop the ma- chine even when switching between FORWARD and REVERSE, Place directional lever (1) in the desired position, Forward Neutra IX reverse Asetore changing direc check that itis safe. AXNever change between FOR- 'WARD and REVERSE at high speed. TURNING When wheel (1) to turn the machine, traveling, use steering %* With this machine, the front frame is joined to the rear frame at the center of the machine by the center pin. The front and rear frames bend at this point, and the rear wheels follow in the same track as the front wheels when turning, + Turn the steering wheel lightly to follow the machine as it turns. When turning the steering wheel fully, do not turn it beyond the end of the stroke, -31- (OPERATING YOUR MACHINE Ait: is dangerous to turn the ma- ‘chine suddenly at high speed, or to turn on steep hills. This is particularly dangerous on hills, so never stop the when the machine isOPERATING YOUR MACHINE TO STOP THE MACHINE 1. Release accelerator pedal (1), 4. Fit safety lock (5) on the direc- and depress brake pedal (2) to tional lever. stop the machine 2. Place directional lever (3) in N Se (neutral) j Forwara SY eta 5. Operate work equipment control lever (6) and lower the bucket to 3. Pull parking brake lever (4) to the ground, then lock safety lock apply the parking brake. lever (7) for work equipment con- trol lever. * When the parking brake is ap- plied, the transmission is automa- tically returned to neutral —32-(OPERATING YOUR MACHINE TO STOP THE ENGINE AAstop the machine in a safe 1. Run the engine et low idling * If the engine is abruptly stopped place on firm level ground. If speed for about 5 minutes to before it has cooled down, the machine has to be stopped —_allow it to gradually cool down. engine life may be greatly short- fon a slope, put blocks under 2. Return starting switch (1) to the ened. Consequently, do not ab- the wheels. In addition, dig the OFF position and remove the key. ruptly stop the engine apart from bucket into the ground to in- an emergency. crease safety. en OF ‘In particular, if the engine has ‘overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop it oy aweas wr -33-(OPERATING YOUR MACHINE MAXIMUM DEPTH OF WATER When working in water or on swampy ground, do not let the water come above the bottom of the axle housing, ‘* After finishing the operation, wash and check the lubricating points, Axle housing IF WHEEL BRAKE DOES NOT work If the machine is not stopped by depressing brake pedal, use the parking brake to stop the machine. PRECAUTIONS WHEN DRIVING. UP OR DOWN SLOPES Lower the center of gravity when turning. ‘When turning on slopes, lower the work equipment to lower the center of gravity before turning, It is dangerous to turn the machine with the work equipment raised, Braking on downhill slopes ‘When going down slopes, put the speed control lever in a low gear Position (the same position as when driving up the slope). Make full use of the engine to slow the machine, and use only the right brake pedal. If the speed control lever is not placed in a proper speed position, the torque converter oil may over- heat. If it overheats, place the speed control lever in the next lower gear ‘speed to lower the oil temperature -34— It the temperature gauge does ‘ot indicate the green range of the scale even with the lever in the 1st speed position, stop the machine, place the lever in neutral, and run the engine at medium speed until the gauge indicates the green range. engine stops If the engine stops on a slope, dopross the right brake pedal fully. Next, lower the work equipment to the ground and apply the parking brake. Then put the directional and speed control levers in nerural, and start the engine again. (If the direc- tional lever is not in nuetral, the engine will not start)‘The boom kickout makes it possi- ble to set the bucket so that it auto- ‘matically stops at the desired lifting height (lft arm higher than horizon- tal) and the bucket positioner makes it possible to set the bucket so that it automatically stops at the desired digging angle. The setting can be ad- justed to match the working conditions. 1. Raise the bucket to the desired height, set the work equipment control lever at HOLD and lock the lever in position. Then stop the engine and adjust as follows, 2. Loosen two bolts (1), and adjust plate (2) so that the bottom edge is in line with the center of the sensing surface of proximity switch (3). Then tighten the bolts to hold the plate in position, = 35 — ADJUSTMENT OF WORK EQUIPMENT ADJUSTMENT OF WORK EQUIPMENT ADJUSTING BOOM KICKOUT 3. Loosen two nuts (4) to make 2 clearance of 3 to 5 mm between plate (2) and the sensing surface of proximity switch (3). Then tighten the nuts to hold in position. + Tightening torque: 1.78 0.25 kgm 4. After adjusting, start the engine and operate the work equipment control lever. Check that the lever is automatically returned to HOLD when the bucket reaches the desired height‘ADJUSTMENT OF WORK EQUIPMENT ADJUSTING BUCKET POSITIONER, 3. Loosen bolt (6) to give a clear- 5. After adjusting, start the engine ance of 0.5 to2 mm between bar —_—_and raise the lift arm. Operate the (2) and support (6). Then tighten work equipment control lever to the nuts to hold in position, the DUMP position, then operate % Tightening torque: it to the TILT position and check 1.75 +0.25kgm that the work equipment control 4. Loosen two nuts (7) and to make _—_—lever is automatically returned to a clearance of 3 to 5 mm be- HOLD when the bucket reaches tween bar (2) and the sensing _the desired angle. surface of proximity switch (3) Then tighten the nuts to hold in 1. Lower the bucket to the ground —_position. and adjust the bucket to the * Tightening torque: desired digging angle. Set the 1.75 = 0.25 kam work equipment control lever at HOLD, stop the engine and adjust as follows. 2. Loosen two bolts (1) and adjust ‘mounting bracket (4) of the prox- imity switch so that the rear tip Of bar (2) is in line with the center of the sensing surface of proximi- ty switch (3). Then tighten the bolts to hold the bracket in position. oYBUCKET LEVEL INDICATOR (A) and (B) at the top rear of the bucket are the level indicators, so the bucket angle can be checked uring operations, A: Parallel with cutting edge B: 90° to cutting edge -37- [ADJUSTMENT OF WORK EQUIPMENTHANDLING THE TIRES. PRECAUTIONS WHEN HANDLING TIRES If the following defects are found in tires, for safety reasons the tire should be replaced with a new tire. © Bead wire is broken or bent, or the tire is greatly deformed ‘© Wear is excessive and the car- cass ply (excluding breaker is ex- posed for more than 1/4 of the circumference. ‘© Damage to the carcass exceeds 1/8 of the tire width. ‘© Tire layors are soparated © Radial cracks reach the carcass © Deformation or damage which makes the tire unsuitable for use. Sidewalls~ HANDLING THE TIRES PRECAUTIONS WHEN DRIVING MACHINE When the machine travels at high speed for a long distance, the tires become extremely hot. This ‘causes early wear of the tires, so it should be avoided as far as possible. If the machine must be driven for a long distance, take the following precautions. ‘© Follow the regulations related to this machine, and drive carefully © The most suitable tire pressure, travel speed, or tire type differ ac- cording to the condition of the travel surface. Contact your Komatsu distributor or tire dealer for information, saps The following is a guide to suita- ble tire pressures and speeds when traveling on a paved sur- face with standard tires. Tire pressure: 2.8 kg/em* Speed: 25 1030 km/h (16 to 18 MPH) Check the tire pressure before starting, when the tire is cool. After traveling for 1 hour, stop for 30 minutes. Check the tires and other parts for damage; also check the oil and coolant levels. Always travel with the bucket empty, Never put calcium chloride or dry bollast in the tires when travelingTIRE PRESSURE Measure the tire pressure before starting operations, when the tires are cool. If the inflation pressure is too low, it causes overload on the tires; if the inflation pressure is too high, the tire may be cut or may burst under shock. Therefore adjust the inflation pressure to the values in ‘the following table. HANDLING THE TIRES. «¢ For operations on normal road surfaces, rock digging operations: High end of range in air pressure chart ¢¢ Stockpile operations on soft ground: . Average pressure in ar pressure chart ‘© Operations on sand (operations not using much digging force) Low end of range in air pressure chart If the deflection of the tre is excessive, raise the inflation pressure within the limits given in the table to give @ suitable deflection (see deflection ratio) * Stockpile operations mean the loading of sand and other loose materials, Tnflation pressure glen Tie size (pattern) | Ply rating Normal red When shipped around! | Stockpite | Digging | Mm feetory 165-25 2 Traction! i 17 ~ 28 ' ey 2 8-30 | 20-35 | 25-35 30 140-24 (2 Traction! 2 —39-HANDLING THE TIRES % Deflection ratio (detlection/free height) Hah x100 H: Free height bh: Height when loaded ‘As a guide for visual checks, the deflection ratio (deflection/free height) of the front tire should be as follows Normal loading and carrying operations (lift arm horisontal: ‘approx.15 — 25% Digging operations (rear wheels off ground): ‘approx.25 — 35% + When checking the tire pressure, check also for small cracks and damage, and for wire or small pieces of metal which may cause punctures. Check also for abnor- mal wear. % Operating costs can be reduced ‘and tire life increased by keeping the operating area in good condi- tion and free from fallen rocks. = 40 -TOWING THE MACHINE This machine must not be towed except in emergencies. When towing the machine, take the follow- ing precautions. Ait there is a faiture in the brake line, the brakes cannot be used, s0 be extremely careful when towing. TOWING When engine can be used. © Always keep the engine running when towing the machine, so that the steering and braking can be used, are TOWING When engine cannot be used. @ No lubrication oil flows in the transmission, so disconnect the front and rear drive shafts before ‘moving the machine. ‘© The steering cannot be used, so disconnect the steering cylinder and steering linkage. ‘* The machine should be towed only to the nearest place for in- spection and maintenance. Do not tow the machine for long distances.‘COLD WEATHER OPERATION COLD WEATHER OPERATION PREPARATION FOR LOW TEMPERATURE . ‘@ Change lubrication oll by that with prescribed viscosity. ‘© Fuel of low pour point shall be used. ASTM D975 No. 1 diesel fuel should be used at at- mospheric temperature lower ‘than — 10°C, ‘Add antifreeze in the cooling water When deciding the ratio of anti- freeze to water, check the lowest temperature in the past, and decide from the mixing rate table given below. It is actually better to estimate a temperature about 10°C lower when deciding the mixing rate. Mixing rate of water and antifreeze Min atmospheric Tempersture tet 15 |-20]-25 “Amount of ntireeze o as|e¢|7 |e |e | 10 Amount of ‘ar 155 1¢ [13 [2 | a1 | 10 Coolant capacity: 20% ~42— =9 Ah tae care tor 1) Permanent type antifreeze shall be used, 2) Soft water (ex: city water) shall be used as mixing water. 31 Cooling systems must be thor- oughly flushed before filling with antifreeze mixture. 4) When the climate becomes ‘warmer so that antifreeze (with- out corrosion inhibitor) is not needed, replace by clean water lex: city water) after perfectly cleaning the cooling system. as antifreeze is inflammable.Antifreeze Use 2 Parmanent Antifreeze (ethylene glycol mixed with corro- sion inhibitor, antifoam agent, etc) meeting the standard requirements as shown below. With permanent antifreeze, no change of coolant is required for a year. If it is doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for information. Standard requirements for perma- nent antifreeze + SAE sees. J1034 + FEDERAL STANDARD - O-A-648D * Never use any antifreeze made from alcohol which may be a cause of engine trouble. Where no permanent antifreeze is available, an ethylene glycol an- tifreeze without corrosion inhibi- tor may be used only for the cold season. In this case, coolant must be changed two times a year (at the beginning and at the fend of the cold season) Do not mix an antifreeze with one of different brand. Absolutely avoid using any water leak preventing agent irrespective of whether it is used indepen- dently or mixed with an antifreeze, Battery ‘As ambient temperature drops, battery capacity will drop, and electrolyte may sometimes freeze if battery charge is low. Maintain battery at a charge level of approx. 100% and insulate it against cold temperature so that machine can be readily started the next morning. =43- COLD WEATHER OPERATION + Measure specific gravity of fluid and obtain rate of charge from the following conversion table: orc [-10°¢-20°e|-a0re ¥28 [130] 1a | iae rar ]120| 129 | 120 125120 | 127 | 128 12a | 12s | 126 fray ‘* When electrolyte level is low, add distilled water in the morning before work instead of after the day's work. This is to prevent fluid from freezing at night. By To avoid gas explosions, do not bring fire or sparks near the battery. Ait the electrolyte gets on your skin or clothes, immediately wash with plenty of clean water.‘COLD WEATHER OPERATION STARTING IN COLD WEATHER: For the pre- and post-starting in- The table below gives a guide to 2. When heater signal (3) becomes spection, refer to the section preheating times. red-out, depress accelerator "OPERATING YOUR MACHINE" pedal (1) halfway and turn key eran” (2) to START position to start temperature eee engine, Ce °C 1 — 10° 20 seconds =10ct—20° | 30 seconde + The preheating time should not be too long or too short. Always start after proper preheating. 3. Release the key of starting 1. Place starting key (2) in HEAT po- switch (2, and the key will return sition to red-hot heater signal (3). automatically to ON. OF est OFF —44—(COLD WEATHER OPERATION CAUTIONS AFTER * Do not allow the starting motor COMPLETION OF WORK to run continuously for more 1. Mud and water on the machine 2. Drain water collected in fuel than 20 seconds. body should be completely system so that such water may + If the engine does not start up removed be frozen at night under the above procedure, Park the machine on concrete or 3. As battery capacity drops at low repeat steps 1 end 2 after wsiting hard ground. If this is impossible, ambient temperature, cover the for about 2 minutes. ark the machine on wooden battery or remove it from the ma- boards. This will prevent the ac- chine to be kept warm at night. Ai never use starting aid fluids as cessories from freezing to the they may cause explosions. ‘ground thereby preventing me- chine movement the next morn + The standard specification ma-_ing. Particular attention should be chine is designed to work in am- given to water drops collected on bient temperature from —20 to _the surface of the hydraulic cylin- 40°. er piston rods. Such droplets When operting the machine at must be fully wiped off because temperatures below —20°C, _if water's frozen to the rod when special equipment is needed. the cylinder is utilized, the cylin- Contact your Komatsu distributor der oil seals may be damaged. for details. 45 —PERIODIC MAINTENANCE Proper lubrication and maintenance assure trouble-free operation and long machine life. Time and money spent for scheduled periodic mainte- ‘nance will be amply compensated by prolonged machine operation and re- duced operating cost. All hourly figures given in the following descriptions are based on service meter readings. In practice, however, itis recommended to rearrange all of them into units of days, weeks and months to make the maintenance schedule more convenient. Under rough job site or operating conditions, itis necessary to somewhat shorten the maintenance intervals stated in this manual. -4a7— PERIODIC MAINTENANCEBLEEDING AIR FROM CIRCUIT BLEEDING AIR FROM CIRCUIT LEEDING AIR FROM HYDRAULIC CIRCUIT « After replacing oil iter element or strainer, bleed the air from the circuit. ‘© To bleed the air from the hydrau- lic cylinders or hydraulic piping, dos follows 1) Run the engine at low idling ‘and operate each hydraulic cylinder (steering, dump, lift) 4 to 5 times, stopping 100 mm from stroke end. 2) Next, operate each cylinder 3 to 4 times to the end of its stroke, then stop the engine and loosen the air bleed plug of the hydraulic tank to blood the ar. 3) Next, start the engine at high idling and repeat Step 2) to bleed the air. Continue this op- eration until no more air comes out from the plug. 4) After bleeding the air, tighten the plug to the specified tightening torque. Tightening torque: 1.15 + 0.16 kgm X ‘Airbleeding plvg w iA + If the engine is run at high speed at first, or if the cylinder is moved to the end of its stroke, the air in the cylinder may damage the piston pack- ing, ete, — 48 —The users of our machine should carry out periodi- cal maintenance in order to ensure the working and op- eration safety. Those parts, as listed on the right, which are closely connected with safety, must be re- placed periodically so that the highest safety standard can be maintained. ‘These parts with the passage of time have a great tendency to deteriorate in quality, and to wear ratter soar. Furthermore, their defective condition is difficult to detect during periodical maintenance. These parts must, therefore, be replaced with new ones after a pre- determined service period even though there is no ap- parent abnormality Wt goes without saying that if any abnormality should be found, these parts must be replaced or repaired even before the predetermined period expires. ‘The periodical replacement is completely different from the replacement due to the claim against the guarantee by the manufacturer, so they must be treat- ed separately, PERIODICAL REPLACEMENT OF SAFETY PARTS PERIODICAL REPLACEMENT OF SAFETY PARTS Safety pars for Replacement interval | Remarks Brake hose Every year Piston and packing oF svery year PRICE wi 2 | master evinder Every yoor repair kt Packing seals, O-rings of lever, 2 yeara 3 | steorng yinder Fro 4. | Runbor hose for stering cylinder very 2 years © | Fuetnose every 2 years =49-MAINTENANCE TABLE MAINTENANCE TABLE Ne. rem SERVICE No. Trem SERVICE [PAGE CHECK BEFORE STARTING © | Beckup buzzer Crwck fonction | 26 | Welk-sround check - 23 e | Electrical wiring Check 26 | Coolant Checkandsuppy | 22g | Water separator Cheek [2s | Engine oil pon Cheek andsuppiy | 24 | | 4 | Fost sonk Check andsuppiy | 24 EVERY 50 HOURS SERVICE : © | Dust indicator check 25a | Fuct tank ‘[ bginneerer | sa 7 [eeteorane coccenaupsy [2 0 | Te Cie TT | oy 3 | Parking broke | creck tuneton | 28 | Foor brake creck finetion | 26 EVERY 100 HOURS SERVICE 7 | Hom Creek function | 28 | Luoreting _ 5 1 [tomes (Cheek function 26 Bucketpin Lubricate 2p0ints | 55 + | Rearview miror Cneck 2 2 | Buekerlink in Lubriate2 pein | 65 {| exmavst eas and cofor Che 26 3 | Assraxle pivot pin brea 2 pointe | 66 mm | nstument here 2b | Hvarauictank =| Gheckandsuppiy | 66 1 | steering west [ eneek tay 26 | ~50- wosMAINTENANCE TABLE No. rem SERVICE Pace No, rem seavice [race INITIAL 250 HOURS SERVICE EVERY 500 HOURS SERVICE a | Fuel iter Repioce carridse | 87 _@ | Lubricating By | Trenton o ter Replace cement | 87 4 | Centerdrveshattapine | Lubricate pone | 63 € | Enineoltpan anainer | Seaneesland | 57-2 | Canterningo pin Lubricate points | 63 “a | naive vate clewonce Check arcade | 67 | Fuel fier | Replace cartiage | 63 T ¢ | Transmission oil filter Replace element 64 EVERY 250 HOURS SERVICE [ | 2 | Lubricating | 7 | 4 | Titov pin Lubricate 1 point | 58 EVERY 1000 HOURS SERVICE 2 | Dump cylinder pin Lubricate 2 points 7 s | Lubricating 65 Lit eytinge pn Lbriate@ pone | 88 Front driveshaft Lubricate 2 pointe | 65 To fue iter When float (2) is at or above red line (1), drain the water according to the following procedure: 1. Loosen drain plug (3) and drain the accumulated water until the float reaches the bottom. 2. Tighten drain plug (3) 3. f the air is sucked into fuel line when drain the water, be sure to bleed air in the same manner as for the fuel filter. (See Fuel Filter Cartridge in EVERY 500 HOURS SERVICE section)ADJUSTMENT ADJUSTING PARKING BRAKE Inspection Adjustment If 12 or more ratchets are count- ed before the parking brake comes into effect, perform the following adjustment. waasse -87- ADJUSTMENT 1. Move lever (1) back fully to release caliper (6). 2. Loosen lock nut (2) and remove levis pin (4), 3. Adjust with adjustment bolt (7) 0 that clearances (A) and (B) be- tween the disc and pad are each 0.05 — 0.2 mm,ADJUSTMENT 4. Push up by an amount equal to clearance of the caliper lever, and screw in clevis (3). Align the pin hole of caliper lever (6), then assemble clevis pin (4) and tight- en locknut (2). iz + Don’t tight adjusting bolt (7) too much + After adjusting, make sure that When the thickness (including there is no play of adjustment ining) of e pad wears out to 7 mm bolt (7) in the axial direction orless, replace the pad. + After adjustment, check the * Replace two pads as one set, and stroke when the lever is pulled replace the retraction plate (Blot (approx. 5 kg) three or fourclicks _the same time. ‘rom released position + Have the pads replaced by your Kemet ante Adtsii locking tn front of and behind the wheels Before ad. D0 not get any ol or grease on disc — 88 wozTROUBLE SHOOTING GUIDE TROUBLE SHOOTING GUIDE This guide is not intended to cover every conditions, however many of the more common possibilities are listed, ELECTRICAL SYSTEM ‘The voltmeters not stable while the engine is running at a con- stant speed. Lamp does not glow brightly even when engine runs at high speed Lamp flickers white engine runs. © Check for loose terminals and open-circuit wiring ‘© Adjust bet tension charge speed Replace the alternator. inspect and repair wiring. imp does not go out even when engine runs at high ‘Unusual noise is emitted from the alternator. © Replace the aterrator. ‘Starting motor does not turn when starting switch is turned on © Inspect and repsie the wiring Charge the battery ‘The pinion ofthe starting motor keeps going in and out. 1@ Charge the batory. ‘Starting motor turns the engine sl © Charge the battery (© Replace the starting motor. jahly =o ‘The starting motor disengages before the engine starts up. (2) Chock ans repair the wing ‘¢ Charge the battery. ‘The heater signal does not glow red. © Check and repair witing, {© piace tho neater relay. '© Roplace the heater signal The engine oil pressure pilot lamp does not light up when ‘engine is stationary (when the starting switch is in ON position.) {© oplece the lame, f© Replace the pilot lamp switch CCharge tamp does not light up when the engine is stationary. (When the starting switch isin ON position) 1© Replace the lamp. {© Inspect and repair the wiring Outside the electrical Intake air heater le not warm when ‘touched withthe hand. 1 Cheek and repair wiring‘TROUBLE SHOOTING GUIDE ENGINE Engine oll pressure caution lamp does not go off immediately fatter starting engine ‘Add the ol to the specified level, Replace the olelament. Check ol eakage from the pipe or the joint, Replace the lap. ‘Steam is emitted from the top part of the radiator (the pressure valve) ‘The engine cooling water temperature gauge indicates red ‘© Supply the cootig water and check eskage Adjust fan bet tension, {© Wach out insise of cooling system. Ciean or repsir the raciator fn, (© Replace the thermostat Tighten the radiator cap firmly or replace the gasket o it Replace the gauge. —90- not start when the starting motor ie turned (© Ropair where aris leaking into fuel system {© Replace tho injection pump or the nozzle © Check the vahe clearance 1 Check engine compression pressure f¢ Foferto the section of electrical system, Exhaust gas is white or blue © Adjust 1 specitied ol quanti. (© Replace with specified fue Exhaust gas occesionaly turns black. {Clean or replace the air cleaner element, Replace the nozzle '© Check engine compression pressure {© len or replace the turbocharger, Combustion noise occasionally cher (© Replace the nozzle 1s 10 breathing sound ‘Unusual combustion noise or mechanical noise, '© Replace with specified fuel Check over-heatng Feplace the muti (© Adjust valve clearance,CHASSIS. Transmission Engine is running but machine will not move, (© Release parking brake ‘© Put cirectional evar in position proper. ‘© Add ol to transmission case to the specified level Even at fll throttl, machine moves slowly and lacks power. 1¢ Add olto transmission case tothe specified level. 1 Disassemble ransmission strainer and clean Oiloverheats {© Add oto transmission case tothe specified ove or drain ol © Use eitable gear speed, 1 Reduce time using torque converter a tall speed Check engine. ‘Abnormal noise is produced '¢ Add ol to transmission case to the specified lave. Axle ‘Abnormal noise is produced. ‘© Add ol to asl case tothe specified level Disc brake [Brake does not work when pedal is depressed, © Replace cise © Ada brake oi {Bleed ai from brake system Brake drags or stays applied (© Adjust brake pedal ploy. TROUBLE SHOOTING GUIDE rake slips. (© Replace ise Parking brake Brake does not work proper (© Adjust inkage. (© Clean brake pad. Steering Stooring whee! is heavy. © Adjust storing gear (© Check linkage, replace parts, Hydraulic system Bucket lacks lifting power. Bucket lifting peed is slow. Addit Repl titer in hydraulic tank, ‘Many bubbles from no fe Replace with specified oi @ Ads ot (© Bloed ar fom iin.SERVICE METER SERVICE METER This meter indicates the in- tegrated work hours. So, use it ac- cording to the following inst- ructions. @ Record the readings at the start and the end of work, this is the work record of the machine. © This record will indicate, when periodical maintenance is due. @ It also indicates the integrated working hours when machine problems are encountered. + How the meter progresses The service meter progresses by 1 when the engine is operated for one hour, regardless of the engine speed Consequently, if the engine is running, the service meter will ad- vance even if the machine does not move. -92- wont[MACHINE AND ENGINE SERIAL NUMBERS, MACHINE AND ENGINE SERIAL NUMBERS When calling for a service of mechanic or when making replacement-parts order, be sure to give Komatsu distributor the ma- chine and engine serial numbers as well as the service meter reading before mentioned. These numbers are founds on the plates shown in the photos below. machine serial This is seen on the center right of the front frame. -93 ~ @ Location of the engine serial number mark This is seen on the left of the cylinder block, when seen from the fan side.FUEL, COOLANT AND LUBRICANTS FUEL, COOLANT AND LUBRICANTS PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERATURE CAPACITY (£) Reservoir | KIND OF a FLUID |22 -# aso t08 122 Sa ron 20 20-10 0B Eas a SAE Se Engine oil pan a SAE ION. 125 10.5 fe TT ST SAE 1 ow-30) f EE ae aoe ral Engine ot rim rake =|) 9 1 Sm nwa z E = ——= —- “Transmision ese Tee Tow 23 185 Hivdrautic system Ske iow m0 «3 ioe caer 16 | caen te {Front and rear) ey ef a | ran | oon ws SRL | ronan ASTM bee No 7 ED Cooling sytem | Water ‘Add antifonze a moaFUEL, COOLANT AND LUBRICANTS. Nore: (1) When fuel sulphur contents less than 0.5%, change (5) We recommend Komatsu genuine oil which has oil inthe ol pan every periodic maintenance hours been specifically formulated and approved for use described in this manual in engine and Hydraulic work equipment applica- Change oil according to the following table if fuel tions. sulphur content is above 0.5% (6) For axl oil, use only recommended oil 28 follows. SHELL DONAX TT or TD Fuel suiphur content | Change interval of oi CALTEX: RPM TRACTOR HYDRAULIC FLUID eee CHEVRON: TRACTOR HYDRAULIC FLUID O50 10% 17 of regular interval TeXACO: TDH OIL ‘Above 1.0% 1/4 of rogular interval MOBIC MOBILANU SUREG UNIVERSE EM ot regular inervel 4 is possibieto substitute engine oil CLASS-CD SAES0 {2} When starting the engine in an atmosphere tem- for axe ol perature of lower than 0°, be sure tuse engine ol If noise comes from the brake, its no problem of of SAETOW, SAETOW-20 and SAEISW-40, even durability though an atmospheric temperature goes up to 40°C more or less in the day time ASTM: American Society of Testing and Material (8) Use API classification CD as engine oll and if API «SAE: Society of Automotive Engineers classiestion CC, reduce the engine llchange inter. «AP American Petroleum Institute val to hal, (8) Thereisno problem ifsingle grade oil's mixed with Specified capacity: Total amount of ol including oil muttigrage ol (SAE10W-20, 18W-40), but be sure to for components and ot in piping. add single grade oil that matches the tempereture __—Rafill capacity: «Amount of oi needed t0 refill in the table on the lef. system during normal inspection and maintenance. wee 95 —SAFETY AND OPERATIONCONTENTS SAFETY HINTS - => db... PRECAUTIONS FOR MAINTENANCE BUCKET OPERATION LOCKING CAP HANDLING OF BATTERY TRANSPORTATION ‘STORAGE COOLANT AND LUBRICANTS 12 16 7 20 21 23OPERATION GENERAL © Wear well-fitting helmet, safety shoes and working clothes. If the nature of the work requires safety, wear protective goggles or mask, thick gloves, ear plugs or other protection. © Take care of your health. Do not operate when tired, or after drinking, © When there is a leader, fix stan- dard signals and always follow ‘these signals when operating, © Learn the prohibitions, cautions and rules about work procedures in the work site. ‘@ Read the Operation and Mainte- nance Manual carefully. Learn how to use the control devices, gauges and warning devices. Be sure you understand the meaning of the caution plates. SAFETY HINTS: -- A Protect yourself and others. Safety is always first. @ Confirm that all gauges and warning devices are functioning correctly, and that the gauge readings are within the prescribed range. @ Learn about the safety devices ‘on your own machine and about how to use them, ‘@ Never allow another person to operate the machine. @ If there should be an accident or fire or any other such unexpected mishap, deal with it quickly, using the nearest apparatus. Learn beforehand the locations of the first aid boxes and fire ext- inguishers and how to use them. It is also important to know the ‘emergency contact system, © Fuel or oil substances. are dangerous Never handle fuel, oil, grease or oily cloth in places where there is any fire of flame,CHECKING JOBSITE CONDITIONS. ¢ Examine the lay of the land and the kind of soil at the work site to determine the dangerous points and the best method of operation. Proceed with the work only after making safety arrangements about the dangerous points. © Do not work when visibility is re- duced by smoke, fog or dust. If the jobsite is dark, install lighting if necessary. ‘© Keep work site flat! By continually grading the work site, work efficiency will be im- proved and machines will be able to drive smoothly over the site. If the work site is very sandy or dusty, sprinkle water over the ground before working on the site Check the load limits of bridges before crossing. When operating @ machine in water or fording streams, survey the water depth, ground condi- tion and velocity of the water in advance. Do not take the machine in water exceeding the allowable depth (up to the underside of the axle housing). The overall height of the machine is restricted by tunnels, root height or overhead electric wires, 80 check first whether the jobsite is safe. Be particularly careful when working near power lines 2s electric shock can be caused i the machine touches the electric cables. BEFORE STARTING OPERATION CHECK BEFORE STARTING © Carry out checks before starting the machine. If any problem is found, do not start the engine, but inform the foreman immediately. Always keep the machine in good condition. ‘© Before operating the machine, be ‘sure to check the bar and pins for setting in storage position. The machine can not be steered with frames locked. {In articulate frame model) @ Always stop the engine when adding fuel. After adding fuel, tighten the fuel cap property. @ Inspect the inside of the en: room and remove any dead leaves or papers. Dead leaves or Papers are highly inflammable and can cause fires.# Do not leave parts or tools lying around in the vicinity of or on the floor of the operator's compart- ment. Keep everything in its proper place. Wipe off thoroughly any grease, oil or mud on the handrail, floor or control levers. Failure to do this may cause you to PRECAUTIONS WHEN GETTING ON THE MACHINE @ If the machine is fitted with ‘cab, make sure the windows are clean and check the visibility. Always lock the door before starting operations. © When getting on or off the machine, use the handrail and step provided. Do not jump up ‘onto or down from the machine. © If a seat belt is provided, always use it. If the belt is damaged or ‘worn, replace it with a new one. PRECAUTIONS WHEN STARTING THE ENGINE © Before starting the engine, con- firm that all control levers are in eutral position. ‘© Exhaust gas is dangerous. When working inside, be particularly Careful to have good ventilation. ‘© To ensure the safety of workers ‘near the machine, always sound the horn to warn them before starting the engine and moving the machine. Be particularly care- ful to check that the rear is clear before backing the mactCHECKS AFTER STARTING THE ENGINE © Before starting work, test drive the machine in a safe place and check that the transmission, brakes, accelerator, and steering are working properly. At the same time, check that there is ot abnormal noise or vibration, ‘or any abnormality in the instru- ments and gauges. DURING OPERATION Always sit in the operator's seat when operating the machine. # Do not allow anyone except the ‘operator on the machine. ‘© Always be aware of the operating capacity of the machine. Using the machine to do work beyond its capacity will not only damage the machine, but may even cause unexpected accidents. © The machine condition can be judged from many factors. Changes in the gauges, sound, vibration, exhaust gas color or re- sponse of the control levers can indicate the occurrence of some disorder. If any disorder occurs, park the machine immediately in a safe place and take appropriate action, ATTENTION TO SURROUNDINGS @ To ensure the safety of workers ‘near the machine, always sound the hom to warn them before starting the engine and moving the machine. Be particularly care- ful to check that the rear is clear before backing the machine. © Do not allow unauthorized per- sons into the work area. © Always concentrate. It is ex- tremely dangerous to allow your- self to be distracted or to think of other things when operating a machine. ‘© When loading trucks or hoppers, be careful not to hit the truck or hopper with the bucket. Do not bring the bucket over people's heads or over the cab of the truck.@ In dangerous places or in places where the visibility is poor, get down from the machine and check that it is safe before con- tinuing the operation. ‘© Always operate slowly in crowd- ed places. On haul roads or in narrow places, give way to loaded machines. @ When traveling, keep the work equipment close to the ground to ‘maintain the stability of the ma- chine, Pay particularly careful at- tention to the stability of the ma- chine when traveling with a load. ‘@ If the machine has to travel on rough ground, be careful to avoid obstacles as far as possible. © Always travel at a slow speed, and do not suddenly change direction Do not use the bucket as a brake except in emergencies. If the engine stops when the ma- chine is traveling, it is impossible to use the steering, This is dangerous, so apply the brake im- mediately to stop the machine. When traveling on hills with a loaded bucket, travel forward up the hill and in reverse down the hil. The machine should always be operated at a speed where it can be correctly controlled. Never do the following: * Speeding % Sudden starting, sudden brak- ing, sudden turning + Snaking * Coasting RESTRICTIONS CREATED BY JOBSITE # Do not approach the edge of the cliff or road shoulder. In dangerous places, always work in teams of two; one man to operate the machine, and the other to give instructions, © On windy days, always load downwind ‘@ When continuing operations after rain, remember that condi- tions will have changed from those before the rain started, so proceed with caution Be careful when working on the place made of piled soil, after earthquakes or after blasting © Always travel directly up or down slopes. When traveling down a slope, use the same geer speed as when going up the slope. When traveling down a slope, never put the transmission in noutralPARKING © If the engine stops on a slope, © Before starting towing opera- —@ When parking the machine, park apply the brake quickly and care- _tions, make sure that no one is _—it in a safe place outside the fully. Next, lower the work equip- near the machine. Start the ma- working area, or in the specified ment to the ground and apply the chine slowly to take up the slack place. The following factors parking brake. Then putthedireo- in’ the wire rope. Then start shouldbe considered when tional and speed control levers in towing carefully. Do not tow any choosing _@ parking place: it neutral, and start the engine machine whose brakes or steer- should be on flat, firm ground again ing have broken down, where there is no danger of rock- © Be careful when traveling on falls, landslides or floods. planks or steel plates, as these © If the machine has to be parked can cause slippage. ‘on a slope, it should be parked ‘¢ When operating at night, remem- facing directly up or down the ber the following points: slope, and chocks should be © Be sure to arrange an adequate placed under the tires, lighting system When leaving the machine, © Atnnight itis very easy to make always lower the work equipment mistakes in assuming the dis- completely to the ground, and tance and height of objects ut all control levers in neutral and land, ‘Next, apply the parking brake and © Before towing operations, lock all levers. Then put blocks always check the wire rope under the tires. @ After stopping the engine, always remove the starting key.PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE GENERAL ¢ Wear well-ftting helmet, safety shoes and working clothes. When dling, grinding or hammering, always wear protec- tive goggles. When working with others, choose 2 group leader and work according to his instructions. Do not perform any maintenance beyond the agreed work ‘¢ Hand @ caution sign in the opera- tor’s compartment (for example “Do not start” or “Maintenance in progress"). This will prevent anyone from starting or moving the machine by mistake ‘© Smoke only in designated places, Never smoke while working © Always keep the work shop in good condition. Make sure there is no mud or oil on the floor. ‘© Keep oily cloths and other com- bustible things in a safe place away from fire. In addition, learn the location and method of oper ation of fire extinguishers. '® Always stop the engine before cleaning the machine or adding fuel. ‘© Flame should never be used i stead of lamps. Never use a naked flame to check leaks or the level of oil, fuel, ant electrolyte. © Always use _non-inflammable cleaning agents when cleaning parts. BEFORE MAINTENANCE @ Before starting work, stop the machine on a firm, level surface, and use blocks to keep the ma- chine from moving during operations, ‘© Lower the bucket to the ground. If this is impossible, use the safety pin and blocks to hold the work equipment securely in position. In addition, apply the locks to all control levers. © Always lock the front and rear frames before inspecting and ser- vicing the machine. (in articulate frame model) © Remove all oil and mud from the machine. in particular, be sure that the steps, hand grips, and the floor of the operator's com- partment are clean, © Always use the standard ROPS equipment. Do not modify the ROPS equipment.DURING MAINTENANCE @ When getting on or off the machine, use the steps, hand grips and ladders. Never jump on Or off the machine. If the steps, hhand grips, or ladder cannot be used, use a stand to give firm footing @ If necessary, remove the cables from the battery terminals. When charging the battery, make sure the area is well ventilated. Exhaust gas is dangerous. When working inside, be particularly careful to have good ventilation. ‘© When opening inspection covers, stop the engine. If the hood or other covers are fitted with a lock, always apply the locks securely when opening or closing the hood or cover. @ Always stop the engine before adjusting belt tension or before checking or servicing the water pump. ¢ Be particularly careful when removing the radiator cap or the hydraulic oil tank filler cap. If this is done immediately after using the machine, there is a danger that boiling water or oll may spurt out. ‘© Always release the pressure in the circuit before checking or ser- vicing the oil, water or air circuits. © When the engine stops, the water and ol in the circuit is hot, 80 be careful not to get burned, Wait for the water and oil to cool before starting any work on the machine, PRECAUTIONS FOR MAINTENANCE MISCELLANEOUS @ Thoroughly wash the machine, particularly the oiling and greas- ing parts and the vicinity, thereof, in order to prevent the ingress of dust. © Use genuine Komatsu replace- ment parts specified in the parts list © Use Komatsu specified oil and grease. Use oil and grease having the recommended viscosity for the particular ambient temperature. @ Use clean oil and grease and keep them in clean containers to avoid the ingress of dust. @ Inspect or replace oil in a dust- free location to prevent the in- gress of dirt © Drain off used oil after heating it to @ suitable temperature (about 20 t0 40°C).PRECAUTIONS FOR MAINTENANCE © When the strainer is located in the oil filler, the strainer must not be removed while adding oil ‘© When adding oil or checking the oil level, check that the oil is at the correct level @ After greasing up, always wipe off the old grease that was forced out. @ When changing the oil or filter, check the drained oil and filter for any signs of excessive metal particles or other foreign materials. @ When removing parts containing O-rings, gaskets or seals, clean the mounting surface and replace with new sealing parts. When washing the machine, ensure that water does not get ‘onto the alternator. Special measuring apparatus is needed for testing hydraulic pressure, Thoroughly wash the machine. In particular, be careful to clean the filer caps, grease fittings and the area around the dipsticks. Be careful not to let any dirt or dust into the system. When check an open cover there is a risk of dropping things in, Before removing the covers to in spect cover, empty everything from your pockets. Be particularly careful to remove wrenches and nuts. =10- ‘© When working on the sea shore, carefully clean all electrical equip- ment to ensure that is does not corrode, ‘© Before working in muddy water, rain or snow, check that the vari- ous plugs, valves, are properly screwed up. Upon completion of work, wash the machine, then check the various parts of the machine for cracking, scratching, loose or missing nuts and bolts ‘Also, oil and grease the various parts of the machine, © When working on rocky ground, be careful of damage to the undercarriage, loose nuts and bolts, cracks, wear and other damage.@ When working in @ dusty loce- tion, be careful of the following: 1) Inspect the dust indicator to see Whether the ir cleaner is blocked up. Clean the air cleaner as soon as it becomes dirty. 2) Clean the radiator core so that it does not become blocked up. 3} Clean or replace the fuel filter as soon as it becomes dirty 4) Clean the electrical equipment, particularly the starting motor and alternator, to prevent ac- ‘cumulation of dust. ‘© When installing car radio and @ walkie-talkie or citizen band, con- tact your Komatsu distributor. ‘© When washing the machine, take care not to splash water over the electrical equipment. If it is soaked with water, it may not operate normally @ After disconnecting the con- rector, cover it with a vinyl bag to prevent oil or dust from stick- ing toits contact section ‘© When welding, be careful of the following: 1) Turn OFF the power (starting switch). 2) Do not continuously apply more than 200 V, 3) Install the ground cable at least 1 m from the range to be welded. 4) Take care not to install the seals between the grounded point and the range to be welded. + Use ordinary automobile washer fluid, Be careful not to let dirt or dust get in, ue PRECAUTIONS FOR MAINTENANCEBUCKET OPERATION BUCKET OPERATION Various types of attachments are available to extend the range of 2. After the bucket has fully application beyond the applica- penetrated into the soil, place the lift arm control lever in raise posi- tion while moving the machine EXCAVATION forward. Move the bucket control © Scoop up the piled soil by lever to tilt position from time to moving the machine forward as _time until the bucket is filled with shown below. If the tires begin _—_ soil. slipping under heavy load, raise the bucket slightly to reduce the load. 1. Force the bucket into the pile of soil while moving the machine forward. ‘When it is difficult for the bucket to penetrate into the piled soil, move the bucket control lever left and right to move the bucket teeth up and down.BUCKET OPERATION © In an excavating-loading opera tion on flat ground, move the ma- 2. Scrape the soil gradually by push- * When digging with the bucket, chine fornard with'the buckat ig te aft orm comet ever a aveldimpoatng the dgghg tose sso cia [asrs ei om ss fabvar[ whaslrnoina stem Uris cal ove ect in sal Seo conan nor pose the load on one ie Ainiover tig or 20009 when the only. machine body is articulated. 1. Direct the bucket teeth some- what downward from the horizontal. Precautions when scooping up materials. ‘When scooping up materials, be careful not to let the counterweight 3. Move the machine forward while at the rear touch the ground. adjusting the digging depth by * Do not allow tires slipping to means of the lift arm control occur during operation. Tires lever. ping shortens tire’s life. PPOGOM oD 709% O° worn ~13-BUCKET OPERATION LEVELING LOAD AND CARRY 1. Scoop soil into the bucket. Move OPERATIONS the machine backward while Load and carry operation is a spreading soil from the bucket series of processes (scooping — litle by tite. dump the bucket beyond 20°, carrying — loading to a hopper of 2. Go over the spread soil with the This will prevent quick wear glory hole) carried out by the wheel bucket teeth touching the and damage of the work equip-_ loader. ground and level the ground by _-mentand frame. + Always maintain the road in good back-dragging condition 3. Scoop some more soil into the bucket, put the lift arm in float, Aower the bucket to bring level the bucket at ground level, ‘down the center of gravity and smooth the ground by moving backward. * Always move the machine back- ward during leveling operations, -14-LOADING Select and proceed effective op- eration which avails less turning and the shortest hauling distance ac- cording to ground conditions. CROSS DRIVE LOADING When a wheel loader is operated, the digging should be made at a right angle toward accumulated soil When the scooping is completed, the machine should be traveled backwards as it is. Then, bring the truck between the accumulated soil and the wheel loader for the purpose of loading upon the dump truck. A Provide a fiat road tree of rocks and hollows. When the boom is raised with the bucket loaded, do not make quick turns or quick braking because it is very dangerous. Ado ‘not oad the bucket by thrusting into a pile of soil or Gravel at high speed because it is dangerous. 16 - BUCKET OPERATION \V-SHAPE LOADING Stop the truck with the angle of about 60° toward the scooping di- rection of the wheel loader. After scooping the soil, back the wheel loader in such a way that it makes a right angle to the truck. The loading fon the truck is made by the wheel loader going forward, ‘The smaller the turning angle, the higher the efficiency. However, turn- ing of 90° can be made if necessary.Lockine CAP LOCKING CAP A locking cap is available as an optional fuel tank cap or hydraulic tank cap. Open and close locking caps as follow: 1. To open the cap 2. Tolock the cap 1) Insert the key into the cap. 1) Turn the cap into place. * When the cap is locked (against * Insert the key as far as it 2) Turn the key clockwise and ——_vandalisml, it rotates freely. will go. If the key is turned take the key out before it is inserted all the way, it may break. 2) Turn the key counterclockwise land bring the rotor groove in line with the aligning mark on the cap. Turn the cap slowly until a “clicking” sound is made. This releases the lock and allows the cap to be opened. Aligning mark ‘Shoulder 16 - weenHANDLING OF BATTERY HANDLING OF BATTERY PRECAUTIONS FOR CHARGING BATTERY 1. Before charging, disconnect the 3. If the electrolyte temperature ex- 6. Do not mix up cables (positive cable from the negative (-) ceeds 45°C, stop charging fora (+) to negative (—) or negative terminal of the __ battery, while, (=) to positive (+), as it will Otherwise, an unusually high vol- 4. Turn off the charger as soon as _-damage the alternator. tage will damage the alternator. the battery is charged. 7. When inspecting or servicing 2 2.While charging the battery, Overcharging the battery may battery, be sure to stop the remove all battery plugs for satis- cause followings: engine and tun the starting factory ventilation. 1) Overheating the battery switch key to “OFF” position. To avoid gas explosions, do not _—2) Decreasing the quantity of 8. When performing any service to bring fire or sparks near the electroiyte. battery besides checking the battery. 3) Damaging the electrode plate. electrolyte level or measuring the 5.1f the electrolyte gets on your specific gravity, disconnect skin or clothes, immediately cables from the battery. wash with plenty of clean water, woner WeHANDLING OF BATTERY REMOVAL AND INSTALLATION OF BATTERY ‘¢ When removing battery, first cis- connect the cable from the ground (normally, from the neg: tive (=) terminal. If a tool touches a cable connecting the positive terminal and the chassis, there is danger of sparks being emitted @ When installing battery, the ground cable should be connect- ed to the ground terminal as the last step. STARTING ENGINE WITH A BOOSTER CABLE When starting up the engine with a booster cable, do as follows: 1. Before connecting the booster cable 1) Size of booster cable and clip should be suitable for the bat- tory.size 2) Check cables and clips for breaks, corroded surfaces, etc. 3) Make sure cables and clips are firmly secured. 4) Keep the starting switch in “OFF” position. 5) The battery of the running engine must be the same capacity as that of engine to be started aoe 2. Connect the booster cables in the following manner. 1) Connect one clip of booster cable A to the positive (+) terminal of the engine to be started. 2) Connect the other clip to the positive (+) terminal to the engine which is running. 3) Connect one clip of booster cable B to the negative (—) terminal of the engine which is running. 4) Connect the other clip to the engine block to be started. %* Make sure the clips are firmly connected to battery terminals. Then, start the engine. o Battery for Battoy for engine running engine @ tobertarted Engine block to be waned, ==liaise eae never contact the positive (+) Amare sure that the booster cable connections are correct. Connect the booster cable to ‘the engine block as far as possi ble from the battery. 3. Starting engine 1) Turn the starting switch to START position and start up the engine. 2) f the engine doesn’t start at first, try again after 2 minutes or so. After the engine has started, the booster cables should be dis- connected in the reverse order in which they were connected. 1. Disconnecting the booster cables 1) Disconnect the clip of booster cable B from the engine block which was started, 2) Disconnect the other clip from the negative (—) terminal of the running engine. ai ce HANDLING OF BATTERY 3) Disconnect the clip of booster cable A from the positive (+) terminal of the running engine. 4) Disconnect the other clip from the positive (+) terminal of the engine which was started. -19- ‘Engine block which wes sare wd Tor engine which was started ©TRANSPORTATION TRANSPORTATION ‘When transporting the machine, observe the v good idea to obtain a speci chine. When it is unavoidably neces ious road rules, road ransportation vehicle laws and vehicle limit ordinances, etc. Itisa | platform for loading and unloading the ma- ry to use a gangplank, however, at the very least observe the following for the sake of safety. 1. Properly apply the brakes on the A, Remove the mud from the un- trailer and insert blocks beneath —dercarriage to prevent the m the tires to ensure that it does chine from slipping to the side not move. Then fix the gangplenk _onlopes. in line with the centers of the trailer and the machine A. bo not on any account change ‘+ Make sure the gangplank has suf- the direction of the machine ficient width, length and thick- while itis on the gangplank. To ness to enable the machine to be change the direction of the ma- safely loaded and unloaded. chine, first take it down from If the gangplank sags apprecia- _the gangplank. bly, reinforce it with blocks, ete. 2. Determine the direction of the 3. Correctly load the machine onto gangplank, then slowly load or —_the specified part of the trailer. unload the machine. 4. Lower the bucket and lock each * When transmission cut-off _control lever using safety lock. switch is put in OFF, the left 5. Lock front frame and rear frame brake pedal and accelerator —_with safety bar. pedal are operated at the same time. = 20- 6. When transportating the ma- chine, place blocks underneath the front and rear wheels to pre- vent the machine from moving about Also, hold it down with chains or wire ropes. % Determine the route for trans- porting the machine by taking into account the width, height and weight of the machine. Ai wren loading the machine, park the aller on a fat firm Foadbed. Keop fly long di tence between the read shoul dor andthe machineBEFORE STORAGE To place the machine in storage for an extended period of time, the following measures must be taken to insure that it can be returned to operation with minimum of service, © After every part is washed and dried, the machine shall be housed in a dry building. Never leave it outdoors. In case itis indispensable to leave it outdoors, lay wood plates on the ground, and park the machine fon the wood plates and cover it with canvas ete. ‘© Completely fill fuel tank, lubricate and change oil before storage. STORAGE Apply @ thin coat of grease to metal surface (hydraulic piston rods and splined shaft) ‘As to batteries, remove the termi- nals and cover them, or remove ‘them from the machine and store separately. When the ambient temperature is anticipated to drop below 0°C, always add antifreeze in the cool- ing water. Set each control levers to neutral or hold position, lock them and apply the parking brake. ore STORAGE DURING STORAGE ‘© Operate the engine and move the machine for a short distance once a month so that new oil film will be coated over movable parts and component surfaces. © Before operating the work equipment, wipe off the grease (on the hydraulic piston rod. Adi it is unavoidably necessary ‘to carry out rust-preventive op- eration while the machine is indoors, open up doors and win- dows to improve vetilation and prevent the gas poisoning.‘STORAGE AFTER STORAGE After storage [when it is kept without cover or the rust-preventive operation once a month is not made, you shall apply the following ‘treatment before operation, @ Wipe off the grease on the hy- draulic piston rod. ‘© Loosen the drain plugs on oil pan and other cases and drain mixed water. © After the engine is started, oper ate it until it is warmed up completely © You should request Komatsu dis- tributor for following service. © Remove the cylinder head cover and lubricate sufficiently valves and rocker arms. And inspect the valve operation, Engine with turbocharger only Remove the oil pipe flange on the turbocharger oil inlet, fill with 0.5 to 10 engine oil, and leave the flange lightly loosened, Then, rotate the engine by the starting motor without fuel injection and decompression so that the discharger of oil is con- firmed. Then, tighten the flange and start the engine. —22-COOLANT AND LUBRICANTS COOLANT AND LUBRICANTS Engine oi! Bee a eaeceg Pe “ ‘even ferns i eee ll Permanent Type KOMATSU £0304 eu { re io Diesel sigma S — a : 5 thotine WEP 2 = 6 o RPM delo 450 Ultra-duty grease 2 -23~‘COOLANT AND LUBRICANTS Engin OF (Borers rome No] supper SAE OM 3,40 ‘uaa (The 15W40 oil (AGI No. 2 motel | conoco + Ret motor ot Suporte goa - ttinedormance 36 rns eP 0 a Performance 3C ‘Tranself EP type 2 Glocett oe 08 SEiathe kos 1] Bexon {Eats 0:8 era cae 2 A seson coolant + Eis noe ony boon hen day Super dy moor ot Guterown EF2 | cur Sage ety ctr Saison EF Antec and eootnt onl 300 Mois Era t3| most Pleo enor Mablarese 72 - ‘owt, ewso | Moblresse seco -24-COOLANT AND LUBRICANTS Engine Oi cD or ce} foaune ‘SAETOW, 90, 40 a caer No. Supper rosters Wish Basel [ethylene Giycot {The 18040 oil nn = saried "is CE) Permanent Type ‘Supreme dy Meio 708, ‘A-teeze and 1 * Supreme duty ite gronee ot 0028 a a) Gao “eet motor ot | 707L Wake ‘summer coolant Bearing arease 15| PETROFINA FINA kappa 1D FINA marcon €PL2 FINA tamidor ve] sae imate x ‘Avania EP groaso 5 ‘Sunoco ultra aa oe : prestige 2EF Sond simmer olant Sun protige 782 a * ures super plus Mutifok £2 (Code 2055 stores al eet Urs peoriurn Starplon 2 fnitrente coolant 19] Tora eeee Muti €P2 Artigoinstrecze * Rubia x 20 uwoN * Guardol ‘Unobe EP -

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