‘SEAM02250600 KOMATSU PC2050-6 HYDRAULIC EXCAVATOR SERIAL NUMBERS PC20-24001 PC30-10001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 in- dicated with 4). 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 and tested before shipment. However, ‘a new machine requires careful operation during the first 100 hours to break in the various parts, If a machine is subjected to unreasonably hard use at the initial operation stage, the potential of performance will prematurely deteriorate and the ser- vice life will be reduced. A new machine must be operated with car Llarly with regard to the following items. @ After starting, let the engine idle for 5 minutes to allow proper engine warm-up prior to actual operation. ‘© Avoid operation with heavy loads or at high speeds. © Sudden starting or acceleration, unnecessarily abrupt braking and sharp turning should be avoided. © Atthe first 50 hours of operation, ‘the machine should be main- tained in the following manner in addition to usual 50 hours service. 1)Replacement of hydraulic oil filter element 2) Cleaning of hydraulic tank strainer @ At the first 250 hours of opera- tion, the machine should be main- tained in the following manner in addition to usual 250 hours service: 1) Checking and adjustment of ‘engine valve clearance 2) Changing of engine oil pan oil, final drive case and swing machinery case oil {3} Replacing engine cil pan oil partic % 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 OIL FILLER AND LEVEL GAUGE POSITIONS CHECK BEFORE STARTING OPERATING YOUR MACHINE REPLACEMENT OF BUCKET COLD WEATHER OPERATION CONTENTS 4 19 20 24 37 38 MAINTENANCE PERIODIC MAINTENANCE MAINTENANCE TABLE INITIAL 80 HOURS SERVICE EVERY 50 HOURS SERVICE EVERY 100 HOURS SERVICE INITIAL 250 HOURS SERVICE EVERY 250 HOURS SERVICE EVERY 500 HOURS SERVICE EVERY 1000 HOURS SERVICE EVERY 2000 HOURS SERVICE WHEN REQUIRED HANDLING RUBBER SHOES... SERVICE METER MACHINE AND ENGINE SERIAL NUMBERS. FUEL, COOLANT AND LUBRICANTS: a 42 45 45 47 48 49 54 57 59 61 68 72 73 74GENERAL LOCATIONS AND SPECIFICATIONS GENERAL LOCATIONS AND SPECIFICATIONS 1. Bucket 6. Boom cylinder 2. Bucket cylinder 7. Sprocket 3. Arm 8. Track frame 4, Arm cylinder 9. Track shoe 5. Boom 10. Front blade With cab PC20-6 ( ):PC30-6 Operating Weight With canopy 2838 kg (3235 kg) With ROPS cab 2936 kg (3335 ka) Performance Bucket capacity (SAE) 0.08 m? (0.10 m*) (CECE) 0.07 m* (0.09 m*) Travel speed 2.4 km/h (High: 3.6 kra/hy Low: 2.1 km/h) ‘Swing speed 10 rpm (11 rpm) Engine Mode! Komatsu 3084-1F Diesel Engine (Komatsu 3084-16 Diesel Engine) Flywheel housepower/Rated rpm 28.6 HP/2600 rpm (29.6 HP/2700 rpm) NOTE: Speciiestions er subject to change without note.METERS AND LAMPS 1, SERVICE METER, fame I ane |) es INSTRUMENTS AND CONTROLS INSTRUMENTS AND CONTROLS This meter shows the total opera- tion hours of the machine. The ser- vice meter advances while the engine is running — even if the ma- chine is not traveling Refer to the section “SERVICE METER”. 2. ENGINE WATER ‘TEMPERATURE GAUGE When indicator is in the green range during operation, water tem- perature is normal. ‘After engine start-up, warm up the engine until indicator moves into green range. If indicator moves from green into red range during operation, run the engine at low idling speed until indicator returns green range.INSTRUMENTS AND CONTROLS 3. FUEL GAUGE 5, ENGINE OIL PRESSURE 6. THERMOSTART SIGNAL LAMP WARNING LAMP O- This gauge indicates the amount Normally this lamp is out during When the starting switch is of fuel in the fue! tank. operation. If it comes on during turned to HEAT, thermostart signal operation, the oil pressure has lamp will come on, thus indicating 4. CHARGING LAMP dropped. In such a.case, immediately _thermostart is heated. The lamp will stop the engine and check the go off inapprox. 18 seconds. cause of the trouble, 4 Normally this lamp comes on when the starting switch is tuned to the ON position and gradually go ‘out as the engine speed increases,SWITCHES 1. LAMP SWITCH INSTRUMENTS AND CONTROLS 2, WIPER SWITCH With lamp switch in position I panel lamps will ight, With lamp switch in position I, head lamp and working lamp will also light. This switch is used to turn on the front windshield wiper. ON: For operationINSTRUMENTS AND CONTROLS. 3. CAB HEATER SWITCH This switch is used to heat the operator's cab. The flow of warm air can be adjusted in 2 steps: H: Strong L: Weak: * The cab is heated by means of warm water from the engine. Accordingly, heating can not take place while the engine cool- ing water is warming up. 4, STARTING SWITCH ext OF Se BX 6) was OFF Key insertion-withdrawal_posi- tion. None of electrical circuits activate. on Charging and lamp circuits acti- vate. Keep key at ON after starting. START [At this key position, the starting motor will crank the engine. Release key immediately after starting. HEAT Use this position when starting in cold weather. Release the key to allow it to return automatically to OFF and then, without delay, turn it to START,INSTRUMENTS AND CONTROLS 5. HORN SWITCH 6. ROOM LAMP SWITCH ON <=> oFF a= When this switch is pressed, the When this switch is moved to ON horn will sound. position, room lamp will ight. ue -9-INSTRUMENTS AND CONTROLS LEVERS AND PEDALS 1. SAFETY LevERS ‘he safety levers oe used telock 2, LEFT WORK EQUIPMENT fforworkeaulpmentlovers) _thework equipment ver. ever : {arm/swing control lever) Biwien stopping the machine or Teaving the machine, be sure to Lock lower the bucket to the ground, bag 8 then operate the levers to lock the lett and ®) Neutral When the lever in this position, the upper works and the arm willbe retained in the position in which they stop, ‘Arm operation @® Arm moves out. ® Armmovesin ‘Swing operation © Upper works swings to the right. ® Upper works swings to the left,If the swing/boom swing selector lever isin the boom swing position. Boom operation © Boom swings to the right. ) Boom swings to the left. INSTRUMENTS AND CONTROLS 3, RIGHT WORK EQUIPMENT LEVER (boom/bucket control lever) 4, TRAVELING AND STEERING LEVERS A ® Neutral: ‘When the lever in this position, the boom and the bucket will be ‘The traveling and steering levers are used to operate the left and right travel motors. retained in the position in which (DForward: they stop. Push the levers forward. ® Reverse: Boom operation Pull the levers backward, @ Boom raises. Neutral Parking brake is applied and the machine stops. ® Boom lowers. Bucket operation ® Bucket dumps. ® Bucket curls =nINSTRUMENTS AND CONTROLS 5. SWING/BOOM SWING 6. BLADE CONTROL LEVER SELECTOR LEVER Ait the wack frame is fecing _Whon switching this lever, the Leverpostion backwards, operate the travel- left work equipment control lever is): LOWER ing and steering lovers In the used t0 swing the boom and the). RAISE reverse manner to that when upper works. (W : NEUTRAL, ‘the track frame is facing ‘): Boom swing operation. Blade is stopped and held in this forward. ®: Swing operation. position. ABetore operating the traveling ‘and._steering levers, _ check Whether the tack frame. is facing forward or backward. Assuming the machine is in @ position to advance by means of being the sprocket at the rear. -12- Pane7. FUEL CONTROL LEVER 8, TRAVELING ACCELERATOR PEDAL (Only for PC30) This lever is used to control the _If the pedal is depressed, the ma- engine speed and output. chine speed will increase, @_ Low idling position: Push the lever fully ® High idling position: Pull the lever fully Posts =13- INSTRUMENTS AND CONTROLSINSTRUMENTS AND CONTROLS DUST INDICATOR FUSE BOX 9. SWING Lock LEVER The fuses protect the electric devices and. wiring from burning Q out. I any fuse is rusted or coated with white powder. replace it. a. When this lever is placed to the lock poston, the Upper works is This device indicates clogging of focea the ait clener slement. When red S"Guing lock tver must bein ock ston {tT eppearenthetcnenaceet position during traveling of part of this indicator, the element is mmochine Clogged Immediately ceenslement| Loosen bolt {1) and remove 4 Thslever ust bein thelockpo- "After soaring’ “push” indomor cover Sion afer the upper works f= button (2) to retum ed piston to. Replace @ fuse with another of porate withthe wack Fame engl positon ae aera ust indoator is on air cleaner Ai. not attempt to rotate the brecketin engine hood Airetore reptacing fuse, be le escenario ture to turn off tho starting (au lover iin the took switch -14-Fuse arrangement er L 204 Room lamp: " aoe eae : @ cy 208 Engine stop motor - 16 = INSTRUMENTS AND CONTROLS OPERATOR'S SEAT 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 over 120 mm in 6 stages.INSTRUMENTS AND CONTROLS ® Backrest adjustment Pull lever (2) in the direction of arrow, move the backrest to the desired position and release the lever. Location of tool kit, The tool kit is kept behind the operator's seat. OPERATOR'S SEAT (Bucket type reclining seat with armrest) Forward-backward adjustment Set the seat in the disired position by moving lever (1) to the direction Of arrow; then release the lever. ‘The seat can be adjusted forward or backward 160 mm fin 9 steps) = 16- Seat cushion adjustment Move knob (2) until clearance be- tween tip of chain (3) and frame be- comes zero, Seat is now adjusted in the most comfortable condition. Backrest adjustment Set seat in desired position by pulling lever (4) upward, then release lever.DOOR Lock To hold an open door stably, use 2 door lock. The door will be held Positively when pushed against catch (1). In order to release the door, depress the black button (2) in the operator's cab. FRONT WINDOW, ‘The upper part of the front window can be opened and closed. To fully close the front window (when washing the machine or during rainfall), close the upper part and ingert the center sash between the upper and lower parts. ni INSTRUMENTS AND CONTROLS. CEILING WINDOW Ceiling window is opened by releasing the lock in the direction of the arrow and pushing the ceiling window.INSTRUMENTS AND CONTROLS LOCKING CAP ‘The fuel tank filler port is equipped with a lock, + Use the starting key to open and close the cap. Open and close locking cap as follows: © To open the cap, 1. Insert the key into the cap. + Insert the key as far as it will go. If the key is turned before itis in- serted all the way, it may break. 7 I Tum the kay counterclockwise, align the match mark on the cap with the rotor groove, then remove the cap. To lock the cap. Shouider . Turn the cap into place. Tum the key clockwise and take the key out. Sag PawnOIL FILLER AND LEVEL GAUGE POSITIONS OIL FILLER AND LEVEL GAUGE POSITIONS 1. Swing machinery case level gauge and oil filler Final drive case drain plug Final drive case level plug 4, Swing machinery case drain plug 5. Fuel tank oil filler 6. Hydraulic tank oil filer 7. Engine oll pan oi filler 8. Cooling water inlet 9. Cooling water drain valve 10. Engine oil pan drain plug B. ee: at -19- 11. Engine oil pan level gauge 12. Hydraulic tank level gauge 13. Hydraulic tank drain plug 14. Fuel tank drain valve i \ 1413121110 9(CHECK BEFORE STARTING CHECK BEFORE STARTING re-operation checks forestall machine trouble. Never neglect them. a. WALK-AROUND CHECK b. CHECK AND REFILL COOLANT 1. Check for oil leak at high pressure hose, high pressure hose joints and hydraulic cylinder seal. 2. Check swing machinery case for oil leak. 3. Check hydraulic tank for oil leak. 4. Check final drive case for oil leaks. 5. Check radiator for water leak. 6. Check around the engine for water and cil leaks. 7. Check tightness of exhaust pipe Check thelevelofhe coolant. J, Do not open the radiator cap mounting bok The water level must be between “-~ unless necessary. When check: 8. Check tightness of battery the FULL and LOW marks on sub- ing the coolant, always check terminal tank (1, H the lve is t00 low, add when the engine is cold (check 9. Check tightenss of air cleaner water to sub-tank (1). the sub-tank). mounting bolt. —20- Pastcc. CHECK OIL LEVEL IN ENGINE Check the engine oll level. The oil level should be between H and L of ‘gauge (G). ‘% When checking the oil level, park the machine on a level surface, stop the engine and wait for 15 minutes before checking, + The type of lubricant used depends on the amibient tem- perature. Select according to the tabel “FUEL, COOLANT AND LUBRICANTS” . CHECK FUEL LEVEL Check the fuel level using sight gauge (G). Upon completion of work, pour in additional fuel from filler until the fuel tank is full. + If breather hole in the cap is blocked up, fuel flow to the engine may stop. Accordingly, clean it from time to time. + Feul capacity: 50.9 + When filing with fuel, do not let the fuel overflow. This may cause fire. -21- (CHECK BEFORE STARTING @. CHECK AND REFILL OF OIL IN HYDRAULIC TANK Run the engine at low speed, re- tract the arm and bucket oylinder, lower the boom until the tips of teeth touch the ground and then stop the engine,‘CHECK BEFORE STARTING 1803 aces eR 2. Check the oil level in the hydraulic system. ‘The oil level should be between top H and bottom L lines of sight gauge (G). + The type of lubricant used depends on the ambient tempera- ture. Select according to the table "FUEL, COOLANT AND LUBRICANTS: {. CHECK DUST INDICATOR When air cleaner element is clogged, the red piston of dust in- Gicator (1) reaches service level and gets locked. In that case, clean element refer- ring to the section "WHEN REQUIRED”. After cleaning element, buttom (2) to return red piston. = 22- push 9g. CHECK FOR SEDIMENT AND WATER IN THE WATER SEPARATOR Check for water with red ring (1) inside the water separotr. % If there is water inside the water separator, red ring (1) will float to the surface of the water, so drain the water as follows,1. Place handle (2) to the CLOSED position, 2. Loosen ring (3), then remove case (4) and throw away the water inside it. 3. install case (4) and tighten ring @) 4 Drain the water and sediment from the fuel tank. See EVERY 50 HOURS SERVICE. h. CHECK ELECTRICAL WIRING Check for any sign of disconnec- tion or short circuit in the electric wiring. Check elso for loose termi- nals and tighten any loose parts. Check the following points carefully © Battery # Starting motor © Alternator -23- CHECK BEFORE STARTINGOPERATING YOUR MACHINE OPERATING YOUR MACHINE BEFORE STARTING THE ENGINE TO START THE ENGINE 1. Put the traveling and the steering 9. Check that the blade control 1. Pull the fuel control lever ttle control levers in the N (neutral) leveris at the neutral poston towards you trom the low idling position positon. ; tet lowing Forward = ei A avers } q Nc Oi . i 2. Put the left and right work equip- 2, Tum the starting Key to. the ment levers in neutral and check START positon that the safety levers are locked. —24- aie3. When engine is started, release the starting key and the key will return automatically to ON. we 1 A. &) + Hf engine wil not stat, repeat the starting procedure after 2 minutes, 4 Do not leave the key in START formore than 20 seconds + iF the engine has been warmed up, it is possible to start it by put- ting the fuel control lever in the ow idling position. awss Special starting When starting after running out of fuel, fll with fuel, then fill the fuel filter cartridge with fuel and bleed the air from the fuel system before starting. Rofer to FUEL FILTER in EVERY 500 HOURS SERVICE, = 25 = OPERATING YOUR MACHINE STARTING AT LOW TEMPERATURE 1. Check the oil level in the termos- tart fuel tank. 2. Fully pull the fuel control lever. Low iting(OPERATING YOUR MACHINE 3. Move the key to HEAT position, 5. Release the starting key, and the If the engine does not start up and thermostart signal lamp will key will retuin automatically to under the above procedure, come on. The preheating will be ON. repeat steps 3 and 4 after waiting completed in approx. 18 ore for about 2 minutes seconds, and the lamp will go off ve at the same time ‘ % Airever use starting aid tuids as iN they may cause explosions. bY 4. Then turn the key in the START 6. Put the fuel control lever in the position and start up the engine low idling position, — 26 —CHEKS AFTER STARTING After starting, make the following checks 1, Run the engine at low idling speed, and check that the engine oll pressure warning lamp has ‘gone out. | 2. Pull the fuel control lever and run the engine at medium speed. Low iting ~“ Mecium speed 3. Free the safety lever of the bucket control lever. 4. Leaving the bucket control lever in either pushing or pulling side, tun the engine for about 5 mi- nutes to warm up the hydraulic oil = OPERATING YOUR MACHINE Avoid abruptly accelerating the engine until the completion of warm-up. ‘After warm-up run is completed, check gauges, warning lamp for proper operation, Check if the exhaust color is normat or whether there is any abnormal noise or vibration, Do not run for more than 20 mi nutes at low idling or at high idling(OPERATING YOUR MACHINE TO MOVE THE MACHINE OFF 1. Put the swing lock lever into the lock position by pushing the lever down, 3. Free the safety levers of left and right work equipment levers, ‘move the work equipment in and raise it to a height of about 40 to 50 cm, 2. Pu the fuel conrl lever to it~. Pll he bade cont lever and crese angie speed rise the ble eae Las ee es are 5. Slowly incline left and right tabel- ing and the steering levers in the forward {forward moving off) or reverse (revers moving off) direc- tion, and move off. Fervor Reverse Zp 6. Depress the accelerator pedal (only for PC30) to increase travel speed.OPERATING YOUR MACHINE TURNING AX check whether the track frame (CHANGING DERECTION) When changing direction with ma: is facing forward or backward Operating the travel levers to chine stopped before operating the traveling change direction. Operated the two travel lovers as follows. “Turning eft wien When the sprockets are at the traveling forwars (= traveling and steering levers front, the operation of the travel with the fuel control lever fully levers. is reversed, so before ‘open, as this will cause the ma- _operating the travel levers, check chine to move off suddenly. ‘the position of the sprockets. * Avoid sudden changes in direc- tion as far as possible. When car- ring out conterrotation turns (spin tums}, stop the machine first before turning it. % When changing direction in places where there is large resis- tence to turning, do not use the ‘travel booster pedal. (only for P30) When tuming left, operate the RIGHT travel lever as follows. When traveling FORWARD, push lever FORWARD. When __ traveling REVERSE, pull lever BACK. % When turning right, operate the left travel lever in the same way. sin = 29-OPERATING YOUR MACHINE 19 direction when traveling (when both left and right travel levers are in the same position) %, When turning to the left, retum the left travel lever to neutral, and the machine will tum to the left (pivot turn). + When turing right, operate the right travel lever in the same way. When making a counterrotation ‘turn (spin turn) When turning to the left on the spot, pull the left travel lever back ‘and push the right lever forward. When making a counterrotation turn to the right, pull the right travel lever back and push the left lever forward ~30- SWING OPERATIONS ‘Always check that the surround- ing area is safe before swinging the upper works, 1. Before swinging, pull out the swing lock lever and release the lock. ‘* Beofre starting swing operations, always check that the lock is released. 2. Use the left work equipment con- trol lever to swing the upper works. + Never insert the swing lock lever when swinging,OPERATING YOUR MACHINE OPERATION OF THE WORK 3. When not swinging, align the EQUIPMENT ARM OPERATION upper works with the track The work equipment is operated frame, and insert the swing lock using the right and left work equif lever to lock the upper works. ment control levers, and blade con- trol levers. ‘The left work equipment control lever controls the arm, the swing and boom swing operation and the right work equipment control lever ‘controls the boom and the bucket If you release the lever it returns to the neutral position and the work * Do not operate the swing lock — equipmentis held in that position. lever in any other position. % When switching swing/boom swing selector lever, the left work equipment control lever is used to swing the boom and the upper works. Arwen operating the work caulpment, do not depress the # I tho swing/boom swing selector travel accelerator pedal. only lever isin the (@) postion for PC30). rose -3t-OPERATING YOUR MACHINE BOOM OPERATION BUCKET OPERATION y TO STOP THE MACHINE BOOM SWING OPERATION 1. Put the left and right traveling ‘and the steering levers in the neu- tral position. ‘* If the swing/boom swing selector 2, Lower the engine speed using lever is in the (A} position. the fuel control lever. tow ing BLADE OPERATION S\N High tog Si 32- assoTO STOP THE ENGINE 3. Lower the bucket horizontally — 1 until its underside touches the ground. 4. Lock the work equipment levers 2. with the safety levers. 5. Lower the blade to ground. Aiwien stopping the machine, feloct flat hard ground and avold dangerous places fiefs tinavoidably necessary to park the machine on a slope, invert ee aes are eee Shoes. As an additionel safety measure, thrust the, bucket into the ground. Run the engine at low idling speed for about 5 minutes to allow it to gradually cool down. Return the starting key to the OFF position stop the engine and remove key. < oF Am “R if the engine is abrupty stopped before it has cooled. down, engine ife ry be greatly short ened Consequently, do not ab- rupty stop the engine apart from an emergency. In particule f the engine has dverheated, do not abrupty stop iv but run fat medium speed to allow it t0 coal gradually, then stop —33- OPERATING YOUR MACHINE PRECAUTIONS FOR OPERATION @ Be careful not to compact the soil or damage earth mounds as aresults of the swining force. ¢ When swinging, do not dig the bucket teeth into the soil ¢ Do not move off and excavate with the bucket leaving dug into the ground. © When working with the machine, do not move the cylinder to the ‘end of its stroke but leave a small safety margin, ‘¢ Do not use the dropping force of the bucket as a pickaxe, breaker, or pile driver. ¢ Do not use the dropping force of the machine for digging. ¢@ tis better to excavate hard rocky ground after breaking it up by some other means. This will not only reduce damage to the ma- chine but make for better ‘economy.(OPERATING YOUR MACHINE @ Never allow the blade to butt — @ Note that the following phenom against, or give strong impact. To _na are not faults: do such work will damage the 1) When the arm is pulled back, it blade and the hydraulic cylinder. will sometimes stop when be- ‘© Never hit the blade by the bucket _ comes more or less vertical, because they interfere in lowering 2) The arm may sometimes stop and retracting for moving and when the bucket teeth become transportation. ‘more or less horizontal ‘@ Do nt support the machine on 3) At the beginning and end of a teisee fone end of the blade to use it as swinging, a noise may sometimes an outrigger. bbe emitted from the brake valve, @ Do not immerse the machine in ‘© Do not hit the boom cylinder 4) When descending a steep slope _—_wateer by more than the permissi- against the blade when digging at low speed, a noise may some- _ble depth (under swing circle (1) the deep ditch in front of the times be emitted from the travel _In addition, properly grease parts blade. Back hoe work should be motor. which have been immersed in carried out after keeping the water for a long time, until the blade to the opposite position of JI it is necessary to use the old grease comes out from the the bucket. ‘equipment control levers when —_bearings (vicinity of bucket pins, ‘the machine is traveling, tem- swing circle system, etc) porarily stop the machine, then ‘operate the work equipment. —34— esse* When removing the machine from water, if the machine is given a posture of climbing at 9 steep angle (less than 30 de- ‘grees, however), the rear part of the upper swing body may dip into the water, with its radiator fan scooping up water. In that event, the fan may break. Be sufficiently careful when removing the machine from water for this reason © When traveling down a hill adjust the speed with the travel lever and fuel control lever. If the grade exceeds 15°, set the machine in the posture shown in the diagram above, and reduce the engine speed, Y20 ~ 30em A.2% not travel on slopes of over 30° as thore fe danger thet the machine may overt. @ To. brake the machine during downhill runs, put the traveling and steering lever in the neutral position. This will cause the brake to be automatically applied. @ When climbing a hil, if the shoes slip or the travel motor relieves, preventing the machine from climbing by means of the tracks alone, it is possible to use the force of the arm as an aid. @ When the engine stops on a slope, move the traveling and steering levers to neutral position and lower the bucket. Thereafter, turn starting key to START. @ When the engine stops on a slope, the boom will move by it's ‘own weight if the swing lever is, moved. Therefore, do not move ‘the swing lever under any conditions. —35— OPERATING YOUR MACHINE HOW TO ESCAPE FROM MUD ‘© Always operate carefully to avoid getting stuck in mud. If the ma- chine does get stuck in mud, use the following procedures to get ‘the machine out, ¢ When one side is stuck. When only one side is stuck in mud, use the bucket to raise the track, then lay boards or logs and drive the machine out. If ne sary, put a board under the bucket also. ‘* When using the boom or arm to raise the machine, always have the bottom of the bucket in con- tact with the ground. (Never push with the teeth) The angle be- tween the boom and arm should be 90° to 110°,OPERATING YOUR MACHINE © When both sides are stuck. When the tracks on both sides are stuck in mud and the machine will not move, lay boards as ex- plained on the left, and dig the bucket into the ground in front. ‘Then pullin the arm as in normal digging operations and put the travel levers in the FORWARD position to pull the machine out. PRECAUTIONS WHEN USING RUBBER SHOES @ When traveling, avoid traveling over sharp objects or over stones on the road, and avoid using the machine in unstable conditions. @ Turing suddenly on road sur- faces with a high friction coeffi- cient (uch as concrete) will cause the rubber shoes to break. ¢ Do not rub along concrete walls when driving @ Be careful not to let oll get stuck ‘on the rubber shoes. If there is any oil on the shoes, wipe it off immediately. @ When storing for long periods, keep indoors away from direct sunlight and rain @ The adhesion of the metal core is. attacked by salt, so avoid using near the sea. © Because of the properties of rubber, use the rubber crawler within a range of —25°C to +58°C = 36 -REPLACEMENT OF BUCKET REPLACEMENT OF BUCKET ‘Stop the machine on a firm, flat surface. When performing joint work, ‘make clear signals to each other and work carefully for safety’s sake. 1. Select a flat surface and stabilize 3. Couple the arm to hole (1), then the bucket, connect the link to hole (2). 2. After removing the stop bolt and 4. After mounting the stop bolt and nut for each pin, extract pins A nut for each pin, apply grease to and B. each pin. % After removing the pins, make sure that they do not become contaminated with sand or mud and that the seals of bushing on both sides do not become damage pease -37-COLD WEATHER OPERATION COLD WEATHER OPERATION PREPARATION FOR LOW TEMPERATURE Change lubrication oil by thet @ Add antifreeze in the cooling + Cautions for using antifreeze with prescribed viscosity. water 1) Permanent type antifreeze shall ‘¢ Fuel of low pour point shall be When deciding the ratio of anti-_beused used. ASTM D975 No. 1 diesel _freeze to water, check the lowest 2) Soft water (ex: city water) shell fuel should be used at at- temperature in the past, and be used as mixing water. mospheric temperature lower decide from the mixing rate table 3) Cooling systems must be thor- than — 10°C. given below. oughly flushed before filing with It is actually better to estimate a antifreeze mixture temperature about 10°C lower 4) When the climate becomes when deciding the mixing rate warmer so that antifreeze (With- out corrosion inhibitor) is not Mixing rate of water and anti- needed, replace by clean water freeze (ex: city water) after perfectly 9 cleaning the cooling system smospheric epee Ai Take care for fire as antifreeze Tamgunt ot snateese | 12| 15] 18 | 2 is “mer | 3e| 35 | 32 | 29 Coolant capacity: 5 2 —38- i)Care in using antifreeze Use a Permanent 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 antirfreeze + SAE J1034 + FEDERAL STANDARD 0-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 tend of the cold season) Do not mix an antifreeze with a 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 the ambient temperature drops, the battery capacity will drop, and electrolyte may some- times freeze if the battery charge is low. Maintain the battery at a charge level of approx. 100%, and insulate it against cold tem- perature so that machine can be readily started the next morning, ~39- ‘COLD WEATHER OPERATION + Measure the specific gravity of fluid and obtain the rate of charge from the following con- version table: ate | 2orc | orc | —10rc| 20% REN | 22 | oe | ee|-27¢ voox | 128 | 128] 190 | 131 sox | 126 | 127] 128 | 129 sox | 124] 125] 126 | 127 15% | 123 | 124] 125 | 126 + When electolyte level is low, add distiled water in tho morning before work instead of after the day's work. This is to prevent ‘uid from freezing at night. Ai1o avoid gas explosions, do not bring fire or sparks near the battery. If the electrolyte gets on your ‘skin or clothes, immediately wash with plenty of clean water.(COLD WEATHER OPERATION CAUTIONS AFTER COMPLETION OF WORK 1. Mud and water on the machine body should be completely removed, Park the machine on concrete or hard ground. If this is impossible, park the machine on wooden boards. This will prevent the ac- cessories from freezing or the track and undercarriage from freezing to the ground thereby preventing vehicle movement the ext morning, Particular attention should be given to water drops collected on the surface of the hydraulic cylinder piston rods. Such droplets must be fully wiped off because if water is frozen to the rod when the cylin- der is utilized, the oylinder cit seals may be damaged. 2.Drain water collected in fuel system so that such water may be frozen at night. =40-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 -41- PERIODIC MAINTENANCEMAINTENANCE TABLE MAINTENANCE TABLE te re senvice [Paseo ew senvice pace CHECK BEFORE STARTING EVERY 60 HOURS SERVICE 7 [were ek 7a | Fane Bain mawrond [ap [coolant Check and supply | 20 | Out eum ‘clean a | Engine oil pan Check and supply. a ¢ | Lubricating - 46 a | Fut tank Check and-supply | 21-1 | Swing cele pinion “[ tubrcate point | 46 | Hydraulic tank Check and-suppiy | 21 EVERY 100 HOURS SERVICE 1 | but iene chek | ermine @ | wer pomr Check 22 __~1] Boorrawing cng oot in a tein wing cet 2a] boomeviner foot sn a (eee INITIAL 60 HOURS SERVICE ral Boom foot in tute point | 3 | vera ter wot werent | 45-5 | Boomawing acer pin | wabeenea pores | 47 Se ee | Boomevinderodend | tatreaes pon | #7 “| fim eine foot in Lusetate point | #7 y 8| Arm cylinder rod end - Lubricate 1 point 47 -42—MAINTENANCE TABLE Ne eM seavice [pace rrew senvice [pace “a| soomarm eoupingpin | Lubrente tpi | 7 INITIAL 250 HOURS SERVICE “Tol suctsevtnaeriocton | tumnexnipom [7 a | Eronocteanmatner [RASTER | 8 “11| euctarevindervodena | tatrcate + point _| 47 Fina rive cae Change ot «6 12) Link coupling pin Lubricate t point | 47 {| Swing machinery case Change ol 8 “13| Bueketink coupling in| tvbrewet poi | 47” | Engine ave trance Cheek and acne | 48 “ra[ Armbueketcouping pin | Lbreawe tpoie | 7 Core t point | 47 EVERY 250 HOURS SERVICE Lariene 1 point | 48 Fraidivecoe ___[erwckandwnny | 49 17 | toe oyna foot in Lure pine | 48 Fan ol Check tension | 8 18| Blade 001 pin Looriate2poins | 48 Hydrate fer Replace element | £0 | sing echiney ene Check ond wpe | 42 | Battery teewolne Cheek tuidiew | 81 1 | ter sepaatreterent | Clan = mann -43-MAINTENANCE TABLE No rem SERVICE [PAGE Wo vem Senvice EVERY 600 HOURS SERVICE WHEN REQUIRED fol [Exe aes [enlere c/n iaa Bea) | (mau indesto Shee shen rewured_| 8 [Ereneotpen natin | ShammecTard= | se a] coatngsystam ian = Rociator fins lean 56 | Track Creckond adios Tos : 56 d | Bucket teeth Replace er 1 [Sena cre Uiveeapoin| 88 EVERY 1000 HOURS SERVICE | ® | Final drive case Change oll 37 ~ 1b | Swing machinery case ‘Change oi 37 - EVERY 2000 HOURS SERVICE — = [rau Seected [as © [Alara an ring motor] Cck a [Ero vaieciornn | Orckandacir | 44INITIAL 50 HOURS SERVICE Perform the following mainte- nance after running the machine for the first 50 hours. a. HYDRAULIC FILTER b. HYDRAULIC TANK STRAINER For details of the method of replacing or maintaining, see the section on EVERY 250 HOURS AND 2000 HOURS SERVICE. Simultaneously, maintenance for 50 hours should be carried out. INITIAL 50 HOURS SERVICE EVERY 50 HOURS SERVICE EVERY 50 HOURS SERVICE a. FUEL TANK b. AIR CLEANER DUST CUP Loosen valve (1) on the bottom 1. Remove dust cup (1), dispose of the tank so that the sediment and _—the dust init, mixed water will be drained in ac- 2, Clean inside of the cup. compeniment with fuel, = 45 —EVERY 50 HOURS SERVICE ¢. LUBRICATING Apply grease to the grease fit- tings shown by arrows. 1. Swing circle pinion —_—_(1 point) Tum the chassis slowly and apply grease through the grease fit- ting under the front face of the panel. — 46EVERY 100 HOURS SERVICE ‘* Maintenance for e EVERY 100 HOURS SERVICE ry 50 hours should be car- ried out at the same time. a. LUBRICATING Apply grease to the grease fit- tings shown by arrows. \ \/ 964 vas -47- 10, "1 12, 13, 14, 15, Boom-swing cylinder foot pin (1 point) Boom cylinder foot pin (1 point) Boom-swing cylinder rod end (1 point) Boom foot pin (1 point) Boom-swing bracket pin (2 points) Boom eylinderrod end (1 point) ‘Arm cylinder foot pin (1 point) ‘Arm cylinderrodend {1 point) Boom-arm coupling pin (1 point) Bucket cylinder foot pin (1 point) Bukcet cylinder rod end (1 point) Link coupling pin (1 point) Bucket-link coupling pin(1 point) ‘Arm-bucket coupling pin ( point) ‘Arm-link coupling pin (1 point)EVERY 100 HOURS SERVICE INITIAL 260 HOURS SERVICE 16, Blade cylinder rod end. (1 point) 17. Blade cylinder foot pin_(1 point) 18. Blade foot pin (2 points) b. SWING MACHINERY CASE Day Check the oil level in the swing ‘machinery case. The cil level should be between H and_L of gauge (G). % Check that dipstick (G) is com- pletely inserted in. * The type of lubricant used depends on the ambient tempera- ture. Select according to the table "FUEL, COOLANT AND LUBRICANTS". ae INITIAL 250 HOURS SERVICE Perform the following mainte- nance after running the machine for the first 260 hours, a. ENGINE OIL PAN AND FILTER b. FINAL DRIVE CASE c. SWING MACHINERY CASE d. ENGINE VALVE CLEARANCE For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS, 1000 HOURS AND 2000 HOURS SERVICE.EVERY 250 HOURS SERVICE EVERY 250 HOURS SERVICE % Maintenance for 50 and 100 hours should be car- out at the same time. a, FINAL DRIVE CASE b. FAN BELT 1. Set the machine with plug (F) * The type of lubricant used 1. The belt tension should normally £/ (Crankshett puley uit —49—EVERY 250 HOURS SERVICE Ts 2. To adjust the belt ten * bolt (1) and nut (2) and shift alter- nator (3) slightly. When adjusting the V-belt, do not attempt to push alternator (3) directly with a bar or the like, but use a wood pad to prevent damage to the core. Check each pulley for damage, and V-grooves and V-belt for wear. Particularly, check whether V-belt is in contact with bottom of V-groove through wear. Replace belt if it has stretched, leaving no allowance for adjust- ment, or if there is a cut or crack con bot Oe ¢. HYDRAULIC FILTER 1. Gradually loosen cap (F) of the oil filler to relieve inner pressure, 2. Remove the bolts (2) and cover @)0 [S 5 Na 3. Remove element (1) and replace it with a new one after cleaning the removed parts and the case interior. Zs when removing the cover, Undo the bolts (4 bots) gradual. iy to prevent the cover tiving OM under the force. of the toetog. d. BATTERY ELECTROLYTE 1. Remove the cap. 2. lf the electrolyte level is lower than the prescribed level (10 to 12 mm above the plate), supply distiled water. + Should any of the acid be spilt, have it replenished by the neerest battery shop with acid of the cor- rect specific gravity. + When inspecting electrolyte level, clean the air hole of the bat- tery cap. -51- EVERY 250 HOURS SERVICE Ait te etectotvte gots on your Skin or clothes, immediately ‘rach with, plenty of clean ae AiTeeveia gas exptosions, do not bring Tre or sparks near the amareEVERY 250 HOURS SERVICE AIR CLEANER ELEMENT 1. Remove clip (1) and dust cup (2) 2. Remove wing bolt (3) and ele- ment (4). Clean the element, inside of the case and the dust cup, and install them, * Cover the air inlet port when removing element. Be sure to assemble seal washer (5) when mounting element. Install the dust cup holding it's arrow mark upward. Replace the element which has been cleaned 6 times repeatedly or used throughout a year. Replace seal washer (5), wing bolt (3) if they are broken. Ad%% rt clean or replace the sir ‘cleaner element engine running. with the —52— Cleaning element ‘With compressed air = Direct dry compressed air (less ‘than 7 kg/cm’) to element from inside along its folds, then direct it from outside along its folds and again from inside, and check element. Aiwren using compressed air, wear safety glasses and other tinge required. to. maintain safety.EVERY 250 HOURS SERVICE {. WATER SEPARATOR ELEMENT ‘% If small holes or thinner parts are 1. Tighten handle (1) found on element when it is 2. Loosen ring (2), then remove checked an electric bulb —_case (3) and the element. after cleaning and drying, replace 3. Clean the inside of the case and the element, the element with diesel oil + Do not use element whose folds 4. Install the element and case (3), or gasket or seal are damaged. then tighten ring (2). * When cleaning element, do not —_ Be careful not to lose the red ring hit it or beat it against something inside the case. 5. Open handle (1) Passe -53-EVERY 5OO HOURS SERVICE EVERY 500 HOURS SERVICE a, FUEL FILTER 1. Loosen the ring (1) and take the clement out of the filter, using the service tools furnished with ‘the machine. 2. Wash element cup (2) in light oil or ina cleaning oil and install a new element in the filter. * When replacing a fuel filter ele- ment, replace the filter O-ring at the same time ‘* Maintenace for every 50, 100 and 250 should be carried out at the same time. Turn the starting switch key to the ON position. Push air bleed button (3) of the fuel filter, and continué to press it Until no more bubbles come out ‘rom the air bleed hose. Push air bleed button (4) of the injection pump inlet port, and continue to press it until no more bubbles come out form the air bleed hose, When no more bubbles come out, turn the starting switch key to the OFF position. ‘When the machine has been out of use for 2 long time, bleed the air also before starting the engine. eae », i 3 ENGINE OIL PAN AND FILTER To facilitate filter replacement, stop the engine after turning the upper frame a little (about 30°) Remove the drain plug (P) to drain oil. After draining, tighten- ing the drain plug. Using a filter wrench, remove car- tridge (1) of the engine oil filter by turning it counterclockwise. If filter cartridge (1) is removed immediately after stopping the engine, oil will spill, Wait at least 10 minutes after stopping the engine before replacing the filter cartridge.Engine ol fiter carwisge 4, Clean the filter base and fill 6. Run the engine for a short time at new filter cartridge with engine idling, then stop the engine and oil. Then, apply engine oll to the leave ‘for about five minutes. seal Measure the oil level and check %* To install cartridge, bring its that itis between H and L marks packing surface into contact with on the gauge. sealing surface of filter base and Refill capacity: 4.2 @ then tighten cartridge 1/2 to 3/4 The type of lubricant used ‘turn by hand, depends on the ambient tempera- 5. After replacing the cartridge, ture. Select according to the our in the specified quantity of table "FUEL, COOLANT AND engine oil from oil filler (F) LUBRICANTS”, esse = 85 — * EVERY S00 HOURS SERVICE Be sure to fit a genuine Komatsu cartridge. Replace once every 6 months, regardless of the number of hours operated. When fitting the cartridge, be careful not to tighten it up excessively. Uso API category CD class oil. If CC class oil must be used, ‘change the oil and replace the oil filter at half the usual interval (250 hours)EVERY 500 HOURS SERVICE c. RADIATOR FINS. dd. LUBRICATING Apply grease to the grease fit- ‘tings shown by arrows. 1. Swing circle (2 points) Ee Clean the radiator fins clogged with mud, dust and leaves with compressed air. Steam or water may be used instead of compressed air. % The rubber hose should be checked at the same time. If the hose is found to have cracks or to be hardened by ageing, such hose should be replaced by new one, Further, loosened hose clamp should also be checked. eeEVERY 1000 HOURS SERVICE a. FINAL DRIVE CASE 1. Set the machine with plug (F) and plug (P) perpendicular to the ground surface, 2. Drain the oil from drain plugs (P) fon both sides of the machine. After draining, tighten the drain plugs. 3. Remove plug (1) and supply new engine oil through oil filler (F) re- spectively to the specified level Refer to EVERY 250 HOURS SERVICE) EVERY 1000 HOURS SERVICE ‘# Maintenace for every 50, 100, 250 and 500 hours should be carried out at the same time. * The type of lubricant used depends on the ambient tempera- ture. Select according to the table “FUEL, COOLANT AND LUBRICANT: + Refill capacity: 0.75 leach side) —57- b. SWING MACHINERY CASE 1. Drain off oil from drain plug (P) at the bottom of the machine. After draining, tightening the drain plug,EVERY 1000 HOURS SERVICE 2. Pour in the specified amount of | Refill capacity: 13¢ engine oil from gauge hole (F) (Refer to EVERY 100 HOURS SERVICE) + The type of lubricant used depends on the ambient tempera- ture. Select according to the table "FUEL COOLANT AND LUBRICANTS”, =58- PastEVERY 2000 HOURS SERVICE a, HYDRAULIC TANK 1. Retract the arm and bucket cylin- der, then lower the boom and put the tips of the teeth in contact with the ground. 2. Remove drain plug (P) to drain Off the oil. After draining off the oil, tighten up drain plug (P) EVERY 2000 HOURS SERVICE ‘* Maintenance for every 60, 100, 250, 500 and 1000 hours should be carried out at the same time. 3. Loosen hose band (1) and bolt (2), Remove flange (3) and wash the strainer (¢) 4. Pour in the specified amount of engine oil from oil filler. Refer to CHECK STARTING) + The type of lubricant used de- pends on the ambient tempera- ture. Select according to the table “FUEL COOLANT AND LUBRICANTS". % Refill capacity: 352 BEFORE -59- @ \ + After changing oil, put the control levers in N (neutral) position and run the engine at low idling speed for a few minutes before opera tion of work equipment.EVERY 2000 HOURS SERVICE b, ALTERNATOR AND STARTING MoTOR ‘As the hours of engine employ- ment indicate that the brushes are already worn out, you should re- quest repair from a Komatsu distributor. % They should be repaired every 1000 hours, if the machine is fre- quently operated at night. . ENGINE VALVE CLEARANCE Ask Komatsu distributor to check engine valve clearance be- cause special tools should be used, —60-WHEN REQUIRED a. CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT (with dust indicator) Checking ‘Whenever the red piston in dust indicator (1) appears, clean the air cleaner element. Stop the engine ‘when cleaning the element. Cleaning or replacing element WHEN REQUIRED 1. Remove clip (1) and dust cup (2) 2. Remove wing bolt (3) and ele- ment (4). Clean the element, inside of the ‘case and the dust cup and install ‘them: 3. Push the dust indicator reset button to return the red piston to the original position, ~e1- Cover the air inlet port when removing element. Be sure to assemble seal washer (5) when mounting element. Install the dust cup holding it's arrow mark upward. Replace the element which has been cleaned 6 times repeatedly or used throughout a year.Wien REQUIRED * Replace seal washer (5), wing bolt (3) if they are broken. Bio not clean oF replace the air Fe as at ar ongine runing. Cleaning element With compressed air Direct dry compressed air (less than 7 kg/om*) to element from inside along its folds, then direct it from outside along its folds and again from inside, and check element. Aiwren using compressed air, ‘wear safety glasses and other things required to maintain safety -~62- If small holes or thinner parts are found on element when it is checked with an electric bulb after cleaning and drying, replace the element. Do not use element whose folds ‘or gasket or seal are damaged. When cleaning element, do not hit tor beat it against something.[WHEN REQUIRED b. CLEANING INSIDE OF Water filler COOLING SYSTEM © Clean the inside of the cooling system, replace the antifreeze, and add the corrosion resistor agent KI, according to the table. © Change water after first parking the machine on a level surface. 1. Stop the engine, turn radiator cap (1) slowly until it comes off. 2, Loosen drain valve (2) at the bottom of radiator and drain plug Type of ontitreze earings ot ‘Ading comosion (3) at the side of cylinder block sais feplaeing anttreeze resatorogent I and drain off the cooling water. Every 1000 hours and when cevyectnmemner _ [Sememtocericn | Aw ste wae tomporaure to Permanent type antifreeze | every 2000 hours whieh 2" | Cooling stam a ere high, do not remove the cap. ‘comes first replecing antifreeze - : This is because of the possibili- ther parmanent ype | Exar month oring, | var 1090 haus and wen ty of scalding water spurting snletzgafetvere | Shtrgeantitece ony | cooing tm ord nan out. ‘navn | Flcon tose When removing the cap, turn Every yarns or | Exar 1000 hours and when the cap slowly to allow pres- when otesingantoee. | srry 2000hour wacheer | ern teat ofthe sure tobe relieved. cmt ae Soong syst . ost —63—WHEN REQUIRED Drain valve (radiator) Drain plug (cylinder block) ‘Sub-tank 3. After draining the water, close 5. After washing the cooling 7. After washing the cooling drain valve (2) and drain plug (3), system, stop the engine. Open system, drain off all the water, then pourin water to fil the radia- drain valve (2) and plug (3) to _then close up drain valve (2) and tor. When the radiator is full, drain water and close drain valve plug (3) and pour in clean water start the engine and run itat low —_(2) and plug (3) (ex. city water! slowly up to the idling. 6. After draining off the cooling vicinity ofthe water filler 4. Keep the engine running at low water, wash out the cooling 8 When the water reaches the idling, open drain valve (2) and system using commercially _ vicinity of the water filler, put the drain plug (8), and flush with run- available detergent. Follow the in- engine at low idling, open the ning water for 10 minutes. structions on the detergent drain valve (2) and plug (3), then % When flushing, adjust the flow container. pass water through the cooling so that water is added at the system until clean water comes same rate os the water s drained ut from the drain valve and plug to keep the radiator always full = 64— Passe‘When flushing, adjust the flow so that water is added at the same rate as the water is drained to keop the radiator always full. 9. When the water becomes com- pletely clean, stop the engine and close the drain valve (2) and plug (3). 10. Add the specified amount of the corrosion resistor agent KI to the radiator. + Use a genuine Komatsu corro- sion resistor agent. For details of the adding procedure, follow the instructions on the agent, 11. Supply water until it overflows, from water filler 12. 13, 14, Run the engine 5 minutes at low idling and then for another 5 minutes at high idling to eli nate air trapped in the cooling system leave radiator cap off during this operation), After draining water in sub-tank (4), wash the sub-tank interior, ‘and supply water so that the water level is between H and L marks. Stop the engine and wait for about 3 minutes. Supply cooling water up to the specified level Tighten the cap. Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. 65 — ‘WHEN REQUIRED ©. CHECK TRACK TENSION The wear of pins and bushings fon the undercarriage will vary with the working conditions and soil properties. It is thus neces- sary to continually inspect the track tension so as to maintain the standard tension on If the track tension is not at the standard value, adjust it in the fol- towing manner:‘WHEN REQUIRED Inspection 7 Raise the machine by means of the boom and arm, and measure the clearance between the tread of the 2nd track roller from the sprocket and the roller contact face of the track link Ifthe clearance is between 30 and 50 mm, the track tension is normal Adjustment For tightening the tension, pressurize grease through lubricator (1). On the other hand, for loosening the tension, extract grease by reversely rotating lubricator (1) gradually. oe Grease may be pressurized till S will be O mm. In case the tension is yet loose after applying pressurized injection of grease till the above- mentioned limit, it indicates that the pin bush is reduced by too much abrasion. So it is necessary either to turn or replace the pins and bush- ings. Consult your Komatsu distribu- tor for repair.wen REQUIRED d. REPLACE BUCKET TEETH Replace the teeth before they weerdown, 0% not loosen the ubricator (1) 1. Reise the bucket to 8 suitable Tightening torque of mounting ‘over one complete rotation. height, and fit a block under the bolt. 26.6 + 3.5 kgm Also, be careful not to loose bucket to prevent it from coming _ After using the bucket for several any part other than the lubrica- down hours, tighten the mounting bolts tor (1), % Set the bottom of the bucket again If the lubricator (1) or any other —_ horizontal. part should be loosened exces- 2. Remove nuts and bolts (1) and sively, it will be liable to fly _(2), then remove tooth (3). out under the high pressure of 3. Install the new tooth to the jammed grease. If grease does —_bucket. not ooze smoothly, try moving 4. Adjust clearance inserting shim the machine back and forth for _—_(4) when finding much clearance a short distance. between the teeth and the bucket.HANDLING RUBBER SHOES HANDLING RUBBER SHOES INSPECTION OF RUBBER REPLACEMENT OF RUBBER SHOES @ Check the contact surface be- SHOE Replace the rubber shoes tween the rubber shoe and the new parts if they are in the follow- _track roller, and replace the shoe Installing rubber shoe ing condition. if more than half of the metal 1. Raise the chassis with the boom ‘core can be seen from therubber and arm, ‘@ When dimention “a” is less than shoe. 112.2mm Holes in rubber for machine of sprocket Wear surface ee @ When there are deep cracks that 2. Loosen lubricator (1) and drain extend to the iron wire in the the grease inside. middle of the rubber shoe —68— pasAi. not loosen the lubricator (1) over" one. complete. rotation Also, be careful not to looee any part other than the lubrce. ford IF the lubricator (tor any other pert should be loosened exces: tively, it will be lable to fy out under the high pressure of jammed grease, 3. Mesh the rubber shoe with the sprocket and fit it over the idler. 4. Rotate the sprocket in reverse and push in the rubber shoe. 5. Using a steel pipe, fit the rubber shoe and rotate the sprocket again. Stee pioe 6. Check that the rubber shoe is fitted securely on the sprocket and idler, 7. Adjust the track tension. (For details, see REQUIRED) 8. Check that the track tension is correct and that the rubber shoe is correctly meshed on the sprocket and idler, then lower the machine to the ground, WHEN ~69— HANDUNG RUBBER SHOES CHECK TRACK TENSION ‘The wear of pins and bushings fon the undercarriage will vary with the working conditions and soil preperties. It is thus neces- sary to continually inspect the track tension so as to maintain the standard tension on it. If the track tension is not at the standard value, adjust it in the fol- lowing manner:HANDLING RUBBER SHOES Inspection Adjustment 10 = 20mm Raise the machine by means of the boom and arm, and measure the clearance between the tread of the 3rd track roller from the sprocket and the roller contact face of the track link, Ifthe clearance is between 10 and 20 mm, the track tension is normal For tightening the tension, pressurize grease through lubricator (1). On the other hand, for loosening the tension, extract grease by reversely rotating lubricator (1) gradually =10- Grease may be pressurized till S will be 50 mm. In case the tension is yet loose after applying pressurized injection of grease till the above- mentioned limit, it indicates that the pin bush is reduced by too much abrasion. So it is necessary either to turn or replace the pins and bush- ings. Consult your Komatsu distribu- tor for repair.HANDLING RUBBER SHOES £A.0% not loosen the ubrcator (1) Steel onal coreiee ction fis, be careful not to looce any art other than the brie. fort Ifthe lubricator (tor any other part should be loosoned exec ively i will be Table. to My cat uncer the high pressure of jammed grease. If grease does hot core smooth. ty moving the mochine back and forth far a chor distance, -n-SERVICE METER This meter indicates the in- tegrated work hours. So, use cording to instructions. the SERVICE METER ‘© Record the readings at the start and the end of work, this is the work record of the machine. © This record will indicates, when periodical maintenance is due. @ It also indicates the integrated working hours when machine problems are encountered, + How the meter progresses ‘This meter shows the total opera- tion hours of the machine. As long 2s the starting swich is put in ON po- sition, this meter indicates every 1/10 hour of operation ragardless: of the engine speed. The lowest figure indicates 6 minutes of operation, ==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. @ Location of the machine serial Location of the engine serial number mark number mark This is seen on the front left of This is seen on the upper left of the frame. the cylinder head, when seen from the fan side. sn -73-FUEL, COOLANT AND LUBRICANTS FUEL, COOLANT AND LUBRICANTS PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS. "AMBIENT TEMPERATURE CAPACITY (0) RESERVOIR: or w 2 6 BORE FLUID Se SAE 30 ioe Engine oi pan a2 42 Tia ‘Sing machinery cave enone on - <= 13 13 Final ive cave (seh) 078. 078 Hydrol tan 2 35 — — ee Fuel tank toa i %0 : BSW BUEN eer Cooting sytem water Td aniteeze $ E 8 ASTM D975 No. 1 74NOTE: (1) When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic mainte- nance hours described in this manual Change oil according to the following table if fuel sulphur content is above 0.5% Change interval of oil in Fuel sulphur content eee en nen 05 to 1.0% 1/2 of regular interval ‘Above 1.0% 1/4 of regular interval ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers FUEL, COOLANT AND LUBRICANTS. (2) When starting the engine in an atmospheric tem- perature of lower than 0°C, be sure to use engine oll of SAE OW, even though an atmospheric tem- perature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change in- terval to halt. ‘Specified capacity: Total amount of oll including oil for components and oil in piping. Refill capacity: Amount of cil needed to refill system during normal inspection and maintenance.SAFETY AND OPERATIONCONTENTS SAFETY HINTS « - A HANDLING OF BATTERY. ‘TRANSPORTATION PRECAUTIONS FOR MAINTENANCE STORAGE . A COOLANT AND LUBRICANTS "1 4 15 20 21SAFETYHINTS- - - A OPERATION GENERAL ‘© Wear well-fitting helmet, safety @ If there should be an accident or @ Read the Operation and Mainte- shoes and working clothes. If the fire or any other such unexpected nance Manual carefully. Learn nature of the work requires mishap, deal with it quickly, how to use the control devices, safety, wear protective goggles _using the nearest apparatus. gauges and warning devices. Be for mask, thick gloves, ear plugs Learn beforehand the locations —_—_sure you understand the meaning or other protection. Of the first aid boxes and fire ext- of the caution plates. Remember, ‘© Accidents or injuries are liable to _—_inguishers and how to use them. the check points and checking ‘occur when the operator is care- It is also important to know the method for engine cil, fuel, cool~ less or slack. It is most important __emergeney contact system. ing water and hydraulic oil levels. to bear safe operation in mind at @ Learn about the safety devices When operating inside a building all times. ‘on your own machine and about — always be sure of the clearance @ Take care of your health. Do not «show to use them. Confirm that of ‘the ceiling, entrances, aisles, operate when tired, or efter they are correctly attached in the __etc. and the load limit of the floor. drinking, prescribed position. Such safety Never allow other person than ‘@ Learn the prohibitions, cautions _—_ devices include’ ‘the operator to ride on the ma- and rules about work procedures —_-* Protective-Devices chine during operation. in the work site, Seat Belts When there is a leader, fix stan- @ Exhaust gas is dangerous. When dard signals and always follow running the engine for long peri- ‘these signals when operating. ods in @ poorly ventilated area, there is a danger of gas poisoning, so open the windows or doors to ensure @ good supply of fresh air.BEFORE STARTING OPERATION ‘© 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. « Inspect leakages from the fuel, lu- bricating and hydraulic systems. Check that the shoe bolts are not loose, and that no other parts are damaged or missing. Machines having such failures should not be operated. © When getting on or off the machine, use the handrail Provided. Do not jump up or down from the machine, @ Do not leave parts or tools lying around in the vicinity of or on the floor of the operator's cab. Keep everything in its proper place. Wipe off thoroughly any grease, oil or mud on the handrail, floor or control levers. Failure to do this may cause you to Check the level of the fuel, lubri- ants and cooling water. Ext- inguish cigarettes before check- ing or replenishing. Check that the radiator cap and each oil filler ‘caps or plugs are firmly tightened. Adjust the operator's seat until it is in the most comfortable posi tion for operating. Always sit in the seat while operating. Do not operate the machine from any other position. To ensure the safety of workers near the machine, always sound the hor 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. ‘© Inspect the inside of the engine room and remove any dead leaves or papers. Dead leaves or papers are highly inflammable and can cause fires. ‘© Before starting the engine, con- firm that all contro! levers are in NEUTRALAFTER STARTING THE ENGINE © Confirm that all gauges and warning devices are functioning correctly, and that the gauge readings are within the prescribed range. ‘© Check the play and travel of each lever. © Operate the work equipment to confirm that they are functioning ‘normally. @ Before operating the traveling and steering levers, check wheth- er the track frame is forward or backwards. If the track frame is facing backwards, operate the traveling and steering levers in ‘the reverse manner to that when the track frame is facing forward, © Move the machine slowly and listen carefully to the engine or gears to confirm that they are ‘not making any unusual noises. © Choosing a safe place, turn the machine to the left and right to confirm that the traveling and steering levers are functioning normally If these tests reveal anything wrong, however slight is may be, contact the man in charge of the machine and operate the machine only after obtaining his permission, DURING OPERATION ‘© Maintain the bucket at 2 height of 40 to 50 cm above the ground 0 that it can be quickly lowered to the ground and the machine ‘stopped in an emergency. © As far as possible, operate the machine so that it does not tilt (Do not tit it by more than 35° in either the forward, rear, left or right directions, even under static conditions.) ‘© Always operate slowly in crowd- ed places. On haul roads or in narrow places, give way to loaded vehicles. ¢ Do not allow unauthorized per- sons into the work area @ Before reversing or turning, ‘ensure that there is nobody in the vicinity. Also, be careful of obstacles.‘© When operating on slopes, as far as possible, avoid turning the ma- chine on a slope. It may cause the machine to roll over or slip sideways. © When operating the machine along a road, retract the work equipment to improve machine stability. As far as possible pro- ceed along a flat road. © The machine should always be operated at a speed where it can be correctly controlled. Never do the following: 1) Speeding 2) Sudden starting, sudden brak- ing, sudden turning, 3) Snaking 4) Coasting @ When operating on uneven ‘ground or in places where there are obstacles, remember the fol- lowing points: % Operate at as low a speed as possible and avoid sudden ‘changes in direction. ‘* Wherever possible, avoid trav- ling over large rocks, fallen trees, tree stumps and other such obstacles. Either use the work equipment to remove them, or travel round them. ‘When it is impossible to avoid traveling over them, reduce speed and mount over the obstacle. Just before the front of the machine tips down, reduce speed even more to make the shock of hitting ground as small as possible. ‘ Never mount over an obstacle at an angle; never disengage ‘one traveling and steering lever to travel over an obstacle. ‘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 2 safe place and take appropriate action. Be especially careful in the case of a fuel leak as there is danger of fire. The work area should be made as flat as possible. If the work area is flat, operation is made much easier and this reduces operator fatigue.© Always concentrate, It is ex- @ When passing through s narrow * When raising the undercer- tremely dangerous to allow your- _space, be careful of the side and riage by means of the boom or self to be distracted or to think of overhead clearances. Take spe- farm, push the bottom of the other things when operating a cial care not to touch any obste- bucket against the ground (on machine. In dangerous places, or oles on either side or overhead. If rho account use the teeth) until where there is restricted visibility, necessary, have someone outside the angle between the boom it is important to get down from the machine call out instructions, and the arm is 90° to 110°, the machine and confirm whether @ Be careful not to operate the ma- 2) If both tracks of the machine itis safe before continuing work. chine into a bog. In the event that are in the bog and slip, pre- @ Be careful of those around you, the machine goes into a bog, ex- venting the machine from get and always confirm that there is _tract it in the following manner: ting in, place logs or timber Ro person or obstacle in the way _—1)If only one track of the ma- under the tracks in the manner before moving or turning the chine is in the bog, push the described in 1), then thrust machine. bucket down against the the bucket into the soil in front ‘@ When using the work equipment, ground on the side of the ma- of the machine and drag it out be sure to keep your eyes on it all chine which is stuck s0 as to by bending the arm in the the time. Failure to do this may float the track. Then place same manner as when ex- resultin an accident. logs or timber underneath the cavating and putting the trav- track and free the machine. fling and steering lever into ‘the forward position@ After earthquakes, confirm that @ Check the load limits of bridges When operating in water or when the ground is stil firm; after before crossing. crossing shallows, first check the blasting, confirm that there are © When working in water or bed soil condition and the depth no unexploded charges _-—=smarshy ground, be careful of the and flow speed of water, then remaining, following: proceed, taking care not to go © When working on river embank- * When working on soft _—_—beyond the permitted depth. ments or other places made of ground, place thick boards on First check the water depth, piled soil, there is the danger that, the ground to prevent the ma- the firmness of the ground the weight of vibration of the ma- chine sinking. Place the and the strength of the chine may cause the machine to boards horizontally and ar- current. Do not enter if the sink into the piled soil, so be ex- range them as neatly as water exceeds the permissible tremely careful when operating possible, depth (up to the bottom of the insuch places. swing circle) © When continuing operations @ When operating in fog, mist or after rain, remember that condi- smoke, where visibility is bad, be tions will have changed from especially careful to confirm first those before the rain started, so whether operation is safe. proceed with caution. When visibility drops below Be particularly careful when ap- safety level, stop work and wait proaching the shoulder of the for the visibility to improve, road of cliffs, as they may have been loosened by the rain.‘¢ When operating at night, remem- * Depending upon the supply vol @ Do not perform excavation at the ber the following points: tage itis conceivable that anelec- bottom of a precipice as it is % Be sure to arrange an adequate —_—tric shock may be received by dangerous practice. lighting system merely coming into the vicinity of @ If it is unavoidably necessary to % Atnightitis very easy tomake an electric feeder wire. Accord- operate the work equipment mistakes in assuming the dis- ingly, observe the minimum dis- _lever when traveling the machine tance and height of objects tances given in the table below, in the vicinity of a precipice, road and land. taking into account the inertia of shoulders, on sloping ground or the boom when in motion, through a confined space, stop @ Be very careful not to touch elec- the machine momentarily before tric wires, always bearing in mind Sepp wotage ‘emanate operating the work equipment that there is @ possibility of re- — _Sunverotinevators!_| lever in order to minimize danger ceiving an electric shock. 3 iv (aotutonte 3m ‘© When working on loose, crumbly ‘% Wear rubber or leather soled 33011 to austen) am soil, do not dig deeply and back shoes. 65.015 108 houston) = the machine off smartly. If the % Position a full-time watcher at 54.0 1010 18 neuen) ground crumbles, preventing the the site to ensure that operator ee aa | aon machine from getting away in is not exposed to the risk of | 2eOCPwS0imvaw) | 10m time, do not panic and raise the electric shock work equipment. Its often better %* Become familiar with the neces- _in the interests of stability to Sary measures to be taken in the _leave it down. event that a operator receives an electric shockPARKING @ Do not undercut the machine, @ Take care not to swing the @ When parking the machine, park unless absolutely necessary. bucket against the sides of it in a safe place outside the H necessary, always take care to trenches or dump trucks. Load working area, or in the specified Prevent the machine falling, the truck from the rear. place. The following factors ¢ When operating at the edge of a should be considered when cliff or on the shoulder of a road, choosing a parking place: it remember the following points: should be on flat, firm ground + When operating in a place where there is no danger of where there is danger of the rockfalls, landslides or floods. If machine falling over the side, the machine has to be parked on be doubly careful. Do not ap- @ slope, it should be parked proach the edge of the cliff or facing directly up or down the road shoulder by mistake, slope, and chocks should be @ If you suspect that there are laced under the tracks. When buried facilities (water or gas the machine is facing downhill, pipes, etc) at the work site lower the bucket so that it cuts check with the companies re- slightly into the ground to further sponsible for looking after such increase the safety. facilities and also try a different method of excavation, Then, after confirming the existence and location of such facilities, carefully carry out excavation work.If it is absolutely necessary to park the machine on a slope, park it facing downhill and put cchocks against the tracks. If the ground is soft enough, dig the bucket into the ground for added safety. @ When parking the machine, return the work equipment levers, to neutral, apply the brake lock, ower the bucket to the ground, and put all safety levers in tho lock position. Switch off the engine and remove the key. ‘© Before leaving the machine, carry out the following: * * ‘Apply the swing lock. Lower the bucket to the ground. Put the work equipment lever inneutral and lock it. Stop the engine and remove the key to prevent other people using the machine. Lock the cab. =10-HANDLING OF BATTERY PRECAUTIONS FOR CHARGING BATTERY 1. Before charging, disconnect the cable from the negative {—) terminal of | the battery. Otherwise, an unusually high voltage damage the alternator. 2. While charging the battery, remove all battery plugs for satisfactory ventilation. To avoid gas explosions, do not bring fire or sparks near the battery. 3, 4 If the electrolyte temperature exceeds 45°C, stop charging for awhile Tum off the charger as soon as the battery is charged. Overcharging the battery may cause followings: 1) Overheating the battery 2) Decreasing the quantity of electrolyte. 3) Damaging the electrode plate. If the electrolyte gets on your skin or clothes, immediately wash with plenty of clean water. = 6 8. HANOLING OF BATTERY Do not mix up cables (positive (+) to negative (—) or negative (=) to positive (+0), as it will ‘damage the alternator. When inspecting or servicing 2 battery, be sure to stop the engine and turn the starting switch key to “OFF” position. When performing any service to battery besides checking the electrolyte level or measuring the specific gravity, disconnect cables from the battery,WANDLING OF BATTERY REMOVAL AND INSTALLATION OF BATTERY @ When removing battery, first disconnect the cable from the ground {normally from the negative (—) 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 shouldbe connected to the ground terminal as the last step. STARTING ENGINE WITH A BOOSTER CABLE When starting up the engine with a booster cable, do as follows: 1. Before connecting the booster cable 1) Size of booster cable and clip should be suitable for the battery size. 2) Check cables and clips for breaks, corroded surfaces, etc 3) Make sure cables and clips are firmly secured, 4) Keep the starting switch in “OFF” position, 5) The battery of the running engine must be the same capacity as that of engine to be started, ei 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. funsingenvine engine to be sartes @ — Engine block to be stortedAvinen connecting the cables, never contact the positive (+) and negative (-) terminals. Aimake sure that the booster ‘cable connections are correct. Connect the booster cable to ‘the engine block as far as possible from the battery. 3. Starting engine 1) Turn the starting switch to START position and start up ‘the engine 2) If the engine doesn’t start at first, try again after 2 minutes orso. After the engine has started, the booster cables should be disconnected in the reverse ord 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. Fannin engine Barren for engine which was started ® HANDLING OF BATTERY 3) Disconnect the clip of booster cable A from the positive (+) terminal of the running engine. 4) Disconnect the other clip from the positive (+) terminal of the engine which was started Engine block which was startod 135TRANSPORTATION TRANSPORTATION When transporting the machine, observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, ete. It is a good idea to obtain a special platform for loading and. unloading the machine. When it is unavoidably necessary to use a gangplank, however, at the very least observe the following for the sake of safety. 1. Properly apply the brakes on the * Move the machine backward to 4. When transporting the machine, trailer and insert blocks benosth get on the trailer place rectangular timber unde the tires to ensure that it does * Do not on any account change _—neath the front and rear track not move, Then fixthe gangplank the. direction of the machine shoes to prevent the machine in tine with the centers of the while it i on the gangplank. To from moving about. Also, hol it trailer and the machine change the direction of the ma- down with chains or rope. Be par- 4% Moke sure the gangplankhas suf- chine, fst take it down from the ticularly careful to ensure. that jent width, length and thick- __gangplank the machine does not slip ness to enable the machine to be 3, Correctly load the machine onto _ sideways safely loaded and unloaded the specified part of thettraler. ‘8. Lock the swing lock lever and If the gangplank sags apprecia- After loading the machine, fully apply the lock to the work equip- bly, reinforce it with biocks, et. extend the bucket and arm cylin- ment levers. + Lock the upper works using the ders, then slowly ower theboom. * Determine the route for trans- swing lock lever. + When transporting the ma- porting the machine by taking 2. Determine the direction of the chine, place rectangular timber into account the width, height gengplank, then slowly load or under one end of the bucket and weight of the machine. unload the machine cylinder to prevent it touching AdFemove the mud from the un- the ground, thereby saving it ‘dercarriage to prevent the m trom possible damage. Chine from slipping to the side ‘on slopes. 14 aoaPRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE SAFETY . or ¢ Wear wellfitting helmet, safety © Exhaust gas is dangerous. When @ Do not go underneath the ma- shoes and working clothes. working inside, be particularly chine after raising it up using the When driling, grinding or -—_careful to have good ventilation, boom and the arm, hammering, always wear protec- @ Unless you have special instruc- @ When working with others, tive goggles. tions to the contrary, mainte- choose a group leader and work e Fuel or oll are dangerous nance should always be carried according to his instructions. Do substances, out with the engine stopped. not perform any maintenance Never handle fuel, oil, grease or ‘Lock the swing lock lever and _beyond the agreed work. ‘lly clothes in places where there also all of the safety levers. if © When maintenance has to be car- is any fire or flame. maintenance is carried out with _ried out with the work equipment ‘As preparation in case of fire, the engine running, there must raised, they must be securely always know the location and di-. be two men present: one sitting supported by blocks. rections for use of fire extinguish- in the operator's seat and the ers and other fire-fighting «other one performing the equipment. maintenance. In such a case, @ Do not handle electrical equip- __ never touch any moving part ment while wearing wet gloves, @ When working underneath the or in wet places, as this can machine, place @ sign to that cause electric shock effect on the operator's seat and During maintenance do not allow _‘if necessary, put a similar signs in any unauthorized person to the vicinity as well stand near the machine. rosie -15-PRECAUTIONS FOR MAINTENANCE. @ Always remember that the hy- © Flames should never be used in- @ Do not allow anybody other than draulic oil circuit is under stead. of lamps. Never use a the necessary workers to go near pressure. When feeding or drain- naked flame to check leaks or the ‘the machine while it is being in- ing the oil or carrying out inspec- level of oil, fuel, antifreeze or _spected or maintained. Also, be tion and maintenance, release _ electrolyte. careful of people in the vicinity. It the pressure first ‘© Immediately remove any oll or —_is necessary to exercise particular Method of relieving pressure ‘grease on the floor of the opera- care when performing grinding 1) Lower the work equipment tothe tor’ compartment, or on the or welding, or when swinging a ground and stop the engine after handrail. It is very dangerous if _large hammer. idling it for two of three minutes. someone slips while on the @ Use the tool which is suitable for Then operate the various opera- machine. the maintenance work. tion levers. (work equipment, @ Be particularly careful when _@ Remove the minus terminal from traveling and steering lever removing the radiator cap. If this the battery in maintaining the through their full stroke in each is done immediately after using _ electrical system. direction) the machine, there is a danger @ When the tracks are removed, When removing air instruments _that boiling water may spurt out. never put your fingers between or pipings, open the drain valve @ Do not check the fan belt tension _the shoes. under the air reservoir to relieve while the engine is running. Be @ When carrying out other difficult air pressure, sure to turn off the engine before maintenance works, carrying 2) Gradually unscrew the cap of the inspecting other rotating parts them out carelessly can cause hydraulic tank and leave it for 2. _and the vicinity thereof unexpected accidents. If you con- few minutes. sider the maintenance is too difi- cult, always request Komatsu dis- tributor to carry out it. —16- neaPRECAUTIONS FOR MAINTENANCE MISCELLANEOUS @ Thoroughly wash the machine, © After replacing oil, filter element @ When washing the machine, particularly the oiling and greas- oF strainer, bleed the air from the ensure that water does not get ing parts and the vicinity, thereof, circuit. onto the alternator. ‘order to prevent the ingress of @ When the strainer is located in @ Special measuring apparatus is dust. the oil fille, the strainer must nots needed for testing hydraulic '® Use genuine Komatsu replace- _be removed while adding oil pressure. ‘ment parts specified in the parts @ When adding oil or checking the @ ‘Thoroughly wash the machine. In list. oll level, check that the oil is at _particular, be careful to clean the © Use Komatsu specified oil and _the correctllev filler caps, grease fittings and the ‘grease. Use oll and grease having @ After greasing up, always wipe area around the dipsticks. Be the recommended viscosity for off the old grease that was careful not to let any dirt or dust the particular ambient. ——_—forced out. into the system. temperature. ‘When changing the oil or filter, When check an open cover there @ Use clean oil and grease and check the drained oll and filter isa risk of dropping things in. keep them in clean containers to for any signs of excessive metal Before removing the covers to in- avoid the ingress of dust. particles or other foreign _—spect cover, empty everything ‘@ Inspect or replace oil in a dust- materials. from your pockets. Be particularly free location to prevent the in- _ @ When removing parts containing careful to remove wrenches and gress of dirt. O-rings, gaskets or seals, clean nuts. ‘¢ Drain off used ol after heating it the mounting surface and replace to a suitable temperature (about _with new sealing parts. 20 to 40°C) Pes TSPRECAUTIONS FOR MAINTENANCE ‘@ When working on the sea shore, check that the various plugs and valves, etc, are tightened up properly. After the completion of work, thoroughly wash the ma- chine and carefully clean all electrical equipment to ensure that is does not corrode. © Before working in muddy water, rain or snow, check that the vari- ous plugs, valves, are properly screwed up. Upon completion of work, wash the machine, then check the various parts of the machine for cracking, scratching, loose or missing nuts and bolts ‘Also, oil and grease the various parts of the machine @ When working in a dusty location, be careful of the following 1) Inspect the dust indicator to see Whether the air cleaner is, blocked up. Clean the air cleaner 8 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 a0- cumulation of dust. ‘© When working on rocky ground, be careful of damage to the undercarriage, loose nuts and bolts, cracks, wear and other damage. Also, adjust the track tension so that itis a little slacker than usual ices When installing car radio and a walkie-talkie or citizen band, con- tact your Komatsu distributor. When washing the machine, take care not to splash water over the electrical equipment. If it is soaked with water, it may not ‘operate normally After disconnecting the con- ector, cover it with a vinyl bag to prevent oil or dust from stick- ing to its contact section ‘When welding, be careful of the following: 1) Turn OFF the power (starting switch) 2)Do not continuously apply more than 200 V. 3) Install the ground cable at least 1 m from the range to be welded 4) Teke care not to install the seals between the grounded point and the range to be welded,PRECAUTIONS FOR MAINTENANCE ‘© After replacing oil, filter element or strainer, bleed the air from the ireuit. ‘© After replacing hydraulic oil and filter element, or replacing the hy- draulic cylinder or the piping system for the machine, the air vent operation is necessary. Low- idle the engine, and proceed as follows: 1, Extend and contract each cylinder 4 to § times, taking care not al- lowing it to reach its stroke end lie,, allowing it to return from a point of about 100 mm before the s:toke end.) 2. Then, extend and contract each cylinder 3 to 4 times up to the stroke full end, + Sudden running of the engine at 2 high speed and allowing of the cylinder to reach the stroke end cause damage to the piston pack- ing, etc. due to the air trapped in the cylinder. oa -19-STORAGE 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 ‘on the wood plates and cover it with canvas ete. ‘© Completely fill fuel tank, lubricate and change oil before storage. ‘© Apply @ thin coat of grease to metal surface (hydraulic piston rods and front idler adjusting rods! @ As to batteries, remove the termi- nals and cover them, or remove them from the machine and store separately. STORAGE ‘© When the ambient temperature is anticipated to drop below °C, always add antifreeze in the cool- ing water. ‘© The fuel control lever shall be set to STOP position. DURING STORAGE © Operate the engine and move the machine for a short distance ‘once 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 Con the hydraulic piston rod. Att it i unaveidabiy necessary te cary out ust proventive op- oration while the machine Te Indoors. open up doors and win. owe 1 improve vetiaton and prevent the gee poeoning re 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. © Loosen the drain plugs on oil pan and other cases and drain mixed water. ‘@ Remove the cylinder head cover and lubricate sufficiently valves and rocker arms. And inspect the valve operation. ‘© After the engine is started, oper- ate it until it is warmed up ‘completelyCOOLANT AND LUBRICANTS COOLANT AND LUBRICANTS wagon = aera 0) jium-Base) ane Glycol Base) No. | Supplier Name | SAETOW, SAEO. Crime Pena SAE10W/30, SAETSW/40 NK [Permanent Type] 1 [ase ‘Superdiesel Multigrade GR M = 4 | 8P Energrease LS2 Lalla eee RPM Delo 400 Marfak All Purpose: ‘AF Engine Cootent 7 | CHEVRON Delo 400 | View Duty Grease 2 7 Performance 3C_ EPEXA2 a onCOOLANT AND LUBRICANTS Engine Ol! ‘Grease | anti-rreeze coolant , ‘co (tinue! | (Euryiae Gieet ae No. | Supplier Nome SAE10W, SAE3O, NLGI2 [Permanent Type) SAEt0W 908A 8W/40 Gureown Grew We? | Grumman Aner to | owe suet Duty Gatroun €P spec on Gente. summa Cott Daves 1300 bigs ‘arene 11 | most. Daler 1400 Mepiaene 7, Permazone Putas taco sive —_| Meble suoreme Ouy Feet | tutPurpote No. 708 | ami Freee & 12° | PENNZOIL | pjuis-Duty Wheel BooringNo.707L | Summer Cooiant v3 fsweue Ea ivr Grete EP unfue ibe xt. | Sonn Sunoco Mut Sn at ‘Sunfleet Super © ‘Sun Prestige 742 EP Anti-Freeze Cr Sper Pn Tnupuoe 15 | Texaco | une ot va Mertac nt Prpow 2 | Sumer Gotan ‘Ursa Super LA “ v6 | Tora Runes wats re nite 17 [onion Guard note EF s -22-