UEAM000106
Operation &
Maintenance Manual
PW150ES-
6K
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PW150ES-6K - K35001
and up
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
3
FOREWORD 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 late st available information for your machine or for questions re gardin g 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 ca n
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 n ot 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
4
FOREWORD FOREWORD
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 6. and in "SAFETY" from page 19
5
SAFETY INFORMATION FOREWORD
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.
6
FOREWORD SAFETY INFORMATION
NOISE
● 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
7
SAFETY INFORMATION FOREWORD
These results were obtained by accelerometer s 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 so urce 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.
8
FOREWORD INTRODUCTION
INTRODUCTION
INTENDED USE
T his Komatsu H YDRAULI C EXCAVATOR is des igned 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 136 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:
9
INTRODUCTION FOREWORD
● 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 em ergency.
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 temperat ure 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 cons ideration of safety in such operations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstances.
10
FOREWORD 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 valve cover (A).
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.:
Engine Serial No.:
Product Identification Number :
Manufacturer’s name: Komatsu UK Ltd.
Address
Durham Road
Birtley
Chester-Le-Street
County Durham DH32QX
United Kingdom
A
Distributor
Address
Phone
11
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD
MACHINE SERIAL PLATES
Valid until 31 December 2003
STANDARD SERIAL PLATE
GERMANY SERIAL PLATE
ITALIAN SERIAL PLATE
12
FOREWORD LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Valid as of 1 January 2004
STANDARD SERIAL PLATE
MODEL
SERIAL NUMBER
MAX. DRAWBAR PULL
MASS
ENGINE POWER
PRODUCT ID NUMBER
MANUFACTURER
GERMANY SERIAL PLATE
MODEL
SERIAL No.
MANUFACT. YEAR
MAX. DRAWBAR PULL
MASS
ENGINE POWER
Product Identification Number
MANUFACTURER
Manufactured by Komatsu UK Ltd.
for Komatsu Ltd.,Tokyo,Japan
Manufactured by Komatsu UK Ltd.
for Komatsu Ltd., Tokyo, Japan
TYP
FABR. NR.
BAUJAHR
ZUL. ZUGKRAFT
ZUL.GESAMTGEWICHT
LEISTUNG
ZUL.ACHSLAST VORN
ZUL.ACHSLAST HINTEN
Produkt Identifizierung Nummer
HERSTELLER
Hergestellt vom Komatsu UK Ltd. Birtley Co Durham,
United Kingdom unter lizenz der Komatsu Ltd.
MANUFACTURING YEAR
N
kg
kW
20G-00-K2382
N
kg
kW
kg
kg
ITALIAN SERIAL PLATE
MANUFACTURER
TIPO
TYPE-MODEL
NUMERO DI OMOLOGAZIONE
HOMOLOGATION NUMBER
MATRICOLA
SERIAL NUMBER
MASSA TOTALE AMMISSIBILE
TOTAL MAX WEIGHT
CARICO AMMISSIBILE ASSE ANT.
WEIGHT FRONT AXLE
CARICO AMMISSIBILE ASSE POST.
WEIGHT REAR AXLE
POTENZA MOTORE
ENGINE POWER
Numero di Identificazione del Prodotto.
Product Identification Number
Massa rimorchiabile ammissibile:
- Massa rimorchiabile con frenata: non atto
- Massa rimorchiabile con frenatura indipendente: non atto
- Massa rimorchiabile con frenatura ad inerzia: non atto
- Massa rimorchiabile con frenatura assistita: non atto
20G-00-K2392
Manufactured by Komatsu UK Ltd.
for Komatsu Ltd.,Tokyo,Japan.
DA
FROM
DA
FROM
DA
FROM
kW
A
kg
TO
A
kg
TO
A
kg
TO
ANNO
YEAR
20E-00-K1932
kg
kg
kg
13
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD
14
CONTENTS
FOREWORD.........................................................................................................3
FOREWORD ........................ ................................. ................................ .................................................................. 4
SAFETY INFORMATION ........................................................................................................................................ 6
SAFETY MESSAGES ................................................................................................................................... 6
NOISE ............................ ............................. ............................. ............................. ........................................ 7
VIBRATION ................................................................................................................................................... 7
EMERGENCY STEERING ........................................................................................................................... 8
INTRODUCTION ......................... ... ... .... ... ... ... ....................................... ... .... ... ... ... ... ............................................... 9
INTENDED USE ........................................................................................................................................... 9
FEATURES .................................... ............................. ............................. ..................................................... 9
BREAKING IN YOUR NEW MACHINE ........................................................................................................ 9
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ........................................... 11
MACHINE SERIAL NO. PLATE POSITION ................................................................................................ 11
ENGINE SERIAL NO. PLATE POSITION .................................................................................................. 11
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR .............................................................................. 11
MACHINE SERIAL PLATES ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... .......................................... ... ... ... ... ................ 12
SAFETY.............................................................................................................19
GENERAL PRECAUTIONS ................................................................................................................................. 20
PRECAUTION DURING OPERATION ................................................................................................................. 26
BEFORE STARTING ENGINE ................................................................................................................... 26
OPERATING MACHINE ...... ... .... ... .......................................... .......................................... ......................... 27
TRANSPORTATION ................... ................................ ................................... ............................................. 32
BATTERY ................................................................................................................................................... 33
TOWING ..................................................................................................................................................... 34
BUCKET WITH HOOK OR BUCKET LINK ................................................................................................. 35
PRECAUTIONS FOR MAINTENANCE ................................................................................................................ 39
BEFORE CARRYING OUT MAINTENANCE ............................................................................................. 39
DURING MAINTENANCE ........................................................................................................................... 42
POSITION FOR ATTACHING SAFETY LABELS ................................................................................................ 45
POSITION FOR ATTACHING SAFETY LABELS ....................................................................................... 45
OVERLOAD CAUTION ........................................................................................................................................ 60
OPERATION.......................................................................................................61
15
GENERAL VIEW ........ .... ... ... ... ... .... ... ... ....................................... ... ... .... ... ... ... .... .................................................. 62
GENERAL VIEW OF MACHINE ................................................................................................................. 62
GENERAL VIEW OF CONTROLS AND GAUGES ..................................................................................... 63
EXPLANATION OF COMPONENTS .................................................................................................................... 65
MACHINE MONITOR ................................................................................................................................. 65
SWITCHES ................................................................................................................................................. 76
CONTROL LEVERS, PEDALS ................................................................................................................... 86
DOOR LOCK .............................................................................................................................................. 93
CAP, COVER WITH LOCK ......................................................................................................................... 94
FUSE .......................................................................................................................................................... 95
LUGGAGE TRAY ..... ... ... ... .... ...................................... .... ... ... ... .... ... ... ... ...................................................... 96
ASHTRAY ................................................................................................................................................... 96
CUP HOLDER ............................................................................................................................................ 96
HEATER ..................................................................................................................................................... 97
AIR CONDITIONER .................................................................................................................................... 99
FUSIBLE LINK .......................................................................................................................................... 102
CONTROLLERS ....................................................................................................................................... 102
TOOL BOX ................................................................................................................................................ 102
REFUELLING PUMP ..................... .... ... ... ... .... ... ... ... .......................................... ....................................... 102
CAB RADIO (OPTION) ............................................................................................................................. 103
WARNING LAMPS .. ... ... ... .... ... ... ....................................... ... ... .... ... ....................................... ................... 104
HANDLING THE ACCUMULATOR .......................................................................................................... 105
OPERATION ................................... .......................................................... .......................................................... 106
CHECK BEFORE STARTING ENGINE ... ... .... ... ... ... ... .... ... ... .......................................... ... .... ... ... ... ... .... ... 106
STARTING ENGINE ................................................................................................................................. 115
MOVING MACHINE OFF .......................................................................................................................... 123
STEERING ........................ ....................... ....................... ...................... ....................... ............................. 126
STOPPING ............................................................................................................................................... 127
SWINGING (Slewing the upper carriage) ................................................................................................. 128
OPERATION OF WORK EQUIPMENT ....................................................................................................129
WORKING MODE SELECTION ............................................................................................................... 130
PROHIBITIONS FOR OPERATION ............................................ ... ... ... .... ... ............................................. 132
PRECAUTIONS FOR OPERATION ......................................................................................................... 133
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS ................................................................... 134
HOW TO ESCAPE FROM MUD ............................................................................................................... 135
WORK POSSIBLE USING HYDRAULIC EXCAVATOR ........................................................................... 136
REPLACEMENT AND INVERSION OF BUCKET .................................................................................... 137
PARKING MACHINE ...................................................................... ... ... .... ... ... ... ... .................................... 140
CHECK AFTER FINISHING WORK .................................. ... ... .......................................... .... ... ................ 141
STOPPING ENGINE ... ... ... .... ... ... ... ....................................... ... .... ... ... ... .... ... ... .......................................... 141
CHECK AFTER STOPPING ENGINE ...................................................................................................... 142
LOCKING .............................. ................................................... ................................................................. 142
OVERLOAD WARNING DEVICE ............................................................................................................. 142
HANDLING THE WHEELS ....................................................................................................................... 143
16
TRANSPORTATION ............................. ...... ....... ...... ...... ....... ...... .... ...... ....... ...... ...... ....... ...... .............................. 148
LOADING, UNLOADING WORK ...... .......................................... ... .... ......................................... .... .......... 148
PRECAUTIONS FOR LOADING ................................................... .... ... ... ... ... ........................................... 150
PRECAUTIONS FOR TRANSPORTATION .................................................. .... ... ... ... .... ... ... ... ... .... ... ... ... . 152
TRAVELLING POSTURE ......................................................................................................................... 153
COLD WEATHER OPERATION ........................................................................................................................ 154
PRECAUTIONS FOR LOW TEMPERATURE ............................... .... ... ... ... ... .... ... ... ... .... ... ....................... 154
PRECAUTIONS AFTER COMPLETION OF WORK ............................................... ... .... ... ... ... ... .... ... ... ... . 155
AFTER COLD WEATHER ........................................................................................................................ 156
LONG-TERM STORAGE .................. .... ... ... ... .... ... ... ....................................... ... ... ... .... ... ... ... .............................. 157
BEFORE STORAGE ................................................................................................................................. 157
DURING STORAGE ................................................................................................................................. 157
AFTER STORAGE .................................................................................................................................... 158
STARTING MACHINE AFTER LONG-TERM STORAGE ........................................................................ 158
TROUBLESHOOTING ...................... ....... ...... ....... ...... ....... ...... ....... ... ...... ....... ...... ....... ...... ....... .......................... 159
PHENOMENA THAT ARE NOT FAILURES ............................................................................................. 159
METHOD OF TOWING MACHINE ........................................................................................................... 160
PRECAUTIONS ON PARTICULAR JOBSITES ....................................................................................... 160
IF BATTERY IS DISCHARGED ................................................................................................................ 161
OTHER TROUBLE ................................................................................................................................... 163
MAINTENANCE ...............................................................................................167
GUIDES TO MAINTENANCE ............................... ... ... ... .... ... .......................................... .................................... 168
OUTLINES OF SERVICE ................................................................................................................................... 171
OUTLINE OF OIL, FUEL, COOLANT ....................................................................................................... 171
OUTLINE OF ELECTRIC SYSTEM .......................................................................................................... 174
OUTLINE OF HYDRAULIC SYSTEM ....................................................................................................... 174
WEAR PARTS LIST ........................................................................................................................................... 176
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE .......................... 177
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ......................................................... 177
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS ..................................................................... 181
INTRODUCTION OF NECESSARY TOOLS ............................................................................................ 181
TORQUE LIST .......................................................................................................................................... 181
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 183
SAFETY CRITICAL PARTS ................................. .......................................... .... ... ... ................................. 184
MAINTENANCE SCHEDULE CHART .... ... ... .......................................... .... ... ... ............................................. .... 185
MAINTENANCE WHEN USING HYDRAULIC BREAKER ....................................................................... 190
USE OF BIO-DEGRADEABLE OIL .......................................................................................................... 190
17
SERVICE PROCEDURE ...... ... ... .... ... ... ... .... ... .......................................... .......................................................... 191
INITIAL 250 HOURS SERVICE ................................................................................................................ 191
WHEN REQUIRED ............... ... ... ... .... ... ... ....................................... ... ... .... ... ... ... ... .... ................................ 192
CHECK BEFORE STARTING ....... .... ... ... ... .... ... ... ... ... .... ... ... .......................................... ... .... ................... 205
EVERY 50 HOURS ................................................................................................................................... 209
EVERY 100 HOURS SERVICE ................................................................................................................ 209
EVERY 250 HOURS SERVICE ................................................................................................................ 214
EVERY 500 HOURS SERVICE ................................................................................................................ 219
EVERY 1000 HOURS SERVICE .............................................................................................................. 225
EVERY 2000 HOURS SERVICE .............................................................................................................. 229
EVERY 4000 HOURS SERVICE .............................................................................................................. 232
EVERY 5000 HOURS SERVICE .............................................................................................................. 232
SPECIFICATIONS............................................................................................237
SPECIFICATIONS .............................................................................................................................................. 238
OPTIONS, ATTACHMENTS ............................................................................245
GENERAL PRECAUTIONS . ... ... .... ................................................................................ .................................... 246
PRECAUTIONS RELATED TO SAFETY ................................................................................................. 246
PRECAUTIONS WHEN INSTALLING ATTACHMENTS .......................................................................... 247
HANDLING BUCKET WITH HOOK ............................ ... ... ... .... ... ... ... .... ... .......................................................... 248
CHECKING FOR DAMAGE TO BUCKET WITH HOOK .......................................................................... 248
PROHIBITED OPERATIONS ................................................................................................................... 248
PRECAUTIONS DURING OPERATIONS ................................................................................................ 248
MACHINES READY FOR ATTACHMENTS ...................................................................................................... 249
GENERAL LOCATIONS ........................................................................................................................... 249
HANDLING THE CLAMSHELL BUCKET ................................................................................................. 251
OPERATION ..................... ....................................................... ................................................................. 252
HANDLING ACCUMULATOR ................................................................................................................... 253
LONG-TERM STORAGE .......................................................................................................................... 254
INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE .................................... 256
HYDRAULIC BREAKER ........................................................................................................................... 256
POWER RIPPER ...................................................................................................................................... 259
FORK GRAB ............................................................................................................................................. 260
GRAPPLE BUCKET ...... ... .... ... ... ... .... ... ... ... .......................................... .................................................... 261
SCRAP GRAPPLE .......................................... ... ... ... ... .... ... ... ....................................... ... ... ....................... 262
CRUSHER & SMASHER .......................................................................................................................... 264
HYDRAULIC PILE DRIVER ...................................................................................................................... 265
HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE ................................................................. 266
ROTATING ARM ...................................................................................................................................... 268
18
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.
19
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 140.
● 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 137.
Cleaning of air cleaner element, see “WHEN REQUIRED”
on page 192. in service procedure.
UNAUTHORISED MODIFICATION
● Any modification made without authorisation from Komatsu
can create hazards.
20
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 140.
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 th em and tighten an y
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.
● Tighten all fuel and oil caps securely.
21
GENERAL PRECAUTIONS SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
● 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:
● Turn engine off.
● Allow water to cool.
● Slowly loosen cap to relieve pressure before removing.
● To prevent hot oil from spurting out:
● Turn engine off.
● Allow oil to cool.
● 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
22
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 , pla ce a lamin ate
coating sheet over the windshield.
23
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 w orking 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).
24
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 105.
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 105.
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 an d 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.
25
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 133.
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 106.
❍ 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 co ntrol
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.
26
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 123.
AB
27
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 trav el at low
speed. Never travel over obstacles which make the machine
tilt strongly (10° or more).
A0067190PW
AM089000PW
INCORRECT
28
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 ov er.
● 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 134.
Do not travel up and down on grass, fallen leave s, 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
29
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.
30
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.
● 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.)
INCORRECT
31
PRECAUTION DURING OPERATION SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
● 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 134.
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.
● When parking on public roads, provide fences and signs,
CORRECT
such as flags or lights, on the machine to warn passers-by to
be careful. Be sure that the machine, flags or lights do not
obstruct traffic.
Parking procedure, see “PARKING MACHINE” on
Thrust the bucket
Chock
page 140.
● 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 140.
Places to lock, see “LOCKING” on page 142.
TRANSPORTATION
LOADING AND UNLOADING
● 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.
Ramp
Block
● 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.
32
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 car e 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 148.
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.
33
PRECAUTION DURING OPERATION SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
● When removing or installing, check which is the positive (+)
terminal and negative (-) terminal.
● Tighten the battery cap securely.
● Tighten the battery terminals securely. Loosened terminals
can generate sparks and lead to an explosion.
● When removing battery cap wear rubber groves to prevent
electrolyte contact with skin.
STARTING WITH BOOSTER CABLES
● ALWAYS wear safety glasses or goggles when starting the
machine with booster cables.
INCORRECT
● When starting from another machine, do not allow the two
machines to touch.
● Be sure to connect the positive (+) cable first when installing
the booster cables. Disconnect the ground or negative (-)
cable first when removing them.
● If any tool touches between the positive (+) terminal and the
A0067320A
chassis, it will cause sparks. This is dangerous, so be sure to
work carefully.
● Connect the batteries in parallel: positive to positive and neg-
ative to negative.
● When connecting the ground cable to the frame of the
machine to be started, be sure to connect it as far as possib le
from the battery.
Starting with booster cables, see “IF BATTERY IS DISCHARGED” on page 161.
TOWING
WHEN TOWING, ATTACH WIRE TO FRAME
● Injury or death could result if a disabled machine is towed
incorrectly.
● If you machine is towed by ano ther machine, ALWAYS use a
wire rope with a sufficient towing capacity.
● NEVER allow a disabled machine to be towed on a slope.
● Do not use a chinked or frayed wire rope.
● Do not straddle the towing cable or wire rope.
Towing holes
Undercarriage
● When connecting up a towing machine, do not let anyone
enter the area between the towing machine and the equipment being towed.
34
SAFETY PRECAUTION DURING OPERATION
WARNING: Failure to follow these safety precautions may lead to a serious accident.
● Set the towing machine and the towing connection of the
equipment being towed in a straight line when connecting it.
● Place pieces of wood between the wire ropes and body to
protect them from wear of damage.
● Never tow the machine using the light-duty towing hole.
Towing method, see “METHOD OF TOWING MACHINE”
on page 160.
When towing the machine without the engine running or in the
advent of loss of hydraulic pressure, its is necessary to manually
release the park brake, as follows.
View on transmission from front
Releasing the park brake before towing:
1. Unscrew the lock nuts on the park brake release bolts (A)
completely (3 places).
2. Screw in the park brake release bolts (A) until the torque
increases sharply. The park brake is now released.
Resetting the park brake (A) after towing:
1. Unscrew the park brake release bolts (A) completely.
2. Screw in the park brake release bolts by hand until a contact
can be felt at the bolt end. Lock the bolts with the lock nuts.
BUCKET WITH HOOK OR BUCKET LINK
GENERAL PRECAUTIONS
SPECIAL HOOK
● When carrying out lifting work, the special lifting hook is or lift-
ing eye is necessary.
● The following operations are prohibited.
❍ Lifting loads with a wire rope fitted around the bucket
teeth.
A
❍ Lifting loads with the wire rope wrapped directly around
the boom or arm.
CHECKING HOOK
● When lifting a load, carry out the following checks to confirm
that there is no abnormality before starting operations.
❍ Check that there are no cracks or deformation in the lift-
ing equipment.
35
PRECAUTION DURING OPERATION SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
❍ Check that there is no abnormality in the stopper device.
HOOKING WIRE ROPE SECURELY TO HOOK
● When performing lifting operation, securely hook the wire
rope onto the special lifting hook or lifting eye.
PRECAUTIONS FOR MACHINE INSTALLATION
● After carrying out a preliminary inspection of ground condi-
tions, select a flat, solid location. Confirm that the machine
can be safely operated without toppling or rolling.
PROHIBITED OPERATIONS OTHER THAN MAIN APPLICATIONS
● When performing lifting operation, never raise or lower a per-
son.
NO PERSONS SHALL BE PERMITTED TO ENTER THE
WORKING AREA
● Due to the possible danger of the load falling or of collision
with the load, no persons shall be allowed in the wo rking
area.
OPERATION SUPERVISOR
● Before performing lifting operation, designate an operation
supervisor.
Always execute operation according to his instructions.
❍ Execute operating methods and procedures under his
direction.
❍ Select a person responsible for signalling. Operate only
on signals given by such person.
HANDLING OF WIRE ROPES ETC.
● Wear leather gloves when handling wire ropes.
HANDLING OF FLUIDS
● Some oils and other fluids, such as Antifreeze, can be harm-
ful to you and the environment, you should therefore always
follow the manufacturers instructions regarding storage, handling and disposal.
HANDLING OF USED ENGINE OILS
● Avoid contact with used engine oils.
● Refer to engine oils data sheet for handling and storage pre-
cautions.
36
SAFETY PRECAUTION DURING OPERATION
WARNING: Failure to follow these safety precautions may lead to a serious accident.
HANDLING OF OILS
● For diesel oils, hydraulic oils and oils used in the swing
machinery, PTO, transmission axles and hubs avoid prolonged or frequent contact with skin.
● Refer to manufacturers data sheet for handling and storage
precautions.
HANDLING OF FLUIDS
● For antifreeze and grease refer to manufacturers data sheet
for handling and storage precautions.
PROTECTING EYES
● Some oils and fluids can damage eyes. Refer to manufac-
tured data sheet for handling and storage instructions.
PRECAUTIONS FOR LIFTING OPERATION
GRADUAL LIFTING OPERATION
● When carrying out lifting operations, run the engine at low
idling and use the L.O. (lifting operation mode).
● Avoid sudden lever shifting and acceleration.
● Swing speed is three to four times that of movable cranes.
Therefore, be especially careful when performing swing operation.
NEVER LEAVE THE OPERATOR’S SEAT
● Never leave the operator’s seat while lifting a load.
NEVER CARRY OUT EXCESSIVE OPERATIONS
● Operation exceeding machine performance may result in
accident or failure.
● Carry out lifting operation within specified load limit.
INCORRECT
37
PRECAUTION DURING OPERATION SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
● Never carry out operations which may damage the machine
such as overload or over-impact-load.
● Never drag a load laterally or longitudinally, nor retract the
arm, otherwise, a dangerous situation may result.
INCORRECT
NEVER TRAVELLING WHILE LIFTING A LOAD
● Never travel while carrying a load.
OPERATING POSTURE
● If the machine posture is not correct, the wire ropes or ring
may detach from the hook. Confirm that the hook angle is correct to avoid this.
38
SAFETY PRECAUTIONS FOR MAINTENANCE
WARNING: Failure to follow these safety precautions may lead to a serious accident.
PRECAUTIONS FOR MAINTENANCE
BEFORE CARRYING OUT MAINTENANCE
WARNING TAG
● If others start the engine or operate the controls while you ar e
performing service or lubrication, you could suffer serious
injury or death.
● ALWAYS attach the WARNING TAG to the control lever in the
operator’s cab to alert others that you are working on the
machine. Attach additional warning tags around the machine,
if necessary.
● These tags are available from your Komatsu distributor. (Part
no. 20E-00-K1340)
PROPER TOOLS
● Use only tools suited to the task. Using damaged, low quality,
faulty, or makeshift tools could cause personal injury.
Tools, see “INTRODUCTION OF NE CESSARY TOOLS” on
page 181.
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
● Replace the following fire-related components periodically:
Fuel system: Fuel hose, spilling hose, and fuel tube cap.
Hydraulic system: Pump outlet hose.
● Replace these components periodically with new ones,
regardless of whether or not they appear to be defective.
These components deteriorate over time.
● Replace or repair any such components if any defect is found,
event though they have not reached the tim e sp ecif ied .
Replacement of safety critical components,see “PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS” on
page 183.
39
PRECAUTIONS FOR MAINTENANCE SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
STOP THE ENGINE BEFORE CARRYING OUT INSPECTION
AND MAINTENANCE
● Always stop the machine on firm flat ground and stop the
engine before carrying out inspection and maintenance.
OFF
● If it is necessary to run the en gine when carrying out mainte-
nance, such as when cleaning the inside of the radiator,
Raise the tilting arm rest to the LOCK position and carry out
the operation with two workers.
● One worker should sit in the operator’s seat so that he can
stop the engine immediately if necessary. He should also be
HEAT
ON
START
AM089160A
extremely careful not to touch any lever by mistake. Touch the
levers only when they have to be operated.
● The worker carrying out the maintenance should be
extremely careful not to touch or get caught in the moving
parts.
RULES TO FOLLOW WHEN ADDING FUEL OR OIL
● Spilt fuel and oil may cause you to slip, so always wipe it up
immediately.
● Always tighten the cap of the fuel and oil fillers securely.
40
SAFETY PRECAUTIONS FOR MAINTENANCE
WARNING: Failure to follow these safety precautions may lead to a serious accident.
● Never use fuel for washing any parts.
● Always add fuel and oil in a well-ventilated place.
RADIATOR WATER LEVEL
● If it is necessary to add water to the radiator, stop the engine
and allow the engine and radiator to cool down before adding
the water.
● Slowly loosen the caps to relieve pr essure before removing
the caps.
41
PRECAUTIONS FOR MAINTENANCE SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
USE OF LIGHTING
● When checking fuel, oil, coolant, or battery electrolyte, always
use lighting with anti-explosion specifications.
If such lighting equipment is not used, there is danger of
explosion.
DURING MAINTENANCE
PERSONNEL
● Only authorised personnel can service and repair the
machine. Extra precaution should be used when grinding,
welding, and using a sledge-hammer.
ATTACHMENTS
● Place attachments that have been removed from the machine
in a safe place so that they do not fall. If they fall on you or
others, serious injury could result.
WORK UNDER THE MACHINE
● Always lower all movable work equipment to the ground or to
their lowest position before p erforming service or repairs
under the machine.
● Always chock the wheels of the machine securely.
● Never work under the machine if the machine is poorly sup-
ported.
KEEP THE MACHINE CLEAN
● Spilt oil or grease, or scattered tools or broken pieces are
dangerous because they may cause you to slip or trip.
Always keep your machine clean and tidy.
42
SAFETY PRECAUTIONS FOR MAINTENANCE
WARNING: Failure to follow these safety precautions may lead to a serious accident.
● If water gets into the electrical system, there is danger that
the machine may not move or may move unexpectedly.
Do not use water or steam to clean the sensors, connectors,
or the inside of the operator’s compartment.
PRECAUTIONS WITH BATTERY
● When repairing the electrical system or when carrying out
electrical welding, remove the negativ e (-) ter m i na l of th e ba ttery to stop the flow of current.
HANDLING HIGH-PRESSURE HOSES
● Do not bend high-pressure hoses or hit them with hard
objects. Do not use any bent or cracked piping, tubes or
hoses. They may burst during use.
● Always repair any loose or broken fuel hoses or oil hoses. If
fuel or oil leaks, it may cause a fire.
PRECAUTIONS WITH HIGH PRESSURE OIL
● Do not forget that the work equipment circuits are always
under pressure.
● Do not add oil, drain oil, or carry out maintenance or inspec-
tion before completely releasing the internal pressure.
● If oil is leaking under high pressure from small holes, it is dan-
gerous if the jet of high-pressure oil hits your skin or enters
your eyes. Always wear safety glasses and thick gloves, and
use a piece of cardboard or a sheet of wood to check for oil
leakage.
● If you are hit by a jet of high-pressure oil, consult a doctor
immediately for medical attention.
A0055180A
A055190A
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT
HIGH TEMPERATURE OR HIGH PRESSURE
● Immediately after stopping operations, the engine cooling
water and oil at all parts is at high temper ature and under hig h
pressure.
In this condition, if the cap is removed, or the oil or water are
43
SAFETY PRECAUTIONS FOR MAINTENANCE
WARNING: Failure to follow these safety precautions may lead to a serious accident.
drained, or the filters are replaced, this may result in burns or
other injury. Wait for the temperature to go down, then carry
out the inspection and maintenance in accordance with the
procedures given in this manual.
Cleaning inside or cooling system, see “WHEN
REQUIRED” on page 192.
Checking cooling water level, hydraulic oil level, see
“CHECK BEFORE STARTING” on page 205.
Checking lubricating oil level, adding oil, see “USE FUEL,
COOLANT AND LUBRICANTS ACCORDING TO AMBIENT
TEMPERATURE” on page 177.
Changing oil, replacing filters, see “OUTLINE OF OIL,
FUEL, COOLANT” on page 171.
ROTATING FAN AND BELT
● Keep away from rotating parts and be careful not to let any-
thing get caught in them.
● If your body or tools touch the fan blades or fan belt, they ma y
be cut off or sent flying, so never touch any rotating parts.
WASTE MATERIALS
● Never dump waste oil in a sewer system, rivers, etc.
● Always put oil drained from your machine in containers.
Never drain oil directly on the ground.
● Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters, batteries, and others.
A0055220A
44
POSITION FOR ATTACHING SAFETY LABELS SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
POSITION FOR ATTACHING SAFETY LABELS
Always keep these labels clean. If they are lost or damage, attach
them again or replace them with a new label
There are other labels in addition to the safety labels listed as follows, so handle them in the same way.
Safety labels are available from your Komatsu distributor.
POSITION FOR ATTACHING SAFETY LABELS
45
POSITION FOR ATTACHING SAFETY LABELS SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
1. Warnings for keep clear of swing area, emergency steering,
power lines, do not ride on machine, falling objects and
bucket cab interference. (20E-00-K1890)
● Improper operation and maintenance can cause serious
injury or death.
● Read the manuals before operation.
● Follow instructions and warnings in the manuals and labels
on the machine.
● Keep this manual in the machine cab, near operator.
● If this manual is lost, please contact Komatsu distributor for
replacement.
● Always apply lock when leaving operators seat.
● Normal steering can only be operated when the engine is r un-
ning.
● Emergency steering only to be used when stopping the
machine safely.
● Serious injury or death can occur if machine or attachments
are not kept a safe distance away from electric lines.
● No passengers allowed to ride on machine while it is moving.
● Do not operate where a danger of falling objects exists. Con-
sult your dealer for fitting of FOPS protection.
● Bucket hits operator cab. Read manual before operation.
2. Warning for staying clear (20E-00-K1260)
46
SAFETY POSITION FOR ATTACHING SAFETY LABELS
WARNING: Failure to follow these safety precautions may lead to a serious accident.
3. Amber reflector (20G-46-K1680)
4. Warning for unsafe machine (20E-00-K1340)
Do not start
5. Warning for accumulato r (20E-00-K1210)
Warnings for handling accumulator.
Explosion hazard
● Keep away from flame.
● Do not weld or drill.
● Read operation manual before operation.
6. Warning for staying clear (20E-00-K1150)
Keeping out of moving area.
To prevent SEVERE INJURY or DEATH.
Do the following before moving the 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. Follow above even if
machine equipped with travel alarm and mirrors.
47
POSITION FOR ATTACHING SAFETY LABELS SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
7. Warning for hot objects (20E-00-K1190)
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.
8. Control lever pad safety lock (20E-00-K1850)
9. Warning for staying clear (20E-00-K1140)
Keeping out of moving area.
To prevent SEVERE INJURY or DEATH.
Do the following before moving the 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. Follow above even if
machine equipped with travel alarm and mirrors.
48
SAFETY POSITION FOR ATTACHING SAFETY LABELS
WARNING: Failure to follow these safety precautions may lead to a serious accident.
10. Warnings for staying clear
(20G-00-K2350) R.H.
(20G-00-K2360) L.H.
11. Falling from upper structure warning
(20E-00-K1110)
● WARNING
falling from upper structure.
● Keep away from sides of machine.
● Keep of counterweight.
● Do not ride on machine when it is moving.
12. Stop engine warning (20E-00-K1310)
● Do not open cover while engine is running.
49
POSITION FOR ATTACHING SAFETY LABELS SAFETY
13. Front windows lock back warning (20E-00-K1230)
● Always apply lock when leaving operator’s seat.
14. High pressure oil warning (20E-00-K1270)
15. 20E-00-K1280
Pump control override switch and swing lock override switch.
Read operation manual before operation.
16. Red reflector (20G-47-K1690)
17. 20Y-00-K2220
● Emergency exit
● Read operation manual before operation
50
SAFETY POSITION FOR ATTACHING SAFETY LABELS
18. Travel Height -UK spec only (20E-00-K1720)
19. Operation of attachments (20G-00-K2273)
ONE PIECE BOOM
When removing bucket, linkage or cylinder, lifting capacities can
be increased by their respective weights.
A - Reach from swing center
B - Bucket hook height
C - Lifting capacities, including bucket (462 kg),
linkage (84 kg) and bucket cylinder (9 2 kg)
OF: Lifting capacity (rating overfront)
OS: Lifting capacity (Rating overside)
MAX - Rating at maximum reach
51
POSITION FOR ATTACHING SAFETY LABELS SAFETY
Height max 6.0 m 4.5 m 3.0 m 1.5
Under-
carriage
Without stabilizer
Rear outrigger
Arm
7.5 m * 3650 * 3650
6.0 m * 2750 2550 * 4100 * 3400
4.5 m * 2500 1900 3800 2500 * 4450 3350
3.0 m * 2450 1650 3750 2000 * 5400 3200
1.5 m * 2600 1550 3700 1950 5800 2950
0.0 m * 2950 1650 3650 1900 5750 2900 * 5950 5250
-1.5 m * 3700 1950 5750 2900 * 9300 5350 * 5450 * 5450
-3 m * 3950 2800 * 4500 3000 * 7050 5500
7.5 m * 3650 * 3650
6.0 m * 2750 * 2750 * 4100 * 4100
4.5 m * 2500 * 2500 * 3900 3200 * 4450 * 4450
3.0 m * 2450 * 2450 * 4350 3150 * 5400 5000
1.5 m * 2600 2550 * 4400 3100 * 6250 4750
0.0 m * 2950 2650 4350 3050 * 6700 4700 * 5950 * 5950
-1.5 m * 3700 3150 * 6300 4700 * 9300 * 9300 * 5450 * 5450
-3 m * 3950 3950 * 4500 * 4500 * 7050 * 7050
OF OS OF OS OF OS OF OS OF OS
Rear Blade
Front outrigger + rear blade
7.5 m * 3650 * 3650
2100
6.0 m * 2750 * 2750 * 4100 4100
4.5 m * 2500 2350 * 3900 2500 * 4450 4050
3.0 m * 2450 2050 * 4350 2450 * 5400 3900
1.5 m * 2600 1950 * 4700 2400 * 6250 3600
0.0 m * 2950 2050 * 4850 2350 * 6700 3600 * 5950 * 5950
-1.5 m * 3700 2400 * 6300 3550 * 9300 6700 * 5450 * 5450
-3 m * 3950 3450 * 4500 3700 * 7050 6900
7.5 m * 3650 * 3650
6.0 m * 2750 * 2750 * 4100 * 4100
4.5 m * 2500 * 2500 * 3900 3850 * 4450 * 4450
3.0 m * 2450 * 2450 * 4350 3800 * 5400 * 5400
1.5 m * 2600 * 2600 * 4700 3750 * 6250 5800
0.0 m * 2950 * 2950 * 4850 3700 * 6700 5750 * 5950 * 5950
-1.5 m * 3700 * 3700 * 6300 5750 * 9300 * 9300 * 5450 * 5450
-3 m * 3950 * 3950 * 4500 * 4500 * 7050 * 7050
52
SAFETY POSITION FOR ATTACHING SAFETY LABELS
Height max 6.0 m 4.5 m 3.0 m 1.5
Under-
carriage
Without stabilizer
Rear outrigger
Arm
7.5 m * 2650 * 2650
6.0 m * 2100 * 2100 * 3600 3400
4.5 m * 1950 1700 * 3800 2050 * 4050 3400
3.0 m * 1950 1500 3750 2000 * 5050 3200 * 7250 5950
1.5 m * 2050 1400 3700 1950 5900 3000 * 6150 5500
0.0 m * 2350 1500 3600 1850 5750 2900 * 6500 5300
-1.5 m * 2900 1700 3600 1850 5700 2850 * 9750 5300 * 5000 * 5000
-3 m * 3900 2350 * 5250 2900 * 7850 5400
7.5 m * 2650 * 2650
6.0 m * 2100 * 2100 * 3600 * 3600
4.5 m * 1950 * 1950 * 3800 3200 * 4050 * 4050
3.0 m * 1950 * 1950 * 4150 3150 * 5050 * 5050 * 7250 * 7250
1.5 m * 2050 * 2050 4400 3100 * 6050 4800 * 6150 * 6150
0.0 m * 2350 * 2350 4350 3000 * 6650 4700 * 6500 * 6500
-1.5 m * 2900 2800 4350 3000 * 6450 4650 * 9750 9250 * 5000 * 5000
-3 m * 3900 3750 * 5250 4700 * 7850 * 7850
7.5 m * 2650 * 2650
2500
6.0 m * 2100 * 2100 * 3600 * 3600
4.5 m * 1950 * 1950 * 3800 2500 * 4050 * 4050
3.0 m * 1950 * 1850 * 4150 2450 * 5050 3900 * 7250 * 7250
OF OS OF OS OF OS OF OS OF OS
Rear Blade
Front outrigger + rear blade
1.5 m * 2050 1800 * 4550 2400 * 6050 3700 * 6150 * 6150
0.0 m * 2350 1850 * 4800 2300 * 6650 3550 * 6500 * 6500
-1.5 m * 2900 2150 * 4500 2300 * 6450 3550 * 9750 6700 * 5000 * 5000
-3 m * 3900 2900 * 5250 3600 * 7850 6850
7.5 m * 2650 * 2650
6.0 m * 2100 * 2100 * 3600 * 3600
4.5 m * 1950 * 1950 * 3800 * 3800 * 4050 * 4050
3.0 m * 1950 * 1950 * 4150 3800 * 5050 * 5050 * 7250 * 7250
1.5 m * 2050 * 2050 * 4550 3750 * 6050 5900 * 6150 * 6150
0.0 m * 2350 * 2350 * 4800 3650 * 6650 5750 * 6500 * 6500
-1.5 m * 2900 * 2900 * 4500 3650 * 6450 5700 * 9750 * 9750 * 5000 * 5000
-3 m * 3900 * 3900 * 5250 * 5250 * 7850 * 7850
53
POSITION FOR ATTACHING SAFETY LABELS SAFETY
Height max 6.0 m 4.5 m 3.0 m 1.5
Under-
carriage
Without stabilizer
Rear outrigger
Arm
7.5 m * 2000 * 2000
6.0 m * 1650 * 1650 * 2650 2050
4.5 m * 1550 1450 * 3400 2050 * 3500 3400
3.0 m * 1650 1250 3750 2000 * 4500 3250 * 6150 * 6150
1.5 m * 1650 1200 3650 1900 * 5650 3000 * 9100 5550
0.0 m * 1850 1250 3550 1800 5700 2850 * 6800 5200
-1.5 m * 2200 1450 3500 1800 5650 2750 * 9350 5150 * 4300 * 4300
-3 m * 3050 1900 5600 2750 * 8600 5250 * 7700 * 7700
7.5 m * 2000 * 2000
6.0 m * 1650 * 1650 * 2650 * 2650
4.5 m * 1550 * 1550 * 3400 3200 * 3500 * 3500
3.0 m * 1550 * 1550 * 3800 3150 * 4500 * 4500 * 6150 * 6150
1.5 m * 1650 * 1650 * 4300 3050 * 5650 4850 * 9100 * 9100
0.0 m * 1850 * 1850 4300 2950 * 6400 4650 * 6800 * 6800
-1.5 m * 2200 * 2200 4250 2950 * 6500 4550 * 9350 9100 * 4300 * 4300
-3 m * 3050 * 3050 * 5650 4500 * 8600 * 8600 * 7700 * 7700
7.5 m * 2000 * 2000
3000
6.0 m * 1650 * 1650 * 2650 2500
4.5 m * 1550 * 1550 * 3400 2500 * 3500 * 3500
3.0 m * 1550 * 1550 * 3800 2450 * 4500 3950 * 6150 * 6150
OF OS OF OS OF OS OF OS OF OS
1.5 m * 1650 * 1550 * 4300 2350 * 5650 3700 * 9100 6950
Rear Blade
Front outrigger + rear blade
0.0 m * 1850 1600 * 4650 2250 * 6400 3500 * 6800 6600
-1.5 m * 2200 1800 * 4650 2250 * 6500 3450 * 9350 6550 * 4300 * 4300
-3 m * 3050 2350 * 5650 3400 * 8600 6650 * 7700 * 7700
7.5 m * 2000 * 2000
6.0 m * 1650 * 1650 * 2650 * 2650
4.5 m * 1550 * 1550 * 3400 * 3400 * 3500 * 3500
3.0 m * 1550 * 1550 * 3800 * 3800 * 4500 * 4500 * 6150 * 6150
1.5 m * 1650 * 1650 * 4300 3700 * 5650 * 5650 * 9100 * 9100
0.0 m * 1850 * 1850 * 4650 3600 * 6400 5700 * 6800 * 6800
-1.5 m * 2200 * 2200 * 4650 3600 * 6500 5650 * 9350 * 9350 * 4300 * 4300
-3 m * 3050 * 3050 * 5650 5600 * 8600 * 8600 * 7700 * 7700
.Note for lift capacity tables:
1. Ratings are based on ISO 10567
2. Lifting capacities are given for:
a) 75% of tipping load
b) rated hydraulic lift capacity 87% of max.
3. Capacities marked with an asterisk (*) are limited by hydraulic
capacities
54
SAFETY POSITION FOR ATTACHING SAFETY LABELS
TWO PIECE BOOM
When removing bucket, linkage or cylinder, lifting capacities can
be increased by their respective weights.
A - Reach from swing center
B - Bucket hook height
C - Lifting capacities, including bucket (462 kg),
linkage (84 kg) and bucket cylinder (9 2 kg)
OF - Rating over rear
OS - Rating over side or 360 degrees
MAX - Rating at maximum reach
55
POSITION FOR ATTACHING SAFETY LABELS SAFETY
Height max 6.0 m 4.5 m 3.0 m 1.5
Arm
Under-
carriage
7.5 m * 3350 * 3350
6.0 m * 2600 * 2600 * 4250 3950
4.5 m * 2400 2100 3750 2350 * 4800 3850
3.0 m * 2450 1800 3700 2300 * 5900 3700
1.5 m * 2600 1750 3650 2250 5850 3500
0.0 m * 2950 1850 3550 2200 5700 3400 * 4850 * 4850
Without stabilizer
Rear outrigger
-1.5 m 3500 2150 3600 2200 5700 3350 * 10100 6400
-3 m * 4500 3000 * 5450 3450 * 8100 6600
7.5 m * 3350 * 3350
6.0 m * 2600 * 2600 * 4250 * 4250
4.5 m * 2400 * 2400 * 4350 3150 * 4800 * 4800
3.0 m * 2450 * 2450 4450 3100 * 5900 4950
1.5 m * 2600 2400 4400 3050 * 6950 4750
0.0 m * 2950 2500 4300 2950 6950 4650 * 4850 * 4850
-1.5 m * 3750 2900 4300 3000 6950 4600 * 10100 9200
-3 m * 4500 4050 * 5450 4700 * 8100 * 8100
7.5 m * 3300 * 3300
2100
6.0 m * 2550 * 2550 * 4250 4050
OF OS OF OS OF OS OF OS OF OS
Rear Blade
Front outrigger + rear blade
4.5 m * 2350 2150 * 4350 2450 * 4750 4000
3.0 m * 2400 1900 * 4700 2400 * 5900 3800
1.5 m * 2550 1800 * 5150 2300 * 6950 3650
0.0 m * 2950 1900 * 5300 2250 * 7400 3500 * 4800 * 4800
-1.5 m * 3700 2200 * 4800 2250 * 7050 3500 * 10050 6700
-3 m * 4500 3100 * 5450 3600 * 8150 6850
7.5 m * 3350 * 3350
6.0 m * 2600 * 2600 * 4250 * 4250
4.5 m * 2400 * 2400 * 4350 3800 * 4800 * 4800
3.0 m * 2450 * 2450 * 4700 3750 * 5900 * 5900
1.5 m * 2600 * 2600 * 5150 3700 * 6950 5800
0.0 m * 2950 * 2950 * 5300 3650 * 7350 5700 * 4850 * 4850
-1.5 m * 3750 3550 * 4850 3650 * 7050 5700 * 10100 * 10100
-3 m * 4500 * 4500 * 5450 * 5450 * 8100
56
SAFETY POSITION FOR ATTACHING SAFETY LABELS
Height max 6.0 m 4.5 m 3.0 m 1.5
Under-
carriage
Without stabilizer
Rear outrigger
Arm
7.5 m * 2500 * 2500
6.0 m * 2050 * 2050 * 3800 3400
4.5 m * 1900 1550 3800 2000 * 4350 3350
3.0 m * 1900 1350 3750 1950 * 5500 3150 * 8300 5950
1.5 m * 2050 1300 3650 1850 5850 2950
0.0 m * 2350 1350 3550 1800 5700 2800 * 5350 5200
-1.5 m * 2900 1600 3550 1800 5650 2800 * 9100 5200 * 4550 * 4550
-3 m 4150 2100 5700 2850 * 8950 5300
7.5 m * 2500 * 2500
6.0 m * 2050 * 2050 * 3800 * 3800
4.5 m * 1900 * 1900 * 4000 3200 * 4350 * 4350
3.0 m * 1900 * 1900 * 4450 3100 * 5500 5050 * 8300 * 8300
1.5 m * 2050 * 2050 4400 3050 * 6650 4750
0.0 m * 2350 2250 4300 2950 6950 4650 * 5350 * 5350
-1.5 m * 2900 2600 4300 2950 6900 4600 * 9100 * 9100 * 4550 * 4550
-3 m * 4200 3450 * 6050 4650 * 8950 * 8950
7.5 m * 2500 * 2500
2500
6.0 m * 2050 * 2050 * 3800 * 3800
4.5 m * 1900 * 1900 * 4000 2450 * 4350 4050
3.0 m * 1900 1700 * 4450 2400 * 5500 3850 * 8300 7400
OF OS OF OS OF OS OF OS OF OS
Rear Blade
Front outrigger + rear blade
1.5 m * 2050 1650 * 4950 2300 * 6650 3650
0.0 m * 2350 1700 * 5300 2250 * 7300 3500 * 5350 * 5350
-1.5 m * 2900 2000 * 5100 2250 * 7150 3450 * 9100 6600 * 4550 * 4550
-3 m * 4200 2650 * 6050 3500 * 8950 6700
7.5 m * 2500 * 2500
6.0 m * 2050 * 2050 * 3800 * 3800
4.5 m * 1900 * 1900 * 4000 3850 * 4350 * 4350
3.0 m * 1900 * 1900 * 4450 3800 * 5500 * 5500 * 8300 * 8300
1.5 m * 2050 * 2050 * 4950 3700 * 6650 5850
0.0 m * 2350 * 2350 * 5300 3600 * 7300 5700 * 5350 * 5350
-1.5 m * 2900 * 2900 * 5100 3600 * 7150 5650 * 9100 * 9100 * 4550 * 4550
-3 m * 4200 * 4200 * 6050 5700 * 8950 * 8950
57
POSITION FOR ATTACHING SAFETY LABELS SAFETY
Height max 6.0 m 4.5 m 3.0 m 1.5
Under-
carriage
Without stabilizer
Rear outrigger
Arm
7.5 m * 1900 * 1900
6.0 m * 1550 * 1550 * 2900 2050
4.5 m * 1450 1300 * 3600 2000 * 3750 3350
3.0 m * 1500 1150 3700 1950 * 4900 3150 * 6950 6100
1.5 m * 1550 1100 3600 1850 5850 2950 * 6550 5400
0.0 m * 1750 1150 3500 1750 5650 2750 * 5550 5100
-1.5 m * 2150 1300 3450 1700 5550 2700 * 8050 5050 * 3850 * 3850
-3 m * 2950 1700 3500 1750 5600 2700 * 9700 5150 * 7050 * 7050
7.5 m * 1900 * 1900
6.0 m * 1550 * 1550 * 2900 * 2900
4.5 m * 1450 * 1450 * 3600 3200 * 3750 * 3750
3.0 m * 1500 * 1500 * 4100 3100 * 4900 * 4900 * 6950 * 6950
1.5 m * 1550 * 1550 4350 3000 * 6200 4750 * 6550 * 6550
0.0 m * 1750 * 1750 4250 2900 6900 4550 * 5550 * 5550
-1.5 m * 2150 * 2150 4200 2850 6800 4500 * 8050 * 8050 * 3850 * 3850
-3 m * 2950 2800 4250 2900 * 6500 4500 * 9700 9100 * 7050 * 7050
7.5 m * 1900 * 1900
3000
6.0 m * 1550 * 1550 * 2900 2500
4.5 m * 1450 * 1450 * 3600 2450 * 3750 * 3750
3.0 m * 1500 * 1500 * 4100 2400 * 4900 3850 * 6950 * 6950
OF OS OF OS OF OS OF OS OF OS
1.5 m * 1550 1400 * 4700 2300 * 6200 3600 * 6550 * 6550
Rear Blade
Front outrigger + rear blade
0.0 m * 1750 1500 * 5100 2200 * 7050 3450 * 5550 * 5550
-1.5 m * 2150 1650 * 5150 2150 * 7200 3350 * 8050 6450 * 3850 * 3850
-3 m * 2950 2150 * 4300 2200 * 6500 3400 * 9700 6550 * 7050 * 7050
7.5 m * 1900 * 1900
6.0 m * 1550 * 1550 * 2900 * 2900
4.5 m * 1450 * 1450 * 3600 * 3600 * 3750 * 3750
3.0 m * 1500 * 1500 * 4100 3750 * 4900 * 4900 * 6950 * 6950
1.5 m * 1550 * 1550 * 4700 3650 * 6200 5850 * 6550 * 6550
0.0 m * 1750 * 1750 * 5100 3550 * 7050 5650 * 5550 * 5550
-1.5 m * 2150 * 2150 * 5150 3500 * 7200 5550 * 8050 * 8050 * 3850 * 3850
-3 m * 2950 * 2950 * 4300 3550 * 6500 5600 * 9700 * 9700 * 7050 * 7050
.Note for lift capacity tables:
1. Ratings are based on ISO 10567
2. Lifting capacities are given for:
a) 75% of tipping load
b) rated hydraulic lift capacity 87% of max.
3. Capacities marked with an asterisk (*) are limited by hydraulic
capacities
58
SAFETY POSITION FOR ATTACHING SAFETY LABELS
ROTATING ARM
OF: Lifting capacity (rating overfront)
OS: Lifting capacity (Rating overside)
.
Height max 6.0 m 4.5 m 3.0 m 1.5
Arm
Undercarriage
7.5 m * 1850 * 1850
6.0 m * 1550 1550 * 2850 * 2850
4.5 m * 1400 * 1400 * 3400 * 3400 * 3600 * 3600
3.0 m * 1400 * 1400 * 3850 * 3850 * 4650 * 4650 * 6700 * 6700
1.5 m * 1500 * 1500 * 4400 4250 * 5850 * 5850 * 6600 * 6600
0.0 m * 1700 * 1700 * 4800 4100 * 6650 * 6650 * 5650 * 5650
Blade + outrigger
-1.5 m * 2050 * 2050 * 4800 4050 * 6750 6650 * 8200 * 8200 * 3950 * 3950
-3 m * 2850 * 2850 * 3700 * 3700 * 6050 * 6050 * 9050 * 9050
2600
7.5 m * 1850 * 1850
6.0 m * 1550 1550 * 2850 * 2850
4.5 m * 1400 * 1400 * 3400 * 3400 * 3600 * 3600
3.0 m * 1400 * 1400 * 3850 3550 * 4650 * 4650 * 6700 * 6700
1.5 m * 1500 * 1500 * 4400 3400 5500 * 5850 * 6600 * 6600
Front outrigger
0.0 m * 1700 * 1700 * 4800 3300 5250 * 6650 * 5650 * 5650
-1.5 m * 2050 * 2050 * 4800 3250 5150 6550 * 8200 * 8200 * 3950 * 3950
OF OS OF OS OF OS OF OS OF OS
-3 m * 2850 * 2850 * 3700 3300 5200 * 6050 * 9050 * 9050
Note for lift capacity tables:
1. Ratings are based on ISO 10567
2. Lifting capacities are given for:
a) 75% of tipping load
b) rated hydraulic lift capacity 87% of max.
3. Capacities marked with an asterisk (*) are limited by hydraulic
capacities
59
OVERLOAD CAUTION SAFETY
OVERLOAD CAUTION
This machine is equipped with an overload caution system which
gives a visual warning (on monitor) and an audible warning when
lifting a load close to the to the lift capacity of the machine (active
in L.o. mode only).
A decal inside the operators cab shows the loads at which the
caution warning is given for various work equipment positions.
Due to the simple nature of the system the overload warning is
given at a lower load than actually allowable (see full lift capacity
charts)
If lifting to the full capacity of the machine is required it is necessary to fit a full overload caution system (with work equipment
position sensing to the machine.
Decal showing lifting loads (in kg) at overload warning.
60
OPERATION
61
GENERAL VIEW OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
If directions are indicated in this section, they refer to the directions shown by in the arrows in the diagram below.
A : FRONT B : REAR C : RIGHT D : LEFT
1. Bucket 5. Boom
2. Bucket cylinder 6. Boom Cylinder
3. Arm 7. Undercarriage
4. Arm cylinder
62
OPERATION GENERAL VIEW
GENERAL VIEW OF CONTROLS AND GAUGES
1. Control lever pad safety lock 15. Swing lock switch
2. Horn 16. Control lever lock switch
3. Left work equipment control 17. Lamp switch
4. Power max. Button 18. Alarm buzzer stop switch
5. Horn, wiper, washer, dip/main headlights indicators 19. Lower switch
6. L.H. Clamshell rotation switch 20. Beacon switch
7. Boom switch 21. Heated seat switch
8. Machine monitor 22. Heater/Air conditioner control
9. R.H. Clamshell rotation, switch/breaker switch 23. 12 V power supply
10. Undercarriage attachment switch
11. Right work equipment control lever 25. Travel pedal
12. Star ting switch 26. Brake pedal
13. Fuel control dial 27. Steering column, Release pedal
14. Cigarette lighter 28. Two piece boom pedal
24. Outriggers L/R, Hazard, park brake, roadlight,
Axle lock switches.
63
GENERAL VIEW OPERATION
11
1
12
2
3
4
5
6
7
8
9
10
1. Display (for clock and fault indication 11. Service meter
13
14
15
16
17
18
19
20
AD32421D
2. Engine water temperature gauge 12. Fuel gauge
3. Engine water temperature monitor 13. Fuel level monitor
4. Radiator water level monitor 14. Engine oil level monitor
5. Engine oil pressure monitor 15. Hydraulic oil level monitor
6. Air cleaner clogging monitor 16. Charge level monitor
7. Overload caution monitor 17. Engine preheating monitor
8. Working mode selector switch 18. Swing lock monitor
9. Power-max, swift slow-down switch 19. Engine oil replacement monitor
10. Travel speed switch 20. Auto-deceleration switch
64
OPERATION EXPLANATION OF COMPONENTS
EXPLANATION OF COMPONENTS
The following is an explanation of the devices needed for operating the machine.
To carry out suitable operations correctly and safely, it is important
to understand fully the methods of operating the equipment and
the meanings of the displays.
MACHINE MONITOR
D
A. BASIC CHECK ITEMS
This displays the basic items that should be checked before starting the engine.
If there is any abnormality, the appropriate monitor lamp will flash.
NOTICE
When carrying out checks before starting, do not simply
rely on the monitor . Always refe r to the p eriodic ma intenance
items or“OPERATION” on page 106 to carry out the checks.
AD324220B
65
EXPLANATION OF COMPONENTS OPERATION
B. CAUTION ITEMS
CAUTION
If these monitor items flash, check and rep air the appropriate
location as soon as possible.
These are items which need to be observed while the engine is
running.
If any abnormality occurs, items which need to be repaired as
soon as possible are displayed.
If there is any abnormality, the appropriate monitor lamp will flash
to indicate the location of the abnormality.
C. EMERGENCY STOP I TEMS
CAUTION
If these monitors items flash, stop operations immediately,
then check and repair the appropriate location.
These are items which need to be observed while the engine is
running. If any abnormality occurs, items which need to be
repaired immediately are displayed.
If there is any abnormality, the appropriate monitor lamp will flash
to indicate the location of the abnormality and the buzzer will
sound.
D. METER DISPLAY PORTION
This portion consists of pre-heating monitor, swing lock monitor,
engine water temperature gauge, fuel gauge and display.
E. SWITCHES
The switches are used for setting clock time and for selecting
working mode and travel speed.
66
OPERATION EXPLANATION OF COMPONENTS
A: BASIC CHECK ITEMS
4
NOTICE
Do not rely on the “BASIC CHECK ITEMS” only for the
check before starting
Always refer to the periodic maintenance items or "OPERATION" to carry out the checks.
1. RADIA TOR WATER LEVEL
This warns that the radiator cooling water level is too low. If the
monitor lamp flashes, check the cooling water level in the radiator
and reserve tank, and add water.
2. ENGINE OIL LEVEL
This warns that the oil level in the engine oil pan is too low. If the
monitor lamp flashes, check the oil level in the engine oil pa n, and
add oil.
AD324230
67
EXPLANATION OF COMPONENTS OPERATION
B: CAUTION ITEMS
CAUTION
If the caution monitor lamp flashes, repair the problem as
soon as possible.
1. CHARGE LEVEL
This monitor indicates an abnormality in the charging system
while the engine is running. If the monitor lamp flashes, check the
V-belt tension.
If any abnormality is found, see “OTHER TROUBLE” on
page 163.
REMARK
While the starting switch is ON, the lamp will remain lit and
will go off once the engine is started.
2. FUEL LEVEL
If the fuel drops below 55 liters, the lamp will flash. Top up the fuel
before this.
3. AIR CLEANER CLOGGING
This warns that the air cleaner is clogged.
If the monitor lamp flashes, stop the engine then inspect and
clean the air cleaner.
4. OVERLOAD CAUTION (When in LO mode)
This warns that the machine is close to tipping due to the load (an
audible warning is also given), if the warning is given lower the
load. Refer to the lifting capacity chart for safe load.(see section
10)
68
OPERATION EXPLANATION OF COMPONENTS
C: EMERGENCY STOP ITEMS
If any monitor lamp flashes, stop the engine or run it at low idling,
and take the following action.
1. ENGINE WATER TEMPERATURE
If the temperature of the engine cooling water becomes abnormally high, the monitor lamp flashes, and the overheat prevention
system is automatically actuated to reduce the engine speed.
Stop operations and run the engine at low idling until the engine
water temperature gauge enters the green range.
2. RADIATOR WATER LEVEL
If the radiator water level drops, the monitor lamp flashes. Stop
the engine, check the radiator water level, and add water if necessary.
3. ENGINE OIL PRESSURE
If the engine oil pressure drops below the normal pressure, the
monitor lamp flashes. At this item, stop the engine and inspe ct it
according to “OTHER TROUBLE” on page 163
REMARK
While the starting switch is ON, the lamp remains lit and goes
off once the engine is started. When the engine starts, the buzzer
may sound for a short time, however, this does not indicate a
fault.
69
EXPLANATION OF COMPONENTS OPERATION
D: METER DISPLAY PORTION
PILOT DISPLAY
When the starting switch is ON, the pilot display lights up when
the display items are functioning.
1. ENGINE PRE-HEATING MONITOR
This monitor lamp indicates the pre-heating time required when
starting the engine at an ambient temperature below 0°C.
The monitor lamp lights when the starting switch is turned to
HEAT position and flashes after about 30 seconds to show that
the pre-heating is completed. (The monitor lamp will go off after
about 10 seconds.)
2. SWING LOCK MONITOR
This informs the operator that the swing lock is being actuated.
Actuated: Lights up
When the swing lock switch is turned ON (ACTUATED), the monitor lamp lights up.
AD324240A
AD313430A
When the swing lock override switch is turned on, this monitor
lamp flashes.
70
OPERATION EXPLANATION OF COMPONENTS
REMARK
A disc brake is installed in the swing motor to mechanically
stop motor rotation.
The brake is always applied while the swing lock is actuated.
METERS
3. ENGINE WATER TEMPERATURE GAUGE
This gauge indicates the engine cooling water temperature.
If the temperature is normal during operation, the green range (A)
will light up.
(A)
If the red range lights (C) up during operation, the overheat prevention system will be actuated.
The overheat prevention system acts as follows.
Red range (1) lights up:
Output horsepower drops, and water temperature monitor (3)
flashes.
When red range (2) lights up:
Engine speed is lowered further to low idling, engine water temperature monitor (3) lights up, and alarm buzzer sounds at the
same time.
The overheat prevention system is actuated until the temperature
enters the green range.
When red range (2) lights, if the engine water temperature is
reduced and the fuel control dial is turned to the low idling position, the display will be cancelled.
4. FUEL GAUGE
This gauge indicates the amount of fuel in the fuel tank. If the fuel
level is normal during operation, the green range (2) will light up.
(B)
C
3
AW34991D
If only the red range (1) lights up during operation, there is less
than 55 liters of fuel remaining in the tank, so check and add fuel.
After the starting switch is turned ON, the correct level may no t be
displayed for a moment, but this does not indicate any abnormality.
When stopping the engine, turn the starting switch ON and check
that the monitor lamps on items A, B, C and D and the meters
light up.
1
2
AW34992C
71
EXPLANATION OF COMPONENTS OPERATION
A
5. DISPLAY
This normally displays the clock time. If there is any abnormality,
the type of failure is indicated when the starting switch is turned
ON.
Manual setting
1. When the time is displayed, depress clock switch (1) for 2.5
sec. or more.
2. “TIME” flashes.
3. Pressing H switch (2) increases hours and pressing M switch
(3) in-creases minutes. If switch (2) or (3) is pressed for 2.5
seconds or more, hours or minutes increase continuously.
AD31347C
4. When the correct time is reached, press clock switch (1). This
completes clock setting.
Correct time setting
1. When the time is displayed, depress the clock switch for 2.5
sec. or more.
2. “TIME” flashes.
3. When SET switch is pressed, the hour is rounded off for 0 to
14 minutes and rounded up for 45 to 59 minutes.
[Examples) 10:14 becomes 10:00 /rounded off)
10:45 becomes 11:00 (rounded up)
When SET switch (4) is pressed at the time signal or standard
clock, the correct time is obtained.
4. When the correct time is reached, press clock switch (1).
This, completes clock setting.
If the machine has a fault, error information appears while the
starting switch is turned ON. The monitor flashes and displays all
error informations sequentially.
Monitor indications Error mode
E02 PC-EPC valve system error
AD324250
E03 Swing brake system error
E05 Governor system error
CALL Non-operating error
If any of these monitors flashes, see “ELECTRONIC CONTROL SYSTEM” on page 166.
72
OPERATION EXPLANATION OF COMPONENTS
6. SERVICE METER
This displays the accumulated hours of operation of the machine.
Use the display to determine the intervals for periodic maintenance.
The service meter will advance while the engine is running even if
the machine is not moving.
The service meter reading advances by 1 for every hour that the
engine is running, regardless of the engine speed.
E: SWITCHES
1. WORKING MODE SELECTOR SWITCH (Basic switch)
This switch is used to set the movement or power for the work
equipment. By selecting the mode to match the working conditions, it is possible to carry out operations more easily.
H.O. (heavy-duty operation mode) lights up:
This is used for heavy-duty work.
G.O. (general operation model lights up:
This is used for ordinary work.
F.O. (finishing operation mode) lights up:
This is used for levelling or grading work.
L.O. (lifting operation mode) light s up:
This is used for lifting operation
B.O. (breaker operation mode) lights up:
This is used for breaker work.
AD324260B
H/O G/O F/O L/O B/O
HM
AD157770A
73
EXPLANATION OF COMPONENTS OPERATION
When starting the engine, G.O. (general operation) mode is automatically selected. Each time the switch is pressed, the mode
selection changes.
NOTICE
When the breaker is used, never select the H.O. (heavy-
duty operation) mode.
REMARK
H switch is also used for setting “hours” in the clock and M
switch for setting “minutes”. see “DISPLAY” on page 72.
2. AUTO-DECELERATION SWITCH (Selection switch)
This switch acts to activate the function that automatically lowers
the engine speed and reduces fuel consumption when the control
lever is at neutral.
ON lights up: Auto-deceleration is actuated.
OFF: Auto-deceleration is cancelled.
Each time the switch is pressed, the auto-deceleration is actuated
or cancelled.
3. TRAVEL SPEED SWITCH
If the Hi-Lo switch is operated when the machine is travelling, the
machine may deviate even when travelling in a straight line. To
prevent this, always stop the machine before operating the travel
speed switch.
This is used to select the three travel speeds.
Lo lights up: Low speed travel
Mi lights up: Mid range speed travel
Hi lights up: High speed travel
When the engine is started, the travel speed is automatically set
to Lo.
When travelling in Hi, the travel speed is automatically adjusted to
match the travel surface on soft ground or when travelling uphill,
so there is no need to operate this switch. The monitor indication
keeps lamp Hi lighted.
REMARK
Switching from Hi to Mi or Lo can only be done when the
machine is stationary and the service brake is applied (locked).
If the Mi or Lo button is pressed without the service brake applied
the indicator lamp will show selection of the desired mode but the
machine will remain in Hi mode until such time as the service
brake has been fully applied (locked). Switching from Mi to Lo or
Hi or from Lo to Mi or Hi can be done at any time and whilst travelling. see “MOVING MACHINE FORWARD” on page 123.
AD157780A
AD157790A
74
OPERATION EXPLANATION OF COMPONENTS
4. POWER MAX./SWIFT SLOW-DOWN SWITCH
During operations, the digging power can be increased and the
speed reduced by a one-touch operation of the knob button /single click while pushing).
Power max. (power up) lights up :
When the working mode is heavy-duty and general operation
mode only, the power can be increased while the knob button is
being pressed. Even if the knob button continues to be pressed,
the increase in power finishes after approx. 8.5 sec.
AD157800A
Swift slow-down (speed down) lights up:
When the working mode is heavy-duty operation and general
operation mode only, the speed is reduced while the knob button
is being pressed.
When the engine is started, the power max. lamp lights up. Each
time this switch on the monitor panel is pressed, the mode is
switched.
75
EXPLANATION OF COMPONENTS OPERATION
SWITCHES
1. STARTING SWITCH
This switch is used to start or stop the engine.
OFF position
The key can be inserted or withdrawn. Except for the cab lamp,
radio (if fitted) and clock, the switches for the electric system are
all turned off and the engine is stopped.
ON position
Electric current flows in the charging and lamp circuits.
Keep the starting switch key at the ON position while the engine is
running.
START position
This is the engine-start position. Keep the key at this position during cranking. Immediately after starting the engine, release the
key which will automatically return to the ON position.
HEAT (preheat) position
HEAT
OFF
ON
START
AM089390A
When starting the engine in winter, set the key to this position.
When the key is set to the HEAT position, the pre-heating monitor
lights up.
Keep the key at this position until the monitor lam p goes off.
Immediately after the pre-heating monitor goes off, release the
76
OPERATION EXPLANATION OF COMPONENTS
key . The key automatically retu rns to the OFF position. The n, start
the engine by turning the key to the START position.
2. FUEL CONTROL DIAL
(WITH AUTO-DECELERATION MECHANISM)
This adjusts the engine speed and output.
(1) Low idling (MIN): Turned fully to the left
(2) Full speed (MAX): Turned fully to the right
3. CIGARETTE LIGHTER
This is used to light cigarettes. To use, push the lighter in. After a
few seconds it will spring back.
Pull out the lighter and light your cigarette.
Nothing may be connected to the cigarette lighter without the prior
permission of an authorised Komatsu distributor.
4. SWING LOCK SWITCH
WARNING
● When the machine is travelling under its own power, or
when the swing is not being operated, always set the
switch to the ON (ACTUATED) position.
● On a slope, the work equipment may swi ng to the down
side even if the swing lock switch is located at the ON
position. Be careful concerning this point.
This switch is used to lock the upper structure so that it cannot
swing. ON position (actuated):
The swing lock is always applied, and the upper structure will not
swing even if the swing is operated. In this condition, the swing
lock lamp lights up.
OFF position (cancelled):
The swing lock is applied only when the swing control lever is at
neutral; when the swing control lever is operated, it is cancelled.
The swing lock is actuated approx. 4 seconds after the swing
lever is placed in neutral.
77
EXPLANATION OF COMPONENTS OPERATION
5. CONTROL LEVER LOCK SWITCH
WARNING
When travelling on public roads, set this switch to the off
position. This prevents operation of the work equipment and
activates the rear facing brake lamp circuits.
This switch enables operation of the work equipment control
levers.
ON position (actuated):
Operation of the control levers must be disabled by use of this
switch when the machine is travelling on Public roads.
OFF position (deactivated):
The switch is lit in the on (actuated) position.
6. LAMP SWITCH
This switch turns on the working lamps and monitor illumination.
(1) OFF
(2) Standard work lamps
(3) Standard and additional work lamps (if fitted)
7. ALARM BUZZER STOP SWITCH
This is used to stop the alarm buzzer when it has sounded to
warn of some abnormality in the EMERGENCY STOP ITEMS
while the engine is running.
8. LOWER WIPER SWITCH (If fitted)
1 2
ON
OFF
3
AM089440A
This switch actuates the front lower wiper.
OFF: wiper stops
ON: wiper moves continuously
NB. Do not operate with front lower screen removed.
78
OPERATION EXPLANATION OF COMPONENTS
9. HORN BUTTON
When the lower button on the left work equipment control lever is
pressed, the horn will sound.
Note: Additional horn switch is switch 25.
10. KNOB BUTTON
The upper button of the left work equipment control lever is used
to actuate the power max./swift slow-down functions. Press the
button once (single click) and keep it depressed. In the heavyduty and general operation modes, the power max. function actuates for max. 8.5 seconds and the swift slow-down function actuates while the button is depressed.
11. HEATED OPERATOR SEAT SWITCH (If fitted)
This switch is used to switch on the heated seat.
OFF: seat not heated
ON: seat heated
12. BEACON SWITCH (If fitted)
This switch is used to switch on the rotating beacon.
OFF
ON: beacon lights, lights and rotates.
OFF
OFF
79
EXPLANATION OF COMPONENTS OPERATION
13. CAB LAMP SWITCH
This lights up the cab lamp.
1
2
AM089510A
ON position: Lights up
The cab lamp can be turned on even when the starting switch is
at the OFF position, so be careful not to leave it on by mistake.
13
AM166910B
14. PUMP CONTROL OVERRIDE SWITCH
(2) When normal: Switch is down
(1) When abnormal: When the monitor display shows E02 (TVC
valve system error), it is possible to carry out operation when this
switch is moved up. The pump control override switch is de signed
to allow operations to be carried out for a short period when there
is an abnormality in the pump control system (TVC valve system
error). The abnormality must be repaired immediately.
15. SWING LOCK OVERRIDE SWITCH
14 15
AM166920B
1
2
AM089520A
(2) When normal: Switch is down
(1) When abnormal: When the monitor display shows E03 (swing
brake system error), the brake is cancelled and it becomes possible to swing the upper structure when this switch is moved up, so
normal operations can be carried out. However, the swing brake
remains cancelled.
The swing lock override switch is designed to allow operations to
be carried out for a short period when there is an abnormality in
the swing brake electrical system (swing brake system error). The
abnormality must be repaired immediately.
80
1
2
AM089520A
OPERATION EXPLANATION OF COMPONENTS
16. PARK BRAKE SWITCH
This switch is used to apply and release park brake.
OFF: Park brake released (warning light not illuminated)
ON: Park brake applied (warning light illuminated)
Note1: When moving off from a standstill up an incline it will be
necessary to depress the travel pedal slightly before releasing
park brake to build pressure to the travel hydraulics and prevent
initial rearwards movement
Note 2: A warning buzzer will sound if the travel pedal is
depressed and the park brake is applied.
Do not apply the park brake while the machine is in motion or the
park brake may be damaged.
17. SUSPENSION LOCK SWITCH
Release the front axle suspension lock, using switch).
Position (1) : Front axle suspension travels freely.
Position (2) : Front axle suspension is in ‘auto’ mode i.e. when
travel pedal is depressed, front axle suspension travels freely and
when travel pedal is not depressed, front axle suspension is
locked.
Position (3): Front axle is locked.
The lamp within the switch will illuminate when the front axle is
locked, and will not be illuminated when the front axle is unlocked.
WARNING
Take care when using undercarriage attachments to stabilize
the machine, and suspension lock simultaneously, as locked
front axle may suddenly become free.
When machine is fitted with blade and outriggers it is necessary
to Position outrigger switch (20) in its central (R.H. Attachment)
Position in order to disengage suspension lock during dozer op erations.
18. ROADLIGHTS SWITCH
This switch is used to switch on the side lights and road lights.
(1) OFF
(2) Sidelights (parking lights) on
(3) Roadlights on.
81
EXPLANATION OF COMPONENTS OPERATION
19. HAZARD SWITCH
This switch is used to switch on the hazard warning lights.
OFF: Hazard warning lights off.
ON: Hazard warning lights on.
(Warning light within switch will flash when switched on).
20. OUTRIGGER LEFT/RIGHT SWITCH (IF FITTED)
This switch enables operation of left, right or simultaneous outrigger(s)
(1) Simultaneous LH + RH
(2) Right hand attachment
(3) Left hand attachment
21. UNDERCARRIAGE ATTACHMENT SWITCH
This switch enables operation of outriggers and/or dozer blade.
● Machines equipped with dozer blade only:
When this button is pressed (a) warning light a in position of
switch (20) is activated.
● Machines equipped with outriggers or dozer/outrigger:
When this button is pressed switch (20) will illumate.
22. BOOM SWITCH
This switch enables operation of the boom when this button is
pressed. The warning light in the panel assembly next to switch
20 is not illuminated.
OPERATION OF DOZER + OUTRIGGERS
(ensure safety lock lever is unlocked and front axle is locked)
A. To operate front attachment(s)
1. Ensure park brake switch (16) is on.
2. Set outrigger left/right switch (20) to appropriate position.
3. Press undercarriage attachment switch (21).
4. Move right hand wrist lever forw ard to lower the attachment
and rear-wards to raise the attachment.
82
OPERATION EXPLANATION OF COMPONENTS
22a. UNDERCARRIAGE ATTACHMENT OPERATION WARNING LAMP (For machines fitted with dozer blade only)
This lamp will illuminate when undercarriage attachment switch
has been pressed and indicates that when right hand wrist lever
is moved forward or rearwards the undercarriage attachment will
move.
When this lamp is not illuminated the right hand wrist lever will
operate the boom raise/lower as normal.
REMARK
If the machine is fitted with outriggers operation of the undercarriage attachment switch will illuminate the outrigger left/right
switch (20).
B. TO OPERATE REAR ATTACHMENT(S)
1. Ensure park brake switch (16) is off.
2. Set outrigger left/right switch (20) to appropriate position.
3. Press undercarriage attachment switch (21).
4. Move right hand wrist lever forward to lower the attachment
and rearwards to raise the attachment.
WARNING
When moving the machine, confirm that the chassis attachment is raised.
PRECAUTIONS FOR USING THE DOZER
1. When using the dozer blade as on outrigger.
Use the dozer blade in the same way as an outrigger. How-
ever, use it only on level ground so that uneven loads will not
be applied to the blade.
2. When using the dozer blade with the upper structure facing
the rear of the undercarriage, the steerin g wheel acts in the
opposite direction to that normal travel.
83
EXPLANATION OF COMPONENTS OPERATION
3. Refer to item 17 (suspension lock switch) to ensure that suspension lock system is fully free when required for dozing
operations.
REMARK
Dozer blade is to be used only for stabilizing and light dozing.
23. CLAMSHELL ROT ATION CLOCKWISE/BREAKER SWITCH
This switch operates clockwise rotation of clamshell (if fitted) or
operation of breaker (if fitted).
24. CLAMSHELL ROTATION ANTI-CLOCKWISE
This switch operates anti-clockwise rotation of clamshell (if fitted)
25. HORN SWITCH
When the button at the tip of the L.H. steering column stalk is
pressed the horn will sound.
REMARK
Additional horn switch is switch (9).
26. WINDSCREEN WASH SWITCH
When the sleeve switch on the left hand steering column stalk is
pushed towards the steering column the windscreen wash will
operate.
27. DIRECTION INDICATOR SWITCH
This switch is used to indicate the driver’s intention to ch ange
direction.
(1) Turn right: push lever fully forward
(2) Turn left: pull lever fully back
(Pilot light to the rear of the steering wheel hub will flash and
buzzer will sound)
To cancel, return lever to neutral position (no auto-cancel function
exists)
84
OPERATION EXPLANATION OF COMPONENTS
28. ROADLIGHTS DIP/MAIN BEAM/FLASH SWITCH
This switch has two functions.
● To alternate between headlight dipped and main beams. Pull
left hand steering column stalk fully upwards and release.
(Note roadlights switch (18) must be at position (3) for this
function)
A warning light will illuminate on the steering column when
main beam headlights are illuminated.
● To flash headlights pull left-hand steering column stalk fully
upwards.
29. MAIN WINDSCREEN WIPER SWITCH
This rotary switch on left hand steering column stalk controls main
windscreen wiper.
● Rotate switch 30° away.
From operator for intermittent wipe
● Rotate switch a further 30° away
From operator for continuous wipe.
30. 12V POWER SUPPLY
The 12V socket provided on the right hand panel may be used
only for electrical accessorIes drawing 1,5 A. maximu m. Any
accessories attached to this socket must carry the EC mark.
85
EXPLANATION OF COMPONENTS OPERATION
CONTROL LEVERS, PEDALS
1. CONTROL LEVER PAD SAFETY LOCK
WARNING
● When leaving the operator’s compartment, switch PPC
lock switch to off position, raise the control lever pad to
the LOCK position. If the control levers are not locked,
and they are touched by mistake, this may lead to a serious accident.
If the control lever pad safety lock lever is not placed
securely in the LOCK position and lock switch is not off,
the control levers may not be properly locked. Check that
the situation is as shown in the diagram.
● When the control lever pad safety lock lever is raised,
take care not to touch the work equipment control lever.
If the safety lock lever is not properly locked at the upper
position, the work equipment and swing will move, creating a potentially dangerous situation.
● When the control lever pad safety lock is lowered, take
care not to touch the work equipment control lever.
86
OPERATION EXPLANATION OF COMPONENTS
The control lever pad locks the work equipment, swing and
attachment controls.
This device is a hydraulic lock, so even if it is in the lock position,
the work equipment control lever will move, but the work equipment and swing motor will not work.
2. LEFT WORK EQUIPMENT CONTROL LEVER
(with auto-deceleration de vi ce )
WARNING
If any lever is operated when in the deceleration range, the
engine speed will suddenly increase, so be careful when
operating the levers.
This lever is used to operate the arm and upper structure.
Arm operation Swing operation
(A) Arm OUT (C) Swing to right
(B) Arm IN (D) Swing to left
N (Neutral)
When the lever in this position, the upper structure and the arm
will be retained in the position in which they stop.
3. RIGHT WORK EQUIPMENT CONTROL LEVER
(with auto-deceleration de vi ce )
WARNING
If an lever is operated when in the deceleration range, the
engine speed will suddenly increase, so be careful when
operating the levers.
AM089560A
AM089570A
This lever is used to operate the boom and bucket.
Boom operation Bucket operation
(1) RAISE (3) DUMP
(2) LOWER (4) CURL
N (Neutral)
When the lever in this position, the boom and the bucket will be
retained in the position in which they stop.
87
EXPLANATION OF COMPONENTS OPERATION
For levers (2), (3) and (5), the engine speed changes as follows
because of the auto-deceleration mechanism.
● When the travel lever and work equipmen t control levers are
at neutral, even if the fuel control dial is above the mid-range
position, the engine speed will drop to a mid-range speed. If
any of the levers are operated, the engine speed will rise to
the speed set by the fuel control dial.
● If all control levers are set to neutral, the engine speed will
drop by approx. 100 rpm, and after approx. 4 seconds, the
engine speed will drop to the deceleration speed (approx.
1400 rpm).
4. PPC LOCK SWITCH
WARNING
When travelling on public roads, set this switch to the off
position. This prevents operation of the work equipment and
activates the rear facing brake lamp circuits.
This switch enables operation of the work equipment control
levers.
ON position (actuated):
Operation of the control levers must be disabled by use of this
switch when the machine is travelling on Public roads.
OFF position (deactivated):
The switch is lit in the on (actuated) position.
5. TRAVEL PEDAL
(1) Forward
(2) Neutral
(3 Reverse
88
OPERATION EXPLANATION OF COMPONENTS
CEILING WINDOW
The operator cab is provided with a fixed clear ceiling widow for
improved visibility. An optional guard can be provided for work ing
in areas at risk from damage.
CLEAR RAIN VISOR
PULL DOWN SUN VISOR
The operator cab is fitted with a pull down sun visor. The visor is
simply pulled down and hooked into the retainers mounted on the
front window. The position of the retainers can be adjusted to one
of three pre-set locations by removing the bolts holding the brackets, and re-attaching to one of the other prepared locations.
A second set of retainers is positioned at the bottom of the front
window to allow coverage of the clear roof when the front window
is in the raised position.
A third set of retainers is fitted to the cab ro of to allow cover age o f
the clear roof when the front window is in the normal position.
When the visor is no longer required, remove the sh aft from the
retainers and allow the blind to return to its’ natural position.
89
EXPLANATION OF COMPONENTS OPERATION
FRONT WINDOW
WARNING
When opening the front window, always hold grip firmly with
both hands and pull up. If you use only one hand, your hand
may slip and get caught.
It is possible to store (pull up) the front window (top) in the roof of
the operator’s compartment.
When opening
WARNING
When the front window is open, there is danger that it will
fall, so always lock it with left and right lock pins (A).
1. Place the work equipment on flat ground and stop the engine.
2. Securely lock the control lever pad safety lock.
3. Confirm that the wiper is stored inside the right frame.
90
OPERATION EXPLANATION OF COMPONENTS
4. Pull lock pins (A) at the top left and right sid es of the front win dow to the inside to release the lock.
B
C
A
AM089670A
5. From the inside of the operator’s cab, hold the bottom grip
with the left hand and the top grip with the right hand, pull up
the window, and push it in fully until it is locked by catch (C).
6. Lock with lock pins (A) on the left and right sides.
91
EXPLANATION OF COMPONENTS OPERATION
When closing
WARNING
When closing the window, lower it slowly and be careful not
to get your hand caught.
1. Place the work equipment on a flat ground and stop the
engine.
2. Securely lock control lever pad safety lock.
3. Release the lock pin (A).
4. Hold the grip at the bottom of the front window with your left
hand and the grip at the top with your right hand, release the
lock of catch (C) with your right thumb, then pull the top grip
slowly and lower the front window. When releasing the lock of
catch (C), push release lever (D) in the direction of the arrow
to release the lock.
92
OPERATION EXPLANATION OF COMPONENTS
5. Lock securely (A) with lock pins at the left and right sides
B
C
A
AM089670A
Removing front window (bottom)
Ensure lower wiper (if fitted) is in correct park position.
With the front window open, remove lock pins (E), and the bottom
part of the front window can be removed.
AM089730PW
Store the removed bottom part of the front window at the rear of
the operator’s cab and lock with lock pins (E) .
NOTICE
Do not operate lower wiper (if fitted) when front window
(bottom) is removed.
DOOR LOCK
Use the door lock to fix the door in position after opening it.
1. The door will become fixed in place when it is pressed against
catch (1).
2. To release the lock, press knob (2) down at the left side of the
operator’s seat to release the catch.
When fixing the door, fix it firmly to the catch.
Storage position
AM089740A
93
EXPLANATION OF COMPONENTS OPERATION
CAP, COVER WITH LOCK
The fuel filler, operator’s cab, engine hood, tool box cover, right
side door and left side door of the machine body are fitted with
locks.
Use the starting switch key to lock or unlock these places.
METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port)
To open the cap
1. Insert the key into the cap.
2. Turn the key clockwise, align the match mark on the cap with
the rotor groove, then remove the cap.
To lock the cap
1. Turn the cap into place .
2. Turn the key and take the key out.
Insert the key as far as it will go. If the key is turned before it is
inserted all the way, it may break.
type A
2
1
AW34934D
type B
3
1
2
AW34935D
METHOD OF OPENING AND CLOSING COVER WITH LOCK (cover with Iock)
To open the cover (locked cover)
1. Insert the key.
2. Turn it counterclockwise and open the cover by pulling the
cover grip.
To lock the cover
1. Close the cover and insert the key.
2. Turn the key clockwise and take the key out.
94
A
AL067870A
OPERATION EXPLANATION OF COMPONENTS
FUSE
REMARK
Before replacing a fuse, be sur e to tu rn off the starting switch.
The fuses protect the electrical equipment and wiring from burning out.
If the fuse becomes corroded, or white powder can be seen, or
the fuse is loose in the fuse holder, replace the fuse.
Replace a fuse with another of the same capacity.
Fuse capacity and name of circuit
No
(1) 20 A Pump and governor, breaker switch
(2) 10 A Solenoid valve
(3) 20 A OPT
(4) 10 A LH boom + rear work lamps
(5) 10 A
(6) 15 A Horn
(7) 15 A Wiper controller
(8) 20 A Additional (cab) work lamps, beacon
(9) 20 A Lower wiper, refuelling pump
(10) 10 A
(11) 20 A Roadlights
Fuse
capacity
Name of circuit
Radio, cigarette lighter, air conditioner
panel, heater , wind ows washer, left knob
button
Key switch signal, heated seat, indicators
(12) 30 A Headlights, engine room lamp, hazard
(13) 10 A Alarm signal, monitor
(14) 20 A Start signal
(15) 10 A Cab lamp, radio (back up)
95
EXPLANATION OF COMPONENTS OPERATION
LUGGAGE TRAY
This tray is located to the rear of the operator’s seat. Always keep
the operation & maintenance manual in this box for easy reading
access.
AM089770A
ASHTRAY
This is on the side of the operator’s seat. Always make sure that
you extinguish the cigarette before closing the lid.
CUP HOLDER
A cup holder is provided for holding cups or cans. Drinks should
not be left in the cup holder whilst operating the machine,
because spillage may occur.
96
OPERATION EXPLANATION OF COMPONENTS
HEATER
VIEW OF CONTROL PANEL
1. Inlet air control slider
Change between internal air recirculation & external fresh air
intake.
Internal air circulation.
Purpose
This is used when wishing to quickly
warm the cab
Lever position.
AN113590PW
2. Air outlet selector slider
The operator can select a suitable outlet as required.
Sending air to upper area of oper-
Purpose
ator’s seat and defrosting upper
part of front window
Lever position
AN11550PW
External air intake. This is used for
fresh air intake or to remove condensation on windows or when the air
inside the cab is stale
AN113600PW
Sending air to lower area of operator’s seat and de-frosting lower
part of front window.
AN11560PW
Air outlets
For complete defrosting of the front window, set the selector to
the mid-point of its stroke.
97
EXPLANATION OF COMPONENTS OPERATION
3. Temperature control slider
This adjust out air temperature
To increase temperature of outlet air: move slides to left (red)
To decrease temperature of outlet air: move slides to right (blue)
4. Air flow selector switch
This switch adjust air flow in three steps
5. Defroster selector lever
This lever is used to remove condensation or ice from the lower
part of front window.
Selector lever forward: defrost
Selector lever backward: warms operator’s feet
Defroster is available when air outlet slider is in the position
shown marked:
(1) FEET
(2) DEFROSTER
1
2
AA30814C
98
OPERATION EXPLANATION OF COMPONENTS
AIR CONDITIONER
VIEW OF CONTROL PANEL
When a function is activated, the related indicator lamp lights up.
1. AIR OUTLET SELECTOR SWICH
The operator can select a suitable outlet as required.
Purpose
Switch
Air outlets
Sending air to upper area of
operator’s seat
Sending air to lower area of
operator’s seat
2. EXTERNAL/INTERNAL AIR CHANGEOVER SWITCH
Changes between internal air circulation an d ex te rn al air intake.
99
EXPLANATION OF COMPONENTS OPERATION
Internal air circuit. This is used
Purpose
when wishing to quickly cool or
warm the cab or when the air
This is used for fresh air intake or
to remove condensation on
inside the cab is stale.
Switch
3. TEMPERATURE CONTROL SWITCH
This switch continuously adjusts the temperature between high
and low.
Purpose To low temperature To high temperature
External air intake
windows
Switch
Bleu Red
AA30813C
Blue range indicates low temperature and red range high temp erature.
The range is divided into eight steps, each of which is continuously
adjustable
4. AIR FLOW SELECTOR SWITCH
This switch adjusts air flow in three steps.
Purpose To “Low” To “intermediate” To “High”
Switch
100
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