Komatsu PC210-7K, PC210LC, PC210NLC-7K, PC230NHD-7K, PC240LC Service Manual
...
UEAM001704
Operation &
Maintenance Manual
PC210-7K
PC210LC, PC210NLC-7K
PC230NHD-7K
PC240LC, PC240NLC-7K
HYDRAULIC EXCAVATOR
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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 personel who
will come into contact with the machine.
FOREWORD
11
1
FOREWORD FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times while operating or performing maintenance . Most accidents are
caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents
can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and
maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
• Always be sure to read and understand this manual thoroughly before performing operation and
maintenance.
• Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully.
Keep this manual in the storage location for the Operation and Maintenance Manual given below, and
have all personnel read it periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual
immediately from Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety devices and specifications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
Storage location for the Operation and Maintenance Manual:
Storage box on the left side of the operator's seat.
2
FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
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 potentially 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
WARNING
CAUTION
Example of safety message using signal word
Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor
or moderate injury. This word is used also to alert against unsafe practices that may
cause property damage.
WARNING
To avoid hitting unlocked operation levers, lower equipment to ground and move SAFETY LOCK LEVER
(located near seat) to LOCK position before getting up from the operator's seat.
Sudden and unwanted machine movement can cause serious injury or death.
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 useful to know.
.
NOTICE
REMARKS
This word is used for precautions that must be taken to avoid actions which could shorten the
life of the machine.
This word is used for information that is useful to know.
3
SAFETY INFORMATION FOREWORD
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condition at the top or left side, and the method of avoiding the hazardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Part No.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, it is your
responsibility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: → (1))
4
FOREWORD SAFETY INFORMATION
NOISE (PC210,210LC,210NLC, PC230NHD)
• Sound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method,simulated
working cycle).
• Sound power level emmited. This is the guaranteed value
as specified in the European directive 2000/14/EC
VIBRATION
The weighted root mean square acceleration value to which
the operator’s arms are subjected does not exceed 2.5 m/s²
The weighted root mean square acceleration value to which
the operator’s body is subjected does not exceed 0.5 m/s²
These results were obtained by accelerometers during trench digging.
5
SAFETY INFORMATION FOREWORD
NOISE (PC240LC,240NLC)
• Sound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method,simulated
working cycle).
• Sound power level emmited. This is the guaranteed value
as specified in the European directive 2000/14/EC
VIBRATION
The weighted root mean square acceleration value to which
the operator’s arms are subjected does not exceed 2.5 m/s²
The weighted root mean square acceleration value to which
the operator’s body is subjected does not exceed 0.5 m/s²
These results were obtained by accelerometers during trench digging.
6
FOREWORD INTRODUCTION
INTRODUCTION
This Komatsu HYDRAU L I C E XCAVATO R is designed to be u s e d mainly for the fo l l o w i ng works:
● Digging work
● Leveling work
● Ditching work
● Loading work
● Demolition work
See the section "RECOMMENDED APPLICATIONS (PAGE 166)" for further details.
DIRECTIONS OF MACHINE
FRONT
Operator’s seat
LEFT
RIGHT
Sprocket
REAR
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's cab when
the operator's cab is facing the front and the sprocket is at the rear of the machine.
7
PRODUCT INFORMATION FOREWORD
PRODUCT INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION
On the bottom right of the operator's cab
PRODUCT IDENTIFICATION NUMBER
A
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION
On the top of the No.1 cylinder head cover (The EPA auxiliary nameplate is on the top of the No. 5 cylinder head
cover.)
EPA: Environmental Protection Agency, U.S.A.
8
FOREWORD PRODUCT INFORMATION
SERVICE METER LOCATION
On top of the machine monitor
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product Identification Number
Manufacturers name:
Address:
Distributor
Address
Phone
KOMATSU UK Ltd.
Durham Road
Birtley
Chester-Le street
County Durham DH32QX
United Kingdom
9
PRODUCT INFORMATION FOREWORD
MACHINE SERIAL PLATE
Valid until 31 December 2003
MODEL
SERIAL
WEIGHT
ENGINE POWER
MANUFACTURER
MANUFACTURING YEAR
MASS
Komatsu UK Ltd, Birtley, Co. Durham, United Kingdom
205-00-K1290
Komatsu UK Ltd, Birtley, Co Durham, United Kingdom
Valid as of 1 January 2004
MODEL
SERIAL
WEIGHT
ENGINE POWER
PRODUCT ID
NUMBER
MANUFACTURER
MANUFACTURING YEAR
MODEL
SERIAL No.
MANUFACT. YEAR
MASS
ENGINE POWER
Product Identification Number
MANUFACTURER
Manufactured by Komatsu UK Ltd.
for Komatsu Ltd.,Tokyo,Japan
Komatsu UK Ltd, Birtley, Co Durham, United Kingdom
kg
kW
205-00-K1291
10
FOREWORD PRODUCT INFORMATION
11
CONTENTS FOREWORD
CONTENTS
FOREWORD
FOREWORD............................................................................................................................................................ 2
SAFETY INFORMATION......................................................................................................................................... 3
NOISE (PC210,210LC,210NLC, PC230NHD) ............................................................................................... 5
VIBRATION.................................................................................................................................................... 5
NOISE (PC240LC,240NLC)........................................................................................................................... 6
VIBRATION.................................................................................................................................................... 6
INTRODUCTION...................................................................................................................................................... 7
DIRECTIONS OF MACHINE ......................................................................................................................... 7
PRODUCT INFORMATION ..................................................................................................................................... 8
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION ......................................................................... 8
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION ............................................................................ 8
SERVICE METER LOCATION ...................................................................................................................... 9
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ................................................................................. 9
MACHINE SERIAL PLATE .......................................................................................................................... 10
SAFETY
SAFETY INFORMATION....................................................................................................................................... 18
POSITION FOR ATTACHING SAFETY LABELS................................................................................................. 20
POSITION FOR ATTACHING SAFETY LABELS ........................................................................................ 20
SAFETY LABELS ........................................................................................................................................ 21
SAFETY INFORMATION....................................................................................................................................... 28
SAFETY MACHINE OPERATION......................................................................................................................... 38
STARTING ENGINE .................................................................................................................................... 38
OPERATION ................................................................................................................................................ 40
TRANSPORTATION .................................................................................................................................... 46
BATTERY .................................................................................................................................................... 47
TOWING ...................................................................................................................................................... 49
LIFTING OBJECTS WITH BUCKET ............................................................................................................ 50
SAFETY MAINTENANCE INFORMATION ........................................................................................................... 51
OPERATION
GENERAL VIEW ................................................................................................................................................... 60
GENERAL VIEW OF MACHINE .................................................................................................................. 60
12
FOREWORD CONTENTS
GENERAL VIEW CONTROLS AND GAUGES............................................................................................ 61
EXPLANATION OF COMPONENTS..................................................................................................................... 62
MACHINE MONITOR .................................................................................................................................. 62
BASIC CHECK ITEMS................................................................................................................................. 65
SWITCHES .................................................................................................................................................. 87
CONTROL LEVERS, PEDALS .................................................................................................................... 93
CEILING WINDOW...................................................................................................................................... 96
FRONT WINDOW........................................................................................................................................ 97
EMERGENCY EXIT FROM OPERATOR'S CAB ...................................................................................... 102
DOOR LOCK ............................................................................................................................................. 102
CAP, COVER WITH LOCK........................................................................................................................ 103
HOT AND COOL BOX ............................................................................................................................... 104
CAB RADIO ............................................................................................................................................... 104
MAGAZINE BOX........................................................................................................................................ 104
ASHTRAY .................................................................................................................................................. 105
HANDLING AIR CONDITIONER ............................................................................................................... 106
CAR RADIO ............................................................................................................................................... 119
FUSE ......................................................................................................................................................... 120
FUSIBLE LINK ........................................................................................................................................... 121
CONTROLLER (COMPUTER) .................................................................................................................. 122
TOOLBOX.................................................................................................................................................. 122
GREASE GUN HOLDER ........................................................................................................................... 122
REFUELLING PUMP ................................................................................................................................. 123
HANDLING THE ACCUMULATOR ........................................................................................................... 123
MACHINE OPERATIONS AND CONTROLS...................................................................................................... 125
BEFORE STARTING ENGINE .................................................................................................................. 125
STARTING ENGINE .................................................................................................................................. 138
AFTER STARTING ENGINE ..................................................................................................................... 142
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION) ............................................................... 146
STOPPING THE ENGINE ......................................................................................................................... 150
CHECK AFTER SHUTTING OFF ENGINE ............................................................................................... 150
MACHINE OPERATION ............................................................................................................................ 151
STEERING THE MACHINE....................................................................................................................... 155
SWINGING ................................................................................................................................................ 157
WORK EQUIPMENT CONTROLS AND OPERATIONS ........................................................................... 158
OPERATING WORKING MODE ............................................................................................................... 159
PROHIBITED OPERATIONS .................................................................................................................... 160
GENERAL OPERATION INFORMATION ................................................................................................. 162
TRAVELING ON SLOPES......................................................................................................................... 163
ESCAPE FROM MUD................................................................................................................................ 165
RECOMMENDED APPLICATIONS........................................................................................................... 166
REPLACEMENT AND INVERSION OF BUCKET ..................................................................................... 168
PARKING MACHINE ................................................................................................................................. 171
CHECK AFTER FINISHING WORK .......................................................................................................... 172
LOCKING................................................................................................................................................... 173
TRANSPORTATION............................................................................................................................................ 174
13
FOREWORD CONTENTS
TRANSPORTATION PROCEDURE.......................................................................................................... 174
SPECIAL TRANSPORTATION INSTRUCTIONS FOR PC210NLC-7 AND PC230NHD-7 ....................... 174
LOADING AND UNLOADING WITH TRAILER ......................................................................................... 175
LIFTING MACHINE.................................................................................................................................... 182
COLD WEATHER OPERATION ......................................................................................................................... 184
COLD WEATHER OPERATION INFORMATION...................................................................................... 184
AFTER DAILY WORK COMPLETION....................................................................................................... 186
AFTER COLD WEATHER SEASON ......................................................................................................... 187
LONG TERM STORAGE..................................................................................................................................... 188
BEFORE STORAGE.................................................................................................................................. 188
DURING STORAGE .................................................................................................................................. 188
AFTER STORAGE..................................................................................................................................... 189
TROUBLESHOOTING......................................................................................................................................... 190
AFTER RUNNING OUT OF FUEL............................................................................................................. 190
PHENOMENA THAT ARE NOT FAILURES.............................................................................................. 190
TOWING THE MACHINE .......................................................................................................................... 191
LIGHTWEIGHT TOWING HOOK............................................................................................................... 191
PRECAUTIONS ON PARTICULAR JOBSITES ........................................................................................ 192
DISCHARGED BATTERY ......................................................................................................................... 193
OTHER TROUBLE .................................................................................................................................... 197
MAINTENANCE
MAINTENANCE INFORMATION ........................................................................................................................ 204
LUBRICANTS, COOLANT AND FILTERS ......................................................................................................... 207
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................................... 207
EXPLANATION OF LUBRICATION CHART DECAL ................................................................................ 211
ELECTRIC SYSTEM MAINTENANCE ...................................................................................................... 213
HANDLING HYDRAULIC SYSTEM........................................................................................................... 213
WEAR PARTS LIST ............................................................................................................................................ 214
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ..................... 215
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS .......................................................... 215
TIGHTENING TORQUE SPECIFICATIONS ....................................................................................................... 218
TIGHTENING TORQUE LIST.................................................................................................................... 218
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ........................................................................... 219
SAFETY CRITICAL PARTS....................................................................................................................... 219
MAINTENANCE SCHEDULE.............................................................................................................................. 220
MAINTENANCE SCHEDULE CHART....................................................................................................... 220
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...................................................................... 222
MAINTENANCE PROCEDURE........................................................................................................................... 223
14
FOREWORD CONTENTS
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) .................................... 223
WHEN REQUIRED .................................................................................................................................... 224
CHECK BEFORE STARTING ................................................................................................................... 248
EVERY 100 HOURS MAINTENANCE....................................................................................................... 248
EVERY 250 HOURS MAINTENANCE....................................................................................................... 250
EVERY 500 HOURS MAINTENANCE....................................................................................................... 257
EVERY 1000 HOURS MAINTENANCE..................................................................................................... 265
EVERY 2000 HOURS MAINTENANCE..................................................................................................... 268
EVERY 4000 HOURS MAINTENENCE..................................................................................................... 270
EVERY 5000 HOURS MAINTENANCE..................................................................................................... 271
SPECIFICATIONS
SPECIFICATIONS............................................................................................................................................... 274
EXPLANATION OF LIFTING CAPACITY CHART (PC210, PC210LC, PC210NLC-7K) ........................... 277
EXPLANATION OF LIFTING CAPACITY CHART (PC210, PC210LC, PC230NHD - 2 PIECE BOOM)... 281
EXPLANATION OF LIFTING CAPACITY CHART (PC230NHD-7K) ......................................................... 284
EXPLANATION OF LIFTING CAPACITY CHART (PC240LC, PC240NLC-7K) ........................................ 286
EXPLANATION OF LIFTING CAPACITY CHART (PC240LC,NLC-7K 2 PIECE BOOM) ......................... 289
ATTACHMENTS AND OPTIONS
GENERAL PRECAUTIONS ................................................................................................................................ 294
PRECAUTIONS RELATED TO SAFETY .................................................................................................. 294
PRECAUTIONS WHEN INSTALLING ATTACHMENTS ........................................................................... 296
HANDLING BUCKET WITH HOOK .................................................................................................................... 297
CHECKING FOR DAMAGE TO BUCKET WITH HOOK ........................................................................... 297
PROHIBITED OPERATIONS .................................................................................................................... 297
MACHINES READY FOR ATTACHMENTS ....................................................................................................... 298
EXPLANATION OF COMPONENTS ......................................................................................................... 298
HYDRAULIC CIRCUIT............................................................................................................................... 301
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE ................................................................... 304
OPERATION.............................................................................................................................................. 306
LONG-TERM STORAGE........................................................................................................................... 308
SPECIFICATIONS ..................................................................................................................................... 308
ATTACHMENT GUIDE........................................................................................................................................ 309
COMBINATIONS OF WORK EQUIPMENT............................................................................................... 309
SELECTION OF TRACK SHOES.............................................................................................................. 312
SELECTION OF BUCKET TEETH ............................................................................................................ 313
STANDARDS FOR SELECTING VERTICAL PIN TYPE AND HORIZONTAL PIN TYPE TEETH............ 313
HANDLING OF RUBBER PAD SHOE AND ROAD LINER ....................................................................... 314
HANDLING TRAPEZOIDAL BUCKET....................................................................................................... 316
HANDLING EXTENSION ARM.................................................................................................................. 317
15
FOREWORD CONTENTS
HANDLING CLAMSHELL BUCKET .......................................................................................................... 318
RECOMMENDED ATTACHMENT OPERATIONS ............................................................................................. 319
HYDRAULIC BREAKER ............................................................................................................................ 319
2-PC BOOM......................................................................................................................................................... 324
FEATURES OF 2-PIECE BOOM & ARM .................................................................................................. 324
OPERATION.............................................................................................................................................. 325
TRANSPORTATION.................................................................................................................................. 328
STRAIGHT BOOM PC210/240-7K...................................................................................................................... 331
OPERATION.............................................................................................................................................. 331
WORKING RANGE (PC 210 STRAIGHT BOOM) ..................................................................................... 335
TRANSPORTATION (PC 210 Straight Boom equipment)......................................................................... 336
WORKING RANGE (PC 240 STRAIGHT BOOM) ..................................................................................... 337
TRANSPORTATION (PC 240 Straight Boom equipment)......................................................................... 338
SUPER LONG FRONT BOOM AND ARM PC210/240-7
OPERATION INSTRUCTION FOR SUPER LONG FRONT BOOM AND ARM ................................................. 340
CONTROL LEVERS, PEDALS .................................................................................................................. 345
TRANSPORT & STORAGE OF SUPER LONG FRONT MACHINE ......................................................... 348
WORKING RANGE OF SUPER LONG FRONT........................................................................................ 350
LIFTING CAPACITY PC210 LC 15 m SUPER LONG FRONT.................................................................. 351
LIFTING CAPACITY PC210 NLC 15 m SUPER LONG FRONT ............................................................... 352
LIFTING CAPACITY PC240 LC 18 m SUPER LONG FRONT.................................................................. 353
LIFTING CAPACITY PC240 NLC 18 m SUPER LONG FRONT ............................................................... 354
MAINTENANCE................................................................................................................................................... 355
SPECIAL SERVICE REQUIREMENTS FOR SUPER LONG FRONT WORK EQUIPMENT .................... 355
EVERY 50 HOURS SERVICE ................................................................................................................... 356
EVERY 100 HOURS SERVICE ................................................................................................................ 357
16
SAFETY
11
WARNING
Please read and make sure that you fully understand precautions described in this manual and the safety labels on
the machine. When operating or servicing the machine,
always follow these precautions strictly.
17
SAFETY INFORMATION SAFETY
SAFETY INFORMATION
SAFETY INFORMATION ....................................................................................................................................... 18
POSITION FOR ATTACHING SAFETY LABELS .................................................................................................. 20
POSITION FOR ATTACHING SAFETY LABELS ............................................................................................. 20
SAFETY LABELS.............................................................................................................................................. 21
SAFETY INFORMATION ....................................................................................................................................... 28
SAFETY RULES .......................................................................................................................................... 28
IF ABNORMALITIES ARE FOUND ............................................................................................................. 28
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS ...................................................................... 28
FIRE EXTINGUISHER AND FIRST AID KIT ............................................................................................... 28
SAFETY EQUIPMENT................................................................................................................................. 29
KEEP MACHINE CLEAN ............................................................................................................................. 29
KEEP OPERATOR'S COMPARTMENT CLEAN ......................................................................................... 29
LEAVING OPERATOR'S SEAT WITH LOCK.............................................................................................. 29
HANDRAILS AND STEPS ........................................................................................................................... 30
MOUNTING AND DISMOUNTING .............................................................................................................. 31
NO PERSONS ON ATTACHMENTS........................................................................................................... 31
BURN PREVENTION .................................................................................................................................. 31
FIRE PREVENTION AND EXPLOSION PREVENTION.............................................................................. 32
ACTION IF FIRE OCCURS ......................................................................................................................... 33
WINDSHIELD WASHER FLUID .................................................................................................................. 33
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS
PREVENTION.............................................................................................................................................. 33
ATTACHMENT INSTALLATION .................................................................................................................. 33
ATTACHMENT COMBINATIONS................................................................................................................ 34
CAB WIDOW GLASSES.............................................................................................................................. 34
UNAUTHORIZED MODIFICATIONS ........................................................................................................... 34
SAFETY AT JOBSITE ................................................................................................................................. 34
WORKING ON LOOSE GROUND............................................................................................................... 34
DISTANCE TO HIGH VOLTAGE CABLES.................................................................................................. 35
ENSURE GOOD VISIBILITY ....................................................................................................................... 35
VENTILATION FOR ENCLOSED AREA ..................................................................................................... 36
SIGNALMAN'S SIGNAL AND SIGNS .......................................................................................................... 36
EMERGENCY EXIT FROM OPERATOR'S CAB......................................................................................... 36
ELECTROMAGNETIC INTERFERENCE ....................................................................................................36
ASBESTOS DUST HAZARD PREVENTION............................................................................................... 37
SAFETY MACHINE OPERATION ......................................................................................................................... 38
STARTING ENGINE ......................................................................................................................................... 38
CHECKS BEFORE STARTING ENGINE .................................................................................................... 38
SAFETY RULES FOR STARTING ENGINE ............................................................................................... 39
STARTING ENGINE IN COLD WEATHER .................................................................................................39
OPERATION ..................................................................................................................................................... 40
CHECKS AFTER STARTING ENGINE ....................................................................................................... 40
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS .................................................................... 40
SAFETY RULES FOR TRAVELLING .......................................................................................................... 41
TRAVELLING ON SLOPES ......................................................................................................................... 42
OPERATIONS ON SLOPES........................................................................................................................ 43
PROHIBITED OPERATIONS ...................................................................................................................... 43
OPERATIONS ON SNOW ........................................................................................................................... 45
PARKING MACHINE ................................................................................................................................... 45
TRANSPORTATION ......................................................................................................................................... 46
18
SAFETY SAFETY INFORMATION
SHIPPING THE MACHINE .......................................................................................................................... 46
BATTERY ......................................................................................................................................................... 47
BATTERY HAZARD PREVENTION ............................................................................................................ 47
STARTING ENGINE WITH BOOSTER CABLES ........................................................................................ 48
TOWING ........................................................................................................................................................... 49
SAFETY RULES FOR TOWING.................................................................................................................. 49
LIFTING OBJECTS WITH BUCKET ................................................................................................................. 50
SAFETY RULES FOR LIFTING OBJECTS ................................................................................................. 50
SAFETY MAINTENANCE INFORMATION............................................................................................................ 51
WARNING TAG ........................................................................................................................................... 51
KEEP WORK PLACE CLEAN AND TIDY.................................................................................................... 51
APPOINT LEADER WHEN WORKING WITH OTHERS ............................................................................. 51
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE ..................................................................... 52
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING .................................................... 53
PROPER TOOLS......................................................................................................................................... 53
ACCUMULATOR ......................................................................................................................................... 54
PERSONNEL............................................................................................................................................... 54
ATTACHMENTS .......................................................................................................................................... 54
WORK UNDER THE MACHINE .................................................................................................................. 54
NOISE.......................................................................................................................................................... 55
WHEN USING HAMMER............................................................................................................................. 55
WELDING WORKS...................................................................................................................................... 55
REMOVING BATTERY TERMINALS .......................................................................................................... 55
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION ................. 56
DO NOT DISASSEMBLE RECOIL SPRINGS ............................................................................................. 56
SAFETY RULES FOR HIGH-PRESSURE OIL............................................................................................ 56
SAFETY HANDLING HIGH-PRESSURE HOSES....................................................................................... 57
WASTE MATERIALS................................................................................................................................... 57
AIR CONDITIONER MAINTENANCE.......................................................................................................... 57
COMPRESSED AIR .................................................................................................................................... 57
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .................................................................... 58
19
POSITION FOR ATTACHING SAFETY LABELS SAFETY
POSITION FOR ATTACHING SAFETY LABELS
The following warning signs and safety labels are used on this machine.
• Be sure that you fully understand the correct position and content of labels.
• To ensure that the content of labels can be read properly. Be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline, there may cause the labels to
peel off.
• There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
• If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
POSITION FOR ATTACHING SAFETY LABELS
611
X
Z
10
e
c
b
d
9
X
2
2
3
4
20
12
a
f
7
13
5
8
9
10
SAFETY POSITION FOR ATTACHING SAFETY LABELS
SAFETY LABELS
1. (207-00-K1950)
• Warnings for operation, inspection and maintenance
• Improper operation and maintenance can cause serious
injury or death.
• Read the manual and labels before operation and maintenance.
Follow instructions and warnings in manual and in labels
on machine.
• a. Keep the manual in machine cab near operator.
If this manual is lost, please contact your Komatsu distribu-
tor for a replacement.
21
POSITION FOR ATTACHING SAFETY LABELS SAFETY
• b. Always apply lock when leaving operator’s seat.
• c. WARNING - No passengers
No passengers allowed to ride on machine while it is moving
• d. WARNING - DANGER OF FALLING OBJECTS
Do not operate where a danger of falling objects exists.
Consult your dealer for fitting of FOPS protection
.
22
SAFETY POSITION FOR ATTACHING SAFETY LABELS
•e. HAZARDOUS - Voltage hazard
Serious injury or death can occur if machine or attachments are not kept safe distance away from electric lines
•f. Control levers operational function diagram.
2. (09083-A0481)
• Warning when opening front window
• When raising window, lock it in place with lock catchers on
both sides.
• Falling window can cause injury.
23
POSITION FOR ATTACHING SAFETY LABELS SAFETY
3. (20Y-00-K2220)
• Emergency exit
• Read operation manual before operation
4. (207-00-71370)
• Pump Control override switch and swing lock override
switch
• Read the operation manual before operation
5. (09133-A3281)
Keeping out of moving area
To prevent SEVERE INJURY or DEATH do the following before
moving machine or its attachments:
• Sound horn to alert people nearby.
• Be sure no one is on or near machine or in the swing area.
• Rotate cab for full view of travel path if it can be done
safely.
• Use spotter if view is obstructed.
Always follow the above
24
SAFETY POSITION FOR ATTACHING SAFETY LABELS
6. (09805-A0881)
Keeping out of working range area.
• Make sure no one is in the work equipment swing area.
7. (09667-A0481)
• Do not open cover while engine is running.
8. (09659A057B) Warnings for handling the accumulator
Explosion hazard
• Keep away from flame.
• Do not weld or drill.
• Read operation manual before operation.
25
POSITION FOR ATTACHING SAFETY LABELS SAFETY
9. (09653-A0581)
Warning for high temperature coolant and oil.
• Hot water and oil hazard
• To prevent hot water and oil from spurting out:
• Turn engine off.
• Allow water to cool.
• Slowly loosen cap to relieve pressure before removing.
Read operation manual before operation.
10. (09657-A0881)
• Precautions when adjusting track tension
11. (09808-A0881)
• Precautions when handling cable
12. (09805-A0881)
• Warning for falling from upper-structure.
• Keep away from sides of machine.
• Keep of counterweight.
• Do not ride on machine when it is moving
26
SAFETY POSITION FOR ATTACHING SAFETY LABELS
13. (09805-C0881)
• Roll-over precautions
• Sign indicates a hazard of falling.
• Do not stand on this place here.
27
SAFETY INFORMATION SAFETY
SAFETY INFORMATION
SAFETY RULES
• Only trained and authorized personnel can operate and maintain the machine.
• Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
• If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine
may be severely impaired putting yourself and everyone else on your jobsite in danger.
• When working with another operator or with a person on worksite traffic duty, be sure that all personnel understand all hand signals that are to be used.
IF ABNORMALITIES ARE FOUND
If you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the abnormality has been corrected.
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS
• Do not wear loose clothing or accessories. There is a danger that they may catch on control levers or other protruding parts.
• If you have long hair and it hangs out from your hard hat,
there is a danger that it may get caught up in the machine.
Tie your hair up and be careful not to let it get caught.
• Always wear a hard hat and safety shoes. If the nature of
the work requires it, wear safety glasses, mask, gloves, ear
plugs, and safety belt when operating or maintaining the
machine.
• Check that all protective equipment functions properly
before using it.
FIRE EXTINGUISHER AND FIRST AID KIT
Always follow the precautions below to prepare for action if any injury or fire should occur.
• Make sure that fire extinguishers have been provided and
read the labels to ensure that you know how to use them in
emergencies.
• Carry out periodic inspection and maintenance to ensure
that the fire extinguisher is up to date and usable.
• Store a first aid kit on board. Carry out periodic checks and
add to the contents if necessary.
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