ThismaterialisproprietarytoKomatsuAmericaInternationalCompanyandisnottobereproduced,used,ordisclosed exceptinaccordancewithwrittenauthorizationfromKomatsuAmericaInternationalCompany.
Itisourpolicytoimproveourproductswheneveritispossibleandpracticaltodoso.Wereservetherighttomake changesoraddimprovementsatanytimewithoutincurringanyobligationtoinstallsuchchangesonproductssold previously.
Duetothiscontinuousprogramofresearchanddevelopment,periodicrevisionsmaybemadetothispublication.Itis recommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision.
PRODUCTPUBLICATIONSINFORMATION
VariousproductPartsandServicePublicationsareavailabletoallKOMATSUconstructionequipment owners,includingoperationandmaintenancemanuals,partsbooksandservicemanuals.
Specialpublications,suchasservicetool,airconditioningandturbochargerservicemanualsarealso availableaswellasselectedOperationandServicemanualsinforeignlanguages.
ThePublicationslistedbelowareavailableforthisparticularmachine(s). DESCRIPTIONFORMNUMBER
PARTSBOOK-PAPER: ChassisandEngine..........................................BEPB005700
PARTSBOOK-MICROFICHE:
PartsandServicePublicationscanonlybeacquiredbyauthorizedKOMATSUdistributorsusingthe KomatsuAmericaInternationalCompanyPartsInventoryProcessingSystem(PIPS).
IfthePIPSsystemisnotavailableatthedistributorlocation,thenthefollowingRequisitionforTechnical ServicePublicationsandServiceFormscanbeused.FormKDC91Eisshownonthereversesideofthis page.
COMPLETEFORM ANDRETURNTO
•DataKomPublishingCorporation
440NorthFairwayDrive
VernonHills,IL60061-8112U.S.A.
Attn:ServicePublications
FaxNo.(847)970-4186
TelNo.(847)970-5887
COMPANYNAME
SHIPTO • TYPEorPRINT ONLY
ATTN.
STREETADDRESS
CITY,STATE,ZIPCODE COUNTRY
PURCHASEORDERNO.
ORDERDATE
• PHONENO.FAXNO.SHIPPINGMETHODDISTR/BRANCHCODE
IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERANDMACHINE SERIALNUMBERMUSTBESHOWN.
QTY.PUBLICATIONFORMNO.P-Paper
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FOREWORD
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SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepair techniquesrecommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Some oftheseoperationsrequiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.The cautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarises ormaypossiblyarise,firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONSPREPARATIONSFORWORK
Mistakesinoperationareextremelydangerous.Readthe7.Beforeaddingoilormakingrepairs,parkthemachine OPERATION&MAINTENANCEMANUALcarefullyonhard,levelground,andblockthewheelsortracks beforeoperatingthemachine.topreventthemachinefrommoving.
1.Beforecarryingoutanygreasingorrepairs,readall8.Beforestartingwork,lowerblade,ripper,bucketor theprecautionsgivenonthedecalswhicharefixedtoanyotherworkequipmenttotheground.Ifthisisnot themachine.possible,insertthesafetypinoruseblocksto
preventtheworkequipmentfromfalling.Inaddition,
2.Whencarryingoutanyoperation,alwayswearsafetybesuretolockallthecontrolleversandhangwarning shoesandhelmet.Donotwearlooseworkclothes,signsonthem. orclotheswithbuttonsmissing.
•Alwayswearsafetyglasseswhenhittingpartswithamachinewithblocks,jacksorstandsbeforestarting hammer.work.
•Alwayswearsafetyglasseswhengrindingpartswith10.Removeallmudandoilfromthestepsorother agrinder,etc.placesusedtogetonandoffthemachine.Always
9.Whendisassemblingorassembling,supportthe usethehandrails,laddersorstepswhengettingon
3.Ifweldingrepairsareneeded,alwayshaveatrained,oroffthemachine.Neverjumponoroffthemachine. experiencedweldercarryoutthework.Whencarry-Ifitisimpossibletousethehandrails,laddersor ingoutweldingwork,alwayswearweldinggloves,steps,useastandtoprovidesafefooting. apron,glasses,capandotherclothessuitedfor weldingwork.
PRECAUTIONSDURINGWORK
4.Whencarryingoutanyoperationwithtwoormore11.Whenremovingtheoilfillercap,drainplugorhydrauworkers,alwaysagreeontheoperatingprocedurelicpressuremeasuringplugs,loosenthemslowlyto beforestarting.Alwaysinformyourfellowworkerspreventtheoilfromspurtingout.Beforedisconnecting beforestartinganystepoftheoperation.Beforeorremovingcomponentsoftheoil,waterorair startingwork,hangUNDERREPAIRsignsonthecircuits,firstremovethepressurecompletelyfromthe controlsintheoperator'scompartment.circuit.
5.Keepalltoolsingoodconditionandlearnthecorrect12.Thewaterandoilinthecircuitsarehotwhenthe waytousethem.engineisstopped,sobecarefulnottogetburned.
Waitfortheoilandwatertocoolbeforecarryingout
6.Decideaplaceintherepairworkshoptokeeptoolsanyworkontheoilorwatercircuits. andremovedparts.Alwayskeepthetoolsandparts intheircorrectplaces.Alwayskeeptheworkarea13.Beforestartingwork,removetheleadsfromthe cleanandmakesurethatthereisnodirtoroilonthebattery.ALWAYSremovetheleadfromthenegative floor.Smokeonlyintheareasprovidedforsmoking.(G)terminalfirst. Neversmokewhileworking.
14.Whenraisingheavycomponents,useahoistor•Wheninstallinghosesandwires,besurethatthey crane.Checkthatthewirerope,chainsandhookswillnotbedamagedbycontactwithotherpartswhen arefreefromdamage.Alwaysuseliftingequipmentthemachineisbeingoperated. whichhasamplecapacity.Installtheliftingequipmentatthecorrectplaces.Useahoistorcraneand20.Wheninstallinghighpressurehoses,makesurethat operateslowlytopreventthecomponentfromhittingtheyarenottwisted.Damagedtubesaredangerous, anyotherpart.Donotworkwithanypartstillraisedsobeextremelycarefulwheninstallingtubesforhigh bythehoistorcrane.pressurecircuits.Alsocheckthatconnectingparts
15.Whenremovingcoverswhichareunderpressureor underpressurefromaspring,alwaysleavetwobolts21.Whenassemblingorinstallingparts,alwaysusethe inpositiononoppositesides.Slowlyreleasethespecifiedtighteningtorques.Wheninstallingprotecpressure,thenslowlyloosentheboltstoremove.tivepartssuchasguards,orpartswhichvibrate
16.Whenremovingcomponents,becarefulnottobreakthattheyareinstalledcorrectly. ordamagethewiring,Damagedwiringmaycause electricalfires.22.Whenaligningtwoholes,neverinsertyourfingersor
17.Whenremovingpiping,stopthefueloroilfromhole. spillingout.Ifanyfueloroildripsontothefloor,wipe itupimmediately.Fueloroilonthefloorcancause23.Whenmeasuringhydraulicpressure,checkthatthe youtoslip,orcanevenstartfires.measuringtooliscorrectlyassembledbeforetaking
18.Asageneralrule,donotusegasolinetowashparts. Inparticular,useonlytheminimumofgasolinewhen24.Takecarewhenremovingorinstallingthetracksof washingelectricalparts.track-typemachines.Whenremovingthetrack,the
trackseparatessuddenly,soneverletanyonestand
19.Besuretoassembleallpartsagainintheiroriginalateitherendofthetrack. places.Replaceanydamagedpartwithnewparts. arecorrectlyinstalled. violentlyorrotateathighspeed,becarefultocheck hand.Becarefulnottogetyourfingerscaughtina anymeasurements.
