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Komatsu Utility 15001 Operation & Maintenance Manual Download Page 175

MAINTENANCE SCHEDULE

173

4.8 MAINTENANCE SCHEDULE

If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different.  For
details, see "4.8.2 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER" to confirm the correct maintenance
schedule when  carrying out maintenance.

4.8.1 MAINTENANCE SCHEDULE CHART

WHEN REQUIRED

a. CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ......................................................................................... 175
b. CLEAN INSIDE OF COOLING SYSTEM......................................................................................................................... 177
c. CHECK LEVEL OF BATTERY ELECTROLYTE .............................................................................................................. 180
d. CLEANING THE FUEL FILTER (WITH WATER SEPARATOR) ...................................................................................... 182
e. DRAIN WATER AND SEDIMENT FROM FUEL TANK .................................................................................................... 182
f.

CHECK AND ADJUST TRACK TENSION (Machines equipped with steel shoes) ......................................................... 183

g. CHECKING THE RUBBER SHOES (Machines equipped with rubber shoes) ................................................................ 185
h. CHECK AND ADJUST RUBBER SHOE TENSION (Machine equipped with rubber shoes) .......................................... 187
i.

REPLACE RUBBER SHOES (Machine equipped with rubber shoes) ............................................................................ 189

j.

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (Machine equipped with cab) ............................................... 191

k. CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER (Machine equipped with cab) ................. 192
l.

BLEEDING AIR FROM HYDRAULIC SYSTEM............................................................................................................... 192

CHECKS BEFORE STARTING

EVERY 500 HOURS MAINTENANCE

a. LUBRICATING ................................................................................................................................................................. 194
b. CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................................................... 196
c. CHANGING THE FUEL FILTER ELEMENT (WITH WATER SEPARATOR) ................................................................... 197
d. CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL .................................................................................................. 198
e. REPLACE FEED PUMP PRE-FILTER............................................................................................................................. 199
f.

CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS............................................................................... 199

g. CHECK AND ADJUST COOLING FAN BELT TENSION................................................................................................. 200

EVERY 1000 HOURS MAINTENANCE

a. CHANGING THE HYDRAULIC OIL FILTER ELEMENT.................................................................................................. 201
b. CHANGE OIL IN FINAL DRIVE CASE ............................................................................................................................ 202
c. CHECK ENGINE VALVE CLEARANCE, ADJUST........................................................................................................... 202

EVERY 2000 HOURS MAINTENANCE

a. CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER ............................................................................................. 203
b. CHECK ALTERNATOR, STARTING MOTOR.................................................................................................................. 204

Summary of Contents for 15001

Page 1: ...s and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodically reviewed by all personnel who will come into contact with the machine WARNING PC20MR 2 HYDRAULIC EXCAVATOR SERIAL NUMBER PC20MR 2 15001 and up ...

Page 2: ......

Page 3: ...the maintenance operations that have been carried out are important to have a clear prospect of the situation and to know exactly what has been done and what has to be done after the next maintenance interval Therefore it is advisable to consult either the hour meter and the maintenance plan frequently Over the years Komatsu Dealers have gathered considerable experience in customer service If more...

Page 4: ...r or moderate injury It may also be used to alert against unsafe practices Other signal words In addition to the above the following signal words are used to indicate precautions that should be followed to pro tect the machine or to give information that is are useful to know IMPORTANT This word is used for precautions that must be taken to avoid actions which could shorten the life of the machine...

Page 5: ...the hydraulic system WARNING Before carrying out any electrical welding disconnect the battery and the alternator See 2 8 13 PRE CAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR WARNING Install only authorized additional equipment See 6 1 ATTACHMENTS AND OPTIONS GENERAL IN FORMATION DANGER It is absolutely forbidden to operate the machine while standing on the ground Every single manoeuvre must ...

Page 6: ...nd the hydraulic couplings necessary for the operation of the equipment are grouped in the final section of this manual Komatsu MACHINES are constructed exclusively for the handling excavation and treatment of inert materials therefore the following uses are absolutely forbidden USE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS USE OF THE MACHINE FOR LIFTING PERSONS OR OBJECTS TRANSPORT OF CON...

Page 7: ...ns and abrupt reversals SYNTHETIC BIODEGRADABLE OIL TYPE HEES On machines in which the synthetic biodegradable oil type HEES is used the following operations are to be per formed besides the standard maintenance operations After the first 50 hours of operation change the hydraulic circuit drain filter After the first 500 hours of operation change the hydraulic circuit oil IMPORTANT When changing t...

Page 8: ...ON NUMBER PIN The Komatsu EXCAVATORS described in the present manual are provided with the CE mark which certifies that they are in compli ance with the harmonized standards of the European Community The plate provided with the mark is applied onto the front wall of the main frame on the left side RKA01330 RKA01331 RWA39210 MODEL SERIAL No MANUFACT YEAR MASS ENGINE POWER kg kw Product Identificati...

Page 9: ...r is stamped on the plate positioned on the engine The exhaust gas emission plate is positioned on the radiator chassis 1 4 4 TRAVEL REDUCTION GEAR SERIAL NUMBER The serial number is stamped on the plate positioned inside the travel reduction gear and can be seen after removing the cover 1 RKAA0300 1 ...

Page 10: ...REDUCTION GEAR SERIAL NUMBER The serial number is stamped on the plate positioned on the up per side of the swing motor 1 4 6 CAB SERIAL NUMBER The CAB serial number is stamped on the plate positioned on the top left side RKAB2570 RKAB1750 ...

Page 11: ...ENTIFICATION 9 1 4 7 SERIAL NUMBERS AND DEALER S ADDRESS Machine n Model Product identification number PIN Swing reduction gear n Cab n Dealer Address Tel Person to contact NOTES Travel reduction gear n Engine n ...

Page 12: ...24 2 1 4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY 25 2 1 5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED 25 2 2 GENERAL PRECAUTIONS 26 2 2 1 GENERAL SAFETY RULES 26 2 2 2 SAFETY DEVICES AND GUARDS 26 2 2 3 CLOTHING AND PERSONAL PROTECTION ITEMS 26 2 2 4 UNAUTHORIZED MODIFICATIONS 27 2 2 5 LEAVING THE OPERATOR S SEAT 27 2 2 6 GETTING ON AND OFF THE MACHINE 28 2 2 7 PREVENTING FIRES DUE ...

Page 13: ...T 45 2 8 5 WORKING UNDER THE MACHINE 45 2 8 6 CLEANING THE MACHINE 45 2 8 7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS 46 2 8 8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY 46 2 8 9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION 46 2 8 10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP 47 2 8 11 CHECKING THE COOLANT LEVEL IN THE RADIATOR 47 2 8 1...

Page 14: ...ANUAL STORAGE 89 3 2 16 TOOL BOX 89 3 2 17 GREASE GUN HOLDER 89 3 2 18 ASHTRAY Machines equipped with cab 89 3 3 MACHINE OPERATIONS AND CONTROLS 90 3 3 1 BEFORE STARTING ENGINE 90 3 3 1 1 WALK AROUND CHECKS 90 3 3 1 2 CHECKS BEFORE STARTING 92 3 3 1 3 ADJUSTMENT 98 3 3 1 4 OPERATIONS BEFORE STARTING ENGINE 101 3 3 1 5 STARTING ENGINE 103 3 3 2 AFTER STARTING ENGINE 106 3 3 2 1 BREAKING IN THE NEW ...

Page 15: ...N 142 3 5 1 1 FUEL AND LUBRICANTS 142 3 5 1 2 COOLING SYSTEM COOLANT 142 3 5 1 3 BATTERY 143 3 5 2 CAB HEATER IN COLD WEATHER Machines equipped with cab 143 3 5 3 AFTER DAILY WORK COMPLETION 144 3 5 4 AFTER COLD WEATHER SEASON 144 3 6 LONG TERM STORAGE 145 3 6 1 BEFORE STORAGE 145 3 6 2 DURING STORAGE 145 3 6 3 AFTER STORAGE 145 3 7 TROUBLES AND ACTIONS 146 3 7 1 RUNNING OUT OF FUEL 146 3 7 2 PHEN...

Page 16: ...73 4 8 1 MAINTENANCE SCHEDULE CHART 173 4 8 2 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 174 4 8 2 a CHANGING THE HYDRAULIC OIL FILTER 174 4 8 2 b CHANGING THE HYDRAULIC OIL 174 4 9 MAINTENANCE PROCEDURE 175 4 9 1 WHEN REQUIRED 175 4 9 1 a CHECK CLEAN AND REPLACE AIR CLEANER ELEMENT 175 4 9 1 b CLEAN INSIDE OF COOLING SYSTEM 177 4 9 1 c CHECK LEVEL OF BATTERY ELECTROLYTE 180 4 9 1 d CLEANING THE F...

Page 17: ... 9 5 a CHANGE OIL IN HYDRAULIC TANK CLEAN STRAINER 203 4 9 5 b CHECK ALTERNATOR STARTING MOTOR 204 TECHNICAL SPECIFICATIONS 5 1 SPECIFICATIONS 206 5 2 LIFTING CAPACITIES 208 5 2 1 LIFTING CAPACITIES WITH CANOPY 208 5 2 2 LIFTING CAPACITIES WITH CABIN 211 AUTHORIZED OPTIONAL EQUIPMENT 6 1 ATTACHMENTS AND OPTIONS GENERAL INFORMATION 216 6 1 1 SAFETY FIRST 216 6 1 2 ATTACHMENT INSTALLATION 217 6 1 3 ...

Page 18: ...16 PAGE INTENTIONALLY LEFT BLANK ...

Page 19: ...SAFETY AND ACCIDENT PREVENTION 17 ...

Page 20: ...an them with a solution made of water and detergent Do not use fuel petrol or solvents If the plates are damaged ask for new ones to Komatsu or to your Komatsu Dealer In case of replacement of a component provided with a safety plate make sure that this plate is applied also on the new piece The machine can be provided with other plates in addition to those indicated below keep also to the instruc...

Page 21: ...at they look like and their respective meanings DANGER IN THE WORK AREA Do not approach or stand within the equipment operating radius when the boom and the bucket are raised DO NOT OPEN THE HOOD Do not open or remove the hood when the engine is running CONSULT THE MANUAL Carefully read the contents of the manual before using the ma chine or performing maintenance operations SAFETY DISTANCE Do not...

Page 22: ...Y LOCK FILLING THE HYDRAULIC SYSTEM WITH OIL Only for machines in which the synthetic biodegradable oil type HEES is used HYDRAULIC OIL TOPPING UP REFUELLING ENGINE LUBRICATING OIL FILTER RKA01380 22L 98 R2390 RWA34380 BIO OIL RWA00050 D RWA00040 RWA00080 ...

Page 23: ...TY NOISE AND VIBRATION PLATES 21 FUEL FILTER ENGINE AIR SUCTION FILTER ENGINE COOLANT ENGINE COOLANT PRESSURE HYDRAULIC OIL LEVEL HYDRAULIC OIL FILTER D RWA00060 RWA00090 RWA00130 RWA00110 RWA00100 RWA00070 ...

Page 24: ...SAFETY NOISE AND VIBRATION PLATES 22 ELECTRIC OUTLET ANCHORAGE POINT EMERGENCY EXIT LIFTING POINT 12 V RWA00120 RWA00200 RWA00190 RWA04920 ...

Page 25: ... AND VIBRATION PLATES 23 LIFTING CAPACITIES L A B 22K 98 R2110 3m 2m 1m 0 1m 0 L 1015mm L 1365mm 640kg 585kg 560kg 570kg 555kg 335kg 320kg 310kg 300kg 380kg 265kg 235kg 255kg 350kg 210kg A B 2m 3m MAX W 450mm kg 34 ...

Page 26: ...damaged ask for new ones to Komatsu or to your Komatsu Dealer In case of replacement of a component provided with a noise plate make sure that this plate is applied also on the new piece NOISE OUTSIDE THE CAB This value indicates the noise level outside the machine and re fers to the noise perceived by persons in the vicinity of the work area NOISE INSIDE THE CAB This value indicates the maximum n...

Page 27: ...replacement of a component provided with a noise plate make sure that this plate is applied also on the new piece EXTERNAL NOISE This value indicates the noise level outside the machine and re fers to the noise perceived by persons in the vicinity of the work area 2 1 5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED According to the results of the tests carried out to determine the vibrations trans...

Page 28: ...rating conditions Any improper use of the safety devices may result in serious injuries or even death 2 2 3 CLOTHING AND PERSONAL PROTECTION ITEMS Do not wear large or loose clothes rings and watches and do not approach the machine with loose long hair since they can get entagled in the moving parts of the machine and cause seri ous injuries or damage Avoid also wearing clothes dirty with oil or f...

Page 29: ...e sure that the machine is in a safe position See 2 4 13 PARK ING THE MACHINE Before leaving the operator s seat carry out the following oper ations in the sequence indicated below 1 Rest the equipment onto the ground 2 Connect the safety devices of the boom swing optional equipment and upper structure rotation controls 3 Lock the equipment control by shifting the safety device le ver to the lock ...

Page 30: ...arefully Never hold or rest on the control levers Either when getting on and when getting off the machine al ways maintain three points of contact holding or resting points in order to avoid losing your balance and falling down Tighten the handle connection screws if they are loose and clean the handles and tracks if they are dirty with oil or grease Carefully clean the cab floor if it is dirty wi...

Page 31: ...topping up tighten the fuel and oil safety caps securely Do not fill the tank completely in order to leave room for the fuel to expand In case some fuel is spilled wipe it up immediately 2 2 8 PREVENTING BURNS If the engine coolant the engine oil and the hydraulic oil are hot use heavy cloths and wear gloves heavy clothing and safety goggles before carrying out any check or touching the hot parts ...

Page 32: ...ovides suitable protection use an ap proved and homologated respirator 5 The powder gathered during the cleaning operations must be dampened and put in a sealed and marked container so that it can be safely disposed of according to the regula tions in force 2 2 10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT Do not stand within or approach the operating radius of the work equipment even when the...

Page 33: ...B STRUCTURE If the cab is inadvertently hit or the machine overturns during work the cab may be damaged with consequent reduction of its stiffness and of the safety that must be guaranteed to the operator Consult Komatsu or your Komatsu Dealer to have the cab structure and resistance checked in case of impact or damage 2 2 13 PRECAUTIONS CONCERNING THE EQUIPMENT When installing and using optional ...

Page 34: ... of the operations Be careful not to sever or damage any of these lines Check the depth and flow of water before operating in water or on river banks 2 3 2 FIRE PREVENTION Completely remove all wood chips rubbish paper and other flammable materials that may have accumulated inside the en gine compartment since they can cause fires Check the fuel and hydraulic system pipes for leaks and if nec essa...

Page 35: ...ch a way as to ensure perfect visibility on the work area Make sure that the working lights are installed as prescribed Make also sure that they come on correctly 2 3 6 CLEANING THE WINDOWS CHECKING THE WINDSHIELD WIPER BLADES Remove any trace of dirt from the cab windows in order to ensure perfect visibility on the work area Check the conditions of the windshield wiper blades the scraping wire mu...

Page 36: ...follows to check that the floor is fixed securely in position If it is not fixed securely in position it may cause serious per sonal injury 1 Open the triangular cover the engine rear cover the tank cover and check that floor tilt lock bolts 1 4 places are securely tightened If any abnormality is found always carry out repairs or ask your Komatsu Dealer to carry out repairs 2 4 2 CHECK THE DIRECTI...

Page 37: ...le to evaluate the space required for the movements more precisely and at the same time ensures the stability of the machine Make sure that the driver s seat is directed towards the blade Otherwise pay attention to the steering and advance manoeu vres since they are inverted If the equipment control levers must be used during travel avoid moving them abruptly sudden manoeuvres change the attitude ...

Page 38: ...re than 15 set the machine with the sprocket 1 at the downhill end and the work equipment in the posture shown in the diagram on the right then lower the engine speed and travel downhill Do not change direction and avoid travelling obliquely when working on slopes It is advisable to go down or up to a flat place to perform these operations Do not travel on wet grass or thick layers of leaves if th...

Page 39: ...rm on which the machine can be positioned 2 4 7 UNAUTHORIZED OPERATIONS Never dig the work face under an overhang There is a hazard that rocks may fall or that the overhang may collapse and fall on top of the machine Do not excavate too deeply under the front of the machine The ground under the machine may collapse and cause the ma chine to fall To make it easier to escape if there is any problem ...

Page 40: ...ent or a hazard of serious personal injury being caused by flying pieces of broken materials or of the machine tipping over due to reac tion from the impact Generally speaking the machine is more liable to overturn when the work equipment is at the side than when it is at the front or rear When using a breaker or other heavy work equipment there is a hazard of the machine losing its balance and ti...

Page 41: ... of operations warn everyone standing in the work area to keep at the minimum dis tance prescribed from the machine and the work equipment Ask the electricity company what are the voltage of the cables and the minimum safety distance in advance DANGER The minimum distances from overhead lines can vary in the different countries according to the climate and to the humidity percentage in the air Ind...

Page 42: ...ovided In case of work in areas where stones or other material may fall on the machine install the FOPS protection de vice 2 4 13 PARKING THE MACHINE Park the machine on firm and level ground If this is not possible and it is necessary to park on a slope position the machine with the bucket directed downwards and carry out the following op erations 1 Rotate the bucket to the dumping position and l...

Page 43: ...y have the same length Position the ramps with a maximum inclination of 15 Make sure that the ramp surface is clean and there is no trace of grease oil soil and ice remove dirt from the tracks before starting to load the machine on the vehicle The machine must be loaded on the vehicle with the bucket di rected forwards that is in the direction of advancement of the vehicle Do not correct the traje...

Page 44: ...all sparks or naked flames Before working with batteries stop the engine and remove the ignition key Avoid short circuiting the battery terminals through accidental contact with metal objects or tools or through the inversion of the terminals Tighten the battery terminals securely Loose terminals may generate sparks and even cause the explosion of the battery 2 6 2 STARTING WITH BOOSTER CABLES Whe...

Page 45: ... cable Do not get astride the cable Remove the machine only as much as necessary to permit the required repairs Put wooden blocks between the towing cable and the machine body in order to avoid wear or damage Do not remove the machine in any way other than that indicated at point 3 7 3 TOWING THE MACHINE CAUTION The maximum applicable force for the removal is the fol lowing PC30MR 2 F 1665 kg for ...

Page 46: ...onal warning tags al so around the machine and in particular on the cab door handles 2 8 2 TOOLS Use only the tools provided with the machine and high quality tools suitable for the tasks to be performed Do not use worn damaged low quality tools or tools that are not suitable for the tasks to be performed in order to avoid any personal injury 2 8 3 PERSONNEL Only authorized and duly trained person...

Page 47: ...es are dan gerous because they may cause someone to slip or trip Al ways keep the machine and the work site clean and tidy To clean the machine use a pressurized jet of warm water or steam and the appropriate detergents available on the market Do not use gas oil oil or solvents since the former leave an oily coat that favours the sticking of dust while the latter even if weak damage the painted su...

Page 48: ...ant to prevent fires Fuel supply system fuel delivery and return pipes Hydraulic system main delivery pipes of the hydraulic pump Even if they seem to be in good conditions these components must be periodically changed with new ones In fact these components tend to deteriorate over time If one of these parts is defective change or repair it even if the change interval has not elapsed yet See 4 7 S...

Page 49: ...uel gun firmly and keep it constantly in contact with the filler until you have finished in order to avoid sparks due to static electricity Do not fill the tank completely in order to leave room for the fuel to expand 2 8 11 CHECKING THE COOLANT LEVEL IN THE RADIATOR Let the engine and the radiator cool down before checking the coolant level If it is necessary to remove the cap with hot engine wea...

Page 50: ...and also the al ternator 2 8 14 PRECAUTIONS CONCERNING THE STARTER Do not start the engine by tampering with the terminals of the starter since the machine may move Sudden or accidental movements of the machine may cause serious injuries or even death 2 8 15 HANDLING HIGH PRESSURE PIPES Do not bend high pressure pipes or rub them with abrasive or cutting objects Do not use any bent or cracked pipe...

Page 51: ...ing the inspections and use a piece of cardboard or a sheet of ply wood to check for oil leakages If you are hit by a jet of high pressure oil or are injured even if slightly immediately consult a doctor 2 8 17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERA TURES AND HIGH PRESSURE When the machine is stopped at the end of operations the en gine coolant the oil and all the components are ho...

Page 52: ...eload in order to absorb the im pacts of the front idler roller Do not attempt to remove the spring since this may lead to serious accidents and even death For any operation on the shock absorber unit contact your Komatsu Utility Dealer 2 8 20 HYDRAULIC ACCUMULATOR The hydraulic accumulator contains pressurized nitrogen When carrying out any operation on the accumulator do not pro ceed carelessly ...

Page 53: ...her protective equipment 2 8 24 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADA BLE OIL TYPE HEES It is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils since when the temperature increases insoluble compounds are generated which are deposited on the filters and clog them the maximum concentration of ordinary oil cannot exceed 1 of the total quantity o...

Page 54: ...52 PAGE INTENTIONALLY LEFT BLANK ...

Page 55: ...THE MACHINE AND ITS OPERATIONS 53 ...

Page 56: ...LUSTRATIONS 54 3 1 MACHINE VIEW ILLUSTRATIONS 3 1 1 OVERALL MACHINE VIEW 1 2 3 4 5 6 Bucket Bucket cylinder Arm Arm cylinder Boom Boom cylinder 7 8 9 10 11 12 Track shoe Sprocket Track frame Idler Blade cylinder Blade ...

Page 57: ...ch Right work equipment control lever Safety lock lever right canopy specification machine Blade control lever 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Machine monitor Fuel control lever Starting switch Heater switch cab specification machine Floor lock cancel lever Service meter Engine water temperature gauge Fuel gauge Engine pre heating monitor Charge level monitor Engine oil pressure monitor ...

Page 58: ...devices needed for operating the machine To perform suitable operations correctly and safely it is important to completely understand the methods of operat ing equipment and meanings of the displays 3 2 1 MONITORING SYSTEM A B Emergency Monitors Meter Display Portion C D Pilot Lamps Monitor Switch Portion ...

Page 59: ...he abnormal location on the monitor will lights up and the buzzer will second Carry out the necessary repairs immediately 1 Engine Oil Pressure Monitor This monitor 1 flashes and the buzzer sounds if the engine and lubricating oil pressure goes below the specified level If the monitor flashes stop the engine and carry out inspec tion For details see 3 7 6 OTHER TROUBLE NOTE While the starting swit...

Page 60: ...g when the engine is running this monitor 2 flashes and the buzzer sounds If the monitor flashes stop the engine and check the V belt tension If any abnormality is found see 3 7 6 OTHER TROUBLE NOTE While the starting switch is ON the lamp will remain lit and will go off once the engine is started ...

Page 61: ...uring operation the indicator should be in range A If the indicator enters red range B during operation pilot lamp C flashes and the buzzer sounds at the same time If this happens run the engine at low idling and wait until pilot lamp C goes out and the indicator goes down to range A 1 2 Engine Water Temperature Gauge Fuel Gauge 3 Service Meter ...

Page 62: ...pilot lamp B flashes check the fuel level and add fuel The correct level may not be displayed for a short time after the starting switch is turned to the ON position but this is not an abnormality 3 Service Meter This meter 3 shows the total time that the machine has been operated Use this display to manage the specified service intervals If the engine is running the service meter advances even if...

Page 63: ...eed Boost Monitor This monitor 2 lights up when the speed range selector switch is at high speed When the speed range is low speed the monitor goes out NOTE When traveling at high speed if the machine travels on soft ground or up a slope and the load increases the travel is au tomatically switched to low speed travel but the travel speed boost monitor displays stays lighted up 1 Engine Pre heating...

Page 64: ...1 4 MONITOR SWITCHES PORTION 1 Lamp Switch Use this switch 1 to turn on the headlamps and the lamp in side the machine monitor Each time the switch is pressed it is switched between ON and OFF 1 Lamp Switch 2 Travel Speed Selector Switch ...

Page 65: ... switch 2 to switch the travel speed to low speed or high speed Each time the switch is pressed it is switched between low speed and high speed When the machine is traveling at high speed the travel speed boost monitor lights up NOTE When the engine is started the travel speed is automatically set to low speed When traveling at high speed if the machine travels on soft ground or up a slope and the...

Page 66: ...e key It will automatically return to the ON position HEAT preheat position When starting the engine in cold weather turn the key to this position When the key is set to the HEAT position the preheating monitor lights up Keep the key at this position until the preheating monitor goes out When the preheating monitor goes out release the key When the key is released it will return to the OFF positio...

Page 67: ...e speed switch and operates the fan motor Turn the switch 5 clockwise to increase the fan speed If operated after the opening of the tap installed on the heater it ensures the circulation of warm air and serves as heating switch See 3 5 2 VENTILATION AND HEATING The temperature of the air delivered by the heater is adjusted through the knob T Turn the knob clockwise to increase the temperature and...

Page 68: ...o the washer spray posi tion for more than 10 seconds continuously Do not press the switch to the washer spray position if the washer fluid tank is empty 7 Room Lamp Switch Machines equipped with cab This switch 7 is used to turn on the room lamp Position A Lights off Position B Lights up 8 Cigarette Lighter 12V Machines equipped with cab This lighter 8 is used to light cigarettes When the cigaret...

Page 69: ...ab left side only Left Work Equipment Control Lever Right Work Equipment Control Lever Fuel Control Lever Blade Control Lever 6 7 8 9 10 11 Travel Lever pedal is equipment Pedal Lock for boom swing control pedal Boom Swing Control Pedal Floor Lock Cancel Lever Pedal Lock for attachment control pedal Attachment Control Pedal ...

Page 70: ...it is set to LOCK position L This safety lock lever is a hydraulic lock type so even when it is at LOCK position L the control levers and ped als move but the work equipment and and the machine do not move NOTE If the safety lock lever on either the left or right is not at LOCK position L the engine will not start Check that the safety lock lever is at LOCK position L before operating the starting...

Page 71: ... to right b Swing to left Arm operation c Arm IN d Arm OUT N Neutral The upper structure and arm are held in that posi tion when they come to a stop and do not move This right work equipment control lever 3 is used to operate the arm and upper structure Boom operation e RAISE f LOWER Bucket operation g DUMP h CURL N Neutral The boom and bucket are held in that position when they come to a stop and...

Page 72: ...nd output a Low idling Push the lever fully b High idling Pull the lever fully 5 Blade Control Lever IMPORTANT When digging operations using the blade are continued for more than one hour pay careful attention to the rise in the water temperature This lever 5 is used to control the blade a Lower b Raise ...

Page 73: ... care when traveling or steering the machine using the pedal When getting in or out of the operator s compartment there is danger that your toes may catch on the travel pedal so always fold back the pedal so that it cannot be operated This lever 6 is used to change the direction of travel This indicates operation of the pedal a FORWARD This lever is pushed forward The pedal is angled forward b REV...

Page 74: ...al Boom is stopped and held in this position 9 Floor Lock Cancel Lever WARNING Always observe the warning and caution items when opening or closing the floor If the operation is car ried out mistakenly it may lead to serious personal injury Do not open or close the floor on slopes Do not open or close the floor when there is a strong wind When opening or closing the floor pull this lever 9 to FREE...

Page 75: ...dentally pressed while it is not locked a serious accident may occur This plate 10 is a device to lock the attachment control pedal When the pedal is covered by the plate it is locked 11 Attachment Control Pedal This pedal 11 is used to operate the attachment Top of pedal depressed Oil flows to right side of arm hydrau lic tank side Bottom of pedal depressed Oil flows to left side of arm opera tor...

Page 76: ...ening the front window hold the grip securely with both hands pull up and do not let go until the automatic lock catch is locked When closing the front window hold the handle with your both hands and close it firmly It is possible to stow pull up the front window in the roof of the operator s compartment The front window bottom can be removed and stored at the rear inside the cab Opening 1 Stop th...

Page 77: ...A and pull the front window up diagonally 5 When it will move no further to the rear push up knobs A to lock securely When pushing up check that lock lever B moves in lock release direction F then returns in the lock direction L Push up knobs A to lock securely ...

Page 78: ...front and pull knobs A down to release the lock 4 Grip left and right knobs A and slowly lower the front window diagonally to the front 5 When the bottom of the window reaches the top of the bottom window push left and right knobs A to the front and push against left and right stoppers C to engage the lock When pushing to the front check that lock lever B moves in lock release direction F then ret...

Page 79: ...w 2 After removing the lower window stow it in left and right brackets B at the rear of the operator s cab Installing Lower Windshield With the front window open install the bottom part of the front window 1 Open the front window then hold grip A pull up and re move the bottom window 2 Install the lower window and push it down securely ...

Page 80: ...d knob 2 Be careful not to get your hands caught between the front pillar or center pillar If there is anyone inside the cab call out to that person before opening or closing the door IMPORTANT Always clean the step at the entrance to the cab and take action to prevent snow or mud from accumu lating If snow accumulates it may freeze and make it impossible to open the door Door Lock When closing th...

Page 81: ... fragments remained in the windowsills not to get hurt with them Moreover watch your step not to slip over the broken glasses scattered on the ground To prevent injury from pieces of glass remove all the broken glass from the window frame Be careful al so not to slip on the broken glass that has fallen to the ground In case it becomes impossible to open the door a hammer 1 to be used for escape fr...

Page 82: ...s inserted only partially into the lock it may break OPENING AND CLOSING CAPS WITH LOCK Opening 1 Insert the key in the lock 2 Turn the key clockwise then open the cap Closing 1 Tighten the cap thoroughly then insert the key in the lock 2 Turn the key counterclockwise and then extract it OPENING AND CLOSING COVERS WITH LOCK Opening 1 Insert the key in the lock 2 Turn the key counterclockwise and o...

Page 83: ... 2 of the cover does not move 1 Release lock 1 of the cover For details of the method of opening and closing the cov er with the lock see Section 3 2 8 CAPS AND COVERS WITH LOCK 2 Pull opening knob 2 of the cover and open engine rear cover 3 Pull engine rear cover 3 and open it fully Cover 3 is secured in position by rod 4 4 When closing engine rear cover 3 lift up rod 4 and close cover 3 slightly...

Page 84: ...ion with the rod 1 Open engine rear cover 1 until it is secured in position For details see Section 3 2 9 ENGINE REAR COVER 2 Pull cover opening lever 2 and open cooling cover 3 3 Pull engine rear cover 3 and open it fully Cover 3 is secured in position by rod 4 4 When closing engine rear cover 3 lift up rod 4 and clo se cover 3 slightly When the rod comes out from the groove close the cover Push ...

Page 85: ...ance operations Carefully check the direction of the slot to make sure that the cap is locked 1 Release the lock of the cap 1 and remove it then remo ve the gasket 2 For further details see 3 2 8 CAPS AND COVERS WITH LOCK 2 Loosen the four screws 3 M10 and remove the tank co ver 4 3 After installing the tank cover 4 make sure that the screws 3 have been correctly tightened and put back the gasket ...

Page 86: ...there is any breakage or abnormality in the lock when the floor is opened stop the operation and ask your Ko matsu Dealer to carry out repairs Do not remove the canopy There is danger that the floor may suddenly come up Do not remove the floor mounting bolts 1 There is danger that the floor may suddenly come up When opening tilt open 1 Lower the blade 2 Extend the bucket and arm cylinders fully th...

Page 87: ...trian gular cover 3 6 Open the engine rear cover 4 completely then secure it for further details see 3 2 9 ENGINE REAR COVER 7 Open the cooling cover 5 completely then secure it for further details see 3 2 10 COOLING COVER 8 Loosen the four fastening screws of the platform 6 M14 ...

Page 88: ...r closing the floor do not let any part of your body enter the area under the floor NOTE The floor opening operation is assisted by a gas cylinder so when the ambient temperature is low the operating effort in creases 10 After the floor rises push knob 9 up until lock pin 10 fits in the lock groove 12 of lock plate 11 When lock pin 10 moves to lock groove 12 the 1st stage lock is completed 11 Inse...

Page 89: ...eft hand to pull floor lock release lever 8 in the direction of the arrow to the rear while holding knob 9 with your right hand and pulling it down in the direction of the arrow approx 45 IMPORTANT Lower slowly and check that there is no damage or catching of the wiring or piping When opening or closing the floor do not let any part of your body enter the area under the floor 3 Tighten floor tilt ...

Page 90: ...s is at the top surface of the battery For details of the method of opening and closing the cover on the right side of the machine see 3 2 10 COOLING COVER NOTE A block fuse is a large fuse wire installed to the circuit where a large capacity current is flowing It acts in the same way as a normal fuse to protect the electrical equipment and wir ing from burning out under abnormal current No Fuse c...

Page 91: ...2 17 GREASE GUN HOLDER WARNING Immediately after the engine is stopped the parts are at a high temperature and will cause burns Wait for the temperature to go down before starting the operation The grease pump support is positioned in the upper internal part of the cooling cover When the grease pump is not going to be used insert it in the apposite support Put back the pump with the handle directe...

Page 92: ...essive wear or play in the work equipment cylinders linkage or hoses If any abnormality is found repair it 2 Remove dirt and dust from around engine battery and radiator Check that there is no dirt or dust accumulated around the engine or radiator Check also that there is no flammable material dry leaves twigs etc accumulated around the engine muffler or high temperature parts of the engine or aro...

Page 93: ...ngular cover open the engine rear co ver the cooling cover and make sure that the 4 faste ning screws of the tilting platform 1 are correctly tightened If some screws are loose tighten them If any abnormality is found always carry out repairs or ask your Komatsu Dealer to carry out repairs ...

Page 94: ...o check the coolant level in this condition there is a haz ard of burns Wait for the temperature to go down then turn the cap slowly to release the pressure be fore removing it 1 Open the engine rear cover and cooling cover For de tails see Section 3 2 10 COOLING COVER 2 Check that the cooling water level is between the FULL and LOW range on sub tank 1 If the water level is low add water through t...

Page 95: ...For details see section 3 2 9 ENGINE REAR COVER 2 Remove dipstick G and wipe the oil off with a cloth 3 Completely insert dipstick G into the oil filler pipe then remove it and check the oil level 4 The oil level should be between the H and L marks on dip stick G If the oil level is below the L mark add oil through oil filler F IMPORTANT A blow by reduction device is used Be careful not to let the...

Page 96: ...el 1 Insert the key in starting switch 1 and turn in to the ON position to light up the monitor 2 Check the fuel level on the fuel level indicator 2 If the fu el level is low unlock and remove the cap and refuel through the filler F checking the indicator G Tank capacity 28 l 3 After refuelling tighten the cap thoroughly and lock it IMPORTANT If breather hole 3 in the cab is clogged the pressure i...

Page 97: ...ooling cover For de tails see Section 3 2 10 COOLING COVER 3 Confirm that the oil level is between the H and L marks of sight gauge G IMPORTANT Do not add oil above the H line This will damage the hy draulic circuit or cause the oil to spurt out If oil has been added above the H level stop the upper structure so that the drain plug P under the hydraulic tank will be between both tracks and stop th...

Page 98: ...EAN AND REPLACE AIR CLEANER ELEMENT 4 After checking cleaning or replacing the filtering element press the small piston of the clogging indicator 1 to move it back to its original position CHECKING AND CLEANING THE FILTERING ELEMENT If red ring 1 of the water separator is at the bottom of case 2 there is no water If the ring 1 is floating there is water up to the bottom of the ring so drain the wa...

Page 99: ...hat a fuse of the specified capacity is being used that there are no signs of any disconnection breakage or short circuit in the electric wiring check for any loose terminals and tight en any loose terminals that are found Be particularly careful to check the wiring for the battery starting motor and alternator In addition if any flammable material is accumulated around the battery remove it For t...

Page 100: ...ng out deep digging operations slide the seat to the front to improve the view below the front of the machine B Adjusting reclining Pull up lever 2 and set the seat back to a position which is comfortable for operation then release the lever Sit with your back against the seat back when adjusting If your back is not touching the seat back the seat back may suddenly move forward C Adjusting suspens...

Page 101: ...MACHINE OPERATIONS AND CONTROLS 99 REARVIEW MIRRORS Adjust the angle so that the area behind the operator s compartment can be seen clearly Machine equipped with canopy Machine equipped with cab ...

Page 102: ...t is 24 5 4 9 Nm If the belt surface is scratched or frayed or if the fittings are broken or deformed replace the seat belt unit Fastening and Removing 1 Adjust the seat so that the operator still feels that there is sufficient knee room when fully depressing the pedal while seated with the operator s back against the back rest 2 After adjusting the seat poaition sit in the seat Grip buck le 1 and...

Page 103: ...h a cab there is only a safety lock lever on the left 2 Check the position of each levers 3 Insert the key in starting switch 2 turn the key to the ON position then carry out the following checks 4 The buzzer sounds for approx 1 second then the moni tors and gauges light up for approx 3 seconds Preheating monitor 3 Charge monitor 4 Engine oil pressure monitor 5 Engine water temperature caution lam...

Page 104: ...5 Press lamp switch 9 and check that the working lamp lights up If it does not light up there is probably a blown bulb or disconnection so contact your Komatsu Dealer for repairs 6 Press horn switch 10 to confirm that the horn will sound ...

Page 105: ...gine in confined spaces be particularly careful to ensure good ventilation IMPORTANT Do not keep the starting motor rotating continuously for more than 20 seconds If the engine does not start wait for at least one minute then try again 1 Check the safety lock lever 1 is at the LOCK position L If the safety lock lever is in the FREE position F the en gine does not start NOTE For machines equipped w...

Page 106: ...ing aid fluids as they may cause explosions Exhaust gas is toxic When starting the engine in confined spaces be particularly careful to ensure good ventilation IMPORTANT Do not keep the starting motor rotating continuously for more than 20 seconds If the engine does not start wait for at least one minute then repeat the operation from Step 3 When starting in low temperatures do as follows 1 Check ...

Page 107: ...zzer sounds and pre heating monitor 4 goes out to indicate that the preheat ing is completed NOTE The monitor and gauge also light up when the key is at the HEAT position but this does not indicate any abnormality 4 When pre heating monitor 4 goes off turn the key in stating switch 3 to the START position to start the en gine 5 When the engine starts release the key in starting switch 3 The key wi...

Page 108: ...tions described in this manual Idle the engine for 5 minutes after starting it up Avoid operation with heavy loads or at high speeds Immediately after starting the engine avoid sudden starts sudden acceleration unnecessary sudden stops and sudden changes in direction 3 3 2 2 WARMING UP OPERATION IMPORTANT When the hydraulic oil is at a low temperature do not carry out operations or move the lever ...

Page 109: ... stop position and hold it there for 5 minutes 4 After carrying out the warming up operation check that each gauge and monitor is in the following condition If any abnormality is found carry out maintenance and re pair Engine water temperature gauge 4 Indicator is in cor rect range Fuel gauge 5 Indicator is in correct range Engine oil pressure monitor 6 Monitor is off Charge monitor 7 Monitor is o...

Page 110: ...operated 10 The boom swing does not move when the boom swing control pedal is operated 3 3 3 STOPPING THE ENGINE IMPORTANT If the engine is stopped abruptly service life of component parts of the engine may be considerably re duced Hence do not stop the engine abruptly except in an emergency If the engine has overheated do not try to stop it abruptly but run it at medium speed to allow it to cool ...

Page 111: ... moving Clear all personnal from the machine and the area Clear all obstracles from the path of the machine Check that the travel alarm works properly 3 3 4 1 PREPARATIONS FOR MOVING THE MACHINE OFF 1 Pull fuel control lever 1 towards the high idling position to increase the engine speed A Low idling B High idling 3 3 4 2 MOVING MACHINE FORWARD 1 Set safety lock lever 2 to the FREE position then r...

Page 112: ...ravel speed boost monitor 5 lights up For details of the travel speed values see Section 5 1 SPECIFICATIONS NOTE When the engine is started the travel speed is automatically set to low speed When traveling at high speed if the machine travels on soft ground or up a slope and the load increases the travel is automatically switched to low speed travel so there is no need to operate the switch The tr...

Page 113: ...slowly to move the machine off When the sprocket A is at the front of the machine Push levers 3 forward slowly to move the machine off 4 Switch the travel speed as follows When the travel speed selector switch 4 is pressed the travel speed can be switched between high speed and low speed Each time the switch is pressed the travel speed is switched between low speed and high speed When the machine ...

Page 114: ...travel so there is no need to operate the switch The travel speed boost monitor displays stays lighted up When the load is reduced the travel system returns to high speed travel 5 Check that the travel alarm sounds If the alarm dose not sounds please contact your Komatsu Dealer for repairs 3 3 4 4 STOPPING MACHINE WARNING Avoid stopping suddenly Give yourself ample room when stopping 1 Put the lef...

Page 115: ...e transmission to low speed and the machine travels slowly When the load decreases it automatically returns the transmission to high speed travel Use the travel levers to change direction Avoid sudden changes of direction as far as possible In partic ular when carrying out counter rotation spin turn stop the machine first before turning Operate two travel levers 1 as follows STEERING THE MACHINE W...

Page 116: ...urn to the left NOTE When turning to the right operate the right travel lever in the same way COUNTER ROTATION TURN SPIN TURN When using counter rotation spin turn to turn left pull the left travel lever back and push the right travel lever forward NOTE When using counter rotation spin turn to turn right pull the right travel lever back and push the left travel lever forward ...

Page 117: ...nt control lever 1 to the N position The swing holding brake will be applied NOTE When using the swing on a slope run the engine at low idling and operate the swing lever extremely slowly Be particularly careful to avoid sudden movement when the bucket is loaded When the bucket is loaded and the left work equipment con trol lever is operated the swing holding brake is released so the upper structu...

Page 118: ...t is held in that position Arm control Move the left work equipment control lever to the front or rear to operate the arm Swing control Move the left work equipment control lever to the left or right to swing the upper structure Boom control Move the right work equipment control lever to the front or rear to operate the boom Bucket control Move the right work equipment control lever to the left or...

Page 119: ... CONTROLS 117 Boom swing operation The boom swing operation can be carried out with the boom swing control pedal Blade control Move the lever on the right side of the operator s seat to the front or rear to operate the blade ...

Page 120: ...use the travel force to carry out excavation This will damage the machine or work equipment Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends When operating the cylinder do not operate it to the end of its stroke Always leave a small margin If the cylinder is operated to the end of its stroke force will be brought to bear on the cylinder and this may cause dam age to the pins boom...

Page 121: ...achine Operations Using Machine Dropping Force It is prohibited to carry out digging operations using the drop ping force of the machine When excavating hard rock bed use some other method to break the rock into small pieces before excavating This avoids damage to the machine and also is more economical Support Blade on Both Sides When using the blade as an outrigger never suport the ma chine with...

Page 122: ...peed keep the work equipment close to the ground and try to travel so that the center of the track pass es over the obstacle Folding in Work Equipment When folding in the work equipment to the travel or transpor tation posture be careful not to let the bucket hit the blade Avoid Hitting Blade Be careful not to hit the blade against rocks or boulders This will cause premature damage to the blade or...

Page 123: ...r will be thrown up by the radiator fan This may cause the fan to break Be extremely careful when driving the machine out of water Do not work with the machine immersed in water if the depth exceeds the allowed limits under the track sliding plate 1 In addition for parts that have been immersed in water for a long time pump in grease until the old grease comes out from the bearings Around the buck...

Page 124: ... may be longer but it will ensure safety Always operate or travel in such a way that it is possible to stop safely at any time if the machine slips or be comes unstable When traveling uphill if the shoes slip or it is impossi ble to travel uphill using only the force of the tracks do not use the pulling force of the arm to help the machine travel uphill There is danger that the machine may turn ov...

Page 125: ... the ground stop the machine then start the engine again CAB DOORS ON SLOPE If the engine stops when the machine is on a slope never use the left work equipment control lever to carry out swing operations The upper structure will swing under its own weight Do not open or close the sliding door cab specifications on slopes when traveling or operating The operating effort may change suddenly Always ...

Page 126: ...with the ground Never push with the teeth The angle between the boom and arm should be 90 to 110 When only one side is affixed in mud use the bucket to raise the track then lay boards or logs and drive the machine out STUCK BOTH SIDES OF TRACKS If the track on both sides are in mud and the machine slips and cannot move use the procedure given above to lay logs or timber dig the bucket into the gro...

Page 127: ... The range for excavating with the arm is from a 45 angle away from the machine to a 30 angle toward the machine There may be some differences depending on the digging depth not try to keep within the above range rather than oper ating to the end of the cylinder stroke DITCHING WORK Ditching work can be performed efficiently by attaching a bucket which matches the digging operation and then settin...

Page 128: ...26 SMOOTHING WORK When refilling after excavation and when smoothing the ground surface use the blade SIDE DITCHING WORK The machine can be used for side ditching in a confined work site by combining the swing and boom swing operations ...

Page 129: ...ments The described procedures are valid also for the cou pling of the mechanical constraints of the optional equi pment 1 Position the bucket on a level surface directing it so that the flat part of its back rests on the ground 2 Remove the tie rod pin 1 and the arm connection pin 2 3 Change the bucket taking care to clean the pins the bu shings and the seals perfectly and to grease the pins sli ...

Page 130: ...ving If the control levers are touched by accident the work equipment or machine may move suddenly and this may lead to a serious accident Before standing up from the operator s seat always set the safety lock lever se curely to the LOCK position Set the blade on the downhill side and lower it to the ground 1 Put the left and right travel levers 1 in the NEUTRAL po sition then stop the machine 2 L...

Page 131: ... and undercarriage also check for any leakage of oil or coolant If any abnormalities are found repair them 2 Fill the fuel tank 3 Check the engine compartment for paper and debris Clean out any paper and debris to avoid a fire hazard 4 Remove any mud affixed to the undercarriage 3 3 17 LOCKING Always lock the following places 1 Operator s cab door machines equipped with cab Always close the window...

Page 132: ...o suffer damage such as the corners of steel plates U shaped ditch lin ers blocks on crushed rock or the sharp edges of rocks iron beams or scrap iron Any damage resulting from the customer s mistaken use of the machine shall not be included in the scope of the warranty 3 3 18 3 USING THE RUBBER SHOES PROHIBITED WORKS Do not carry out the following types of work Rotations or other operations on ha...

Page 133: ... vegetables squeezed for oil or wash the machine after use Avoid handling materials that will attack the adhesion of the steel core such as salt ammonium sulphate potas sium chloride potassium sulphate or calcium superphosphate or wash the machine after use The adhesion of the core will be attacked by salt so avoid using the machine in coastal areas When handling salt sugar flour or soy seeds the ...

Page 134: ... 3 Do not proceed along the edge of slopes or on rough ground keeping one track in horizontal position and the other inclined or partially lifted with the machine inclined more than approx 10 To avoid damaging the rubber shoes always proceed with both tracks in horizontal posi tion 4 If the machine is operated as explained in 1 to 3 above the rubber shoes is slackened Do not steer the machine in t...

Page 135: ...ere the rubber shoe cannot move to the side because of the object it is passing over or because of some other object When the rubber shoe has moved out of alignment and the idler or track roller are not aligned with the core If the machine travels in reverse in this condition the rubber shoe will come off If the machine is turned in this condition the rubber shoe will come off ...

Page 136: ... length thickness and strength and install them at a maximum slope of 15 When using piled soil compact the piled soil fully to prevent the slope face from collapsing Remove the mud from the undercarriage to prevent the machine from slipping to the side on the ramps Remove any water snow grease oil or other substanc es stuck to the ramps Never change the direction of travel when the machine is on t...

Page 137: ...n the trailer and put blocks un der the tires to ensure that the trailer does not move Make the slope of the ramps a maximum of 15 3 Run the engine at low speed A Low idling 4 Check that the travel speed boost monitor is off If the monitor is on the speed is set to high speed travel so press the travel speed selector switch The monitor goes out and the speed is shifted to low speed travel Ramp Dis...

Page 138: ...th the ramps and that the centerline of the machine matches that of the trail er Align the direction of travel with the ramps and travel slowly Lower the work equipment as far as possible without causing interference When on the ramps operate only the travel lever Do not operate any other lever 7 Stop the machine at the specified place then swing the upper structure slowly 180 8 Load the machine a...

Page 139: ...ith the safety lock lever NOTE For machines equipped with a cab there is only a safety lock lever on the left 5 Lock the sliding door cab specification and covers with locks See Section 3 2 8 CAPS AND COVERS WITH LOCK IMPORTANT Do not use the hole at the back of the track frame for towing or lifting the machine 6 Place blocks under both ends of the tracks to prevent the machine from moving during ...

Page 140: ...ening the machine 4 Start the engine Warm the engine up fully 5 Check that the travel speed boost monitor is off If the monitor is on the speed is set to high speed travel so press the travel speed selector switch The monitor goes out and the speed is shifted to low speed travel 6 Set the safety lock lever to the FREE position Machine equipped with canopy Machine equipped with cab NOTE For machine...

Page 141: ...Raise the blade 9 Raise the work equipment align the direction of travel with the ramp and travel slowly Lower the work equipment as far as possible without causing interference When on the ramps operate only the travel lever Do not operate any other lever or pedal ...

Page 142: ...of the cab to lift the machine This will damage the cab It is prohibited to use the transportation holes in the track frame to lift the machine This will damage the track frame IMPORTANT For the details on the machine weight see the section of 5 1 SPECIFICATIONS The lifting procedure applies to machines with standard specifications The method of lifting differs according to the attachmen ts and op...

Page 143: ...ely 7 Install shackles to the lifting holes 2 places on both ends of the blade then install the wire ropes 8 Pass the wire rope through the bracket on the boom see diagram on right IMPORTANT Be sure to use the three brackets Do not lift the machine with the boom or the upper structure swung Be careful not to get the hoses caught 9 Set the lifting angle of the wire rope to 30 to 40 then lift the ma...

Page 144: ...e Do not smoke when handling antifreeze IMPORTANT Never use methanol ethanol or propanol based antifreeze Never use any water leakage prevention agent or any antifreeze containing such an agent Do not mix different types of antifreeze For details of the antifreeze mixture when changing the coolant see 4 9 1 b CLEAN INSIDE OF COOLING SYS TEM Use a Permanent Antifreeze ethylene glycol mixed with cor...

Page 145: ...lose as possible to 100 and insulate it against cold temperature so that the machine can be started easily the next morning NOTE Measure the specific gravity and calculate the rate of charge from the following conversion table As the battery capacity drops markedly in low temperatures cover the battery or remove it from the machine keep it in a warm place and install it again the next morning If t...

Page 146: ...the machine on wooden boards The boards help protect the tracks from being frozen in soil so the machine can move next morning Open the drain valve and drain any water collected in the fuel system to prevent it from freezing After operation in water or mud remove water from undercarriage as described below to extend undercarriage service life 1 Swing 90 with engine at low idling and bring the work...

Page 147: ... po sition 3 6 2 DURING STORAGE WARNING When it is necessary to perform the rust preventive operation while the machine is indoors open the doors and windows to improve ventilation and prevent gas poisoning During storage always operate the machine once a month so that a new film of oil will be coated over movable parts and component surfaces At the same time also charge the battery When operating...

Page 148: ...ork equipment is lowered under no load from a high position the bucket speed will drop momentarily when the bucket teeth are more or less at the horizontal position When starting or stopping the swing noise will be emitted from the brake valve When going down a steep slope at low speed a noise will be emitted from the travel motor brake valve 3 7 3 TOWING THE MACHINE WARNING When towing the machin...

Page 149: ...nything that will cause sparks Battery electrolyte is dilute sulphuric acid and it will at tack your clothes and skin If it gets on your clothes or on your skin immediately wash it off with a large amount of water If it gets in your eyes wash it out with fresh water and consult a doctor When handling batteries always wear protective gog gles and rubber gloves When removing the battery first discon...

Page 150: ...o as follows Flammable hydrogen gas is generated when the battery is charged so remove the battery from the chassis take it to a well ventilated place and remove the battery caps before charging it Tighten the battery caps securely If any battery cap is dam aged replace it immediately Set the voltage of the charger to match the voltage of the battery to be charged If the correct voltage is not se ...

Page 151: ...cise good care so that the booster cable clips may not contact each other or they contact the chassis IMPORTANT The size of the booster cable and clip should be suitable for the battery size The battery of the normal machine must be the same capacity as that of the engine to be started Check the cables and clips for damage or corrosion Make sure that the cables and clips are firmly connected Check...

Page 152: ...arting switch of the problem machine to the START position and start the engine If the engine doesn t start at first try again after 2 minutes or so BOOSTER CABLE DISCONNECTION After the engine has started disconnect the booster cables in reverse order of connection 1 Remove one clip of booster cable B from the engine block of the problem machine 2 Remove the other clip of booster cable B from the...

Page 153: ...nator Defective wiring Replace Check repair Abnormal noise is generated from alternator Defective alternator Replace Starting motor dose not turn when starting switch is turned to ON Defective wiring Insufficient battery charge Blown fuse Check repair Charge Replace Starting motor pinion repeatedly moves in and out makes rattling sound Insufficient battery charge Charge Starting motor turns engine...

Page 154: ...emedy Engine oil pressure monitor flashes buzzer sounds at same time Engine oil pan oil level is low sucking in air Clogged oil filter cartridge Defective tightening of oil pipe joint oil leakage from damaged part Defective engine oil pressure sensor Add oil specified level see CHECK BEFORE STARTING Replace cartridge see EVERY 500 HOURS SERVICE Check repair Replace sensor Steam is emitted from top...

Page 155: ...G Replace pump or nozzle See ELECTRICAL SYSTEM See ELECTRICAL SYSTEM Adjust valve clearance Exhaust gas is whiter or blue Too mach oil in oil pan Improper fuel Add oil specified level see CHECK BEFORE STARTING Change to specified fuel Exhaust gas occasionally turns black Clogging air cleaner element Defective nozzle Defective compression Clean or repalce see WHEN REQUIRED Replace nozzles See defec...

Page 156: ...154 PAGE INTENTIONALLY LEFT BLANK ...

Page 157: ...MAINTENANCE 155 ...

Page 158: ...Use automobile window washer fluid and be careful not to let any dirt get into it FRESH AND CLEAN LUBRICANTS Use clean oil and grease Also keep the containers of the oil and grease clean Keep foreign materials away from oil and grease CHECK DRAINED OIL AND USED FILTER After oil is changed or filters are replaced check the old oil and filters for metal particles and foreign materials If large quant...

Page 159: ...e to a place that is free of dust to prevent dirt from getting into the oil AVOID MIXING LUBRICANTS If a different brand or grade of oil has to be added drain the old oil and replace all the oil with the new brand or grade of oil Never mix different brand or grade of oil LOCKING THE INSPECTION COVERS Lock inspection cover securely into position with the lock bar If inspection or maintenance is per...

Page 160: ...dangerous if parts are dropped inside the machine and get caught in the lever linkage mechanism Is there any coolant or oil leaks Have all nuts and bolts been tightened Checks when operating engine For details of the checks when operating the engine see 2 8 7 USE OF THE ENGINE DURING MAINTE NANCE OPERATIONS and pay careful attention to safety Are the inspection and maintenance items working proper...

Page 161: ...e oil always replace the related filters at the same time We recommend you have an analysis made of the oil periodically to check the condition of the machine For those who wish to use this service please contact your Komatsu Dealer When using commercially available oil it may be necessary to shorten the oil change interval For this reason we recommend making full use of the Komatsu oil clinic 4 2...

Page 162: ...freeze to water differs according to the ambient temperature For details of the mixing proportions see 4 9 1 b CLEAN INSIDE OF COOLING SYSTEM If the engine overheats wait for the engine to cool before adding coolant If the coolant level is low it will cause overheating and will also cause problems with corrosion from the air in the coolant 4 2 1 4 GREASE Grease is used to prevent twisting and nois...

Page 163: ... for action to take This low cost service can save you high costs and inconven ience in the future so we strongly recommend you to avail yourself of this service KOWA ANALYSIS ITEMS Analysis of metal wear particles This uses an ICP Inductively Coupled Plasma analyzer to measure the density of metal wear particles in the oil Measurement of particle quantity This uses a PQI Particle Quantifier Index...

Page 164: ...t 4 2 1 7 FILTERS Filters are extremely important safety parts They prevent impurities in the fuel and air circuits from entering im portant equipment and causing problems Replace all filters periodically For details see the Operation and Maintenance Manual However when working in severe conditions replace the filters at shorter intervals according to the oil and fuel sulfur content being used Nev...

Page 165: ...rations and immediately after operations During opera tions it is also under high pressure so be careful of the following points when carrying out inspection and main tenance of hydraulic related equipment Stop the machine on level ground lower the bucket completely to the ground and set so that there is no pressure on the cylinder circuits Always stop the engine Immediately after the engine is st...

Page 166: ...er of the machine serial number and check for the latest part number when ordering parts 4 3 1 WEAR PARTS LIST The parts in parentheses are to be replaced at the same time Item Part No Part name Q ty Replacement frequentcy Engine oil filter YM119305 35151 Cartridge 1 Every 500 hours service Fuel filter with water separator YM119810 55650 YM102103 55520 Element O Ring 1 Every 500 hours service Fuel...

Page 167: ...raulic system with biodegradable oil See 4 4 1 Fuel tank DIESEL FUEL Grease fitting GREASE HYPER WHITE GREASE Cooling system WATER Add antifreeze Engine oil pan Final drive case each Hydraulic system Fuel tank Cooling system Specified capacity liters 3 7 0 6 29 28 3 0 Refill capacity liters 3 4 0 6 19 30 20 10 0 10 20 30 40 50 C SAE 30 SAE 15W 40 SAE 10W 30 1 ASTM D975 N 2 SAE 30 SAE 10W SAE 10W 3...

Page 168: ...he engine oil change interval to half There is no problem if single grade oil is mixed with multigrade oil SAE10W 30 15W 40 but be sure to add sin gle grade oil that matches the temperature range in the table We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications Specified capacity Total amount of oil includi...

Page 169: ... engine coolant 7 CASTROL Turbomax RX super CRD EP EPX Hypoy Hypoy B Hypoy C MS3 Spheerol EPL2 Anti freeze 8 CHEVRON Delo 400 Universal gear Ultra duty grease 2 9 CONOCO Fleet motor oil Universal gear lubricant Super sta grease 10 ELF Multiperformance 3C Performance 3C Tranself EP Tranself EP type 2 Glacelf 11 EXXON ESSO Essolube D3 Essolube XD 3 Essolube XD 3 Extra Esso heavy duty Exxon heavy dut...

Page 170: ...ltifak EP2 Starplex 2 Code 2055 startex antifreeze coolant 19 TOTAL Rubia S Rubia X Total EP Total transmission TM Multis EP2 Antigel antifreeze 20 UNION Guardol MP gear lube LS Unoba EP 21 VEEDOL Turbostar Diesel star MDC Multigear Multigear B Multigear C Antifreeze No Supplier Engine oil CD o CE SAE10W 30 40 10W30 15W40 The 15W40 oil marked is CE Gear oil GL 4 o GL 5 SAE80 90 140 Grease Lithium ...

Page 171: ...e en dothermic motor the transmissions the braking system etc Before introducing the synthetic biodegradable oil in the hydraulic system empty the system complete ly disconnecting the cylinders and all the parts that may contain ordinary oil and replace the drain filter with a new one Start the engine and let it idle without using the work equipment wait until the oil reaches a temperature of at l...

Page 172: ...This driving torque table is not valid for screws or nuts that must lock parts made of nylon or similar ma terials on to washers or components made of nylon or nonferrous materials RYA02980 Thread diameter of bolt a mm Width across flats b mm Tightening torque Target value Service limit Nm kgm Nm kgm 8 10 12 14 10 13 17 19 22 13 2 31 66 113 172 1 35 3 2 6 7 11 5 17 5 11 8 14 7 27 34 59 74 98 123 1...

Page 173: ...MPORTANT For the lubrication procedures for the single points see 4 9 3 a LUBRICATING The type of lubricant to be used is indicated in the lubricant table See 4 4 LUBRICANTS FUEL AND COOLANT SPECIFICATIONS Grease Oil Filter SWING CIRCLE GREASING POINT RKAA0380 ...

Page 174: ...Tighten a loos ened clamp again or replace a defective hose as such abnormality requires When replacing the hoses always replace the O rings gaskets and other such parts at the same time Ask your Komatsu Dealer to replace the critical parts 4 7 1 SAFETY CRITICAL PARTS LIST Type of check Check item Check before starting Leakages from joints hydraulic pipes or fuel pipes Periodical check monthly che...

Page 175: ...equipped with rubber shoes 187 i REPLACE RUBBER SHOES Machine equipped with rubber shoes 189 j CHECK WINDOW WASHER FLUID LEVEL ADD FLUID Machine equipped with cab 191 k CHECK CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER Machine equipped with cab 192 l BLEEDING AIR FROM HYDRAULIC SYSTEM 192 CHECKS BEFORE STARTING EVERY 500 HOURS MAINTENANCE a LUBRICATING 194 b CHANGE OIL IN ENGINE OIL PAN REP...

Page 176: ... the right If the machine contains synthetic biodegradable oil type HE ES the filter must be changed after the first 50 hours of opera tion 4 8 2 b CHANGING THE HYDRAULIC OIL Change the hydraulic oil in the tank according to the intervals indicated in the table on the right On machines containing synthetic biodegradable oil type HE ES change the oil after the first 500 hours of operation and for t...

Page 177: ... see section 3 2 9 ENGINE REAR COVER 2 If the dust indicator 1 shows red clean the air cleaner el ement IMPORTANT Do not clean the air cleaner element before the red pis ton in dust indicator 1 appears If the air cleaner element is cleaned frequently before the red piston in the dust indicator appears the air cleaner cannot provide the proper performance and the cleaning efficiency is lowered Clea...

Page 178: ...f small holes or thinner parts are found on the element when it is checked by shining a light through it after clean ing replace the element IMPORTANT When cleaning the element do not hit it or beat it against something Do not use an element whose folds or gasket or seal are damaged Wrap unused element and store them in a dry place 9 Remove the cloth or adhesive tape used to cover the air connecto...

Page 179: ...e coolant has the important function of preventing corrosion as well as preventing freezing Even in the areas where freezing is not an issue the use of antifreeze coolant is essential Komatsu machines are supplied with Komatsu Supercoolant AF NAC Komatsu Supercoolant AF NAC has ex cellent anticorrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours Komatsu...

Page 180: ... it con tacts the stopper to release the pressure 3 Following this push radiator cap 1 turn it until it contacts the stopper then remove it 4 Place a container to catch the coolant under the drain ho se installed to drain valve 2 and under coolant drain plug 3 on the engine block 5 Open drain valve 2 and drain the water Remove drain plug 3 from the engine cylinder block and drain the water 6 After...

Page 181: ...aining off the cooling water of reserve tank 4 clean the inside of the reserve tank and refill the water be tween FULL and LOW level 12 Stop the engine About 3 minutes later supply city water up to the water filler then close radiator cap ...

Page 182: ...re starting operations in the morning to prevent the electrolyte from freezing Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below When Checking Electrolyte Level from Side of Battery If it is possible to check the electrolyte level from the side of the battery check as follows 1 Open the cover at the right side of the machine 2 Use a wet ...

Page 183: ... add distilled water so that the level reaches the bottom of the sleeve UP PER LEVEL line without fail Use the diagram below for reference and check if the electrolyte reaches the bottom of the sleeve 3 After adding distilled water tighten cap 1 securely NOTE If distilled water is added to above the bottom of the sleeve use a syringe to lower the level to the bottom of the sleeve Neutralize the re...

Page 184: ... 2 7 Turn the lever 1 of the filter to position OPEN B 8 After washing the fuel filter bleed the circuit For further details on the bleeding procedure see para graph 4 9 3 c CHANGING THE FUEL FILTER ELEMENT WITH WATER SEPARATOR BLEEDING THE CIR CUIT 4 9 1 e DRAIN WATER AND SEDIMENT FROM FUEL TANK IMPORTANT Never use trichlene for washing the inside of the tank Use diesel fuel only Carry out this p...

Page 185: ...ween the top surface of the track and the bottom surface of the wooden block Standard deflection Deflection a should be 5 to 15 mm 0 197 to 0 6 in If the track tension is not at the standard value adjust it in the following manner ADJUSTMENT WARNING There is danger of plug 1 flying out under the high in ternal pressure of the grease Never loosen plug 1 more than 1 turn Never loosen any part other ...

Page 186: ...re given below If the track tension is not relieved by this procedure please contact your Komatsu Dealer for repairs 1 Loosen plug 1 gradually to release the grease 2 When loosening plug 1 turn it a maximum of one turn 3 If the grease does not come out smoothly move the ma chine forwards and backwards a short distance 4 Tighten plug 1 5 To check that the correct tension has been achieved run the e...

Page 187: ...aler LUG HEIGHT If lug height a is reduced by wear the drawbar pull will drop If a is less than 5 mm 0 2 in replace with a new part If the lug wears and the steel cord inside the shoe is ex posed for two links or more replace with a new part Machine equipped with rubber shoes RUBBER SHOE STEEL CODE CUTS If more than half of the steel cord layer on one side is cut re place with a new part RYA05200 ...

Page 188: ...gation of the rubber shoe but also damage to the grease cylinder RUBBER SHOE CRACKS If the cracks between the rubber shoe lugs increase to a size of approx 60 mm 2 36 in the rubber shoe must be repaired Even if the crack is small and short if the steel cord can be seen inside carry out repairs immediately If the length is less than 30 mm 1 18 in or the depth of the crack is less than 10 mm 0 39 in...

Page 189: ... the track sliding plate 2 then position it on the track 3 Measure the maximum deflection between the top surface of the rubber shoe and the bottom surface of the wooden block Standard deflection Deflection a should be 1 to 3 mm 0 039 to 0 118 in If the track tension is not at the standard value adjust it in the following manner ADJUSTMENT WARNING There is danger of the plug flying out under the h...

Page 190: ... gradually to release the grease 2 When loosening plug 1 turn it a maximum of one turn 3 If the grease does not come out smoothly move the ma chine forwards and backwards a short distance 4 Tighten plug 1 5 To check if the tension is correct run the engine at low idling move the machine slowly forward by an amount equal to the length of track on ground then stop the ma chine 7 Check the track tens...

Page 191: ... check that the track tension is correct run the engine at low idling move the machine forward a distance equal to the length of track on ground then stop the ma chine IMPORTANT It is possible to switch from rubber to steel shoes In any case it is necessary to remove and adjust the shock absorber of the idler roller For this operation contact your Komatsu Dealer Prepare a grease gun Prepare a stee...

Page 192: ...ub ber shoe come up from the idler then to the side to re move RUBBER SHOES INSTALLATION 1 Raise the chassis with the boom and arm When doing this operate the levers slowly 2 Mesh the rubber shoe with the sprocket and fit it over the idler 3 Rotate the sprocket in reverse then push in the rubber shoe and stop the rotation 4 Fit a steel pipe in the rubber shoe then rotate the sprock et again and fi...

Page 193: ...omobile window washer fluid if necessary At this time take care that dust does not enter the tank NOTE Open the engine rear cover and cooling cover For details see Section 3 2 10 COOLING COVER When adding fluid be careful not to let any dust get in Mixture Ratio of Pure Washer Fluid and Water The proportion differs according to the ambient temperature so dilute the washer fluid with water to the f...

Page 194: ...rtup or a cylinder is pushed up to its stroke end air taken inside the cylinder may cause damage to the piston packing 3 Run the engine at low idling and extend and retract each cylinder 4 to 5 times taking care so that a cylinder may not be brought up to its stroke end Stop the cylinder approx 100 mm 3 9 in short of its stroke end 4 Next operate each cylinder 3 to 4 times to the end of its stroke...

Page 195: ... see 3 3 1 2 CHECKS BEFORE STARTING Check coolant level add coolant Check oil level in engine oil pan add oil Check fuel level add fuel Check oil level in hydraulic tank add oil Check dust indicator Checking and cleaning the fuel filter element Check electric wirings Check function of horn ...

Page 196: ...ng the swing circle and swing pinion turn the chassis little by little to change the position while carrying out the lubrication LUBRICATING WORK EQUIPMENT IMPORTANT When breaking in a new machine carry out lubrication every 10 hours for the first 100 hours of opera tion If any abnormal sound comes from the greasing point carry out greasing regardless of the inspection and maintenance interval Aft...

Page 197: ...Blade cylinder foot pin 1 place 7 Blade cylinder rod end 1 place 8 Blade foot pin 2 places 9 Boom swing bracket pin 2 places 10 Boom swing cylinder rod end pin 1 place 11 Boom foot pin 2 places 12 Boom cylinder foot pin 1 place 13 Boom cylinder rod end 1 place 14 Arm cylinder foot pin 1 place 15 Arm cylinder rod end 1 place 16 Boom Arm connecting pins 1 place 17 Bucket cylinder foot pin 1 place ...

Page 198: ...y to avoid getting oil on your self and drain the oil 3 Check the drained oil and if there are excessive metal particles or foreign material please contact your Komatsu Dealer 4 Install drain plug P 5 Open the engine rear cover 6 Using a filter wrench turn filter cartridge 1 counterclock wise to remove it 7 Clean the filter holder coat the new filter cartridge packing and threaded portion with cle...

Page 199: ...the new filter element cup with fuel coat the packing surface with engine oil then install it to the filter holder 6 Tighten the filter ring until the gasket makes contact with the filter carrier surface then give a further 2 3 turn IMPORTANT If the filter element cup is tightened too far the packing will be damaged and this will lead to leakage of fuel If the filter element cup is too loose fuel ...

Page 200: ... inside the case the oil or plug may fly out Loosen the plug slowly to release the pressure Prepare a container to catch drained oil Prepare a hexagon wrench 1 Set so that plug G is at the top with plug G and plug P perpendicular to the ground 2 Set the container to catch oil under plug P 3 Remove plug G with a hexagonal wrench Oil level shouldbe near the bottom of the plug hole G 4 If the oil lev...

Page 201: ...6 to a new precleaner and fa sten them with the clamps 3 and 5 6 Install the precleaner in the clamp 2 and bleed the fuel supply circuit See 4 9 3 c CHANGING THE FUEL FIL TER ELEMENT WITH WATER SEPARATOR 4 9 3 f CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS WARNING If compressed air high pressure water or steam hit your body directly or they cause dirt or dust to be blown up there is a hazar...

Page 202: ...see Section 3 2 12 METHOD OF OPENING TILTING FLOOR When opening tilt open for details 2 Insert a bar between alternator 1 and the cylinder block to fix alternator 1 in position When fixing alternator 1 in position insert a wooden block between the bar and al ternator 1 to prevent any damage to the alternator 3 Loosen alternator adjustment bolt 2 and mounting bolts 3 4 Move alternator 1 to adjust s...

Page 203: ... when carrying out maintenance On machines containing synthetic biodegradable oil type HEES this must be changed for the first time after the first 50 hours of operation and successively every 1000 hours of operation 1 Remove the tank cover 1 For further details see para graph 3 2 11 TANK COVER 2 Loosen bolts 2 then remove plate 3 to the front 3 Remove the cap from oil filler F and release the int...

Page 204: ...ll pressure remaining inside the case the oil or plug may fly out Loosen the plug slowly to release the pressure Oils filters coolants and batteries are considered special waste and must be collected and disposed of according to the regulations in force Prepare a container to catch drained oil Prepare a hexagon wrench 1 Set so that plug G is at the top with plug G and plug P perpendicular to the g...

Page 205: ...enance Immediately after the engine is stopped the parts and oil are at a high temperature and will cause bur ns Wait for the temperature to go down before starting the operation When removing the oil filler cap oil may spurt out so turn it slowly to release the internal pressure befo re removing it Oils filters coolants and batteries are considered special waste and must be collected and disposed...

Page 206: ...oil If strainer 7 is damaged replace it with a new one 12 Secure strainer 7 with bolt 6 then install hose 5 and secure it in position with hose clamp 4 13 After completing the adjustment close the floor For de tails see Section 3 2 12 METHOD OF OPENING TILT ING FLOOR 14 Add the replacement amount of oil through oil filler F Check that the oil level is between the H and L lines on the sight gauge G...

Page 207: ...TECHNICAL SPECIFICATIONS 205 ...

Page 208: ...el engine Engine horsepower KW HP rpm 15 5 21 2500 A Overall length mm 3810 B Overall height mm 2520 C Overall width mm 1450 D Track width mm 250 E Radius of upper structure Canopy specified mm 805 Cab specified 865 F Length of track mm 1880 G Tumbler center distance mm 1440 Min ground clearance mm 285 Travel speed Low High km h MPH 2 8 1 7 4 6 2 9 Continuous swing speed rpm 8 9 ...

Page 209: ...ed mm 4100 Cab specified mm 4100 D Max vertical wall depth mm 1950 E Max dumping height Canopy specified mm 2820 Cab specified mm 2820 F Min swing radius of work equipment mm 1790 Min swing radius of work equipment At boom swing mm 1450 G Max reach at ground level mm 4170 H Max blade lifting height mm 340 I Max blade lowering depth mm 230 ...

Page 210: ...0 kg Do not attempt to lift loads unless the machine is standing on firm level ground NOTE Loads do not exceed 87 of hydraulic capacity or 78 of tipping capacity Load limited by hydraulic capacity rather than tipping STANDARD ARM STANDARD WEIGHT BLADE DOWN Unit kg 2 m 3 m Max 3 0 m 535 370 2 0 m 630 630 550 325 555 255 1 0 m 1380 575 710 310 595 225 0 m 1550 550 805 300 645 245 1 0 m 1240 560 710 ...

Page 211: ...630 550 405 555 320 1 0 m 1380 715 710 390 595 290 0 m 1550 695 805 380 645 310 1 0 m 1240 705 710 430 STANDARD ARM ADDED WEIGHT BLADE UP Unit kg 2 m 3 m Max 3 0 m 535 460 2 0 m 630 630 510 405 405 320 1 0 m 930 715 495 390 370 290 0 m 905 695 485 380 395 310 1 0 m 915 705 550 430 LONG ARM STANDARD WEIGHT BLADE DOWN Unit kg 2 m 3 m Max 3 0 m 400 330 450 425 2 0 m 440 325 470 295 1 0 m 1115 590 625...

Page 212: ...0 290 340 260 LONG ARM ADDED WEIGHT BLADE DOWN Unit kg 2 m 3 m Max 3 0 m 400 400 450 425 2 0 m 440 410 470 270 1 0 m 1115 730 625 390 505 245 0 m 1540 685 780 375 550 260 1 0 m 1405 685 725 370 605 330 LONG ARM ADDED WEIGHT BLADE UP Unit kg 2 m 3 m Max 3 0 m 400 400 445 425 2 0 m 440 410 340 270 1 0 m 945 730 495 390 315 245 0 m 895 685 475 375 330 260 1 0 m 895 685 475 370 420 330 A B A B A B ...

Page 213: ... attempt to lift loads unless the machine is standing on firm level ground NOTE Loads do not exceed 87 of hydraulic capacity or 78 of tipping capacity Load limited by hydraulic capacity rather than tipping STANDARD ARM STANDARD WEIGHT BLADE DOWN Unit kg 2 m 3 m Max 3 0 m 535 425 630 630 630 550 370 555 295 1 0 m 1380 655 710 360 595 265 0 m 1550 635 805 345 645 285 1 0 m 1240 645 710 395 A B RKA01...

Page 214: ...0 550 460 555 365 1 0 m 1380 805 710 445 595 335 0 m 1550 785 805 435 645 355 1 0 m 1240 795 710 490 STANDARD ARM ADDED WEIGHT BLADE UP Unit kg 2 m 3 m Max 3 0 m 535 520 2 0 m 630 630 550 460 460 365 1 0 m 1040 805 555 445 415 335 0 m 1015 785 545 435 445 355 1 0 m 1025 795 620 490 LONG ARM STANDARD WEIGHT BLADE DOWN Unit kg 2 m 3 m Max 3 0 m 400 375 450 325 2 0 m 440 375 470 245 1 0 m 1115 670 62...

Page 215: ... 340 390 300 LONG ARM ADDED WEIGHT BLADE DOWN Unit kg 2 m 3 m Max 3 0 m 400 400 450 400 2 0 m 440 440 470 310 1 0 m 1115 820 625 445 505 285 0 m 1540 775 780 425 550 300 1 0 m 1405 780 725 425 605 380 LONG ARM ADDED WEIGHT BLADE UP Unit kg 2 m 3 m Max 3 0 m 400 400 450 400 2 0 m 440 440 385 310 1 0 m 1055 820 555 445 360 285 0 m 1010 775 540 425 380 300 1 0 m 1010 780 535 425 480 380 A B A B A B ...

Page 216: ...LIFTING CAPACITIES 214 PAGE INTENTIONALLY LEFT BLANK ...

Page 217: ...AUTHORISED OPTIONAL EQUIPMENT 215 ...

Page 218: ...n an attachment is installed the swing range and center of gravity of the machine are different and the machine may move in an unexpected way Be sure that you understand the condition of the machine properly Before starting operations set up a fence around the machine to prevent people from entering Never operate the machine when there are people near the machine To prevent serious accidents cause...

Page 219: ... to stop the swing to the point where the swing stops completely so there is danger of mistaking the distance and hitting other objects Allow a margin to the stopping point when operating In addition the hydraulic drift the gradual downward movement caused by the weight of the work equipment when the work equipment is stopped in a raised condi tion will also increase If the correct procedure is no...

Page 220: ...cu m Measure referred to the tool diameter Measure referred to the tool length EQUIPMENT MAX WEIGHT kg MAX DIMENSIONS MAX SAE CAPACITY m3 MAX OPERA TING PRESSURE bar MAX FLOW RATE l min Width mm Height mm Bucket 45 500 0 075 Ditch cleaning bucket 40 1250 0 050 Ditch digging bucket 50 950 0 070 Clamshell bucket 70 275 1000 0 025 210 24 Hydraulic hammer 150 950 140 35 Drill 90 250 1500 210 35 ...

Page 221: ...NT 6 2 1 LOCATIONS 1 Quick Coupler This quick coupler 1 is used to connect the piping equipped with quick coupler at the attachment end 1 3 4 2 RKA13370 1 2 Quick Coupler Selector Valve 3 4 Attachment Control Pedal Pedal Lock for attachment control pedal RKA01590 1 ...

Page 222: ... This pedal 3 is used to operate the attachment Top of pedal depressed Oil flows to right side of arm hydrau lic tank side Bottom of pedal depressed Oil flows to left side of arm opera tor s seat side 4 Pedal Lock for attachment control pedal WARNING When attachment operation is not required lock the at tachment control pedal with the pedal lock If the attachment control pedal is accidentally pres...

Page 223: ...onstraints carry out the hy draulic connections by proceeding as follows 1 Stop the engine and move the hydraulic controls in all di rections in order to completely release the residual pres sures present in the circuits of the machine 2 Press the optional equipment control pedal to release the residual pressure present in the delivery pipe 3 Slowly loosen the hydraulic oil filling cap in such a w...

Page 224: ... first the engine is run at high speed or the cylinder is operated to the end of its stroke the air insi de the cylinder may cause damage to the piston packing or other parts 3 Bleeding air from attachment if equipped For machine equipped with attachment such as the breaker actuate the attachment pedal about 10 times to bleed the air completely from the attachment circuit while running the engine ...

Page 225: ... your Ko matsu Dealer to carry out the adjustment Precautions when Using Check that selector valve 1 is at the 1 WAY breaker posi tion a When using the breaker pull the fuel control lever back fully then return it slightly and keep it in this position for opera tions The position for 80 of engine output If the breaker is operated with the engine at full throttle it will lead to failure When using ...

Page 226: ... details of other precautions when handling the attach ment read and use correctly the instruction manual provided by the attachment manufacturer 6 3 1 LONG TERM STORAGE If the machine is not to be used for a long time do as follows Install the cap to the quick coupler Set the selector valve to the position for general attachments such as the crusher Lock the attachment control pedal with the peda...

Page 227: ... and the life of the equipment Any injuries accidents or damage resulting from the use of unauthorized attachments or options will not be the responsibility of Komatsu 6 4 1 ATTACHMENT COMBINATIONS WARNING Depending on the type or combination of work equipment there is danger that the work equipment may hit the cab or machine body When using unfamiliar work equipment for the first time check befor...

Page 228: ...ary Hence consult your Komatsu Dealer for the selection of op timum attachments 6 5 1 HYDRAULIC BREAKER MAIN APPLICATIONS Crushed rock Demolition work Road construction This attachment can be used for a wide range of applications including demolition of buildings breaking up road surfaces or slag tunnel work rock crushing and breaking operations in quarries Keep the chisel pushed perpendicularly a...

Page 229: ...ally move out of line with each oth er so always adjust the bucket cylinder to keep them aligned Always keep the chisel pressed against the impact surface properly to prevent using the impact force when there is no re sistance PROHIBITED WORKS To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the ma chine in any of the following ways ...

Page 230: ...erations using the swing force Moving the chisel while carrying out impacting operations Holding the chisel horizontal or pointed up when carrying out impacting operations Twisting the chisel when it has penetrated the rock Pecking operations ...

Page 231: ...ply grease in the correct position IMPORTANT If the breaker is greased in an improper posture it is filled with more grease than necessary As a result soil and sand will enter the hydraulic circuit and can damage the hydraulic components while the breaker is in use Therefore be sure to grease the breaker holding it in the right posture ...

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Page 234: ... 2005 KOMATSU UTILITY EUROPE S p A All Rights Reserved Printed in Europe ...

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