Page 1
WEAM007000
Operation & Maintenance
Manual
PC20MR-2
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PC20MR-2 15001
WARNING
Unsafe use of this machine may cause serious injury
or death. Operators 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.
and up
Page 2
Page 3
FOREWORD
1.1 FOREWORD
• This manual has been carried out by Komatsu Utility in order to supply their customers with all the necessary information on the machine and the safety regulations related to it, together with the use and maintenance instructions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine
efficient over time.
• The operation manual, together with the spare parts catalogue, is an integral part of the machine and must accompany it, even when it is resold, until its final disposal.
• The manual must be handled with the greatest care and always kept on board the machine, so that it can be
consulted at any moment; it must be placed in the appropriate compartment inside the seat support, where also
the ownership documents and the logbook are usually kept.
• This manual must be given to the persons who have to use the machine and carry out the routine maintenance
operations; they must read the contents carefully more than once, in such a way as to clearly understand what
are the correct operating conditions and the dangerous conditions that must be avoided.
In case of loss or damage, request a new copy to Komatsu or your Komatsu Dealer.
• The illustrations contained in this manual may represent machine configurations available on request.
Komatsu machines are constantly improved in order to increase their efficiency and reliability; this manual sums
up all the information regarding the most recent techniques applied at the moment in which the machine is marketed.
For any further and/or updated information, contact your Komatsu Dealer.
• Punctual periodic annotations regarding 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 information is needed, do not hesitate to contact your Komatsu Dealer: he always knows how to get the
best performance from the machine, he can suggest the use of the equipment that is most suitable for specific
needs and can provide the technical assistance necessary for any change that may be required to conform the
machine to the safety standards and traffic rules.
Furthermore, Komatsu Dealers also ensure their assistance for the supply of Komatsu genuine spare parts,
which alone guarantee safety and interchangeability.
• The table included in this manual must be filled in with the machine data, which are the data that must always be
indicated to the Dealer when requiring assistance and ordering spare parts.
CAUTION
• The incorrect use of the machine and inappropriate maintenance operations may cause serious injuries
and even death.
• Operators and maintenance personnel must carefully read this manual before using the machine or performing maintenance operations.
• Any serious accident that may occur during the use of the machine or during maintenance operations is
due to failure to comply with the instructions given herein.
• The procedures and precautions described in this manual are valid for application to the machine only
when it is used correctly.
If the machine is used for any purpose or in any way other than those described herein, the operator
shall be responsible for his own safety and for the safety of any other person involved.
1
Page 4
INFORMATION ON SAFETY
1.2 INFORMATION ON SAFETY
Many accidents are caused by insufficient knowledge of and failure to comply with the safety regulations prescribed for the maintenance operations that must be performed on the machine.
In order to avoid accidents, before starting work and before carrying out any maintenance operation, carefully read
and be sure to understand all the information and warnings contained in this manual and given on the plates applied on to the machine. To enable you to use this machine safely, safety precautions and labels are given in this
manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
DANGER
q Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
This signal word is to be limited to most extreme situations.
WARNING
q Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
q Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
It may also be used to alert against unsafe practices.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is are useful to know.
IMPORTANT
• This word is used for precautions that must be taken to avoid actions which could shorten the life of the
machine.
NOTE
• This gives information that is useful to know.
Komatsu cannot reasonably predict every circumstance that might involve a potential hazard during the operation
or maintenance of the machine; for this reason, the safety messages included in this manual and applied onto the
machine may not include all possible safety precautions.
If all the procedures and operations prescribed for this machine are kept to, you can be sure that the operator and
the persons in the vicinity can work in total safety, with no risk of damaging the machine. In case of doubt regarding the safety measures necessary for some procedures, contact Komatsu or your local Dealer.
DANGER
• Before starting any maintenance operation, position the machine on a firm and level surface, lower the
equipment to the ground, engage the safety locks of either the equipment and the controls and stop the
engine.
DANGER
• To make the information clearer, some illustrations in this manual represent the machine without safety
guards. Do not use the machine without guards and do not start the engine when the engine protection
casing is open, if this is not expressly prescribed for some specific maintenance operations.
2
Page 5
INFORMATION ON SAFETY
WARNING
• It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu cannot be
held liable for any damage to persons, property or the machine, if this has been tampered with by modifying the standard setting of 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 be carried out by the operator, correctly seated in driving position.
3
Page 6
INTRODUCTION
1.3 INTRODUCTION
1.3.1 INTENDED USES
The Komatsu MACHINES described in this manual have been designed and constructed to be used mainly for
EXCAVATI ON a nd EAR TH-MO VIN G OPERATIO NS.
If provided with suitable safety devices, they can be used with authorized optional equipment having the characteristics illustrated at point “6. AUTHORIZED OPTIONAL EQUIPMENT”.
1.3.2 IMPROPER OR UNAUTHORIZED USES
CAUTION
• This paragraph describes some of the improper or unauthorized uses of the machine; since it is impossible to predict all the possible improper uses, if the machine happens to be used for particular applications, contact your Komatsu Dealer before carrying out the work.
IMPORTANT
• The instructions regarding the authorized optional equipment are given in the relevant operation and
maintenance manuals; if the equipment is supplied by Komatsu, these publications are enclosed to this
manual.
• The instructions regarding the assembly of the authorized equipment, the controls requiring special arrangements on the machine and 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 CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.
• USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.
• USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.
1.3.3 MAIN CHARACTERISTICS
• Simple and easy operation.
• Hydrostatic transmission obtained through two axial piston motors that operate epicyclic reduction gears.
• Rotation of the upper structure achieved by means of an axial piston hydraulic motor acting on an epicyclic reduction gear.
• Main equipment servolevers ensuring also combined movements that can be modulated proportionally and continually.
• Pedal controls for the boom swing and the optional equipment.
• Lever controls for travel and blade.
• Travel speed increase achieved through a pedal-operated push button.
• Complete series of instruments visible from the operating position.
• Lever accelerator.
• Easy maintenance with simplified intervals.
4
Page 7
INTRODUCTION
1.3.4 RUNNING-IN
Every machine is scrupulously adjusted and tested before delivery.
A new machine, however, must be used carefully for the first 100 hours, in order to ensure proper running-in of the
various components.
If the machine is subjected to excessive work load at the beginning of operation, its potential yield and its functionality will be shortly and untimely reduced.
Every new machine must be used carefully, paying special attention to the following indications:
• After the start, let the engine idle for 5 minutes, in such a way as to warm it up gradually before actual operation.
• Avoid operating the machine with the limit loads allowed or at high speed.
• Avoid abrupt starts or accelerations, useless sudden decelerations 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 performed 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 the oil filters (cartridges), check their inner part to make sure that there are no deposits.
If considerable deposits are observed, find out what may have caused them before starting the machine.
• The number of operating hours is indicated by the hour meter.
1.3.5 DIRECTIONS OF MACHINE
Front
Operator's seat
Left
Right
Sprocket
Rear
RYA00050
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat is facing the front and the sprocket is at the rear of the machine.
5
Page 8
PRODUCT IDENTIFICATION
1.4 PRODUCT IDENTIFICATION
The Komatsu EXCAVATOR and its main components are identified by serial numbers stamped on the identification plates.
The serial number and the identification numbers of the components are the only numbers that must be indicated
to the Dealer when requiring assistance and ordering spare parts.
1.4.1 MACHINE SERIAL NUMBER
The machine serial number is stamped on the front upper part of
the main frame, on the left side.
RKA01330
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
The Komatsu EXCAVATORS described in the present manual are
provided with the CE mark, which certifies that they are in compliance 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.
Product Identification Number
MANUFACTURER
Product Identification Number
RKA01331
MODEL
SERIAL No.
MANUFACT.YEAR
MASS
ENGINE POWER
KOMATSU UTILITY EUROPE S.p.A 36025 NOVENTA VICENTINA (VI) - I
UNDER LICENSE OF KOMATSU LTD., TOKYO, JAPAN
22L-09-R1370
MODEL
SERIAL No.
MANUFACT.YEAR
MASS
ENGINE POWER
kg
kw
RWA39210
kg
kw
MANUFACTURER
KOMATSU UTILITY EUROPE S.p.A 36025 NOVENTA VICENTINA (VI) - I
UNDER LICENSE OF KOMATSU LTD., TOKYO, JAPAN
6
Page 9
PRODUCT IDENTIFICATION
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
The serial number 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).
1
RKAA0300
7
Page 10
PRODUCT IDENTIFICATION
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER
The serial number is stamped on the plate positioned on the upper 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
8
Page 11
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS
Machine n. Model
Product identification number (PIN)
Engine n.
Travel reduction gear n.
Swing reduction gear n.
Cab n.
Dealer:
PRODUCT IDENTIFICATION
Address:
Person to contact:
NOTES:
Te l.
9
Page 12
TABLE OF CONTENTS
TABLE OF CONTENTS
FOREWORD
1.1 FOREWORD.......................................................................................................................................... 1
1.2 INFORMATION ON SAFETY ................................................................................................................ 2
1.3 INTRODUCTION ................................................................................................................................... 4
1.3.1 INTENDED USES..................................................................................................................... 4
1.3.2 IMPROPER OR UNAUTHORIZED USES ................................................................................ 4
1.3.3 MAIN CHARACTERISTICS ...................................................................................................... 4
1.3.4 RUNNING-IN ............................................................................................................................ 5
1.3.5 DIRECTIONS OF MACHINE .................................................................................................... 5
1.4 PRODUCT IDENTIFICATION ............................................................................................................... 6
1.4.1 MACHINE SERIAL NUMBER .................................................................................................. 6
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) ... 6
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE ................................... 7
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER ................................................................... 7
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER ..................................................................... 8
1.4.6 CAB SERIAL NUMBER ........................................................................................................... 8
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS ................................................................... 9
SAFETY AND ACCIDENT PREVENTION
2.1 SAFETY, NOISE AND VIBRATION PLATES....................................................................................... 18
2.1.1 POSITION OF THE SAFETY PLATES..................................................................................... 18
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS ......................................................................... 19
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB ......................................... 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 TO FUEL AND OIL ...................................................................... 29
2.2.8 PREVENTING BURNS ............................................................................................................ 29
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER ..................................................... 30
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ........................................ 30
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT ......................................................................... 31
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE ...................................................... 31
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT................................................................ 31
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE ................................................. 32
2.3.1 SAFETY ON THE WORK SITE ............................................................................................... 32
2.3.2 FIRE PREVENTION ................................................................................................................ 32
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB.............................................. 32
2.3.4 ROOM VENTILATION ............................................................................................................. 33
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS ................................................................ 33
2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES .................. 33
10
Page 13
TABLE OF CONTENTS
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING............................................................................. 34
2.4.1 STARTING THE ENGINE .......................................................................................................34
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE .......................................... 34
2.4.3 CHECKS FOR TRAVELLING IN REVERSE ........................................................................... 35
2.4.4 MOVING THE MACHINE ........................................................................................................35
2.4.5 MOVING ON SLOPES ............................................................................................................ 36
2.4.6 WORKING ON SLOPES .........................................................................................................37
2.4.7 UNAUTHORIZED OPERATIONS ........................................................................................... 37
2.4.8 PREVENTING ELECTROCUTION .......................................................................................... 39
2.4.9 VISIBILITY ................................................................................................................................ 39
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES ........................................................ 39
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ......................................... 40
2.4.12 WORKING ON LOOSE GROUND ........................................................................................... 40
2.4.13 PARKING THE MACHINE ....................................................................................................... 40
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES ................................................................ 41
2.5.1 LOADING AND UNLOADING ................................................................................................. 41
2.5.2 TRANSPORT ........................................................................................................................... 41
2.6 BATTERY .............................................................................................................................................. 42
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY ............................................ 42
2.6.2 STARTING WITH BOOSTER CABLES .................................................................................. 42
2.7 PRECAUTIONS FOR THE REMOVAL ................................................................................................ 43
2.8 PRECAUTIONS FOR MAINTENANCE................................................................................................. 44
2.8.1 WARNING PLATES ................................................................................................................ 44
2.8.2 TOOLS .................................................................................................................................... 44
2.8.3 PERSONNEL ........................................................................................................................... 44
2.8.4 EQUIPMENT ........................................................................................................................... 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
2.8.12 USING LAMPS ........................................................................................................................ 47
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR ......................... 48
2.8.14 PRECAUTIONS CONCERNING THE STARTER ................................................................... 48
2.8.15 HANDLING HIGH-PRESSURE PIPES .................................................................................... 48
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL ......................... 49
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES
AND HIGH PRESSURE .......................................................................................................... 49
2.8.18 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE
TO ADJUST THE TRACK TENSION ...................................................................................... 50
2.8.19 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK
ABSORBER UNIT .................................................................................................................... 50
2.8.20 HYDRAULIC ACCUMULATOR ............................................................................................... 50
2.8.21 COOLING FAN AND BELT .....................................................................................................51
2.8.22 WASTE MATERIALS .............................................................................................................. 51
2.8.23 COMPRESSED AIR ................................................................................................................. 51
2.8.24 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES .................. 51
11
Page 14
TABLE OF CONTENTS
THE MACHINE AND ITS OPERATIONS
3.1 MACHINE VIEW ILLUSTRATIONS ...................................................................................................... 54
3.1.1 OVERALL MACHINE VIEW ..................................................................................................... 54
3.1.2 CONTROLS AND GAUGES ..................................................................................................... 55
3.2 DETAILED CONTROLS AND GAUGES .............................................................................................. 56
3.2.1 MONITORING SYSTEM........................................................................................................... 56
3.2.1.1 EMERGENCY MONITORS ..................................................................................... 57
3.2.1.2 METER DISPLAY PORTION .................................................................................. 59
3.2.1.3 PILOT LAMPS......................................................................................................... 61
3.2.1.4 MONITOR SWITCHES PORTION .......................................................................... 62
3.2.2 SWITCHES............................................................................................................................... 64
3.2.3 CONTROL LEVERS AND PEDALS ......................................................................................... 67
3.2.4 WINDSHIELD (Machines equipped with cab) .......................................................................... 74
3.2.5 SLIDING DOOR (Machines equipped with cab) ....................................................................... 78
3.2.6 SLIDING WINDOW (Machines equipped with cab) .................................................................. 78
3.2.7 EMERGENCY ESCAPE HAMMER (Machines equipped with cab) ......................................... 79
3.2.8 CAPS AND COVERS WITH LOCK ......................................................................................... 80
3.2.9 ENGINE REAR COVER ........................................................................................................... 81
3.2.10 COOLING COVER ................................................................................................................... 82
3.2.11 TANK COVER .......................................................................................................................... 83
3.2.12 METHOD OF OPENING (TILTING) FLOOR ............................................................................ 84
3.2.13 FUSE ........................................................................................................................................ 88
3.2.14 BLOCK FUSE ........................................................................................................................... 88
3.2.15 OPERATION MANUAL 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 MACHINE...................................................................... 106
3.3.2.2 WARMING-UP OPERATION .................................................................................. 106
3.3.3 STOPPING THE ENGINE ........................................................................................................108
3.3.4 MACHINE OPERATION ........................................................................................................... 109
3.3.4.1 PREPARATIONS FOR MOVING THE MACHINE OFF .......................................... 109
3.3.4.2 MOVING MACHINE FORWARD............................................................................. 109
3.3.4.3 MOVING MACHINE BACKWARD .......................................................................... 111
3.3.4.4 STOPPING MACHINE ............................................................................................ 112
3.3.5 STEERING THE MACHINE...................................................................................................... 113
3.3.5.1 STEERING .............................................................................................................. 113
3.3.6 SWINGING ............................................................................................................................... 115
3.3.7 WORK EQUIPMENT CONTROLS AND OPERATIONS.......................................................... 116
3.3.8 PROHIBITED OPERATIONS ................................................................................................... 118
3.3.9 GENERAL OPERATION INFORMATION ................................................................................ 120
3.3.10 TRAVELING ON SLOPES........................................................................................................ 122
3.3.11 ESCAPE FROM MUD .............................................................................................................. 124
3.3.12 WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR ....................................... 125
3.3.13 CHANGING THE BUCKET.......................................................................................................127
12
Page 15
TABLE OF CONTENTS
3.3.14 PARKING MACHINE ................................................................................................................ 128
3.3.15 CHECK AFTER SHUT OFF ENGINE ...................................................................................... 129
3.3.16 MACHINE INSPECTION AFTER DAILY WORK...................................................................... 129
3.3.17 LOCKING ................................................................................................................................. 129
3.3.18 RUBBER SHOES (Machines equipped only with rubber shoes) ............................................. 130
3.3.18.1 OPTIMAL USE OF THE RUBBER SHOES ............................................................ 130
3.3.18.2 RUBBER SHOE WARRANTY................................................................................. 130
3.3.18.3 USING THE RUBBER SHOES ............................................................................... 130
3.4 TRANSPORTATION ............................................................................................................................. 134
3.4.1 TRANSPORTATION PROCEDURE ........................................................................................ 134
3.4.2 LOADING AND UNLOADING WITH TRAILER ........................................................................ 134
3.4.3 LIFTING MACHINE .................................................................................................................. 140
3.5 COLD WEATHER OPERATION ........................................................................................................... 142
3.5.1 COLD WEATHER OPERATION INFORMATION .................................................................... 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 PHENOMENA THAT ARE NOT FAILURES ............................................................................ 146
3.7.3 TOWING THE MACHINE ......................................................................................................... 146
3.7.4 SEVERE JOB CONDITION ...................................................................................................... 147
3.7.5 DISCHARGED BATTERY ........................................................................................................ 147
3.7.5.1 BATTERY REMOVAL AND INSTALLATION .......................................................... 148
3.7.5.2 BATTERY CHARGES ............................................................................................. 148
3.7.5.3 STARTING ENGINE WITH BOOSTER CABLES ................................................... 149
3.7.6 OTHER TROUBLE ................................................................................................................... 151
3.7.6.1 ELECTRICAL SYSTEM .......................................................................................... 151
3.7.6.2 CHASSIS ................................................................................................................ 152
3.7.6.3 ENGINE .................................................................................................................. 152
13
Page 16
TABLE OF CONTENTS
MAINTENANCE
4.1 MAINTENANCE INFORMATION .......................................................................................................... 156
4.2 LUBRICANTS, COOLANT AND FILTERS ........................................................................................... 159
4.2.1 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ................................... 159
4.2.1.1 OIL........................................................................................................................... 159
4.2.1.2 FUEL ....................................................................................................................... 159
4.2.1.3 COOLING SYSTEM COOLANT.............................................................................. 160
4.2.1.4 GREASE ................................................................................................................. 160
4.2.1.5 CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS) .............................. 161
4.2.1.6 OIL AND FUEL STORAGE ..................................................................................... 162
4.2.1.7 FILTERS..................................................................................................................162
4.2.2 ELECTRIC SYSTEM MAINTENANCE ..................................................................................... 163
4.2.3 HANDLING HYDRAULIC SYSTEM.......................................................................................... 163
4.3 WEAR PARTS....................................................................................................................................... 164
4.3.1 WEAR PARTS LIST ................................................................................................................. 164
4.4 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS.................................................................. 165
4.4.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS.............................. 169
4.5 TIGHTENING TORQUE SPECIFICATIONS ......................................................................................... 170
4.5.1 TIGHTENING TORQUE LIST................................................................................................... 170
4.6 LUBRICATION ...................................................................................................................................... 171
4.6.1 LUBRICATION DIAGRAM........................................................................................................171
4.7 SAFETY CRITICAL PARTS .................................................................................................................. 172
4.7.1 SAFETY CRITICAL PARTS LIST ............................................................................................. 172
4.8 MAINTENANCE SCHEDULE................................................................................................................ 173
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 FUEL FILTER (WITH WATER SEPARATOR) ........................... 182
4.9.1.e DRAIN WATER AND SEDIMENT FROM FUEL TANK........................................... 182
4.9.1.f CHECK AND ADJUST TRACK TENSION
(Machines equipped with steel shoes) .................................................................... 183
4.9.1.g CHECKING THE RUBBER SHOES
(Machines equipped with rubber shoes) ................................................................. 185
4.9.1.h CHECK AND ADJUST RUBBER SHOE TENSION
(Machine equipped with rubber shoes) ................................................................... 187
4.9.1.i REPLACE RUBBER SHOES
(Machine equipped with rubber shoes) ................................................................... 189
4.9.1.j CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID
(Machine equipped with cab) .................................................................................. 191
4.9.1.k CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER
(Machine equipped with cab) .................................................................................. 192
4.9.1.l BLEEDING AIR FROM HYDRAULIC SYSTEM ...................................................... 192
14
Page 17
TABLE OF CONTENTS
4.9.2 CHECK BEFORE STARTING .................................................................................................. 193
4.9.3 EVERY 500 HOURS MAINTENANCE ..................................................................................... 194
4.9.3.a LUBRICATING ........................................................................................................ 194
4.9.3.b
4.9.3.c CHANGING THE FUEL FILTER ELEMENT (WITH WATER SEPARATOR) ......... 197
4.9.3.d CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................... 198
4.9.3.e REPLACE FEED PUMP PRE-FILTER.................................................................... 199
4.9.3.f CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS...................... 199
4.9.3.g CHECK AND ADJUST COOLING FAN BELT TENSION ....................................... 200
4.9.4 EVERY 1000 HOURS MAINTENANCE ................................................................................... 201
4.9.4.a CHANGING THE HYDRAULIC OIL FILTER ELEMENT ......................................... 201
4.9.4.b CHANGE OIL IN FINAL DRIVE CASE.................................................................... 202
4.9.4.c CHECK ENGINE VALVE CLEARANCE, ADJUST ................................................. 202
4.9.5 EVERY 2000 HOURS MAINTENANCE ................................................................................... 203
4.9.5.a CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER .................................... 203
4.9.5.b CHECK ALTERNATOR, STARTING MOTOR ........................................................ 204
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
196
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 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT........................................................ 218
6.1.3.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT....................................... 218
6.2 MACHINE READY FOR ATTACHMENT .............................................................................................. 219
6.2.1 LOCATIONS ............................................................................................................................. 219
6.2.2 HYDRAULIC CIRCUIT ............................................................................................................. 221
6.2.2.1 ASSEMBLYING AND CONNECTING THE EQUIPMENT ...................................... 221
6.2.2.2 MAINTENANCE ...................................................................................................... 222
6.2.2.3 BLEEDING AIR ....................................................................................................... 222
6.3 ATTACHMENT OPERATIONS ............................................................................................................. 223
6.3.1 LONG TERM STORAGE.......................................................................................................... 224
6.3.2 SPECIFICATIONS.................................................................................................................... 224
6.4 ATTACHMENT GUIDE.......................................................................................................................... 225
6.4.1 ATTACHMENT COMBINATIONS ............................................................................................ 225
6.5 RECOMMENDED ATTACHMENT OPERATIONS ............................................................................... 226
6.5.1 HYDRAULIC BREAKER........................................................................................................... 226
15
Page 18
PAGE INTENTIONALLY LEFT BLANK
16
Page 19
SAFETY AND
ACCIDENT PREVENTION
17
Page 20
SAFETY, NOISE AND VIBRATION PLATES
2.1 SAFETY, NOISE AND VIBRATION PLATES
2.1.1 POSITION OF THE SAFETY PLATES
• The safety plates must always be legible and in good conditions; for this reason, if they are dirty with dust, oil or
grease, it is necessary to clean 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 instructions
given in the additional plates, in any case.
18
RKA13410
Page 21
SAFETY, NOISE AND VIBRATION PLATES
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
The warning and danger plates applied onto the machine are accompanied or represented by pictograms.
The personnel in charge with the operation and maintenance of the machine must know the symbols contained in
the pictograms perfectly; the following description illustrates what 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 machine or performing maintenance operations.
3F05B2612
3F30B2612
RWA00020
RWA00010
SAFETY DISTANCE
• Do not get too near the machine and do not stand within its operating radius.
09651-A0481
RWA00030
22L-98-22270
19
Page 22
SAFETY, NOISE AND VIBRATION PLATES
CAB LIFTING SAFETY LOCK
FILLING THE HYDRAULIC SYSTEM WITH OIL
• (Only for machines in which the synthetic biodegradable
oil type HEES is used)
22L-98-R2390
RKA01380
HYDRAULIC OIL TOPPING UP
REFUELLING
BIO-OIL
RWA00050
D
RWA00040
RWA34380
ENGINE LUBRICATING OIL FILTER
20
RWA00080
Page 23
FUEL FILTER
ENGINE AIR SUCTION FILTER
ENGINE COOLANT
SAFETY, NOISE AND VIBRATION PLATES
D
RWA00060
RWA00090
ENGINE COOLANT PRESSURE
HYDRAULIC OIL LEVEL
RWA00130
RWA00110
RWA00100
HYDRAULIC OIL FILTER
RWA00070
21
Page 24
SAFETY, NOISE AND VIBRATION PLATES
ELECTRIC OUTLET
ANCHORAGE POINT
EMERGENCY EXIT
RWA00120
12 V
RWA00200
RWA00190
LIFTING POINT
RWA04920
22
Page 25
LIFTING CAPACITIES
>
B
SAFETY, NOISE AND VIBRATION PLATES
A
W=450mm
kg 34
L
L=1015mm
L=1365mm
B
3m
2m
1m
0
-1m
0
A
2m 3m MAX
380kg
640kg
585kg
560kg
570kg
555kg
335kg
320kg
310kg
300kg
265kg
235kg
255kg
350kg
210kg
>
22K-98-R2110
23
Page 26
SAFETY, NOISE AND VIBRATION PLATES
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB
• The noise plates must always be legible and in good conditions;
for this reason, if they are dirty with dust, oil or grease, it is necessary to clean 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 noise
plate, make sure that this plate is applied also on the new piece.
RKA01410
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 noise level perceived by the
operator’s ears inside the cab when this is completely closed.
RKA13430
RKA01530
2000/14/EC
24
RKA13420
ISO 6396
Page 27
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY
• The noise plates must always be legible and in good conditions;
for this reason, if they are dirty with dust, oil or grease, it is necessary to clean 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 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.
SAFETY, NOISE AND VIBRATION PLATES
RKA01420
RKA13430
2000/14/EC
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
• According to the results of the tests carried out to determine the vibrations transmitted to the operator by the ma-
chine, the upper limbs are subjected to vibrations lower than 2.5 m/sq.sec., while the seated part of the body is
subjected to vibrations lower than 0.5 m/sq.sec.
25
Page 28
GENERAL PRECAUTIONS
2.2 GENERAL PRECAUTIONS
2.2.1 GENERAL SAFETY RULES
• Only trained and authorized personnel can use the machine and perform maintenance operations.
• Follow all the safety rules, precautions and instructions when using the machine or performing maintenance operations.
• When working with other operators or when the work site is often occupied by other operators, make sure that
everyone knows and understands all the agreed signals and, in any case, that everyone works in such a way as
to be able to see the machine and to be visible to the operator.
2.2.2 SAFETY DEVICES AND GUARDS
• Make sure that all the guards and covers are in the correct position. Have guards and covers changed or repaired if damaged. Neither use the machine without guards, nor remove the guards when the engine is running.
• Always use the proper safety devices to lock the machine when parking and fasten the safety belt.
• Do not remove the safety devices and always keep them in good operating 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 serious injuries or damage.
Avoid also wearing clothes dirty with oil or fuel, since they are
flammable.
• Wear a hard hat, goggles, safety shoes, mask, gloves and
headphones when operating the machine or performing maintenance operations.
• Always wear safety goggles, a hard hat and heavy gloves if
your job involves scattering metal chips or minute materials;
these precautions are particularly useful when driving the equipment connection pins with a hammer and when blowing compressed air into the air filter and the radiator to clean them.
During these operations, make also sure that no one is standing
or working near the machine without the necessary protections.
• When working for 8 hours with a noise level exceeding 90 dBA,
it is necessary to use headphones or ear plugs and be particularly careful, especially at the end of the work shift.
RKA00510
26
Page 29
GENERAL PRECAUTIONS
2.2.4 UNAUTHORIZED MODIFICATIONS
• Any modification made without the authorization of Komatsu can involve hazards.
• Before making a modification, consult your Komatsu Dealer. Komatsu declines any responsibility for injuries or
damage caused by unauthorized modifications.
2.2.5 LEAVING THE OPERATOR’S SEAT
• When leaving the operator’s seat, even if temporarily, make
sure that the machine is in a safe position. (See "2.4.13 PARKING THE MACHINE").
• Before leaving the operator’s seat, carry out the following operations 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 position.
4 - Stop the engine (See "3.3.3 STOPPING THE ENGINE").
5 - If you have to go so far away that you will not be able to
see the machine, extract the ignition key.
RKA01600
CABIN
CANOPY
27
Page 30
GENERAL PRECAUTIONS
2.2.6 GETTING ON AND OFF THE MACHINE
• Do not jump on or off the machine, either when it is at rest and
when it is moving.
• When getting on or off the machine, always use the handles
and the tracks; get on and off the machine very carefully.
• 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 with oil, grease, mud or
rubble.
CANOPY
CABIN
28
Page 31
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL
Fuel, oil and some types of antifreeze can be easily ignited if they
get in contact with a flame. Fuel is particularly flammable and
therefore extremely hazardous.
• Keep any naked flame away from flammable fluids.
• Stop the engine and do not smoke when refuelling.
• Top up with fuel and oil only after stopping the engine and in
well ventilated areas.
• Top up with fuel and oil in a well delimited area and do not allow
unauthorized persons to approach.
• When refuelling, hold the fuel gun firmly and keep it constantly
in contact with the filler until you have finished, in order to avoid
sparks due to static electricity.
• After 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.
GENERAL PRECAUTIONS
RKA00480
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.
• Before checking the coolant level, stop the engine and let the
fluid cool down.
If a check is necessary due to the overheating of the engine,
slowly loosen the radiator plug to release any residual pressure
before removing it. The hot fluid that spurts out may cause serious burns.
• Before checking the engine oil and hydraulic circuit oil levels,
stop the engine and let the oil cool down. The hot oil that can be
sprayed out of the tank may cause serious burns.
RKA00490
RKA00500
29
Page 32
GENERAL PRECAUTIONS
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER
• Asbestos powder can be hazardous to your health if it is in-
haled.
• If you handle materials containing asbestos fibers, keep to the
instructions given below:
1 - Do not use compressed air, but only aspirators to clean
the machine and make sure that the room in which you are
working is properly ventilated.
2 - Use low-pressure water to keep down the dust when clean-
ing.
3 - If there is danger that there may be asbestos powder in the
air, operate the machine with the wind to your back whenever possible.
4 - Even if the cab provides 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 regulations in force.
RKA00440
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 operator is on board the machine and the engine is running.
• Do not stand or work under the arms or the articulations when
the arms are lifted, if you are not sure that the safety locks have
been duly engaged.
• Do not carry out any operation requiring the lifting of the arms, if
you are not sure that the locks are correctly positioned and coupled to the arms.
RKA00450
RKA00460
30
Page 33
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT
• Make sure that fire extinguishers have been provided and
check their position.
• Periodically make sure that the fire extinguishers are loaded
and that you know how to use them.
• Find out where the first aid kit has been located.
• Periodically make sure that the first aid kit contains the neces-
sary disinfectants, bandages, medicins, etc.
• It is necessary to know what to do in case of fire.
• Make sure that you have the phone numbers of the persons or
structures you may need to contact in case of an emergency at
hand (either at the work site and where maintenance operations
are performed).
GENERAL PRECAUTIONS
RKA00470
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE
• If the cab is inadvertently hit or the machine overturns during work, the cab may be damaged with consequent
reduction of its stiffness and of the safety that must be guaranteed to the operator.
Consult 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 equipment, carefully read the relevant instruction manual and keep to the in-
dications given therein.
• Do not use optional or special equipment without the authorization of Komatsu or the Komatsu Dealer.
The installation and use of unauthorized equipment may create safety problems and adversely affect the efficiency and life of the machine.
• Komatsu cannot be held liable for any injury, accident, product failure resulting from the installation and use of
unauthorized equipment.
31
Page 34
PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE
2.3.1 SAFETY ON THE WORK SITE
• Before starting the engine, thoroughly check the area for any
unusual condition of the ground due to which work may be dangerous.
• Check the conditions of the ground at the work site and before
starting the engine define the work plan and the best and safest
operating procedure.
• Make the ground surface as level as possible before carrying
out any operation.
• In case of work on the road, protect pedestrians and cars by
designating a person for work site traffic duty and install fences
around the work site.
• If water lines, gas lines, and telephone or high-voltage electrical
lines are located under the work site, contact the relevant utility
company in order to find out their exact positions or to make
them ineffective until the end of the operations. Be careful not to
sever or damage any of these lines.
RWA00220
• 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 engine compartment, since they can cause fires.
• Check the fuel and hydraulic system pipes for leaks and if nec-
essary repair them. Wipe up any excess oil, fuel or other flammable fluids.
• Make sure that fire extinguishers are available in the work area.
RKA00430
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB
• Do not leave objects or tools lying around in the operator's cab. They may hinder the operation of the controls
and cause serious accidents.
• Keep the cab floor and the controls (pedals and levers) clean, by removing any trace of oil and grease and, as
far as the floor is concerned, remove any excess dirt (earth, stones, etc.).
• Check the safety belt and change it if it is broken or damaged.
Replace any component only with homologated parts available at Komatsu or its Dealers.
32
Page 35
PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE
2.3.4 ROOM VENTILATION
• Before starting the machine in confined or poorly ventilated
places, provide for proper ventilation or connect the engine exhaust pipe to a suction duct. The engine exhaust gases can be
deadly.
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS
• Remove any trace of dirt from the lights, in such 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.
RKA00420
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 must be smooth, with no indentations and
attached to the rubber back of the blade.
In case of doubts on the efficiency of the scraping wire, change the blades.
33
Page 36
PRECAUTIONS TO BE TAKEN WHEN WORKING
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING
2.4.1 STARTING THE ENGINE
• Before getting on the machine, walk around it and check for
people and objects that might be in the way.
• Do not start the engine if warning plates have been attached to
the control levers.
• Before starting the engine, check that the safety lock lever is at
the LOCK position.
• When starting the engine, sound the horn as an alert signal.
• Start the engine only while seated with fastened safety belt.
• Do not allow anyone to get on the machine.
• Do as follows to check that the floor is fixed securely in position.
If it is not fixed securely in position, it may cause serious personal 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.
RKA01370
2.4.2 CHECK THE DIRECTION BEFORE
STARTING THE MACHINE
• Before operating the machine travel levers, check the position
of the blade.
If the blade is positioned on the back of the machine, the operation of the travel levers is inverted.
In this condition, take care not to mistake the travel movements
during the use of the machine.
(See "3.3.4 MACHINE OPERATION").
34
RKA01430
Page 37
2.4.3 CHECKS FOR TRAVELLING IN REVERSE
• When operating in areas that may be hazardous or have poor
visibility, designate a person to direct the movements of the machine and traffic on the work site.
• Make sure that no unauthorized person is within the machine
operating radius or in its travel direction.
If necessary, put up appropriate fences.
• Before moving the machine, sound the horn in order to warn the
persons near the work area.
• There are blind spots behind the machine, which cannot be
seen and where someone may be standing: therefore, it is necessary to make sure that there is no one behind the machine
before travelling in reverse.
PRECAUTIONS TO BE TAKEN WHEN WORKING
RWA06760
2.4.4 MOVING THE MACHINE
• When moving the machine, position the bucket at about 40-50
cm from the ground; this position makes it possible 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 manoeuvres, since they are inverted.
• If the equipment control levers must be used during travel,
avoid moving them abruptly; sudden manoeuvres change the
attitude of the machine and make driving difficult.
• When travelling on rough ground, keep the speed low and avoid
sudden movements of the bucket arm.
• If possible, avoid moving on obstacles.
If the machine has to travel over an obstacle, keep the equipment as close to the ground as possible and travel at low
speed.
Never move on obstacles that may incline the machine considerably (over 10°).
• If one of the two rubber tracks moves on an obstacle or gets into
a hole in the ground, the machine may overturn.
In these cases, reduce the speed to minimum and be very careful to the balance of the machine.
RWA06770
RYA00510
35
Page 38
PRECAUTIONS TO BE TAKEN WHEN WORKING
2.4.5 MOVING ON SLOPES
• Operations on slopes and on river or lake banks with damp
ground may result in the tipping over or slipping of the machine.
• On hills, banks or slopes, keep the bucket very close to the
ground (20-30 cm from the ground) and in case of emergency
quickly lower it to the ground to help the machine stop.
• When traveling up a steep slope, extend the work equipment to
the front to improve the balance, keep the work equipment approximately 20 to 30cm (8 to 12 in) above the ground, and travel
at low speed.
• When traveling downhill, lower the engine speed, keep the travel lever close to the neutral position, and travel at low speed.
When traveling down a slope with a grade of more 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 the machine moves obliquely in these conditions, it may slip.
• Do not move on slopes with inclination exceeding 15°, since the
machine may overturn.
• When the fuel level indicator reaches the red reserve area during work on a slope, immediately provide for refuelling; due to
the inclination of the machine, the engine may suck in air and
suddenly stop, which represents a grave risk for the safety of
the operator and of the persons before the machine.
• If the engine should stop all of a sudden, immediately lower the
bucket to the ground.
36
Page 39
2.4.6 WORKING ON SLOPES
• When working on slopes, if possible avoid rotating the upper
structure, since the machine may lose balance and overturn.
It is particularly dangerous to swing on slopes when the bucket
is full.
If these operations must last longer, accumulate soil in such a
way as to create a horizontal platform 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.
PRECAUTIONS TO BE TAKEN WHEN WORKING
RYA00560
• 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, set the
tracks at right angles to the road shoulder or cliff with the
sprocket at the rear when carrying out operations.
RYA00570
-
RYA00580
RYA00590
37
Page 40
PRECAUTIONS TO BE TAKEN WHEN WORKING
• Do not carry out demolition work under the machine. There is a
hazard that the machine may become unstable and tip over.
• When working on or from the top of buildings or other structures, check the strength and the structure before starting operations. There is a hazard of the building collapsing and causing
serious injury or damage.
• When carrying out demolition work, do not carry out demolition
above your head. There is a hazard of broken parts falling or of
the building collapsing and causing serious injury or property
damage.
RYA00600
• Do not use the impact force of the work equipment for breaking
work. There is a hazard of damage to the work equipment, or a
hazard of serious personal injury being caused by flying pieces
of broken materials, or of the machine tipping over due to reaction 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 tipping over.
When operating on flat ground as well as on slopes.
• Do not suddenly lower, swing, or stop the work equipment.
• Do not suddenly extend or retract the boom cylinder. There
is a hazard that impact will cause the machine to tip over.
• Do not pass the bucket over the head of other workers or over
the operator's seat of dump trucks or other hauling equipment.
The load may spill or the bucket may hit the dump truck and
cause serious injury or property damage.
RYA00610
RYA00620
38
Page 41
PRECAUTIONS TO BE TAKEN WHEN WORKING
2.4.8 PREVENTING ELECTROCUTION
• Digging operations near overhead electric lines are extremely dangerous and they may also cause death due to
electrocution; for this reason, when working near overhead electrical lines always respect the minimum safety
distances prescribed by the competent authorities and by the accident-prevention rules in force.
• As far as underground long-distance lines are concerned, the minimum distance depends on the covering of the
ducts in which the cables are laid.
• The basic safety precautions to be taken to prevent this risk are the following:
1 - Wear shoes with thick rubber or leather soles.
2 - Request the aid of another person who can warn you if the machine gets too close to the electric line.
3 - Operate at low speed.
4 - Learn what is to be done first in case of electrocution.
5 - Keep the phone number of the electricity company and of the nearest first aid station at hand.
• If the work equipment gets accidentally entangled in the cables, the operator must not leave the cab until the
electricity company has insulated the line.
• When carrying out this kind of operations, warn everyone standing in the work area to keep at the minimum distance prescribed from the machine and the work equipment.
• Ask the electricity company 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.
Indicatively, the distances indicated in the table should be respected.
Cable voltage
1.0 kV (distribution line) 5 m
6.6 kV (2–3 insulators) 5.2 m
33 kV (min. 3 insulators) 5.5 m
66 kV (min. 6 insulators) 6 m
154 kV (min. 10 insulators) 8 m
275 kV (min. 19 insulators) 10 m
2.4.9 VISIBILITY
• Switch on the working lights as soon as visibility decreases.
• If visibility decreases due to mist, smoke or heavy rain, stop the machine in a safe position and wait for the
weather to improve until visibility becomes acceptable.
Min. safety
distance
RYA00440
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES
• If the ground is icy or covered with snow, even a slight slope may cause the machine to slip sidewards, therefore
it is advisable to move at low speed and to avoid abrupt starts, stops or turns.
• When it has snowed heavily, the road shoulders and any obstacle are buried in the snow and are not visible,
therefore proceed with care when clearing the snow.
39
Page 42
PRECAUTIONS TO BE TAKEN WHEN WORKING
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
• When working in tunnels, galleries, under electric cables or other ducts (air, telephone lines) and wherever the
height is limited, proceed with the greatest care to prevent the bucket or the arms from causing any damage.
2.4.12 WORKING ON LOOSE GROUND
• Avoid operating the machine too close to the edge of cliffs, overhangs and deep ditches.
These areas may collapse, making the machine fall down or tip over and this could result in serious injuries or
death.
Remember that after heavy rain or earthquakes these dangerous conditions usually get worse.
• The earth laid near ditches is loose and can easily collapse due to the weight or vibrations of the machine.
Be extremely careful: always fasten the safety belt and close the cab door, if provided.
• In case of work in areas where stones or other material may fall on the machine, install the FOPS protection device.
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 operations:
1 - Rotate the bucket to the dumping position and lower the
arms until thrusting the teeth into the ground.
2 - Stop the engine.
3 - Put wedges or safety blocks under the tracks.
• Always rest the work equipment on the ground; if it is necessary
to park with raised arms, make sure that the safety locks are engaged.
• Lock the equipment control by shifting the safety device lever to
the lock position.
• When leaving the machine, remove the ignition key.
• If it is necessary to park on public roads, provide for signalling
the presence of the machine according to the local regulations
in force (signalling fires, fences, road works ahead, alternated
direction and direction signs, etc.).
CABIN
CANOPY
40
Page 43
TRANSPORTING THE MACHINE ON MOTOR VEHICLES
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES
2.5.1 LOADING AND UNLOADING
• Loading and unloading the machine on/from a motor vehicle always involves potential hazards. Proceed with extreme care.
• Perform loading and unloading on firm, level ground. Maintain a
safety distance from the edges of ditches or from road sides.
• If the vehicles used have not been appositely equipped, put
support blocks under the ramps, in order to avoid any bending.
• Always lock the wheels of the transporting vehicle with wedges.
• Always use ramps that are sufficiently wide and can support the
weight of the machine. The longitudinal axes of the ramps must
be parallel to each other and perpendicular to the loading side
board and their distance must be suitable for the tread of the
machine.
• Make sure that the ramps are securely positioned and fastened
to the loading board and that they 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.
Ramp
Distance
between
ramps
Max15
Block
Blocks
RYA00670
• The machine must be loaded on the vehicle with the bucket directed forwards, that is, in the direction of advancement of the
vehicle.
• Do not correct the trajectory of the machine on the ramps. If
necessary, get down the ramps and start the operation again.
• After loading the machine, block the tracks with wedges and secure it with tie-downs or chains that prevent even any sideward
shift. (See "3.4 TRANSPORTATION").
2.5.2 TRANSPORT
• Define the route to be followed, taking in consideration the width, height and weight of the transport means and
of the machine.
Make sure that the dimensions of the machine are compatible with the road and any gallery, subway, bridge,
electric and telephone lines, etc.
• Keep to the regulations in force regarding the permissible width, height, weight of the machine and the transport
speed.
41
Page 44
BATTERY
2.6 BATTERY
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY
• Electrolytic batteries contain sulphuric acid that can quickly burn
the skin and corrode clothes making holes in the fabric. If you
spill acid on yourself, immediately rinse the involved area with
plenty of water.
• Battery acid may cause blindness if splashed into the eyes.
If acid gets accidentally into your eyes, flush them immediately
with plenty of water and consult a doctor without delay.
• If you accidentally swallow some acid, drink a large quantity of
water or milk, beaten egg white or vegetable oil and in any case
antiacid substances like magnesia, bicarbonate, etc. call a doctor or a poisoning prevention center immediately.
• When handling batteries, always wear safety goggles.
• Batteries generate hydrogen. Hydrogen is highly explosive and
can be easily ignited with small sparks or naked flames.
• Before working with batteries, stop the engine and remove the
ignition key.
WRONG
ERRATO
RKA00380
• 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
• When starting the machine with booster cables, always wear
safety goggles.
• When starting the engine by means of another machine, avoid
any contact between the two machines.
• Be sure to connect the positive cable (+) first and then the neg-
ative or earth cable (–) when connecting the booster cables.
Disconnect first the negative or earth (–) cable and then the
positive cable (+) after the start.
• Connect the batteries in parallel: positive to positive and nega-
tive to negative.
RKA00370
RKA00360
RKA00350
• When connecting the earth cable to the frame of the machine to
be started, operate as far as possible from the battery.
(See "3.7.5 DISCHARGED BATTERY").
42
Page 45
2.7 PRECAUTIONS FOR THE REMOVAL
• The draw hook must be used only for the first aid and not for
towing the machine.
• Before moving the machine, make sure that all the controls are
in neutral.
• Incorrect manoeuvres may result in serious injuries or even
death.
• To move the machine, use properly dimensioned steel cables;
do not use worn cables or cables with broken strands (A), twisted cables (B), deformed cables (C).
• During the removal, no one can be allowed to get near the machines or the 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".
PRECAUTIONS FOR THE REMOVAL
RYA00820
CAUTION
• The maximum applicable force for the removal is the following:
PC30MR-2
F= 1665 kg (for canopy)
F= 1790 kg (for cabin)
• Use cables having the same length and draw continuosly
and constantly, without jerks.
• Arrange and couple the machine to be removed by positioning it on the same axis as the towing vehicle; the drawing force must be parallel to the axis of movement of the
machine.
RYA00810
43
Page 46
PRECAUTIONS FOR MAINTENANCE
2.8 PRECAUTIONS FOR MAINTENANCE
2.8.1 WARNING PLATES
• Before starting any maintenance operation, position the machine on a firm and level surface, rest the equipment onto the
ground, engage the safety locks of either the equipment and the
controls and stop the engine.
• If another person starts the engine and operates the control levers while the operator is providing for service, this may result
in serious injuries or even death.
• To avoid these risks, always attach warning plates to the control
levers and to the ignition key before performing any maintenance operation; if necessary, attach additional warning tags also around the machine and in particular on the cab door
handles.
N
NO
TERE
MET
IN MOTO
RKA13300
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
DO NOT
START
ENGINE
RKA00340
RKA00330
• Only authorized and duly trained personnel can service and repair the machine; additional precautions must be
taken when grinding, welding and using a sledge hammer or heavy hammers.
• When assemblying the equipment or cylinder connection pins, use wooden, plastic or in any case not excessively hard tools to check the centering of the holes.
Do not use your fingers, since you run the risk of cutting them.
44
Page 47
2.8.4 EQUIPMENT
• The normal or special equipment that must be installed on the
machine or that have been removed must be stored in safe
places, preventing them from falling down. If they fall on someone, they can cause serious bodily harm.
• When assemblying or removing any equipment, make sure that
the ropes and the lifting hook are in good conditions and properly dimensioned for the load to be lifted.
2.8.5 WORKING UNDER THE MACHINE
• Always lower the work equipment to the ground or in any case
to its lowest position before performing service or repairs under
the machine.
• Always lock the machine tracks securely.
PRECAUTIONS FOR MAINTENANCE
RKA00290
• Do not work under the machine, if this is not sufficiently supported.
2.8.6 CLEANING THE MACHINE
• Spilled oil or grease, scattered tools or broken pieces are dangerous, because they may cause someone to slip or trip. Always 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 surfaces and therefore facilitate rusting.
• While cleaning the machine, keep the pressurized jet at a minimum distance of approx. 60 cm in order not to damage the
warning plates and the pictograms.
If the plates are damaged, request Komatsu or your Komatsu
Dealer to send you spare plates and change them.
• Water into the electrical system provokes the oxidation of the
contacts and may hinder the start of the machine or even make
it start suddenly and abruptly. For this reason, never use water
or steam jets to clean sensors, connectors or the inside of the
operator's cab.
RKA00280
RKA00300
45
Page 48
PRECAUTIONS FOR MAINTENANCE
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS
• During maintenance operations, let the engine run only when indispensable. If it is necessary to have the engine
running (for example, to wash the cooling circuit or to check the functionality of the alternator), an operator
should constantly remain in the cab, in order to be able to stop the engine whenever necessary.
• During maintenance operations with running engine, never move the control locking devices from the “lock” position or change the position of the travel levers.
Service personnel must not move any control lever.
• When carrying out maintenance operations, do not touch the moving parts of the machine and avoid wearing
large and loose clothes.
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR
SAFETY
• Periodically change the following parts, which are important 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
SAFETY CRITICAL PARTS").
2.8.9 STOP THE ENGINE BEFORE CARRY-
ING OUT ANY MAINTENANCE OPERATION OR INSPECTION
• Stop the machine only on firm and level ground and stop the engine before carrying out any maintenance operation or inspection.
• If the engine must turn during a maintenance operation, shift the
safety device lever to the LOCK position and carry out the maintenance operation with the help of another person; one operator
must remain on the machine and the words and signs to be
used must be agreed upon in advance.
• The person who carries out the maintenance operation must be
very careful not to touch any moving part of the engine.
RYA00860
CABIN
46
CANOPY
Page 49
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP
• Keep away from naked flames while refuelling or topping up oil.
• Spilled fuel or oil make the ground slippery and may cause acci-
dents; clean any dirty area immediately and carefully.
• Always tighten the fuel tank and the hydraulic circuit oil safety
caps securely.
• Do not use fuel to clean any part of the machine that may be
dirty with oil or dust.
• Always top up the fuel and oil tanks in properly ventilated place
and avoid smoking.
• When refuelling, hold the fuel 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.
PRECAUTIONS FOR MAINTENANCE
RKA00320
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, wear suita-
ble clothes and protections and loosen the cap slowly, in order
to gradually release the pressure.
2.8.12 USING LAMPS
• When checking the fuel, oil, coolant or battery electrolyte levels,
always use homologated explosion-proof lamps.
If such lighting equipment is not used, there is danger of fire or
explosion.
RKA00310
RKA00270
RKA00260
47
Page 50
PRECAUTIONS FOR MAINTENANCE
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR
• When repairing the electrical system, disconnet the battery in
order to stop the flow of current.
IMPORTANT
• Disconnect first the negative earth cable (–) and then the
positive cable (+).
At the end of the operation, reconnect first the positive cable (+) and then the negative cable (–).
• If electrical welding operations are to be carried out on the ma-
chine, it is necessary to disconnect the battery and also the alternator.
REMOVAL
RIMOZIONE
12
RKA00250
RKAB1810
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.
RWA04890
RKAB1820
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 pipes or hoses that were previously rejected because of leaks or fastening defects, since they may burst during use.
• Always repair or replace any loose or faulty fuel or oil pipe. Any leakage of fuel or oil may cause fires.
48
Page 51
PRECAUTIONS FOR MAINTENANCE
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL
• Do not forget that the work equipment circuits are always under
pressure; for this reason, when it is necessary to add or drain
hydraulic oil or to perform maintenance operations or inspections on the hydraulic circuit, it is advisable to lower the equipment to the ground and completely release the pressures and
the residual pressure present in the tank.
Small leakages from pipes under pressure and the resulting jets
are extremely dangerous, since they can perforate the skin and
penetrate in the blood circulation or injure the eyes.
For this reason, always wear goggles and thick gloves during
the inspections and use a piece of cardboard or a sheet of plywood 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.
DANGER!
PERICOLO!
CORRECT
CORRETTO
RKA00240
RKA00220
2.8.17 PRECAUTIONS FOR MAINTENANCE
OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE
• When the machine is stopped at the end of operations, the en-
gine coolant, the oil and all the components are hot and the hydralic circuits are under pressure.
In these conditions, if the coolant, the hydraulic oil and the engine oil are to be drained in order to change them or the filters,
there are serious risks of damage and burns.
Wait for the temperature to lower within the normal operating
range (40–45) before carrying out the maintenance operations
in accordance with the procedures indicated in the relevant sections of this manual).
RKA00230
49
Page 52
PRECAUTIONS FOR MAINTENANCE
2.8.18 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE TRACK TENSION
• The grease contained in the track tension adjustment device is
pressurized. If the adjustment isn't carried out according to the
instructions given in the maintenance section, the grease valve
(1) may be ejected due to the high pressure and this may be
dangerous for the operator.
• When reducing the track tension, do not loosen the valve (1)
more than one turn.
• Keep face, hands and other body parts away from the valve (1).
RYA00950
2.8.19 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT
• The shock absorber unit is provided with a shock absorbing spring with high preload, 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 proceed carelessly, since this may cause an explosion and consequently serious injuries and even death. For this reason, keep to
the following instructions:
• do not remove the accumulator;
• do not bring the accumulator near sparks or naked flames;
• do not make holes in the accumulator, do not weld or use
oxyhydrogen flames;
RKA12540
• do not hit or press the accumulator;
• when disposing of the accumulator, take care to release the gas
it contains.
Have this operation carried out only by a Komatsu Utility Dealer.
50
Page 53
2.8.21 COOLING FAN AND BELT
• Be careful to the revolving parts and do not allow anyone to get
too close to these parts, since clothes or parts of the body may
get caught into them.
• If hands, clothes, or tools touch the fan blades or the belt, they
may be cut, torn or seriously damaged; for this reason, avoid
touching the revolving parts.
2.8.22 WASTE MATERIALS
• Do not dispose of used oil in the sewer system, rivers, etc.
• Always put used oil in containers. Never drain the oil directly onto the ground.
• Keep to the laws and regulations in force when disposing of
harmful substances such as oil, fuel, solvents, used filters and
batteries.
PRECAUTIONS FOR MAINTENANCE
RKA00210
2.8.23 COMPRESSED AIR
• When carrying out cleaning with compressed air, there is a hazard of serious injury or property damage caused
by flying particles.
• When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves,
and other 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 of oil).
• The biodegradable oil can be used only in the hydraulic system; it cannot be used for the endothermic engine,
the transmissions, the braking system, etc.
• Before introducing the synthetic biodegradable oil in the hydraulic system, empty the system completely, disconnecting the cylinders and all the parts that may contain 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
least 40°C, then start moving the equipment, so that all the parts of the system are filled with oil.
Stop the engine and check the oil level. (See "3.3.1.2 CHECKS BEFORE STARTING" - " CHECK OIL LEVEL IN
HYDRAULIC TANK, ADD OIL").
51
Page 54
PAGE INTENTIONALLY LEFT BLANK
52
Page 55
THE MACHINE AND
ITS OPERATIONS
53
Page 56
MACHINE VIEW ILLUSTRATIONS
3.1 MACHINE VIEW ILLUSTRATIONS
3.1.1 OVERALL MACHINE VIEW
(1)
Bucket
(2)
Bucket cylinder
(3)
Arm
(4)
Arm cylinder
(5)
Boom
(6)
Boom cylinder
54
(7)
Track shoe
(8)
Sprocket
(9)
Track frame
(10)
Idler
(11)
Blade cylinder
(12)
Blade
Page 57
3.1.2 CONTROLS AND GAUGES
MACHINE VIEW ILLUSTRATIONS
(1)
Operator's seat
(2)
—
—
(3)
Safety lock lever (left)
(4)
Left work equipment control lever
(5)
Pedal lock
(6)
Attachment control pedal
(7)
Travel lever (pedal is equipment)
(8)
Boom swing control pedal
(9)
Pedal lock
(10)
Horn switch
(11)
Right work equipment control lever
(12)
Safety lock lever (right)
(13)
(canopy specification machine)
Blade control lever
(14)
(15)
Machine monitor
(16)
Fuel control lever
(17)
Starting switch
(18)
Heater switch (cab specification machine)
(19)
Floor lock cancel lever
(20)
Service meter
(21)
Engine water temperature gauge
(22)
Fuel gauge
(23)
Engine pre-heating monitor
(24)
Charge level monitor
(25)
Engine oil pressure monitor
(26)
Travel speed boost monitor
(27)
Lamp switch
(28)
Travel speed selector switch
RKA13310
55
Page 58
DETAILED CONTROLS AND GAUGES
3.2 DETAILED CONTROLS AND GAUGES
The following is an explanation of the devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand the methods of operating equipment and meanings of the displays.
3.2.1 MONITORING SYSTEM
(A)
Emergency Monitors
(B)
Meter Display Portion
(C)
Pilot Lamps
(D)
Monitor Switch Portion
56
Page 59
DETAILED CONTROLS AND GAUGES
3.2.1.1 EMERGENCY MONITORS
CAUTION
• If the monitor flashes or the buzzer sounds, stop the engine immediately or run it at low idling, then inspect the problem point immediately and repair the problem.
These are items which need to be observed when the engine is running. If there is any abnormality, the abnormal
location on the monitor will lights up and the buzzer will second. Carry out the necessary repairs immediately.
(1) Engine Oil Pressure Monitor (2) Charge Level Monitor
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 inspection. For details, 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.
57
Page 60
DETAILED CONTROLS AND GAUGES
2. Charge Level Monitor
If there is an abnormality in the charging 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.
58
Page 61
3.2.1.2 METER DISPLAY PORTION
DETAILED CONTROLS AND GAUGES
(1)
Engine Water Temperature Gauge
(2)
Fuel Gauge
(3) Service Meter
1. Engine Water Temperature Gauge
This meter (1) shows the engine water temperature.
During 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).
59
Page 62
DETAILED CONTROLS AND GAUGES
2. Fuel Gauge
This meter (2) shows the fuel level in the fuel tank.
F indicates that the tank is full.
E indicates that the fuel level is low. If the fuel level goes below 4.5 liters (1.19 US.gall.), the indicator enters red range (A),
and at the same time, pilot lamp (B) flashes.
If the indicator enters red range (A) or 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 the
machine is not being operated.
The meter advances 0.1 for every 1/10 hours (6 minutes) of
engine operation, regardless of the engine speed.
60
Page 63
3.2.1.3 PILOT LAMPS
DETAILED CONTROLS AND GAUGES
(1) Engine Pre-heating Monitor (2) Travel Speed Boost Monitor
1. Engine Pre-heating Monitor
This monitor (1) flashes when the starting switch is set to the
HEAT position. After approx. 18 seconds, the buzzer sounds
and the monitor goes out.
2. Travel Speed 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 automatically switched to low speed travel, but the travel speed
boost monitor displays stays lighted up.
61
Page 64
DETAILED CONTROLS AND GAUGES
3.2.1.4 MONITOR SWITCHES PORTION
(1) Lamp Switch (2) Travel Speed Selector Switch
1. Lamp Switch
Use this switch (1) to turn on the headlamps and the lamp inside the machine monitor.
Each time the switch is pressed, it is switched between ON
and OFF.
62
Page 65
DETAILED CONTROLS AND GAUGES
2. Travel Speed Selector Switch
WARNING
• When loading or unloading from a trailer, always travel at low speed. Never operate the travel speed selector switch during the loading or unloading operation.
• If the travel speed is switched between Hi and Lo when the machine is traveling, the machine may deviate to one side, even when traveling in a straight line.
Stop the machine before switching the travel speed.
Use this 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 load increases, the travel is automatically switched to low speed 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.
63
Page 66
DETAILED CONTROLS AND GAUGES
3.2.2 SWITCHES
RKA13320
(1)
Starting Switch
(2)
Horn Switch
(3)
Lamp Switch
(4)
Travel Speed Selector Switch
(5)
Cab Heater Switch (Machines equipped with cab)
(6)
Windshield Wiper Switch
(Machines equipped with cab)
(7)
Room Lamp Switch (Machines equipped with cab)
(8)
Cigarette Lighter (12V) (Machines equipped with cab)
1. Starting Switch
This switch (1) is used to start or stop the engine.
• OFF position
The key can be inserted or withdrawn. The switches for the
electric system are all turned off and the engine is stopped.
• ON position
Electric current flows in the charging and lamp circuits. Keep
the starting switch key at the ON position while the engine is
running.
• START position
This is the engine-start position. Keep the key at this position during cranking. Immediately after starting the engine, release the 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 position, so turn it immediately to START and start the engine.
64
Page 67
DETAILED CONTROLS AND GAUGES
2. Horn Switch
Press switch (2) at the center of the knob of the right work
equipment lever to sound the horn.
3. Lamp Switch
Use this switch (3) to turn on the headlamps and the lamp inside the machine monitor.
For details, see "3.2.1.4 MONITOR SWITCHES PORTION" - " 1. Lamp Switch".
4. Travel Speed Selector Switch
Use this switch (4) to switch the travel speed to low speed or high speed.
For details, see "3.2.1.4 MONITOR SWITCHES PORTION" - " 2. Travel Speed Selector Switch".
5. Cab Heater Switch
(Machines equipped with cab)
It is a three-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 counterclockwise to reduce it.
6. Windshield Wiper Switch
(Machines equipped with cab)
This switch (6) actuates the front window wiper.
This is also used as the window washer switch.
The switch is operated as follows.
• Wiper only
When the switch is set to position (B), the wiper is actuated.
Position (A): Wiper stopped
Position (B): Wiper actuated
5
T
RKA10600
65
Page 68
DETAILED CONTROLS AND GAUGES
• Wiper and window washer
When the wiper is working and the switch is kept pushed to
position (B), washer fluid is sprayed out.
When the switch is released, it returns, and only the wiper
operates.
NOTE
• Be careful of the following when operating the window washer.
Do not keep the switch pushed in to the washer spray position 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 cigarette lighter is pushed in, it will return to its original position after a few seconds, so take it out to light your cigarette.
66
Page 69
3.2.3 CONTROL LEVERS AND PEDALS
DETAILED CONTROLS AND GAUGES
(1)
Safety Lock Lever
(Machine equipped with cab: left side only)
(2)
Left Work Equipment Control Lever
(3)
Right Work Equipment Control Lever
(4)
Fuel Control Lever
(5)
Blade Control Lever
(6)
Travel Lever (pedal is equipment)
(7)
Pedal Lock (for boom swing control pedal)
(8)
Boom Swing Control Pedal
(9)
Floor Lock Cancel Lever
(10)
Pedal Lock (for attachment control pedal)
Attachment Control Pedal
(11)
RKA13330
67
Page 70
DETAILED CONTROLS AND GAUGES
1. Safety Lock Lever
WARNING
• When leaving the operator's compartment, set the safety lock lever securely to the LOCK position (L). If
the safety lock lever is not at the LOCK position (L) and the control levers are touched by mistake, it may
lead to serious personal injury.
• If the safety lock lever is not set securely to LOCK position (L), it may cause serious personal injury. Always check that the lever is at LOCK position (L).
• When pulling the safety lever up, be careful not to touch the work equipment control lever.
• When pushing the safety lever down, be careful not to touch the work equipment control lever.
This lever (1) is a device to lock the operation of the work equipment, swing, travel, and attachment.
When the lever is pulled up, 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 pedals 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 switch.
If the engine stops when the safety lock lever is at FREE position (F), operate the safety lock lever to LOCK position (L) before operating the starting switch.
• Machine equipped with canopy
(F): Free
(L): Lock
When the left lever is pulled up, the lever stand springs up
and is locked.
When the right lever is pulled up, the lever stand does not
move, but it is locked.
• Machine equipped with cab
(F): Free
(L): Lock
When the left lever is pulled up, the lever stand springs up
and is locked.
NOTE
• For machines equipped with a cab, there is only a safety
lock lever on the left.
68
Page 71
2. - 3. Work Equipment Control Lever
A: Canopy specification
B: Cab specification
DETAILED CONTROLS AND GAUGES
This left work equipment control lever (2) is used to operate
the arm and upper structure.
• Swing operation
(a) Swing 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 position 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
RKA01440
N (Neutral): The boom and bucket are held in that position
when they come to a stop and do not move.
69
Page 72
DETAILED CONTROLS AND GAUGES
4. Fuel Control Lever
This lever (4) is used to control the engine speed and 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
70
Page 73
6. Travel Levers (with pedals)
WARNING
• Do not put your foot on the pedal unless the machine is
traveling. If you leave your foot on the pedal and press it
by mistake, the machine will move suddenly, and this
may lead to a serious accident. Do not rest a foot on the
pedal except when traveling or steering the machine,
using the pedal.
• If the track frame is facing the rear, the direction of travel operations will be reversed.
When operating the travel levers, check if the track
frame is facing the front or the rear.
(If sprocket (A) is at the rear, the track frame is facing
the front.)
• Take good 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.
DETAILED CONTROLS AND GAUGES
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) REVERSE: The lever is pulled back
(The pedal is angled back)
N (Neutral): The machine stops
When operating the pedal, first sit in the operator's seat, then
fold out the pedal.
After finishing pedal operations, fold back the pedal while still
seated in the operator's seat.
NOTE
• If the lever is shifted to the advance or reverse position from
the neutral position, the alarm sounds to warm that the machine is starting to advance.
71
Page 74
DETAILED CONTROLS AND GAUGES
7. Pedal Lock
(For boom swing contol pedal)
WARNING
• When boom swing operation is not required, lock the
boom with the pedal lock. If the operation pedal is accidentally pressed while it is not lock, a serious accident
or injury.
This pedal (7) is used to lock the boom swing pedal.
The pedal is locked by fitting the plate over the pedal.
(F): Free
(L): Lock
8. Boom Swing Control Pedal
This pedal (8) swings the boom to the left and right.
(a): Right swing
(b): Left swing
N (Neutral): 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
(F) position to release the lock.
Open or close the floor while pulling this lever (9).
After opening or closing the floor, release lever (9). It will return automatically to LOCK position (L).
(F): Free
(L): Lock
When opening (tilting) the cab or floor, see "3.2.12 METHOD
OF OPENING (TILTING) FLOOR" for details.
72
Page 75
10. 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 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 (hydraulic tank side).
Bottom of pedal depressed: Oil flows to left side of arm (operator's seat side).
DETAILED CONTROLS AND GAUGES
RKA01600
73
Page 76
DETAILED CONTROLS AND GAUGES
3.2.4 WINDSHIELD (Machines equipped with cab)
WARNING
• When opening or closing the front window, bottom window, or door, always set the safety lock lever to
the LOCK position.
If the control levers are not locked and they are touched by accident, this may lead to a serious accident.
• When opening or closing the window at the front of the cab, stop the machine on horizontal ground, low-
er the work equipment completely to the ground, stop the engine, then carry out the operation.
• When opening 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 the machine on level ground, lower the work equipment completely to the ground, then stop the engine.
2. Lock the safety lock lever (1) securely.
3. Grip knobs (A) on the left and right in the center of the
front window, keep lock lever (B) pressed down with your
thumb, then pull left and right knobs (A) to release the
lock.
74
Page 77
4. Grip left and right knobs (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.
DETAILED CONTROLS AND GAUGES
75
Page 78
DETAILED CONTROLS AND GAUGES
Closing
WARNING
• When closing the window, lower it slowly and be careful not to get your hand caught.
1. Stop the machine on level ground, lower the work equipment completely to the ground, then stop the engine.
2. Lock the safety lock lever (1) securely.
3. Hold left and right knobs (A), then push lock lever (B) with
your thumb to the 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 returns in the lock direction (L). Push knobs (A) to the front to lock securely.
NOTE
• To check that the lock is applied, check that lock (D) is in
front of stopper (C).
76
Page 79
Removing Lower Windshield
1. Open the front window, then hold grip (A), pull up, and re-
move the bottom window.
2. After removing the lower window, stow it in left and right
brackets (B) at the rear of the operator's cab.
DETAILED CONTROLS AND GAUGES
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.
77
Page 80
DETAILED CONTROLS AND GAUGES
3.2.5 SLIDING DOOR (Machines equipped with cab)
CAUTION
• Be sure to check that the sliding door is locked in position both when it is open and when it is closed.
Always stop the machine on level ground when opening or closing the door.
If the door is opened or closed on a slope, there is danger that the operating effort will suddenly change.
Do not open or close the door on slopes.
When opening or closing the door, always use door handle (1) and 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 the door, pull the handle back to remove lock
(3), then pull the door to the front.
3.2.6 SLIDING WINDOW (Machines equipped with cab)
CAUTION
• Do not put your head or hands out of the window when traveling or during operations.
The window on the right side of the cab can be opened.
78
Page 81
DETAILED CONTROLS AND GAUGES
3.2.7 EMERGENCY ESCAPE HAMMER (Machines equipped with cab)
CAUTION
• When you are obliged to break the window glass pane with a hammer, take good care not to get hurt with
flying glass shards.
Before getting out of the operator's cab, remove glass 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 also 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 from the cab is installed.
When escaping, break the window glass with hammer (1).
79
Page 82
DETAILED CONTROLS AND GAUGES
3.2.8 CAPS AND COVERS WITH LOCK
Opening and closing covers with lock
Use the ignition key to open and close the caps and covers
with lock.
For details on the position of the caps and covers with lock,
see "3.3.17 LOCKING".
Insert the key completely (6 mm from the point where the key
narrows), then turn it. If the key is turned when it is 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.
RYA01680
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 open the cover by pul-
ling the grip.
Closing
1 - Close the cover and insert the key in the lock.
2 - Turn the key clockwise and then extract it.
RKA13350
RKA13360
80
Page 83
DETAILED CONTROLS AND GAUGES
3.2.9 ENGINE REAR COVER
CAUTION
• When carrying out inspection and service inside the engine rear cover, always open the cover fully until
it is secured in position by the rod.
IMPORTANT
• Except when opening the cover, always keep it locked.
• When it is locked, opening knob (2) of the cover does
not move.
1. Release lock (1) of the cover.
(For details of the method of opening and closing the cover 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. When the rod comes out from the
groove, close the cover.
Push cover (3) in to lock it.
5. Lock the cover.
81
Page 84
DETAILED CONTROLS AND GAUGES
3.2.10 COOLING COVER
CAUTION
• When carrying out inspection and maintenance inside the cooling cover, open the engine rear cover,
then open the cooling cover.
Always open the engine rear cover fully to a point where it is held in position by the rod.
Always secure the cooling cover in position 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 close cover (3) slightly. When the rod comes out from the
groove, close the cover.
Push cover (3) in to lock it.
5. Close the engine rear cover (1).
For further details, see "3.2.9 ENGINE REAR COVER".
6. Lock the cover.
82
Page 85
DETAILED CONTROLS AND GAUGES
3.2.11 TANK COVER
WARNING
• Never climb on top of the cover. There is danger that you may slip and fall.
IMPORTANT
• Always keep the tank cover closed, unless expressly in-
dicated otherwise for any maintenance 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 (2) and the cap (1).
4. Lock the cap (1).
83
Page 86
DETAILED CONTROLS AND GAUGES
3.2.12 METHOD OF OPENING (TILTING) FLOOR
WARNING
• Always observe the warning and caution items when
opening or closing the floor. If the operation is carried
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.
Do not enter the floor area or the inside of the cab when
the floor is open.
Do not start the engine when the floor is open.
If there is any breakage or abnormality in the lock when
the floor is opened, stop the operation and ask your Komatsu 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, then lower the
boom slowly.
3. Set the safety lock lever to the LOCK position, then stop
the engine.
NOTE
• For machines equipped with a cab, there is only a safety
lock lever on the left.
4. Fit blocks securely under the track to prevent the machine
from moving.
84
9 J A 0 5 4 6 6
Page 87
5. Remove the two screws (2) (M10), then remove the 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).
DETAILED CONTROLS AND GAUGES
85
Page 88
DETAILED CONTROLS AND GAUGES
9. Open inspection window (7), use your left 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
pushing it up in the direction of the arrow (approx 45°).
The canopy or cab form one unit with the floor and rise up
together with the floor.
IMPORTANT
• If the floor does not come up, release lever (8) is not in
the release position.
Pull knob (9) back with your right hand, then repeat the
above procedure again.
• When opening or 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 increases.
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. Insert the locking pin (13) into the hole (14) from the inside.
12. Turn until the coupling at the end of the locking pin (13) is
completely engaged with the pin (15).
NOTE
• Make sure that the locking pin (13) is correctly engaged with
the pin (15)
This completes the 2nd stage lock, and and the operation to
open the floor is completed.
86
Page 89
When closing (tilt close)
IMPORTANT
• Before closing the floor, check that there is no damage
or abnormality in the wiring or piping inside the floor.
If any damage or abnormality is found, please ask your
Komatsu Dealer to carry out repairs.
1. Remove lock pin (13) and insert it into storage hole (16).
NOTE
• If lock pin (13) does not come out, do as follows.
Machine equipped with canopy:
Hold knob (9) and raise while removing lock pin.
Machine equipped with cab:
Hold knob (9) and lower while removing lock pin.
2. Use your left 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.
DETAILED CONTROLS AND GAUGES
• When opening or closing the floor, do not let any part of
your body enter the area under the floor.
3. Tighten floor tilt lock bolts (6) (M14).
Number of floor tilt lock bolts: 4
Tightening torque: 156.8 to 196 Nm
NOTE
• If any bolt (6) is damaged, replace it with a genuine Komatsu
part of the same size.
4. Close the cooling cover (5) and the engine rear cover (4).
5. Install the triangular cover (3) with the two screws (2)
(M10).
This completes the operation for closing the floor.
87
Page 90
DETAILED CONTROLS AND GAUGES
3.2.13 FUSE
IMPORTANT
• Before replacing a fuse, be sure to turn off the starting
switch.
The fuses protect the electrical equipment and wiring from
burning out.
If the fuse becomes corroded, or white powder can be seen, or
the fuse is loose in the fuse holder, replace the fuse.
Replace the fuse with another of the same capacity.
Fuse Capacities and Circuit Names
Fuse capacity
No.
(1) 30A Engine stop solenoid
(2) 10A
(3) 10A
(4) 10A If equipped
(5) 10A 20A Heater, travel alarm buzzer
(6) - 20A
(7) 10A
(8) 10A 20A Working lamp
(9) - (10) - (11) 30A Spare
(12) 10A 20A Spare
(13) 10A Spare
Canopy
specification
Cab
specification
Name of circuit
PPC solenoid, horn,
fuel pump, safety relay
Monitor panel, buzzer,
speed boost solenoid
Room lamp, radio,
windshield wiper,
window washer
Monitor panel, controller,
radio (Cab specification)
3.2.14 BLOCK FUSE
If the starting motor does not turn even when the starting
switch is turned to the ON position, block fuse (1) is probably
blown, so open the cover at the right side of the machine and
check or replace the fuse.
This 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 wiring from burning out under abnormal current.
88
Page 91
3.2.15 OPERATION MANUAL STORAGE
IMPORTANT
• Except when opening the cover for some reason, always keep the cover locked.
This is under the operator's seat.
There is a box for keeping the Operation and Maintenance
Manual in the rear of the operator's seat backrest.
Keep the Operation and Maintenance Manual in the box so
that it can be seen at any time.
3.2.16 TOOL BOX
IMPORTANT
• Except when opening the cover for some reason, always keep the cover locked.
DETAILED CONTROLS AND GAUGES
Store the tools in this box.
3.2.17 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 directed towards the outside of the machine.
The grease nozzle is positioned inside the tool box.
3.2.18 ASHTRAY
(Machines equipped with cab)
This is on the right side of the operator's compartment.
It is a magnetic type, so it can be fitted at any suitable place.
Always check that the cigarette is out before closing the lid.
89
Page 92
MACHINE OPERATIONS AND CONTROLS
3.3 MACHINE OPERATIONS AND CONTROLS
3.3.1 BEFORE STARTING ENGINE
3.3.1.1 WALK-AROUND CHECKS
Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, or
leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system. Check also
for loose wiring, play, and accumulation of dust in places which reach high temperatures.
WARNING
• When opening the engine rear cover and the cooling cover to carry out checks and maintenance operations,
always remember to secure them in the correct position
with the apposite retainer.
• Immediately remove any flammable materials that have
accumulated around the battery or engine muffler and
other high temperature parts of the engine. Leakage of
oil and fuel will cause the machine to catch fire. Always
check thoroughly and repair any problems or contact
your Komatsu distributor.
• Check that the floor is secured properly by bolts (1). If it
is not secured properly, it may cause serious personal
injury. If the machine is at an angle, reposition it level
before checking.
Carry out the following inspections and cleaning every day before starting the engine for the day's work.
1. Check for damage, wear, play in work equipment, cylin-
ders, linkage, and hoses.
Check that there are no cracks, excessive 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 around the battery. Remove all dirt, dust, and flammable materials.
3. Check for leakage of water or oil around engine.
Check that there is no leakage of oil from the engine or leakage of water from the cooling system. If any abnormality is found, repair it.
4. Check for oil leakage from hydraulic equipment, hydraulic tank, hoses, joints
Check that there is no oil leakage. If any abnormality is found, repair the place where the oil is leaking.
5. Check of the undercarriage parts.
Check track shoe, sprocket, idler, guard for damage, wear, loose bolts, or leakage of oil from rollers, etc.
Repair them if any trouble is found.
6. Check of the handrails and steps.
Check the handrails and steps for any damage or loosened bolts, and repair the damaged part and tighten the
loosened bolts, if any.
7. Check for abnormality in gauges and monitor.
Check that there is no abnormality in the gauges and monitor in the operator's cab. If any abnormality is
found, replace the parts. Clean off any dirt on the surface.
8. Seat belt and mounting clamps.
Check that there is no abnormality in the seat belt or mounting clamps. If there is any damage, replace with
new parts.
90
Page 93
9. Inspection of floor tilt lock bolts.
• Remove the triangular cover, open the engine rear cover, the cooling cover and make sure that the 4 fastening 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.
MACHINE OPERATIONS AND CONTROLS
91
Page 94
MACHINE OPERATIONS AND CONTROLS
3.3.1.2 CHECKS BEFORE STARTING
Always check the items in this section before starting the engine each day.
CHECK COOLANT LEVEL, ADD COOLANT
WARNING
• Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine
to cool down and check the sub tank.
• Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under
high internal pressure. If the cap is removed to check the coolant level in this condition, there is a hazard of burns. Wait for the temperature to go down, then turn the cap slowly to release the pressure before 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 the water filler port of sub tank (1) to
the FULL line.
3. After adding water, tighten the cap securely.
4. If the reserve tank is empty, check for leakage of water,
then check the radiator water level. Add water to the radiator if necessary, then add water to the reserve tank.
92
Page 95
MACHINE OPERATIONS AND CONTROLS
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
WARNING
• Engine parts and oil are at high temperature immediately after the engine is stopped, and will cause serious burns. Wait for the temperature to cool down before starting the operation.
CAUTION
• When carrying out inspection and service inside the engine rear cover, always open the cover fully until
it is secured in position by the rod.
NOTE
• If the machine is at an angle, reposition it to level before checking.
When checking the oil level after the engine has been operated, allow the engine to cool for 15 minutes before
checking.
1. Open the engine rear cover. 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 lubricating oil level go above the
upper limit (H) mark when adding oil.
If the oil level goes above the upper limit, a large amount
of oil mist will be sucked into the combustion chamber,
and this will cause white smoke, oil hammer, or rapid rotation.
5. If the oil is above the H mark, drain the excess engine oil
from drain plug (P), and check the oil level again.
6. If the oil level is correct, tighten the oil filler, then close the
engine rear cover.
93
Page 96
MACHINE OPERATIONS AND CONTROLS
CHECK FUEL LEVEL, ADD FUEL
WARNING
• When adding fuel, never spill the fuel or let it overflow. It will cause fire.
If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or
sand.
Fuel is highly flammable and dangerous. Never bring flames near fuel.
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 in
the tank will drop and fuel may not flow. Clean the hole
from time to time and check that breather hole (3) is not
clogged.
94
Page 97
MACHINE OPERATIONS AND CONTROLS
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
WARNING
• The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the
temperature to go down before starting the work.
• When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
1. If the work equipment is not in the condition shown in the
diagram on the right, start the engine, run the engine at
low speed, retract the arm and bucket cylinder rods fully,
then lower the boom, set the bucket teeth in contact with
the ground, and stop the engine.
2. Open the engine rear cover and cooling 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 hydraulic 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 the engine
and wait for the hydraulic oil to cool down, then drain
the excess oil from drain plug (P).
4. If the oil level is below the L mark, remove the filler cap
(F), then top up and close.
NOTE
• The oil level will vary depending upon the oil temperature.
Accordingly, use the following as the guide:
Before operation: around L level
(Oil temperature 10 to 30°C (50 to 86°F))
Normal operation: around H level
(Oil temperature 50 to 80°C (122 to 176°F))
95
Page 98
MACHINE OPERATIONS AND CONTROLS
5. Extend the boom, arm, and bucket cylinder fully as shown
in the diagram on the right, remove the oil filler cap, then
install the cap and pressurize the inside of the tank.
IMPORTANT
• Be sure to pressurize the hydraulic tank. If it is not pres-
surized, the pump will suck in air, and this will adversely
affect the equipment.
CHECK DUST INDICATOR
1. Open the engine rear cover. For details, see Section
"3.2.9 ENGINE REAR COVER".
2. Check that the red piston has not appeared in the transparent portion of dust indicator (1).
3. If the red piston has appeared, clean or replace the element immediately.
For details of the method of cleaning the element, see
"4.9.1.a CHECK, CLEAN 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 water as follows.
• Prepare the filter wrench for fuel filter.
1 - Open the engine rear cover, and set handle to the LOCK
position (A). See "3.2.9 ENGINE REAR COVER".
2 - Using the filter wrench, loosen ring (4), then remove case
(2) and throw out the water inside it.
3 - Set case (2) in position, then tighten ring (4) to install it.
4 - Shift the small lever (3) to the opening position (B).
5 - Drain any water or sediment from the fuel tank. For detai-
ls, see "4.9.1.e DRAIN WATER AND SEDIMENT FROM
FUEL TANK".
A
4
3
B
2
1
RKA13440
96
Page 99
MACHINE OPERATIONS AND CONTROLS
CHECK ELECTRIC WIRINGS
WARNING
• If the fuses frequently blow or if there are traces of short circuits on the electrical wiring, locate the
cause immediately and carry out repairs, or contact your Komatsu Dealer for repairs.
• Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged
with dirt or dust, wash the battery cap to clean the breather hole.
Check that there is no damage to the fuse, that 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 tighten 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 troubleshooting and repairs, contact your Komatsu Dealer.
CHECK FUNCTION OF HORN
1. Turn the starting switch to the ON position.
2. Confirm that the horn sounds immediately when the horn
button is pressed.
If the horn does not sound, please contact your Komatsu
Dealer for repair.
97
Page 100
MACHINE OPERATIONS AND CONTROLS
3.3.1.3 ADJUSTMENT
WARNING
• Adjust the seat position before starting operations or after changing the operator.
• Adjust the seat so that the control levers and switchis can be operated freely and easily with the opera-
tor back against the backrest.
SEAT ADJUSTMENT
(A) Fore-and-aft adjustment
The seat can move forward and backward.
Move lever (1) to the upper, set the operator's seat at the desired poaition, then release the lever.
Amount for fore-and-aft adjustment: 140 mm (5.5 in.)
Adjust the position of the operator's seat to match the operation. For example, when carrying 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 suspension
Turn knob (3) under the seat and adjust to the desired position.
The weight can be adjusted to 50 to 120 kg (110 to 265 lb.).
If you want to make the seat softer, turn the weight adjustment
to a lower weight; if you want to make the seat harder, adjust
to a higher weight.When operating on uneven surfaces, adjust
the seat to a harder setting.
(D) Armrest
Armrest (4) can be made to spring up by hand approx. 90°.
98
Loading...