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1. SAFETY AND ACCIDENT PREVENTION SAFETY NOISE AND VIBRATION PLATES 2 1 SAFETY NOISE AND VIBRATION PLATES 2 1 1 POSITION OF THE SAFETY PLATES e The safety plates must always be legible and in good conditions for this reason if they are dirty with dust oil or grease it is necessary to clean them with a solution made of water and detergent Do not use fuel petrol or solvents e If the plates are damaged ask for new ones to Komatsu or to your Komatsu Dealer e In case of
2. TECHNICAL DATA 5 1 TECHNICAL DATA Q p B Unit of Version with steel Version with road measurement tracks liners Weight of the machine with blade kg 8340 8490 kg 8560 8710 Bucket capacity m3 0 28 Engine Engine diesel Komatsu S4D95LE 3 Engine power kW rpm 51 2000 A Total length mm 6200 6230 B Total height mm 2700 2730 C Total width mm 2330 D Track width mm 450 E Turret swing radius mm 1315 Total length of the tracks mm 2840 2900 G Tumbler distance mm 2235 Min ground clearance mm 360 390 Travel speed low high km h 2 8 4 7 Continuous swing speed rpm 10 0 A uo E 9JA04961 272 TECHNICAL DATA Operating data Unit of Version with steel tracks measurement A Max digging outreach mm 6960 B Max digging depth mm 4160 C Max digging height mm 6570 D Max digging depth on vertical wall mm 2900 E Max dumping height mm 4515 F Work equipment min swing radius 2775 mm Min boom swing radius 1615 G Max outrea
3. AUTHORIZED OPTIONAL EQUIPMENT 6 1 AUTHORIZED OPTIONAL EQUIPMENT CAUTION e When installing and using optional equipment carefully read the relevant manual and keep to the in structions given therein e Use only optional or special equipment recommended and approved by Komatsu and in compliance with the requirements indicated see 6 1 3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT e Komatsu cannot be held liable for any injury damage or product failure resulting from the installation and use of unauthorized equipment 6 1 1 PRECAUTIONS REGARDING SAFETY If attachments or optional equipment other than those authorized by Komatsu are installed this will not only affect the life of the machine but will also cause safety problems Before installing attachments not listed in this manual contact your Komatsu Dealer Komatsu declines any responsibility for accidents or failures due to the use of unauthorized equipment A WARNING e When removing or installing any equipment take the following precautions and be careful to ensure that operations are carried out in total safety e Carry out installation and removal on a firm and flat surface e When the operations are carried out by two or more operators decide the communicati
4. oR FRE 8 5 Oe EA 0 8 2 9JA03372 Machine monitoring system Display Error type Counteraction If the pump system deactivation emergency switch is in position ON it is possible to work In any case have the system checked immediately by a Komatsu Dealer E02 Pump control system error Turn the swing brake exclusion switch to position ON to release the brake Depending on the cause of the E03 Swing brake system error failure it may be possible to release the brake In any case have the system checked immediately by a Ko matsu Dealer If the boom and turret swing brake deactivation emergency switch is in position ON it is possible to E41 Boom swing system error work In any case have the system checked immediately by a Komatsu Dealer The hand accelerator does not work The accelera tion or deceleration function or both is are not work E05 Governor system error ing depending on the type of failure In any case have the system checked immediately by our techni cal assistance dpt Have the machine checked immediately by a Komat Have the machine checked immediately by a Komatsu Dealer su Dealer for details on how to use the pump system deactivation emergency switch and the boom
5. DESCRIPTION AND USE OF THE MACHINE 3 1 DESCRIPTION AND USE OF THE MACHINE 3 1 1 GENERAL VIEW OF THE MACHINE WITH MONOBOOM 68 3 QU 3 2 RKA18400 1 Bucket 9 Sprocket 2 Bucket cylinder 10 Undercarriage 3 Arm 11 Track 4 cylinder 12 Idler roller 5 13 Oylinder blade 6 Lifting cylinder 14 Blade 7 Revolving support 8 Cab DESCRIPTION AND USE OF THE MACHINE 3 1 2 GENERAL VIEW OF THE MACHINE WITH TWO PIECE BOOM Be dr 18410 1 Bucket 9 Revolving support 2 Bucket cylinder 1 Cab 3 Arm 1 Sprocket 4 Arm cylinder 1 Undercarriage 5 Two piece boom cylinder 1 Track 6 Two piece boom 2nd section 1 Idler roller 7 Two piece boom 1st section 1 Blade cylinder 8 Lifting cylinder 1 Blade 69 DESCRIPTION AND USE OF THE MACHINE 3 1 3 CONTROLS AND INDICATORS OB 9 WOW 9 0 21480 70 Overload alarm switch Heating or air conditioning control panel Car radio if installed Control locking lever safety lever Left work equipment control lever Quick deceleration switch Two piece boom control pedal Travel pedals Travel levers Boom swing control pedal Pedal lock Ashtray Machine monitor Horn button Right
6. AMBIENT TEMPERATURE CAPACITY 1 ITEM TANK FLUID SYSTEM 30 20 10 0 10 20 30 40 50 zn 22 14 32 50 68 86 104 122 Stfilling Change SAE 30 OIL SAE 10W Engine oil pan API CD 10 5 10 5 SAE 10W 30 SAE 15W 40 5 reduction 3 0 3 0 SAE 85W 90 Travel reduction 13 13 gears SAE 10W Hydraulic OIL system API CD SAE 10W 30 110 9f SAE 15W 40 Hydraulic system with biodegrada 586 110 64 4 4 1 ble oil Fuel X tank DIESEL OIL 125 ASTM D975 N 2 Engine PERMANENT cooling COOLANT 18 18 system Lithium EP MoS2 NLGI 2 greasing GREASE minae pear Lithium EP NLGI 2 ing ring greasing ASTM D975 1 Special permanent antifreeze biodegradable ethylene glycol based with corrosion inhibitor and with no silicates borates nitrates phosphates and amines Red antifreeze suitable for aluminium radiators diluted with water 50 to ensure protection down to 36 C 202 FUEL COOLANT AND LUBRICANTS IMPORTANT e When the diesel sulphur content is less than 0 5 change the engine oil according to the periodic main tenance intervals indicated in the operation and maintenance manual If the sulphur content exceeds 0 5 change the engine oil according to the following table Sulphur content Engine oil change interval from 0 5 to 1 096 1 2 of regular interval over 1 096 1 4 of regular i
7. 248 4 9 9 8 CHANGING THE FUEL FILTER CARTRIDGE seen 248 4 9 9 b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE 250 4 9 9 CHANGING THE HYDRAULIC OIL FILTER CARTRIDGE 252 4 9 94 CLEANING THE INSIDE AND OUTSIDE FILTERS OF THE AIR CONDITIONER 254 4 9 9 0 CHECKING AND CLEANING THE FINS OF THE RADIATOR THE HEAT EXCHANGER AND THE 256 4 9 9 f LUBRICATING THE SWING BALL BEARING RING eem 258 4 9 9 CHECKING THE GREASE LEVEL IN THE BALL BEARING RING PINION AND TOPPING UP iii e II Dep 258 4 9 9 4 DRAINING THE HYDRAULIC OIL TANK Only for machines in which synthetic biodegradable oil type HEES is used 259 4 9 10 MAINTENANCE EVERY 1000 HOURS OF 260 4 9 10 a CHANGING THE OIL IN THE SWING REDUCTION GEAR 260 4 9 10 6 CHANGING THE OIL IN THE FINAL REDUCTION GEARS 261 4 9 10 c CHANGING THE HYDRAULIC OIL FILTER CARTRIDGE IN THE WORK EQUIPMENT LINE mem 262 4 9 11 MAINTENANCE EVERY 2000 HOURS OF OPERATION eee emm 263 4 9 11 CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER Only for machines in which synthetic biodegradable oil HEES is used 263 4 9 11 b CHANGING THE 26
8. 9JA04981 MAINTENANCE PROCEDURES 4 9 9 4 DRAINING THE HYDRAULIC OIL TANK Only for machines in which synthetic biodegradable oil type HEES is used WARNING e Retract the arm and bucket cylinders completely rest the bucket teeth on the ground and after stopping the engine eliminate the residual pressures from the equipment by shifting the controls more than once and from the tank by slowly loosening the filler cap e Let the oil cool down until it reaches 40 45 C before carry ing out this maintenance operation 9JMO1027 e Immediately clean any area dirty with oil e Oils filters the coolant and the battery are considered spe cial waste and must be collected and disposed of accord ing to the regulations in force 1 Turn the turret so that the lower part of the hydraulic oil tank is not covered by the tracks 2 Retract the arm and bucket cylinders completely and lower the boom until the bucket teeth rest on the ground 3 Lower the blade to the ground 4 Stop the engine and eliminate the residual pressure from the work equipment by shifting the controls more than once 9JM01004 5 Openthe side cover 1 and slowly loosen the filler cap F to release any residual pressure from the tank 6 Remove the drain plug P and let all the condensate flow out of the tank Collect the condensate in a container with suita ble capacity 7 Put back the filler cap F
9. 18660 18670 RKA18700 3 3 10 3 REVERSE 1 Release the safety lever 2 and lift the work equipment 40 50 cm from the ground 2 Liftthe blade 3 Opearate both travel levers 3 or both travel pedals 4 as explained below e When the sprocket A is at the rear of the machine pull the lever 3 slowly backward or press the bottom of the pedal 4 slowly to start moving in reverse e When the sprocket A is at the front of the machine push the lever 3 slowly forward or press the top of the pedal 4 slowly to start moving in reverse 4 Switch over the travel speed by proceeding as follows Press the travel speed selection switch 5 to change over from high Hi to low Lo speed and vice versa The changeo ver from high to low speed or vice versa takes place whenev er the switch is pressed NOTE e When the engine is started the low speed is automatically se lected When the machine travels at high speed on soft ground or up a slope and the load increases the low speed is automat ically selected but the travel speed increase warning light re mains on When the load is reduced the travel system automatically changes over to high speed 5 Make sure that the travel alarm functions correctly If the alarm does not sound contact your Komatsu Dealer which will carry out the necessary repairs USE OF THE MACHINE Gt
10. pared 177 3 5 2 AT TAHE END OF THE WORK DAY siitin a a aa deans 178 3 5 3 AT THE END OF THE COLD 178 3 6 LONG PERIODS OF INACTIVITY aa aapi ariei nad aiias iaasa ianiai 179 3 6 1 BEFORE A PERIOD 179 3 6 2 DURING A PERIOD OF 179 3 6 3 AFTER A PERIOD OF 179 3 7 TROUBLESHOOTING eii eemper nier aai CE RAE EE RE ENTRE S BE a RD DAL ATR E A REDE XR ERR RR AC 180 3 7 1 IF FUEL RUNS OUT COMPLETELY sse 180 3 7 2 OCCURRENCES THAT ARE NOT FAILURES sse nennen 180 343 REMOVING THE MAGHBINE json elt cui re ia ama 180 3 7 4 DEMANDING OPERATING 8 181 3455 JE THEBATIERY IS DOWN eee te eei diee det ete di reete ode 181 3 7 6 REMOVING AND INSTALLING THE 182 367 GHARGING THE BATTERY e em i ep t 183 3 7 8 STARTING WITH BOOSTER 184 3 7 8 1 CONNECTING AND DISCONNECTING THE BOOSTER CABLES 184 3 7 8 2 CONNECTING THE BOOSTER 5 185 3 7 8 3 STARTING THE ENGINE 185 37 84 CONNECTING THE BOO
11. 2 Loosen the bolts 3 to remove the bracket 4 positioned on the battery RKA18780 3 Disconnect first the cable 5 from the negative terminal earthing 4 Disconnect the connection cable 6 and the cable 7 from the positive terminal 5 Loosen the nuts 8 to remove the fastening devices 9 6 Extract the battery through the inspection cover 2 9JA04546 182 TROUBLESHOOTING INSTALLATION IMPORTANT e After securing the battery make sure that it does not move If it moves fix it again 1 Install the battery in the specified position Secure the battery with the fastening devices 9 and the nuts 8 Connect the cable 7 to the positive terminal of the battery Connect first the connection cable 6 to the positive terminal of the battery Connect the cable 5 to the negative terminal earthing Put back the bracket 4 Close the inspection cover 2 and the side cover 1 NOOR WN 3 7 7 CHARGING THE BATTERY If the battery is not handled correctly during recharge there is an explosion hazard Always follow the instructions given in para graph 3 7 5 IF THE BATTERY IS DOWN and the instruction manual supplied together with the charger and proceed as fol lows e Set the voltage of the battery charger so that it corresponds to the voltage of the battery to be charged If the voltage is not set correctly the battery charger may over
12. RKA18920 120 USE OF THE MACHINE 3 3 2 2 CHECKING THE ENGINE OIL LEVEL AND TOPPING UP WARNING e Soon after the machine has been stopped the engine is very hot and may cause burns let the engine cool down to 40 45 C before carrying out any check CAUTION e When carrying out an inspection or maintenance operation inside the engine hood always open it com pletely and make sure that it is kept open by the apposite rod 1 Open the engine hood 2 Remove the dipstick G and wipe it with a cloth F 3 Insert the dipstick G completely into the oil filling pipe then extract it 4 The oil level must be included between the and L marks on the dipstick e If the oil level is below the L mark top up through the filler 7 Pe 2 neck F 5 5 f the level is above the H mark drain the excess c d through the drain plug P and check the oil level again At v G 6 Ifthe oil level is correct tighten the oil filler then close the en gine hood NOTE e If the machine is inclined position it horizontally before carrying out the check If it is necessary to check the oil level when the engine has just been stopped wait approximately 15 minutes before carrying out this operation AD052340 9JA03163 121 USE OF THE MACHINE 3 3 2 3 CHECKING
13. 254 e CHECKING AND CLEANING THE FINS OF THE RADIATOR THE HEAT EXCHANGER AND THE CON ta redu 256 f LUBRICATING THE SWING BALL BEARING 258 g CHECKING THE GREASE LEVEL IN THE BALL BEARING RING PINION AND TOPPING UP 258 h DRAINING THE HYDRAULIC OIL TANK Only for machines in which synthetic biodegradable oil type HEES is 0569 259 MAINTENANCE EVERY 1000 HOURS OF OPERATION a CHANGING THE OIL IN THE SWING REDUCTION GEAR setetett ttt 260 b CHANGING THE OIL IN THE FINAL REDUCTION GEARS 261 c CHANGING THE HYDRAULIC OIL FILTER CARTRIDGE IN THE WORK EQUIPMENT LINE if installed 262 MAINTENANCE EVERY 2000 HOURS OF OPERATION a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER Only for machines in which syn thetic biodegradable oil HEES is 263 b CHANGING iiit he REX REDDE RIP EU DRE 265 c CLEANING AND CHECKING THE TURBOCHARGER 267 d CHECKING THE ALTERNATOR AND THE 5 267 e CHECKING AND ADJUSTING THE ENGINE VALVE emm een 267 f CHECKING THE A C REFRIGERANT GAS QUANTITY only for machines with air conditioner 267 211 MAINTENANCE PLAN MAINTENANCE EVERY 4000 HOURS OF OPERATION a CHANGING THE
14. 008101 Operation amp Maintenance Manual PCSSIMR 6 HYDRAULIC EXCAVATOR SERIAL NUMBER PCS8MR 6 F00008 and up A 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 personnel who will come into contact with the machine KOMATSU FOREWORD 1 1 FOREWORD e This manual has been compiled by Komatsu Utility S p A in order to supply customers with all the necessary in formation on the machine and on safety regulations as well as the use and maintenance instructions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time The operation manual together with the spare parts catalogue is an integral part of the machine and must ac company it even when it is resold until its final disposal The manual must be handled with the greatest care and always kept on board the machine so that it can be consulted at any moment it must be placed in the pocket behind the seat where the registration documents and the logbook are usually kept This manual must be given to the staff who have to use the machine and carry out the routine maintenance op erations they must read the contents carefully more than once in suc
15. 1 Gathering or moving stones with the hydraulic breaker RYA03890 2 Swinging the turret while using the breaker RYA03900 3 Moving the tool while it is hitting the material to be broken RYA03910 4 Working with the breaker in horizontal position or even more inclined RYA03920 288 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 5 Levering with the tool after driving it into the material to be broken RYA03930 6 Hitting the ground with the breaker bit RYA03940 7 Lifting the machine by levering on the breaker bit with the bucket cylinder completely extended RYA03950 289 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER LUBRICATION Take care to lubricate the hammer keeping it in the correct posi tion RYA05800 IMPORTANT e If grease is injected with the hammer in the wrong position the hammer will receive more grease than necessary Con sequently soil and sand may penetrate in the hydraulic cir cuit and damage the hydraulic equipment while the hammer is being used Take care to lubricate the hammer keeping it in the correct position RYA06270 p 06280 290 ARRANGEMENT FOR THE
16. 254 MAINTENANCE PROCEDURES CLEANING THE EXTERNAL AIR FILTER 1 Lift the retainer 4 of the air intake duct on the rear left side of the operator seat The cover 5 will be automatically re leased 2 Pullthe filter 6 upwards 3 Clean the filter 6 with compressed air If there is oil on the filter or if it is very dirty wash it with a neutral detergent After washing the filter dry it completely before use IMPORTANT e If the filtering element is excessively clogged or damaged change it with a new one 9JH01799 4 Install the cleaned filter 6 and fix the cover 5 S 9101800 IMPORTANT e Insert the filter 6 paying special attention to the upper and lower sides RKA18910 255 MAINTENANCE PROCEDURES 4 9 9706 CHECKING AND CLEANING THE FINS OF THE RADIATOR THE HEAT EXCHANGER AND THE CONDENSER WARNING e If compressed air steam or water hit someone they may cause serious injury Always wear a visor and safety shoes IMPORTANT e When using compressed air always keep the nozzle at a safety distance in order to avoid damaging the fins If the fins are damaged they may cause water leakages or overheating e Do not use products containing even a slight quantity of oily substances since these facilitate the adhe sion of dust which affects the heat exchange adversely e Carry out this cleaning operation whenever the radiator the c
17. RKA15170 RKA15180 RKA15190 RKA15200 RKA15210 39 GENERAL PRECAUTIONS 9 FOLD THE ARM With both hands clasped point the thumbs inwards 10 EXTEND THE ARM With both hands clasped point the thumbs outwards 11 FOLD THE BUCKET Keep one hand still and closed Rotate the other hand verti cally with the thumb pointed towards the clasped hand 12 OPEN THE BUCKET Keep one hand still and open Rotate the other hand vertical ly with the thumb pointed towards the open hand 13 TRAVEL WHILE STEERING Lift the forearm corresponding to the inner steering side with clenched fist Rotate the other fist vertically indicating the wheel s turning direction 14 TRAVEL WHILE STEERING Lift the forearm corresponding to the inner steering side with clenched fist Rotate the other fist vertically indicating the wheel s turning direction 40 y RKA15220 A RKA15230 RKA15240 3 RKA15250 EA I b a RKA15260 I I I tae RKA15270 GENERAL PRECAUTIONS 15 TRAVEL STRAIGHT AHEAD Rotate the fists vertically indicating the turning direction of the wheels RKA15280 16 TRAVEL STRAIGHT AHEAD Rotate the fists vertically indicating the turning direction of the wheels RKA15290 17 DISTANCE TO BE COVERED With the hands raised and facing inwards m
18. Date of Nanufacture xxxxxxxx 9 Made in Japan 6204 81 2421 97 RKA19190 RKA19200 1 4 5 SWING REDUCTION GEAR SERIAL NUMBER The serial number is stamped on the plate positioned on the up per side of the swing motor 1 4 6 CAB SERIAL NUMBER The serial number is stamped on the plate positioned on the up per left side PRODUCT IDENTIFICATION 22 9 om oD Dh SK 9 N S RKA19210 RKA19220 PRODUCT IDENTIFICATION 1 4 7 SERIAL NUMBERS AND DEALER S ADDRESS Machine no Model Product identification number PIN Engine no Travel reduction gear no Swing reduction gear no Cab No Dealer Address Tel Contact person NOTES 10 TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD 1 4 FOREWORD 1 2 INFORMATION ON SAFETY 1 3 INTRODUCTION INTENDED USE OF THE MACHINE 1 3 1 1 3 2 1 3 3 1 3 4 1 4 PRODUCT IDENTIFICATION MACHINE SERIAL NUMBER 1 4 1 1 4 2 1 4 3 1 4 4 1 4 5 1 4 6 1 4 7 IMPROPER OR UNAUTHORIZED 05 5 1 3 2 1 MAIN 5 222 22 22 POSITIONS AND DIRECTIONS OF THE MACHINE IDENTIFICATION
19. 167 TRANSPORTING THE MACHINE 3 4 TRANSPORTING THE MACHINE When transporting the machine observe all the laws and regulations in force paying special attention to safety 3 4 1 TRANSPORT PROCEDURE As a general rule the machine must be transported on a trailer Choose the trailer according to the weight and dimensions of the machine indicated in paragraph 5 1 TECHNI CAL DATA It is important to remember that the weight and the transport dimensions indicated in the SPECIFICA TIONS may vary depending on the type of track boom arm and on the other accessories installed on the machine 3 4 2 LOADING AND UNLOADING THE MACHINE WARNING e During loading and unloading operations make sure that the low travel speed is selected Lo warning light on and always travel at low speed During loading and unloading operations let the engine idle reduce speed and operate the machine slowly 9JM01126 e When loading or unloading the machine park the trailer on a firm and level surface There should always be a suffi cient safety distance between the road shoulder and the machine Use ramps with ample width length thickness and strength and install them with a maximum inclination of 15 When using piled soil compact the piled soil fully to prevent the slope face from collapsing Remove any mud from the undercarriage to prevent the machine from slipping laterally when it is on the ramps Remove any w
20. 4 Check the conditions of the gasket 7 and if it is damaged or worn out change it 5 Position the cap 3 with the drain valve 6 facing downwards and secure it with the couplings 2 6 Move the red piston of the filter clogging indicator 1 back to its original position MAINTENANCE PROCEDURES dt i 9JA03399 S 9JA01269 9JA03400 0052091 217 MAINTENANCE PROCEDURES 4 9 1 b CHANGING THE CARTRIDGE IN THE WATER SEPARATOR A WARNING e Change the cartridge after work when the engine has cooled down to 40 45 C e During these operations some fuel may be spilled clean the dirty areas immediately in order to prevent any risk of slipping or fire 1 Open the inspection cover 1 on the left side of the machine and turn the lever 2 of the water separator to position CLOSED a 2 Loosen the ring 3 with a filter wrench extract the cup 4 then remove the cartridge 5 Pay attention not to lose the red ring 6 that is inside the cup 3 Clean the cup 4 with diesel oil or wash oil 4 After washing install a new cartridge 5 5 Insert the red ring 6 in the cup 4 and fill with fuel install it on the filter housing then tighten the ring 3 6 Shiftthe small lever 2 to the opening position B IMPORTANT e When removing the water separator take care not to lose the red ring contained in the cup 7 After chang
21. NOTE e This word is used to indicate a useful piece of information Komatsu cannot reasonably predict every circumstance that might involve a potential hazard during the operation or maintenance of the machine for this reason the safety warnings included in this manual and applied onto the machine may not include all possible safety precautions If all the instructions given in relation to this machine are kept to the operators and anyone in the vicinity can work in total safety and do not run the risk of damaging the machine In case of doubt regarding the safety measures necessary for some procedures contact Komatsu or your local Komatsu Dealer INFORMATION ON SAFETY A DANGER e Before starting any maintenance operation position the machine on a firm and level surface lower the equipment to the ground engage the safety locks of the equipment and the controls and stop the en gine A DANGER e To make the information clearer some illustrations in this manual represent the machine without safety guards Do not use the machine without guards and do not start the engine when the hood is open un less this is expressly prescribed for certain maintenance operations WARNING e It is strictly forbidden to modify the setting of the hydraulic system safety valves Komatsu cannot be held liable for any damage to persons property or the machine if this has been tampered with by modi fying the standard settings of the hydraulic
22. RKA19110 INSTRUMENTS AND CONTROLS 3 2 3 CONTROL LEVERS AND PEDALS RKA18440 1 Safety device control lever safety lever 6 Pedal lock 2 Left work equipment control lever 7 swing control pedal 3 Right work equipment control lever 8 Two piece boom control pedal if installed 4 Blade control lever 5 Travel levers with pedals 89 INSTRUMENTS AND CONTROLS 1 Safety device control lever WARNING e Before leaving the cab lower the equipment to the ground and shift the safety lever to position lock If the safety le ver is not in the locked position and the control levers are touched by mistake this may lead to serious injury e If the safety lever is not in the locked position the con trol levers may move causing accidents or serious injury Always make sure that the lever is in the locked position as shown in the figure e When shifting the safety lever take care to avoid touching the equipment control levers This lever operates the safety device that locks the work equip ment the swing and travel functions and the attachments When pulled upwards it is in locked position The safety device is hydraulic therefore even if the control levers and the pedals move the work equipment and the machine can not be operated NOTE e If the safety lever on the right or left side is not in the locked position the engine cannot be starte
23. 12540 PRECAUTIONS FOR MAINTENANCE 2 4 8 MAINTENANCE STAFF Maintenance and repairs must be carried out exclusively by authorized personnel Do not allow unauthorized per sonnel to go near the machine If necessary ask another worker to check the area 2 4 9 EQUIPMENT e Appoint a supervisor before starting to remove or install the equipment e Position the equipment that has been removed from the ma chine in a safe place in order to prevent it from falling down Take the measures necessary to prevent unauthorized people to approach the area where the equipment has been stored 00910 2 4 10 WORKING UNDER THE MACHINE e If itis necessary to carry out maintenance operations or repairs under the work equipment or under the machine support the equipment and the machine with blocks and supports suitable for bearing their weight e It is extremely dangerous to work under the machine if the tracks are raised from the ground and the machine is supported only by the work equipment If one of the control levers is acci dentally operated or in case of anomalies in the hydraulic pipes the work equipment or the machine may lower suddenly This is extremely dangerous therefore it is important to avoid working EYAQOBZU under the equipment or the machine 2 4 11 NOISE If the noise emitted by the machine is too loud it may cause temporary or permanent hearing damage When servicing the
24. 29 e ee SS 50 6 790 00800 2 3 5 REMOVAL 2 3 5 1 PRECAUTIONS FOR THE REMOVAL e Before removing the machine make sure that all the controls are in neutral e Incorrect manoeuvres may cause serious damage personal in jury and even death e To move the machine use properly dimensioned steel cables do not use worn cables or cables with broken strands A de formed cables B twisted cables C e During the removal no one can be allowed to get near the ma chines or the cable e Do not stand astride the cable e Move the machine only as far as necessary to allow the re quired repairs to be carried out e Put wooden blocks between the towing cable and the machine body in order to avoid wear or damage e Do not remove the machine in any way other than that indicated in paragraph 3 7 3 REMOVING THE MACHINE Ay CAUTION e The maximum applicable force for the removal is F 5000 kg e Use cables having the same length and draw continuosly and constantly without jerks e Position and connect the machine to be removed taking care that it is on the same axis as the towing vehicle the traction force exerted must be parallel to the axis of move ment of the machine PRECAUTIONS FOR USE RYA00810 RYA00820 55 PRECAUTIONS FOR MAINTENANCE 2 4 PRECAUTIONS FOR MAINTENANCE 2 4 1 WARNING PLATES e Before starting any main
25. 3 3 7 2 WARMING UP 3 3 8 STOPPING THE ENGINE ta citer cit ten e Pd e e ha 3 3 9 CHECKS TO BE CARRIED OUT AFTER STOPPING THE 3 3 10 OPERATING THE MACHINE 3 3 10 1 HOW TO MOVE THE MACHINE 3 3 10 2 MOVING THE MACHINE FORWARD 3 3 10 3 REVERSE eue eet eR Facile cue deas cea 3 3 10 4 HOW TO STOP THE MACHINE 3 3 11 STEERING CHANGING 2 3 3 11 1 STEERING xe ee tere ci lee shed en a 3 3 12 SWINGING THE TURRE T net ettet tee n ec een 3 3 13 WORK EQUIPMENT CONTROLS AND 8 2 0 32 14 WORK MOD Bris cust i e a esti n d a TCR Ltd teet a dia tuta 3 3 15 UNAUTHORIZED 3 3 16 IGENERAL INFORMATION THE OPERATION OF THE 3 39 17 MOVING ON SLOPES iii cite tte ed hepate e ite e AIC LAE UO DER TR Eee sits 3 3 18 GETTING THE MACHINE OUT 3 3 19 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR 3 3 20 CHANGING THE 3 3 21 PARKING THE MACHINE oe faces ed e e etl nt a need redes aad 3 3 22 CHECKS TO BE CARRIED OUT ON THE MACHINE AT
26. 55 00 9 OK KK lt gt RYA00960 RWAO1580 e If oil or fuel are sprayed out of high pressure pipes they may cause fires or malfunctions and consequently se rious injury or property damage If there are loose bolts stop working and tighten them at the specified torque If there are damaged pipes immediately stop working and contact your Komatsu Dealer If any of the following problems arises change the pipe e Damaged or leaking hydraulic seals e Worn or cut sheaths or exposed reinforcement layers e Sheaths expanded at various points e Twisted or crushed moving parts e Foreign bodies stuck in the sheaths 2 4 23 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERA TURES AND HIGH PRESSURE e When the machine is stopped at the end of work the engine coolant the oil and all the components are hot and the hydralic circuits are under pressure In these conditions if the coolant the hydraulic oil and the en gine oil are to be drained in order to change them or the filters there are serious risks of damage and burns Wait for the temperature to lower within the normal operating range 40 45 before carrying out any maintenance tion 64 04 00230 PRECAUTIONS FOR MAINTENANCE 2 4 24 COOLING FAN AND BELT e Be careful to the revolving parts and do not allow anyone to get too close to them since clothes or limbs may get caught into
27. 6 Open the side cover 1 and slowly loosen the filler cap F to release any residual pressure from the tank 7 Remove the drain plug P and let the oil flow out gathering it into a container with suitable capacity 8 Loosen the two screws 2 and remove the triangular cover 3 During this operation be careful to the thrusting force of the spring 3 9 Remove the rod 4 the spring 3 and the filter 5 10 Remove any dirt from the filter 5 then wash it with clean diesel oil or wash oil IMPORTANT e Carefully check the filtering element grid and if it is not in perfect conditions change it 11 Insert the filter 5 in the protruding part of the tank 6 and re assemble the whole by proceeding in the reverse order mak ing sure that the gasket of the cover 2 is not damaged and is correctly housed in its seat in the tank 12 Put back the drain plug P and add oil through the filler neck F until reaching a level included between the H and L marks on the gauge G see 3 3 2 4 CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP To top up use oil suitable for the ambient temperature see 4 4 FUEL COOLANT AND LUBRICANTS 13 Move the boom to a central position and extend the boom arm and bucket cylinders completely as shown in the dia gram on the right then remove the filler cap F Put back the cap and pressurize the tank lowering the equip ment to the ground IMPORTANT e Make
28. e Check the conditions of the ground at the work site and before starting the engine define the work plan and the best and safest operating procedure e Make the ground surface as level as possible before carrying out any operation e In case of work on the road protect pedestrians and cars by designating a person for work site traffic duty and install fences around the work site e If water lines gas lines and telephone or high voltage electric lines are located under the work site contact the relevant utility company in order to find out their exact positions or to make them ineffective until the end of the operations Be careful not to XN a sever or damage any of these lines e Check the depth and flow of water before operating in water or on river banks 35 GENERAL PRECAUTIONS 2 2 24 WORKING ON LOOSE GROUND e Avoid moving or using the machine near the edges of cliffs overhangs and deep ditches In these areas the ground may oollapse If the ground should collapse due to the weight or the vibrations of the machine this runs the risk of falling down or overturning It is important to remember that in these areas the ground is likely to col lapse after heavy rains explosions or earthquakes e When the machine works near river or lake banks or near ditches its weight and vibrations may cause the ground to collapse Before starting work take all the precautions necessary to guarantee that the ground is safe
29. them 25 e If hands clothes or tools become entangled in the fan blades or the fan belt they may be cut torn or seriously injured dam aged for this reason avoid touching any revolving parts gt 2 4 25 WASTE MATERIALS To avoid pollution it is important to correctly dispose of waste ma terial 00210 Se 55 55 60400050 e xe es SX SRV e Always put used oil in containers Do not dispose of oil directly onto the ground or into sewage systems rivers seas or lakes eX XX 552555594 E 55555555 555525525000 b M e When disposing of harmful substances such as oil fuel cool ant solvents filters and batteries keep to the laws and regula tions in force 4 90 Ke 55 gt da 940 gt 4690006 e 9050 9590 See 00970 2 4 26 SERVICING THE AIR CONDITIONER If the coolant of the air conditioner comes into contact with the eyes it may cause blindness while contact with the skin may cause freezing Avoid touching the coolant 2 4 27 COMPRESSED AIR e When cleaning the machine or its parts with compressed air flying particles may cause serious injury or property damage e When using compressed air to clean the machine components or the radiator always wear safety goggles mask gloves and other protection items 2 4 28 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY e To ensure that the
30. 3 Keep operating the bucket for about 2 minutes extending Sip and retracting it every time to the end of stroke O TEAS 4 After completing the operation tighten the bleed valve 2 i Sg I ea Je D A 9JA03758 236 Bleeding the cylinders IMPORTANT e If the engine runs at high speed soon after starting or a cyl inder is brought to the end of stroke the air that enters the cylinder may damage the sealing gaskets Let the engine run at an average speed and extend and re tract the cylinders 4 5 times up to a point 100 mm away from the end of stroke Take care to avoid reaching the end of stroke Successively operate each cylinder 3 4 times reaching the end of stroke Finally operate each cylinder 4 5 times reaching the end of stroke to eliminate the air completely Bleeding the swing motor only after draining the oil from the swing motor casing IMPORTANT e If the swing motor is not bled the motor bearings may be damaged Loosen the pipe 3 at the same time letting the engine idle Tighten the pipe again when the oil starts to flow out Do not attempt to carry out a rotation during this operation Let the engine idle and slowly carry out a rotation movement to the right and to the left more than twice per side Bleeding the PPC swing circuit Bleed the circuit through the bleed valve 4 installed on the main valve inside the cover on the right side of the machine MAINTENANCE
31. 8 Close the side cover IMPORTANT e The tank must be drained before starting the engine with temperatures exceeding 0 C when the temperature is be low 0 C the tank must be drained at the end of work or in any case with the machine at operating temperature to prevent the condensate from freezing 9JA03293 259 MAINTENANCE PROCEDURES 4 9 10 MAINTENANCE EVERY 1000 HOURS OF OPERATION Carry out these operations together with those to be performed every 50 100 250 and 500 HOURS 4 9 10 a CHANGING THE OIL IN THE SWING REDUCTION GEAR WARNING e As soon as the machine has been stopped the oil is very hot and may cause burns let the oil cool down until reaching 40 45 C before changing it e Oils filters the coolant and the battery are considered special waste and must be collected and dis posed of according to the regulations in force This operation must be carried out with the machine positioned on level ground and at a temperature of 40 45 C so that the oil be comes fluid and can easily be drained which facilitates the elimi nation of any suspended solid particles e Filling capacity 2 0 1 e 260 Remove the drain plug P and let the used oil flow out com pletely gathering it into a container with suitable capacity Loosen the screws 1 and make the cover 2 slide Remove the dipstick G Once the oil has been drained put back the plug P and pour oil o
32. CHECKING THE ENGINE OIL LEVEL AND TOPPING 3 3 2 3 CHECKING THE FUEL LEVEL AND REFUELLING eee 3 3 2 4 CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING 3 3 2 5 CHECKING THE AIR FILTER CLOGGING INDICATOR 3 3 2 6 CHECKING THE WATER 1 3 3 27 CHECK THE WIRING SYSTEMS sse eere eneereen heres ennenis 3 3 2 0 CHECKING THE HORN n e er e t e t ee eas 3 3 3 ADJUSTMENT Sarnia nani i agen p cuv er nn de ik rv 3 3 3 1 ADJUSTING THE te Ee ene eret ra i ter ce teres 3 8 3 2 REAR VIEW MIRRORS eet ite e dirai data ait side dae 3 34 SEAT BEL uec a e qnoniam ied 3 3 4 1 FASTENING AND UNFASTENING THE SEAT 3 3 4 2 ADJUSTING THE SEAT 3 3 4 8 RETRACTABLE SEAT BELT if provided 3 3 5 OPERATIONAL CHECKS ned e eterne ne e e e 3 3 6 STARTING THE ENGINE init tae b id e Lp d Dente ta 3 3 6 1 STARTING THE ENGINE IN NORMAL OPERATING CONDITIONS 3 3 6 2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES 3 3 7 AFTER STARTING THE 3 3 7 1 RUNNIN IN t EA
33. OFF the windshield wiper is off The windshield wiper operating mode changes in the following or der off intermittent continuous off every time the switch is pressed 80 9JA03137 9 03138 4 Windshield washer switch This switch 4 must be kept pressed to spray the detergent on the front windshield When the switch is released spraying is in terrupted e If the switch 4 is kept pressed with the windshield wiper off the detergent is sprayed on the glass and at the same time the wiper is operated continuously When the switch 4 is released the windshield wiper keeps functioning continuously for two cy cles then stops e If the windshield wiper is operated intermittently and the switch 4 is kept pressed the detergent is sprayed on the glass and at the same time the wiper is operated continuously When the switch 4 is released the windshield wiper keeps functioning continuously for two cycles then returns to the intermittent mode INSTRUMENTS AND CONTROLS 9JA03139 81 INSTRUMENTS AND CONTROLS 3 2 2 SWITCHES AND PUSH BUTTONS D Q RKA18420 1 Ignition switch 9 Boom and turret swing brake deactivation emergency 2 Hand accelerator switch 3 Quick deceleration switch 10 Overhead light 4 Horn but
34. ments DIGGING WITH REVERSED BUCKET The excavator is suitable for carrying out digging operations in a lower position with respect to the machine When the machine is in the position shown in the diagram on the right the maximum digging and thrusting force of each cylinder is achieved when the bucket cylinder and its articulated joint the arm cylinder and the arm are at 90 with respect to each other During the digging operations keep this angle amplitude to opti mize the performance of the machine The operating range for digging operations with the arm is includ ed between an angle of 45 away from the machine and an angle of 30 towards the machine There may be differences depending on the digging depth but it is advisable to work within this range rather than making the cylin der reach the end of stroke DIGGING WITH FRONT BUCKET The bucket is suitable for carrying out digging operations in a higher position with respect to the machine It is possible to carry out loading operations by installing the buck et in reversed position SIDE DITCHING Ditch digging operations may be effectively carried out by install ing a bucket suitable for this type of work and by positioning the tracks parallel to the ditch digging line To create wide ditches first dig on both sides and then remove the earth at the centre 158 AM090900 9JA03547 090920 AW35
35. 5 to facilitate the tightening operation MAINTENANCE PROCEDURES RKA18280 ag 9EA03355 9JA03356 231 MAINTENANCE PROCEDURES 4 9 1 CHECKING THE WINDSHIELD FLUID LEVEL AND TOPPING UP The reservoir 1 is positioned in the side cover and contains de tergent for the front windshield make sure that the reservoir is al ways full If necessary add non flammable detergent of the type used for cars While topping up be careful to prevent dust from getting into the reservoir IMPORTANT e To fill the reservoir use only non flammable detergent of the type used for cars 9JA03223 e Do not use the antifreezes used in engine cooling systems Quantity of detergent to be mixed with water Proportions vary according to the ambient temperature Before topping up it is advisable to dilute the detergent with water according to the quantities indicated in the following table Area season Proportions Freezing temperature Normal Detergent 1 3 Water 2 3 4 C Cold area winter Detergent 1 2 Water 1 2 6 C Very cold area winter Undiluted detergent 16 C 232 MAINTENANCE PROCEDURES 4 9 1 m CHECKING CLEANING AND LUBRICATING THE GUIDE OF THE CAB SLIDING DOOR CHECK When opening or closing the sliding door this may not slide smoothly due to the presence of dirt in the sliding guide In this case thoroughly clean the guide 1
36. 6 2 6 3 6 4 6 5 18 AUTHORIZED OPTIONAL EQUIPMENT 282 6 1 1 PRECAUTIONS REGARDING 5 0 282 6 1 2 PRECAUTIONS REGARDING THE INSTALLATION OF 283 6 1 3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT 284 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION 285 6 2 1 DESCRIPTION AND CONTROL 2 285 6 22 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED 286 6 2 3 INSTALLING AND REMOVING THE DEMOLITION HAMMER 291 6 2 3 1 e te ire Tete Cole 291 6 2 3 2 REMOVING THE HAMMER oe rrari A A EEA A TE E EAE 292 6 24 MAINTENANCE 122i ce dti ide ree dad Lake date NAA edes 292 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET SWING SYSTEM second hydraulic 2 1 cte cicer cernere nicis rei anna ie des 293 ARRANGEMENT FOR THE INSTALLATION OF THE BUCKET QUICK COUPLING SYSTEM Third hydraulic line 5 2 Irene ERES 295 INSTALLING AND REMOVING THE ADDITIONAL 297
37. 9EA03186 RKA18680 RKA18690 RKA18700 143 USE OF THE MACHINE 3 3 10 4 HOW TO STOP THE MACHINE WARNING e Avoid stopping the machine abruptly Always calculate sufficient safety distance when stopping Shift the right and left travel levers 1 to neutral then stop the machine RKA18710 RKA18720 144 USE OF THE MACHINE 3 3 11 STEERING CHANGING DIRECTION 3 3 11 1 STEERING WARNING e Before operating the travel control levers check the position of the sprocket If the sprocket is at the front the operation of the travel levers is inverted e Avoid abrupt changes of direction as much as possible Carry out counter rotations with the machine at rest e Due to the strong friction generated by changes of direction do not use the travel speed increase con trol Use the travel levers to change direction If possible avoid changing direction suddenly In particular when carrying out a counter rotation stop the machine before steering Operate the two travel levers 1 as follows RKA18710 CHANGING DIRECTION WITH THE MACHINE AT REST Push the right travel lever forward to steer to the left moving for ward pull the lever backward to steer to the left moving in re verse 4 NOTE e To steer to the right operate th
38. MAINTENANCE PROCEDURES 4 9 1 4 CHECKING AND ADJUSTING THE RUBBER TRACK TENSION For machines equipped with rubber tracks The rubber tracks wear out to different degrees depending on the work conditions and on the characteristics of the surface on which the machine is working Therefore it is necessary to check the track wear and tension fre quently in order to keep the tracks correctly tensioned IMPORTANT e To carry out the check and the corresponding maintenance operation stop the machine on firm and lev el ground Check both tracks e In particular on new machines or after the installation of new tracks it is advisable to carry out a first check after 10 hours of operation e Adjusting the track tension frequently until the initial slackening does not occur any longer will prevent the tracks from coming off due to insufficient tension e If the machine works with loose rubber tracks they may come off and cause the steel cores to wear out too early CHECK 1 Run the engine at idling speed move the machine slowly for ward covering a distance equal to the length of the track on the ground then stop the machine 2 Choose a straight bar 3 long enough to cover the distance between the idler roller 1 and the carrier roller 2 then po sition it on the track 3 Measure the maximum deflection between the upper surface of the track and the bar e Standard deflection 9JA03590 The
39. TOTAL HYDROBIO 46 VALVOLINE CAUTION e It is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils since when the temperature increases insoluble compounds are generated which deposit on the filters and clog them the maximum concentration of ordinary oil must not exceed 1 of the total quantity of oil e Biodegradable oil can be used only in the hydraulic system it cannot be used for the engine the trans missions the braking system etc e Before introducing biodegradable oil in the hydraulic system drain the system completely disconnect ing the cylinders and all the parts that may contain traditional oil then change the drain filter with a new one Start the engine and let it idle before using the equipment wait for the engine temperature to reach at least 40 C then start moving the equipment to fill all the circuits with oil Stop the engine and check the oil level see 3 3 1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE 3 3 2 4 CHECK ING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP 204 4 5 TIGHTENING TORQUES TIGHTENING TORQUES 4 5 1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS CAUTION e If screws nuts or other parts are not tightened with the required torque they may become loose or dam age the components with which they cooperate and this may cause machine failures or operation prob lems Always pay the utmost attention whe
40. USE OF THE MACHINE 3 3 3 2 REAR VIEW MIRRORS Adjust the inclination of the rear view mirrors so that the rear low er part of the machine which cannot be seen because of the en gine hood is well visible 7 C a O 9JA03173 3 3 4 SEAT BELT WARNING e Before fastening the seat belt make sure that the fastening brackets or the belt itself do not show any anomaly If there are damaged or worn parts change the belt e The seat belt must be changed every 3 years even if there are no anomalies or signs of wear The date of manufacture is indicated on the reverse side of the belt e Adjust and fasten the seat belt before operating the machine e Always fasten the seat belt when working with the machine e Make sure that none of the two parts of the belt is twisted Make sure that the bolts of the retainer that fastens the seat belt to the frame are not loose and if necessary tighten them at the torque of 24 5 4 9 Nm 2 5 0 5 kgfm Change the belt unit if the surface of the belt is damaged or if the couplings are broken or deformed 3 3 4 1 FASTENING AND UNFASTENING THE SEAT BELT 1 Adjust the seat in such a way as to ensure that there is suffi cient knee room when pressing the pedal thoroughly while seated with the back resting against the backrest 2 After adjusting the position seat down Take the buckle 1 and the tang 2 and i
41. and to prevent the machine from rolling or falling down 2 2 25 PREVENTING ELECTROCUTION e Digging operations near overhead electric lines are extremely dangerous and they may also cause death due to electrocution for this reason when working near overhead electric lines always respect the minimum safety dis tances prescribed by the competent authorities and by the accident prevention rules in force e As far as underground long distance lines are concerned the minimum distance depends on the covering of the ducts in which the cables are laid e The basic safety precautions to be taken to prevent this risk are the following Wear shoes with thick rubber or leather soles Request the aid of another person who can warn you if the machine gets too close to the electric line Operate at low speed Get acquainted with the behaviour rules to be followed in case of electrocution Keep the phone number of the electricity company and of the nearest first aid station at hand af ON gt e If the work equipment gets accidentally entangled in the cables the operator must not leave the cab until the electricity company has insulated the line e When carrying out this kind of operations warn everyone standing in the work area to keep a safety distance from the machine and the work equipment e Ask the electricity company in advance the voltage of the cables and the minimum safety distance DANGER e The minimum distances from overhead l
42. ble to the bracket supplied to secure the machine during transport since this procedure may damage the machine 7 The angle between the metal cables should range between 30 and 40 lift the machine slowly 8 When the machine is not in contact with the ground any long er check the conditions of the hook and the lifting position then lift slowly 9JA03208 175 USING THE MACHINE IN COLD CLIMATES 3 5 USING THE MACHINE IN COLD CLIMATES 3 5 1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON During the cold season or in areas where temperatures are particularly low especially during the night it is neces sary to take some countermeasures meant to limit any damage deriving from low temperatures 3 5 1 1 FUEL AND LUBRICANTS Change fuel and oil with low viscosity products for all components For details on the required viscosity see 4 2 MAINTENANCE NOTES 3 5 1 2 COOLANT WARNING e Antifreeze is toxic Avoid any contact with the eyes or the skin In case of contact with the eyes or the skin wash with plenty of running water and consult a doctor without delay e The coolant containing antifreeze is flammable do not smoke and do not use naked flames during the checks and when preparing the mixture 1 Use only red permanent antifreeze suitable for aluminium radiators Pure antifreeze must be diluted with wa ter 50 to ensure protection down to 36 C 2 Do
43. e Do not open or remove the hood when the engine is running 13 SAFETY DISTANCE e Do not get too near the machine and do not stand within the tur ret swinging range 14 WORK IN PROGRESS e Do not approach or stand within the operating range of the equipment when it is lifted and under load 24 09808 0881 09667 0481 09133 1681 15 DO NOT GET ON THE MACHINE e Do not allow anyone to get on the machine while it is moving 16 FALLING OBJECTS e Avoid working in places where there is the risk of falling objects Contact your Komatsu Dealer for the installation of safety guards RISK OF EXPLOSION OF THE HYDRAULIC ACCUMULATOR e Precautions to be taken for operations on the hydraulic accu mulator HYDRAULIC OIL TOPPING UP e Only for machines in which synthetic biodegradable oil type HEES is used HYDRAULIC OIL TOPPING UP SAFETY NOISE AND VIBRATION PLATES 220 00 11910 RWA34380 RWAO0050 25 SAFETY NOISE AND VIBRATION PLATES REFUELLING ENGINE OIL FILTER FUEL FILTER RWAO0060 ENGINE AIR INTAKE FILTER ENGINE COOLANT ENGINE COOLANT PRESSURE 26 HYDRAULIC OIL LEVEL HYDRAULIC OIL FILTER POWER OUTLET ANCHORAGE POINT EMERGENCY EXIT LIFTING POINT SAFETY NOISE AND VIBRATION PLATES Cr RWAO00100 a RWAO00070 N A lt RKA18250
44. 25 555 OX XX 00620 e When using a breaker or other heavy duty equipment the machine may lose its balance and overturn Both when operating on flat ground and when operating on slopes keep to the following instructions Do not lower swing or stop the work equipment suddenly Do not extend or retract the boom cylinder suddenly since the impact may cause the machine to overturn e Do not move the bucket over the head of other workers or over the operator seat of dump trucks or other trans port equipment The load may be spilled or the bucket may hit the dump truck and cause serious injury or prop erty damage 50 PRECAUTIONS FOR USE 2 3 2 7 WORKING ON ICY OR SNOW COVERED SURFACES e Snow covered or icy surfaces are slippery therefore it is advisable to be very careful when travelling or using the machine Do not operate the levers suddenly Even a slight gradient may cause the machine to slip therefore it is important to proceed with care when working on slopes e If the ground is icy when the temperature increases it may collapse and cause the machine to overturn e If the machine gets into deep snow it runs the risk of overturning or getting stuck in the snow Take care to avoid moving away from the road edge and getting stuck in a heap of snow e During clearing operations the road shoulders and any obstacle are buried under the snow and are not visible The machine may lose stability or hit any obstacle or obje
45. 3 2 2 pos 3 Quick deceleration switch 9EA03185 141 USE OF THE MACHINE 3 3 10 2 MOVING THE MACHINE FORWARD 1 Release the safety lever 2 and lift the work equipment 40 50 cm from the ground 2 Liftthe blade 3 Opearate both travel levers 3 or both travel pedals 4 as explained below e When the sprocket A is at the rear of the machine push the lever 3 slowly forward or press the top of the pedal 4 slowly to move the machine off e When the sprocket A is at the front of the machine pull the lever 3 slowly backward or press the bottom of the pedal 4 slowly to move the machine off 4 Switch over the travel speed by proceeding as follows Press the travel speed selection switch 5 to change over from high Hi to low Lo speed and vice versa The changeo ver from high to low speed or vice versa takes place whenev er the switch is pressed NOTE e When the engine is started the low speed is automatically se lected When the machine travels at high speed on soft ground or up a slope and the load increases the low speed is automat ically selected but the travel speed increase warning light re mains on When the load is reduced the travel system automatically changes over to high speed 5 Make sure that the travel alarm functions correctly If the alarm does not sound contact your Komatsu Dealer which will carry out the necessary repairs 142 GL 9EA03186
46. 5 Ge 5 5 256 25 K at L 9JM01071 TRAVELLING AT HIGH SPEED When the machine travels on rocky ground with many uneven stretches or with plenty of stones always travel at low speed Lo warning light on If the machine travels at high speed Hi warn KOMATSU ing light on manoeuvre the machine so that the idler roller faces the travelling direction 9JA03200 FOLDING THE WORK EQUIPMENT When folding the work equipment to the travel or transport posi m tion be careful to prevent the bucket from hitting the blade 9JA01648 153 USE OF THE MACHINE AVOID HITTING THE BLADE Be careful not to hit the blade against rocks or boulders since this may damage the blade or the cylinders Dy K BOR Fre KORN Ee ETERNI AW351450 POSITION OF THE BLADE DURING DIGGING OPERATIONS WITH THE EXCAVATOR When carrying out deep digging operations with the blade at the front be careful to prevent the boom cylinder from hitting the blade If possible always position the blade at the rear of the ma chine MAXIMUM WATER DEPTH Ay CAUTION e When driving the machine out of water if the inclination of the machine exceeds 15 the rear of the turret will be sub merged and this may cause the cooling fan to break Be extremely careful when driving the machine out of wa ter Do not work with the mac
47. 500 ZZZ 555 5555 5255 55 5556 5559 5 Sete 5595 LOOK P 5 5 LE L 9JM01071 47 PRECAUTIONS FOR USE 2 3 2 4 MOVING ON SLOPES Operations on slopes and on river or lake banks with damp ground may cause the machine to tip over or slip On hills banks or slopes keep the bucket very close to the ground 20 30 cm from the ground and in case of emergency quickly lower it to the ground to help the machine stop When travelling up a steep slope extend the work equipment forward to improve the balance of the machine keep the work equipment approximately 20 30 cm above the ground and trav el at low speed When travelling downhill lower the engine speed keep the travel lever close to the neutral position and travel at low speed When travelling downhill position the machine with the turret rotated by 180 so that the sprocket 1 and the boom are in travelling direction as shown in the figure and proceed at low speed Do not change direction on slopes side movements must be carried out on level ground or with inclination not exceeding 10 Do not move on slopes whose inclination exceeds 15 since the machine may overturn When the fuel level indicator reaches the red reserve area dur ing work on a slope immediately provide for refuelling due to the inclination of the machine the engine may suck in air and stop suddenly which represents a grave ri
48. 650 750 800 1100 1150 2050 2100 0 0m 650 700 700 750 1050 1100 2000 2050 1 5m 750 850 1050 1100 2000 2050 276 Load limited by the hydraulic lifting capacity and not by the tipping limit LIFTING CAPACITIES dL Ok kg 26 5 MPa 265 bar i L 650 mm 17 kg 175 3405 RKA21460 277 LIFTING CAPACITIES 5 2 3 LIFTING CAPACITIES WITH TWO PIECE BOOM NOTE e The load does not exceed 87 of the hydraulic lifting capacity or 75 of the tipping limit LIFTING CAPACITIES WITH ARM L 7 1650 Q kg L A B max 6 0m 5 0m 4 0m 3 0m 45m 900 800 950 815 1450 1365 3 0 m 750 650 500 500 950 750 1350 1130 2190 2190 2 1 5m 500 450 550 500 1000 750 1250 1200 1740 1440 0 0 m 450 400 500 500 900 725 1250 1150 3000 2175 1 5m 750 600 850 700 1250 1150 2950 2150 LIFTING CAPACITIES WITH ARM L 1900 AND 215 kg ADDITIONAL COUNTERWEIGHT Q kg L A B max 6 0m 5 0m 40 3 0m 4 5m 700 650 900 800 1500 1300 z 3 0 m 450 400 450 400 850 700 1400 1250 2 1 5m 375 350 400 350 800 600 1200 1150 2400 2000 9 0 0 450 375 550 400 750 550 1850 1400 2800 2150 1 5m 550 400 550 400 750 550 1800 1400 2750 2100 LIFTING CAPACITIES WITH ARM L 2250 AND 465 kg
49. 7 a LUBRICATION IMPORTANT e Clean the grease nipples before applying the greasing pump e After lubrication remove all the contaminated grease that may have spread out of the nipples e If the machine is used in difficult conditions carry out this operation more frequently than usual e As a general rule it is important to consider that each cylinder is provided with two grease nipples posi tioned on the couplings and that each pin serving as fulcrum point for a movement is provided with at least one grease nipple e When running in a new machine lubricate every 10 hours for the first 100 hours of operation e After carrying out digging operations with the equipment immersed in water always lubricate the pins that have been in contact with water e Prepare a grease gun 1 Set the machine in the correct position for the lubrification procedure as shown in the diagram on the right lower the work equipment to the ground then stop the engine 2 Use the grease pump to inject grease through the lubrication points indicated by the arrows 3 After completing the lubrication procedure remove any grease that may have come out of the lubrication points G 9JA03549 Blade cylinder base pin 1 point Blade cylinder rod end pin 1 point Blade base pin 2 points ananasa N gt aH 9JA03425 4 Boom base pin 2 points 5 Boom cylinder base pin 1 point 2
50. 8 Loosen the two screws 2 and remove the triangular cover 3 During this operation be careful to the thrusting force of the spring 3 9 Remove the rod 4 the spring 3 and the filter 5 10 Remove any dirt from the filter 5 then wash it with clean diesel oil or wash oil IMPORTANT e Carefully check the filtering element grid and if it is not in perfect conditions change it 11 Insert the filter 5 in the protruding part of the tank 6 and re assemble the whole by proceeding in the reverse order mak ing sure that the gasket of the cover 2 is not damaged and is correctly housed in its seat in the tank 12 Put back the drain plug P and add oil through the filler neck F until reaching a level included between the H and L marks on the gauge G see 3 3 2 4 CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING Use only synthetic biodegradable hydraulic oil type HEES see 4 4 1 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES 13 Move the boom to a central position and extend the boom arm and bucket cylinders completely as shown in the dia gram on the right then remove the filler cap F Put back the cap and pressurize the tank lowering the equip ment to the ground IMPORTANT e Make sure that the hydraulic tank is pressurised If the tank isn t under pressure the pump will suck in air and this will damage the equipment 16 Make sure that all the control levers are in neut
51. 950 1000 1050 1900 1950 LIFTING CAPACITIES WITH ARM L 1650 AND 215 kg ADDITIONAL COUNTERWEIGHT Q kg L A B max 5 5m 45 m 4 5m 1100 1200 1300 1350 E 3 0m 800 850 850 900 1250 1300 2400 2500 2 1 5m 750 800 800 850 1150 1200 2100 2150 0 0 m 750 800 750 800 1100 1150 2050 2100 1 5m 950 1050 1100 1150 2100 2150 LIFTING CAPACITIES WITH ARM L 1900 Q kg L A B max 5 5m 4 5m 45m 900 975 1150 1200 E 3 0m 675 725 725 775 1100 1150 1 5m 600 650 675 725 1025 1075 1925 1975 9 0 0 m 625 675 675 725 975 1025 1850 1900 1 5m 750 850 975 1025 1875 1925 275 LIFTING CAPACITIES LIFTING CAPACITIES WITH ARM L 1900 AND 215 kg ADDITIONAL COUNTERWEIGHT L A B max 5 5m 4 5m 3 0 m 4 5m 1000 1075 1250 1300 E 3 0 m 750 800 825 875 1225 1275 9 1 5m 725 775 775 825 1125 1175 2075 2125 9 0 0m 700 750 725 775 1075 1125 2025 2075 1 5m 850 950 1075 1125 2050 2100 LIFTING CAPACITIES WITH ARM L 2250 Q kg L A B max 5 5m 4 5m 3 0 m 4 5m 750 850 E 3 0 m 600 650 700 750 1050 1100 1 5m 550 600 650 700 1000 1050 1900 1950 0 0m 550 600 650 700 950 1000 1850 1900 1 5m 650 750 950 1000 1850 1900 LIFTING CAPACITIES WITH ARM L 2250 AND 215 kg ADDITIONAL COUNTERWEIGHT Q kg L A B max 5 5m 4 5m 3 0 m 45m 850 950 E 3 0m 700 750 800 850 1200 1250 1 5m 600
52. AND ADJUSTING THE ENGINE VALVE CLEARANCE A special tool is required for removing and adjusting the involved parts Have this operation performed by your Ko matsu Dealer 4 9 11 CHECKING THE A C REFRIGERANT GAS QUANTITY only for machines with air conditioner A DANGER e The refrigerant used in the air conditioning system is very dangerous If it is sprayed into the eyes or in case of contact with the skin it may cause blindness or frostbite To avoid any explosion do not gener ate sparks and do not use naked flames near the air conditioner e Maintenance of the air conditioning system must be carried out exclusively by specialized personnel Specific equipment is required to check the refrigerant gas have this maintenance operation carried out only by specialized personnel and for this purpose contact your Komatsu Dealer 267 MAINTENANCE PROCEDURES 4 9 12 MAINTENANCE EVERY 4000 HOURS OF OPERATION Carry out these operations together with those to be performed every 50 100 250 500 1000 and 2000 hours of operation 4 9 12 a CHANGING THE A C FILTER DRIER only for machines with air conditioner DANGER e The coolant used in the air conditioning system is very dangerous If it is sprayed into the eyes or in case of contact with the skin it may cause blindness or frostbite To avoid any explosion do not generate sparks and do not use naked flames near the air conditioner e Have the filter drier changed only by
53. CARRIED OUT BEFORE STARTING THE ENGINE a CHECKING THE COOLANT LEVEL AND TOPPING 120 b CHECKING THE ENGINE OIL LEVEL AND 121 c CHECKING THE FUEL LEVEL AND 122 d CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP 123 e CHECKING THE AIR FILTER CLOGGING 125 CHECKING THE WATER 125 g CHECK THE WIRING SYSTEMS siini trat iei tuta titer eame te dae ina n LL tee ATREA S 126 hi CHECKING THE HORN tite tet i Et b i ra e n ebd cet e VL Rada 126 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION Only for ma chines in which synthetic biodegradable oil type HEES is used a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER Only for machines in which syn thetic biodegradable oil HEES is 263 MAINTENANCE EVERY 50 HOURS OF OPERATION a DRAINING THE FUEL TANI a atum utut aD use Diet ueque pde 240 MAINTENANCE EVERY 100 HOURS OF OPERATION a LUBRICATION 241 210 MAINTENANCE PLAN MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION Operations to be carried out together with those prescribed in paragraph 4 9 7 MAIN TENANCE EVERY 250 HOURS OF OPERATION a CHANGING THE FUEL FILTER CARTRIDGE ssssssseeeeetetnn tette ttes 2
54. CONTROLS RKA18450 150 Pattern E 47 9JM03955 p d 9JA03310 Onder 9JA03144 91 INSTRUMENTS AND CONTROLS 4 Blade control lever WARNING e Before moving the machine make sure that the blade is completely raised It is used to control the movements of the blade a Lower b Lift IMPORTANT e When the safety lever is in the locked position all the movements are inhibited see 3 2 3 pos 1 Safety device control lever 5 Travel levers WARNING e Before carrying out any manoeuvre with these levers the operator must seat in the work position and fasten the seat belt e Before moving the machine make sure that the sprocket A is positioned at the rear of the machine and that the safety locks are engaged if the turret is rotated by 180 the controls are inverted see 3 3 10 1 HOW TO MOVE THE MACHINE e 3 3 11 1 STEERING e Use the travel control pedals only when the machine is moving If a pedal is inadvertently pressed when the ma chine is not moving or steering this may move suddenly and cause serious accidents e When travelling or carrying out steering manoeuvres use the pedals with the maximum care These levers are used to operate the travel motors right and left and control the forward and reverse travel according to the move ments indicated a FORWARD levers pushed forward b REVERSE levers pulled towards the o
55. Clean the electrical components especially the starter and the alternator to avoid any accumulation of dust e Do not mix oils of different brands Do not top up with oils different from those being used If you cannot use the same oil drain the tank and change the oil completely 195 MAINTENANCE NOTES 4 2 MAINTENANCE NOTES e Use only Komatsu genuine spare parts e Do not mix different types of oil e Unless specified otherwise the oils and the coolant used by Komatsu to fill the tanks before the delivery of the machine are the following ITEM TANK SYSTEM SPECIFICATIONS e Engine oil SAE 10W 30 Specifications API CF CF2 CD e Hydraulic system oil SAE 30 Specifications API CD e Biodegradable hydraulic system oil Only for machines in which synthetic biodegradable oil SHELL NATURELLE HFX 32 type HEES not of plant origin is used e Swing reduction gear oil SAE 90 Specifications API GL5 e Travel reduction gears oil SAE 90 Specifications API GL5 e Fuel With ambient temperature over 10 C use Diesel oil ASTM D975 N 2 With ambient temperature below 10 C use Diesel oil ASTM D975 21 e Radiator Special permanent antifreeze biodegradable ethylene glycol based with corrosion inhibitor and with no silicates borates nitrates phosphates and amines Red antifreeze suitable for aluminium radiators diluted with water 50 to ensure protection down to 36 C 4 2 1 OIL FU
56. FILTER DRIER only for machines with air 268 b CHECKING THE OPERATING CONDITIONS OF THE A C COMPRESSOR only for machines with air condi MONON O LUE i E 268 CHECKING THE WATER PUMP eniti en tdi dn s 268 MAINTENANCE EVERY 5000 HOURS OF OPERATION a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER se 269 212 MAINTENANCE PLAN 4 8 2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC The hydraulic oil used in the machines provided with demolition hammer deteriorates more quickly than the oil BREAKER used in normal digging machines therefore it is advisable to respect the following maintenance plan e Changing the hydraulic oil filter cartridge On new machines change the hydraulic oil filter cartridge after the first 100 150 hours of operation and for the successive changes keep to the indications given in the table on the right If the machine contains synthetic biodegradable oil type HEES the filter must be changed after the first 50 hours of operation Changing the oil in the hydraulic tank Change the oil in the tank according to the intervals indicated in the table on the right On machines containing synthetic biodegradable oil type HEES change the oil after the first 500 hours of operation and for the successive changes ke
57. INSTALLATION OF THE DEMOLITION HAMMER 6 2 3 INSTALLING AND REMOVING THE DEMOLITION HAMMER 6 2 3 1 INSTALLATION A WARNING e Park the machine on a firm and level surface and lower the equipment to the ground e For the installation the hammer must be positioned hori zontally with the bit directed towards the machine e When the coupling pins are removed or installed chips may come off always use gloves goggles and helmet e The change of the equipment must be carried out by two operators who must decide together the words and sig nals to be used during work RKAB6970 e Avoid using your fingers to align the holes since the may be injured or even cut off e Before carrying out any operation on the hydraulic circuit eliminate the residual pressure from the equipment circuits by shifting the controls more than once and from the tank by slowly loosening the filler cap e Immediately clean any area dirty with oil For the installation of the demolition hammer it is necessary to connect the mechanical constraints by proceeding as described in paragraph 3 3 20 CHANGING THE BUCKET and to carry out the hydraulic connections using the pipes provided RWA19810 After connecting the mechanical constraints carry out the hydrau lic connections by proceeding as follows 1 Stop the engine and shift the equipment controls in all direc tions in order to release the residual pressure from the cir cuits 2 Turn th
58. KORY 5579 25 2 SERIE 225025492500 gt 2555 xX 525 50 OX 90 s lt lt 9 0 O gt RX 9494 XS 50 sess OX ta x gt gt 5 25 et e When starting the engine with a booster cable always wear safety goggles gt gt 55595 e LS lt lt e Take care to prevent any contact between the failed chine and the machine used as starting aid in order to RYA00790 avoid generating sparks near the battery In fact sparks may cause the explosion of the hydrogen produced by the batteries and lead to serious damage e Take care not to make any mistake when connecting boost er cables In the last connection to the turret frame a spark is generated therefore it is advisable to connect the cable as far from the battery as possible In any case avoid the attachments since they are poor conductors e When disconnecting a booster cable take care to avoid any contact of the clamps with each other or with the ma chine frame IMPORTANT e The booster cable and the clamps must be sized according to the dimensions of the battery e The battery to be used as starting aid must have the same capacity as the battery of the failed machine e The starting system of this machine is powered at 24 V Therefore use a 24V battery for the machine to be used as power source e Make sure that cables and clamps are neither corroded nor damage
59. OPERATION Only for machines in which synthetic biodegradable oil type HEES is 239 4 9 58 MAINTENANCE EVERY 50 HOURS OF 240 4 9 5448 DRAINING THE FUEL TANK 240 4 9 5 MAINTENANCE EVERY 100 HOURS OF 241 4 9 5 a LUBRICATION Gani Aid sez ped Eee dE dae dete 241 4 9 6 MAINTENANCE AFTER THE FIRST 250 HOURS OF 241 4 9 7 MAINTENANCE EVERY 250 HOURS OF 242 49 3 LUBRICATION EE he PUTEM ogg be PODER MARE E E 242 4 9 7 b CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR AND TOPPING UP E 244 4 9 7 CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS AND TOPPING UP 9 tri a di Sec eR ot eie Unde Mad 244 4 9 7 d CHECKING THE BATTERY CHARGE LEVEL eee 245 4 9 76 CHECKING AND ADJUSTING THE FAN BELT 22 22222 246 4 9 7 1 CHECKING AND ADJUSTING THE AIR CONDITIONER COMPRESSOR BELT TENSION x n eee e aree pieds 247 4 9 8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION Only for machines in which synthetic biodegradable oil type HEES is 248 TABLE OF CONTENTS 4 9 9 MAINTENANCE EVERY 500 HOURS OF
60. PLATE AND PRODUCT IDENTIFICATION NUMBER PIN ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE TRAVEL REDUCTION GEAR SERIAL NUMBER sse SWING REDUCTION GEAR SERIAL NUMBER seen CAB SERIAL NUMBER SERIAL NUMBERS AND DEALER S ADDRESS SAFETY AND ACCIDENT PREVENTION SAFETY NOISE AND VIBRATION PLATES 2 1 1 2 1 2 2 1 3 2 1 4 2 2 GENERAL PRECAUTIONS SAFETY 2 2 1 2 2 2 2 2 3 2 24 2 2 5 2 2 6 2 2 7 2 2 8 2 2 9 2 2 10 2 2 11 2 2 12 2 2 13 2 2 14 2 2 15 2 2 16 2 2 17 2 2 18 2 2 19 2 2 20 2 2 21 2 2 22 POSITION OF THE SAFETY PLATES PICTOGRAMS AND RELEVANT POSITION OF THE NOISE PLATES VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED HOW TO BEHAVE IN CASE OF ANOMALIES essen enne CLOTHING AND PERSONAL PROTECTION ITEMS esee enn FIRE EXTINGUISHERS AND FIRST AID KIT sse nem enne SAFETY DEVICES AND GUARDS CLEANING THE MACHINE INSIDE OF THE CAB LEAVING THE OPERATOR SEAT GETTING ON AND OFF THE IT IS FORBIDDEN TO CLIMB ON THE 2 ARTICULATED PARTS PREV
61. THE END OF THE WORK DAY 3 2223 LOCKING THE MACHINE te cures ee beet ce emet 3 3 24 ROAD LINERS AND RUBBER 3 3 24 1 INFORMATION ON THE ROAD LINERS AND THE RUBBER TRACKS 3 3 242 WARRANTY ON THE ROAD LINERS AND THE RUBBER TRACKS 3 3 24 3 USING THE ROAD LINERS AND THE RUBBER TRACKS 3 3 244 HOW TO PRESERVE THE ROAD LINERS AND THE RUBBER TRACKS OVER TIME e e te t eee bee tet deris TABLE OF CONTENTS 3 4 TRANSPORTING THE MACHINE 168 3 4 1 TRANSPORT PROCEDURE e decet e e dia ad deri Poe eeu aa 168 3 4 LOADING AND UNLOADING THE 168 3 4 2 1 LOADING THE 169 3 4 8 HOW TO SECURE THE 171 3423 UNLOADING THE 172 3 4 3 HOW TO LIFT THE MACHINE netten detener trennen teta de tha aed adea 174 3 5 USING THE MACHINE IN COLD CLIMATES 176 3 5 1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON 176 3 5 1 1 FUEL AND LUBRICANT Sirti iiti iet i ieee 176 3 5 1 2 COOLANT re E i a ee lca aan 176 3 5 23
62. WARNING LIGHTS When the ignition switch is in position ON the warning lights display comes on to confirm that the corresponding devices function correctly 1 ENGINE PREHEATING WARNING LIGHT This warning light 1 indicates the preheating time that is neces sary when the engine is started at a temperature below 0 C 32 F The warning light comes on when the ignition switch is turned to position HEAT and starts blinking after approximately 30 seconds to confirm that the preheating stage has been completed The warning light goes out after approximately 10 seconds 9JH01672 76 2 Quick deceleration warning light This warning light 2 informs the operator that the quick decelera tion function has been activated Function activated warning light on Function deactivated warning light off When the quick deceleration switch is pressed the corresponding warning light comes on When the switch is pressed again the light goes out NOTE e When the quick deceleration warning light comes on the en gine rpm remain at the minimum value even if the hand acceler ator is operated INDICATORS AND METERS 3 ENGINE COOLANT TEMPERATURE INDICATOR This indicator 3 shows the engine coolant temperature When the engine is running normally the green area A of the indicator should be lit If the red area B of the indicator lights up during operation let the engine idle and wait for the temperat
63. and turret swing brake deactivation emergency switch see pos 3 2 2 SWITCHES AND PUSH BUTTONS 191 192 THIS PAGE WAS INTENTIONALLY LEFT EMPTY MAINTENANCE GUIDE TO MAINTENANCE 4 1 GUIDE TO MAINTENANCE A WARNING e Oils filters coolant gaskets electric cables and batteries are considered special waste and must be collected and disposed of according to the anti pollution regulations in force e The combust
64. ann 2 3 2 5 WORKING ON SLOPESOS nitet dete det e Lat eite e kn 2 3 2 6 UNAUTHORIZED OPERATIONS 0 2 3 2 7 WORKING ON ICY OR SNOW COVERED SURFACES 2 8 2 8 PARKING THE 2 nennen rennen 2 3 8 TRANSPORTING THE 2 3 3 1 LOADING AND UNLOADING THE MACHINE eee 2 3 32 TRANSPORTING THE 2 34 BATTERY iier iet ete e i tite t ese i teneat ipea bed vns 2 3 4 1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY 2 342 STARTING WITH BOOSTER CABLES see eee eene 2 3 5 REMOVAL eet ire ee dec d t ae dod d ede et debe eet ene 2 3 5 1 PRECAUTIONS FOR THE 2 nennen PRECAUTIONS FOR 2 4 4 WARNING PLATES tct etr i tenet att cr Hi dace siete ahd Eisen but ia bade 242 KEEP THE WORK PLACE CLEAN AND ORDERLY sse 2 4 3 APPOINT A SUPERVISOR WHEN WORKING WITH OTHER 22 2 2 4 4 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPEGTION 5 ite iet mede tede medo eder aee bos 2 4 5 MAINTENANCE OPERATIONS TO BE CARRIED OUT WITH THE ENGINE RUNNING REQUIRE THE PRESENCE OF TWO OPERATORS 4 seem eee 2 AO TOOLS T 247 HYDRAULIC ACCUMULATOR 2 4 8 MAINTE
65. are properly working If necessary change the faulty lamps with new ones making sure that their power is correct 2 2 20 CAB WINDOWS e If a cab window breaks on the side facing the work equipment this may hit the operator Therefore it is advisa ble to stop the machine immediately and to replace the broken glass e The roof window is made of organic glass polycarbonate and as such it can break if its surface is damaged thus losing its protective function If there is any crack or damage due to the fall of a stone or if any trace thereof is observed change it with a new glass 2 2 21 PRECAUTIONS CONCERNING THE CAB STRUCTURE e If the cab is inadvertently hit or the machine overturns during work the cab be damaged with consequent reduction of its stiffness and of the safety that must be guaranteed to the operator Contact Komatsu or an Authorized Komatsu Dealer to have the cab structure and resistance checked in case of impact or damage 2 2 22 UNAUTHORIZED MODIFICATIONS e Any modification made without the authorization of Komatsu can give rise to dangerous situations Before mak ing a modification consult your Komatsu Dealer e Komatsu cannot be held liable for any injury accident or failure due to modifications made without its express authorization 2 2 23 SAFETY AT THE WORKPLACE e Before starting the engine thoroughly check the area for any unusual condition of the ground due to which work may be dan gerous
66. arms in relation to the machine must define the signal independently of the position of the signalman Hand signals must be performed following the indica tions given below 1 LIFT THE LOAD VERTICALLY With a forearm in vertical position and the forefinger pointing upwards rotate the hand making small circles t RKA15140 2 LOWER THE LOAD VERTICALLY With an arm extended and the forefinger pointing down D wards rotate the hand making small circles RKA15150 38 3 MOVE THE LOAD AWAY IN HORIZONTAL DIRECTION With an arm extended forwards and the hand in vertical posi tion directed towards the load to be moved away move the hand in the direction of the movement to be carried out BRING THE LOAD NEARER IN HORIZONTAL DIRECTION With an arm extended forwards and the hand in vertical posi tion directed towards the signalman move the hand in the di rection of the movement to be carried out LIFT THE BOOM With an arm extended in horizontal position and closed fin gers point the thumb upwards LOWER THE BOOM With an arm extended in horizontal position and closed fin gers point the thumb downwards SWING THE BOOM With an arm extended in horizontal position point the forefin ger in the desired swing direction SWING THE BOOM With an arm extended in horizontal position point the forefin ger in the desired swing direction GENERAL PRECAUTIONS RKA15160 A
67. automatically return to the neutral position and the work equipment remain in the position where they stopped The movements of the levers and the corresponding movements of the equipment are shown in the diagrams be low e Arm control Shift the left work equipment control lever forward or backward to operate the arm 9JA03194 e Swing control To swing the turret shift the left control lever to the left or to the right 9JA03195 e Boom control To operate the boom shift the right work equipment control le ver forward or backward 9JA03196 148 e Bucket control To operate the bucket shift the right control lever to the left or to the right e Boom swing control To swing the boom press the control pedal e Blade control Shift the lever positioned to the right of the operator seat for ward or backward to operate the blade USE OF THE MACHINE 9JA03197 9 04909 9JA03198 149 USE OF THE MACHINE 3 3 14 WORK MODE The work mode selection switch allows the most suitable work mode to be selected according to the operations to be carried out and facilitates work Proceed as indicated below to use the different work modes effec tively The Active mode for heavy duty applications and the E mode when fuel saving is desired alternate every time the switch is pressed NOTE 9JA03136 e Whe
68. avoid damaging the filter itself and causing fuel leakages 2 9JA04560 5 After changing the fuel filter cartridge bleed the circuit For details on this operation see 4 9 9 pos BLEEDING THE CIRCUIT 6 After changing the cartridge start the engine and make sure that there are no infiltrations of fuel through the filter gasket In case of leakages check the tightening of the cartridge and if necessary tighten it again If the leakages persist carry out steps 1 and 2 to remove the cartridge then check if the sur face of the gasket is damaged or dirty with foreign matter If the gasket is damaged or dirty with foreign matter change it and then repeat steps from 3 to 6 MAINTENANCE PROCEDURES BLEEDING THE CIRCUIT 1 Fill the fuel tank 2 Loosen the drain screw 1 until no more air is present in the fuel that flows out 3 Tighten the screw 1 IMPORTANT e When all the fuel in the tank has run out bleed the circuit by proceeding as described above 249 MAINTENANCE PROCEDURES 4 9 9 b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE WARNING e Change the oil with the machine parked on a level surface and the work equipment resting on the ground e Soon after the machine has been stopped the engine oil is very hot and may cause burns let the engine cool down until it reaches a temperature of 40 45 C before draining the oil e The oil that may be spilled during the oil change wi
69. by slowly loosening the filler cap e Soon after the machine has been stopped the hydraulic oil is very hot and may cause burns let it cool down to 40 45 C before carrying out this maintenance operation e Immediately clean any area dirty with oil e Oils filters the coolant and the battery are considered special waste and must be collected and dis posed of according to the regulations in force A CAUTION e On machines containing synthetic biodegradable hydraulic oil type HEES this must be changed after the first 500 hours of operation and successively every 2000 hours and in any case at least once a year IMPORTANT e If the machine is equipped with hydraulic hammer the hy draulic oil deteriorates much earlier than during normal bucket operations For further details on maintenance see 4 8 2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER 9JM01027 e Filling capacity 64 1 Turn the turret so that the lower part of the hydraulic oil tank is not covered by the tracks 2 Retract the arm and bucket cylinders completely and lower the boom until the bucket teeth rest on the ground Lower the blade to the ground Stop the engine and eliminate the residual pressure from the work equipment by shifting the controls more than once 9JM01004 5 Shiftthe safety lever to the locked position L 9 gt 18280 269 MAINTENANCE PROCEDURES
70. clogging indicator 1 is visible CHECK 1 Open the engine hood For further details see para graph 3 2 9 ENGINE HOOD 2 Ifthe red piston in the filter clogging indicator 1 is visible clean the filtering element a IMPORTANT e Do not clean the cartridge if the red piston of the filter clog ging indicator 1 is not visible e In any case check the cartridge for clogging every 50 hours of operation 9JA04541 214 CLEANING OR CHANGING THE PRIMARY FILTERING ELE MENT 1 Open the engine hood For further details see para graph 3 2 9 ENGINE HOOD 2 Release the retainers 2 and remove the cover 3 3 Extract the filtering element 4 4 Clean the inside of the filter body the cap 3 and the drain valve 6 IMPORTANT e Do not remove the safety cartridge 5 If the safety car tridge is removed dust may penetrate inside the intake channel and cause serious damage to the engine 5 Slightly strike the filtering element 4 on the palm of your hand in such a way as to remove the dust and blow compressed air on the inner surface keeping the air jet at a distance of approximately 15 cm and the pressure below 4 5 bars 6 After the cleaning operations inspect the filtering surface for damage by introducing a lamp into it and carefully check the front gaskets If the cartridge is damaged change it IMPORTANT e When changing the primary filtering element change also the safet
71. e The boom swing is useful to displace the digging line be yond the track outline do not use this function during the work cycle 8 Two piece boom control pedal if installed It controls the extension and folding of the two piece boom ac cording to the movements indicated a Boom folding b Boom extension N Neutral boom at rest IMPORTANT e When the safety lever is in the locked position all the movements are inhibited see 3 2 3 pos 1 Safety device control lever INSTRUMENTS AND CONTROLS d 18270 CS RKA18500 RKA18490 93 INSTRUMENTS AND CONTROLS 3 2 4 WINDSHIELD A WARNING e When opening or closing the upper windshield the lower windshield or the cab door always lock the controls with the safety device lever L If the control levers are not locked and are inadvertently operated there is the risk of serious accidents e Before opening or closing the windshield stop the ma chine on a level surface lower the work equipment com pletely to the ground and stop the engine e When opening the windshield hold it firmly with both hands pull upward and do not leave hold until the automat ic retainer is locked e When closing the windshield hold the handle with both hands and close securely The upper windshield can be positioned under the cab roof The lower windshield can be removed and stored inside the cab on the lef
72. forget to lock the cover INSTRUMENTS AND CONTROLS 9JA04979 105 INSTRUMENTS AND CONTROLS 3 2 12 FUSES IMPORTANT e When changing a fuse make sure that the ignition key is in position OFF e If the fuses are oxidized corroded or do not fit perfectly in their seat replace them only with new fuses having the same capacity e If the engine doesn t run when the ignition switch is turned to position START check the main fuse and replace it if necessary RKA18530 The fuses are grouped on a single base positioned inside the cab s rear compartment and can be reached by removing the cov er 1 Fuse capacity and circuits involved POSITION COLOUR CAPACITY A CIRCUIT INVOLVED F1 F2 F3 Orange 5 Bucket swing power supply F4 Orange 5 Horn power supply F5 Orange 5 Bucket opening and folding power supply F6 Red 10 Monitor power supply VB F7 Red 10 Revolving light switch warning lights power supply F8 Orange Overhead light power supply F9 Orange 5 Radio power supply directly from the battery F10 Violet 3 Controller power supply VB F11 Light blue 15 Acceleration deceleration relay power supply F12 F13 F14 F15 z 3 F16 Orange 5 Right and left PPC power supply F17 Orange 5 Controller power supply VIS F18 Brown 7 5 Emergency guide pump switch po
73. fuel pipes Deteriorated twisted Periodically yearly damaged hydraulic or fuel pipes cracks wear and tear or pipes in con tact with other parts of the machine 208 PERIODICAL CHANGE OF SAFETY RELATED COMPONENTS 4 7 1 SAFETY RELATED PARTS N Safety related components that periodically need changing Quantity Change interval 1 Fuel pipe fuel tank water separator 1 2 Fuel pipe water separator fuel pump prefilter 1 3 Fuel pipe fuel pump prefilter fuel filter 1 4 Fuel pipe fuel filter injection pump 1 5 Fuel pipe fuel tank stop valve 1 6 Fuel pipe fuel tank air bleed pipe 1 7 Fuel recovery pipe injection pump filler neck pipe 2 8 Return pipe injector filler neck pipe 1 a years df 4000 9 Fuel pipe fuel tank filler neck 2 hours whichever occurs 10 Fuel pipe filler neck filler neck pipe 1 TE 11 Hydraulic pipe main pump delivery 3 12 Hydraulic pipe main pump suction 3 13 Hydraulic pipe boom cylinder distributor 4 14 Hydraulic pipe arm cylinder distributor 4 15 Hydraulic pipe bucket cylinder distributor 4 16 Hydraulic pipe swing motor distributor 2 17 Hydraulic pipe blade cylinder distributor 4 18 Seat belt 1 Every 3 years 209 MAINTENANCE PLAN 4 8 MAINTENANCE PLAN If the machine is equipped with hydraulic breaker the maintenance schedule for some components wil
74. limited resistance Consequently it is important to understand what advantages are offered by the road liners and the rubber tracks and to take the necessary precautions for use avoiding operations that are not allowed This will increase the duration of the road liners and the rubber tracks and will allow their characteristics to be fully ex ploited Before using the road liners or the rubber tracks read paragraph 3 3 24 3 USING THE ROAD LINERS AND THE RUBBER TRACKS 3 3 24 2 WARRANTY ON THE ROAD LINERS AND THE RUBBER TRACKS It is important to carry out inspections and maintenance operations and to ensure that the track tension is always correct Furthermore these tracks should not be used near objects that may damage them such as sharp steel plates U grooves broken or pointed rocks steel bars or scraps The warranty does not cover any damage due to the incorrect use of the machine 3 3 24 3 USING THE ROAD LINERS AND THE RUBBER TRACKS Unauthorized uses Keep to the following instructions e Avoid steering or performing other operations on broken rocks very hard rocks steel bars scraps or near the edges of steel plates since this may damage the road liners and the rubber tracks e In places like river beds where there is a great quantity of large and small stones these may get stuck in the road liners and the tracks thus damaging them or causing them to come off Carrying out levelling operations if the road liners or the track
75. machine used as starting aid and let it run at maximum rpm 3 Turn the ignition switch of the failed machine to position START and start the engine If the engine cannot be started at the first attempt try again after approximately 2 minutes 3 7 8 4 CONNECTING THE BOOSTER CABLES After starting the engine disconnect the booster cables proceed ing in the reverse order 1 Disconnect one clamp of the booster cable B from the turret iS of the machine that has been started 2 Disconnect the other clamp of the booster cable B from the negative terminal of the machine used as starting aid Battery of the Battery of the normal machine B problem machine 3 Disconnect one clamp of the booster cable A from the posi sa tive terminal of the machine used as starting aid Revolving frame of 4 Disconnect the other clamp of the booster cable A from the eevee positive terminal of the machine that has been started 185 TROUBLESHOOTING 3 7 9 LOWERING THE WORK EQUIPMENT WHEN THE ENGINE STOPS BECAUSE OF A FAILURE CAUTION e This procedure should be carried out only in case of break age or if the battery is down WARNING e Before loosening the cap make sure that everything is in order under the work equipment and the blade e Do not allow anyone to go under the work equipment or the blade e While the work equipment is being lowered keep holding the cap with a suitable t
76. materials are burnt they send out gas and become highly toxic Once they have cooled down these materials must be collected in tight bags using heavy waterproof gloves then gloves and materials must be disposed of according to the current regulations in force The contaminated parts of the machine must be washed with highly alkaline detergents and then with a solution of water and detergent Avoid burning gaskets eletric cables sealing rings Dispose of elastomeric and polymeric waste according to the regulations in force gt In case of contact with the skin immediately rinse with a solu y tion made of water and an alkaline detergent for about 30 min y utes and then contact a poisoning treatment center without mm delay Do not touch any burnt elastomeric or polymeric waste and in case of accidental burning avoid inhaling the toxic gases pro duced RKA13780 2 4 30 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODE GRADABLE OIL TYPE HEES e It is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils since when the temperature increases insoluble compounds are generated which deposit on the filters and clog them the max imum concentration of ordinary oil must not exceed 196 of the total quantity of oil e Biodegradable oil can be used only in the hydraulic system it cannot be used for the engine the transmissions the braking system etc e Before introducing b
77. not mix different brands of antifreeze 3 The use of red permanent antifreeze requires only the check of the level and the periodical change of the flu id It is not necessary to wash the cooling circuit 4 Incase of doubt regarding the applicable standards for the use of permanent antifreeze contact your Komat su Dealer who will supply you with exhaustive and precise information 176 USING THE MACHINE IN COLD CLIMATES 3 5 1 3 BATTERY WARNING e The battery produces flammable gas therefore keep flames and sparks away from it e The battery electrolyte is dangerous In case of contact with the eyes or the skin wash with plenty of running water and consult a doctor without delay e The battery electrolyte melts paint In case of contact with the machine body wash immediately with wa ter e If the battery electrolyte freezes do not charge the battery or start the engine with a different power sup ply since the battery may explode e The battery electrolyte is toxic therefore it is necessary to avoid draining it in sewage systems or con taminating the ground When the ambient temperature drops the capacity of the battery decreases accordingly If the battery charge is low the electrolyte may freeze Keep the battery completely charged and protect it from low temperatures so that the machine can be started without problems in the morning NOTE e Measure the specific weight of the fluid and calculate the charge
78. or cold days since this would increase the fogging of the inside of the windows The air conditioner can be started by means of the switch A C positioned on the left cabinet After starting the air conditioner switch LED on adjust the temperature and the ventilation flow The ideal temper ature must be 5 or 6 C below the outside temperature CAUTION e Even in the periods in which the air conditioner is not used operate the compressor at low speed for ap proximately 3 5 minutes at least once a month This operation ensures the constant lubrication of all the moving parts of the compressor 112 INSTRUMENTS AND CONTROLS 3 2 16 1 AIR CONDITIONER CONTROL PANEL a amp wD 498 fungo RKA18990 1 Air conditioner switch 4 Air flow selection switches 2 Temperature control switch 5 Air recirculation selection switch 3 Ventilation selection switches 6 Defrosting lever 1 Air conditioner switch This is a two position ON OFF switch and is used to start and stop the air conditioner AIC RKA19090 2 Temperature control switch This is a rotary switch used to start and stop the ventilation sys tem and to control the temperature inside the cab OY V The position ON or OFF is signalled by a click of the switch when this is turned completely anticlockwise The temperature can be adjusted by turning the switch Turning
79. precautions are particularly useful when hammering the equipment connection pins and when blowing compressed air into the air filter and the radiator During these operations make also sure that no one is standing or working near the machine without the necessary protection items p When working for 8 hours with a noise level exceeding 90 dBA it is necessary to use headphones or ear plugs and be particu larly careful especially at the end of the work shift N 9 GENERAL PRECAUTIONS 2 2 4 FIRE EXTINGUISHERS AND FIRST AID KIT e Make sure that fire extinguishers have been provided and check their position e Periodically make sure that the fire extinguishers are loaded ea and that you know how to use them 2 e Find out where the first aid kit has been placed e Periodically make sure that the first aid kit contains the neces sary disinfectants bandages medicins etc 00310 e It is necessary to know what to do in case of fire e Make sure that you have the phone numbers of the persons or structures you may need to contact in case of an emergency at hand both at the worksite and where maintenance operations are performed 2 2 5 SAFETY DEVICES AND GUARDS e Make sure that all the guards and covers are in the correct position Have guards and covers changed or re paired if damaged Neither use the machine without guards nor remove the guards when the engine is
80. replacement of a component provided with a safety plate make sure that such a plate is applied also to the new part e The machine can be provided with other plates in addition to those indicated below keep also to the instructions given in the additional plates in any case RKA19230 20 SAFETY NOISE AND VIBRATION PLATES 2 1 2 PICTOGRAMS AND RELEVANT MEANINGS The warning and danger plates applied onto the machine include or are accompanied by pictograms The staff in charge with the operation and maintenance of the machine must be perfectly familiar with the symbols contained in the pictograms the following list illustrates what they look like and their respective meanings 1 CONSULT THE MANUAL e Carefully read the contents of the manual before using the ma chine or performing maintenance operations n _ 09651 A0841 2 SAFETY DISTANCE e Do not get too near the machine and do not stand within its op erating range 22M 98 12110 3 BEFORE LEAVING THE WORK POSITION e Before leaving the machine lower the work equipment to the ground shift the safety lever to position lock stop the engine and remove the ignition key 21 SAFETY NOISE AND VIBRATION PLATES 4 RISK OF ELECTROCUTION e Minimum safety distances from overhead lines Cable voltage Min dis 1 0 kV dis
81. same time press the upper part of the switch B RKA21500 NOTE e The warning light on the switch is always on and indicates that the quick coupler is at rest It goes out temporarily only when the switch is pressed to indicate that the bucket or other equip ment is being coupled or released RKAB8190 295 ARRANGEMENT FOR THE INSTALLATION OF THE BUCKET QUICK COUPLING SYSTEM Third hydraulic line CONNECTING THE HYDRAULIC CIRCUIT A WARNING e Avoid connecting any equipment to the hydraulic lines before said equipment has been correctly in stalled from a mechanical point of view and fixed to the arm e Before carrying out any operation on the hydraulic circuit stop the engine and eliminate any residual pressure from the equipment circuit by shifting the controls more than once and from the oil tank by slowly loosening the filling cap Immediately clean any area dirty with oil e All the equipment disassembly and assembly operations must be carried out with the machine parked on firm and level ground e When removing the hydraulic connections be extremely careful in order to prevent any impurities from getting into the pipes After mechanically installing the equipment position the machine on firm and level ground stop the engine release the residual pressures from the system and proceed as indicated below 1 Remove the plugs 5 Be careful not to loose or damage any of the parts removed 2 Conn
82. short circuits in the wiring or damaged covers Also make sure that there are no loose terminals and tighten them if necessary Carefully check the cables of the battery the starter and the alternator Always check for flammable material around the battery and remove it if necessary 3 3 2 8 CHECKING THE HORN 1 Turn the ignition switch to position ON 0 F f oN A at 2 Press the button positioned on the right lever and make sure 5 that the horn functions correctly O If the horn does not sound contact your Komatsu Dealer who will carry out the necessary repairs RYA17290 AM089470 126 USE OF THE MACHINE 3 3 3 ADJUSTMENTS A WARNING e Adjust the position of the seat before starting work or when taking the place of another operator e Adjust the seat so that the control levers and the switches can be easily used by the operator seated with his back against the backrest 3 3 3 1 ADJUSTING THE SEAT A Longitudinal adjustment Shift the lever 1 upwards move the operator seat to the desired position then release the lever Longitudinal adjustment 50 mm B Backrest inclination NOTE e The backrest can be tilted to a greater degree by pushing the seat forward The possible degree of inclination of the backrest is reduced if the seat is moved backward to be able to push the seat backward set the backrest in vertical position Pull the lever 2 and set the backrest so that it is
83. specialized personnel and for this purpose contact your Komatsu Dealer The filter must be changed every 4000 hours of operation or eve ry 2 years whichever occurs first The filter must also be changed whenever work in the air condi tioning system is performed 9 03224 4 9 12 b CHECKING THE OPERATING CONDI TIONS OF THE A C COMPRESSOR only for machines with air conditioner Specific equipment is required to check the operating conditions of the compressor 1 have the compressor checked only by spe cialized personnel and for this purpose contact your Komatsu Dealer RKA18940 4 9 12 c CHECKING THE WATER PUMP Make sure that the slack in the pulley is not excessive that the drain hole is not clogged and check for oil or water leakages If there is any anomaly contact your Komatsu Dealer who will provide for the necessary repairs or changes 268 MAINTENANCE PROCEDURES 4 9 13 MAINTENANCE EVERY 5000 HOURS OF OPERATION Carry out these operations together with those to be performed every 50 100 250 500 and 1000 HOURS 4 9 13 a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER WARNING e Retract the arm and bucket cylinders completely rest the bucket teeth on the ground and after stopping the engine eliminate the residual pressures from the equipment by shifting the controls more than once and from the tank
84. speed move the machine slowly forward covering a distance equal to the length of the track on the ground then stop the machine 5 Check the track tension again If it is not correct adjust it again IMPORTANT e The pins and bushings wear out to different degrees de pending on the work conditions and on the characteristics of the surface on which the machine is working It is there fore necessary to check the track tension frequently in or der to ensure that it is always correct 9JA03792 e When working on rocky or very irregular surfaces increase the track tension in order to prevent stones or debris to get stuck between the tracks and the sprocket on the other hand reduce the track tension when working on soft or muddy ground since the soil penetrates between rollers and tracks and tends to increase the tension 222 MAINTENANCE PROCEDURES 4 9 1 6 CHECKING THE ROAD LINERS OR THE RUBBER TRACKS For machines equipped with road liners or rubber tracks If the road liners or the rubber tracks are in the conditions illustrated below they must be repaired or changed so contact your Komatsu Dealer for the necessary operations HEIGHT OF THE RUBBER CLAW e If the height of the rubber claw has decreased due to wear the traction force decreases accordingly If a is less then 5 mm change the track 1 Roller 2 Rubber track Il RKA18810
85. starting opera tions to the machine steering or stopping procedure see section DESCRIPTION AND USE OF THE MACHINE Bleeding the pump IMPORTANT e If the pump is operated without filling it with hydraulic oil it may be damaged Make sure that the bleeding operation has been completed 1 Loosen the air bleed plug 1 installed on the drain opening and make sure that oil flows out this means that the air bleeding operation has been completed 2 After completing the bleeding operation tighten the plug Bleeding the air between the pump and the hydraulic tank 310242 e If the engine runs at high speed and the air between the pump and the hydraulic tank has not been bled an anoma lous generation of heat will take place and this may dam age the pump 1 Start the engine and make it run at an average speed For further details see 3 3 6 STARTING THE ENGINE 2 Operate the work equipment slowly for approximately 5 min utes in such a way as to bleed the circuit Bleeding the Load Sensing circuit This operation must be carried out only when changing the hydraulic pump the valve or a pipe in the Load Sensing cir cuit IMPORTANT e Failure to bleed the Load Sensing circuit may cause mal functions in the work equipment 7 1 Loosen the bleed valve 2 installed on the LS Load Sens ing port of the hydraulic pump 2 Letthe engine idle for 2 minutes
86. system WARNING e Before carrying out any electric welding disconnect the battery and the alternator See 2 4 17 PRE CAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR WARNING e Install only authorized optional equipment see 6 1 3 CHARACTERISTICS OF THE OPTIONAL EQUIP MENT A DANGER e It is absolutely forbidden to operate the machine while standing on the ground Every single manoeuvre must be carried out by the operator correctly seated in driving position INTRODUCTION 1 3 INTRODUCTION 1 3 1 INTENDED USE OF THE MACHINE The Komatsu machines described in this manual have been designed and constructed to be used mainly for EX CAVATION and EARTH MOVING OPERATIONS If provided with suitable safety devices they can be used with authorized optional equipment having the character istics illustrated in paragraph 6 1 AUTHORIZED OPTIONAL EQUIPMENT 1 3 2 IMPROPER OR UNAUTHORIZED USES CAUTION e This paragraph describes some of the improper or unauthorized uses of the machine since it is impos sible to predict all the possible improper uses if it is necessary to use the machine for particular appli cations contact your Komatsu Dealer before carrying out the work IMPORTANT e The instructions regarding the authorized optional equipment are given in the relevant operation and maintenance manuals if the equipment is supplied by Komatsu these publications are enclosed to this manu
87. that the switch is in the correct position This switch 9 is used to allow the machine to work temporarily in case of failure in the braking system of the turret swing when E03 appears on the display or the boom swing when E41 ap pears on the display functions a EMERGENCY abnormal situation shift the lever switch up ward the boom and turret swing functions can be temporari ly operated b NORMAL normal situation shift the lever switch downward If the codes E03 or E41 appear on the display shift the lever Switch upward to be able to go on working 86 9JA03339 9JA03339 10 Overhead light IMPORTANT e Make sure to switch off the overhead light after use If it is not switched off the battery will run down The overhead light 10 is used to check the instruments and the inside of the cab when visibility is scarce Position ON to switch it on Position OFF to switch it off NOTE e The overhead light can be switched on or can be left on even when the ignition switch is in position OFF therefore it is impor tant not to forget to switch it off 11 Cigarette lighter The cigarette lighter 11 is used to light cigarettes Push it in wards it will return to its original position after a few seconds Ex tract it to light your cigarette If the cigarette lighter is removed the socket can be used as pow er supply IMPORTANT e This is a 24 V cigarette lig
88. the arm e Before carrying out any operation on the hydraulic circuit stop the engine and eliminate any residual pressure from the equipment circuit by shifting the controls more than once and from the oil tank by slowly loosening the filling cap Immediately clean any area dirty with oil e All the equipment disassembly and assembly operations must be carried out with the machine parked on firm and level ground e When removing the hydraulic connections be extremely careful in order to prevent any impurities from getting into the pipes After mechanically installing the equipment position the machine on firm and level ground stop the engine release the residual pressures from the system and proceed as indicated below 1 Remove the plugs 5 Be careful not to loose or damage any of the parts removed 2 Connect the pipes for the clamshell bucket swing making sure that the characteristics and dimensions of the fittings 6 correspond to those indicated in the diagram NOTE e For the characteristics of the threads and the functions of the equipment couplings refer to the user manual provided by the manufacturer 3 After connecting the pipes start the engine see 3 3 6 STARTING THE ENGINE and let it idle for at least 10 min utes 4 Lift the equipment from the ground and rotate it clockwise and anticlockwise for a dozen times in such a way as to bleed the circuit 5 After the bleeding operation stop the eng
89. the switch clockwise red range increases the temperature while turning it anticlockwise light blue range decreases the temperature RKA19030 113 INSTRUMENTS AND CONTROLS 3 Ventilation selection switches These switches are used to select the direction of the air coming from the heater and the selection is indicated by a LED The LEDs slide progressively and follow the direction of the ar rows stamped on the switches The selected flow is indicated by the coming on of the corresponding LED Three directions of the flow can be selected 1 Air flow towards the operator s face 2 Airflow towards the operator s face and feet 3 Air flow towards the operator s feet 114 J es RKA19040 RKA19020 4 Airflow selection switches These switches are used to select the intensity of the air flow coming from the heater and four ventilation levels are available The LO low switch is used to decrease the air flow while the HI high switch is used to increase the air flow The selected flow is indicated by the coming on of the corre sponding LED The LEDs slide progressively and follow the direction of the ar rows stamped on the switches 5 Airrecirculation selection switch This is an ON OFF switch and is used to activate the air recircula tion inside the cab which is useful to cool the cab more quickly and when
90. with wedges ramps RYA00670 Always use ramps that are sufficiently wide and can support the weight of the machine The longitudinal axes of the ramps must be parallel to each other and perpendicular to the loading board and their distance must be suitable for the tread of the machine Make sure that the ramps are securely positioned and fastened to the loading board and that they have the same length Position the ramps with a maximum inclination of 15 Make sure that the surface of the ramps is clean and there is no trace of grease oil soil or ice remove dirt from the tracks be fore loading the machine on the vehicle The machine must be loaded on the vehicle with the bucket di rected forwards that is in the driving direction of the vehicle Do not correct the trajectory of the machine on the ramps If necessary get down the ramps and start the operation again If the machine is equipped with cab always lock the door after loading the machine Failure to carry out this operation may cause the door to open suddenly while the machine is being transported After loading the machine block the tracks with wedges and se cure it with tie downs or chains to prevent any sideward move ment see 3 4 TRANSPORTING THE MACHINE 2 3 3 2 TRANSPORTING THE MACHINE CAUTION e During transport the machine must be secured to the vehicle e Define the route to be followed taking in consideration the width height and weig
91. working in extremely polluted areas IMPORTANT e Do not use the air recirculation function for long periods in rainy or cold days since this would increase the fogging of the inside of the windows 6 Defrosting lever The lever 6 is used to activate the defrosting function of the front windshield in case of cold or rainy weather Lever pushed forward Defrosting function on Lever pulled backward Defrosting function off INSTRUMENTS AND CONTROLS O O O O 8195 gt 19050 RKA19060 RKA19080 115 INSTRUMENTS AND CONTROLS 3 2 17 TECHNICAL DOCUMENTATION COMPARTMENT On the back of the operator seat there is a compartment for the Use and maintenance manual and other documents Always keep the Use and maintenance manual in this compart ment in such a way as to be able to consult it at any moment 3 2 18 TOOL BOX IMPORTANT e Keep the cover locked Open it only if necessary Open the cover on the right side of the machine Put the tools in this compartment 3 2 19 GREASING PUMP SUPPORT Open the cover on the right side of the machine The grease pump support is positioned inside the compartment When the grease pump is not going to be used insert it in the apposite sup port 116 RKAB6950 2 9JA03160 INSTRUMENTS AND CONTROLS 3 2 20 ASHTRAY The ashtray is positioned to the right of
92. you by making signals The operators must pay the maximum attention to the signs and fol low the instructions of the signalman e There can be only one signalman e Before starting work make sure that all operators understand the meaning of the agreed signals and of the signs 37 GENERAL PRECAUTIONS 2 2 29 HAND SIGNALS WARNING e When it is necessary to position loads make excavations or move the machine with reduced field of vi sion the operator must be helped by another person standing on the ground and making signals to indi cate the manoeuvres to be carried out according to the specific signals defined by the relevant regulations e No movement or operation should be carried out if the signals have not been clearly understood by the operator and the signalman e When additional instructions different from those defined by the manual signalling system are neces sary these must be agreed upon by the operator and the signalman before starting the job e Only one person must be entrusted with making signals e The operator must make sure that the signalman is always within his field of vision and follow all his sig nals The use of hand signals serves to direct the lifting handling and positioning of the loads lifted by the work equip ment Hand signals can also be used during digging operations or when the machine travels if the field of vision of the operator is reduced The direction of movement of the hands and
93. 20 SUDDEN MOVEMENTS OF THE LEVERS 1 Do not shift up or down suddenly since this may cause the machine to start abruptly 2 Avoid any sudden shifting from forward to reverse or vice versa 3 Avoid any sudden manoeuvre for example stopping abruptly when the machine is running at very high speed releasing the lever RKA18790 OPERATIONS IN WHICH THE BLADE IS USED AS SUPPORT ON ONE SIDE ONLY When using the blade as a support for the machine do not rest the machine only on one end of the blade tt tt tf AW351470 152 USE OF THE MACHINE 3 3 16 IGENERAL INFORMATION ON THE OPERATION OF THE MACHINE TRAVEL FUNCTION Travelling over boulders tree stumps or other obstacles means submitting the frame and in particular the tracks to considerable stress and this may damage the machine For this reason al ways remove any obstacles and avoid passing over them If an obstacle cannot be avoided reduce the travel speed lower the work equipment to the ground and try to manoeuvre the ma chine so that the obstacle is equidistant from the tracks t 5900 9059 SR 5 s e 5950 o gt 5 e ex 990009 z gt 50 0 x 9 0 xD 50 0 ex 552 5 52 00 505 KBB ex xy 9 5 5 29 55 ex z 555 2555 50 0 2505 55 BRK sess 52 LX A RY 55 o
94. 20 0 4 68 3 1 1 GENERAL VIEW OF THE MACHINE WITH 0040 68 3 1 2 GENERAL VIEW OF THE MACHINE WITH TWO PIECE 69 3 1 3 CONTROLS AND 70 INSTRUMENTS AND CONTROLS sees 71 8 2 1 5 nitride en aan d hehe en eas 71 3 2 1 1 WARNING LIGH IS 1 a tete ee e eiui ss 72 3 2 1 2 EMERGENCY WARNING LIGHTS sss nennen 74 3 2 1 3 WARNING LIGHTS AND INDICATORS 76 3 2 14 SWITCHES DISPLAY i t i ede iet ined ha diel ea dee diene 79 3 22 SWITCHES AND PUSH 82 3 2 3 CONTROL LEVERS AND 5 89 3 2 4 WINDSHIBID sz ai ii tette e Aas rer e Pert RE Le n x saved 94 3 25 SEIBING AIDOQOR ie Ee E pi pen Eae puc E e 99 3 2 EMERGENCY EXIT HAMMER 99 327 SIDE WINDOW inet ertt E ie gebe EP ERU eda Lee LER aut LIA Ride a MM tena 100 3 2 87 CAP WITEUEOQGNK titt bee beta tette en Masta see tt lg t aet eee ie locut 102 3 2 02 ENGINE HOOD etie i c pei 103 9 210 SIDE COVER rin reet rne rt epe e ee E dat equi eade tud a 104 3 2 11 BATTERY INSPECTION COVER iie re Etre Dena tti dene dune ba cet sabio
95. 3 3 10 OPERATING THE MACHINE A WARNING e Before moving the machine make sure that you perfectly know the control functions and all the relevant safety regu lations e The operator must be seated in the driving position with fastened seat belt e Before operating the travel levers check the direction of the undercarriage If the sprocket is at the front the nn RKATBET0 tion of the travel levers is inverted e Before moving the machine make sure that there is no one within its operating range and that there are no obstacles in the surrounding area e Be extremely careful when reversing and make sure that there are no persons other equipment or obstacles in the way e Avoid any travel manoeuvre or change of direction with the accelerator at maximum speed since manoeuvres carried out in these conditions may cause abrupt and dangerous movements e Do not use the speed increase function when changing di rection or carrying out a counter rotation e Make sure that the travel alarm functions correctly 3 3 10 1 HOW TO MOVE THE MACHINE 1 Turn the hand accelerator 1 towards position MAX to in crease the engine speed Full speed NOTE e f the engine speed cannot be increased the quick deceleration switch may be in position ON Check the corresponding warn ing light For further details on the operation of the quick decel eration switch see
96. 30 GENERAL PRECAUTIONS 2 2 7 INSIDE OF THE CAB e Before seating on the operator seat remove any trace of mud or oil from the soles of your shoes If the pedal is pressed with dirty shoes these may slip on the pedal itself thus causing serious accidents e Do not leave objects or tools scattered inside the cab e Do not apply suckers on the cab windows since they may behave as lenses and cause fires e Do not use mobile phones inside the cab while driving or operating the machine e Do not introduce dangerous objects for example flammable objects or explosives inside the cab e Check the seat belt and change it if itis broken or damaged Replace any component only with homologated parts available at Komatsu or its Dealers 2 2 8 LEAVING THE OPERATOR SEAT e When leaving the operator seat even if temporarily make sure A that the machine is in a safe position See 2 3 2 8 PARKING THE MACHINE e Before leaving the operator seat carry out the following opera tions in the sequence indicated below 1 Lower the equipment to the ground al gt c RKA18260 d 18270 2 Engage the safety lock of the boom swing control 3 Lock the equipment control by shifting the safety lever to the locked position Stop the engine See 3 3 8 STOPPING THE ENGINE 5 f you have to go so far away that you will not be able to see the machine extract the ignition key RK
97. 40408550600 60400 007 AW351630 Do not proceed along the edges of a slope or on uneven ground keeping one track in horizontal position and the other inclined or partially raised with machine inclination exceed ing 10 C To avoid damaging the road liners and the rubber tracks always proceed with both tracks resting on the same level surface LESSEE PROD gt 5 lt 5 50 2462 259924 9 0 0 2559 x RRAS ORS ex foo BS IX Se SAKE RRR oes ERRIRE AW351640 If the machine is operated as described in points from 1 to 3 the rubber tracks will become loose Do not steer when the machine is in the positions shown in the figure Kx 45 16040 TOSA RL e 55 020 RLA SA 552 eset 554 KS RISI RLA 504 Set 9054 RL QS RSLS RSA KSS 5 RO Kd 9552 504 RS RY waned 04 xh RY c 59 20 02024 S55 5 46 x 250 Ry 292 905 LRS x AW351650 165 USE OF THE MACHINE Detachment of the rubber track from the track frame 1 When the machine moves over an obstacle a gap forms be tween the carrier roller and the rubber track In these condi tions the rubber track may come off the sliding guide 2 Furthermore if the machine travels in reverse a gap forms b
98. 42 6 Boom cylinder rod end pin 1 point 7 Arm cylinder base pin 2 points 8 Arm cylinder rod end pin 1 point 9 Boom arm coupling pin 1 point 10 Bucket cylinder base pin 1 point 11 Arm articulation pin 1 point 12 13 14 15 Articulation coupling pin 2 points Bucket cylinder rod end pin 1 point Articulation bucket connection pin 2 points 15 Arm bucket coupling pin 1 point we was WH 16 Boom swing support pins 2 points 17 Boom swing cylinder rod end pin 1 point 18 Boom swing cylinder base pin 1 point MAINTENANCE PROCEDURES 9JA03236 9JA03237 9JA04915 243 MAINTENANCE PROCEDURES 4 9 7 6 CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR AND TOP PING UP WARNING e Soon after the machine has been stopped the engine oil is very hot and may cause burns let the oil cool down to 40 45 C before carrying out any check 1 The operation must be carried out with the machine posi tioned on firm and level ground 2 The oil level must be checked on the dipstick G and must be included between the H and L marks if this is not the case top up by proceeding as explained in paragraph 4 9 10 CHANGING THE OIL IN THE SWING REDUC TION GEAR and using the oil recommended in the lubricant chart see 4 4 FUEL COOLANT AND LUBRICANTS 4 9 7 c CHECKING THE OIL LEVEL IN THE FINAL R
99. 48 b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE 250 MAINTENANCE EVERY 250 HOURS OF OPERATION JIEUBRIGCATION i ee 242 b CHECKING THE OIL LEVEL THE SWING REDUCTION GEAR AND TOPPING 244 c CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS AND TOPPING 244 d CHECKING THE BATTERY CHARGE 245 e CHECKING AND ADJUSTING THE FAN BELT 246 f CHECKING AND ADJUSTING THE AIR CONDITIONER COMPRESSOR BELT TENSION 247 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION Only for machines in which synthetic biodegradable oil type HEES is used Opera tions to be carried out together with those prescribed in paragraph 4 9 9 MAINTE NANCE EVERY 500 HOURS OF OPERATION a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER Only for machines in which syn thetic biodegradable oil is 263 MAINTENANCE EVERY 500 HOURS OF OPERATION a CHANGING THE FUEL FILTER CARTRIDGE 248 b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE ee 250 c CHANGING THE HYDRAULIC OIL FILTER 252 d CLEANING THE INSIDE AND OUTSIDE FILTERS OF THE AIR
100. 5 4 9 11 c CLEANING AND CHECKING THE 267 4 9 11 d CHECKING THE ALTERNATOR AND THE STARTER 267 4 9 11 e CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE 267 4 9 11 CHECKING THE A C REFRIGERANT GAS QUANTITY only for machines with air 267 4 9 12 MAINTENANCE EVERY 4000 HOURS OF 268 4 9 12 a CHANGING THE A C FILTER DRIER only for machines with air conditioner 268 4 9 12 b CHECKING THE OPERATING CONDITIONS OF THE A C COMPRESSOR only for machines with air 268 4 9 12 c CHECKING THE WATER emere nennen 268 4 9 13 MAINTENANCE EVERY 5000 HOURS OF 269 4 9 13 a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER 269 TECHNICAL SPECIFICATIONS 5 1 5 2 TECHNICAL DATA iic Drain iens Era e CER XE E ET 272 LIFTING CAPACITIES AL REL FRE RARO CA Ig Ei a aA 274 9 2 1 3bBIETING OAPAGCITIES iit reete ete ite d aha E ER Feb ER 274 5 22 LIFTING CAPACITIES WITH 275 5 2 83 LIFTING CAPACITIES WITH TWO PIECE 278 17 TABLE OF CONTENTS AUTHORIZED OPTIONAL EQUIPMENT 6 1
101. 5 floats this means that there is water under the ring so drain the water by proceeding as indicated below 1 Open the inspection cover 1 on the left side of the machine and turn the knob 2 of the filter to position CLOSED a 2 Using the filter wrench loosen the ring 3 then remove the cup 4 and throw out the water that is inside it 3 Fill the cup 4 with fuel install it on the filter housing then tighten the ring 3 Turn the knob 2 to position OPEN b 5 Drain any water or sediment from the fuel tank For further details see 4 9 4 a DRAINING THE FUEL TANK USE OF THE MACHINE a 9JA04541 0052091 9JA03373 125 USE OF THE MACHINE 3 3 2 7 CHECK THE WIRING SYSTEMS A WARNING e If the fuses are corroded oxidized or not perfectly held in their seat replace them only with fuses having the same capacity before changing a fuse make sure that the ignition key is in position OFF e If the wirings show traces of short circuits contact your Komatsu Dealer who will locate the fault and carry out any necessary repairs e Before checking the wiring take all the necessary safety precautions e Always keep the battery surface clean and make sure that the charge level warning light is always visi ble Make sure that the fuses are not damaged that fuses with the specified capacity are used that there are no inter ruptions or
102. 590 49 PRECAUTIONS FOR USE e Do not carry out demolition work under the machine since it may become unstable and tip over e When working on the top of buildings or other structures check these structures and their strength before starting work In fact the buildings may collapse and cause serious injury or damag es 00600 e When carrying out demolition work do not position the machine under the structure being demolished since broken parts may fall down or the building may collapse causing serious injury or property damage el lt lt Ry gt 55 x ROX 59 55 55 22 95 x 9 gt OK 9 res 55 ex e 55 x oS 55 aren LORY RY 00 s 5555 CES eee 555 ete sas SO KE 55 KE 925 x EU 525555209099 00610 e Do not use the impact force of the work equipment for breaking work Flying pieces of broken materials may damage the work equipment or even cause serious personal injury e As a general rule the machine is more liable to overturn when the work equipment is swung to one side than when it is at the front or rear oon 2 55500 RRL SOP ORR ORK RRO 4 Ss lt e LE 5 5505 5 e 3 5050 EEE ee KEES
103. 781B LOADING THE MACHINE In places where the swinging angle is reduced the effectiveness of the operation can be increased by positioning the truck so that the operator can see it The loading operation is easier and the loading capacity higher if the hydraulic excavator loads the truck from the back and not from the sides FILLING AND LEVELLING OPERATIONS Use the blade to fill the excavations and to level the ground sur face SIDE DITCHING WORK The machine can be used to create side ditches by exploiting the combined action of the turret and boom swing functions USE OF THE MACHINE Gr 090940 9JA01649 9JA01960 159 USE OF THE MACHINE 3 3 20 CHANGING THE BUCKET WARNING e When the coupling pins are removed or installed chips may come off always use gloves goggles and helmet e The change of the equipment must be carried out by two operators who must decide together the words and signals to be used during work e Avoid using your fingers to align the holes since they may be cut off in case of sudden or uncontrolled movements e The described procedures are valid also for the coupling of the mechanical connections of the optional equipment To carry out the work stop the machine on firm and level ground When working in a team it is necessary to appoint a sup
104. A18280 31 GENERAL PRECAUTIONS 2 2 9 GETTING ON AND OFF THE MACHINE e Do not jump on or off the machine neither when it is at rest nor when it is moving e When getting on or off the machine always use the handles and the tracks get on and off the machine very carefully e Do not hold or rest on the control levers e Both when getting on and when getting off the machine always maintain three points of contact holding or resting points in or der to avoid losing your balance and falling down e Tighten the handle screws if they are loose and clean the han dles and tracks if they are dirty with oil or grease Carefully clean the cab floor if it is dirty with oil grease mud or rubble 2 2 10 IT IS FORBIDDEN TO CLIMB ON THE EQUIPMENT RWA18670 Do not allow anyone to climb on the bucket the grapple forks or other equipment There is the risk of falling down and be seriously injured 2 2 11 ARTICULATED PARTS The free space around the work equipment changes depending on the movement of the articulated parts Becom ing entangled in the articulated parts may be the cause of serious injuries Do not allow anyone to get too near ro tating or telescopic parts of the machine 32 GENERAL PRECAUTIONS 2 2 12 PREVENTING BURNS e If the engine coolant the engine oil and the hydraulic oil are hot 5 use heavy cloths and wear gloves heavy clothing and safety goggles before carryin
105. ADDITIONAL COUNTERWEIGHT Q kg L A B max 6 0m 5 0m 40 3 0m 45m 650 600 950 900 E 3 0m 400 350 500 450 900 850 1500 1400 2 1 5m 350 300 450 400 850 800 1450 1350 0 0 400 350 600 450 800 750 1400 1300 2300 1900 1 5m 600 450 600 450 800 750 1400 1300 2200 1900 278 Load limited by the hydraulic lifting capacity and not by the tipping limit LIFTING CAPACITIES 5 26 5 265 bar L i L 650 mm kg 175 WY RKA21470 279 280 THIS PAGE WAS INTENTIONALLY LEFT EMPTY AUTHORISED OPTIONAL EQUIPMENT
106. Active mode for heavy duty applications E on Economy mode when fuel saving is desired The work mode changes every time the switch is pressed NOTE e When the engine is started the Active mode for heavy duty ap plications is automatically selected 9JA03136 79 INSTRUMENTS AND CONTROLS 2 Travel speed selection switch WARNING e When loading or unloading the machine on from a trailer always select the low speed Never operate the travel speed selection switch during the loading or unloading op eration e Changing over from high to low speed during travel may cause the machine to deviate laterally even if it is moving on a straight line e Stop the machine before using the travel speed selection Switch This switch 2 is used to select the high or slow travel speed Position Lo low travel speed Position Hi high travel speed The travel speed changes every time the switch is pressed NOTE e When the engine is started the low speed is automatically se lected e When the machine travels at high speed Hi if more power is required in case of soft ground or on slopes the low speed Lo is automatically selected therefore there is no need to use the switch The high speed Hi warning light remains on 3 Windshield wiper switch Use the switch 3 to operated the front windshield wiper ON the windshield wiper works continuously INT the windshield wiper works intermittently
107. Dirt oil and fuel in the engine compartment near hot parts may damage the machine and even cause fires Check frequently and repair any leakage immediately if they occur repeatedly contact your Komatsu Dealer For details on the following items see 3 3 2 DAILY CHECKS a CHECKING THE COOLANT LEVEL AND TOPPING UP b CHECKING THE ENGINE OIL LEVEL AND TOPPING UP c Check the fuel level and top up d CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP e Check the air filter clogging indicator f CHECKING THE WATER SEPARATOR g Check the wiring systems h CHECKING THE HORN 4 9 3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION Only for machines in which synthetic biodegradable oil type HEES is used The following maintenance operation should be carried out after the first 50 hours of use a CHANGE THE HYDRAULIC OIL DRAIN FILTER For further details see paragraph EVERY 1000 HOURS 239 MAINTENANCE PROCEDURES 4 9 4 MAINTENANCE EVERY 50 HOURS OF OPERATION 4 9 4 a DRAINING THE FUEL TANK A WARNING e When draining the fuel tank avoid spilling fuel since this may cause fires e If some fuel is accidentally spilled clean the dirty area immediately in order to prevent it from getting slippery and to avoid fires Carry out this procedure before starting the machine 1 Swing the turret so that the inspection cover 1 is positioned between the tracks 2 Open the inspection cover 1 3 Position a co
108. E 9JA01563 00950 2 4 20 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT The shock absorber unit is provided with a shock absorbing spring with high preload in order to absorb the im pacts of the front idler roller Do not attempt to remove the spring since this may lead to serious accidents and even death For any operation on the shock absorber unit contact your Komatsu Dealer 63 PRECAUTIONS FOR MAINTENANCE 2 4 21 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH PRESSURE OIL e Do not forget that the work equipment circuits are always under pressure for this reason when it is necessary to add or drain hydraulic oil or to perform maintenance operations or inspec tions on the hydraulic circuit it is advisable to lower the equip ment to the ground and completely release the pressures and the residual pressure present in the tank Small leakages from pipes under pressure and the resulting jets are extremely dangerous since they can perforate the skin and penetrate in the blood circulation or injure the eyes For this reason always wear goggles and thick gloves during the inspections and use a piece of cardboard or a sheet of ply wood to check for oil leakages If you are hit by a jet of high pressure oil or are injured even if slightly immediately consult a doctor 2 4 22 HANDLING HIGH PRESSURE HOSES 5 255 lt lt P 5555555 555559
109. EDUCTION GEARS AND TOPPING UP WARNING e Soon after the machine has been stopped the engine oil is very hot and may cause burns let the oil cool down to 40 45 C before carrying out any check e Loosen the cap slowly to release any residual pressure 1 The operation must be carried out with the machine posi tioned on firm and level ground The check must be carried out on each reduction gear with the drain plug P in low po sition and perpendicular to the ground If necessary move the machine slightly until reaching the specified position which is indispensable for an accurate check 2 This is a visual check and serves to make sure that the lubri cant reaches the height of the hole G if this is not the case top up by proceeding as explained in paragraph 4 9 10 b CHANGING THE OIL IN THE FINAL REDUCTION GEARS and using the oil prescribed in the lubricant chart see 4 4 FUEL COOLANT AND LUBRICANTS 244 OR 9JA04983 RKA18870 MAINTENANCE PROCEDURES 4 9 7 4 CHECKING THE BATTERY CHARGE LEVEL WARNING e Check the charge level only with the engine at rest e To prevent gas explosions do not use naked flames do not smoke and avoid producing sparks due to short circuits e The battery electrolyte is dangerous in case of contact with the eyes or skin rinse with plenty of water and consult a doctor without delay The battery is maintenance free IMPORTANT e M
110. EL AND COOLANT 4 2 1 1 OIL e The oil used for the engine and the work equipment is subjected to demanding conditions high temperature high pressure and deteriorates with use Always use oil suitable for the characteristics and temperatures indi cated in the use and maintenance manual Change the oil after the prescribed interval even if it is not dirty e The engine oil must be selected very carefully since it lubricates the engine which is the machine s heart the main maintenance operations required for the engine oil are the following 1 daily check of the oil level 2 check of the degree of pollution of the oil 3 periodical change e When changing the oil change also the filters e It is advisable to have the oil periodically analysed in order to check the conditions of the machine The analysis must be carried out by specialized personnel at Komatsu Dealers 196 MAINTENANCE NOTES 4 2 1 2 FUEL e Always use fuel suitable for the engine Other fuels with different specifications may damage the engine or re duce its power e Always refuel at the end of the workday e When refuelling make sure that there is no water on the fuel drum cover and take care not to draw condensate from the drum bottom e If fuel runs out or if the fuel filter has been replaced it is necessary to bleed the circuit 4 2 1 3 COOLANT e The coolant serves to keep the engine at the correct temperature and therefore to ensure optimal opera
111. ENTING BURNS PREVENTING FIRES DUE TO FUEL AND HOW TO BEHAVE IN CASE DETERGENT FOR THE WINDOWS PROTECTION AGAINST FALLING OBJECTS FLYING OBJECTS FOREIGN BODIES PRECAUTIONS CONCERNING THE EQUIPMENT eene COMBINING THE WORK EQUIPMENT WORK LIGHT AND CAB LIGHTS CAB WINDOWS PRECAUTIONS CONCERNING THE CAB STRUCTURE see UNAUTHORIZED MODIFICATIONS OAA HARA 20 20 21 28 28 29 29 29 29 30 30 30 31 31 32 32 32 33 33 34 34 34 34 34 35 35 35 35 11 TABLE OF CONTENTS 2 3 2 4 12 2 2 23 2 2 24 2 2 25 2 2 26 2 2 27 2 2 28 2 2 29 2 2 30 2 2 31 2 3 1 BEFORE STARTING THE 2 3 1 1 CHECKS AND ADJUSTMENTS TO BE CARRIED OUT BEFORE STARTING TAE ENGINE eee ete e te ere Rims ERE 2 3 4 2 PRECAUTIONS TO BE TAKEN DURING THE START PROCEDURE 2 3 1 3 PRECAUTIONS BE TAKEN IN COLD 2 3 2 PRECAUTIONS TO BE TAKEN WHEN WORKING 2 3 2 1 CHECKS AFTER STARTING THE ENGINE semen 2 3 2 2 PRECAUTIONS TO BE TAKEN WHEN CHANGING DIRECTION 2 323 PRECAUTIONS TO BE TAKEN DURING TRAVEL eee 2 3 24 MOVING ON SLOPES cr eu
112. G e Park the machine on firm and level ground Avoid parking the machine on slopes If it is absolutely necessary to park the machine on a slope put blocks under the tracks and thrust the work equipment into the ground to prevent the machine from moving e If the control levers are inadvertently touched the work equipment or the machine may move suddenly and cause serious accidents Before leaving the operator seat shift the safety lever to the locked position 9JA03529 e Position the blade facing downhill and lower it to the ground 1 Stop the machine For further details on how to stop the ma chine see 3 3 10 4 HOW TO STOP THE MACHINE RKA18770 2 Reduce the engine rpm to MIN using the hand accelerator 1 Low idling 0320 9JA03528 3 Lower the bucket keeping it in horizontal position until its bot tom touches the ground 4 Lower the blade to the ground 161 USE OF THE MACHINE 5 Shift the safety lever 2 to the locked position 3 3 22 CHECKS TO BE CARRIED OUT ON THE MACHINE AT THE END OF THE WORK DAY eo oai Check th i lantt ture 1 th i il _ Gj and the w 138888 5 iere 9JA03203 3 3 23 LOCKI
113. IMPORTANT e To carry out the check and the corresponding maintenance operation stop the machine on firm and lev el ground Check both tracks CHECK 1 With the engine idling move the machine forward of a distance corresponding to the length of the track on the ground then lower the equipment to the ground and stop the engine 2 Choose a perfectly flat bar 3 long enough to cover the distance between the idler roller 1 and the track sliding roller 2 then position it on the track 3 Measure the maximum deflection between the upper surface of the track and the lower surface of the rod Standard deflection 9JA03403 The deflection value a should be included between 10 and 30 mm If the track tension does not correspond to the standard value ad just it by proceeding as indicated below ADJUSTMENT A DANGER e The grease contained in the hydraulic cylinder is pressu rized For this reason do not give the grease valve 1 more than one turn when loosening it in fact if the valve is loos ened excessively it may be pushed out due to the grease pressure and this is very dangerous for the operator Do not loose any component apart from the valve 1 If the track tension does not decrease after this operation con tact your Komatsu Dealer WARNING e If the resistance met when injecting the grease is exces sive move the machine forward and backward coveri
114. N seen eee 200 TABLE OF CONTENTS 4 3 4 4 4 5 4 6 4 7 4 8 4 9 16 PARTS SUBJECT TO WEAR rrr rete einer Erbe at eaa 201 4 3 1 OF THE PARTS SUBJECT TO 201 FUEL COOLANT AND EUBRICANTSS 1 erento nre ertt cxcneceeeesanpnccecsadezsdeecavessdeserdecesseces 202 4 4 1 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS 204 0222220 ur Ren ae 205 4 5 1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS 205 4 5 2 STANDARD TIGHTENING TORQUES FOR HOSES WITH ORFS eee 206 LUBRICATION ge 207 406 1 LUBRICATION DIAGRAM rir REESE EUR ERE E MR Dec DU 207 PERIODICAL CHANGE OF SAFETY RELATED COMPONENTS eem een 208 47 27 tinet eei FE REAL ATEREA 209 MAINTENANCE PLAN 5 PERNA KEARE ENAS 210 4 3 1 MAINTENANCE PLAN tre 210 4 8 2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER 213 MAINTENANCE nime E aao ara
115. NANCE STAFE tecti irte tenet eret 2 4 9 EQUIPMENT rc i tre e deo E ie esed ceat e dee id bees debe d E oe b e ode 2 4 10 WORKING UNDER THE V Bez 2 4 12 PRECAUTIONS TO BE TAKEN WHEN USING THE HAMMER 24 13 REPAIR WEEDS ette eame n nean iae st ERR RN EE eae 2 4 14 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING 2 4 15 CHECKING THE COOLANT LEVEL IN THE RADIATOR sse 24 16 USING LAMPS ette ce tates lain dea Lec abad Ee LIEN AER cuts x dE sade 2 4 17 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR 2 4 18 PRECAUTIONS CONCERNING THE STARTER SAFETY AT THE WORKPLACE Hates asl IRL geb xk WORKING ON LOOSE PREVENTING ELECTROCUTION ira ROOM VENTILATION rte nre p bcc rhet I eR CHECKING THE SIGNALS OF THE SIGNALMAN AND THE FIXED SIGNS HAND SIGNALS tete doen eet e tede etd bae E dep efe b Panes et Dn doa d PREVENTING DAMAGE DUE TO ASBESTOS POWDER PRECAUTIONS F
116. NG THE MACHINE Do not forget to lock 1 Cab door 2 Fuel filler flap 3 Engine hood 4 Side cover 5 Battery inspection cover NOTE e Use the ignition key to open and lock the doors and covers list ed above 9JA03204 162 USE OF THE MACHINE 3 3 24 ROAD LINERS AND RUBBER TRACKS for machines equipped with road liners or rubber tracks 3 3 24 1 INFORMATION ON THE ROAD LINERS AND THE RUBBER TRACKS The road liners and the rubber tracks have exceptional characteristics that cannot be found in steel tracks Howev er if they are used as if they were steel tracks it is impossible to exploit all the advantages they offer Do not subject the road liners or the rubber tracks to excessive stress and always take in consideration the condi tions of the worksite and the nature of the operations to be performed Comparative table Road liners rubber tracks and steel tracks Road liners Rubber track Steel track Reduction of vibrations Excellent Excellent Average Smooth travel Good Excellent Good Noiselessness Excellent Excellent Average ne of damages to paved surfac Excellent Excellent Average Manoeuvrability Average Excellent Average Resistance to damage Good Average Excellent Traction force Excellent Excellent Excellent Considering the properties of the material used rubber tracks offer various advantages However their weak point is
117. NTROL A WARNING e When installing the clamshell bucket on the excavator arm consider the greater overall dimensions due to the swing ing of the equipment e Read the contents of the equipment instruction manual carefully before using the machine or carrying out mainte nance operations The machine is equipped for the installation of a clamshell bucket with hydraulic swing on the arm instead of the standard bucket An independent hydraulic circuit second hydraulic line is availa ble for the bucket swing The clamshell bucket swinging movements are managed through the push buttons 1 and 2 on the left control lever The swing movements are the following 1 Push button 1 pressed oil flow delivered to the hydraulic line 3 positioned in the left side of the arm 2 Push button 2 pressed oil flow delivered to the hydraulic line 4 positioned in the right side of the arm IMPORTANT e For the use of the controls refer to the diagram on the right window and to the instructions contained in the use and maintenance manual 8150 21W 973 8720 RKA21490 RKAB8140 293 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET SWING SYSTEM second hydraulic line CONNECTING THE HYDRAULIC CIRCUIT A WARNING e Avoid connecting any equipment to the hydraulic lines before said equipment has been correctly in stalled from a mechanical point of view and fixed to
118. OR USE 35 36 36 37 37 37 38 43 43 44 44 44 44 45 46 46 46 47 48 49 49 51 51 52 52 52 53 53 54 55 55 56 56 56 56 57 58 58 58 59 59 59 59 60 60 60 61 61 62 62 2 4 19 2 4 20 2 4 21 2 4 22 2 4 23 2 4 24 2 4 25 2 4 26 2 4 27 2 4 28 2 4 29 2 4 30 TABLE OF CONTENTS PRECAUTIONS TO BE TAKEN WHEN USING HIGH PRESSURE GREASE TO ADJUST THE TRACK TENSION rie ro ntt Lee cad doar lair e eaae 63 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT E 63 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH PRESSURE OIL 64 HANDLING HIGH PRESSURE 5 6 64 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE e tette tt eerta tdi tage RED sra trie 64 COOLING FAN AND BEET eid eh aite ned 65 WASTE MATERIALES 2 x3 t ep Det Imt ie beber ti lee D 65 SERVICING THE AIR 65 COMPRESS DA R een C eei e e d D d Pci 65 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY 65 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS 66 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL PYRE BEES uendere titt bera ccce Lees uod 66 DESCRIPTION AND USE OF THE MACHINE 3 1 3 2 DESCRIPTION AND USE OF THE MACHINE 0
119. PROCEDURES TM 9JA03759 9JA03760 237 MAINTENANCE PROCEDURES Bleeding the travel motor only after draining the oil from the travel motor casing 1 Let the engine idle remove the pipe 5 from the opening D then when the oil has flown out tighten it again 2 Letthe engine idle and turn the work equipment 90 to move them to the side of the track 3 Lift the machine using the jacks until the track is slightly raised from the ground Make the track turn idly for 2 min utes Repeat this procedure on both the left and right side of the machine Bleeding the attachments when installed IMPORTANT e If the manufacturer of an attachment indicates a specific bleeding procedure follow the instructions If a hammer or another attachment is installed on the machine let the engine idle and operate the attachment control pedal repeat edly approximately 10 times until bleeding the circuit completely IMPORTANT e After the bleeding operation stop the engine and wait at least 5 minutes before starting work This will eliminate the air bubbles from the oil present inside the hydraulic cylin ders e Make sure that there are no oil leakages and remove any oil that may have been spilled 238 9JA03761 9JA04116 MAINTENANCE PROCEDURES 4 9 2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE A WARNING e
120. RWA00200 RWA00190 RWA04920 27 SAFETY NOISE AND VIBRATION PLATES 2 1 3 POSITION OF THE NOISE PLATES e The noise plates must always be legible and in good conditions for this reason if they are dirty with dust oil or grease it is nec essary to clean them with a solution made of water and deter gent Do not use fuel petrol or solvents e If the plates are damaged ask for new ones to Komatsu or to your Komatsu Dealer e In case of replacement of a component provided with a noise plate make sure that such a plate is applied also to the new part EXTERNAL NOISE e This value indicates the noise level outside the machine and re fers to the noise perceived by persons in the vicinity of the work area NOISE INSIDE THE CAB e This value indicates the maximum noise level perceived by the operator s ears inside the cab when this is completely closed 2 1 4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED RKA19240 ISO 6396 e According to the results of the tests carried out to determine the vibrations transmitted to the operator by the ma chine the upper limbs are subjected to vibrations lower than 2 5 m sq sec while the seated part of the body is subjected to vibrations lower than 0 5 m sq sec 28 GENERAL PRECAUTIONS 2 2 GENERAL PRECAUTIONS 2 2 1 SAFETY RULES e Only trained and authorized staff can use the machine and perform m
121. RWA06560 e If the rubber claw wears out and the steel core is visible in two or more points change the track For machines equipped with rubber tracks RYA07510 CUTS IN THE STEEL CORE OF THE RUBBER TRACK When more than one half of the steel core layer is cut on one side change the track RYA07520 223 MAINTENANCE PROCEDURES SEPARATION OF THE STEEL CORE FROM THE RUBBER TRACK If the steel core has detached from the track in one or more points change the track RUBBER TRACK TENSION If the tension of the rubber track is still insufficient even after the injection of grease change it with a new track or change the gas ket inside the cylinder IMPORTANT e If the track tension is such that the track may come off its seat the track may be lengthened and the track tensioner cylinder damaged BREAKAGE OF THE RUBBER TRACK If the broken area between the rubber track support claws reach es a length of approximately 60 mm the track must be repaired If the broken part is small and short but the steel core is visible it is necessary to repair it immediately IMPORTANT e If the length of the broken area is less then 30 mm or its depth is less than 10 mm there is no need for repairs e When it is necessary to decide whether to change repair or continue to use a road liner or a rubber track contact your Komatsu Dealer 224 RYA03240 RAY07530
122. STER CABLES esee emen 185 3 7 9 LOWERING THE WORK EQUIPMENT WHEN THE ENGINE STOPS BECAUSE OF A FAILURE eiit tte e Ap biet 186 3 7 10 OTHER TROUBLES ite ted ier Ree la edes 187 3 10 1 ELECTRICAL SYSTEM i rire tette cer peni tte tee 187 3 10 2 FRAME iiti it eerte deli den ioi ter ede derive t vea nen Ea Pe dee raa duae 188 3 7 70 3 ENGINE iir vos adii tubos ttr eure ia eda waa Pe A ODDO 189 3 7 10 4 ELECTRONIC CONTROL 5 5 191 MAINTENANCE 4 4 GUIDE TO 4 194 4 2 MAINTENANCE NOTES so rk ia an ssa cid Ea D RD e aa Lai d o 196 42 1 OIL F EL AND COOLAN T tete te eo tue Due nk nemi Ea 196 4 2 1 1 TD TL 196 4242 FUEL i addi belessunctelasenere neutre teer 197 4 2 153 COOLANT iita ite re n dusts ned I UT DR TERIS 197 4214 KOWA KOMATSU OIL WEAR ANALYSIS sse 198 4 2 1 5 STORING OIL AND FUEL e bees 199 4 210 EIETERS iine eite te tn dg et ep e 199 4 2 2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM 200 4 2 3 NOTES ON THE MAINTENANCE OF THE HYDRAULIC 200 4 2 4 MAINTENANCE NOTES REGARDING LUBRICATIO
123. THE FUEL LEVEL AND REFUELLING A WARNING e When refuelling avoid spilling fuel since this may cause a fire hazard If fuel is spilled wipe it up imme diately e Fuel is highly flammable do not use naked flames and do not smoke when refuelling Hold the fuel gun constantly in contact with the filler 1 Insert the key in the ignition switch 1 and turn in to position ON so that the machine monitor 2 lights up RKA18630 2 Check the fuel indicator 3 to verify the quantity of fuel still available in the tank 9JA03165 3 f necessary refuel through the filler neck F checking the sight gauge G Fuel tank capacity 125 1 4 After refuelling tighten the fuel cap IMPORTANT e It is advisable to refuel after work in order to avoid the for mation of water condensate 122 USE OF THE MACHINE 3 3 2 4 CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP WARNING e Carry out this check when the oil is cold with the machine positioned on level ground bucket and arm cylinders retracted and bucket teeth resting on the ground e Before topping up stop the engine and eliminate the residual pressure from the equipment circuits by shifting the controls more than once and from the tank by slowly loosening the filling cap Check the oil level in the hydraulic tank w
124. Wash and dry all the parts of the machine then store it in a dry place If it is necessary to leave the machine outdoors park it on a level surface and cover it with a tarpaulin e Fill the fuel tank completely lubricate where necessary and change the oil e Apply a thin film of grease on the metal surface of the hydraulic cylinder rods e Disconnect the negative terminals of the battery and cover it or alternatively remove it from the machine and store it separately e Lock all the control levers and the pedal using the safety lever and the pedal locking device e If the machine is configured for the installation of attachments set the stop valve to position lock Install the blind plugs on the 90 elbows e If the machine can be equipped with attachments shift the selection lever to position Hammer or other attach ments 3 6 2 DURING A PERIOD OF INACTIVITY WARNING e If it is necessary to carry out a rust prevention treatment while the machine is kept indoors open doors and windows to increase ventilation and avoid poisoning by gas Start the engine and move the machine for a short distance once a month so that a new oil film covers all the mov ing parts and the surface of the components Charge the battery at the same time e If the machine is equipped with air conditioner switch it on e Make the tracks turn 3 6 3 AFTER A PERIOD OF INACTIVITY IMPORTANT e If the machine has been stored
125. accidents e If the battery electrolyte is frozen do not charge the battery or start the engine with a different power source since the battery may catch fire Before charging the battery or starting the engine with a different power source let the electrolyte melt then make sure that it isn t frozen any more and that there are no leakages 45 PRECAUTIONS FOR USE 2 3 2 PRECAUTIONS TO BE TAKEN WHEN WORKING 2 3 2 1 CHECKS AFTER STARTING THE ENGINE When performing checks move the machine to a larger area without obstacles and proceed very slowly Do not allow anyone to approach the machine e Make sure that the movements of the machine correspond to those displayed on the control decal If they do not match immediately replace the control decal with a correct one e Make sure that the indicators and the equipment work correctly and check also the operation of the bucket boom and arm and of the travel swing and steering systems e Make sure that there are no anomalies in the noises emitted by the machine in the vibrations temperatures smells or in the operation of the indicators also check that there are no oil or fuel leakages e If any anomaly is found immediately provide for the necessary repairs 2 3 2 2 PRECAUTIONS TO BE TAKEN WHEN CHANGING DIRECTION e Before leaving position the turret so that the sprocket is at the rear of the operator seat If the sprocket is at the front of the op erator seat the machine wil
126. ach the end of stroke 4 Operate the bucket for 30 seconds and the arm for another 30 seconds alternately for a total time of 5 minutes IMPORTANT e When the work equipment is folded be careful to prevent it from interfering with the machine body or touching the ground 138 RKA18590 Mid range speed Low 4 idling 9EA03177 RKA18650 After completing the warming up procedure make sure that the warning lights 5 are in the conditions indicated below e Engine coolant temperature indicator 6 within the green range e Fuel gauge 7 within the green range e Engine coolant temperature warning light 8 OFF e Engine oil pressure warning light 9 OFF e Battery charge level warning light 10 OFF e Fuel level warning light 11 OFF e Pre heating warning light 12 OFF e Display 13 OFF Check the colour of the exhaust gas and verify if there are noises or vibrations If any anomaly is observed contact your Komatsu Dealer Shift the safety lever 2 to position lock and make sure that the controls levers the work equipment the blade the swing and travel functions cannot be operated Set the work mode selection switch 14 positioned on the warning lights panel 5 to the current work mode When the warning light E comes on E mode when fuel saving is desired When the warning light E does not come on A
127. aintenance operations e Follow all the safety rules precautions and instructions when using the machine or performing maintenance op erations e When working with other operators or when the work site is often occupied by other operators make sure that everyone knows and understands all the agreed signals and in any case that everyone works in such a way as to be able to see the machine and to be visible to the operator 2 2 2 HOW TO BEHAVE IN CASE OF ANOMALIES e If anomalies are observed while the machine is working or is being serviced noise vibrations bad smells incor rect measures smoke oil leakages or any other anomaly indicated by the warning devices or the warning lights inform the staff in charge so that the necessary measures can be taken Do not use the machine until such anomalies have been eliminated 00510 2 2 3 CLOTHING AND PERSONAL TECTION ITEMS e Do not wear large or loose clothes rings and watches and do not approach the machine with loose long hair since they can get entagled in the moving parts of the machine and cause seri ous injury or damage Avoid also wearing clothes dirty with oil or fuel since they are flammable Wear a hard hat goggles safety shoes mask gloves and ear muffs when operating the machine or performing maintenance operations Always wear safety goggles a hard hat and heavy gloves if your job involves scattering metal chips or minute materials these
128. ake sure that the connection terminals are not oxidized if necessary clean them and cover them with anti oxidation grease The battery 2 can be reached after opening the inspection cover 1 A visual gauge indicates the battery charge level in different colours according to the table positioned beside the gauge Green optimal charge Gray the battery needs recharging White the battery must be replaced 9JA03238 WARNING e If a dry battery is used check that the electrolyte level is approximately 6 mm above the plate edge if necessary top up using distilled water only If on the contrary the level is low because some fluid has been spilled add sulphuric acid after diluting it to reach the concentration suitable for the ambient temperature see 3 5 1 3 BATTERY e It is advisable to add distilled water just before starting work in order to prevent if from freezing e Before putting back the cell caps make sure that the breather holes are not clogged 245 MAINTENANCE PROCEDURES 4 9 7 e CHECKING AND ADJUSTING THE FAN BELT TENSION A WARNING e Soon after the machine has been stopped the engine is very hot and may cause burns let the engine cool down before carrying out any check CHECK The fan belt can be reached after opening the engine hood see 3 2 9 ENGINE HOOD 1 The check is manual press the belt with one thumb on the intermediate point between the alternato
129. al e The instructions regarding the assembly of the authorized equipment the controls requiring special ar rangements on the machine and the hydraulic couplings necessary for the operation of such equipment are grouped in the final section of this manual Komatsu machines are constructed exclusively for the handling excavation and treatment of inert materials there fore the following uses are absolutely forbidden e USE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS e USE OF THE MACHINE FOR LIFTING PERSONS OR OBJECTS e TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS e USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES e USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES 1 3 2 1 MAIN CHARACTERISTICS e Simple and easy operation e Hydrostatic transmission obtained through two variable displacement motors that operate epicyclic reduction gears equipped with negative hydraulic brakes e Rotation of the turret achieved by means of an axial piston hydraulic motor acting on an epicyclic reduction gear e Ball bearing ring teeth and pinion lubricated in grease bath e Main equipment controlled through servo levers ensuring also combined movements that can be modulated pro portionally and continually e Boom swing and travel controls with servo pedals ensuring movements that can be modulated proportionally and continuously e Travel speed increase function controlled with a button e Servo controls also for two piece
130. al to be handled contains asbestos fibres it is com pulsory to make sure that all the laws and safety regulations in this regard are respected e If the regulations in force concerning work in environments con taminated by asbestos fibres are not complied with it is forbid den to use the machine e Do not allow other people to approach during work e Always observe the rules and provisions in force at the work place and the applicable environmental regulations No asbestos powder has been used for the construction of this machine but non original parts may contain asbestos powder therefore it is advisable to use always original Komatsu parts 43 PRECAUTIONS FOR USE 2 3 PRECAUTIONS FOR USE 2 3 1 BEFORE STARTING THE ENGINE e f there is a warning plate hanging from the work equipment control lever do not start the engine or touch the control levers Do NOT START THE ENGINE RKA00340 2 3 1 1 CHECKS AND ADJUSTMENTS TO BE CARRIED OUT BEFORE STARTING THE ENGINE Carry out the checks listed below every day before starting the engine e Remove any trace of dirt from the window glass surface in order to ensure good visibility e Remove any trace of dirt from the work lights and make sure that they come on correctly e Check the coolant level the fuel level and the oil level in the pan and make sure that the air filter isn t clogged and the wiring circuits aren t damaged
131. an error signal is displayed while the ignition switch is in position ON The display blinks and all error messages are displayed in sequence If the right part of the display blinks see 3 7 10 4 ELECTRONIC CONTROL SYSTEM 6 HOUR METER The hour meter 6 indicates the total number of operating hours of the machine Use the hour meter as reference for the routine maintenance in tervals The hour meter is active when the engine is in operation inde pendently of whether the machine is moving or not NOTE e The number of hours is increased by 1 every hour of operation independently of the engine speed 78 C im ENV 9JA03134 Informa tion dis Error type played E02 Pump control system error E03 Swing brake system error E05 Speed governor system er ror Sos PY S JPN Sos on ZNS AY Sos DX 9JA03133 3 2 1 4 SWITCHES DISPLAY INSTRUMENTS AND CONTROLS 9 2 D 3 KOMATSU 9JA03135 1 Work mode selection switch 3 Windshield wiper switch 2 Travel speed selection switch 4 Windshield washer switch 1 Work mode selection switch This switch 1 is used to select the power and movements of the work equipment Any work can be carried out more easily by selecting the work mode suitable for the operation at hand E off
132. and the roller 2 and lubri cate the three points indicated in the figure CLEANING 1 Open and close the door more than once and remove the dirt from the guide 1 using a brush 2 Using cloth remove any further residue from the guide 1 LUBRICATION IMPORTANT e Do not use high viscosity oil for lubrication Use only grease 1 Spray the lubricant on the guide 1 and on the roller 2 uni formly 2 After lubrication slide the door and make sure that it can be easily opened and closed If it is still difficult to move the door contact your Komatsu Dealer for the necessary repairs 9JA03596 233 MAINTENANCE PROCEDURES 4 9 1 n WASHING THE FLOOR The floor can be washed with water A WARNING e When the machine is inclined use blocks to stabilize it and carry out the necessary operations very carefully e If the control levers are inadvertently touched the work equipment or the machine may move suddenly and cause serious accidents Before leaving the operator seat shift the safety lever to the locked posi tion IMPORTANT e When washing the cab floor avoid wetting the connector and the filters of the air conditioner HOW TO INCLINE THE MACHINE A How to proceed on a slope CAUTION e The ground should be even and compact Stop the machine so that the work equipment is positioned facing downward Put some blocks under the track and thrust the work e
133. arks due to static electricity e After refuelling or adding oil tighten the fuel or oil cap securely e Do not fill the tank completely in order to leave room for the fuel to expand 00480 e case some fuel is spilled wipe it up immediately RKA00490 33 GENERAL PRECAUTIONS 2 2 14 HOW TO BEHAVE IN CASE OF FIRE In case of fire abandon the machine immediately proceeding as follows e Turn off the ignition switch and stop the engine e Use the handles and tracks to get off the machine 2 2 15 DETERGENT FOR THE WINDOWS Use an ethyl alcohol based detergent Methyl alcohol based detergents may irritate the eyes therefore avoid using them 2 2 16 PROTECTION AGAINST FALLING OBJECTS FLYING OBJECTS FOR EIGN BODIES In work places where there is the risk of objects or foreign bodies hitting or getting into the cab it is necessary to take in considera tion the conditions of use and to install guards suited to protect the operator e When carrying out demolition work install a front guard and use a laminate covering on the front window e When working in mines or places where stones may fall down RYA00410 install the FOPS Falling Objects Protective Structure canopy and a front guard and use a laminate covering on the front win dow e When carrying out the operations mentioned above always close the front window Furthermore always make sure that an yone in the
134. at all the power of the breaker can be exploited RYA03840 2 Itis absolutely necessary to keep the pressure of the excava tor on the breaker constant as the bit penetrates the ground Always accompany the breaker as it penetrates and use the excavator arms to obtain such a pressure as to keep the un dercarriage lifted approx 5 mm from the ground Avoid lifting the undercarriage more than necessary RYA03850 286 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 3 When working on very hard materials it is important to avoid hitting the same point for more than 30 seconds Hit the same point for a few seconds and change position continuously in this way the material breaks more easily RYA03860 4 facilitate the sliding of the tool on its seat check the thrust direction and always correct the hitting position of the breaker using the bucket and arm control RYA03870 5 Always make sure that the thrust is optimal in order to avoid dangerous and useless strokes RYA03880 287 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER UNAUTHORIZED USES Avoid the operations described below in order to extend the life of the machine and to work in total safety IMPORTANT e During work do not use the demolition hammer with the bucket cylinder at the end of stroke but always leave a free space of approximately 5 cm
135. ater snow grease oil or other substances that may be present on the ramps 9 01127 Do not change the trajectory of the machine on the ramps since it may overturn If necessary move the machine down the ramps and find the correct direction It is dangerous to use the work equipment for the loading and unloading operations e When the machine is on the ramps do not operate any lever apart from the travel levers The centre of gravity of the machine will change suddenly in the point where the ramps reach the truck or the semitrailer and the machine may overturn At this point proceed very slowly e If the turret is swung when the machine is on the truck or trailer the machine becomes unstable there fore it is advisable to fold the work equipment and to swing the turret slowly e Always make sure that the sliding door of the cab is secured firmly no matter whether it is open or closed If the door is opened or closed on the ramps or on the flatbed the operating effort may change suddenly Do not open or close the door on the ramps or on the flatbed During the loading and unloading operations always use ramps or a platform and proceed as indicated below 168 3 4 2 1 LOADING THE MACHINE 1 4 Loading and unloading operations must be carried out only on firm and level ground Keep a safety distance from the edge of the road Engage the trailer brakes and place blocks under the trailer wheels to preven
136. bling e Avoid keeping loose objects or tools in your pockets they may fall out and drop into the machine especially when you open covers and work on the machine while bending over it 194 GUIDE TO MAINTENANCE e When working on rocky areas make sure that the undercarriage is not damaged and that there are no breakag es damages worn parts or loose or damaged nuts or bolts e When washing the machine do not direct the high pressure water jet onto the radiator e When washing the machine protect the electric system connectors and avoid wetting the ignition switch e The fuel tank is made of plastic therefore avoid using trichloroethylene to clean it Trichloroethylene reduces the resistance and duration of the tank e Before starting work on muddy ground under rain or snow on seashores or river banks check the tightening of valves and caps Wash the machine immediately after work in order to prevent its components from rusting Make sure that there are no damages missing or loose nuts or pins Lubricate the components more frequently than usual Lubricate the pins of the work equipment carefully every day if during work they are immersed in water e When the work site is particularly dusty proceed as follows 1 Check the air filter for clogging and clean it more frequently than usual 2 Clean the radiator frequently in order to prevent the fins from clogging 3 Change the diesel oil filter more frequently than usual 4
137. boom and blade e Complete series of instruments visible from the operating position e Hand accelerator e Easy maintenance with simplified intervals INTRODUCTION 1 3 3 RUNNING IN Every machine is scrupulously adjusted and tested before delivery A new machine however must be used carefully for the first 100 hours in order to ensure proper running in of the various components If the machine is subjected to excessive work load at the beginning of operation its potential productivity and its functionality will be shortly and untimely reduced Every new machine must be used carefully paying special attention to the following instructions e After the start let the engine idle for 5 minutes in such a way as to warm it up gradually before actual operation e Avoid operating the machine with the limit loads allowed or at high speed e Avoid abrupt starts or accelerations useless sudden decelerations and abrupt reversals e After the first 250 hours of use carry out the following operations in addition to those to be performed every 250 hours 1 Change the engine oil 2 Change the engine oil filter 3 Change the fuel filter SYNTHETIC BIODEGRADABLE OIL TYPE HEES For machines in which synthetic biodegradable oil type HEES is used perform the following operations in addition to the standard maintenance operations e After the first 50 hours of operation change the hydraulic circuit drain filter e After the first 500 h
138. ch at ground level mm 6750 H Max blade lifting height mm 500 Max blade working depth mm 440 F 1 C E H 1 1 0 4 1 9JA04962 273 LIFTING CAPACITIES 5 2 LIFTING CAPACITIES A DANGER e Carry out lifting operations only with the machine positioned on firm and flat ground e Before lifting the load make sure that the overload alarm device has been connected see 3 2 2 pos 12 Overload alarm switch 5 2 1 LIFTING CAPACITIES e Arm length L 1650 mm e Arm length L 1900 mm e Arm length L 2 250 mm e Monoboom length L 3 405 mm e Two piece boom length L 3820 mm e Max operating pressure 26 5 MPa 265 bar e Standard bucket length and weight L 650 kg 175 e Machine parked on firm and level ground e Lifting capacity 274 5 2 2 LIFTING CAPACITIES WITH MONOBOOM NOTE e The load does not exceed 87 of the hydraulic lifting capacity or 75 of the tipping limit LIFTING CAPACITIES WITH ARM L 1650 LIFTING CAPACITIES Q kg L A B max 5 5m 4 5m 4 5m 1000 1100 1150 1200 E 3 0m 750 800 750 800 1150 1200 2300 2350 2 1 5m 650 700 700 750 1050 1100 1950 2000 0 0 m 700 750 700 750 1000 1050 1850 1900 1 5m 850
139. changes of direction that may damage and wear out the road liners and the rubber tracks e Avoid steering when moving on surfaces with considerable differences in height When moving on obstacles or surfaces with considerable differences in height position the machine perpendicular to the obstacle to prevent the tracks from coming off e If the machine has been raised using the bucket lower it slowly e Avoid using the machine to handle materials that once crushed produce oil like soy maize or other vegetable parts from which oil is derived otherwise wash the machine soon after use e Avoid any contact with materials that may affect the adhesion of the steel core like salt ammonium sulphate potassium chloride potassium sulphate or calcium superphosphate or wash the machine after use e Since salt affects the adhesion of the steel core avoid using the machine in coastal areas e When handling materials like salt sugar flour or soy seeds the presence of deep cuts in the road liners or the rubber tracks may cause the infiltration of these products in the tracks or the dispersion of rubber pieces in the products Always repair the tracks before use e Do not rub the tracks against concrete walls or blocks e Road liners and rubber tracks slip very easily on snow or icy surfaces Take care not to slip while travelling or working on slopes e The characteristics of the road liners and the rubber tracks change when they are used in e
140. comfortable for the operator then release the lever During the adjustment operations remain seated with the back against the backrest If the operator s back is not against the backrest this may move suddenly forward C Armrest inclination The armrest 3 can be lifted manually by rotating it by approx 90 Furthermore it is possible to adjust the vertical angle of the arm RKA8640 rest with precision by rotating the control 4 at the end of the arm rest manually Armrest adjusting angle 25 IMPORTANT e If the backrest is inclined forward without lifting the arm rest 3 this will be automatically lifted D Longitudinal adjustment of the whole seat unit Shift the lever 5 to the right After positioning the seat as desired release the lever 5 In this way the operator seat the right and left control levers and the safety lever slide all together Longitudinal adjustment 100 mm E Suspension Set the weight adjustment control according to your own weight turning the knob 6 that is under the operator seat The weight can be adjusted between 50 and 120 kg To obtain a softer suspension set a lower weight to obtain a more rigid suspension set a higher weight When working on uneven surfaces adjust the seat to a harder setting F Cushion Pull the lever 7 and adjust the cushion so that it is comfortable for the operator then release the lever Four posi tions can be selected 127
141. cribed at point 5 9JH01577 Closing WARNING e When closing the windshield lower it slowly and pay atten tion to your hands 1 Stop the machine on a level surface lower the equipment completely to the ground then stop the engine 2 Shift the safety lever to the locked position 3 Seize the right and left handles A and shift the locking lever B downwards to release the retainer RKA18280 9JH01578 96 4 Seizethe handle C at the bottom of the front glass with your left hand and the handle D on the upper part of the same with your right hand push forward then lower slowly 5 When the lower part of the glass reaches the upper part of the lower glass push the upper part of the glass forward against the right and left locks G and engage the retainer 6 Make sure that the safety lever is in the locked position NOTE e The retainer has been correctly fitted if the arrow on the retainer F corresponds to the arrow on the locking lever B e If the arrow on the retainer F does not correspond to the arrow on the locking lever B this means that the retainer hasn t been fitted correctly To engage the retainer correctly repeat the op eration described at point 5 INSTRUMENTS AND CONTROLS 9JH01579 9JH01580 9JH01581 9JH01577 97 INSTRUMENTS AND CONTROLS Removing the lower windsh
142. ct buried under the snow therefore always proceed with the utmost attention 2 3 2 8 PARKING THE MACHINE e Park the machine on firm and level ground e Choose a place where there is no risk of falling stones land slips or floods if the ground level is low e Lower the work equipment completely to the ground and stop the engine 18340 e When leaving the machine shift the safety lever 1 to position lock then stop the engine e Always lock the cab door in order to prevent unauthorized per sons from starting the machine Always remove the key e If it is necessary to park on a slope proceed as follows Position the bucket facing downwards and then thrust it into the ground Place wedges under the tracks to prevent the machine from moving RKA18360 RKA18350 51 PRECAUTIONS FOR USE 2 3 3 TRANSPORTING THE MACHINE 2 3 3 1 LOADING AND UNLOADING THE MACHINE e Loading and unloading the machine on from a motor vehicle al ways involves potential hazards Proceed with extreme care e Perform loading and unloading operations on firm level ground Maintain a safety distance from the edges of ditches or from road sides If the vehicles used are not specially equipped for this purpose put support blocks under the ramps in order to prevent them i Distance Max15 from bending beeen ax15 Block e Always lock the wheels of the transport vehicle
143. ctive mode for heavy duty applications USE OF THE MACHINE e 2 9JA03181 RKA18280 9JA03182 139 USE OF THE MACHINE 3 3 8 STOPPING THE ENGINE IMPORTANT e The sudden stop of the engine while it is running shortens its life e Do not stop the engine suddenly except in case of emergency It is likewise recommended not to stop the engine suddenly if it has been running for a long period and is still hot in this case let the engine run at low idling speed for about 5 minutes in order to allow it to cool down gradually before stopping it 1 Run the engine at low idling speed for about 5 minutes in or der to allow it to cool down gradually RKA18600 2 Turn the ignition key 1 to position OFF to stop the engine 3 Remove the key 1 17470 3 3 9 CHECKS TO BE CARRIED OUT AFTER STOPPING THE ENGINE 1 Carry out a visual check of the work equipment and the undercarriage from the outside verifying also if there are oil or water leakages If any anomaly is observed provide for the necessary repairs 2 Checkthe inside of the engine compartment for paper or debris Remove any trace of paper or debris to avoid a fire hazard 3 Remove the mud that is attached to the undercarriage 140 USE OF THE MACHINE
144. d e Make sure that cables and clamps are secured firmly e Make sure that the safety levers and the parking brake le vers of both machines are in position lock e Make sure that all the levers are in neutral 184 TROUBLESHOOTING 3 7 8 2 CONNECTING THE BOOSTER CABLES Keep the ignition switches of both machines in position OFF Connect the booster cable proceeding as indicated below re specting the numerical order indicated in the diagram 1 Connect one clamp of the booster cable A to the positive terminal of the machine to be started 2 Connect the other clamp of the booster cable A to the posi Battery of the Battery of the tive terminal of the machine used as starting aid normal machine B problem machine 3 Connect a clamp of the booster cable B to the negative Revolving frame of 4 terminal of the machine used as starting aid the problem machine 9 01768 4 Connect the other clamp of the booster cable B to the turret of the machine to be started 3 7 8 3 STARTING THE ENGINE A WARNING e Before starting the engine make sure that the safety lever is in position LOCK If one of the work equipment control levers is inadvertently touched during the starting phase the work equipment may move abruptly and cause serious damage or even injury 1 Make sure that the clamps are correctly connected to the battery terminals 2 Start the engine of the
145. d Before operating the ig nition switch always make sure that the safety lever is in the locked position If the engine stops while the safety lever is in free position shift the lever back to the locked position be fore operating the ignition switch 90 RKA18360 2 3 Work equipment control levers WARNING e Before carrying out any manoeuvre with these levers the operator must seat in the work position and fasten the seat belt e Before leaving the driver seat lower the equipment to the ground lock the controls with the safety lever and stop the engine The control lever 2 is positioned on the operator s left and con trols the arm and the turret swing e Swing function a Swing to the right b Swing to the left e Arm c Fold d Extend N Neutral the turret and the arm are held in the position where they stopped The control lever 3 is positioned on the operator s right and con trols the boom and the bucket e Boom e Lift f Lower e Bucket g Open h Fold N Neutral the boom and the bucket are held in the position where they stopped IMPORTANT e The horn push button is positioned on the right lever grip and must be used to warn all the people in the vicinity be fore starting work and in case of danger e When the safety lever is in the locked position all the movements are inhibited see 3 2 3 pos 1 Safety device control lever INSTRUMENTS AND
146. d the work equipment and keep them at a height of 20 30 cm from the ground e When moving on uneven surfaces proceed slowly and avoid steering suddenly since the machine runs the risk of overturn ing The work equipment may hit the ground and cause the ma chine to lose balance or may damage the machine itself or the structures present in the work area e If possible avoid moving on obstacles If the machine has to travel over an obstacle keep the equipment as close to the ground as possible and travel at low speed Never move on obstacles that may incline the machine consid erably on one side e When travelling or working always keep a safety distance from any persons structures or machines in order to avoid hitting them e When crossing a bridge or an elevated structure first of all make sure that it is sufficiently sturdy to bear the weight of the machine When travelling on public roads check the conditions and characteristics of the route with the competent bodies and follow their instructions e When working in tunnels under bridges electric cables and wherever the height is limited proceed slowly and take care to prevent the work equipment from hitting any obstacle PRECAUTIONS FOR USE 20 30 RKA18330 5 s s 25 SNOB 54 5 552 Xe e 525 205 2 5 t 59 20 00 xe stat 292 e 252 5 5 59204
147. d warnings contained in this manual and given on the plates ap plied onto the machine To enable the operator to use this machine safely safety precautions are explained in this manual and labels and warning plates are affixed to the machine to highlight situations involving potential hazards and suggest how to avoid them Terminology used in the signs The following words are used in the signs to inform the user that there is a potential hazard that may lead to per sonal injury or damage to property In this manual on the labels and on the plates the following words are used to express the potential level of the hazard A DANGER e Indicates a situation of imminent danger that if not avoided may cause serious injury and even death The use of this term must be limited to situations of extreme danger WARNING e Indicates a situation of potential danger that if not avoided may cause serious injury and even death A CAUTION e Indicates a situation of potential danger that if not avoided may cause moderate injury This term can also be used as a warning against dangerous interventions Other terms used in the signs In addition to those indicated above the following warning terms are used to recommend the precautions to be taken to protect the machine or to supply useful information IMPORTANT e This term is used to indicate precautions that must be taken in order to avoid actions that may shorten the life of the machine
148. damaging the engine components e Do not make the starter run for more than 20 seconds with out interruption If the engine does not start wait at least 2 minutes before trying again When starting the engine in cold climates proceed as indicated below 1 Make sure that the safety lever 1 is in the locked position If the lever has been released it is not possible to start the engine 2 Before starting the engine make sure that the hand accelera tor 2 is in idling position 3 Turn the hand accelerator 2 to a central position between MIN and MAX USE OF THE MACHINE RKA18620 rcc a om HAB 58888 8 OE A 9JA03178 RKA18280 Mid range speed V 7 4 Low idling 9EA03177 135 USE OF THE MACHINE 4 Keep the key in the ignition switch 3 in preheating position HEAT and make sure that the preheating warning light 4 comes on After approximately 30 seconds the preheating warning light 4 starts blinking and goes on for 10 seconds indicating that the preheating phase has been completed NOTE e The warning light and the indicator come on even when the key is an 5 6 T 8 136 in preheating position HEAT but this does not indicate any omaly When the preheating warning light 4 goes out turn the i
149. deflection a should be included between 1 and 3 mm If the track tension does not correspond to the standard value ad just it by proceeding as indicated below ADJUSTMENT A DANGER e The grease contained in the hydraulic cylinder is pressu rized For this reason do not give the grease valve 4 more than one turn when loosening it in fact if the valve is loos ened excessively it may be pushed out due to the grease pressure and this is very dangerous for the operator Do not loose any component apart from the valve 4 If the track tension does not decrease after this operation con tact your Komatsu Dealer 21003732 WARNING e If the resistance met when injecting the grease is exces sive move the machine forward and backward covering a short distance 225 MAINTENANCE PROCEDURES INCREASING THE TRACK TENSION IMPORTANT e The standard value is low therefore take care not to tighten the rubber tracks excessively Prepare a grease pump 1 Inject grease with the pump through the grease nipple 5 2 To make sure that the tension is correct run the engine at idling speed move the machine slowly forward covering a distance equal to the length of the track on the ground then 8JA03793 stop the machine 3 Check the rubber track tension again If it is not correct ad just it again 4 f the tension is still insufficient even after the injection of grease change the rubber t
150. der during transport position a wooden block at one end of the cylinder to pre vent it from touching the ground 1 Lower the blade 2 Extend the bucket and arm cylinders completely then lower the boom slowly 3 Stop the engine and remove the ignition key Lock all the control levers with the safety lever 5 Lock the sliding door see cab specifications and the covers with lock 6 Place blocks under both ends of the tracks to prevent the ma chine from moving while it is being transported Secure the machine with sufficiently resistant chains or metal cables In particular fix the machine so that it cannot slide on one side TRANSPORTING THE MACHINE Q 9JA03548 RKA18280 5 S UT CJ U7 9JA03764 171 TRANSPORTING THE MACHINE 3 4 2 3 UNLOADING THE MACHINE 1 Loading and unloading operations must be carried out only on firm and level ground Keep a safety distance from the edge of the road In particular fix the machine so that it cannot slide on one side Engage the trailer brakes and place blocks under the trailer wheels to prevent it from moving Before getting on the ramps make sure that the machine is Blocks in line with the ramps and that the centerline of the machine Distance Max15 ds to the centerline of the trail NOn TER corresponds to the centerline of the trailer ramps The inclination of
151. e Adjust the operator seat selecting a position from which it is easy to carry out the required operations and make sure that the seat belt and the couplings are neither damaged nor worn out e Make sure that the indicators work properly check the angle of incidence of the lights and make sure that all the control levers are in neutral position e Before starting the engine make sure that the safety lever is in position lock e Adjust the angle of the rear view mirror so that seen from the operator seat the lower rear part of the machine which isn t usually visible due to the engine hood can be seen without problems For this adjustment operation see paragraph 3 3 3 2 REAR VIEW MIRRORS e Make sure that there are no persons or obstacles over under or around the machine 2 3 1 2 PRECAUTIONS TO BE TAKEN DURING THE START PROCEDURE e When starting the engine sound the horn as an alert signal e Start and operate the machine only when seated in driving position e Do not allow anyone apart from the operator to get on the machine e Do not short circuit the starter circuit to start the engine This operation is dangerous and will certainly damage the equipment 44 PRECAUTIONS FOR USE 2 3 1 3 PRECAUTIONS TO BE TAKEN IN COLD AREAS e Perform the warming up operation carefully If the machine isn t properly warmed up before operating the control levers its response to the controls will be slow and this may cause unexpected
152. e The coolant used in the air conditioning system is very dangerous If it is sprayed into the eyes or in case of contact with the skin wash with plenty of water and consult a doctor without delay Furthermore to avoid any explosion do not generate sparks and do not use naked flames near the air conditioner e The coolant contained in the air conditioning system is considered special waste and must be collected and disposed of according to the antipollution regulations in force e For specific maintenance operations to be performed on the air conditioning system contact your Ko matsu Dealer Non compliance with these instructions may cause serious damage and even death The cab ventilation and cooling functions have the specific purpose to reduce the operator s stress when the out side temperature is particularly high The internal air recirculation ensures quicker cooling and is very useful when working in areas where air pollution is considerable tunnels dusty places small or badly ventilated rooms etc Air distribution is obtained by means of a series of adjustable vents with variable flow rate both for the air flow in side the cab and for the air flow with defogging function IMPORTANT e At the beginning of the summer and before using the air conditioner clean the intake filters see 4 9 9 d CLEANING THE INSIDE AND OUTSIDE FILTERS OF THE AIR CONDITIONER e Do not use the air recirculation function for long periods in rainy
153. e ignition key to position I and press the hammer control button 4 to release the residual pressure from the hammer delivery pipe 3 Turn the ignition key to position O and remove it 4 Remove the plugs of the machine pipes and of the hammer hoses Use 41 and 50 mm wrenches 5 Connect the right pipe to the coupling 1 and the left pipe to the coupling 2 making sure that the characteristics and the size of the pipe fittings are as required Ay CAUTION e When connecting the pipes take care to prevent any impu rities from getting into them RKAB6980 RWA19820 291 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 6 Turn the selection valve lever 3 anticlockwise until reaching the stop position 7 Startthe machine and raise the demolition hammer positioning it vertically 8 Stop the machine again and lubricate the arm connection joints see 4 9 7 LUBRICATION and the hammer see the specific operation and maintenance manual 9 Before starting work check the tightness of the circuit A WARNING e Wear thick gloves and safety goggles during this check e To check the system for leakages use a piece of cardboard or a wooden board 6 2 3 2 REMOVING THE HAMMER To remove the hammer proceed as follows 1 Position the hammer on the ground taking care to choose a level surface and make sure that it is safe and stable even after disconnection fr
154. e ignition switch is turned to po sition ON the fuse 1 may have blown Open the cover on the right side of the machine to check the fuse and change it if neces sary NOTE e The main fuse is the high capacity fuse installed to protect the electric components and the wiring 3 2 14 CONTROLLER IMPORTANT e Avoid letting water mud or liquids fall on the controller since this may cause damage e If any anomaly is observed on the controller contact your Komatsu Dealer The controller is positioned behind the operator seat 108 AFER 9JA03153 RKA18550 INSTRUMENTS AND CONTROLS 3 2 15 VENTILATION AND HEATING The ventilation and heating of the cab serve to reduce the operator s stress both in summer and in winter these functions also serve to eliminate condensate from the front windshield thus ensuring visibility during both work and travel Air distribution is obtained by means of a series of adjustable vents with variable air flow both for the air flow inside the cab and for the air flows with defrosting and defogging function The ventilation and heating system can also include a function for the recirculation of the air inside the cab This function ensures quicker heating and is very useful when working in areas where air pollution is considerable tun nels dusty places small or badly ventilated rooms etc IMPORTANT e Do not use the air recirculation function for long periods in ra
155. e in any position different from that illustrated below since it may lose stability IMPORTANT e For details on the weight of the machine see paragraph 5 1 TECHNICAL DATA e The lifting procedure is valid only for standard machines e The lifting method changes depending on the accessories and optional equipment installed on the ma chine In these cases contact your Komatsu Dealer who can supply you with more precise information The lifting operation must be carried out on a level surface by proceeding as indicated below 1 Start the engine then swing the turret so that the work equip ment is positioned on the sprocket side 1 with the under carriage and the turret parallel to each other 2 Extend the bucket and arm cylinders completely then lower the work equipment to the ground as indicated in the dia gram on the right using the boom cylinder 3 Lower the blade to the ground 9JA03207 4 Shift the safety lever to the locked position RKA18280 174 TRANSPORTING THE MACHINE 5 Stop the engine make sure that the space around the cab is clear then get off the machine Close the cab door and the front window 6 Passthe metal cables between the first and the second carri er roller starting from the front and between the first and the second carrier roller starting from the back IMPORTANT e Do not attempt to lift the machine by attaching a metal ca
156. e left travel lever the same way 18730 145 USE OF THE MACHINE CHANGING DIRECTION WHEN THE MACHINE IS MOVING Shift the left travel lever to neutral to steer to the left while travel ling forward NOTE e To steer to the right operate the right travel lever in the same way HOW TO CARRY OUT COUNTER ROTATIONS SPIN TURN To carry out a counter rotation to the left pull the left travel lever backward and push the right travel lever forward NOTE e To carry out a counter rotation to the right pull the right travel lever backward and push the left travel lever forward 146 RKA18740 9JA03193 USE OF THE MACHINE 3 3 12 SWINGING THE TURRET WARNING e Before using the swing function make sure that the sur rounding area is free of obstacles 2 0 1 Use the left work equipment control lever 1 to swing the tur ret 2 When the swing function is not used shift the left work equip ment control lever 1 to neutral N The swing brake will be engaged RKA18750 147 USE OF THE MACHINE 3 3 13 WORK EQUIPMENT CONTROLS AND FUNCTIONS The work equipment is controlled by means of the right and left work equipment control levers The left lever con trols the arm and the turret swing while the right lever controls the boom and the bucket When the levers are re leased they
157. e machine or when installing or removing the work equipment appoint a super visor and follow his her instructions during work When working with other people any misunderstanding may cause serious accidents 56 2 4 4 STOP THE ENGINE BEFORE CARRY ING OUT ANY MAINTENANCE OPER ATION OR INSPECTION e Park the machine on firm and level ground e Choose a place where there is no risk of falling stones land slips or floods e Lower the work equipment completely to the ground e Shift the work equipment control lever to neutral and the safety lever 1 to position lock then stop the engine e Engage the safety device of the boom swing control and fit the turret swing safety pin e Place blocks under the tracks to prevent the machine from mov ing PRECAUTIONS FOR MAINTENANCE RKA18360 p e 00860 d 18270 18370 57 PRECAUTIONS FOR MAINTENANCE 2 4 5 MAINTENANCE OPERATIONS TO BE CARRIED OUT WITH THE ENGINE RUNNING REQUIRE THE PRESENCE OF TWO OPERATORS To avoid injuries do not carry out maintenance operation with the engine running Otherwise the presence of two operators who must proceed as indicated below is required e One operator must always be seated in driving position and be ready to stop the engine at any moment The operators must be constantly in contact with each other e Shift the safety lever 1 to po
158. e or less horizontal position of the bucket teeth e When the swinging movement starts or ends the brake valve emits a noise e When the machine travels down a steep slope at low speed the travel motor brake valve emits a noise 3 7 3 REMOVING THE MACHINE A WARNING 091100 091110 e When removing the machine use metal cable suitable for the weight of the machine e Do not apply sudden loads to the metal cable If the machine is stuck in mud and cannot get out using its own power or if the traction force of the excavator is used to remove a heavy object use a metal cable and proceed as illustrated in the diagram on the right Position wooden blocks between the wire cables and the machine body in order to prevent the cables from damaging the body it self CAUTION e The maximum applicable force is 5000 kg 180 RYA00810 3 7 4 DEMANDING OPERATING CONDITIONS TROUBLESHOOTING e When carrying out digging operations with the machine immersed in water if the water reaches the work equip met coupling pins lubricate them every time the machine is used e When carrying out deep excavations or demanding digging operations grease the work equipment coupling pins before every single operation After applying grease operate the boom the arm the bucket and the blade more than once and grease again 3 7 5 IF THE BATTERY IS DOWN WARNING I
159. e window open lower the lever 1 until engaging it in the lower coupling pin 2 as shown in Figure D D p RKAB6900 3 Rotate the window towards the front of the machine until en gaging the coupling 4 in the rubber element 5 as shown in Figure E To close the window turn the knob 6 and release the rubber ele ment 5 from the coupling 4 Close the side windows and cou ple the lever 1 to the lower pin 2 as indicated in Figure A IMPORTANT e When the rear window is partially open or completely closed it must always be locked by coupling the lever 1 with the lower 2 or upper 3 pin e When the rear window is rotated towards the front of the machine in order to open it completely make sure that it is fixed in the relevant rubber element 5 e Periodically lubricate the rubber element 5 with specific greases in order to facilitate the coupling operation 101 INSTRUMENTS AND CONTROLS 3 2 8 CAP WITH LOCK Use the ignition key to open and close the caps and covers with lock For details on the position of caps and covers with lock see 3 3 23 LOCKING THE MACHINE Insert the key completely into the lock and turn it If the key is turned before having been inserted completely it may break OPENING AND CLOSING THE CAPS WITH LOCK Opening 1 Insert the key into the lock 2 Turn the key counterclockwise and open the cap Closing 1 Tighten the cap thoroughly and insert the ke
160. eat belt and its couplings If they are damaged replace them with new parts 119 USE OF THE MACHINE 3 3 2 DAILY CHECKS Carry out the checks listed in this section every day before starting the engine 3 3 2 1 CHECKING THE COOLANT LEVEL AND TOPPING UP WARNING e Do not open the radiator cap unless such operation is absolutely necessary Before checking the cool ant level wait for the engine to cool down Carry out this check using the expansion tank e Immediately after the engine has stopped the coolant is very hot and the pressure in the radiator is very high Removing the radiator cap in these conditions to check the coolant level may pose a burn hazard Wait for the temperature to lower then turn the cap slowly to release the pressure before removing it completely 1 Open the engine hood and make sure that the coolant level is included between the MIN and MAX marks on the expan sion tank of the radiator 1 figure on the right If the level is low top up through the filler neck until reaching the MAX mark 2 Putback the cap after topping up 3 If the expansion tank is empty there may be a coolant leak Y Wo age After checking immediately provide for the necessary aX i repairs If there is no anomaly check the coolant level in the radiator If the level is low add coolant in the radiator and tin then in the expansion tank 1 nm NS
161. ect the pipes to the quick coupler making sure that the characteristics and dimensions of the fittings 6 correspond to those indicated in the diagram NOTE e For the characteristics of the threads and the functions of the equipment couplings refer to the user manual provided by the manufacturer RKAB8200 3 After connecting the pipes start the engine see 3 3 6 STARTING THE ENGINE and let it idle for at least 10 min utes 4 Lift the equipment from the ground and convey pressurized oil to the coupler a dozen times in such a way as to bleed the circuit 5 After the bleeding operation stop the engine and wait at least 5 minutes before starting work This will eliminate the air bub bles accumulated inside the tank 6 Make sure that there are no oil leakages and remove any oil that may have been spilled IMPORTANT e In case of doubts regarding the connection of the hydraulic circuit to the equipment contact your Komatsu Dealer RKA11280 296 INSTALLING AND REMOVING THE ADDITIONAL COUNTERWEIGHT 6 5 INSTALLING AND REMOVING THE ADDITIONAL COUNTER WEIGHT WARNING e To lift the additional counterweight use properly dimen sioned cables and avoid using worn cables or cables with broken strands e Do not lift the additional counterweight in any other way than described here below since it may lose balance e When lifting the additional counterweight make sure that it i
162. ecure them with a suitable retainer e Immediately remove any flammable materials that may have accumulated around the battery the ex haust silencer or other hot parts of the engine Any oil or fuel leakages may set the machine on fire Check carefully repair any anomaly or contact your Komatsu Dealer If the machine is inclined position it horizontally before carrying out the checks Carry out the checks and the cleaning operations listed below every day before starting the engine 1 Check the work equipment the cylinders the articulations and the pipes for damage wear excessive play If any anomaly is observed provide for the necessary repairs 2 Remove any trace of dirt and dust from the area around the engine the battery and the radiator Check for accumulated dirt or dust around the engine or the radiator Check also that there is no flammable material dry leaves twigs grass etc accumulated around the battery or the hot parts of the engine for example the exhaust silencer Remove any trace of dirt or flammable material Carefully check for the presence of dust in particular be tween the exhaust silencer 1 and the relevant cover 2 3 Make sure that there are no water or oil leakages around the engine Make sure that there are no oil leakages from the engine or coolant leakages from the cooling system If any anomaly is observed provide for the necessary repairs 4 Make sure that there are no oil leakages from t
163. engine which means being exposed to considerable noise for long periods wear headsets or ear plugs 59 PRECAUTIONS FOR MAINTENANCE 2 4 12 PRECAUTIONS TO BE TAKEN WHEN USING THE HAMMER When the hammer is used the pins may come off and metal parts may be pushed out causing serious injuries Always proceeds as follows e If rigid metal parts like pins bucket teeth cutting edges or bear ings are hit by a hammer some pieces may come off and cause serious injuries Always wear safety goggles and gloves e When the bucket pins or teeth are hit the broken parts may be thrust in the air and cause injuries to the people in the vicinity Always make sure that there is no one around e If the pins are hit with force these may move suddenly and cause injuries to the people standing nearby 2 4 13 REPAIR WELDS V S wv 00930 Welding operations must be always carried out by a qualified welder a place where suitable equipment is able Welding operations may be the cause of fire and electrocution therefore do not allow unauthorized person nel to make welds 2 4 14 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL e Keep away from naked flames while refuelling or adding oil e Spilled fuel or oil make the ground slippery and may cause acci dents clean any dirty area immediately and carefully e Always tighten the safety caps of the fuel tank and of the hy draulic oil tank
164. ep to the indications given in the table on the right Changing the hydraulic oil filter cartridge in the work equipment line if installed As a general rule change the cartridge after 500 hours of oper ation of the hammer operating percentage for the hammer 5096 or more and successively change the cartridge according to the instructions given in the table on the right Replacement interval H Replacement interval for hydraulic oil 4000 Replacement interval for hydraulic oil type HEES 3000 2000 Work equipment line filter 1000 500 20 40 60 80 100 Breaker operating ratio Hydraulic tank element RKA18960 213 MAINTENANCE PROCEDURES 4 9 MAINTENANCE PROCEDURES 4 9 1 WHEN REQUIRED 4 9 1 a CHECKING CLEANING OR CHANGING THE AIR FILTER CARTRIDGE WARNING e Remove the air filter only after stopping the engine and do not start the engine if the air filter is open e When compressed air is used to clean the filter dust may get into the eyes Wear safety goggles and a dust mask during the cleaning operations IMPORTANT e The air filtering system consists of a primary filtering element with considerable capacity and of a sec ondary cartridge that ensures additional safety protection The primary element can be cleaned with compressed air while the safety cartridge can only be changed e Clean the filtering element if the red piston in the filter
165. ervisor and follow his instructions and signals Bucket cylinder 1 Position the bucket in contact with the ground NOTE e When removing the pins position the bucket so that its contact Link with the ground is superficial If the contact of the bucket with the ground is complete or it has been lowered too powerfully re sistance increases and it becomes more difficult to remove the pins AW35782B IMPORTANT e After removing the pins make sure that they do not come into contact with mud or sand Both ends of the bushings are equipped with dust seals that must not be damaged 2 Remove the lock bolts and the nuts then extract the pins A and B and remove the bucket 3 Align the arm with the holes 1 of the bucket to be installed and the articulation with the holes 2 then grease the pins A and B and fit them in the holes 1 and 2 respectively IMPORTANT e Install the bucket carefully following the reverse order 090960 e During the installation of the bucket the O rings may be easily damaged therefore it is advisable to position them in the arm as shown in the diagram 3 on the right When hitting the pins move the O ring downward in the apposite groove 4 4 Install the lock bolts on each pin then grease it Bucket Arm O ring 9 03315 160 USE OF THE MACHINE 3 3 21 PARKING THE MACHINE WARNIN
166. es not light up or the acoustic alarm does not sound there is probably a burnt bulb or a dis connected element so contact your Komatsu Dealer for the necessary repairs After approximately 3 seconds the warning lights and indica tors listed below will remain on while the others will go out e Battery charge level warning light 3 e Engine oil pressure warning light 4 e Engine coolant temperature indicator 5 e Fuel level warning light 8 USE OF THE MACHINE RKA18570 RKA18280 RYA17290 RKA18580 131 USE OF THE MACHINE 132 2 Press the horn button 11 to make sure that the horn func tions correctly 3 Press the light switch 12 to switch on the work lights If they do not light up there is probably a burnt bulb or a dis connected element so contact your Komatsu Dealer for the necessary repairs AM089470 RKA19270 USE OF THE MACHINE 3 3 6 STARTING THE ENGINE 3 3 6 1 STARTING THE ENGINE IN NORMAL OPERATING CONDITIONS WARNING e Before starting the engine carefully read the instructions and information regarding safety contained in this manual and make sure that you know the controls From the moment at which the engine is started the operator is directly responsible for any damage that may be caused by wrong manoeuvres and non compliance with the safe
167. etween the carrier roller the idler roller and the rubber track The rubber track may come off the guide also in the following con ditions e When the machine steers but the rubber track cannot move lat erally due to the obstacle over which the machine is moving or due to any other obstacle e When the rubber track is not aligned and the idler roller or the carrier roller are not aligned with the centre 166 255 29274 Roo xf Roh te 5 x9 Kod d sA 00 gt gt e 052 x 52 5 255 9 6 4 lt gt 2 5 S 5 RYA02800 po KF gt x9 999 SSK 22 55 55 029 9 x K 9 Se KR OX xD 5 y 505 RYA05830 RYA02810 e If the machine travels in reverse in these conditions the rubber track will come off e If the machine steers in these conditions the rubber track will come off USE OF THE MACHINE 5555 5 Bx 22 Boxe 55 659 Ne 5 en 554 9 RRS 4 26 eoe 554 54 594 5 Kool R lss by RRA 7 YRS RYA02820 55555059 50040020040 SOR 555555555505 0 5 5 3 xd zd 5 655 5565 PRS RYA02830
168. f radiator pressure valve Red area of engine coolant tempera ture indicator lights up Engine coolant level low coolant leakage Fan belt slack Mud or limestone accumulated in cooling system Radiator fins damaged or closed Faulty thermostat Radiator cap loose work at con siderable heights Faulty coolant level sensor Check top up repair see CHECKS TO BE CARRIED OUT BEFORE STARTING THE EN GINE Adjust fan belt tension see EVE RY 250 HOURS OF OPERA TION Change fluid and clean cooling system see WHEN REQUIRED Clean or repair see EVERY 500 HOURS OF OPERATION Change thermostat Tighten cap or change gasket Change sensor White area of engine coolant tempera ture indicator lights up even after sev eral hours of operation Faulty thermostat Change thermostat Engine does not start with starter run ning Fuel level too low Air in the fuel system Pump or fuel injection nozzle faulty Starter makes engine run slowly Preheating warning light does not come on Faulty compression Excessive valve clearance Refuel see CHECKS TO BE CARRIED OUT BEFORE START ING THE ENGINE Repair point where air is sucked in see EVERY 500 HOURS OF OP ERATION Change pump or nozzle See ELECTRICAL SYSTEM See ELECTRICAL SYSTEM Adjust valve clearance Exhaust gases w
169. f the prescribed type through the hole G until reaching a level included between the H and L marks on the dipstick G Put back the dipstick G and close the cover 2 Swing the turret more than once then stop the machine and check the level again Use oil of the prescribed type See 4 4 FUEL COOLANT AND LUBRICANTS 9JA04983 MAINTENANCE PROCEDURES 4 9 10 b CHANGING THE OIL IN THE FINAL REDUCTION GEARS WARNING e As soon as the machine has been stopped the oil is very hot and may cause burns let the oil cool down until reaching 40 45 C before changing it e Loosen the cap slowly to release any residual pressure e Oils filters the coolant and the battery are considered special waste and must be collected and dis posed of according to the regulations in force This operation must be carried out on each reduction gear with the machine parked on level ground and at a temperature of 40 45 C so that the oil becomes fluid and can be drained easily which facilitates the elimination of any suspended solid particles e Filling capacity of each reduction gear 1 3 1 Move the machine until the drain plug P is in low position and perpendicular to the ground 38 2 Remove the drain plug P and let the used oil flow out com 2 af pletely gathering it into a container with suitable capacity While the oil flows out remove the level plug G 3 O
170. first time after the first 50 hours of operation and successively every 500 hours IMPORTANT e If the machine is equipped with demolition hammer the hydraulic oil deteriorates much earlier than dur ing normal bucket operations For further details on maintenance see 4 8 2 MAINTENANCE INTER VALS IN CASE OF USE OF THE HYDRAULIC BREAKER The filter is positioned on the hydraulic system drain outlet and it holds the metal particles that come off the various components due to wear The filter can be reached after opening the side cover 1 To replace the filter proceed as follows Retract the arm and bucket cylinders completely and lower the boom until the bucket teeth rest on the ground N Lower the blade to the ground 3 Stop the engine and eliminate the residual pressure from the work equipment by shifting the controls more than once 4 Open the side cover 1 and slowly loosen the filler cap F to release any residual pressure from the tank 252 5 Loosen the two screws 2 and remove the triangular cover 3 During this operation be careful to the thrusting force of the spring 3 6 Remove the spring 3 the valve 4 and extract the cartridge 5 7 Carefully clean the filter casing and change the cartridge 5 8 Reassemble the whole by proceeding in the reverse order and make sure that the gasket of the cover 2 is not dam aged and is correctly housed in its seat 9 I
171. fter starting the engine and do not operate any control lever or the hand accelerator 6 Make sure that the charge level warning light 4 and the en gine oil pressure warning light 5 do not light up ato om R888888 e 9JA03319 134 3 3 6 2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES WARNING e Before starting the engine carefully read the instructions and information regarding safety contained in this manual and make sure that you know the controls From the moment at which the engine is started the operator is directly responsible for any damage that may be caused by wrong manoeuvres and non compliance with the safety regulations and the rule of the road e Do not attempt to start the engine by causing a short cir cuit with the terminals of the starter This may cause seri ous injury or even fires e Start the engine only while seated with fastened seat belt e Before starting the engine make sure that there is no one within the operating range of the machine and sound the horn e Never use starting aid fluids or products as they may cause explosions e Exhaust gas is toxic When starting the engine in closed places make sure that there is sufficient ventilation IMPORTANT e Do not attempt to start the engine with the hand accelerator set at the maximum rpm in order to avoid
172. g out any check or touching the hot parts 925926 595 555550550 Ne SKS 599502 x 4 22 won 22 55 e Before checking the coolant level stop the engine and let the fluid cool down If a check is necessary due to the overheating of the engine slowly loosen the radiator cap to release any residual pressure before removing it The hot fluid that spurts out may cause seri ous burns e 2924 P 925 Qe 255 0 5 52 Mert po RYA00380 e Before checking the engine oil and hydraulic circuit oil levels stop the engine and let the oil cool down The hot oil that can be sprayed out of the tank may cause serious burns 5 229 OR ROKR MD S CX XX S zZ 60 250 its x 5 55 599 OOO IS 056 00370 2 2 13 PREVENTING FIRES DUE TO FUEL AND OIL Fuel oil and some types of antifreeze can easily ignite if they get in contact with a flame Fuel is lammable and therefore very dan gerous e Keep any naked flame away from flammable fluids e Stop the engine and do not smoke when refuelling e Refuel and add oil only after stopping the engine and in well ventilated places e Refuel and add oil in a well delimited area and do not allow un authorized persons to approach e When refuelling hold the fuel gun firmly and keep it constantly in contact with the filler until you have finished in order to avoid sp
173. g speed When the quick deceleration switch is pressed again the corre sponding warning light goes out and the engine speed returns to the rpm selected with the hand accelerator NOTE e When the hand accelerator is set on idling speed this cannot be further reduced not even by pressing the quick deceleration Switch e If the engine speed cannot be increased this may be due to the fact that the switch is pressed Check the quick deceleration warning light to verify the condition of the switch e If the ignition switch is turned to position OFF when the quick deceleration switch is in position ON the deceleration function is deactivated 4 Horn push button This button is positioned at the centre of the right lever knob and serves to send out a warning signal at the beginning of work and in case of danger 84 AM089480 AM089470 5 Work light switch This switch 5 turns on the work light including an additional one and the corresponding warning light 6 Acoustic alarm stop switch This switch 6 is used with the engine running to stop the acoustic alarm when this sounds to alert the operator in case of failure 7 Revolving light switch optional This switch 7 is used to start the revolving light INSTRUMENTS AND CONTROLS RKA19270 RKA19280 RKA19300 85 INSTRUMENTS AND CONTROLS 8 Pump s
174. g this operation pull the belt slightly to make sure that it is correctly locked Unfastening the seat belt Press the button 5 on the buckle 4 and remove the tang 3 from the buckle 4 The belt is automatically retracted at this point seize the grip 2 and slowly help the belt manually into the retractor 1 130 9JH01730 3 3 5 OPERATIONAL CHECKS A WARNING e When starting the engine make sure that the safety lever is in the locked position e If the control levers are not locked and are inadvertently touched when the engine is started the work equipment may move suddenly and cause serious accidents 1 Make sure that the safety lever is in position lock NOTE e The engine cannot be started if the safety lever is not in position lock 2 Make sure that all control levers are in neutral 3 Insert the key in the ignition switch 2 turn the key to posi tion ON then carry out the following checks 1 The acoustic alarm sounds for approximately 1 second then the warning lights and indicators listed below come on for approximately 3 seconds e Battery charge level warning light 3 e Engine oil pressure warning light 4 e Engine coolant temperature indicator 5 e Engine coolant temperature warning light 6 e Fuel level warning light 7 e Fuel gauge 8 e Quick deceleration warning light 9 e Pre heating warning light 10 If a warning light or indicator do
175. ge quantities of metal particles contact your Komatsu Dealer e f the machine is provided with a fuel filter in the filler neck do not remove it while refuelling e Check and change the oil in a clean place and prevent any impurity from getting into the tank e Before carrying out any maintenance operation hang a warning plate to the ignition switch and the control levers to prevent anyone from starting the engine e When performing maintenance operations always take the precautions indicated in the safety plates applied to the machine e Instructions for arc welding 1 Turn the ignition key to position OFF 2 Disconnect the battery first the negative pole and then the positive pole 3 Disconnect the alternator 4 Do not apply more than 200V continuously 5 Connect the earth cable within 1 m from the point where the welding operation must be carried out 6 Avoid placing gaskets and bearings between the welding area and the earth cable If the earth cable is con nected near instruments connectors etc these may not function correctly 7 Do not use the area around the work equipment pins or the hydraulic cylinders as earth e Do not use flammable fluids to clean any parts of the machine e Keep naked flames away from these fluids and avoid smoking When O rings and gaskets are removed clean the sealing surfaces thoroughly and replace the O rings and gaskets with new ones Fit the O rings and gaskets correctly when reassem
176. gni tion key 3 to position START to start the engine As soon as the engine starts release the key 3 which will automatically return to position ON Let the engine idle for the first 15 seconds soon after starting the engine and during this lapse of time do not operate any control lever or the hand accelerator Make sure that the charge level warning light 5 and the en gine oil pressure warning light 6 go out RKA16310 RKA16320 RYA17370 Blo om E Es 58888 8 mec 6 S 9JA03320 USE OF THE MACHINE 3 3 7 AFTER STARTING THE ENGINE A WARNING e Emergency stop if there is any anomaly or malfunction turn the ignition switch to position OFF e If the work equipment is operated without warming up the engine sufficiently the response of the work equipment to the movements of the control levers will be slow and in some cases the work equipment will not behave as desired by the operator so always carry out the warming up procedure in particular when working in cold areas or climates 3 3 7 1 RUNNING IN CAUTION e Komatsu machines are adjusted and tested completely before shipment However operating the ma chine under severe conditions at the beginning can adversely affect the performance of the machine and shorten its life The running in stage should last for the first 100
177. h a way as to clearly understand what are the correct operating conditions and the dangerous conditions that must be avoided In case of loss or damage request a new copy to Komatsu or your Komatsu Dealer The illustrations contained in this manual may represent machine configurations available on request Komatsu machines are constantly improved in order to increase their efficiency and reliability this manual sums up all the information regarding the most recent technology applied at the moment in which the machine is launched For any further and or updated information contact your Komatsu Dealer Punctual periodic annotations regarding the maintenance operations that have been carried out are important since they provide a clear report on the situation and say exactly what has been done and what has to be done after the next maintenance interval Therefore it is advisable to consult both the hour meter and the mainte nance plan frequently Over the years Komatsu Dealers have gathered considerable experience in customer service If more information is needed do not hesitate to contact your Komatsu Dealer he always knows how to get the best performance from the machine he can recommend the equipment that is most suitable for specific needs and can provide the technical assistance necessary for any change that may be required to conform the ma chine to the safety standards and traffic rules Furthermore Komatsu Dealers also offer assista
178. he check after 200 hours of operation e If the screws 1 become loose and are not tightened at the required torque the useful life of the tracks will be shorter e After tightening make sure that the nut and the track are in contact with the surface of the link The check must be carried out with the machine parked on level ground How to tighten the steel tracks Tighten the screws with an initial torque of 118 19 6 Nm 12 2 kgm making sure that the nut and the track are in contact with the surface of the link Then give an additional turn of 90 10 How to tighten the road liners Tighten the screws with a torque of 196 19 6 Nm 20 2 kgm making sure that the nut and the track are in contact with the sur face of the link Tightening sequence The screw tightening sequence for each element must be 1 2 3 4 as shown in the figure After tightening make sure that the nut and the track are in con tact with the surface of the link 220 AE301700 AE302590 AD053090 MAINTENANCE PROCEDURES 4 9 11 CHECKING AND ADJUSTING THE TRACK TENSION For machines equipped with steel tracks road liners The pins and bushings of the undercarriage wear out to different degrees depending on the work conditions and on the characteristics of the surface on which the machine works Therefore it is necessary to check the track ten sion frequently and to adjust it when necessary
179. he hydraulic system the hydraulic tank pipes and joints If any anomaly is observed provide for the necessary repairs 5 Check the undercarriage tracks sprocket idler roller guard and make sure that there are no damaged parts signs of wear loose bolts or oil leakages from the rollers If any anomaly is observed provide for the neces sary repairs 6 Check the handrails and the steps for any anomaly If any anomaly is observed provide for the necessary re pairs Tighten any loose bolts 7 Check the indicators and the machine monitor for any anomaly If any anomaly is observed provide for the necessary repairs Remove any trace of dirt from all surfaces 9JA03554 118 10 USE OF THE MACHINE Check if the windows are damaged or if they are out of place In case of damage or displacement provide for the necessary repairs In particular if a window has broken or gone out of place during work immediately pro vide for the necessary repair Do not attempt to continue work if the necessary repairs have not been carried out Check and clean the rear view mirror Check the rear view mirror for any anomaly and replace it with a new one if it is damaged Keep the rear view mirror clean and adjust its inclination so that the rear lower part of the machine which cannot be seen be cause of the engine hood is visible from the operator seat Seat belt and couplings Make sure that there are no anomalies in the s
180. he rubber track and install the steel track or the road liner 2 Install the idler roller guard 2 with the relative bolts 1 230 4 9 1 k ADJUSTING THE BUCKET CLEARANCE WARNING e Any accidental movement of the work equipment during the adjustment of the bucket clearance is dangerous Lower the work equipment to the ground in a stable posi tion then shift the safety lever to position lock and stop the engine 1 Position the work equipment as indicated in the diagram on the right then stop the engine and shift the safety lever to po sition LOCK 2 Move the O ring 1 of the articulation and measure the clear ance a The measurement is easier if the bucket is moved completely to one side right side in the diagram or the other so that the entire clearance can be measured in a single point To obtain a precise measurement use a gauge 3 Loosen the 4 plate bolts 2 and loosen the plate 3 The shim is of the type in two pieces therefore the operation can be carried out without removing the bolts 4 Remove a number of shims 4 corresponding to the dimen sion of the clearance One pair of shims makes up a set and each single shim measures 0 5 mm If the clearance is smaller than one single shim do not attempt to tighten the bolt 2 to carry out the adjustment 5 Tighten the four bolts 2 If the bolts 2 are too stiff to be tightened extract the bolt 5 that retains the pin
181. heat and cause an explo sion RYA02970 Connect the positive clamp of the battery charger to the pos itive terminal of the battery then connect the negative clamp of the battery charger to the negative terminal of the bat tery Make sure that the clamps are secured firmly Set the recharge current at 1 10 of the value of the rated capac ity of the battery in case of a quick recharge set it to a lower value than the rated capacity of the battery If the recharge cur rent is too high the electrolyte may flow out or dry up and this may cause the battery to ignite and explode If the battery electrolyte is frozen do not charge the battery or start the engine with a different power supply This may lead to the ignition of the electrolyte and the explosion of the battery Do not use or charge the battery if the electrolyte level is below the MINIMUM mark This may cause an explosion Check the electrolyte level periodically and top up with distilled water until reaching the MAX reference mark 183 TROUBLESHOOTING 3 7 8 STARTING WITH BOOSTER CABLES When starting the engine with booster cables proceed as indicated below 3 7 8 1 CONNECTING AND DISCONNECTING THE BOOSTER CABLES WARNING e When connecting the cables avoid any contact between the positive cable and the negative cable 2 5 lt lt LLE ZERO 55555550 gt Loon 20 495
182. hine immersed in water if the depth ex 77003362 ceeds the allowed limits under the centre of the carrier roller 1 Furthermore when a component has been immersed in water for along time grease it using a pump until the old grease comes out of the bearings around the bucket pins 9JA03543 154 3 3 17 MOVING ON SLOPES WARNING e When travelling downhill on steep slopes slow down using the travel levers and the hand accelerator Do not travel downhill on slopes whose inclination exceeds 15 Steering or using the work equipment during operations on slopes may cause the machine to lose balance and over turn therefore it is advisable to avoid such operations It is particularly dangerous to swing the turret on slopes when the bucket is full If such operations have to be carried out pile soil and cre ate a platform so that the machine can be kept horizontal during work Do not travel up or down steep slopes since the machine may overturn During travel lift the machine at about 20 30 cm from the ground Do not move the machine downhill in reverse Do not change direction on slopes side movements must be carried out on level ground or with inclination not ex ceeding 10 Always operate the machine or travel in such a way as to be able to stop it safely at any time if it slips or becomes unstable When travelling uphill if the tracks slip or if it is
183. hite or light blue Too much oil in oil pan Unsuitable fuel Quick acceleration soon after cold start of the engine Add oil up to specified level see CHECKS TO BE CARRIED OUT BEFORE STARTING THE EN GINE e Change with fuel in compliance with standards Avoid quick accelerations until en gine has warmed up 189 TROUBLESHOOTING TROUBLE MAIN CAUSES SOLUTION Air filter clogged Clean or replace see WHEN RE Exhaust gases occasionally become QUIRED black Faulty nozzle Change nozzle Faulty compression See Faulty compression Combustion noise occasionally re Faulty nozzle Change nozzle sembles a blow Fuel with low cetane rating Change with fuel in compliance with standards Abnormal noises during combustion s overeating mee arca of enone goplani or in mechanical parts temperature indicator lights up Inside of exhaust silencer dam Change exhaust silencer aged Excessive valve clearance Adjust valve clearance Fuel pump prefilter clogged Change filter cartridge Engine stepsiquringropersuete Faulty engine and fuel pipe Check and repair 190 TROUBLESHOOTING 3 7 10 4 ELECTRONIC CONTROL SYSTEM If an error code appears on the display of the machine 1 it normally displays the time adopt the counteractions described in the following self diagnostics table
184. hours of operation as indicated by the hour meter During running in follow the instructions given in this manual e After starting the engine let it idle for 5 minutes e Avoid using the machine with excessive loads and avoid high speeds e Immediately after starting the engine avoid sudden starts sudden accelerations unnecessary sudden stops and sudden changes in direction 137 USE OF THE MACHINE 3 3 7 2 WARMING UP PROCEDURE IMPORTANT e Do not carry out any operation and do not shift the levers suddenly when the hydraulic oil temperature is too low The warming up procedure should be always carried out since it certainly ensures longer machine life e Do not accelerate abruptly before completing the warming up operations Do not let the engine run at idling or maximum speed for more than 20 minutes without interruption If it is neces sary to let the engine idle accelerate every now and then or increase the speed up to an intermediate value After starting the engine do not start working immediately Carry out the operations and checks indicated below 1 Turn the hand accelerator 1 to a central position between MIN and MAX and let the engine run at medium speed for approximately 5 minutes without load 2 Release the safety lever 2 and lift the bucket from the ground 3 Slowly operate the bucket control lever 3 and the arm con trol lever 4 in such a way as to make the bucket and arm cylinders re
185. ht of the transport means and of the machine Make sure that the dimensions of the machine are compatible with the road and any gallery subway bridge electric and telephone lines etc e Keep to the regulations in force regarding the permissible width height weight of the machine and the transport speed 52 2 3 4 BATTERY 2 3 4 4 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY e Electrolytic batteries contain sulphuric acid which can cause burns It can also corrode clothing and make holes in it In case of contact with battery acid immediately wash the affected part with plenty of water e Battery acid may cause blindness if sprayed into the eyes If acid gets accidentally into your eyes flush them immediately with plenty of water and consult a doctor without delay e If you accidentally swallow battery acid drink a large quantity of water or milk beaten egg white or vegetable oil and in any case antiacid substances like magnesia bicarbonate etc and call a doctor or a poison treatment center immediately e When handling batteries always wear safety goggles e Batteries produce hydrogen which is highly explosive and can easily ignite with small sparks or naked flames e Before working on the battery stop the engine and remove the ignition key e Avoid short circuiting the battery terminals through any contact even if accidental with metal objects or tools or by inverting them e Tighten the battery ter
186. hter Therefore be careful not to use the socket as a power source for 12 V electric equip ment since it may be damaged The capacity of the cigarette lighter is 85 W 24 V x 3 5 A 12 Overload alarm switch This switch 12 is used to activate the overload warning light The overload warning light can be activated by pressing part A The overload warning light can be deactivated by pressing OFF INSTRUMENTS AND CONTROLS ON OFF RKA18430 AM089410 OFF A RKA19290 87 INSTRUMENTS AND CONTROLS 13 POWER OUTLET There is a power outlet on the top of the cab for the connection of a lighting device for routine and maintenance operations It is a two pole outlet and is in compliance with the ISO 4165 1979 standard Power supply 24 V To activate the power outlet use the revolving light switch 14 CLAMSHELL BUCKET OPENING BUTTON IF IN STALLED This is a single function button and allows the opening of the clamshell bucket When it is released the bucket stops 15 CLAMSHELL BUCKET CLAMPING OR DEMOLITION HAMMER CONTROL BUTTON IF INSTALLED This is a single function button and allows the clamshell bucket to be clamped or the demolition hammer to be operated according to which equipment is installed on the machine When it is re leased the bucket or the hammer stops 88 RKAB6930 N S RKA19100
187. hts C Warning lights and indicators display B Emergency lights D Switches display 71 INSTRUMENTS AND CONTROLS 3 2 1 1 WARNING LIGHTS CAUTION e If a warning light blinks or comes on while the engine is running check the problem and carry out the necessary maintenance operations Do not neglect any problem signalled by the warning lights in order to avoid machine failures These warning lights must always be checked while the engine is running In case of anomaly the necessary re pair is indicated immediately In case of anomaly the corresponding warning light starts blinking and the acoustic alarm sounds fr xl HER E I HEBSSBH Ae 0 M 9JA04338 1 Battery charge level warning light 2 Fuel level warning light 72 1 BATTERY CHARGE LEVEL WARNING LIGHT This warning light 1 signals any anomaly in the charging system during the operation of the engine If the warning light blinks check the V belt tension In case of anomaly refer to paragraph 3 7 10 OTHER TROUBLES If the warning light blinks stop the engine or let it idle then check the problem and carry out the necessary repair NOTE e This warning light comes on when the ignition switch is turned to position ON with the engine off but this does not indicate any anomaly e When the engine is sta
188. ible material of some components may become extremely dangerous if it burns For this reason avoid any contact of burnt material with your skin or eyes and do not inhale its fumes e Do not carry out any inspection or maintenance operation not prescribed in this manual e Check the hour meter every day to verify if it is necessary to carry out any maintenance operation e Before opening the engine hood engage all the safety locks and stop the engine e f it is necessary to check the hydraulic oil level retract the bucket and arm cylinders completely and lower the bucket teeth to the ground e Carry out these operations on firm and level ground e Use Komatsu genuine oils and greases choose oils suitable for the ambient temperature e Use clean oils and greases Keep the oil and grease containers clean and prevent any foreign matter from get ting into them e Keep the machine thoroughly clean this facilitates troubleshooting In particular grease nozzles breather holes and the areas where fluid levels are checked should be kept clean to prevent the infiltration of impurities e Draining water or oil and changing filters soon after work is dangerous wait for the engine to cool down to a safe temperature of 40 45 C If itis necessary to drain the oil when it is cold warm it up to a suitable temperature approximately 20 40 C be fore draining it e When changing oils or filters check if metal particles are present If there are lar
189. ield 1 Open the front windshield then seize the grip A pull up and remove the lower windshield 9JH01582 2 After removing the lower windshield position it on the left in ner side of the cab then secure it with the locking lever B RKA18510 98 3 2 5 SLIDING DOOR A WARNING e Make sure that the sliding door is locked in the correct po sition both when open and when closed e Always stop the machine on a level surface when it is nec essary to open or close the door If the door is opened or closed on a slope the operating ef fort may change suddenly Do not open or close the door on slopes e Always use the handle 1 and the knob 2 to open or close the door e Be careful to your hands in order to prevent them from be ing caught between the door and the front or centre pillar e If there is anyone inside the cab warn him her before open ing or closing the door Lock When closing the door pull the handle backward to release the lock 3 then pull the door forward 3 2 6 EMERGENCY EXIT HAMMER WARNING e When it is necessary to break a window with the hammer be careful not to get injured by glass chips e Before leaving the operator cab remove any glass frag ments from the window edges and take care not to injure yourself Be careful not to slip on the glass fragments scat tered on the ground If for any reason
190. impossible to keep moving exploiting only the track force do not use the thurst force of the arm to move the machine more easi ly The machine runs the risk of overturning 1 When the machine travels downhill the sprocket 1 must be positioned on the side of the machine that is directed down ward If the machine travels downhill with the sprocket 1 on the side that is directed upward the tracks tend to loosen and the machine may slip USE OF THE MACHINE 00550 00560 20 30 15 max RKA17490 RKA17500 155 USE OF THE MACHINE 2 When travelling uphill on a slope position the work equip ment as shown in the diagram on the right RKA17480 BRAKING WHEN TRAVELLING DOWNHILL To brake when travelling downhill shift the travel levers to the neutral position In this way the brake will be applied automatically WHEN THE ENGINE STOPS ON A SLOPE If the engine stops while the machine is travelling uphill shift the travel levers to neutral stop the machine then start the engine again PRECAUTIONS TO BE TAKEN ON SLOPES e f the engine stops when the machine is a slope do not use the left work equipment control lever to swing the turret The turret will swing due to its own weight e Do not open or close the sliding door while travelling on slopes or carrying out any operation The effort required may change suddenly Always keep the s
191. in hydraulic tank Clean see EVERY 5000 HOURS OF OPERATION Hydraulic oil temperature increases excessively Fan belt slack Hydraulic oil too low Adjust fan belt tension see EVE RY 250 HOURS OF OPERA TION Top up oil until reaching correct level see CHECKS TO BE CAR RIED OUT BEFORE STARTING THE ENGINE Tracks come off Sprocket abnormally worn out Tracks excessively slack Adjust the track tension see WHEN REQUIRED Bucket can only be lifted slowly or cannot be lifted Hydraulic oil too low Top up oil until reaching correct level see CHECKS TO BE CAR RIED OUT BEFORE STARTING THE ENGINE Engine speed does not change not even using hand accelerator Quick deceleration switch in posi tion ON Press quick deceleration switch making sure that the correspond ing warning light goes out 188 3 7 10 3 ENGINE TROUBLESHOOTING TROUBLE MAIN CAUSES SOLUTION Engine oil comes on pressure warning light Oil level in oil pan too low air sucked in Oil filter cartridge clogged Faulty tightening of oil pipe or pipe coupling oil leakage from a defec tive point Faulty warning light Top up oil until reaching correct level see CHECKS TO BE CAR RIED OUT BEFORE STARTING THE ENGINE Change cartridge see EVERY 500 HOURS OF OPERATION Check and repair Change Steam comes out o
192. ine and wait at least 5 minutes before starting work This will eliminate the air bub bles accumulated inside the tank 6 Make sure that there are no oil leakages and remove any oil that may have been spilled IMPORTANT e In case of doubts regarding the connection of the hydraulic circuit to the equipment contact your Komatsu Dealer 294 8160 11260 ARRANGEMENT FOR THE INSTALLATION OF THE BUCKET QUICK COUPLING SYSTEM Third hydraulic line 6 4 ARRANGEMENT FOR THE INSTALLATION OF THE BUCKET QUICK COUPLING SYSTEM Third hydraulic line DESCRIPTION AND CONTROL A WARNING e Read the contents of the equipment instruction manual carefully before using the machine or carrying out mainte nance operations An hydraulically controlled quick coupler can be installed on the machine to enable the bucket or other equipment to be changed more easily and quickly An independent hydraulic circuit third hydraulic line controlled through a switch 1 positioned on left cabinet is used to connect and disconnect the bucket or other equipment This is a two position switch with automatic return to the centre equipped with a mechanical retainer 2 to prevent accidental im pacts COUPLING POSITION A To couple the bucket or other equipment press the lower part of the switch A 2 RELEASE POSITION B To release the bucket slide the safety lever 2 backward and at the
193. ines can vary in the different countries according to the climate and to the humidity percentage in the air Indicatively the distances indicated in the following table should be respected Cable voltage Min safety distance 1 0 kV distribution line 5m Sst 4 6 6 kV 2 3 insulators 5 2m S 33 kV min 3 insulators 5 5 m 66 kV min 6 insulators 6m 4 154 kV min 10 insulators 8m 7 275 kV min 19 insulators 10m BE RKA18300 36 GENERAL PRECAUTIONS 2 2 26 VISIBILITY e Make sure that there are no people or obstacles in the area surrounding the machine and check the conditions of the worksite to ensure that all operations and movements can be carried out safely e Switch on the work lights as soon as visibility decreases e If visibility is reduced due to mist smoke or heavy rain stop the machine in a safe position and wait for the weather to improve until visibility becomes acceptable 2 2 27 ROOM VENTILATION e Before starting the machine in confined or poorly ventilated places provide for proper ventilation or connect the engine ex haust pipe to a suction duct The engine exhaust gases can be deadly RKA00420 2 2 28 CHECKING THE SIGNALS OF THE SIGNALMAN AND THE FIXED SIGNS e Position signs to indicate the road edges and the fact that the ground may collapse If visibility is not good ask a colleague to direct
194. ing installation make the gasket come in contact with the sealing surface of the filter housing then give a further 1 2 turn 250 MAINTENANCE PROCEDURES 8 After changing the filter cartridge add engine oil through the filler neck F until reaching a level included be tween the and L marks on the dipstick To top up use oil suitable for the ambient temperature see 4 4 FUEL COOLANT AND LUBRICANTS 9 Put back the filler cap F start the engine and stop it after 5 minutes Check the level again and top up if necessary 10 Close the engine hood Start the engine make sure that there are no leakages and that the engine oil pressure warning light goes out IMPORTANT e Do not use the wrench to lock the filter in order to avoid damaging the filter itself and causing oil leakag es 251 MAINTENANCE PROCEDURES 4 9 9 c CHANGING THE HYDRAULIC OIL FILTER CARTRIDGE A WARNING e Soon after the machine has been stopped the hydraulic oil is very hot and may cause burns let it cool down to 40 45 C before changing the filter e The hydraulic system is under pressure slowly loosen the filler cap to release any residual pressure e Oils filters the coolant and the battery are considered special waste and must be collected and dis posed of according to the regulations in force CAUTION e On machines containing synthetic biodegradable type HEES this must be changed for the
195. ing the cartridge bleed the circuit For details on the bleeding procedure see 4 9 9 a BLEEDING THE CIRCUIT pos 9JA03354 218 MAINTENANCE PROCEDURES 4 9 1 c CLEANING THE FUEL TANK WARNING e When draining the fuel tank avoid spilling fuel since this may cause fires e If some fuel is accidentally spilled clean the dirty area immediately in order to prevent it from getting slippery and to avoid fires e Never use trichloroethylene to wash the inside of the tank Use exclusively diesel oil 1 Drain the fuel tank proceeding as indicated in points from 1 to 3 of paragraph 4 9 4 a DRAINING THE FUEL TANK 2 Remove the floor mat 3 Remove the cover 1 9JA03220 4 Remove the fuel sensor 2 9JA03221 5 Wash the inside of the tank carefully using only diesel oil 6 After the washing cycle tighten the drain valve 3 and install the fuel sensor 2 the cover 1 and the mat 7 Close the inspection cover 4 9JA03222 219 MAINTENANCE PROCEDURES 4 9 1 4 CHECKING THE TIGHTENING OF THE TRACKS For machines equipped with steel tracks road liners WARNING e compensate for the inevitable settling movements it is indispensable to check the tightening torque of the screws 1 after the first 30 hours of operation Carry out another check after the first 100 hours of run ning in and if the screws have become loose again repeat t
196. iny or cold days since this would increase the fogging of the inside of the windows 3 2 15 1 HEATING AND DEFROSTING CONTROL PANEL oe e 5 seu meso RKA18980 1 Temperature control switch 4 Air recirculation selection switch 2 Ventilation selection switches 5 Defrosting lever 3 Air flow selection switches 1 Temperature control switch This is a rotary switch used to start and stop the heating system and to control the temperature inside the cab OY YA The position ON or OFF is signalled by a click of the switch when this is turned completely anticlockwise The temperature can be adjusted by turning the switch Turning the switch clockwise red range increases the temperature while turning it anticlockwise g light blue range decreases the temperature RKA19030 109 INSTRUMENTS AND CONTROLS 2 VENTILATION SELECTION SWITCHES These switches are used to select the direction of the air coming from the heater and the selection is indicated by a LED The LEDs slide progressively and follow the direction of the ar rows stamped on the switches The selected flow is indicated by e O O the coming on of the corresponding LED P Three directions of the flow can be selected 7 27 v RKA19040 1 Air flow towards the operator s face 2 Ai
197. iodegradable oil in the hydraulic system drain the system completely disconnecting the cyl inders and all the parts that may contain traditional oil then change the drain filter with a new one Start the engine and let it idle before using the equipment wait for the engine temperature to reach at least 40 C then start moving the equipment to fill all the circuits with oil Stop the engine and check the oil level see 3 3 2 4 CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP 66 THE MACHINE AND ITS OPERATIONS
198. irt or other impurities from getting into them e When storing drums for a long period position them on one side so that the opening is lateral This prevents moisture from being sucked in through the drum filling opening If drums have to be stored outside cover them with a waterproof sheet or take other measures to protect them e To prevent any change in quality during long term storage be sure to use the fluids following the first in first out use the oldest oil or fuel first method 4 2 1 6 FILTERS e Filters are very important components for safety They prevent any impurities from getting into the oil fuel or in the air circuits thus avoiding problems to important components of the machine Periodically change all the filters For further information see the relevant Use and Maintenance manual However when working in extreme conditions it is necessary to change the filters more frequently depending on the type of oil and fuel used sulphur content e Do not attempt to clean the filters type with cartridge and reuse them Always change them with new filters e When changing the oil filters check if metal particles are present If you find large quantities of metal particles contact your Komatsu Dealer e Do not open the spare filter packages before using them e Always use Komatsu original spare parts 199 MAINTENANCE NOTES 4 2 2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM e f the cables wet
199. ith the machine in the conditions A or B illustrated below A Start the engine and let it idle lower the blade to the ground retract the arm and bucket cylinders completely swing the boom to the centre Lower the boom until the bucket teeth touch the ground and then stop the engine CoO 9JM01004 Start the engine and let it idle lower the blade to the ground extend the arm and bucket cylinders completely swing the boom to the centre Lift the boom completely and stop the engine 9JM01026 123 USE OF THE MACHINE 2 Open the battery inspection cover 1 and check the oil level through the sight gauge If the level is as indicated below it is correct Machine in position A included in the range a Machine in position B included in the range b IMPORTANT e Do not add oil above the H mark in order to avoid damag ing the hydraulic circuit or causing oil leakages e If the H mark has been exceeded turn the turret so as to position the drain plug P which is under the hydraulic tank between the tracks then stop the engine and wait for the hydraulic oil to cool down At this point drain the ex cess oil through the drain plug P 3 Ifthe oil level is below the L mark open the side cover and top up through the filler neck F NOTE e The oil level varies according to its temperature Consequently itis advisable to keep to the instructions given below e Before opera
200. l be differ ent For further details see 4 8 2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAK ER to verify the correct maintenance plan 4 8 1 MAINTENANCE PLAN WHEN REQUIRED a CHECKING CLEANING OR CHANGING THE AIR FILTER CARTRIDGE seen 214 b CHANGING THE CARTRIDGE IN THE WATER SEPARATOR 00 cece cece teeter teat etre eee eren eren 218 CLEANING THE FUEL TANK etae tb ede e qtd daa detta 219 d CHECKING THE TIGHTENING OF THE 220 e CHECKING AND ADJUSTING THE TRACK 221 f CHECKING THE ROAD LINERS OR THE RUBBER 223 g CHECKING AND ADJUSTING THE RUBBER TRACK 225 h CHANGING THE ROAD EINEROS x iiiter iie eit ei ipe e D i Deis utei ea se 226 i CHANGING THE RUBBER 5 227 j REPLACING THE ROAD LINERS OR STEEL TRACKS WITH RUBBER 230 k ADJUSTING THE BUCKET 231 l CHECKING THE WINDSHIELD FLUID LEVEL AND TOPPING 232 m CHECKING CLEANING AND LUBRICATING THE GUIDE OF THE CAB SLIDING DOOR 233 n WASHING THE FLOOR tb tet tte etd Dates e Pare Pra haus aanas 234 o BLEEDING THE HYDRAULIC 5 236 CHECKS TO BE
201. l forces the hy draulic cylinders run the risk of being damaged and the operator of being injured Avoid performing operations in which the hydrau lic cylinders are extended or retracted completely DIGGING OPERATIONS ON HARD ROCKY GROUND Do not attempt to dig directly into hard rocky ground with the work equipment It is advisable to carry out the digging operations after breaking the rock with another means This will not only safe guard the machine but also ensure a more economic use of the same x 2 So 060604 lt 6 e EN 259 25 255025 gx D QR 5 Se 90009 SOR Ao gt ORY 7 5 seer 09 BEX BOS 95556552 RUD 50 RO LORY 760000074 999605050 Qo Qe SRK RRA RRS gt lt lt s 52 LIOR XGA ROC OC OC COGO 9JM01076 9JM01117 9JM01118 151 USE OF THE MACHINE OPERATIONS IN WHICH THE FALL FORCE OF THE BUCKET IS EXPLOITED Do not exploit the fall force of the machine when performing dig ging operations or the fall force of the bucket to use it as a pick axe breaker or pile driver since this may considerably reduce the life of the machine 9JM01119 OPERATIONS IN WHICH THE FALL FORCE OF THE MA CHINE IS EXPLOITED Do not exploit the fall force of the machine to carry out excava tions 9JM011
202. l not carry out the movements se lected with the control lever but the opposite for example forward travel becomes reverse left becomes right etc It is advisable to prevent the machine from performing these invert ed movements Before any movement check again that there is no one in the surrounding area and that there are no obstacles RKA18320 Before any movement sound the horn to warn all the people standing nearby Operate the machine only when you are seated in driving posi tion o e Fasten the seat belt securely e Do not allow anyone apart from the operator to get on the ma chine e Make sure that the travel alarm optional functions correctly C e Always lock the cab door and windows in the desired position open or closed gt RYA00490 In workplaces where flying objects may get in the operator cab make sure that the door and the windows are correctly closed If behind the machine there is an area that is not visible ask someone to stand there and make signals to direct your ma noeuvres Take care to avoid hitting other machines or people when steering or performing a rotation movement with the ma chine gt EI RYA00480 46 2 3 2 3 PRECAUTIONS TO BE TAKEN DURING TRAVEL e It is dangerous to drive at excessive speed to start or stop the machine suddenly or to steer abruptly e When moving on even surfaces fol
203. levers slowly Mesh the rubber track with the sprocket and fit it on the idler roller Turn the sprocket as if in reverse then push the track in wards and stop turning Insert a steel tube in the rubber track then turn the sprocket again and fit the rubber track securely on the idler roller Stop turning and make sure that the rubber track is correctly positioned on the sprocket and the idler roller Adjust the tension of the rubber track For further details see 4 9 1 9 CHECKING AND ADJUSTING THE RUBBER TRACK TENSION Make sure that the track tension is correct and that the track is correctly positioned on the sprocket and the idler roller then rest the machine on the ground MAINTENANCE PROCEDURES 9JA04116 RYA05230 RYA05240 05250 229 MAINTENANCE PROCEDURES 4 9 1 3 REPLACING THE ROAD LINERS OR STEEL TRACKS WITH RUBBER TRACKS A WARNING e When switching from steel tracks or road liners to rubber tracks or vice versa it is necessary to remove and adjust the shock absorber of the idler roller and this operation should be carried out by a Komatsu Dealer REPLACING THE ROAD LINERS OR STEEL TRACKS WITH RUBBER TRACKS 1 Remove the bolts 1 and the idler roller guard 2 2 Remove the steel track or road liner and install the rubber track 9JA03404 REPLACING THE RUBBER TRACKS WITH STEEL TRACKS OR ROAD LINERS 1 Remove t
204. lic cylinder is pressu rized For this reason do not give the grease valve 1 more than one turn when loosening it in fact if the valve is loos ened excessively it may be pushed out due to the grease pressure and this is very dangerous for the operator Do not loose any component apart from the valve 1 If the track tension does not decrease after this operation con 9JA01563 tact your Komatsu Dealer e It is extremely dangerous to let the grease out following any procedure different from the one indicated below e When installing or removing the tracks before turning the sprocket make sure that the grease contained in the cylin der has been removed WARNING e If the resistance met when injecting the grease is exces sive move the machine forward and backward covering a short distance 227 MAINTENANCE PROCEDURES 1 Lift the frame by means of the boom and the arm Operate the levers slowly 2 Loosen the grease valve 1 gradually to release the grease 3 When loosening the grease valve 1 do not give more than one turn 4 Introduce the steel tubes in the rubber track turn the sprock et as if in reverse so that the steel tubes lift the track from the idler roller then make the track slide sidewards and remove it 228 9JA04116 9JA01563 RYA05220 INSTALLING THE RUBBER TRACKS Lift the frame by means of the boom and the arm Operate the
205. liding door locked e Pay special attention when opening or closing the sliding door while the machine is at rest on a slope The weight of the door may cause it to be opened or closed suddenly 156 USE OF THE MACHINE 3 3 18 GETTING THE MACHINE OUT OF MUD Always proceed carefully to avoid getting stuck in mud However if the machine gets stuck in mud proceed as in dicated below WHEN ONE SIDE ONLY GETS STUCK NOTE e When using the boom or arm to raise the machine always place the bottom of the bucket in contact with the ground Nev er push with the bucket teeth The angle between the boom and the arm should be included between 90 and 110 When only one side gets stuck in mud use the bucket to raise the track then lay boards or logs under the track and drive the ma chine out UU Ha 9JM01 129 WHEN BOTH SIDES GET STUCK When both tracks get stuck in mud and the machine slips but can not move put some boards or logs under the tracks proceeding as indicated above Thrust the bucket into the ground in front of the machine operate the arm as for normal digging operations and shift the travel levers to position FORWARD to drive the ma chine out of mud 9JM01130 157 USE OF THE MACHINE 3 3 19 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR In addition to those indicated below many other applications are possible thanks to the use of various attach
206. ll make the ground slippery use anti slip shoes and immediately remove any trace of oil from the floor e Oils filters the coolant and the battery are considered special waste and must be collected and dis posed of according to the regulations in force CAUTION e On new machines change the engine oil and the engine oil filter cartridge after the first 250 hours of op eration and successively every 500 hours Open the engine hood see 3 2 9 ENGINE HOOD Remove the drain plug P of the engine oil pan gathering the used oil that flows out of it into a container with suitable es capacity While the oil flows out remove the filler cap F so that the oil can flow out freely 3 Check the used oil and if there are many metal particles or foreign bodies contact your Komatsu Dealer 4 Put back the drain plug P 5 Using a filter wrench turn the filter 1 anticlockwise to re move it N 9JA03163 NOTE e Position a cloth in contact with the cut part of the oil container guide This allows the area around the filter housing to be kept clean 6 Clean the filter housing cover the threading and the gasket of the new cartridge with new engine oil or with a thin layer of grease then install it NOTE e Make sure that there are no residues of the previous gasket at tached to the filter housing since this may cause oil leakages 9JA04562 7 Dur
207. machine can be used as long as possible in total safety it is necessary to add oil and carry out the required maintenance operations at regular intervals To increase safety safety related components like pipes and belts must be periodically changed For the replacement of the parts that are critical for safety see 4 7 PERIODICAL CHANGE OF SAFETY RE LATED COMPONENTS e The material used for making these components naturally changes over time and prolonged use may cause de terioration wear and excessive stress with the consequent risk of breakages thay may lead to serious injury and property damage It is difficult to evaluate the conditions of these components through an external check or based on the operator s feelings during work therefore it is advisable to change them according to the recom mended intervals e If any defect should be found out change or repair the components that are critical for safety even before the end of the recommended intervals 65 PRECAUTIONS FOR MAINTENANCE 2 4 29 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLY MERS AND ELASTOMERS DANGER e Some components of the machine contain polymeric and elastomeric materials Viton sealing rings Te flon rings piston rings made of fluoroelastomers electric cable insulating materials etc At ambient temperature and up to approximately 200 C these materials can be handled without taking special precautions since they are completely inert If these
208. main frame on the left side 1 4 2 MACHINE IDENTIFICATION PLATE 2 The plate with the CE marking is applied to the front wall of the gt RKA19130 4 Mass ENGINE POWER Product Identification Number MANUFACTURER KOMATSU UTILITY EUROPE S p A 36025 NOVENTA VICENTINA UNDER LICENSE OF KOMATSU LTD TOKYO JAPAN e KOMATSU 22109 1370 RKA16030 PRODUCT IDENTIFICATION 1 4 3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE The plate indicating the engine serial number and the exhaust emissions is positioned on the outside of the engine block 1 4 4 TRAVEL REDUCTION GEAR SERIAL NUMBER The serial number is stamped on the plate positioned on the outer cover of the travel reduction gear RKA19180 o 1asertgat fagise 22002211002 Model Xxxxxxxxx ESN xxxxxx KOMATSU LTD Gross rated HP KW xal ph may uli and warrants is seid Low Idle RPM xxx RPM if fuel altitudes Engine xxx xin valves Tor this ande an alien Code This enne 1o CA V S EB Displacement 3 2611 far fr cmt compression inition This ensine is certified lo serate on diesel fuel Tinins BTDC xdesrees Valve Lash Intake 0 35mm Cert Family XXXXXXX cold ensinel Exhaust 0 Sonn European Approval ET TT Fuel rate at rated HP kW xx xam3 st
209. maintenance operation must be carried out after the first 500 hours of operation together with those to be performed EVERY 500 HOURS a CHANGE THE HYDRAULIC OIL AND CLEAN THE INTAKE FILTER For further details see paragraph EVERY 2000 HOURS 4 9 9 MAINTENANCE EVERY 500 HOURS OF OPERATION Carry out these operations together with those to be performed every 50 HOURS and every 100 HOURS 4 9 9 a CHANGING THE FUEL FILTER CARTRIDGE A WARNING e Change the filtering element after work when the engine has cooled down to 40 45 C e During these operations some fuel may be spilled clean the dirty areas immediately in order to prevent any risk of slipping or fire e Oils filters the coolant and the battery are considered special waste and must be collected and dis posed of according to the regulations in force CAUTION e On new machines change the fuel filter cartridge after the first 250 hours of operation and successively every 500 hours FUEL FILTER 1 Puta cloth under the filter cartridge 2 Using a filter wrench turn the cartridge 1 anticlockwise to remove it 3 Clean the filter housing fill a new cartridge with clean fuel cover the surface of the gasket with engine oil then install the cartridge on the filter housing 4 Tighten the cartridge until the gasket makes contact with the sealing surface then give a further 2 3 turn IMPORTANT e Do not use the wrench to lock the filter in order to
210. mal noise Faulty alternator Change Starter does not turn with key in posi Faulty cables Check and repair tion START Battery charge insufficient Charge Starter pinion engages and disengag Battery charge insufficient Charge es repeatedly Battery charge insufficient Charge Starter makes engine run slowly Faulty starter Change Starter disengages before engine start Faulty cables Battery charge insufficient Check and repair Charge Preheating warning light does not Faulty cables Faulty warning light Change Engine oil pressure warning light does Faulty warning light Change not come on when engine stops igni Faulty oil pressure sensor Change tion switch in position ON Faulty relay Change Faulty deceleration device Change hand accelerator does not work Faulty controller The engine speed does not decrease or increases even after the decelera tion switch has been pressed Faulty cables Blown fuse 187 TROUBLESHOOTING 3 7 10 2 FRAME TROUBLE MAIN CAUSES SOLUTION Travel speed swing speed boom arm and bucket speed are low Hydraulic oil too low Top up oil until reaching correct level see CHECKS TO BE CAR RIED OUT BEFORE STARTING THE ENGINE Pump emits an abnormal noise Clogged filter
211. minals securely Loose terminals may generate sparks and may cause the battery to explode PRECAUTIONS FOR USE RKA00380 ee A 2S 555 OX 55 09 9 300 00040 55209 5 55 2x 52 BS 555525505 555559 60005 c 255 5552005 55 5 55252 90266 555 L 50 x S 206 70202 RY RYA00790 2 1 00360 N 53 PRECAUTIONS FOR USE 2 3 4 2 STARTING WITH BOOSTER CABLES e When starting the machine with booster cables always wear safety goggles e When starting the engine by means of another machine avoid any contact between the two machines e When connecting the booster cables make sure to connect the positive cable first and then the negative or earth cable After the start disconnect first the negative or earth cable and then the positive cable e Connect the batteries in parallel positive to positive and nega tive to negative e When connecting the earth cable to the body of the machine to be started operate as far as possible from the battery See 8 7 5 IF THE BATTERY IS DOWN 54 SEIKO 555555 NS L x 559 LL 20262620 555555000 550505 0202 5 55555 555555506 555055 5 50 te 55 525 XZ 5 L 2 25 5 2x lt gt RR
212. mud This will make it easier to start the ma chine in the morning e Open the drain valve and drain the water accumulated in the fuel system to prevent it from freezing e Fill the fuel tank completely in order to prevent the formation of condensate inside the tank when the tempera ture decreases e After working in water or mud remove the water from the undercarriage by proceeding as indicated below in or der to extend the life of the undercarriage 1 Swing the turret by 90 with the engine idling and bring the work equipment to the side of the tracks 2 Lift the machine using a jack until the track is slightly raised from the ground Make the track rotate idly Repeat this pro cedure on both the left and the right side of the machine 9JA04116 3 5 3 AT THE END OF THE COLD SEASON At the end of the cold season when the climate becomes warmer proceed as follows e Change fuel and oil with products having suitable viscosity For further details see paragraph 4 2 MAINTENANCE NOTES 178 LONG PERIODS OF INACTIVITY 3 6 LONG PERIODS OF INACTIVITY 3 6 1 BEFORE A PERIOD OF INACTIVITY IMPORTANT e When the machine is going to remain unused position the work equipment as shown in the diagram on the right to protect the hydraulic cylinder rod This serves to prevent the cylinder rod from rusting If the machine is going to remain unused for a long period pro SS ceed as indicated below e
213. n carrying out tightening operations If not specified otherwise tighten the screws and nuts applying the torques specified in the table If itis necessary to replace a screw or a nut always use Komatsu original spare parts having the same size of the part to be re placed Nm Newton metre 1 Nm 0 102 kgm D RYA02980 Thread diame Pitch Wrench size 8 8 10 9 ter a mm mm b mm kgm Nm kgm Nm 6 1 10 0 96 0 1 9 5 1 1 3 0 15 13 5 1 5 8 1 25 13 2 3 0 2 2342 3 2 0 3 32 2 3 5 10 1 5 17 4 6 0 5 45 49 6 5 0 6 63 6 5 12 1 75 19 7 8 0 8 77 8 11 1 108 x 11 14 2 22 12 5 1 122 13 17 5 x2 172 18 16 2 24 195 2 191 21 27 3 268 29 18 2 5 27 27 3 262 28 37 4 366 36 20 2 5 30 38 4 372 t 40 53 6 524 57 22 2 5 32 52 6 511 57 73 8 719 80 24 3 36 66 7 644 70 92 10 905 98 27 3 41 96 10 945 100 135 15 1329 140 30 3 5 46 131 14 1287 140 184 20 1810 190 33 3 5 50 177 20 1740 200 250 27 2455 270 36 4 55 230 25 2250 250 320 35 3150 350 39 4 60 295 33 2900 330 410 45 4050 x 450 IMPORTANT e This tightening torque table is not valid for screws or nuts that must fasten parts made of nylon or simi lar materials onto washers or components made of nylon or nonferrous metals or requiring specific tightening torques 205 TIGHTENING TORQUES 4 5 2 STANDARD TIGHTENING TORQUES FOR HOSES WITH ORFS If not specified othe
214. n the engine is started the Active mode for heavy duty ap plications is automatically selected when fuel saving is desired sired Warning EM Set speed Work mode light E Applications rpm Active un Off normal digging operations loading 2300 50 for heavy duty applications operations E normal digging operations loading On operations when fuel saving is de 2000 100 this value corresponds to the engine rpm with the hand accelerator set to without load e When changing over from the Active mode to the E mode with the hand accelerator set to MAX the engine rpm in some way decrease but this is not an anomaly 150 3 3 15 UNAUTHORIZED OPERATIONS USE OF THE MACHINE WARNING e Do not attempt to operate the work equipment control levers during travel OPERATIONS IN WHICH THE SWING FORCE IS EXPLOITED Do not use the swing force to compact the ground or break ob jects Beside being dangerous this will certainly shorten the life of the machine OPERATIONS IN WHICH THE TRAVEL FORCE IS EXPLOITED Do not thrust the bucket into the ground and do not use the travel force of the machine to carry out digging operations since this may damage the machine or the work equipment OPERATIONS IN WHICH THE HYDRAULIC CYLINDERS REACH THE END OF STROKE If the work equipment is used with the cylinder rods at the end of stroke and is subjected to impacts due to externa
215. nce for the supply of Komatsu genuine spare parts which guar antee safety and interchangeability e The table included in this manual must be filled in with the machine data which are also the data that must be communicated to the Dealer when requiring assistance and ordering spare parts CAUTION e The incorrect use of the machine and inappropriate maintenance operations may cause serious injury and even death e Operators and maintenance personnel must carefully read this manual before using the machine or per forming maintenance operations e Any serious accident that may occur during the use of the machine or during maintenance operations is due to failure to comply with the instructions given herein e The application of the procedures and precautions described in this manual will ensure safety only pro vided that the machine is used correctly If the machine is used for any purpose or in any way other than those described herein the operator shall be responsible for his own safety and for the safety of any other person involved INFORMATION ON SAFETY 1 2 INFORMATION ON SAFETY Many accidents are caused by insufficient knowledge of and failure to comply with the safety regulations pre scribed for the maintenance operations that must be performed on the machine In order to avoid accidents before starting work and before carrying out any maintenance operation carefully read and be sure to understand all the information an
216. nce the oil has been drained put back the plug 2 and pour 2 oil of the prescribed type through the hole until reaching the lower edge of the hole itself 4 Putback the plug G Carry out some forward and backward movements stop the ma GILL chine and check the levels again Always use oil of the prescribed type see 4 4 FUEL COOLANT AND LUBRICANTS RKA18870 261 MAINTENANCE PROCEDURES 4 9 10 c CHANGING THE HYDRAULIC OIL FILTER CARTRIDGE IN THE WORK EQUIP MENT LINE if installed WARNING e Soon after the machine has been stopped the hydraulic oil is very hot and may cause burns let it cool down to 40 45 C before changing the filter e The hydraulic system is under pressure slowly loosen the filler cap to release any residual pressure e Oils filters the coolant and the battery are considered special waste and must be collected and dis posed of according to the regulations in force IMPORTANT e If the machine is equipped with demolition hammer the hy draulic oil deteriorates much earlier than during normal bucket operations For further details on maintenance see 4 8 2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER 1 Open the side cover and position a container under the filter cartridge to collect the oil RKA18820 2 Rotate the filter body 1 to the left to remove it then extract the cartridge 2 3 Remove the plug 3 from the filte
217. nd clog them the maxi mum concentration of ordinary oil must not exceed 1 of the total quantity of oil e Biodegradable oil can be used only in the hydraulic sys tem it cannot be used for the engine the transmissions the braking system etc 9JM01027 e On new machines the oil must be changed after the first 500 hours of operation and successively every 2000 hours and in any case at least once a year IMPORTANT e If the machine is equipped with hydraulic hammer the hy draulic oil deteriorates much earlier than during normal bucket operations For further details on maintenance see 4 8 2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER e Filling capacity 64 8JM01004 1 Turn the turret so that the lower part of the hydraulic oil tank is not covered by the tracks 2 Retract the arm and bucket cylinders completely and lower the boom until the bucket teeth rest on the ground Lower the blade to the ground Stop the engine and eliminate the residual pressure from the work equipment by shifting the controls more than once 5 Shift the safety lever to the locked position L gt RKA18280 263 MAINTENANCE PROCEDURES 6 Open the side cover 1 and slowly loosen the filler cap F to release any residual pressure from the tank 7 Remove the drain plug P and let the oil flow out gathering it into a container with suitable capacity
218. ne cannot be started if the safety lever isn t in position lock 2 Hand accelerator The hand accelerator 2 is used to control the engine speed and output a ldling the knob is rotated completely to the left anticlock wise b Maximum the knob is rotated completely to the right clock wise NOTE e When the quick deceleration warning light comes on the en gine rpm remain at the minimum value even if the hand acceler ator is operated To increase the engine speed press the quick deceleration switch on the left work equipment control lever and deactivate the deceleration function INSTRUMENTS AND CONTROLS Ww RYA16920 RKA18280 9JA03141 83 INSTRUMENTS AND CONTROLS 3 Quick deceleration switch WARNING e Before using the quick deceleration switch always shift the work equipment and travel levers to neutral If the switch is pressed with one or more of these levers shifted the engine torque changes suddenly This switch 3 is used to reduce the engine speed and fuel con sumption when no power is required of the engine for example when the travel levers the travel pedals and the work equipment control levers are in neutral When the quick deceleration switch positioned at the centre of the grip of the left work equipment control lever is pressed the corre sponding warning light comes on and the engine rpm decrease until reaching the idlin
219. ne hood For details see paragraph 3 2 9 ENGINE HOOD 2 Loosen and remove the upper cap 1 of the radiator 3 Remove the cover under the drain plug 4 Remove the radiator drain plug 2 remove the drain plug 3 situated on the engine block and let the fluid flow out gather ing it in a container with suitable capacity Drain the coolant tank 4 while the fluid flows out 5 Close the drain plug 2 put back the plug 3 on the engine block and fill the radiator with new fluid see 4 4 FUEL COOLANT AND LUBRICANTS Put back the cover under the drain plug Start the engine and let it run at high idling speed for a few minutes check the level again and top up before putting back the upper cap 1 9JA03218 noo 9JA04548 265 MAINTENANCE PROCEDURES 8 9 Fill the tank 4 until reaching the maximum level MAX Close the engine hood 4 inn MAX MIN RKA18930 MAINTENANCE PROCEDURES 4 9 11 c CLEANING AND CHECKING THE TURBOCHARGER To carry out this operation contact your Komatsu Dealer 4 9 11 d CHECKING THE ALTERNATOR AND THE STARTER The brush may be worn or the bearing may be without grease so contact your Komatsu Dealer who will provide for the necessary checks or repairs If the engine is started frequently have this check carried out every 1000 hours 4 9 11 e CHECKING
220. ng a short distance 9JA03792 221 MAINTENANCE PROCEDURES INCREASING THE TRACK TENSION Prepare a grease pump 1 Inject grease with the pump through the grease nipple 5 2 To make sure that the tension is correct run the engine at idling speed move the machine slowly forward covering a distance equal to the length of the track on the ground then stop the machine 3 Check the track tension again If it is not correct adjust it again 9JA03793 4 Keep injecting grease until the distance S becomes equal to zero 0 If the tension is still insufficient the pins and bush ings are excessively worn so they must be swapped or re placed Contact your Komatsu Dealer who will carry out the necessary operations SAM091 260 HOW TO DECREASE THE TRACK TENSION DANGER e It is extremely dangerous to let the grease out following any procedure different from those illustrated below e If the track tension cannot be reduced with this operation contact your Komatsu Dealer who will pro vide for the necessary repairs 1 Gradually loosen the grease valve 4 to let the grease out do not give the valve more than one turn 3 Ifthe grease does not come out smoothly move the machine slowly forward and backward covering a short distance 3 Tighten the grease valve 4 and remove any trace of grease 4 To make sure that the tension is correct run the engine at idling
221. nn aka no rne reus 214 4 9 173 WHEN REQUIRED iib ec Dx 214 4 9 1 CHECKING CLEANING OR CHANGING THE AIR FILTER CARTRIDGE 214 4 9 1 5 CHANGING THE CARTRIDGE IN THE WATER 218 4 9 1 CLEANING THE FUEL 219 4 9 1 4 CHECKING THE TIGHTENING OF THE TRACKS 220 4 9 1 6 CHECKING AND ADJUSTING THE TRACK 221 4 9 1 f CHECKING THE ROAD LINERS OR THE RUBBER 223 4 9 1 9 CHECKING AND ADJUSTING THE RUBBER TRACK TENSION 225 4 9 1 4 CHANGING THE ROAD LINERS 226 4 9 1 1 CHANGING THE RUBBER 5 227 4 9 1 REPLACING THE ROAD LINERS OR STEEL TRACKS WITH RUBBER TRACKS 230 4 9 1 k ADJUSTING THE BUCKET CLEARANCE esee eene nnns 231 4 9 1 CHECKING THE WINDSHIELD FLUID LEVEL AND TOPPING UP 232 4 9 1 m CHECKING CLEANING AND LUBRICATING THE GUIDE OF THE CAB SLIDING DOOR em heen eat pde oett Ende 233 4 977 WASHING THE FLOOR t eite tete ated uten et ded aec 234 4 9 1 0 BLEEDING THE HYDRAULIC SYSTEM 236 4 9 2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE 239 4 9 3 MAINTENANCE AFTER THE FIRST 50 HOURS OF
222. nsert the tang 2 in the buckle 1 Pull the belt to make sure that the tang is securely inserted and locked in the buckle 3 To unfasten the seat belt press the red button on the buckle 1 Fasten the belt without twisting it Adjust the length of the belt on the tang side 9JA03174 128 3 3 4 2 ADJUSTING THE SEAT BELT How to shorten the belt Pull the free end of the belt on the tang side How to lengthen the belt Pull the part of the belt including the tang perpendicularly to the tang itself USE OF THE MACHINE 9JA01005 9JA01006 129 USE OF THE MACHINE 3 3 4 3 RETRACTABLE SEAT BELT if provided A WARNING e Before fastening the seat belt make sure that the fastening brackets or the belt itself do not show any anomaly If there are damaged or worn parts change the belt e The seat belt must be changed every 3 years even if there are no anomalies or signs of wear The date of manufacture is indicated on the reverse side of the belt e Always fasten the seat belt when working with the machine e Fasten the seat belt taking care not to twist it Fastening and unfastening the seat belt This belt is provided with a retractor therefore it is not necessary to adjust its length Fastening the seat belt Seize the grip 2 and extract the belt from the retractor 1 make sure that the belt is not twisted then insert the tang 3 in the buckle 4 After completin
223. nstall the oil filler cap F and close the side cover 1 10 Start the engine and let it idle for at least 10 minutes in order to bleed the circuit NOTE e After stopping the engine wait at least 5 minutes in order to elim inate all the air bubbles from the oil present in the tank 11 Check for oil leakages and remove any oil that has been spilled MAINTENANCE PROCEDURES 9JA03280 253 MAINTENANCE PROCEDURES 4 9 9 4 CLEANING THE INSIDE AND OUTSIDE FILTERS OF THE AIR CONDITIONER A WARNING e When compressed air is used to clean the filter dust may get into the eyes Wear safety goggles and a dust mask during the cleaning operations IMPORTANT e If the machine is used in particularly dusty places shorten the maintenance intervals and clean the filter more frequently e When washing the floor take care to avoid wetting the filtering element CLEANING THE AIR FILTER 1 Roll the mat 1 on the front left side of the cab floor then open the door 2 2 Extract the inner filter 3 3 Clean the inner filter 3 with compressed air If there is oil on the filter or if it is very dirty wash it with a neutral detergent After washing the filter dry it completely before use IMPORTANT e If the filtering element is excessively clogged or damaged change it with a new one 2 2 4 Install the cleaned filter 3 close the door 2 and lay the mat 1 on the floor
224. ntainer under the drain valve to collect sedi ments and water 4 Open the drain valve 2 and drain the fuel together with the sediments and water accumulated on the bottom of the tank When carrying out this operation be careful not to spil fuel on yourself 5 When only clean fuel flows out close the drain valve 2 6 Close the inspection cover 1 IMPORTANT e The tank must be drained before starting the engine with temperatures exceeding 0 C when the temperature is be low 0 C the tank must be drained at the end of work or in any case with the machine at operating temperature in or der to prevent the condensate from freezing 9JA03233 e The condensate and the impurities that may have accumu lated inside the tank must be drained before refuelling e Never use trichloroethylene to wash the inside of the tank Use exclusively diesel oil 9JA03234 240 MAINTENANCE PROCEDURES 4 9 5 MAINTENANCE EVERY 100 HOURS OF OPERATION Carry out these operations together with those to be performed every 50 HOURS 4 9 5 a LUBRICATION IMPORTANT e Clean the grease nipples before applying the greasing pump e After lubrication remove all the contaminated grease that may have spread out of the nipples e If the machine is used in difficult conditions carry out this operation more frequently than usual e As a general rule it is important to consider that each cyl inde
225. nterval e It is advisable to use only engine oil with API CF CF2 CD classification in order to ensure the correct operation and constant reliability of the engine e Use Komatsu genuine products whose characteristics have been specifically formulated and approved for use in the engine in the work equipment hydraulic circuit and in the reduction gears First filling quantity total quantity of oil including the oil for the components and pipes Oil change quantity quantity of oil necessary to fill the system or unit during the normal inspection and mainte nance operations ASTM American Society of Testing and Materials SAE Society of Automotive Engineers API American Petroleum Institute NLGI National Lubricant Grease Institute 203 FUEL COOLANT AND LUBRICANTS 4 4 1 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin and therefore the use of the oils indicated in the following table is authorized and recommended SUPPLIER SYNTHETIC BIODEGRADABLE OIL TYPE HEES KOMATSU BO 46 G4 KES 07 872 AGIP ARAL AVIA BP CONDAT CONDAT D 46 K ELF ESSO FINA BIOHYDRAN SE 46 FUCHS KENDALL KUWAIT PETROLEUM K8 MOBIL EAL SYNDRAULIC MOBIL USA PAKELO PANOLIN HLP SYNTH 46 SHELL NATURELLE HFX 32 TAMOIL TEXACO
226. om the machine 2 Stop the engine and shift the equipment controls in all directions in order to release the residual pressure from the hydraulic circuits 3 Turn the ignition key to position I and press the hammer control button 4 to release the residual pressure from the hammer delivery pipe 4 Turn the ignition key to position O and remove it 5 Disconnect the hammer delivery and return pipes Use 41 and 50 mm wrenches 6 Fitthe pipe plugs A WARNING e Make sure that the plugs are properly tightened and that there are no leakages if the circuit is inadvert ently pressurized small leakages can be turned into thin jets that may perforate the skin or injure the eyes e Always wear thick gloves and safety goggles to carry out this check e To check the system for leakages use a piece of cardboard or a small wooden board 7 Disconnect the hammer from the mechanical retainers proceeding as described in paragraph 3 3 20 CHANGING THE BUCKET 6 2 4 MAINTENANCE The hydraulic system does not require any operation and inspection other than those prescribed for the routine maintenance of the machine Regarding the maintenance operations required for the hammer see the specific operation manual 292 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET SWING SYSTEM second hydraulic line 6 3 ARRANGEMENT FOR THE INSTALLATION OF THE CLAM SHELL BUCKET SWING SYSTEM second hydraulic line DESCRIPTION AND CO
227. on signals in ad vance and respect them during work e Use a crane to handle objects weighing more than 25 kg e Always support any heavy part of the machine before removing it When lifting heavy parts be always careful to the position of their centre of gravity e It is dangerous to carry out any operation with suspended loads Always position the load on a suitable support and make sure that it is stable e When installing or removing any equipment make sure that it is stable and cannot fall down e Never stand under loads being lifted by a crane Take care to choose a safe position in such a way as to avoid any risk in case the load should fall down IMPORTANT e Cranes must be operated by specialized personnel Do not allow untrained personnel to use cranes For further details regarding installation and removal operations contact your Komatsu Dealer AUTHORIZED OPTIONAL EQUIPMENT 6 1 2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT A WARNING e The installation of long or heavy work equipment may affect the stability of the machine Therefore be particularly careful when moving down a steep slope or when swinging the equipment on a slope since the machine may lose its balance and overturn e Avoid carrying out the following operations since they are particularly dangerous 1 Travelling downhill with lifted equipment p xo 9 20 30 cm RYA16760 42 00550 2 Crossing slopes tran
228. ondenser or the heat exchanger are acci dentally dirtied with oil diesel oil or greasy or oily substances e If the machine is used in dusty places clean the radiator the condenser and the heat exchanger more frequently in order to prevent the fins from clogging 1 Open the engine hood 2 Remove the cover 1 DL RT 9JA04563 3 Remove the bracket that fastens the condenser 2 4 Loosen the fastening bolts 3 positioned in the inner part of the condenser and incline it 4 256 MAINTENANCE PROCEDURES 5 Direct a jet of compressed air on the radiator fins 5 and the condenser fins 4 to remove dirt dust and any residues of dry leaves It is possible to use steam or water instead of ELM Y AR compressed air a a i gt 28 em A dll BI _ RKA19250 6 Remove the intermediate cover 6 and eliminate any dirt dust and residues of dry leaves that may have fallen on the bottom RKA19260 7 Check the rubber pipe If the pipe is broken or too hard due to the prolonged use change it Check if the pipe clamps are loose 8 Put back all the parts that have been removed making sure to place them in their original positions 257 MAINTENANCE PROCEDURES 4 9 9 f LUBRICATING THE SWING BALL BEAR ING RING This maintenance operation must be carried ou
229. ool in such a way as to be able to interrupt the descent of the equipment at any moment If it becomes impossible to lower the work equipment proceed as indicated below 1 Open the side cover IMPORTANT e Do not loosen the cap with more than 5 turns Otherwise the cap comes off and the hydraulic oil is sprayed out 2 Slowly loosen the cap 1 of the main valve to lower the work equipment Loosen the cap giving approx 3 5 4 turns 3 When the work equipment has been lowered to the ground tighten the cap 1 Driving torque from 34 to 44 Nm from 3 5 to 4 5 kgfm 186 9JA03215 TROUBLESHOOTING 3 7 10 OTHER TROUBLES Always contact your Komatsu Dealer when you have to carry out this operation In case of anomalies or problems that are not listed here below contact your Komatsu Dealer who will provide for the necessary repairs 3 7 10 1 ELECTRICAL SYSTEM TROUBLE MAIN CAUSES SOLUTION Lights do not work satisfactorily even with engine running at high speed Lights come on intermittently with en gine running Faulty cables Faulty fan belt tension Check and repair any loose termi nals and connections Adjust fan belt tension For details see EVERY 250 HOURS OF OP ERATION Battery charge warning light does not Faulty alternator Change go out even with engine running Faulty cables Check and repair Alternator emits abnor
230. oolant temperature When the temperature increases abnormally the warning light starts blinking In this case stop working and let the engine idle until the engine coolant temperature indicator returns to the green area 2 ENGINE OLI PRESSURE WARNING LIGHT This warning light 2 signals that the engine oil pressure is below the set values If it starts blinking stop the engine and check the oil level in the oil pan and in the lubrication system NOTE e This warning light comes on when the ignition switch is turned to position ON with the engine off but this does not indicate any anomaly e When the engine is started or stopped with the ignition switch in position ON the warning light may come on and the acoustic alarm may sound for a while but this does not indicate any anomaly 3 OVERLOAD ALARM WARNING LIGHT WHEN THE ALARM IS CONNECTED This warning light 3 blinks when an excessively heavy object is lifted If it starts blinking stop working and reduce the load INSTRUMENTS AND CONTROLS 9JA03306 9JH01670 9JA04341 75 INSTRUMENTS AND CONTROLS 3 2 1 3 WARNING LIGHTS AND INDICATORS DISPLAY 9JA04340 1 Engine preheating warning light 3 Engine coolant temperature indicator 2 Quick deceleration warning light 4 Fuel gauge 5 Display 6 Hour meter
231. or their insulating material is damaged the electrical system leaks and this may result in malfunctions of the machine e The maintenance operations required for the electrical system are the following 1 Check ofthe alternator belt tension 2 Check of the alternator belt for damage or breakages 3 Check of the battery charge level e Do not remove or eliminate any electric component installed on the machine and do not install any electric com ponent with characteristics different from those specified and approved by Komatsu e Keep the electric system dry e When working on the seashore or on river or lake banks protect the jack plugs from corrosion e Do not connect any optional device to the fuses ignition switch battery relays etc for the installation of any op tional equipment contact your Komatsu Dealer e If any electric welding operation has to be carried out disconnect the battery and the alternator 4 2 3 NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM e Be extremely careful when performing maintenance operations on the hydraulic system since soon after work the oil is very hot The circuit is pressurized not only during work but also at the end of work e The maintenance operations required for the hydraulic system are the following 1 Daily check of the oil level in the tank 2 Periodical change of the oil filter 3 Periodical change of the oil and cleaning of the intake filter e Always bleed the circ
232. ositive cable At the end of the operation reconnect first the positive ca ble and then the negative cable e If electric welding operations are to be carried out on the ma chine it is necessary to disconnect the battery and also the al ternator 2 4 18 PRECAUTIONS CONCERNING THE STARTER e Start the engine only when correctly seated in the driving posi tion e Do not start the engine by tampering with the terminals of the starter since the machine may move e Sudden or accidental movements of the machine may cause serious injury or even death 62 REMOVAL RWAO01370 57 RA eee 555 6 94 X 5555 0004 cx 090 4 BEERS 555590 555505 eo 10200 lt gt SS 555555 RZ R OG 5 18380 6860 2 4 19 PRECAUTIONS TO BE TAKEN WHEN USING HIGH PRESSURE GREASE TO ADJUST THE TRACK TENSION e The grease pumped in the track tension adjustment device is pressurized If the specified maintenance procedure is not carried out cor rectly during the adjustment the grease drain valve 1 may come off and cause serious injury or property damage e When loosening the grease drain valve 1 to reduce the track tension do not give more than one turn Loosen the valve slow ly e Keep your face hands feet and other body parts away from the grease drain valve 1 PRECAUTIONS FOR MAINTENANC
233. ours of operation change the hydraulic circuit oil IMPORTANT e When changing the oil filters cartridges check their inner part to make sure that there are no deposits If considerable deposits are observed find out what may have caused them before starting the machine e The number of operating hours is indicated by the hour meter INTRODUCTION 1 3 4 POSITIONS AND DIRECTIONS OF THE MACHINE Operator s seat Left lt gt Right Sprocket In this manual the terms front forward rear backward left and right refer to the travel direction as seen from the operator seat when it is facing the front and the sprocket is at the rear of the machine PRODUCT IDENTIFICATION 1 4 PRODUCT IDENTIFICATION The Komatsu excavator and its main components are identified by serial numbers stamped on the identification plates The serial number and the identification numbers of the components are the only numbers that must be communi cated to the Dealer when requiring assistance and ordering spare parts 1 4 1 MACHINE SERIAL NUMBER The machine serial number is stamped on the front upper part of po the main frame d oo l 1 RKA19120 AND PRODUCT IDENTIFICATION gt NUMBER The Komatsu excavators described in this manual CE marked in fact they are in compliance with the EU harmonised d standards
234. out all the routine maintenance operations prescribed Furthermore the operator must periodically change the components indicat ed in the table in the following page which are especially related to safety and fire prevention rules These compo nents are subject to wear and since it is particularly difficult to evaluate their conditions through simple routine maintenance after a certain time interval it is advisable to change them independently of their state in order to keep them efficient over time Repair or replace these components immediately in case of failures or anomalies even if the time interval prescribed for their change has not elapsed yet If the pipe clamps show signs of deterioration like deformations or cracks provide for changing them together with the pipes In addition to the periodical change of the components listed in the following page the inspections described be low are to be carried out on the hydraulic pipes If any anomaly is observed For the quantities and codes of the safety related components to be changed see the spare parts catalogue When changing pipes always change O rings gaskets and analogous components Type of check Items to be checked Before starting the engine Leakages from joints hydraulic pipes or fuel pipes Leakages from joints hydraulic pipes or fuel pipes Damaged hydraulic or Penodically monthly fuel pipes cracks wear and tear Leakages from joints hydraulic pipes or
235. out or when they reach the wear limits The timely change of these parts ensures an economic use of the machine Use only Komatsu genuine parts which alone can guarantee excellent quality and interchangeability Due to our constant efforts aimed at improving product quality the spare parts codes may be changed therefore when ordering spare parts it is advisable to indicate also the machine serial number to the Komatsu Dealer in or der to receive the most updated version of the component required 4 3 1 LIST OF THE PARTS SUBJECT TO WEAR The parts between parenthesis must be replaced at the same time Part Code Description Qty Change interval ne EVERY 500 HOURS Engine oil filter 600 211 2110 Cartridge 1 OF OPERATION 1 EVERY 500 HOURS Fuel filter 600 311 2110 Cartridge 1 OF OPERATION Hydraulic oil filter 22E 60 12212 Cartridge 1 EVERY 500 HOURS 22E 60 11250 O ring 1 OF OPERATION Water separator 21W 04 41480 Cartridge 1 WHEN REQUIRED Air filter 21W 01 R9250 Main filtering element 1 WHEN REQUIRED 21W 01 R9260 Safety cartridge 1 Work equipment line hy draulic oil filter if installed 201 973 7480 Cartridge 1 WHEN REQUIRED 226 70 11410 Bit holder AR Bucket 226 70 11420 Bit AR 226 70 11430 Pin AR 226 70 11440 Ring AR 201 FUEL COOLANT AND LUBRICANTS 4 4 FUEL COOLANT AND LUBRICANTS
236. ove the hands laterally indicating the distance to be covered RKA15300 18 CARRY OUT THE MOVEMENTS SLOWLY One hand still in front of the hand that indicates the move ment to be carried out The figure represents the lift slowly control RKA15310 19 STOP With one arm extended laterally open the hand facing down wards and move the arm forwards and backwards RKA15320 20 EMERGENCY STOP With both arms extended in horizontal position open the hands downwards and move both arms forwards and back wards RKA15330 41 GENERAL PRECAUTIONS 21 42 STOP THE ENGINE Pass thumb or forefinger across the throat RKA15340 GENERAL PRECAUTIONS 2 2 30 EMERGENCY EXIT e In case of emergency if the cab door cannot be opened use the hammer provided in the cab to break the glass and use the window as emergency exit For further details see 3 2 6 EMERGENCY EXIT HAMMER e When leaving the machine remove the glass fragments from the window frame in order to avoid being injured Take care not to slip on the scattered glass fragments 2 2 31 PREVENTING DAMAGE DUE TO ASBESTOS POWDER If inhaled the asbestos powder present in the air may cause lung cancer There is the risk of inhaling asbestos powder when work ing in places where demolition work is carried out and when han dling industrial waste Always keep to the following instructions e If the materi
237. p INSTRUMENTS AND CONTROLS Free Lock 9EA03227H 9JA03228 103 INSTRUMENTS AND CONTROLS 3 2 10 SIDE COVER A WARNING e Avoid climbing up the cover since there is the risk of slip ping e When carrying out an inspection or maintenance operation inside the side cover always open it completely and make sure that it is kept open by the apposite lever IMPORTANT e The side cover should be kept locked unless there is a pre cise reason for opening it To make sure that it is locked check the direction of the slot on the opening button 1 Release the lock 1 of the side cover For details see 3 2 8 CAP WITH LOCK 2 Press the opening button 1 of the side cover 2 and open it 3 side cover can be kept open in two different positions us ing the stay rod 3 or 4 After opening the side cover 2 insert the stay rod 3 or 4 to lock it in the desired position 4 close the side cover 2 remove the stay rod 3 or 4 in sert it in the apposite retainer then lower the cover slowly and press it downwards to make the lock snap 104 3 2 11 BATTERY INSPECTION COVER IMPORTANT e Keep the cover locked Open it only if necessary 1 Release the lock 1 of the cover For details see 3 2 8 CAP WITH LOCK 2 Insert a finger in the hole 2 and pull to open the cover 3 3 Close the cover 3 Do not
238. perator N Neutral machine at rest IMPORTANT e When the safety lever is in the locked position all the movements are inhibited see 3 2 3 pos 1 Safety device control lever NOTE e On machines equipped with travel alarm shifting the lever to the forward travel or reverse position makes the alarm sound to signal that the machine is starting to move RKA18460 oo RKA18470 RKA18480 6 Pedallock For the boom swing control pedal WARNING e Always shift the safety lever to position when the boom swing is not required during travel and when park ing the machine If the control pedal is inadvertently pressed this may cause serious accidents This device is used to lock the movements of the boom swing control pedal 7 Boom swing control pedal WARNING e When the boom is swung to the left with retracted work equipment if the bucket is wider than a standard bucket it may come into contact with the cab e Always check the distance between the bucket and the cab and work manoeuvring the equipment with care This pedal controls the boom swing to the right and to the left ac cording to the movements indicated below a Swing to the right b Swing to the left N Neutral boom at rest IMPORTANT e When the safety lever is in the locked position all the movements are inhibited see 3 2 3 pos 1 Safety device control lever
239. percentage according to the following conver sion table CHARGE PER TEMPERATURE CENTAGE 20 40 C 20 100 1 28 1 29 1 30 1 31 90 1 26 1 27 1 28 1 29 80 1 24 1 25 1 26 1 27 75 1 23 1 24 1 25 1 26 e Since the capacity of the battery decreases considerably at low temperatures cover the battery or remove it from the machine store it in a warm place and install it again the following morning e If the electrolyte level is low add distilled water in the morning before starting work Do not add water at the end of the work day since the fluid inside the battery may freeze during the night 177 USING THE MACHINE IN COLD CLIMATES 3 5 2 AT THE END OF THE WORK DAY WARNING e Making the tracks turn idly is dangerous therefore it is advisable to keep away from the tracks when car rying out this operation To prevent the mud and water present on the undercarriage from freezing thus making it impossible to move the machine the following morning always take the following precautions e Remove any trace of mud and water from the machine body In particular clean the hydraulic cylinder rod to avoid damaging the gasket due to the penetration of mud or dirt present on the rod together with water drops e Park the machine on firm and dry ground If this is not possible park it on wooden boards in order to protect the tracks and to prevent them from freezing and remaining stuck in the
240. quip ment into the ground N RKA18830 B How to proceed using a block A CAUTION e Find an area where the ground is even and compact e Position some blocks under the frame to stabilize the ma chine carry out this operation with the maximum care Lift the machine using the bucket and the arm Operate the levers slowly 2 Insert a block firmly between the ground and the lifted track and make sure that the machine is stable FRISATROAO 3 Lift the bucket slowly and lower the machine Make sure that the machine is always stable during this oper ation RKA18850 WASHING THE FLOOR 1 Incline the machine For further details see How to incline the machine Swing the turret slowly so that the water draining hole 1 on the cab floor is positioned on the lower side Rest the work equipment on the ground and position the ma chine so that it is stable Shift the safety lever to position lock and stop the machine Remove the floor mat Remove the plug 2 Wash the floor with water draining the dirt through the hole 1 After completing the washing operation put back the plug 2 and the mat MAINTENANCE PROCEDURES RKA18860 RKA18280 9JA03231 235 MAINTENANCE PROCEDURES 4 9 1 0 BLEEDING THE HYDRAULIC SYSTEM For further details see 3 3 6 STARTING THE ENGINE If it is necessary to refer to the engine
241. r body 1 4 Clean the components that have been removed then install a new cartridge 2 and the O ring 4 5 During installation make the filter body come into contact with the filter housing then give a further 1 2 turn 8 G3 AM103050 262 MAINTENANCE PROCEDURES 4 9 11 MAINTENANCE EVERY 2000 HOURS OF OPERATION Carry out these operations together with those to be performed every 50 100 250 500 and 1000 HOURS 4 9 11 a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER Only for machines in which synthetic biodegradable oil HEES is used A WARNING e Retract the arm and bucket cylinders completely rest the bucket teeth on the ground and after stopping the engine eliminate the residual pressures from the equipment by shifting the controls more than once and from the tank by slowly loosening the filler cap e Soon after the machine has been stopped the hydraulic oil is very hot and may cause burns let it cool down to 40 45 C before carrying out this maintenance operation e Immediately clean any area dirty with oil e Oils filters the coolant and the battery are considered special waste and must be collected and dis posed of according to the regulations in force CAUTION e It is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils since when the temperature increases insoluble compounds are generat ed which deposit on the filters a
242. r is provided with two grease nipples positioned on the Cy couplings and that each pin serving as fulcrum point for a movement is provided with at least one grease nipple 9JA03549 e When running in a new machine lubricate every 10 hours for the first 100 hours of operation e After carrying out digging operations with the equipment immersed in water always lubricate the pins that have been in contact with water e Prepare a grease pump 1 Set the machine in the correct position for the lubrification procedure as shown in the diagram on the right lower the work equipment to the ground then stop the engine 2 Use the grease pump to inject grease through the lubrication points indicated by the arrows 3 After completing the lubrication procedure remove any grease that may have come out of the lubrication points 9JA03235 1 Arm bucket coupling pin 1 point 4 9 6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION The following maintenance operation must be carried out after the first 250 hours of operation together with the maintenance operations to be carried out EVERY 250 HOURS e CHANGING THE FUEL FILTER CARTRIDGE e CHANGING THE ENGINE OIL AND THE FILTER CARTRIDGE For further details see paragraph EVERY 500 HOURS 241 MAINTENANCE PROCEDURES 4 9 7 MAINTENANCE EVERY 250 HOURS OF OPERATION Carry out these operations together with those to be performed every 50 HOURS 4 9
243. r pulley A and the fan pulley B exerting a force equal to 58 8 Nm 6 kgf the resulting deflection must be approximately 8 mm A Alternator pulley A Fan pulley C Drive shaft pulley 2 If the deflection exceeds this value adjust by proceeding as indicated below ADJUSTMENT 1 Remove the fan guard 1 2 Insert a lever between the alternator 2 and the engine block and a wooden block between the lever and the alternator to avoid damaging the latter 2 3 Loosen the fastening screws 3 and the adjusting screw 4 4 Push the alternator 2 towards the front of the machine so that the belt deflection is approximately 8 mm approx 58 8 N 6 kgf 5 Tighten the adjusting screw 4 and the fastening screw 3 IMPORTANT e If the belt is worn or in case of doubt on its conditions change it and check the tension again after a few hours of operation 6 Put back the fan guard 1 246 9JA04555 RKA18880 MAINTENANCE PROCEDURES 4 9 7 4 CHECKING AND ADJUSTING THE AIR CONDITIONER COMPRESSOR BELT TENSION If installed A WARNING e Soon after the machine has been stopped the engine is very hot and may cause burns let the engine cool down before carrying out any check e The coolant used in the air conditioning system is very dangerous If it is sprayed into the eyes or in case of contact with the skin it may cau
244. r solutions The customer immediately receives a report containing the results of the analysis and suggestions for the opera tions to be carried out This low cost service is very useful and allows customers to save money and avoid many problems KOWA ANALYSIS STAGES Analysis of metal particles In this stage a ICP Inductively Coupled Plasma analyser is used to measure the density of the metal particles present in the oil LUN 9 AW527790 Measurement of particle quantity In this stage a PQI Particle Quantifier Index machine is used to measure the quantity of large iron particles present in the oil Tomi amp 0 7022 AW527800 Other analyses and measurements In this stage other aspects such as the percentage of water or fuel in the oil and the dynamic viscosity are analysed OIL SAMPLING e Collection interval Every 500 hours engine and other components e Precautions to be taken when sampling the oil Make sure that the oil is well mixed before sampling Carry out sampling regularly at fixed intervals Do not carry out sampling on rainy or windy days when water or dust can get into the oil For further details on KOWA please contact your Komatsu Dealer 198 MAINTENANCE NOTES 4 2 1 5 STORING OIL AND FUEL e Keep oil and fuel indoors to prevent any water d
245. racks or the gasket inside the cyl inder Contact your Komatsu Dealer who will carry out the necessary operations HOW TO DECREASE THE TRACK TENSION A DANGER e It is extremely dangerous to let the grease out following any procedure different from those illustrated below e If the track tension cannot be reduced with this operation contact your Komatsu Dealer who will provide for the nec essary repairs 1 Gradually loosen the grease valve 4 to let the grease out 9JA03792 do not give the valve more than one turn 2 Ifthe grease does not come out smoothly move the machine slowly forward and backward covering a short distance 3 Tighten the grease valve 4 and remove any trace of grease 4 make sure that the tension is correct run the engine at idling speed move the machine slowly forward cov ering a distance equal to the length of the track on the ground then stop the machine 5 Check the rubber track tension again If it is not correct adjust it again IMPORTANT e The rubber tracks wear out to different degrees depending on the work conditions and on the character istics of the surface on which the machine is working It is therefore necessary to check the track ten sion frequently in order to ensure that it is always correct e When working on soft or muddy ground reduce the track tension to extend the service life of the com ponents e After the installation of new track
246. ral position and let the engine idle for at least 2 3 minutes before operat ing the work equipment Move each piston more than once to deaerate the system check and top up if necessary For details on the bleeding procedure see 4 9 1 0 BLEED ING THE HYDRAULIC SYSTEM CAUTION e Do not start the engine with empty tank since this would certainly damage the pump 264 RKA18950 9JA03294 9JM01026 MAINTENANCE PROCEDURES 4 9 11 b CHANGING THE COOLANT CAUTION e The coolant must be changed every 2000 hours of operation or every 2 years whichever occurs first WARNING e Soon after the machine has been stopped the coolant is very hot and under pressure and it may cause serious burns let the engine cool down until it reaches approxi mately 40 45 C before changing the coolant CU e Slowly loosen the radiator cap in order to release any re sidual pressure A e Oils filters the coolant and the battery are considered spe cial waste and must be collected and disposed of accord ing to the regulations in force Do 219 5S 3 CJ 2 lt P qus Jg SN 2 vas S e f 6 8 C C D 9 56 B 1 Ae ees 4 LY IMPORTANT e The change of the permanent coolant does not require any washing cycle for descaling the circuit 1 Open the engi
247. re always wear headphones when using it 6 2 1 DESCRIPTION AND CONTROL The machine is equipped for the installation of a demolition ham mer on the arm instead of the standard bucket It is controlled by means of a button 1 positioned on the right joystick The hammer is operated by pressing the button 1 since in this way pressurized oil is conveyed into the delivery circuit left side release the button to stop the hammer Ay CAUTION e Before using the demolition hammer make sure that the le ver of the selection valve 2 is completely turned anti clockwise RKA18970 285 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 6 2 2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED The choice of the suitable hammer is a very important factor when maximum productivity is required The shape and size of the tool must be defined according to the nature of the material to be bro ken and to the type of work to be carried out The hammer is used to break floors cement structures walls small rocky surfaces excavations with open section aspahlt etc With the application of special accessories it can also be used as asphalt cutter or compactor RYA03830 HOW TO USE THE BREAKER CORRECTLY 1 Make sure that the position of the breaker with respect to the material to be broken is as perpendicular as possible and that the arm thrust is sufficient so th
248. rflow towards the operator s face and feet 3 Air flow towards the operator s feet RKA19020 110 3 AIR FLOW SELECTION SWITCHES These switches are used to select the intensity of the air flow coming from the heater and four ventilation levels are available The LO low switch is used to decrease the air flow while the HI high switch is used to increase the air flow The selected flow is indicated by the coming on of the corre sponding LED The LEDs slide progressively and follow the direction of the ar rows stamped on the switches 4 AlR Recirculation selection switch This is an ON OFF switch and is used to activate the air recircula tion inside the cab which is useful to heat the cab more quickly and when working in extremely polluted areas IMPORTANT e Do not use the air recirculation function for long periods in rainy or cold days since this would increase the fogging of the inside of the windows 5 Defrosting lever The lever 5 is used to activate the defrosting function of the front windshield in case of cold or rainy weather Lever pushed forward Defrosting function on Lever pulled backward Defrosting function off INSTRUMENTS AND CONTROLS O O O O gt gt 19050 RKA19060 RKA19070 111 INSTRUMENTS AND CONTROLS 3 2 16 AIR CONDITIONER if installed DANGER
249. rted or stopped with the ignition switch in position ON the warning light may come on and the acoustic alarm may sound for a while but this does not indicate any anomaly 2 FUEL LEVEL WARNING LIGHT This warning light 2 indicates that the fuel level in the tank has decreased The fuel level warning light starts blinking when there are still ap prox 30 litres of fuel in the tank At this point it is necessary to re fuel as soon as possible INSTRUMENTS AND CONTROLS 9JH01666 9JA03305 73 INSTRUMENTS AND CONTROLS 3 2 1 2 EMERGENCY WARNING LIGHTS CAUTION e If a warning light does not go out or comes on when the engine is running stop the machine immediate ly and try to find the cause of the failure These warning lights must always be checked while the engine is running In case of anomaly the corresponding warning light starts blinking and the acoustic alarm sounds Carry out the necessary repairs immediately 88888 8 9JA04339 RE S Qoc mir f 1 Engine coolant temperature warning light 3 Overload alarm warning light 2 Engine oil pressure warning light 74 1 ENGINE COOLANT TEMPERATURE WARNING LIGHT This warning light 1 signals any abnormal increase in the engine c
250. running e Always use the proper safety devices to lock the machine when parking always fasten the seat belt e Do not remove the safety devices and always keep them in good operating conditions e Any improper use of the safety devices may result in serious injury or even death 2 2 6 CLEANING THE MACHINE e Spilled oil or grease scattered tools or broken pieces are dan gerous because they may cause someone to slip or trip Al ways keep the machine and the work site clean and tidy ME e To clean the machine use a pressurized jet of warm water or steam and the specific detergents available on the market Do not use diesel oil oil or solvents since the former leave an oily coat that favours the sticking of dust while the latter even if weak damage the painted surfaces and therefore facilitate rust ing 00320 While cleaning the machine keep the pressurized jet at a mini mum distance of approx 60 cm in order not to damage the warning plates and the pictograms If the plates are damaged request Komatsu or your Komatsu Dealer to send you spare plates and change them lt lt SOON ett 7500 oie xs Water into the electrical system provokes the oxidation of the contacts and may hinder the start of the machine or even make it start suddenly and abruptly For this reason avoid using water or steam jets to clean sensors connectors or the inside of the operator s cab
251. rwise tighten the nuts of the hoses applying the torque specified in the table If it is necessary to replace a hose always use Komatsu original spare parts having the same size of the part to be replaced RKA12600 Nm Newton metre 1 Nm 0 102 kgm Thread diameter Wrench size TIGHTENING TORQUE a mm kgm Nm 9 16 18 17 3 1 3 5 30 34 11 16 16 22 5 6 6 6 55 65 13 16 16 24 7 6 8 7 75 85 17 14 30 11 7 12 7 115 125 1 3 16 12 36 15 8 16 8 155 165 1 7 16 12 41 18 4 20 4 180 200 1 11 16 12 50 20 4 22 4 200 220 2 12 57 22 4 25 5 220 250 206 LUBRICATION 4 6 LUBRICATION 4 6 1 LUBRICATION DIAGRAM IMPORTANT e For details on how to lubricate specific parts see 4 9 5 a LUBRICATION and 4 9 7 a LUBRICATION e The type of lubricant to be used is indicated in the lubricant table see 4 4 FUEL COOLANT AND LUBRI CANTS Grease KOMATSU 7 4 gt Filter 10 gt Y 1 Z NW Y 2508 500h 10008 gt h 00h gt 5000h gt RKA18800 207 PERIODICAL CHANGE OF SAFETY RELATED COMPONENTS 4 7 PERIODICAL CHANGE OF SAFETY RELATED COMPONENTS To ensure safety at any moment while driving and using the machine the operator must carry
252. s it is advisable to carry out a first check after 10 hours of operation 4 9 1 h CHANGING THE ROAD LINERS For machines equipped with road liners e If it is necessary to change all the road liners contact your Komatsu Dealer who will carry out the necessary op erations e When on the other hand only some road liners must be changed use the special tool that can be required to Komatsu Dealers 226 MAINTENANCE PROCEDURES 4 9 11 CHANGING THE RUBBER TRACKS For machines equipped with rubber tracks A WARNING e This operation must be carried out by two persons One operator must be seated in the cab and ma noeuvre the machine following the signals of the other operator who carries out the change and the ad justment e The track must be changed with the frame raised from the ground be careful not to shift any control le ver while the operator is working e During the change do not remove any component apart from the track e If the track tension cannot be reduced by means of the procedure described above contact your Komat su Dealer for the necessary repairs IMPORTANT e It is possible to switch from rubber shoes to steel shoes and road liners However it is necessary to re move the guard of the idler roller and to carry out an adjustment then it is advisable to have the change carried out by a Komatsu Dealer REMOVING THE RUBBER TRACKS 55555 Ze e The grease contained in the hydrau
253. s 105 3 2 12 IET 106 3 213 MAIN FUSE utu aai haec dst itid cttm Sere esie due 108 3 214 CONTROLLER re ir eee ee edes ae d te dete 108 3 2 15 VENTILATION AND 109 3 2 15 1 HEATING AND DEFROSTING CONTROL 109 3 2 16 AIR CONDITIONER if installed sse e enne enne 112 3 2 16 1 AIR CONDITIONER CONTROL PANEL seen 113 3 2 17 TECHNICAL DOCUMENTATION COMPARTMENT 116 3 2 18 TOOL BOX poate con ast saat ites p tig tna a Det acetone 116 3 2 19 GREASING PUMP 5 116 3 2 20 ASHTRAY t cte e no aaa ES 117 3 2 21 FIRE EXTINGUISHERS in eee e haa ncaa 117 3 2 22 EIRSTSAIDKIT uh e suet Saves hate asta a 117 TABLE OF CONTENTS 3 3 14 USE OR THE MACHINE 5 nerit er repetat citer stasavanniucestcassdevechunapasasnvunsslleduuesaibutevacdisaasteunsted 3 3 1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE 33 11 VISUAL GHEGNKS iii ttai ee eee Oe noti ear Savane e eat 332 DAILY CHECKS rene Ie rt ii tee ain dn a a t sd nn d 3 3 2 1 CHECKING THE COOLANT LEVEL AND TOPPING 3 3 2 2
254. s correctly balanced proceed slowly and do not allow any one to get near the load 9JA03838 e Before lifting the additional counterweight make also sure that the eyebolts are correctly fastened to the upper holes 1 Loosen the 4 screws 1 and remove the rear plate 2 2 Remove the plugs 3 3 Liftthe additional counterweight 4 with a crane and install it on the back of the standard counterweight IMPORTANT e Use a cable A and eyebolts B properly dimensioned for the weight to be lifted Weight of the additional counterweight 220 kg 4 Install the washers 6 and the nuts 5 and fix the additional counterweight by tightening the nuts 5 with the appropriate torque Driving torque from 455 to 565 Nm from 46 5 to 58 kgfm 3JA03840 5 Install the plugs 7 on the holes provided for fastening the eyebolts 6 Put back the rear plate 2 9JA03841 297 298 THIS PAGE WAS INTENTIONALLY LEFT EMPTY 2006 KOMATSU UTILITY EUROPE S p A All Rights Reserved Printed in Europe 12 2006
255. s slip reduces their duration e Do not dirty the road liners and the rubber tracks with oil fuel or chemical solvents If one of these substances gets on the tracks clean them immediately Furthermore do not travel on road surfaces that are dirty with oil e When the machine is going to remain unused for a long period 3 months or more keep it indoors away from direct sunlight and protected from rain 163 USE OF THE MACHINE e Do not use the machine in areas where the temperature is particularly high for example in the presence of burn ing wood hot steel plates or on roads that have just been asphalted e Do not use the machine lifting one track only by means of the work equipment This damages the rubber tracks and may also cause them to come off e When the rubber parts of the road liners are worn out or damaged to the extent that the head of the bolts is scratched change the track immediately If the bolt heads break they cannot be removed any more e When installing the road liners always install them on all the articulations and on both sides If they are installed on one side of the articulations only their duration is reduced considerably 3 3 24 4 HOW TO PRESERVE THE ROAD LINERS AND THE RUBBER TRACKS OVER TIME To avoid damaging the road liners and the rubber tracks keep to the following instructions during work e Avoid counter rotations on concrete surfaces since concrete may scrape the rubber off e Avoid sudden
256. se blindness or frostbite To avoid any explosion do not gener ate sparks and do not use naked flames near the air conditioner e The adjustment of the belt tension is a mechanical operation and must be carried out without working on the air conditioning system CHECK The compressor belt can be reached after opening the engine hood see 3 2 9 ENGINE HOOD 1 The check is manual press the belt with one thumb on the intermediate point between the compressor pulley A and the fan pulley B exerting a force equal to 58 8 Nm 6 kgf the resulting deflection a must be approximately 10 12 mm A Compressor pulley A Fan pulley 2 If the deflection exceeds this value adjust by proceeding as indicated below RKA19310 RKA18900 ADJUSTMENT 1 Loosen the screws 1 and 2 2 Insert a lever between the compressor 3 and the engine block and push the compressor towards the outside of the machine so that the belt deflection is approximately 10 12 mm approx 58 8 N or 61 kgf 3 Tighten the screws 1 and 2 to fix the compressor IMPORTANT e If the belt is worn or in case of doubt on its conditions change it and check the tension again after a few hours of RKA19320 operation 247 MAINTENANCE PROCEDURES 4 9 8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION Only for machines in which synthetic biodegradable oil type HEES is used The following
257. securely e Do not use fuel to clean any part of the machine that is dirty with oil or dust e Always top up the fuel and oil tanks in properly ventilated areas and refrain from smoking e When refuelling hold the fuel gun firmly and keep it constantly in contact with the filler until you have finished in order to avoid sparks due to static electricity e Do not fill the tank completely in order to leave room for the fuel to expand 60 00320 00310 2 4 15 CHECKING THE COOLANT LEVEL IN THE RADIATOR e Let the engine and the radiator cool down before checking the coolant level e If it is necessary to remove the cap with hot engine wear suita ble clothes and protections and loosen the cap slowly in order to release the pressure gradually 2 4 16 USING LAMPS e When checking the fuel oil coolant or battery electrolyte level always use homologated explosion proof lamps If such lamps are not used there is danger of fire or explosion PRECAUTIONS FOR MAINTENANCE RKA00270 00260 61 PRECAUTIONS FOR MAINTENANCE 2 4 17 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR e When carrying out repairs on the electric system or electric welding operations remove the negative terminal of the bat tery to prevent the passage of current IMPORTANT e Disconnect first the negative earth cable and then the p
258. sition lock e When carrying out operations near the fan the fan belt or other rotating parts be careful to avoid getting entangled in these parts and proceed very carefully e Do not touch any control lever If it is necessary to operate a control lever warn the other workers so that they can move to a safer place e Be careful to avoid introducing or letting tools or other objects fall in the fan or the fan belt Some parts may break or be eject ed 2 4 6 TOOLS Use only tools that are suitable for the job at hand and make sure to use them in the correct manner The use of damaged low quality faulty or unsuitable tools or the incorrect use of the tools may cause serious injuries 2 4 7 HYDRAULIC ACCUMULATOR The hydraulic accumulator contains pressurized nitrogen When carrying out any operation on the accumulator do not pro ceed carelessly since this may cause an explosion and conse quently serious injury and even death For this reason keep to the following instructions e do not remove the accumulator e do not bring the accumulator near sparks or naked flames e do not make holes in the accumulator do not weld or use oxy hydrogen flames e do not hit or press the accumulator e when disposing of the accumulator take care to release the gas it contains Have this operation carried out only by a Komatsu Dealer 58 00880 18360 00890
259. sk for the safety of the operator and of the persons standing before the machine If the engine stops suddenly immediately lower the bucket to the ground 48 LL 15 max RKA17470 SA 20 30 cm T ur 15 max RKA17480 im 20 30 cm RKA17490 42 RYA00550 2 3 2 5 WORKING ON SLOPES e Operations on slopes and on river or lake banks with damp ground may cause the machine to tip over or slip e When working on slopes max inclination 10 avoid turning the turret if possible since this may cause the machine to lose balance and overturn It is particularly dangerous to swing the equipment on slopes when the bucket is full If these operations are going to last long accumulate soil in such a way as to create a horizontal platform on which the ma chine can be positioned 2 3 2 6 UNAUTHORIZED OPERATIONS e Do not carry out excavations under overhangs Stones may fall down or the overhang may collapse on the machine e Do not excavate too deeply under the front of the machine The ground under the machine may collapse and cause the ma chine to fall e To make it easier to escape from the machine in case of emer gency set the tracks at right angles to the road shoulder or coast with the sprocket at the rear when carrying out digging operations PRECAUTIONS FOR USE RYA00560 00570 00580 00
260. sure that the hydraulic tank is pressurised If the tank isn t under pressure the pump will suck in air and this will damage the equipment 16 Make sure that all the control levers are in neutral position and let the engine idle for at least 2 3 minutes before operat ing the work equipment Move each piston more than once to deaerate the system check and top up if necessary For details on the bleeding procedure see 4 9 1 0 BLEED ING THE HYDRAULIC SYSTEM A CAUTION e Do not start the engine with empty tank since this would certainly damage the pump 270 RKA18950 9JA03294 9JM01026 TECHNICAL SPECIFICATIONS
261. sversally 3 Swinging the turret on slopes RYA03680 e When work equipment with overall dimensions exceeding those of the standard equipment is installed be particularly careful since more space is necessary for manoeuvring the equipment and for swinging the turret e Always follow the correct procedure when installing the boom and the arm Any incorrect procedure may lead to serious risks contact your Komatsu Dealer before installation 283 AUTHORIZED OPTIONAL EQUIPMENT 6 1 3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT Specific weight of the handled material 1 8 t cu m MAX MAX DIMENSIONS MAX MAX OPERAT MAX WEIGHT CAPACITY ING FLOW EQUIPMENT Width Height SAE PRESSURE RATE kg mm mm m3 bar I min Backhoe bucket 200 750 0 28 Ditch cleaning bucket 180 1500 0 28 Ditch digging bucket 180 1600 900 0 38 Adjustable bucket 250 1500 1000 0 25 280 m 130 Clamshell bucket 300 400 1000 0 20 280 m 130 Hydraulic breaker 400 1400 280 m 130 System pressure W System capacity 284 Hydraulic rotor included ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 6 2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLI TION HAMMER A WARNING e For the characteristics of the hammer see 6 1 3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT e The demolition hammer is very noisy therefo
262. t Opening 1 Stop the machine on a level surface lower the equipment completely to the ground then stop the engine 2 Shiftthe safety lever to the locked position Make sure that the windshield wiper is positioned correctly 4 Seize the handles A on the top right and left of the front windshield then pull the locking levers B towards yourself to release the front windshield The upper part of the front windshield can be extracted w 94 RKA18280 LO lt Tau I 9 403146 9JH01572 9JH01573 Seize the lower handle C with your left hand from the inside of the cab and with your right hand seize the upper handle D pull it upwards and push it against the retainer E until engaging the glass INSTRUMENTS AND CONTROLS a 9JH01574 9JH01576 95 INSTRUMENTS AND CONTROLS 6 Make sure that the safety lever is in the locked position NOTE e The retainer has been correctly fitted if the arrow on the retainer F corresponds to the arrow on the locking lever B e If the arrow on the retainer F does not correspond to the arrow on the locking lever B this means that the retainer hasn t been fitted correctly To engage the retainer correctly repeat the op eration des
263. t is dangerous to charge the battery when it is installed in the machine Always remove it before recharge Before carrying out any work on the battery stop the en gine and turn the ignition key to position OFF The battery produces hydrogen which may explode Do not smoke and avoid producing sparks near the battery The battery electrolyte is made of diluted sulphuric acid that may corrode clothes and even the skin in case of con tact with this fluid immediately rinse the involved part with plenty of water If the acid gets into the eyes immediately rinse with plenty of water and consult a doctor without de lay When working on the battery always wear goggles and rubber gloves When removing the battery disconnect the earth cable first When installing the battery connect the positive ter minal first If a tool touches the positive terminal and the frame of the machine at the same time sparks may be generated thus causing an explosion hazard Carefully tighten the connection terminals since false con tacts may generate sparks with consequent risk of explo sion The accumulation of oxide around the terminals causes the battery to discharge Clean the terminals carefully and cov er them with a thin film of grease before installation ot RYA02950 181 TROUBLESHOOTING 3 7 6 REMOVING AND INSTALLING THE BATTERY REMOVAL 1 Open the side cover 1 and the battery inspection cover 2
264. t it from moving The distance between the ramps and their alignment must be adapted to the wheelbase of the trailer and the track gauge of the machine Make sure that the two sides are at the same height The inclination of the ramps cannot exceed 15 Select the low speed using the travel speed selection switch warning light Lo on Run the engine at low speed During the loading operations position the work equipment at the front and the blade at the rear of the machine with the turret and the undercarriage parallel to each other Before getting on the ramps make sure that the machine is in line with the ramps and that the centerline of the machine corresponds to the centerline of the trailer Move the machine toward the ramps and travel slowly Lower the work equipment as much possible avoiding any contact with the trailer When the machine is on the ramps operate only the travel levers TRANSPORTING THE MACHINE Distance between ramps 00670 9JA03200 Low idling 9EA03202 oer 9JA03599 169 TRANSPORTING THE MACHINE T 170 Stop the machine where required then swing the turret slow ly by 180 9JA03600 3 4 2 2 HOW TO SECURE THE MACHINE After loading the machine on the trailer secure it by proceeding as indicated below IMPORTANT e To avoid damaging the bucket cylin
265. t with the work equipment resting on the ground The lubrication must be carried out after thoroughly cleaning the grease nipples by applying the grease pump filled with the pre Scribed grease see 4 4 FUEL COOLANT AND LUBRI CANTS Once the lubrication procedure has been completed make sure that all the points have been lubricated and remove the used grease that has spread out of the ball bearing ring IMPORTANT e It is advisable to inject grease in all the grease nipples no 2 arranged to form an angle of 180 in order to obtain a correct distribution and a sufficient quantity of new grease 4 9 9 4 CHECKING THE GREASE LEVEL IN THE BALL BEARING RING PINION AND TOP PING UP WARNING e Carry out this check with the machine at rest on level surface and at the end of work that is at operating temper ature e Oils filters the coolant and the battery are considered spe cial waste and must be collected and disposed of accord ing to the regulations in force 1 Loosen the screws 1 and remove the cover 2 2 Loosen the screws 3 on the top of the turret and remove the cover 4 3 Check the grease 4 Ifthe grease is milky white change it To carry out this opera tion contact your Komatsu Dealer The total quantity of grease is 5 5 5 kg 5 Install the grease filling cover 4 and the cover 2 258 9JA03428 9JA04980
266. tenance operation position the ma chine on a firm and level surface lower the equipment to the ground engage the safety locks of the equipment and the con trols and stop the engine e f another person starts the engine and operates the control le vers while the operator is servicing the machine this may result in serious injury or even death e To avoid these risks always attach warning plates to the control levers and to the ignition key before performing any mainte nance operation if necessary attach additional warning tags al so around the machine and in particular to the cab door handles Do NOT START THE ENGINE RKA00340 2 4 2 KEEP THE WORK PLACE CLEAN AND ORDERLY e Do not leave hammers or other tools lying around in the cab Remove any trace of grease oil or other substanc es that may cause the floor or the steps to become slippery Always keep the cab clean and orderly in order to be able to carry out any operation in total safety If the cab isn t clean the operator runs the risk of slipping stum bling or even falling on the floor e To clean the roof window which is made of organic glass polycarbonate use tap water and avoid using organic solvents Organic solvents like benzene toluene or methanol may cause a chemical reaction with glass thus de teriorating the polycarbonate surface 2 4 3 APPOINT A SUPERVISOR WHEN WORKING WITH OTHER PEOPLE e When carrying out repairs on th
267. the operator seat Be sure to have put your cigarette off completely before closing the cover 9JHO1693 3 2 21 FIRE EXTINGUISHERS E e The owner of the machine is responsible for installing and fixing the fire extinguisher where prescribed e Periodically make sure that the fire extinguisher is full 254 If the operator fears that he may need a fire extinguisher on the 2 machine he must fix it in the apposite compartment behind the 2 8JA03553 seat 3 2 22 FIRST AID KIT Ay CAUTION e Periodically make sure that the first aid kit contains the necessary disinfectants bandages medicins etc and check their condition and expiry date The first aid kit case must be positioned inside the cab and pre cisely in the rear storage compartment by the owner of the ma chine RKA18560 117 USE OF THE MACHINE 3 3 USE OF THE MACHINE 3 3 1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE 3 3 1 1 VISUAL CHECKS Before starting the engine look around the machine and under the machine to check for loose nuts or bolts oil fu el or coolant leakages and check the conditions of the work equipment and the hydraulic system Check also for loose wires excessive gaps and accumulation of dust in places that reach high temperatures A WARNING e When carrying out checks or maintenance operations inside the engine hood or the side cover make sure that they are completely open and s
268. the ramps cannot exceed 15 3 Remove the chains and metal cables that fix the machine 4 Start the engine and warm it up 5 Release the safety lever 9EA03180 6 Runthe engine at low speed 7 the blade 2 4 Low idling 8 Select the low speed using the travel speed selection switch warning light Lo on KOMATSU 9JA03200 172 TRANSPORTING THE MACHINE Raise the work equipment make sure that the travelling di rection of the machine corresponds to the direction of the ramps and proceed slowly Lower the work equipment as much possible avoiding any contact with the trailer When the machine is on the ramps operate only the travel levers 9JA03601 173 TRANSPORTING THE MACHINE 3 4 5 HOW TO LIFT THE MACHINE WARNING e Do not lift the machine if the operator is still on board e Always make sure that the metal cable used to lift the machine is sufficiently strong for the weight being lifted e Do not lift the machine with the turret swung laterally Before lifting the machine swing the work equip ment to the sprocket side then position the undercarriage and the turret parallel to each other e Always keep the machine in horizontal position during the lifting operations e Do not stand under the machine when this is suspended e Do not attempt to lift the machin
269. ting con ditions check the coolant level in the expansion tank daily and top up when necessary e The coolant containing antifreeze is flammable do not use naked flames near the coolant and do not smoke while topping up e Use only red permanent ethylene glycol based antifreeze with corrosion inhibitors and antifoam products suita ble for aluminium radiators If pure dilute with water 50 e The use of permanent antifreeze requires only the check of the level and the periodical change of the fluid It is not necessary to wash the cooling circuit e Use drinkable water and in any case soft water e Do not use corrosion inhibitors containing soluble oil since they damage the rubber couplings e In case of doubt regarding the applicable standards for the use of coolant contact your Komatsu Dealer who will supply you with exhaustive and precise information 197 MAINTENANCE NOTES 4 2 1 4 KOWA KOMATSU OIL WEAR ANALYSIS This system requires that oil samples be periodically collected and analysed This is a preventive maintenance service which makes it possible to identify faulty parts or worn machine components timely It also allows many failures to be prevented and machine downtime to be reduced Many years of experience and the availability of countless data and information allow Komatsu to accurately deter mine the conditions of the machine This also allows us to locate troubles and suggest the most suitable and fast repai
270. tion around level L Oil temperature from 10 to 30 C e Normal operation near level H Cil temperature ranging from 50 to 80 C 4 When topping up the hydraulic tank with the machine in posi tion A extend the boom arm and bucket cylinders complete ly as shown in the diagram on the right then tighten the oil cap again and pressurize the hydraulic tank IMPORTANT e Make sure that the hydraulic tank is pressurized If the tank isn t under pressure the pump will suck in air and this will damage the equipment 124 9JA03169 9JA00561 9JM01026 3 3 2 5 CHECKING THE AIR FILTER CLOGGING INDICATOR 1 Open the engine hood and make sure that the red piston is not visible in the indicator 1 2 If the red piston is visible clean or replace the filtering ele ment immediately For further details on how to clean the filtering element see 4 9 1 4 CHECKING CLEANING OR CHANGING THE AIR FILTER CARTRIDGE 3 After the check cleaning operation or change press the but ton on the indicator 1 to move the red piston back to its orig inal position 3 3 2 6 CHECKING THE WATER SEPARATOR WARNING e Fuel is flammable do not use naked flames and do not smoke while draining the water separator e If fuel is spilled wipe it up immediately If the red ring 5 of the water separator is on the bottom of the cup 4 this means that there is no water If the red ring
271. ton 11 Cigarette lighter 24V 5 Work light switch 12 Overload alarm switch 6 Acoustic alarm stop switch 13 Power outlet 24V 7 Revolving light switch optional 14 Clamshell bucket opening button 8 Pump system deactivation emergency switch 15 Clamshell bucket clamping or demolition hammer control button 82 1 Ignition switch This is a four position rotary switch and is used to switch the en gine on and off Position OFF The key can be inserted or removed The switches of the electric system are all off except for the overhead light and hour meter switches and the engine is off Position ON Electric current flows in the recharge circuit and in the lighting cir cuit Keep the ignition switch in position ON while the engine is running Position START This is the engine start position Keep the key in this position while starting the engine As soon as the engine starts release the key which will automatically return to position ON Position HEAT preheating When starting the engine in cold climates turn the key to this po sition When the key is in position HEAT the preheating warning light comes on Keep the key in this position until the preheating warning light starts blinking As soon as the warning light starts blinking release the key Release the key which will automatical ly return to position OFF At this point start the engine by turning the key to position START NOTE e The engi
272. tribution line 5m 6 6 kV 2 3 insulators 5 2m 33 kV min 3 insulators 5 5m 66 kV min 6 insulators 6m 154 kV min 10 insulators 8m 275 kV min 19 insulators 10m 5 ISO PATTERN e Indicates the movements of the machine and of the work equip ISO PATTERN ment 22M 98 12120 6 OPENING THE FRONT WINDSHIELDS e To open or close the front windshields upper and lower stand up from the operator seat only after shifting the safety lever to position lock If a control lever is inadvertently operated the machine may move suddenly and cause serious accidents 22 SAFETY NOISE AND VIBRATION PLATES 7 LOCKING THE FRONT WINDSHIELD e Make sure that the front windshield is always locked 09803 A0481 esp 8 RISK OF BURNS e Do not open the radiator and the hydraulic oil tank when the en gine is still hot 09653 A0481 9 HOT PARTS OF THE MACHINE e Risk of burns in case of contact with hot parts like the engine or the exhaust silencer soon after the engine has been stopped 09817 A0753 10 ADJUSTING THE TRACK TENSION e The adjustment of the tracks involves the risk of injuries Keep to the instructions given in this manual AN Li 09657 0881 SAFETY NOISE AND VIBRATION PLATES 11 BATTERY AND ELECTRIC CABLES e Risk of electric charges in case of work on the battery or the electric cables 12 DO NOT OPEN THE ENGINE HOOD
273. ty regulations and the rule of the road e Do not attempt to start the engine by causing a short circuit with the terminals of the starter This may cause serious injury or even fires e Start the engine only while seated with fastened seat belt e Before starting the engine make sure that there is no one within the operating range of the machine and sound the horn e Exhaust gas is toxic When starting the engine in closed places make sure that there is sufficient venti lation IMPORTANT e Do not attempt to start the engine with the hand accelerator set at the maximum rpm in order to avoid damaging the engine components Q e Do not make the starter run for more than 20 seconds with is out interruption If the engine does not start wait at least 2 2 minutes before trying again WS 2 RKA18620 1 Make sure that the safety lever 1 is in the locked position L If the lever has been released it is not possible to start the engine RKA18280 2 Shiftthe hand accelerator 2 to the idling position 2 4 Low idling 9EA03202 133 USE OF THE MACHINE 3 Turn the ignition key 3 to position START to start the en gine RYA17360 4 As soon as the engine starts release the key 3 which will automatically return to position ON RYA17370 5 Letthe engine idle for the first 15 seconds soon a
274. uit after changing the oil filter or the oil e When a component is removed from the circuit check the gaskets and O rings and change them if they are dam aged e When a cylinder or a component of the hydraulic circuit is removed after reassembly bleed the circuit by pro ceeding as follows 1 Startthe engine and let it idle 2 Extend all the cylinders 4 5 times stopping them at approx 100 mm from the end of stroke 3 Slowly make all the cylinders reach the end of stroke for 3 4 times 4 2 4 MAINTENANCE NOTES REGARDING LUBRICATION e Lubrication makes the operations carried out with the machine and work equipment smoother while preventing wear and the noise that may be produced if the joints are dry Lubricate with grease or oil e The maintenance operations required for the components that need lubricating are the following 1 Check ofthe levels 2 Oil change 3 Injection of grease through the grease nipples e Use only the specified lubricants according to the ambient temperature e Always clean the grease nipples before injecting grease and remove any excess grease after lubrication this cleaning operation must be performed with extreme care on the revolving parts e Maintain correct lubricant levels avoiding excessive or insufficient quantities 200 PARTS SUBJECT TO WEAR 4 3 PARTS SUBJECT TO WEAR The parts subject to wear like filters bucket teeth etc must be changed when periodical maintenance is carried
275. ure to decrease until the green area A lights up again After starting the engine keep warming it up until the coolant temperature increases and the green area of the indicator lights up instead of the white area C NOTE e When segment D lights up also the engine coolant temperature warning light F starts blinking e When segment E lights up also the engine coolant temperature warning light F starts blinking The acoustic alarm sounds at the same time 4 FUEL GAUGE This indicator 4 shows the fuel level in the tank When the en gine is running normally the green area A of the indicator should be lit If the red area B starts blinking while the engine is running this means that there are still 30 litres of fuel in the tank therefore it is necessary to check and refuel The correct level may not be indicated for a short lapse of time soon after the ignition switch has been turned to position ON but this does not mean that there is an anomaly NOTE e When the red area B of the fuel gauge lights up also the fuel level warning light C starts blinking INSTRUMENTS AND CONTROLS 9JA03130 9JA03131 9JA03132 77 INSTRUMENTS AND CONTROLS 5 DISPLAY This display 5 gives failure signals if any anomaly is detected on the machine NOTE e In case of machine failure
276. vicinity keeps a safety distance and that he she does not run the risk of being hit by falling or flying objects e The advice given above is based on the assumption that the machine works in standard operating conditions but it may be necessary to add further guards depending on the specific con ditions of the workplace Contact your Komatsu Dealer for fur ther advice on this matter RYA00420 2 2 17 PRECAUTIONS CONCERNING THE EQUIPMENT e When installing and using optional equipment carefully read the relevant manual and keep to the instructions given therein e Do not use optional or special equipment without the authorization of Komatsu or one of its Dealers The installation and use of unauthorized equipment may create safety problems and adversely affect the effi ciency and life of the machine e Komatsu cannot be held liable for any injury damage or product failure resulting from the installation and use of unauthorized equipment 2 2 18 COMBINING THE WORK EQUIPMENT Depending on the type or combination of the equipment this may hit the cab or other parts of the machine Before using work equipment with which he is not familiar the operator should check if there is the risk of interferences and proceed with care 34 GENERAL PRECAUTIONS 2 2 19 WORK LIGHT AND CAB LIGHTS e Remove any trace of dirt from the lights in such a way as to ensure perfect visibility on the work area e Make sure that all the lights
277. wer supply F19 F20 F21 Light blue 15 Work lights power supply F22 Red 10 PPC buttons power supply F23 F24 F25 F26 Red 10 Work lights power supply F27 Red 10 Monitor power supply F28 Red 10 Optional equipment revolving light and radio power supply F29 Yellow 20 Fans power supply F30 Orange 5 Air conditioning power supply electronic F31 106 INSTRUMENTS AND CONTROLS F32 F33 Red 10 Controller power supply VIS F34 Red 10 Cigarette lighter and windshield washer power supply F35 Light blue 15 Engine stop power supply 2 Gs NJ A zx RKA18540 107 INSTRUMENTS AND CONTROLS 3 2 13 MAIN FUSE If the starter does not run when th
278. whatsoever it should be impossible to open the cab door and it should be necessary to leave the cab because of an emergency use the hammer A To get out of the cab break the glass with the hammer A and pass through the resulting opening INSTRUMENTS AND CONTROLS 9JA03147 9JA03577 L Z SWE NES S AE301660 99 INSTRUMENTS AND CONTROLS 3 2 7 SIDE WINDOW A WARNING e When opening or closing the side window always shift the safety lever to position lock If the control levers are not locked and are inadvertently operated there is the risk of serious accidents The rear part of the side window can be opened either partially or completely To open the window partially proceed as follows 1 Release the lever 1 from the lower coupling pin 2 follow ing the direction of the arrow shown in Figure A 2 Lift the lever 1 with a simple sliding movement and at the same time push the lever toward the outside of the cab After lifting the lever 1 push its end downward in order to engage it in the upper coupling pin 3 as shown in Figure B If it is necessary to open the rear part of the side window com pletely proceed as follows 1 Release the lever 1 from the upper coupling pin 3 follow ing the direction of the arrow shown in Figure C 100 RKA18280 RKAB6890 INSTRUMENTS AND CONTROLS 2 With th
279. without carrying out the monthly rust prevention treatment and it is nec essary to use it contact your Komatsu Dealer Before using the machine after a long period of inactivity carry out the operations listed below e Remove the grease from the hydraulic cylinder rods e Add oil and grease where necessary e When the machine is not used for a long period the air humidity contaminates the oil Check the oil before and after starting the engine If there is water in the oil change the oil e The fuel tank is made of plastic therefore do not clean it using trichloroethylene based solvents The use of trichloroethylene may damage the tank 179 TROUBLESHOOTING 3 TROUBLESHOOTING 3 7 1 IF FUEL RUNS OUT COMPLETELY After running out of fuel refuel and bleed the fuel system before starting the machine For further details on the bleeding procedure see 4 9 9 a pos BLEEDING THE CIRCUIT 3 7 2 OCCURRENCES THAT ARE NOT FAILURES Pay attention to the following occurrences that are not consid ered failures e When the arm control lever is shifted to the folding position and the work equipment is lowered without load from a high posi tion the arm speed drops momentarily according to the more or less vertical position of the arm itself e When the bucket control lever is shifted to the folding position and the work equipment is lowered without load from a high po sition the bucket speed drops momentarily according to the mor
280. work equipment control lever Cigarette lighter 24V Blade control lever Ignition switch Hand accelerator Work light switch No NO ND ND BRON BRWWWWWWWWWWNNND NB UOUN V LL rr Acoustic alarm stop switch Revolving light switch optional Pump system deactivation emergency switch Boom and turret swing brake deactivation emergency Switch Travel speed selection switch Work mode selection switch Battery charge level warning light Engine oil pressure warning light Engine coolant temperature indicator Engine coolant temperature warning light Display for displaying failures Fuel level warning light Fuel gauge Hour meter Overload alarm warning light Preheating warning light Quick deceleration warning light Windshield wiper switch Windshield washer switch Quick hydraulic coupling lock release button INSTRUMENTS AND CONTROLS 3 2 INSTRUMENTS AND CONTROLS The following paragraphs describe the devices that are necessary for correct operation of the machine To perform the required operations correctly and safely it is important to understand the equipment operating methods and the meaning of the information displayed 3 2 1 DASHBOARD 88888 89 9JA04337 A Warning lig
281. xtremely cold areas in particular their duration is reduced e In consideration of the properties of rubber it is advisable to use the road liners and the rubber tracks at temper atures included between 25 C and 65 C between 13 F and 149 F e When performing operations with the bucket take care not to damage the road liners and the rubber tracks with the bucket itself To prevent the rubber tracks from coming off pay the utmost attention to the following Even when the track ten sion is correct carry out every operation with the maximum care 164 USE OF THE MACHINE Avoid steering when moving on kerbs rocks or areas with considerable differences in height more than 20 cm When the machine moves in these conditions always position it 555555555 666666 perpendicular to the obstacles gt 2S 7056 99 5050 2592 XO 44 RS AW351620 When travelling up slopes in reverse avoid steering at the beginning of the slope If it is necessary to steer on a slope carry out this manoeuvre gradually LIIR SEO gt BRK KS see lt 5 gt 0 25 90 50 0 55 0 ie KX PII 52 9 554 9094 RSSA 552 eg Were Rod PXA 15 04 594 Rex WA 550 Ro 6 05 KR 505505 lt x 9 7040
282. y cartridge MAINTENANCE PROCEDURES 9JA03399 9JA02097 X X x 5 A00 NM NOY 9JA03563 9JA03564 215 MAINTENANCE PROCEDURES 7T Install the cleaned cartridge 4 or a new cartridge AN314710 8 Position the cap 3 with the drain valve 6 facing downwards and secure it with the couplings 2 9JA03398 9 Press the button on the filter clogging indicator 1 so that the red piston returns to its original position IMPORTANT e If shortly after installing the cleaned filtering element the red piston of the clogging indicator is visible again it is necessary to change the primary filtering element and the NS safety cartridge e Change the primary filtering element after cleaning it for 6 times after one year The safety cartridge must be changed together with the primary filtering element 0052091 e As reference for the successive change always mark the date of the cleaning operation on the primary filtering ele ment 216 CHANGING THE SAFETY CARTRIDGE To change the safety cartridge after removing the primary filtering element proceed as follows 1 Clean the inside of the filter body the cap 3 and the drain valve 6 2 Remove the safety cartridge 5 and throw it away 3 Install a new safety cartridge 5 and a new primary element 4 making sure that they are correctly fitted in their seats
283. y into the lock 2 Turn the key clockwise and extract it OPENING AND CLOSING THE COVERS WITH LOCK Opening 1 Insert the key into the lock 2 Turn the key counterclockwise and open the cover by pulling the grip Closing 1 Close the cover and insert the key into the lock 2 Turn the key clockwise and extract it 102 01680 18520 A RKA13360 3 2 9 ENGINE HOOD A WARNING e Do not open the engine hood when the engine is running e Do not use the machine without engine hood and do not start the engine when the hood is open unless this is ex pressly prescribed for certain maintenance operations e When carrying out an inspection or maintenance operation inside the engine hood always open it completely and make sure that it is kept open by the apposite rod e Non compliance with these rules may lead to serious acci dents IMPORTANT e The hood should be kept locked unless there is a precise reason for opening it To make sure that it is locked check the direction of the slot on the opening button 1 Release the engine hood lock 1 For further details see 3 2 8 CAP WITH LOCK 2 Press the engine hood opening button 1 to open the hood 2 3 After opening the hood use the stay rod 3 to keep it open To close the hood 2 remove the stay rod 3 insert it in the apposite retainer then lower the hood slowly and press it downwards to make the lock sna
284. ystem deactivation emergency switch IMPORTANT e This switch allows the machine to work temporarily in case of failure in the pump control system It must not be used permanently The failure that caused the anomaly must be repaired immediately e If this switch is inadvertently pressed and set to position EMERGENCY while the machine is in normal operating conditions the code E02 appears on the display e If the code E02 is displayed during work make sure that the switch is in the correct position This switch 8 is used to allow the machine to work temporarily in case of failure in the pump control system when E02 appears on the display a EMERGENCY abnormal situation shift the lever switch up ward b NORMAL normal situation shift the lever switch downward If the code E02 appears on the display shift the lever switch up ward to be able to go on working 9 Boom and turret swing brake deactivation emergency switch IMPORTANT e This switch allows the machine to work temporarily in case of failure in the turret swing or boom swing braking sys tems It must not be used permanently The failure that caused the anomaly must be repaired immediately e If this switch is inadvertently pressed and set to position EMERGENCY while the machine is in normal operating conditions the codes E03 or E41 appear on the dis play e If the codes E03 or E41 are displayed during work make sure

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