Komatsu PW150ES-6K Service Manual
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).
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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.
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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.
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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
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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.
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