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.
FOREWORD
11
FOREWORDFOREWORD
FOREWORD1
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 when performing operation and maintenance. Mo st accidents
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machi nes. Accidents can be prevented by knowing beforehand conditio ns that may cause a haz ard when performing op eration
and maintenance.
WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe
the following points.
q Read this manual thoroughly and understand its contents fully.
q Read the safety messages and safety labels given in this manual carefully so that they should be
understood fully.
q Keep this manual at the storage location for the Operation and Maintenance Manual given below so
that all personnel involved in working on the machine can consult it periodically.
q In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu dis-
tributor to obtain a new copy.
q When you sell the machine, make sure that this manual should be provided to the new owne r to get her
with the machine.
In this manual, measurements are expressed in internationa l standard units (SI). For the reference purpose, weight units used in the p ast are also displayed in ( ).
Storage location fo r the Operation and Maintenance Manual:
magazine box on the left side of the operator's seat.
1-2
FOREWORDSAFETY INFORMATION
SAFETY INFORMATION1
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 words1
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
WARNING
CAUTION
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.
Example of safety message using signal word 1
WARNING
When standing up from the operator's seat, always place the lock lever in the LOCK position.
If you accidentally touch the control levers when they are n ot locked, this may cau se a serious injury or
death.
Other signal words1
In addition to the above, the following signal words are used to indicate precaution s that shou ld be followed to protect the machine or to give information that is useful to know.
NOTICE
REMARKSThis word is used for information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
1-3
SAFETY INFORMATIONFOREWORD
q 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 pr ocedur es.
Example of safety label using words1
Part No.
Safety labels using pictogram1
Safety pictograms use a picture to expre ss 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 maintena nce.
Therefore, the safety messages in this manual and on the machine may not include all po ssible 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 -> (1))
1-4
FOREWORDSAFETY INFORMATION
NOISE1
q Sound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method,simulated
working cycle).
75
q Sound power level emmited. This is the guaranteed value
as specified in the European directive 2000/14/EC
108
1-5
SAFETY INFORMATIONFOREWORD
Vibration levels1
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the operator’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO
7096.
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleration
value for the body is less than or equal to 0.5 m/s².
These values were determined using a representative machine and measured during the typical operating condi-
tion indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.
The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
q Tension of crawler (for crawler machines)
q Brake and steering systems
q Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling in good condition
q Remove any large rocks or obstacles
q Fill any ditches and holes
q Site manager should provide machine operators with machine and schedule time to maintain terrain con-
ditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
q Adjust the seat and suspension for the weight and size of the operator
q Wear seat belt
q Inspect and maintain the seat suspension and adjustment mechanisms
5. Steer, brake, accelerate, and move the attachment levers and pedals slowly so that the machine moves
smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
q When pushing with bucket or blade, avoid sudden loading; load gradually
q Drive around obstacles and rough terrain conditions
q Slow down when it is necessary to go over rough terrain
q Make the curve radius of traveling path as large as possible
q Travel at low speed when traveling around sharp curves
1-6
FOREWORDSAFETY INFORMATION
7. Minimize vibrations for long work cycle or long distance traveling
q Reduce speed to prevent bounce
q Transport machines long distances between worksites
8. The following guidelines can be effective to minimize risks of low back pain
q Operate the machine only when you are in good he alt h.
q Provide breaks to reduce long periods of sitting in the same posture
q Do not jump down from the cab or machine
q Do not repeatedly handle and lift loads
1-7
INTRODUCTIONFOREWORD
INTRODUCTION1
This Komatsu machine is designed to be used mainly for the following work:
q Digging work
q Leveling work
q Ditching work
q Loading work
q Demolition work
See the section “RECOMMENDED APPLICATIONS (3-119)“ for further det ails.
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.
1-8
FOREWORDINTRODUCTION
VISIBILITY FROM OPERATOR'S SEAT1
The visibility standards (ISO 5006) for this machine require a view shown in the diagram below.
PROXIMITY VISIBILITY1
The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown
in the diagram below. The hatched area (A) shows the area where the view is blocked by part of the machine when
mirrors or other aids to visibility are installed as standard. Please be fully aware that there are places that cannot
be seen when operating the machine.
12M CIRCUMFERENCE VISIBILITY1
The visibility at a radius of 12 m from the machine is as shown in the diagram below. The hatched areas (B) show
the areas where the view is blocked when mirrors or other aids to visibility are installed as standard. Please be
fully aware that there are places that cannot be seen when operating the machine.
1-9
INTRODUCTIONFOREWORD
BREAKING-IN THE NEW MACHINE1
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, ope rating the machine under full load before bre aking the machine in can adverse ly affect the perf ormance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points
when breaking in the machine.
q Run the engine at idle for 15 seconds after starting it. Dur-
ing this time, do not operate the control levers or fuel control dial.
q Idle the engine for 5 minutes after starting it up.
q Avoid operation with heavy loads or at high speeds.
q Immediately after starting the engine, avoid sudden starts,
sudden acceleration, unnecessary sudden stops, and sud
den changes in direction.
-
1-10
FOREWORDPRODUCT INFORMATION
PRODUCT INFORMATION1
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1
On the bottom right of the operator's cab
The design of the nameplate differs according to the territory.
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION1
On the upper side of the engine cylinder head cover.
EPA: Environmental Protection Agency, U.S.A.
1-11
PRODUCT INFORMATIONFOREWORD
SERVICE METER LOCATION1
On top of the machine monitor
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR1
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 DH3 2QX
United Kingdom
1-12
FOREWORDPRODUCT INFORMATION
MACHINE SERIAL PLATE1
MANUFACTURING YEAR
MODEL
SERIAL
WEIGHT
ENGINE POWER
PRODUCT ID
NUMBER
MANUFACTURER
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
CONTROL LEVERS AND PEDALS ......................................................................................................... 3-41
SUN ROOF............................................................................................................................................... 3-44
EMERGENCY EXIT FROM OPERATOR'S CAB ..................................................................................... 3-50
DOOR LOCK ............................................................................................................................................ 3-50
CAP WITH LOCK...................................................................................................................................... 3-51
HOT AND COOL BOX.............................................................................................................................. 3-52
AFTER DAILY WORK COMPLETION.................................................................................................... 3-138
AFTER COLD WEATHER SEASON......................................................................................................3-138
LONG TERM STORAGE.................................................................................................................................. 3-139
BEFORE STORAGE............................................................................................................................... 3-139
DURING STORAGE............................................................................................................................... 3-139
AFTER STORAGE.................................................................................................................................. 3-140
STARTING MACHINE AFTER LONG-TERM STORAGE ...................................................................... 3-140
TROUBLES AND ACTIONS ............................................................................................................................ 3-141
RUNNING OUT OF FUEL ....... .... ... ... ... .... ... ....................................... ... ... ... ... ........................................ 3-141
PHENOMENA THAT ARE NOT FAILURES........................................................................................... 3-142
TOWING THE MACHINE ....................................................................................................................... 3-143
SEVERE JOB CONDITION.................................................................................................................... 3-143
OUTLINE OF SERVICE........................................................................................................................................ 4-4
WEAR PARTS LIST.................................................................................................................................... 4-9
1-17
CONTENTS
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS............................................................................... 4-10
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU
Please read and make sure that you fully understand the precautions discribed in this manual and the safety labels on
the machine. When operating or servicing the machine,
always follow these precaustions strictly.
If problems are found.................................................................................................................................2-132
Working wear and personal protective items.............................................................................................2-132
Fire extinguisher and first aid kit ................................................................................................................ 2-132
Fire prevention and explosion prevention..................................................................................................2-172
Action if fire occurs.....................................................................................................................................2-182
Safety at jobsite..........................................................................................................................................2-192
Working on loose ground........................................................................................................................... 2-192
Distance to high voltage cables .................................................................................................................2-202
Ensure good visibility .................................................................................................................................2-202
Ventilation for enclosed area......................................................................................................................2-212
Signalman's signal and signs.......................... .... ... ... ... ... .... ... ... ... .... ... ... ... .... ............................................. 2-212
Emergency exit from operator's cab .......................................................................................................... 2-212
Warning Tag .............................................................................................................................................. 2-342
Keep Work Place Clean and Tidy... ... ... ... .......................................... ........................................................ 2-342
Appoint Leader when Working with Others.................. ... ... ... .... ... ... ... .... ... ................................................. 2-342
Stop Engine Before Carrying Out Maintenance......................................................................................... 2-352
Two Workers for Maintenance when Engine is Running ........................................................................... 2-352
Work Under the Machine ........................................................................................................................... 2-372
When Using Hammer................................................................................................................................. 2-372
Precaution for High Voltage...................................................................... ... .............................................. 2-392
Air Conditioner Maintenance...................................................................................................................... 2-402
Periodic Replacement of Safety Critical Parts ........................................................................................... 2-402
............................. 2-362
2-3
SAFETY LABELSSAFETY
SAFETY LABELS2
The following warning signs and safety labels are used on this machine.
q Be sure that you fully understand the correct position and content of labels.
q 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. These may cause the labels
to peel off.
q There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
q If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the p art
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
2-4
SAFETYSAFETY LABELS
LOCATION OF SAFETY LABELS2
A
2-5
SAFETY LABELSSAFETY
SAFETY LABELS2
1. (207-00-K1951)
q Warnings for operation, inspection and maintenance
q Improper operation and maintenance can cause serious
injury or death.
q Read the manual and labels before operation and mainte-
nance.
Follow instructions and warnings in manual and in labels
on machine.
a. Keep the manual in machine cab near operator.
q Warning!
q Read the manual before operating, maintenance, disas-
sembly, assembly and transportation.
2-6
SAFETYSAFETY LABELS
b. Always apply lock when leaving operator’s seat.
c. WARNING - No passengers
q No passengers allowed to ride on machine while it is mov-
ing
d. WARNING - DANGER OF FALLING OBJECTS
q Do not operate where a danger of falling objects exists.
Consult your dealer for fitting of FOPS protection
2-7
SAFETY LABELSSAFETY
.e. HAZARDOUS - Voltage hazard
q Sign indicates an electrocution hazard if the machine is
brought too near electric power lines.
q Keep a safe distance from electric power lines.
q f. Control levers operational function diagram.
WARNING
In order to prevent an accident resulting in injury or death
caused by error-operation, confirm the machine motion
and indicated operating pattern, when operating
machines. Pay attention to the circumference and operate
slowly when confirming the machine motion.
2. (20E-00-K1230)
q Warning when opening front window
q Sign indicates a hazard from falling window.
q After raising window, be sure to lock it in place with lock
pins.
2-8
Loading...
+ 288 hidden pages
You need points to download manuals.
1 point = 1 manual.
You can buy points or you can get point for every manual you upload.