Komatsu PW130ES-6K User Manual
UEAM000902
Operation &
Maintenance Manual
PW130ES-6K
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PW130ES-6K - K34001
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.
and up
FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this
manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can
not be read, request a replacement manual from Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners.
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 for your machine or
for questions regarding information in this manual.
WARNING
● This operation & maintenance manual may contain
attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you require.
● This machine complies with EC directive (89/392/EEC).
Machines complying with this directive display the CE
mark
● Improper operation and maintenance of this machine can
be hazardous and could result in serious injury or death.
● Operators and maintenance personnel should read this
manual thoroughly before beginning operation or maintenance.
● Some actions involved in operation and maintenance of
the machine can cause a serious accident, if they are not
done in a manner described in this manual.
● The procedures and precautions given in this manual
apply only to intended uses of the machine. If you use
your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for
you and others. In no event should you or others engage
in prohibited uses or actions as described in this manual.
● Komatsu delivers machines that comply with all applica-
ble 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.
● The description of safety is given see “SAFETY INFOR-
MATION” on page 2. and in "SAFETY" from page 15.
1
SAFETY INFORMATION
SAFETY INFORMATION
SAFETY MESSAGES
Most accidents are caused by the failure to follow fundamental
safety rules for the operation and maintenance of machines.
To avoid accidents, read, understand and follow all precautions
and warnings in this manual and on the machine before performing operation and maintenance.
To identify hazards on the machine pictorial decals are used (see
POSITION FOR ATTACHING SAFETY LABELS).
RED WARNING TRIANGLE - This is used on safety
labels where there is a high probability of serious injury or death if
the hazard is not avoided. These safety messages or labels usually describe precautions that must be taken to avoid the hazard.
Failure to avoid this hazard may also result in serious damage to
the machine.
ORANGE WARNING TRIANGLE - This is used on
safety labels where there is a potentially dangerous situation
which could result in serious injury or death if the hazard is not
avoided. These safety messages or labels usually describe precautions that must be taken to avoid the hazard. Failure to avoid
this hazard may also result in serious damage of the machine
YELLOW SAFETY TRIANGLE - This is used on
safety labels for hazards which could result in minor or moderate
injury if the hazard is not avoided. This word might also be used
for a hazard where the only result could be damage to the
machine.
NOTICE - This word is used for precautions that must be taken to
avoid actions which could shorten the life of the machine.
Safety precautions are described in SAFETY from page 1-1.
Komatsu cannot predict every circumstance that might involve a
potential hazard in operation and maintenance. Therefore the
safety message 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, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If
you are unsure about the safety of some procedures, contact
Komatsu or your Komatsu distributor.
2
NOISE
Valid until 31 December 2001
Operator ears noise value (Sound pressure level)
SAFETY INFORMATION
LpA
75
95/27/EC
Ambient noise value (Sound power level)
Noise level indicated is the guaranteed value measured by the
dynamic test method as specified in the directive 86/662/EEC, as
amended by 95/27/EC.
LWA
99
95/27/EC
3
SAFETY INFORMATION
Valid as of 1 January 2002
● Sound pressure level at the operator's station, measured
according to ISO6396 (Dynamic test method, simulated working cycle)
● Sound power level emitted. This is the guaranteed value as
specified in European directive 2000/14/EC.
This machine complies with the requirements of RAL (German
Institute for quality assurance and marking) pertaining to the
award of the environmental mark (blue angel) for low noise.
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 was measured at 0.64 m/s²
4
These results were obtained by accelerometers during trench digging.
EMERGENCY STEERING
This machine is equipped with an emergency steering system
and complies to ISO 5010. In the advent of failure of the source of
power for the steering system (engine failure) whilst travelling the
machine can be steered allowing the machine to be safely
stopped.
In such a case the effort required at the steering wheel and the
number of turns to steer the machine will increase. To confirm
function of emergency steering system raise the front wheels off
the ground (using the work equipment) and with the engine off,
turn the steering wheel and check movement of the wheels.
SAFETY INFORMATION
5
INTRODUCTION
INTRODUCTION
INTENDED USE
This Komatsu HYDRAULIC EXCAVATOR is designed to be used
mainly for the following work:
● Digging
● Smoothing work
● Ditching work
● Loading work
See the section “WORK POSSIBLE USING HYDRAULIC
EXCAVATOR” on page 132 for further details
Features
● This Komatsu HYDRAULIC EXCAVATOR is equipped with
various controls based on an advanced electronics system.
● The monitor panel greatly facilitates daily maintenance and
self-diagnosis.
● Working mode & travel speed are selectable.
● Digging and lifting force can be increased by light-touch con-
trol. (For details, see operation section.)
● Adjustable wrist control levers make operations smooth and
easy.
● Fresh filtered air conditioner assures comfortable operation.
● Low noise level and smart urban style design and colouring.
● Superb operation performance provided by powerful engine
and high-performance hydraulic pump.
● Low fuel consumption controlled by an electronic control sys-
tem provides an environment-friendly machine.
BREAKING IN YOUR NEW MACHINE
Your Komatsu machine has been thoroughly adjusted and tested
before shipment.
However, operating the machine under severe conditions at the
beginning can adversely affect the performance and shorten the
machine life.
Be sure to break in the machine for the initial 100 hours (as indicated by the hour meter.)
During breaking in:
6
● Idle the engine for 5 minutes after starting it up.
● Avoid operation with heavy loads or at high speeds.
● Sudden starting or acceleration, unnecessarily abrupt braking
and sharp turning should be avoided except in cases of emergency.
Additionally for the first 20 hours
● Avoid operating engine for prolonged periods at constant
speed (including idle.)
● Avoid high speed travelling for periods of more than 5 min-
utes.
Pay particular attention to oil pressure and temperature indicators
& check coolant and oil levels frequently during breaking in.
The precautions given in this manual for operating, maintenance,
and safety procedures are only those that apply when this product
is used for the specified purpose. If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any
responsibility for safety. All consideration of safety in such operations is the responsibility of the user.
INTRODUCTION
Operations that are prohibited in this manual must never be carried out under any circumstances.
7
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO.
AND DISTRIBUTOR
MACHINE SERIAL NO. PLATE POSITION
On the front right of the undercarriage
ENGINE SERIAL NO. PLATE POSITION
On the gear case front corner.
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.:
Engine Serial No.:
Manufacturer’s name: Komatsu UK Ltd.
Address
Durham Road
Birtley
Chester-Le-Street
County Durham DH32QX
United Kingdom
Distributor
Address
Phone
8
MACHINE SERIAL PLATES
STANDARD SERIAL PLATE
GERMANY SERIAL PLATE
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
ITALIAN SERIAL PLATE
9
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
10
CONTENTS
FOREWORD ........................................................................................................................................................... 1
SAFETY INFORMATION ........................................................................................................................................ 2
SAFETY MESSAGES ................................................................................................................................... 2
NOISE ........................................................................................................................................................... 3
VIBRATION ................................................................................................................................................... 4
EMERGENCY STEERING ........................................................................................................................... 5
INTRODUCTION ..................................................................................................................................................... 6
INTENDED USE ........................................................................................................................................... 6
Features ........................................................................................................................................................ 6
BREAKING IN YOUR NEW MACHINE ........................................................................................................ 6
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ............................................. 8
MACHINE SERIAL NO. PLATE POSITION .................................................................................................. 8
ENGINE SERIAL NO. PLATE POSITION .................................................................................................... 8
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ................................................................................ 8
MACHINE SERIAL PLATES ......................................................................................................................... 9
SAFETY............................................................................................................. 15
GENERAL PRECAUTIONS ................................................................................................................................. 16
PRECAUTION DURING OPERATION ................................................................................................................. 22
BEFORE STARTING ENGINE ................................................................................................................... 22
OPERATING MACHINE ............................................................................................................................. 23
TRANSPORTATION ................................................................................................................................... 28
BATTERY ................................................................................................................................................... 29
TOWING ..................................................................................................................................................... 30
BUCKET WITH HOOK OR BUCKET LINK ................................................................................................. 32
PRECAUTIONS FOR MAINTENANCE ................................................................................................................ 35
BEFORE CARRYING OUT MAINTENANCE ............................................................................................. 35
DURING MAINTENANCE ........................................................................................................................... 38
POSITION FOR ATTACHING SAFETY LABELS ................................................................................................ 41
POSITION FOR ATTACHING SAFETY LABELS ....................................................................................... 41
OPERATION....................................................................................................... 55
GENERAL VIEW .................................................................................................................................................. 56
GENERAL VIEW OF MACHINE ................................................................................................................. 56
.................................................................................................................................................................... 56
GENERAL VIEW OF CONTROLS AND GAUGES ..................................................................................... 57
11
EXPLANATION OF COMPONENTS .................................................................................................................... 59
MACHINE MONITOR ................................................................................................................................. 59
SWITCHES ................................................................................................................................................. 70
CONTROL LEVERS, PEDALS ................................................................................................................... 80
ROOF HATCH ............................................................................................................................................ 83
FRONT WINDOW ....................................................................................................................................... 85
DOOR LOCK .............................................................................................................................................. 88
CAP, COVER WITH LOCK ......................................................................................................................... 89
FUSE .......................................................................................................................................................... 90
LUGGAGE TRAY ........................................................................................................................................ 91
ASHTRAY ................................................................................................................................................... 91
HEATER ..................................................................................................................................................... 91
AIR CONDITIONER .................................................................................................................................... 93
FUSIBLE LINK ............................................................................................................................................ 96
CONTROLLERS ......................................................................................................................................... 96
TOOL BOX .................................................................................................................................................. 96
REFUELLING PUMP .................................................................................................................................. 96
CAB RADIO (OPTION) ............................................................................................................................... 97
WARNING LAMPS ..................................................................................................................................... 98
HANDLING THE ACCUMULATOR ............................................................................................................ 99
OPERATION ....................................................................................................................................................... 101
CHECK BEFORE STARTING ENGINE .................................................................................................... 101
STARTING ENGINE ................................................................................................................................. 110
MOVING MACHINE OFF .......................................................................................................................... 119
STEERING ................................................................................................................................................ 121
STOPPING ............................................................................................................................................... 123
SWINGING (Slewing the upper carriage) ................................................................................................. 124
OPERATION OF WORK EQUIPMENT ....................................................................................................125
WORKING MODE SELECTION ............................................................................................................... 126
PROHIBITIONS FOR OPERATION ......................................................................................................... 128
PRECAUTIONS FOR OPERATION ......................................................................................................... 129
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS ................................................................... 130
HOW TO ESCAPE FROM MUD ............................................................................................................... 131
WORK POSSIBLE USING HYDRAULIC EXCAVATOR ........................................................................... 132
REPLACEMENT AND INVERSION OF BUCKET .................................................................................... 133
PARKING MACHINE ................................................................................................................................ 136
CHECK AFTER FINISHING WORK ......................................................................................................... 137
STOPPING ENGINE ................................................................................................................................. 137
CHECK AFTER STOPPING ENGINE ...................................................................................................... 138
LOCKING .................................................................................................................................................. 138
OVERLOAD WARNING DEVICE ............................................................................................................. 138
HANDLING THE WHEELS ....................................................................................................................... 138
TRANSPORTATION ........................................................................................................................................... 144
LOADING, UNLOADING WORK .............................................................................................................. 144
PRECAUTIONS FOR LOADING .............................................................................................................. 146
PRECAUTIONS FOR TRANSPORTATION ............................................................................................. 148
12
TRAVELLING POSTURE ......................................................................................................................... 149
COLD WEATHER OPERATION ........................................................................................................................ 150
PRECAUTIONS FOR LOW TEMPERATURE .......................................................................................... 150
PRECAUTIONS AFTER COMPLETION OF WORK ................................................................................ 151
AFTER COLD WEATHER ........................................................................................................................ 152
LONG-TERM STORAGE .................................................................................................................................... 153
BEFORE STORAGE ................................................................................................................................. 153
DURING STORAGE ................................................................................................................................. 153
AFTER STORAGE .................................................................................................................................... 154
STARTING MACHINE AFTER LONG-TERM STORAGE ........................................................................ 154
TROUBLESHOOTING ........................................................................................................................................ 155
PHENOMENA THAT ARE NOT FAILURES ............................................................................................. 155
METHOD OF TOWING MACHINE ........................................................................................................... 156
PRECAUTIONS ON PARTICULAR JOBSITES ....................................................................................... 156
IF BATTERY IS DISCHARGED ................................................................................................................ 157
OTHER TROUBLE ................................................................................................................................... 159
MAINTENANCE. .............................................................................................. 163
GUIDES TO MAINTENANCE ............................................................................................................................. 164
OUTLINES OF SERVICE ................................................................................................................................... 167
OUTLINE OF OIL, FUEL, COOLANT ....................................................................................................... 167
OUTLINE OF ELECTRIC SYSTEM .......................................................................................................... 170
OUTLINE OF HYDRAULIC SYSTEM ....................................................................................................... 170
WEAR PARTS LIST ........................................................................................................................................... 172
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE .......................... 173
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ......................................................... 173
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS ..................................................................... 177
INTRODUCTION OF NECESSARY TOOLS ............................................................................................ 177
TORQUE LIST .......................................................................................................................................... 178
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 179
SAFETY CRITICAL PARTS ...................................................................................................................... 180
MAINTENANCE SCHEDULE CHART ............................................................................................................... 181
.................................................................................................................................................................. 181
MAINTENANCE WHEN USING HYDRAULIC BREAKER ....................................................................... 186
SERVICE PROCEDURE .................................................................................................................................... 187
INITIAL 250 HOURS SERVICE ................................................................................................................ 187
WHEN REQUIRED ................................................................................................................................... 188
CHECK BEFORE STARTING .................................................................................................................. 200
13
EVERY 50 HOURS ................................................................................................................................... 204
EVERY 100 HOURS SERVICE ................................................................................................................ 204
EVERY 250 HOURS SERVICE ................................................................................................................ 209
EVERY 500 HOURS SERVICE ................................................................................................................ 215
EVERY 1000 HOURS SERVICE .............................................................................................................. 221
EVERY 2000 HOURS SERVICE .............................................................................................................. 225
EVERY 4000 HOURS SERVICE .............................................................................................................. 228
EVERY 5000 HOURS SERVICE .............................................................................................................. 228
SPECIFICATIONS............................................................................................ 231
SPECIFICATIONS .............................................................................................................................................. 232
OPTIONS, ATTACHMENTS ............................................................................ 237
GENERAL PRECAUTIONS ............................................................................................................................... 238
PRECAUTIONS RELATED TO SAFETY ................................................................................................. 238
PRECAUTIONS WHEN INSTALLING ATTACHMENTS .......................................................................... 239
HANDLING BUCKET WITH HOOK ................................................................................................................... 240
CHECKING FOR DAMAGE TO BUCKET WITH HOOK .......................................................................... 240
PROHIBITED OPERATIONS ................................................................................................................... 240
PRECAUTIONS DURING OPERATIONS ................................................................................................ 240
MACHINES READY FOR ATTACHMENTS ...................................................................................................... 241
GENERAL LOCATIONS ........................................................................................................................... 241
HANDLING THE CLAMSHELL BUCKET ................................................................................................. 243
OPERATION ............................................................................................................................................. 244
HANDLING ACCUMULATOR ................................................................................................................... 246
LONG-TERM STORAGE .......................................................................................................................... 247
INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE .................................... 248
HYDRAULIC BREAKER ........................................................................................................................... 248
POWER RIPPER ...................................................................................................................................... 251
FORK GRAB ............................................................................................................................................. 252
GRAPPLE BUCKET ................................................................................................................................. 253
SCRAP GRAPPLE .................................................................................................................................... 254
CRUSHER & SMASHER .......................................................................................................................... 256
HYDRAULIC PILE DRIVER ...................................................................................................................... 257
HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE ................................................................. 258
ROTATING ARM ...................................................................................................................................... 260
14
SAFETY
WARNING
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.
This safety section also contains precautions for optional equipment and attachments.
15
GENERAL PRECAUTIONS SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
GENERAL PRECAUTIONS
SAFETY RULES
● ONLY trained and authorised personnel can operate and
maintain the machine.
● Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
● When working with another operator or a person on worksite
traffic duty, be sure all personnel understand all hand signals
that are to be used.
SAFETY FEATURES
● Be sure all guards and covers are in their proper position.
Have guards and covers repaired if damaged.
● Use safety features such as safety lock lever properly.
● NEVER remove any safety features. ALWAYS keep them in
good operating condition.
Safety lever see “PARKING MACHINE” on page 136.
● Improper use of safety features could result in serious bodily
injury or death.
CLOTHING AND PERSONAL PROTECTIVE ITEMS
● Avoid loose clothing, jewellery, and loose long hair. They can
catch on controls or in moving parts and cause serious injury
or death. Also, do not wear oily cloths because they are flammable.
● Wear a hard hat, safety glasses, safety shoes, mask or
gloves when operating or maintaining the machine. Always
wear safety goggles, hard hat and heavy gloves if your job
involves scattering metal chips or minute materials, this is so
particularly when driving pins with a hammer and when cleaning the air cleaner element with compressed air.
Check also that there is no one near the machine.
Driving in pins, see “REPLACEMENT AND INVERSION
OF BUCKET” on page 133.
Cleaning of air cleaner element, see “WHEN REQUIRED”
on page 188. in service procedure.
UNAUTHORISED MODIFICATION
● Any modification made without authorisation from Komatsu
can create hazards.
16
SAFETY GENERAL PRECAUTIONS
WARNING: Failure to follow these safety precautions may lead to a serious accident.
● Before making a modification, consult your Komatsu distribu-
tor. Komatsu will not be responsible for any injury or damage
caused by any unauthorised modification.
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT
● When standing up from the operator’s seat, always raise the
control lever Pad Safety lock to the LOCK position. If you
accidentally touch the travel or swing lever when they are not
locked, the work equipment may suddenly move and cause
serious injury or damage.
● When leaving the machine, lower the work equipment com-
pletely to the ground, set the control lever Pad safety lock
lever to the LOCK position, then stop the engine and use the
key to lock all the equipment. Always take the key with you.
Work equipment posture see “PARKING MACHINE” on
page 136.
MOUNTING AND DISMOUNTING
● NEVER jump on or off the machine. NEVER get on or off a
moving machine.
● When mounting or dismounting, always face the machine and
use the handrails, machine or chassis steps.
● Do not hold any control levers when getting on or off the
machine.
● Ensure safety by always maintaining at least three-point con-
tact of hands and feet with the handrails, steps or wheels.
● Always remove any oil or mud from the handrails, steps and
track shoes. If they are damaged, repair them and tighten any
loose bolts.
● If grasping the door handrail when mounting or dismounting
or moving on the chassis steps, open and lock the door
securely in the open position. Otherwise, the door may move
suddenly, causing you to lose balance and fall.
FIRE PREVENTION FOR FUEL AND OIL
Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS.
● Keep flames away from flammable fluids.
● Stop the engine and do not smoke when refuelling.
17
GENERAL PRECAUTIONS SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
● Tighten all fuel and oil caps securely.
● Refuelling and oiling should be carried out in well ventilated
areas.
● Keep oil and fuel in a secure place and do not allow unautho-
rised persons to enter.
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES
● Immediately after operations are stopped, the engine coolant,
engine oil, and hydraulic oil are at high temperatures, and are
still under pressure. Attempting to remove the cap, drain the
oil or water, or replace the filters may lead to serious burns.
Always wait for the temperature to go down, and follow the
specified procedures when carrying out these operations.
● To prevent hot water from spurting out:
1. Turn engine off.
2. Allow water to cool.
3. Slowly loosen cap to relieve pressure before removing.
● To prevent hot oil from spurting out:
1. Turn engine off.
2. Allow oil to cool.
3. Slowly loosen cap to relieve pressure before removing.
MACHINES FITTED WITH WHEELS
Never perform any repair work or modifications to wheel rims
while the tyres are fitted, and never apply heat in the vicinity on
the tyres
18
SAFETY GENERAL PRECAUTIONS
WARNING: Failure to follow these safety precautions may lead to a serious accident.
ASBESTOS DUST HAZARD PREVENTION
Asbestos dust can be HAZARDOUS to your health if it is inhaled.
Your Komatsu machine and genuine Komatsu spare parts do not
contain any asbestos. Use only genuine Komatsu spare parts. If
spare parts containing asbestos are used, the following precautions must be observed:
● NEVER use compressed air for cleaning.
● Use water for cleaning to keep down the dust.
● Operate the machine with the wind to your back, whenever
possible.
● Use an approved respirator if necessary.
CRUSHING OR CUTTING PREVENTION
Do not enter, or put your hand or arm or any other part of your
body between movable parts such as between the work equipment and cylinders, or between the machine and work equipment.
If the work equipment is operated, the clearance will change and
this may lead to serious damage or personal injury.
FIRE EXTINGUISHER AND FIRST AID KIT
● Know how to use fire extinguisher (if installed).
● Provide a first aid kit at the storage point.
● Know what to do in the event of a fire.
● Be sure you know the phone numbers of persons you should
contact in case of an emergency.
PROTECTION AGAINST FALLING OR FLYING OBJECTS
If there is any danger of falling or flying objects hitting the operator, install protective guards in place to protect the operator as
required for each particular situation.
● For work with breakers, install a front guard on the wind-
shield. Also, place a laminate coating sheet over the windshield.
● For demolition or shear work, install a front guard on the
windshield and a top guard on the cab. Also, place a laminate
coating sheet over the windshield.
19
GENERAL PRECAUTIONS SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
● For work in mines, quarries, demolition, tunnels or other
places where there is danger of falling rocks, put FOPS (falling object protective structure) in place. Also, place a laminate coating sheet over the windshield.
The above comments are made with regards to typical working
conditions. By all means you should put on other guards if
required by conditions at your particular site.
For details of safety guards, please contact your Komatsu distributor.
Also, even for other types of work, if there is any danger of being
hit by falling or flying objects or of objects entering the operator’s
(B)
cab, select and install a guard that matches the working conditions.
(C)
(B): Top guard (C): Front guard (I)
Be sure to close the front window before commencing work.
When carrying out the above operations, make sure to keep all
persons other than the operator outside the range of falling or flying objects. Be particularly sure to maintain a proper distance
when carrying out shear operations.
PRECAUTIONS FOR ATTACHMENTS
● When installing and using an optional attachment, read the
instruction manual for the attachment and the information
related to attachments in this manual.
● Do not use attachments that are not authorised by Komatsu
or your Komatsu distributor. Use of unauthorised attachments
could create a safety problem and adversely affect the proper
operation and useful life of the machine.
● Any injuries, accidents, product failures resulting from the use
of unauthorised attachments will not be the responsibility of
Komatsu.
MACHINES WITH ACCUMULATOR
AB30052C
On machines equipped with an accumulator, for a short time after
the engine is stopped, the work equipment will lower under its
own weight when the work equipment control lever is shifted to
LOWER. After the engine is stopped, set the PPC lock switch to
the off position (and also lock the attachment pedal with the lock
pin).
20
SAFETY GENERAL PRECAUTIONS
WARNING: Failure to follow these safety precautions may lead to a serious accident.
When releasing the pressure inside the work equipment circuit on
machines equipped with an accumulator, follow the procedure
given in the inspection and maintenance section.
Method of releasing pressure see “HANDLING THE
ACCUMULATOR” on page 99.
The accumulator is filled with high-pressure nitrogen gas, and it is
extremely dangerous if it is handled in the wrong way. Always
observe the following precautions.
● Never make any hole in the accumulator or expose it to flame
or fire.
● Do not weld anything to the accumulator.
● When carrying out disassembly or maintenance of the accu-
mulator, or when disposing of the accumulator, it is necessary
to release the gas from the accumulator. A special air bleed
valve is necessary for this operation, so please contact your
Komatsu distributor.
Gas in accumulator, see “HANDLING THE ACCUMULATOR” on page 99.
EMERGENCY EXIT
● When exit by normal means is prevented in an emergency
you can get out through the emergency exit (rear window).
● Pull the ring at the bottom of the window and remove strip.
This will allow you to push out glass.
ROTATING BEACON (Option)
● When the machine is operated on or beside a road, a rotating
beacon is required to avoid a traffic accident.
● Contact your Komatsu distributor to install beacon lamp.
ELECTROMAGNETIC INTERFERENCE
When this machine is operating close to a source of high electromagnetic interference, such as a radar station, some abnormal
phenomena may be observed.
● The display on the monitor panel may behave erratically.
● The warning buzzer may sound.
These effects do not signify a malfunction and the machine will
return to normal as soon as the source of interference is removed.
21
PRECAUTION DURING OPERATION SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
PRECAUTION DURING OPERATION
BEFORE STARTING ENGINE
SAFETY AT WORKSITE
● Before starting the engine, thoroughly check the area for any
unusual conditions that could be dangerous.
● Before starting the engine, examine the terrain and soil condi-
tions of the worksite. Determine the best and safest method
of operation.
● Make the slope as horizontal as possible before continuing
operations.
● If you need to operate on a street, protect pedestrians and
cars by designating a person for worksite traffic duty or by
installing fences around the worksite.
● If water lines, gas lines, and high-voltage electrical lines may
be buried under the worksite, contact each utility and identify
their locations. Be careful not to sever or cut any of these
lines.
● Check the depth and flow of water before operating in water
or crossing a river. NEVER be in water which is in excess of
the permissible water depth.
Permissible water depth, see “PRECAUTIONS FOR
OPERATION” on page 129.
FIRE PREVENTION
● Thoroughly remove wood chips, leaves, paper and other
flammable things accumulated on the engine compartment.
They could cause a fire.
● Check fuel, lubrication, and hydraulic systems for leaks. Have
any leaks repaired. Wipe up any excess oil, fuel or other flammable fluids.
Check point, see “WALK-AROUND CHECK” on page 101.
● Be sure a fire extinguisher is present and working.
IN OPERATOR’S CAB
● Do not leave tools or spare parts lying around in the opera-
tor’s compartment. They may damage or break the control
levers or switches. Always put them in the tool box on the
front right side of the revolving frame or in the tool boxes on
the undercarriage.
● Keep the cab floor, controls, steps and handrails free of oil,
grease, snow, and excess dirt.
22
SAFETY PRECAUTION DURING OPERATION
WARNING: Failure to follow these safety precautions may lead to a serious accident.
VENTILATION FOR ENCLOSED AREAS
If it is necessary to start the engine within an enclosed area, provide adequate ventilation. Exhaust fumes from the engine can
KILL.
PRECAUTIONS FOR MIRRORS, WINDOWS AND LIGHTS
● Remove all dirt from the surface of the windows and lights to
ensure that you can see well.
● Adjust the rear view mirror so that you can see clearly from
the operator’s seat, and always keep the surface of the mirror
clean. If any glass is broken, replace it with a new part.
● Check that the head lamps and working lamps are installed to
match the operating conditions. Check also that they light up
properly.
OPERATING MACHINE
WHEN STARTING THE ENGINE
● Walk around for machine again just before mounting it, to
check for people and objects that might be in the way.
● NEVER start the engine if a warning tag has been attached to
the wrist control.
● Before starting the engine, sound the horn as an alert.
● Start and operate the machine only while seated.
● Do not allow anyone other than the operator to ride in the cab
or on the machine body.
● For machines equipped with a reverse alarm buzzer, check
that the warning device operates correctly.
CHECK DIRECTION BEFORE STARTING MACHINE
Before operating the travel lever, check the direction of the under
carriage.
If the fixed axle is at the front, the forward/reverse pedal and
steering will function in the opposite direction.
A Fixed axle
B Oscillating axle
Travel operations see “MOVING MACHINE OFF” on
page 119.
AB
23
PRECAUTION DURING OPERATION SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
CHECK THAT NO ONE IS IN THE AREA BEFORE SWINGING
OR TRAVELLING IN REVERSE
● Always position a signalman when operating in dangerous
places or places where the view is not clear.
● Make sure that no one comes inside the swing radius or
direction of travel.
● Before starting to move, sound the horn or give a signal to
warn people not to come close to the machine.
A0067200PW
● There are blind spots behind the machine, so if necessary,
swing the upper structure to check that there is no one behind
the machine before travelling in reverse.
PRECAUTIONS WHEN TRAVELLING
● Fold in the work equipment as shown in the diagram below,
and keep it at a height of 40-50 cm from the ground level
before starting to travel.
● When travelling on public roads the control lever pad safety
lock should be down and the control lever lock switch, in the
off position. This prevents operation of the control levers and
activates the rear facing brake lamp circuit.
● When travelling on rough ground, travel at low speed, and
avoid sudden changes in direction.
● Avoid travelling over obstacles as far as possible. If the
machine has to travel over an obstacle, keep the work equipment as close to the ground as possible and travel at low
speed. Never travel over obstacles which make the machine
tilt strongly (10° or more).
A0067190PW
AM089000PW
INCORRECT
24
AM089010PW
SAFETY PRECAUTION DURING OPERATION
WARNING: Failure to follow these safety precautions may lead to a serious accident.
TRAVELLING ON SLOPES
● Travelling on hills, banks or slopes that are steep could result
Downhill
in the machine tipping over or slipping.
● On hills, banks or slopes, carry the bucket closer to the
ground, approximately 20 to 30 cm above the ground. In case
of emergency, quickly lower the bucket to the ground to help
the machine stop and prevent it from tipping over.
● Do not turn on slopes or travel across slopes. Always go
down to a flat place to perform these operations.
Uphill
Method of travelling on slopes, see “PRECAUTIONS
WHEN TRAVELING UP OR DOWN HILLS” on page 130.
Do not travel up and down on grass, fallen leaves, and wet steel
plates. These materials may allow the machine to slip, if it is travelling sideways. Keep travel speed very low.
PROHIBITED OPERATIONS
● Do not dig the work face under an overhang. This may cause
the overhang to collapse and fall on top of the machine
● Do not carry out deep digging under the front of the machine.
The ground under the machine may collapse and cause the
machine to fall.
INCORRECT
.
CORRECT
INCORRECT
INCORRECT
25
PRECAUTION DURING OPERATION SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES
Going close to high-voltage cables can cause electric shock.
Always maintain the safe distance given below between the
machine and the electric cable.
● The following actions are effective in preventing accidents.
1) Wear shoes with rubber or leather soles.
2) Use a signalman to give warning if the machine
approaches too close to the electric cable.
● If the work equipment should touch the electric cable, the
operator should not leave the operator’s compartment.
● When carrying out operations near high voltage cables, do
not let anyone come close to the machine.
● Check with the electricity company about the voltage of the
cables before starting operations.
Voltage Min. safety distance
6.6 kV 3 m
33.0 kV 4 m
66.0 kV 5 m
154.0 kV 8 m
275.0 kV 10 m
DO NOT HIT WORK EQUIPMENT
● When working in places where there are height limits, such as
in tunnels, under bridges, under electric cables, or in garages,
be extremely careful not to hit the boom or arm.
ENSURE GOOD VISIBILITY
● When working in dark places, install working lamps and head
lamps, and set up lighting in the work area if necessary.
● Stop operations if the visibility is poor, such as in mist, snow,
or rain, and wait for the weather to improve to a condition that
allows the operation to be carried out safely.
OPERATE CAREFULLY ON SNOW
● When working on snow or icy roads, even a slight slope may
cause the machine to slip to the side, so always travel at low
speed and avoid sudden starting, stopping, or turning.
26
SAFETY PRECAUTION DURING OPERATION
WARNING: Failure to follow these safety precautions may lead to a serious accident.
● When there has been heavy snow, the road shoulder and
objects placed beside the road are buried in the snow and
cannot be seen, so always carry out snow-clearing operations
carefully.
WORKING ON LOOSE GROUND
● Avoid operating your machine too close to the edge of cliffs,
overhangs, and deep ditches. If these areas collapse, your
machine could fall or tip over and result in serious injury or
death. Remember that the soil after heavy rain or blasting is
weakened in these areas.
● Earth laid on the ground and the soil near ditches are loose.
They can collapse under the weight or vibration of your
machine.
● Install the HEAD GUARD (FOPS) if working in areas where
there is danger of falling rocks and dirt.
DO NOT HIT THE OPERATOR CAB (for two piece boom only)
● When the second boom cylinder is retracted, the bucket or
the attachment can hit the operator cab or chassis.
● Operate work equipment slowly and carefully to avoid any
injury and damage.
OPERATIONS ON SLOPES
● When working on slopes, there is danger that the machine
may lose its balance and turn over when the swing or work
equipment are operated. Always carry out these operations
carefully.
INCORRECT
27
PRECAUTION DURING OPERATION SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
● Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation is
dangerous.
(See the upper diagram on the right.)
● If the machine has to be used on a slope, pile the soil to make
a platform that will keep the machine as horizontal as possi-
CORRECT
ble.
(See the lower diagram on the right.)
Platform
Piled soil on slope see “PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS” on page 130.
PARKING THE MACHINE
Park on level ground whenever possible. If not possible, chock
the wheels, lower the bucket to the ground and thrust the bucket
in the ground.
CORRECT
● When parking on public roads, provide fences and signs,
such as flags or lights, on the machine to warn passersby to
be careful. Be sure that the machine, flags or lights do not
obstruct traffic.
Parking procedure, see “PARKING MACHINE” on
page 136.
● When leaving the machine, lower the work equipment com-
pletely to the ground, raise the control lever Pad Safety lock
to the LOCK position, then stop the engine and use the key to
lock all the equipment. Always take the key with you.
Work equipment posture, see “PARKING MACHINE” on
page 136.
Places to lock, see “LOCKING” on page 138.
TRANSPORTATION
LOADING AND UNLOADING
Chock
Trust the bucket
● Loading and unloading the machine always involves potential
hazards. EXTREME CAUTION SHOULD BE USED.
When loading or unloading the machine, run the engine at
low idling and travel at low speed.
● Perform loading and unloading on firm, level ground only.
Maintain a safe distance from the edge of a road.
● ALWAYS block the wheels of the hauling vehicle and place
blocks under both ramps before loading and unloading.
● ALWAYS use ramps of adequate strength. Be sure the ramps
are wide and long enough to provide a safe loading slope.
28
Ramp
Block
Distance between ramps
Blocks
AD052900B
SAFETY PRECAUTION DURING OPERATION
WARNING: Failure to follow these safety precautions may lead to a serious accident.
● Be sure that the ramps are securely positioned and fastened,
and that the two sides are at the same level as one another.
● Be sure the ramp surface is clean and free of grease, oil, ice
and loose materials. Remove dirt from the machine wheels.
● NEVER correct your steering on the ramps. If necessary,
drive away from the ramps and climb again.
● Swing the upper structure with extreme care on the trailer to
avoid a possible accident caused by body instability.
● After loading, block the machine wheels and secure the
machine with tie-downs.
Loading and unloading, see “TRANSPORTATION” on
page 144.
SHIPPING
● When shipping the machine on a hauling vehicle, obey all
state and local laws governing the weight, width, and length
of a load. Also obey all applicable traffic regulations.
● Determine the shipping route while taking into account the
width, height and weight of the load.
BATTERY
BATTERY HAZARD PREVENTION
● Battery electrolyte contains sulphuric acid and can quickly
burn the skin and eat holes in clothing. If you spill acid on
yourself, immediately flush the area with water.
● Battery acid could cause blindness if splashed into the eyes.
If acid gets into the eyes, flush them immediately with large
quantities of water and see a doctor at once.
● If you accidentally drink acid, drink a large quantity of water or
milk, beaten egg or vegetable oil. Call a doctor or poison prevention centre immediately.
● When working with batteries. ALWAYS wear safety glasses or
goggles.
● Batteries generate hydrogen gas. Hydrogen gas is very
EXPLOSIVE, and is easily ignited with a small spark or flame.
● Before working with batteries, stop the engine and turn the
starting switch to the OFF position.
● Avoid short-circuiting the battery terminals through accidental
contact with metallic objects, such as tools, across the terminals.
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