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Komatsu PW130ES-6K, Operation & Maintenance Manual

The Komatsu PW130ES-6K Operation & Maintenance Manual is an essential resource for users of this powerful excavator. This comprehensive manual covers all aspects of operating and maintaining the machine, ensuring optimal performance and longevity. Download your free manual from manualshive.com today and unleash the full potential of your Komatsu PW130ES-6K.

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SERVICE PROCEDURE

MAINTENANCE.

212

All pulley support bearings, shafts and brackets must be in work-
ing order.

When replacing belts and pulleys, pulley alignment must be
checked with belts tensioned and brackets securely clamped. A
misalignment that can be detected by the naked eye is detrimen-
tal to belt performance.

During belt installation, do not force the belts into the pulley
grooves by prying with a screwdriver on pry bar. This will damage
the belt side cords which will cause the belts to turn and result in
complete destruction of the belts in operation.

Belts on new machines and replacement belts lose their tension
as they seat into the pulley grooves. Check the tension of new
belts at 20 hour intervals until tension is stabilized and thereafter,
every 250 hours. If the tension falls below the required minimum,
the belt slips, and damages the belts and pulley grooves.

REMARK

When operating in abrasive conditions, check tension every

100 hours.

Visually inspect the belts for intersecting cracks. Transverse
(across the belt width) cracks are acceptable. Longitudinal (direc-
tion of belt length) cracks that intersect with transverse cracks are
not acceptable. Replace the belt if it is frayed or has pieces of
material missing.

CHECK FAN BELT TENSION, ADJUST CHECKING 
TENSION

The engine is equipped with an automatic belt tensioner that
maintains correct tension on the drive belt. To check belt tension
a Gates type gauge must be used because of the wide drive belt.
Proper tension should be 355 to 455 N.m gauge value.

If a Gates type gauge is not available, tension may be checked by
belt deflection. Press the belt with your finger at the longest span
and measure the deflection. Maximum deflection 9.5 to 12.7 mm.

Summary of Contents for PW130ES-6K

Page 1: ...ous injury or death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodically reviewed by all personel who will come into contact with the machine Operation Maintenance Manual UEAM000902 WARNING ...

Page 2: ...nd could result in serious injury or death Operators and maintenance personnel should read this manual thoroughly before beginning operation or main tenance Some actions involved in operation and maintenance of the machine can cause a serious accident if they are not done in a manner described in this manual The procedures and precautions given in this manual apply only to intended uses of the mac...

Page 3: ... avoided These safety messages or labels usually describe pre cautions that must be taken to avoid the hazard Failure to avoid this hazard may also result in serious damage of the machine YELLOW SAFETY TRIANGLE This is used on safety labels for hazards which could result in minor or moderate injury if the hazard is not avoided This word might also be used for a hazard where the only result could b...

Page 4: ...erator ears noise value Sound pressure level Ambient noise value Sound power level Noise level indicated is the guaranteed value measured by the dynamic test method as specified in the directive 86 662 EEC as amended by 95 27 EC LpA 95 27 EC 75 LWA 95 27 EC 99 ...

Page 5: ...opean directive 2000 14 EC This machine complies with the requirements of RAL German Institute for quality assurance and marking pertaining to the award of the environmental mark blue angel for low noise VIBRATION The weighted root mean square acceleration value to which the operator s arms are subjected does not exceed 2 5 m s The weighted root mean square acceleration value to which the operator...

Page 6: ...wer for the steering system engine failure whilst travelling the machine can be steered allowing the machine to be safely stopped In such a case the effort required at the steering wheel and the number of turns to steer the machine will increase To confirm function of emergency steering system raise the front wheels off the ground using the work equipment and with the engine off turn the steering ...

Page 7: ...or details see operation section Adjustable wrist control levers make operations smooth and easy Fresh filtered air conditioner assures comfortable operation Low noise level and smart urban style design and colouring Superb operation performance provided by powerful engine and high performance hydraulic pump Low fuel consumption controlled by an electronic control sys tem provides an environment f...

Page 8: ... than 5 min utes Pay particular attention to oil pressure and temperature indicators check coolant and oil levels frequently during breaking in The precautions given in this manual for operating maintenance and safety procedures are only those that apply when this product is used for the specified purpose If the machine is used for a pur pose that is not listed in this manual Komatsu cannot bear a...

Page 9: ... NO PLATE POSITION On the front right of the undercarriage ENGINE SERIAL NO PLATE POSITION On the gear case front corner TABLE TO ENTER SERIAL NO AND DISTRIBUTOR Machine serial No Engine Serial No Manufacturer s name Komatsu UK Ltd Address Durham Road Birtley Chester Le Street County Durham DH32QX United Kingdom Distributor Address Phone ...

Page 10: ...LOCATIONS OF PLATES TABLE TO ENTER SERIAL NO AND DISTRIBUTOR 9 MACHINE SERIAL PLATES STANDARD SERIAL PLATE GERMANY SERIAL PLATE ITALIAN SERIAL PLATE ...

Page 11: ...LOCATIONS OF PLATES TABLE TO ENTER SERIAL NO AND DISTRIBUTOR 10 ...

Page 12: ...E TO ENTER SERIAL NO AND DISTRIBUTOR 8 MACHINE SERIAL PLATES 9 SAFETY 15 GENERAL PRECAUTIONS 16 PRECAUTION DURING OPERATION 22 BEFORE STARTING ENGINE 22 OPERATING MACHINE 23 TRANSPORTATION 28 BATTERY 29 TOWING 30 BUCKET WITH HOOK OR BUCKET LINK 32 PRECAUTIONS FOR MAINTENANCE 35 BEFORE CARRYING OUT MAINTENANCE 35 DURING MAINTENANCE 38 POSITION FOR ATTACHING SAFETY LABELS 41 POSITION FOR ATTACHING S...

Page 13: ...OFF 119 STEERING 121 STOPPING 123 SWINGING Slewing the upper carriage 124 OPERATION OF WORK EQUIPMENT 125 WORKING MODE SELECTION 126 PROHIBITIONS FOR OPERATION 128 PRECAUTIONS FOR OPERATION 129 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS 130 HOW TO ESCAPE FROM MUD 131 WORK POSSIBLE USING HYDRAULIC EXCAVATOR 132 REPLACEMENT AND INVERSION OF BUCKET 133 PARKING MACHINE 136 CHECK AFTER FINISHING WORK ...

Page 14: ...TENANCE 163 GUIDES TO MAINTENANCE 164 OUTLINES OF SERVICE 167 OUTLINE OF OIL FUEL COOLANT 167 OUTLINE OF ELECTRIC SYSTEM 170 OUTLINE OF HYDRAULIC SYSTEM 170 WEAR PARTS LIST 172 USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 173 PROPER SELECTION OF FUEL COOLANT AND LUBRICANTS 173 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 177 INTRODUCTION OF NECESSARY TOOLS 177 TORQUE LIST 178...

Page 15: ... ATTACHMENTS 239 HANDLING BUCKET WITH HOOK 240 CHECKING FOR DAMAGE TO BUCKET WITH HOOK 240 PROHIBITED OPERATIONS 240 PRECAUTIONS DURING OPERATIONS 240 MACHINES READY FOR ATTACHMENTS 241 GENERAL LOCATIONS 241 HANDLING THE CLAMSHELL BUCKET 243 OPERATION 244 HANDLING ACCUMULATOR 246 LONG TERM STORAGE 247 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE 248 HYDRAULIC BREAKER 248 POWER RI...

Page 16: ...15 SAFETY WARNING Read and follow all safety precautions Failure to do so may result in serious injury or death This safety section also contains precautions for optional equip ment and attachments ...

Page 17: ...e 136 Improper use of safety features could result in serious bodily injury or death CLOTHING AND PERSONAL PROTECTIVE ITEMS Avoid loose clothing jewellery and loose long hair They can catch on controls or in moving parts and cause serious injury or death Also do not wear oily cloths because they are flam mable Wear a hard hat safety glasses safety shoes mask or gloves when operating or maintaining...

Page 18: ...you Work equipment posture see PARKING MACHINE on page 136 MOUNTING AND DISMOUNTING NEVER jump on or off the machine NEVER get on or off a moving machine When mounting or dismounting always face the machine and use the handrails machine or chassis steps Do not hold any control levers when getting on or off the machine Ensure safety by always maintaining at least three point con tact of hands and f...

Page 19: ...ill under pressure Attempting to remove the cap drain the oil or water or replace the filters may lead to serious burns Always wait for the temperature to go down and follow the specified procedures when carrying out these operations To prevent hot water from spurting out 1 Turn engine off 2 Allow water to cool 3 Slowly loosen cap to relieve pressure before removing To prevent hot oil from spurtin...

Page 20: ...the work equip ment and cylinders or between the machine and work equip ment If the work equipment is operated the clearance will change and this may lead to serious damage or personal injury FIRE EXTINGUISHER AND FIRST AID KIT Know how to use fire extinguisher if installed Provide a first aid kit at the storage point Know what to do in the event of a fire Be sure you know the phone numbers of per...

Page 21: ...other than the operator outside the range of falling or fly ing objects Be particularly sure to maintain a proper distance when carrying out shear operations PRECAUTIONS FOR ATTACHMENTS When installing and using an optional attachment read the instruction manual for the attachment and the information related to attachments in this manual Do not use attachments that are not authorised by Komatsu or...

Page 22: ...ccumulator A special air bleed valve is necessary for this operation so please contact your Komatsu distributor Gas in accumulator see HANDLING THE ACCUMULA TOR on page 99 EMERGENCY EXIT When exit by normal means is prevented in an emergency you can get out through the emergency exit rear window Pull the ring at the bottom of the window and remove strip This will allow you to push out glass ROTATI...

Page 23: ...ul not to sever or cut any of these lines Check the depth and flow of water before operating in water or crossing a river NEVER be in water which is in excess of the permissible water depth Permissible water depth see PRECAUTIONS FOR OPERATION on page 129 FIRE PREVENTION Thoroughly remove wood chips leaves paper and other flammable things accumulated on the engine compartment They could cause a fi...

Page 24: ...itions Check also that they light up properly OPERATING MACHINE WHEN STARTING THE ENGINE Walk around for machine again just before mounting it to check for people and objects that might be in the way NEVER start the engine if a warning tag has been attached to the wrist control Before starting the engine sound the horn as an alert Start and operate the machine only while seated Do not allow anyone...

Page 25: ... in reverse PRECAUTIONS WHEN TRAVELLING Fold in the work equipment as shown in the diagram below and keep it at a height of 40 50 cm from the ground level before starting to travel When travelling on public roads the control lever pad safety lock should be down and the control lever lock switch in the off position This prevents operation of the control levers and activates the rear facing brake la...

Page 26: ...n on slopes or travel across slopes Always go down to a flat place to perform these operations Method of travelling on slopes see PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS on page 130 Do not travel up and down on grass fallen leaves and wet steel plates These materials may allow the machine to slip if it is trav elling sideways Keep travel speed very low PROHIBITED OPERATIONS Do not dig the work...

Page 27: ...chine Check with the electricity company about the voltage of the cables before starting operations DO NOT HIT WORK EQUIPMENT When working in places where there are height limits such as in tunnels under bridges under electric cables or in garages be extremely careful not to hit the boom or arm ENSURE GOOD VISIBILITY When working in dark places install working lamps and head lamps and set up light...

Page 28: ... soil after heavy rain or blasting is weakened in these areas Earth laid on the ground and the soil near ditches are loose They can collapse under the weight or vibration of your machine Install the HEAD GUARD FOPS if working in areas where there is danger of falling rocks and dirt DO NOT HIT THE OPERATOR CAB for two piece boom only When the second boom cylinder is retracted the bucket or the atta...

Page 29: ...t obstruct traffic Parking procedure see PARKING MACHINE on page 136 When leaving the machine lower the work equipment com pletely to the ground raise the control lever Pad Safety lock to the LOCK position then stop the engine and use the key to lock all the equipment Always take the key with you Work equipment posture see PARKING MACHINE on page 136 Places to lock see LOCKING on page 138 TRANSPOR...

Page 30: ...plicable traffic regulations Determine the shipping route while taking into account the width height and weight of the load BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid and can quickly burn the skin and eat holes in clothing If you spill acid on yourself immediately flush the area with water Battery acid could cause blindness if splashed into the eyes If acid gets ...

Page 31: ...m If any tool touches between the positive terminal and the chassis it will cause sparks This is dangerous so be sure to work carefully Connect the batteries in parallel positive to positive and neg ative to negative When connecting the ground cable to the frame of the machine to be started be sure to connect it as far as possible from the battery Starting with booster cables see IF BATTERY IS DIS...

Page 32: ...When towing the machine without the engine running or in the advent of loss of hydraulic pressure its is necessary to manually release the park brake as follows View on transmission from front Releasing the park brake before towing 1 Unscrew the lock nuts on the park brake release bolts A completely 3 places 2 Screw in the park brake release bolts A until the torque increases sharply The park brak...

Page 33: ...k that there are no cracks or deformation in the lift ing equipment Check that there is no abnormality in the stopper device HOOKING WIRE ROPE SECURELY TO HOOK When performing lifting operation securely hook the wire rope onto the special lifting hook or lifting eye PRECAUTIONS FOR MACHINE INSTALLATION After carrying out a preliminary inspection of ground condi tions select a flat solid location C...

Page 34: ... regarding storage han dling and disposal HANDLING OF USED ENGINE OILS Avoid contact with used engine oils Refer to engine oils data sheet for handling and storage pre cautions HANDLING OF OILS For diesel oils hydraulic oils and oils used in the swing machinery PTO transmission axles and hubs avoid pro longed or frequent contact with skin Refer to manufacturers data sheet for handling and storage ...

Page 35: ...eding machine performance may result in accident or failure Carry out lifting operation within specified load limit Never carry out operations which may damage the machine such as overload or over impact load Never drag a load laterally or longitudinally nor retract the arm otherwise a dangerous situation may result NEVER TRAVELLING WHILE LIFTING A LOAD Never travel while carrying a load OPERATING...

Page 36: ...ibutor Part no 20E 00 K1340 PROPER TOOLS Use only tools suited to the task Using damaged low quality faulty or makeshift tools could cause personal injury Tools see INTRODUCTION OF NECESSARY TOOLS on page 177 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Replace the following fire related components periodically Fuel system Fuel hose spilling hose and fuel tube cap Hydraulic system Pump outlet hos...

Page 37: ...the radiator Raise the tilting arm rest to the LOCK position and carry out the operation with two workers One worker should sit in the operator s seat so that he can stop the engine immediately if necessary He should also be extremely careful not to touch any lever by mistake Touch the levers only when they have to be operated The worker carrying out the maintenance should be extremely careful not...

Page 38: ... the fuel and oil fillers securely Never use fuel for washing any parts Always add fuel and oil in a well ventilated place RADIATOR WATER LEVEL If it is necessary to add water to the radiator stop the engine and allow the engine and radiator to cool down before adding the water Slowly loosen the caps to relieve pressure before removing the caps ...

Page 39: ... and using a sledge hammer ATTACHMENTS Place attachments that have been removed from the machine in a safe place so that they do not fall If they fall on you or others serious injury could result WORK UNDER THE MACHINE Always lower all movable work equipment to the ground or to their lowest position before performing service or repairs under the machine Always chock the wheels of the machine secur...

Page 40: ...s or oil hoses If fuel or oil leaks it may cause a fire PRECAUTIONS WITH HIGH PRESSURE OIL Do not forget that the work equipment circuits are always under pressure Do not add oil drain oil or carry out maintenance or inspec tion before completely releasing the internal pressure If oil is leaking under high pressure from small holes it is dan gerous if the jet of high pressure oil hits your skin or...

Page 41: ...king lubricating oil level adding oil see MAINTE NANCE SCHEDULE CHART on page 181 Changing oil replacing filters see MAINTENANCE SCHEDULE CHART on page 181 ROTATING FAN AND BELT Keep away from rotating parts and be careful not to let any thing get caught in them If your body or tools touch the fan blades or fan belt they may be cut off or sent flying so never touch any rotating parts WASTE MATERIA...

Page 42: ...TTACHING SAFETY LABELS Always keep these labels clean If they are lost or damage attach them again or replace them with a new label There are other labels in addition to the safety labels listed as fol lows so handle them in the same way Safety labels are available from your Komatsu distributor POSITION FOR ATTACHING SAFETY LABELS ...

Page 43: ...in the machine cab near operator If this manual is lost please contact Komatsu distributor for replacement Always apply lock when leaving operators seat Normal steering can only be operated when the engine is run ning Emergency steering only to be used when stopping the machine safely Serious injury or death can occur if machine or attachments are not kept a safe distance away from electric lines ...

Page 44: ...d Keep away from flame Do not weld or drill Read operation manual before operation 6 Warning for staying clear 20E 00 K1150 Keeping out of moving area To prevent SEVERE INJURY or DEATH Do the following before moving the machine or its attachments Sound horn to alert people nearby Be sure no one is on or near machine or in the swing area Rotate cab for full view of travel path if it can be done saf...

Page 45: ...eve pressure before removing Read operation manual before operation 8 Control lever pad safety lock 20E 00 k1850 9 Warning for staying clear 20E 00 K1140 Keeping out of moving area To prevent SEVERE INJURY or DEATH Do the following before moving the machine or its attachments Sound horn to alert people nearby Be sure no one is on or near machine or in the swing area Rotate cab for full view of tra...

Page 46: ...t 10 Warnings for staying clear 20G 00 K2350 R H 20G 00 K2360 L H 11 Falling from upper structure warning 20E 00 K1110 WARNING falling from upper structure Keep away from sides of machine Keep of counterweight Do not ride on machine when it is moving 12 Stop engine warning 20E 00 K1310 Do not open cover while engine is running ...

Page 47: ...ays apply lock when leaving operator s seat 14 High pressure oil warning 20E 00 K1270 15 20E 00 K1280 Pump control override switch and swing lock override switch Read operation manual before operation 16 Red reflector 20G 47 K1690 17 20Y 00 K2220 Emergency exit Read operation manual before operation ...

Page 48: ...cylinder 92 kg OF Lifting capacity rating overfront OS Lifting capacity Rating overside Rating over rear Rating over side or 360 degrees Rating at maximum reach under carriage B A Max 7 5 m 6 0 m 4 5 m 3 0 m 1 5 m OF OS OF OS OF OS OF OS OF OS OF OS Blade 7 5 m kg 2800 2800 6 0 m kg 2300 2200 3450 3300 4 5 m kg 2150 1650 3550 1950 3800 3250 3 0 m kg 2200 1450 3850 1850 4700 3050 6750 5850 1 5 m kg...

Page 49: ...2900 4700 4700 6750 6750 1 5 m kg 2350 2150 4000 2800 5850 4450 7400 7400 0 0 m kg 2700 2250 3950 2700 6150 4250 7550 7550 1 5 m kg 3400 2600 3900 2700 6000 4200 8950 8650 5800 5800 3 0 m kg 3850 3550 4800 4300 7200 7200 Rear outrigger 7 5 m kg 2800 2800 6 0 m kg 2300 2300 3450 3450 4 5 m kg 2150 2150 3550 2450 3800 3800 3 0 m kg 2200 1850 3700 2400 4700 3900 6750 6750 1 5 m kg 2350 1750 3600 2300...

Page 50: ... 4 5 m kg 1750 1750 3300 3000 3450 3450 3 0 m kg 1800 1800 3700 2950 4400 4400 6050 6050 1 5 m kg 1950 1950 4050 2800 5400 4500 8650 8650 0 0 m kg 2200 2050 3950 2750 6050 4300 7950 7950 1 5 m kg 2750 2350 3900 2700 6100 4250 9300 8650 5250 5250 3 0 m kg 3750 3050 5250 4250 7900 7900 8800 8800 Rear outrigger 7 5 m kg 2200 2200 2500 2500 6 0 m kg 1850 1850 2000 2000 4 5 m kg 1750 1750 3300 2500 345...

Page 51: ... 3000 6700 5800 1 5 m kg 2150 1200 3750 1750 5350 2750 0 0 m kg 2450 1250 3650 1650 5850 2600 5300 4900 1 5 m kg 2950 1450 3600 1650 5750 2550 8600 4950 4550 4550 3 0 m kg 3500 1950 4850 2600 7150 5050 Blade rear outrigger 7 5 m kg 2700 2700 6 0 m kg 2200 1950 3100 3100 4 5 m kg 2050 2050 3250 2950 3550 3550 3 0 m kg 2050 2050 3600 2650 4450 4450 6700 6700 1 5 m kg 2150 2000 4000 2750 5350 4400 0 ...

Page 52: ...tabilizer 7 5 m kg 2700 2700 3450 2750 6 0 m kg 2200 2200 3050 1600 3800 2700 4 5 m kg 2050 2050 3000 1550 4700 2500 6750 4750 3 0 m kg 2050 2050 2900 1450 4650 2300 7400 4200 1 5 m kg 2150 2000 2800 1400 4500 2150 7550 3950 0 0 m kg 2450 2050 2800 1400 4500 2150 7550 3950 1 5 m kg 2950 2350 2800 1350 4550 2100 8650 3950 5800 5800 3 0 m kg 3500 3150 4550 2200 7200 4100 under carriage B A Max 7 5 m...

Page 53: ...0 7750 5000 Rear outrigger 7 5 m kg 2100 2100 6 0 m kg 1800 1800 2900 2500 4 5 m kg 1650 1650 3000 2500 3200 3200 3 0 m kg 1650 1550 2100 1600 3400 2900 4150 3950 5900 5900 1 5 m kg 1750 1500 2550 1550 3850 2300 5150 3650 6300 6300 0 0 m kg 2000 1550 3500 2200 5700 3450 5700 5700 1 5 m kg 2400 1750 3500 2150 5600 3400 8450 6750 4200 4200 3 0 m kg 3300 2250 5200 3450 7750 8650 Without stabilizer 7 ...

Page 54: ... 4600 4050 6850 6850 0 0 m 1750 1600 2200 1600 3600 2350 5250 3800 5700 5700 1 5 m 2100 1800 3550 2300 5300 3700 8250 7750 4000 4000 3 m 2900 2350 3100 2400 4750 3750 7150 7150 7200 7200 Front rear outrigger 7 5 m 1950 1950 6 0 m 1600 1600 2600 2600 4 5 m 1500 1500 2650 2650 2850 2850 3 0 m 1500 1500 2300 2300 3000 3000 3700 3700 5300 5300 1 5 m 1600 1600 2400 2300 3450 3400 4600 4600 6850 6850 0 ...

Page 55: ...decal inside the operators cab shows the loads at which the caution warning is given for various work equipment positions Due to the simple nature of the system the overload warning is given at a lower load than actually allowable see full lift capacity charts If lifting to the full capacity of the machine is required it is neces sary to fit a full overload caution system with work equipment posit...

Page 56: ...55 OPERATION ...

Page 57: ...IEW OF MACHINE If directions are indicated in this section they refer to the direc tions shown by in the arrows in the diagram below A FRONT B REAR C RIGHT D LEFT 1 Bucket 5 Boom 2 Bucket cylinder 6 Boom Cylinder 3 Arm 7 Undercarriage 4 Arm cylinder ...

Page 58: ...ower switch 6 L H Clamshell rotation switch 20 Beacon switch 7 Boom switch 21 Heated seat switch 8 Machine monitor 22 Heater Air conditioner control 9 R H Clamshell rotation switch breaker switch 23 12 V power supply 10 Undercarriage attachment switch 24 Outriggers L R Hazard park brake roadlight Axle lock switches 11 Right work equipment control lever 25 Travel pedal 12 Starting switch 26 Brake p...

Page 59: ...ine oil level monitor 5 Engine oil pressure monitor 15 Hydraulic oil level monitor 6 Air cleaner clogging monitor 16 Charge level monitor 7 Overload caution monitor 17 Engine preheating monitor 8 Working mode selector switch 18 Swing lock monitor 9 Power max swift slow down switch 19 Engine oil replacement monitor 10 Travel speed switch 20 Auto deceleration switch AD32421D 1 2 3 4 5 6 7 8 9 10 11 ...

Page 60: ...methods of operating the equipment and the meanings of the displays MACHINE MONITOR A BASIC CHECK ITEMS This displays the basic items that should be checked before start ing the engine If there is any abnormality the appropriate monitor lamp will flash NOTICE When carrying out checks before starting do not simply rely on the monitor Always refer to the periodic maintenance items or OPERATION on pa...

Page 61: ... CAUTION If these monitors items flash stop operations immediately then check and repair the appropriate location These are items which need to be observed while the engine is running If any abnormality occurs items which need to be repaired immediately are displayed If there is any abnormality the appropriate monitor lamp will flash to indicate the location of the abnormality and the buzzer will ...

Page 62: ...A TION to carry out the checks 1 RADIATOR WATER LEVEL This warns that the radiator cooling water level is too low If the monitor lamp flashes check the cooling water level in the radiator and reserve tank and add water 2 ENGINE OIL LEVEL This warns that the oil level in the engine oil pan is too low If the monitor lamp flashes check the oil level in the engine oil pan and add oil 4 AD324230 ...

Page 63: ... starting switch is ON the lamp will remain lit and will go off once the engine is started 2 FUEL LEVEL If the fuel drops below 55 liters the lamp will flash Top up the fuel before this 3 AIR CLEANER CLOGGING This warns that the air cleaner is clogged If the monitor lamp flashes stop the engine then inspect and clean the air cleaner 4 OVERLOAD CAUTION When in LO mode This warns that the machine is...

Page 64: ...idling until the engine water temperature gauge enters the green range 2 RADIATOR WATER LEVEL If the radiator water level drops the monitor lamp flashes Stop the engine check the radiator water level and add water if neces sary 3 ENGINE OIL PRESSURE If the engine oil pressure drops below the normal pressure the monitor lamp flashes At this item stop the engine and inspect it according to OTHER TRO...

Page 65: ...temperature below 0 C The monitor lamp lights when the starting switch is turned to HEAT position and flashes after about 30 seconds to show that the pre heating is completed The monitor lamp will go off after about 10 seconds 2 SWING LOCK MONITOR This informs the operator that the swing lock is being actuated Actuated Lights up When the swing lock switch is turned ON ACTUATED the mon itor lamp li...

Page 66: ...ure monitor 3 lights up and alarm buzzer sounds at the same time The overheat prevention system is actuated until the temperature enters the green range When red range 2 lights if the engine water temperature is reduced and the fuel control dial is turned to the low idling posi tion the display will be cancelled 4 FUEL GAUGE This gauge indicates the amount of fuel in the fuel tank If the fuel leve...

Page 67: ...e clock switch for 2 5 sec or more 2 TIME flashes 3 3 When SET switch is pressed the hour is rounded off for 0 to 14 minutes and rounded up for 45 to 59 minutes Examples 10 14 becomes 10 00 rounded off 10 45 becomes 11 00 rounded up When SET switch 4 is pressed at the time signal or standard clock the correct time is obtained 4 When the correct time is reached press clock switch 1 This completes c...

Page 68: ...ODE SELECTOR SWITCH Basic switch This switch is used to set the movement or power for the work equipment By selecting the mode to match the working condi tions it is possible to carry out operations more easily H O heavy duty operation mode lights up This is used for heavy duty work G O general operation model lights up This is used for ordinary work F O finishing operation mode lights up This is ...

Page 69: ...ng in a straight line To prevent this always stop the machine before operating the travel speed switch This is used to select the three travel speeds Lo lights up Low speed travel Mi lights up Mid range speed travel Hi lights up High speed travel When the engine is started the travel speed is automatically set to Lo When travelling in Hi the travel speed is automatically adjusted to match the trav...

Page 70: ...peration mode only the power can be increased while the knob button is being pressed Even if the knob button continues to be pressed the increase in power finishes after approx 8 5 sec Swift slow down speed down lights up When the working mode is heavy duty operation and general operation mode only the speed is reduced while the knob button is being pressed When the engine is started the power max...

Page 71: ...rting switch key at the ON position while the engine is running START position This is the engine start position Keep the key at this position dur ing cranking Immediately after starting the engine release the key which will automatically return to the ON position HEAT preheat position When starting the engine in winter set the key to this position When the key is set to the HEAT position the pre ...

Page 72: ...ributor 4 SWING LOCK SWITCH WARNING When the machine is travelling under its own power or when the swing is not being operated always set the switch to the ON ACTUATED position On a slope the work equipment may swing to the down side even if the swing lock switch is located at the ON position Be careful concerning this point This switch is used to lock the upper structure so that it cannot swing O...

Page 73: ...e is travelling on Public roads OFF position deactivated The switch is lit in the on actuated position 6 LAMP SWITCH This switch turns on the working lamps and monitor illumination 7 ALARM BUZZER STOP SWITCH This is used to stop the alarm buzzer when it has sounded to warn of some abnormality in the EMERGENCY STOP ITEMS while the engine is running 8 LOWER WIPER SWITCH If fitted This switch actuate...

Page 74: ...slow down functions Press the button once single click and keep it depressed In the heavy duty and general operation modes the power max function actu ates for max 8 5 seconds and the swift slow down function actu ates while the button is depressed 11 HEATED OPERATOR SEAT SWITCH If fitted This switch is used to switch on the heated seat OFF seat not heated ON seat heated 12 BEACON SWITCH If fitted...

Page 75: ...erations to be carried out for a short period when there is an abnormality in the pump control system TVC valve system error The abnormality must be repaired immediately 15 SWING LOCK OVERRIDE SWITCH 2 When normal Switch is down 1 When abnormal When the monitor display shows E03 swing brake system error the brake is cancelled and it becomes possi ble to swing the upper structure when this switch i...

Page 76: ...ne is in motion or the park brake may be damaged 17 SUSPENSION LOCK SWITCH Release the front axle suspension lock using switch Position 1 Front axle suspension travels freely Position 2 Front axle suspension is in auto mode i e when travel pedal is depressed front axle suspension travels freely and when travel pedal is not depressed front axle suspension is locked Position 3 Front axle is locked T...

Page 77: ...rig ger s 21 UNDERCARRIAGE ATTACHMENT SWITCH This switch enables operation of outriggers and or dozer blade Machines equipped with dozer blade only When this button is pressed a warning light a in position of switch 20 is activated Machines equipped with outriggers or dozer outrigger When this button is pressed switch 20 will illumate 22 BOOM SWITCH This switch enables operation of the boom when t...

Page 78: ... will illuminate when undercarriage attachment switch has been pressed and indicates that when right hand wrist lever is moved forward or rearwards the undercarriage attachment will move When this lamp is not illuminated the right hand wrist lever will operate the boom raise lower as normal NOTE If the machine is fitted with outriggers operation of the undercarriage attachment switch will illumina...

Page 79: ...e the steering wheel acts in the opposite direction to that normal travel 3 Refer to item 17 suspension lock switch to ensure that sus pension lock system is fully free when required for dozing operations NOTE Dozer blade is to be used only for stabilizing and light dozing 23 CLAMSHELL ROTATION CLOCKWISE BREAKER SWITCH This switch operates clockwise rotation of clamshell if fitted or operation of ...

Page 80: ...ever to neutral position no auto cancel function exists 28 ROADLIGHTS DIP MAIN BEAM FLASH SWITCH This switch has two functions To alternate between headlight dipped and main beams Pull left hand steering column stalk fully upwards and release Note road lights switch 18 must be at position 3 for this function A warning light will illuminate on the steering column when main beam headlights are illum...

Page 81: ...y the EC mark CONTROL LEVERS PEDALS 1 CONTROL LEVER PAD SAFETY LOCK WARNING When leaving the operator s compartment switch PPC lock switch to off position raise the control lever pad to the LOCK position If the control levers are not locked and they are touched by mistake this may lead to a seri ous accident If the control lever pad safety lock lever is not placed securely in the LOCK position and...

Page 82: ...e not to touch the work equipment control lever The control lever pad locks the work equipment swing and attachment controls This device is a hydraulic lock so even if it is in the lock position the work equipment control lever will move but the work equip ment and swing motor will not work 2 LEFT WORK EQUIPMENT CONTROL LEVER with auto deceleration device WARNING If any lever is operated when in t...

Page 83: ... dial is above the mid range position the engine speed will drop to a mid range speed If any of the levers are operated the engine speed will rise to the speed set by the fuel control dial If all control levers are set to neutral the engine speed will drop by approx 100 rpm and after approx 4 seconds the engine speed will drop to the deceleration speed approx 1400 rpm 4 PPC LOCK SWITCH WARNING Whe...

Page 84: ...ked and they are touched by mis take this may lead to a serious accident When opening 1 Lock the safety lock lever securely 2 Open roof hatch by pulling lock 2 located on both sides then push up and open the ceiling window grasping grip 1 When closing Close the ceiling window grasping grip 1 and lock it with lock 2 If the lock cannot be applied open and close the ceiling window again 1 Forward 2 N...

Page 85: ...he position of the retainers can be adjusted to one of three pre set locations by removing the bolts holding the brack ets and re attaching to one of the other prepared locations A second set of retainers is positioned at the bottom of the front window to allow coverage of the clear roof when the front window is in the raised position A third set of retainers is fitted to the cab roof to allow cov...

Page 86: ...t It is possible to store pull up the front window top in the roof of the operator s compartment When opening WARNING When the front window is open there is danger that it will fall so always lock it with left and right lock pins A 1 Place the work equipment on flat ground and stop the engine 2 Securely lock the control lever pad safety lock 3 Confirm that the wiper is stored inside the right fram...

Page 87: ...ont win dow to the inside to release the lock 5 From the inside of the operator s cab hold the bottom grip with the left hand and the top grip with the right hand pull up the window and push it in fully until it is locked by catch C 6 Lock with lock pins A on the left and right sides B C AM089670A A ...

Page 88: ...uipment on a flat ground and stop the engine 2 Securely lock control lever pad safety lock 3 Release the lock pin A 4 Hold the grip at the bottom of the front window with your left hand and the grip at the top with your right hand release the lock of catch C with your right thumb then pull the top grip slowly and lower the front window When releasing the lock of ...

Page 89: ...can be removed Store the removed bottom part of the front window at the rear of the operator s cab and lock with lock pins E NOTICE Do not operate lower wiper if fitted when front window bottom is removed DOOR LOCK Use the door lock to fix the door in position after opening it 1 The door will become fixed in place when it is pressed against catch 1 2 To release the lock press knob 2 down at the le...

Page 90: ...ise align the match mark on the cap with the rotor groove then remove the cap To lock the cap 1 Turn the cap into place 2 Turn the key and take the key out Insert the key as far as it will go If the key is turned before it is inserted all the way it may break METHOD OF OPENING AND CLOSING COVER WITH LOCK cover with lock To open the cover locked cover 1 Insert the key 2 Turn it counterclockwise and...

Page 91: ...city and name of circuit No Fuse capacity Name of circuit 1 20 A Pump and governor breaker switch 2 10 A Solenoid valve 3 20 A OPT 4 10 A LH boom rear work lamps 5 10 A Radio cigarette lighter air conditioner panel heater windows washer left knob button 6 15 A Horn 7 15 A Wiper controller 8 20 A Additional cab work lamps beacon 9 20 A Lower wiper refuelling pump 10 10 A Key switch signal heated se...

Page 92: ...p holder is provided for holding cups or cans Drinks should not be left in the cup holder whilst operating the machine because spillage may occur HEATER VIEW OF CONTROL PANEL 1 Inlet air control slider Change between internal air recirculation external fresh air intake AM089770A Purpose Internal air circulation This is used when wishing to quickly warm the cab External air intake This is used for ...

Page 93: ...mperature of outlet air move slides to right blue 4 Air flow selector switch This switch adjust air flow in three steps 5 Defroster selector lever This lever is used to remove condensation or ice from the lower part of front window Selector lever forward defrost Selector lever backward warms operator s feet Purpose Sending air to upper area of oper ator s seat and defrosting upper part of front wi...

Page 94: ...rked AIR CONDITIONER VIEW OF CONTROL PANEL When a function is activated the related indicator lamp lights up 1 AIR OUTLET SELECTOR SWICH The operator can select a suitable outlet as required 1 FEET 2 DEFROSTER Purpose Sending air to upper area of operator s seat Sending air to lower area of operator s seat Switch ...

Page 95: ...ator s seat Sending air to lower area of operator s seat Purpose Internal air circuit This is used when wishing to quickly cool or warm the cab or when the air inside the cab is stale External air intake This is used for fresh air intake or to remove condensation on windows Switch Purpose To low temperature To high temperature Switch Blue range indicates low temperature and red range high temperat...

Page 96: ...ny conditions Selector lever forward Defroster 2 Selector lever back Foot 1 The defroster can be used when the vent selector panel is at the position PRECAUTION WHEN USING AIR CONDITIONER During cooling ventilate the air from time to time If operator is smoking during cooling eyes may occasionally smart In this case temporarily change the switch to ventila tion cooling to exhaust the smoke When co...

Page 97: ...he circuit to protect electrical com ponents and wiring from burning similar to an ordinary fuse CONTROLLERS A pump and governor controller is provided It is located in the right rear of the cab underneath panel assy 1 NOTICE Never splash or spill water mud or drink over the con troller as this may cause a fault If a fault occurs in the controller do not attempt repair but consult your Komatsu dis...

Page 98: ...noise extend the antenna If the reception is to strong adjust the sensitivity by retracting the antenna NOTICE When transporting the machine or parking it in a garage always fully retract the antenna to avoid the possibility of breakage PRECAUTION OF USE To ensure safe operation adjust the volume level so that external noise is still audible Ensure no water is splashed over the speaker case or cab...

Page 99: ... lamp will flash and buzzer will sound when indicator lever is not in neutral 2 WORKLIGHTS WARNING LAMP This lamp will illuminate when work lamps are switched on 3 LOW BRAKE PRESSURE LAMP When engine is running and brake system hydraulic pressure is abnormal this lamp will illuminate ...

Page 100: ...tachment control pedal with the lock pin The accumulators are filled with high pressure nitrogen gas and it is extremely dangerous if they are handled in the wrong way Always observe the following precautions Never make any hole in the accumulators or expose them to flame or fire Do not weld any boss to the accumulators When disposing of the accumulators it is necessary to re lease the gas from th...

Page 101: ...cuit accumulator This machine is equipped with the accumulator in the control cir cuit The accumulator is a device to store the pressure in the con trol circuit and when it is installed the control circuit can be operated for a short time even after the engine is stopped There fore if the control lever is moved in the direction to lower the work equipment it is possible for the work equipment to m...

Page 102: ...e machine and under the machine to check for loose nut or bolts or leakage of oil fuel or coolant and check the condition of the work equipment and hydraulic system Check also for loose wiring play and collection of dust at places which reach high temperatures Always carry out the items in this section before starting the engine each day 1 Check for damage wear play in work equipment cylin ders li...

Page 103: ...g 5 Check for damage to wheels tyres 6 Check for damage to handrail loose bolts Repair any damage and tighten any loose 7 Check for damage to gauges monitor loose bolts Check that there is no damage to the gauges and monitor in the operator s cab If any abnormality is found replace the parts Clean off any dirt on the surface 8 Clean rear view mirror check for damage Check that there is no damage t...

Page 104: ...y 3 If the reserve tank becomes empty first inspect for water leaks and then fill the radiator and the reserve tank with water CHECK OIL LEVEL IN ENGINE OIL PAN ADD OIL 1 Open the engine hood 2 Remove dipstick G and wipe the oil off with a cloth 3 Insert dipstick G fully in the oil filler pipe then take it out again 4 The oil level should be between the H and L marks on dipstick G If the oil level...

Page 105: ...UEL LEVEL ADD FUEL WARNING When adding fuel never let the fuel overflow This may cause a fire If spilling fuel thoroughly clean up any spillage 1 Use sight gauge G on the front face of the fuel tank to check that the tank is full 2 If the fuel level is not within the sight gauge add fuel through filler port F while watching sight gauge G ...

Page 106: ...owly to release the internal pressure before removing the cap If oil has been added to above the H mark stop the engine and wait for the hydraulic oil to cool down then drain the excess oil from the drain plug P 1 If the work equipment is not in the condition shown in the dia gram on the right start the engine run the engine at low speed retract the arm and bucket cylinders then lower the boom set...

Page 107: ...ir cleaner clogging monitor does not flash 2 If it flashes immediately clean or replace the element For details of the method of cleaning the element see CHECK CLEAN AND REPLACE THE AIR CLEANER ELEMENT on page 188 CHECK ELECTRIC WIRING WARNING If the fuse blows frequently or there are traces of short cir cuiting in the electric wiring always locate and repair the cause Check for damage of the fuse...

Page 108: ...engine off open the left hand door and locate the water drain at the bottom of the primary fuel filter 2 To open drain valve turn the valve counterclockwise approxi mately 1 5 to 2 turns until draining occurs Drain the filter sump of water until clear fuel is visible 3 Turn the valve clockwise to close NOTICE Do not over tighten the valve Over tightening can dam age the threads ADJUSTMENT BEFORE O...

Page 109: ... harder and when turned anti clockwise softer Adjust the dial so that the suspension best matching the operator s weight is selected G Lumbar adjustment Turn knob 7 to adjust lumbar supports H Air suspension adjustment option When button 8 is pressed the air compressor will harden the sus pension and when the button is pulled out air is released to soften the suspension Note that the compressor ca...

Page 110: ...ition When starting the engine never touch the knob button 3 Insert the key in starting switch 2 turn the key to the ON position then carry out the following checks The buzzer will sound for approx 1 sec and the following moni tors and gauges will light up for approx 3 sec Radiator water level monitor 3 Engine oil level monitor 4 Hydraulic oil level monitor 5 Charge level monitor 6 Fuel level moni...

Page 111: ... A warning lamp on the steering column will illuminate If the lamps do not light up there is probably a broken bulb or dis connection in the wiring so contact your Komatsu distributor for repairs CAUTION It is illegal to travel on the road in certain countries with rear ward facing worklights illuminated STARTING ENGINE NORMAL STARTING WARNING Check that there are no persons or obstacles in the su...

Page 112: ... COLD WEATHER WARNING Check that there are no persons or obstacles in the sur rounding area then sound the horn and start the engine Never use starting aid fluids as they may cause explo sions NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds If the engine fails to start repeat steps from 2 and after wait ing for about 2 minutes When starting in low temperatures ...

Page 113: ...or and gauge also light up when the key is at the HEAT position but this does not indicate any abnormality 3 When preheating monitor 3 flashes turn the key in starting switch 2 to the START position to start the engine 4 When the engine starts release the key in starting switch 2 The key will return automatically to the ON position AM090340A AM090380A HEAT OFF ON START AM090390A HEAT OFF ON ST AR ...

Page 114: ...eration Particularly in cold areas be sure to carry out the warm ing up operation fully WHEN NORMAL NOTICE When the hydraulic oil is at a low temperature do not carry out operations or move the levers suddenly Always carry out the warming up operation This will help to extend the machine life Do not suddenly accelerate the engine before the warm ing up operation is completed Do not run the engine ...

Page 115: ...d raise the bucket from the ground 4 Operate bucket control lever 4 and arm control lever 5 slowly to move the bucket cylinder and arm cylinder to the end of the stroke 5 Carry out bucket and arm operation for 5 minutes at full stroke alternating between bucket operation and arm opera tion at 30 second intervals If the swing lock switch 6 is set to the ON actuated position and swing control lever ...

Page 116: ...or noise or vibration If any abnormality is found repair it 8 Press working mode switch 2 on the monitor panel until the lamp of the mode to be used lights up IN COLD AREAS AUTOMATIC WARMING UP OPERATION When starting the engine in cold areas carry out the automatic warming up operation after starting the engine When the engine is started if the engine water temperature is low below 30 the warming...

Page 117: ...es This will cause leakage of oil from the turbocharger oil supply piping If it is nec essary to run the engine at idling apply a load from time to time or run the engine at a mid range speed 1 Set fuel control dial 1 at the low idling MIN position and run the engine for about 5 minutes without load 2 When the automatic warming up operation is completed press working mode switch 2 on the monitor p...

Page 118: ... this for 30 seconds Next repeat the same operation with the bucket and swing for 30 seconds Operate both fully in turn for 5 minutes NOTICE When pulling in the work equipment be careful not to let it hit the chassis or ground 7 Turn fuel control dial 1 to the full speed MAX position and carry out the operation is Step 6 for 3 5 minutes 8 Repeat the following operation 3 5 times and operate slowly...

Page 119: ...the working mode to be used NOTICE Cancelling automatic warming up operation If it becomes necessary in an emergency to lower the engine speed to low idling cancel the automatic warming up opera tion as follows 1 Turn fuel control dial 1 to the full speed MAX position and hold it for 3 seconds 2 When fuel control dial 1 is returned to the low idling MIN position the engine speed will drop AD157770...

Page 120: ...rection Check service brake just after moving off Check that low brake pressure warning lamp is off 1 Set swing lock switch 1 to the ON actuated position and confirm that swing lock monitor lamp 2 lights up Although the hydraulic swing lock 1 above may be adequate for nor mal job site working it is a legal requirement in some coun tries to use a mechanical lock when driving on public roads 2 Turn ...

Page 121: ...n the front axle is unlocked NOTE Where machine is fitted with combination of blade and outrigger options it is necessary before dozing opera tions to position outrigger switch in its central R H Attachment positions This is in order to Ensure that the suspension lock stays in the free position 7 Set working mode switch to H O as shown 8 Select travel speed using switch 7 According to the ground c...

Page 122: ...rriage is facing in the normal forward direction Engine speed will automatically reduce 4 seconds after selecting forward reverse if no further operation is made This saves fuel consumption Auto decel function 11 When changing direction from forward to reverse or vice versa always allow the machine to stop before changing the position of the travel pedal 12 When travelling in Hi mode a slight shoc...

Page 123: ... the travel pedal is fully depressed with the fuel control dial set to max the machine may start abruptly When driving the machine on a road raise the outriggers and or dozer blade and insert the lock pins to prevent them from falling When auto deceleration is selected if the wrist control lever or travel pedal is operated inside the deceleration range the engine speed will rise suddenly Before mo...

Page 124: ...e the travel pedal 1 and depress the service brake pedal 2 to stop the machine The service brakes may be locked by fully de pressing the service brake pedal until it latches 2 Lower the work equipment until it touches the ground 3 Raise the control lever pad safety lock to lock the work equip ment controls 3 STOPPING MACHINE EMERGENCY The park brake on this machine is a hydraulic mechanical device...

Page 125: ...en operating the swing check that the area around the ma chine is safe 1 Before operating the swing turn swing lock switch 1 OFF CANCELED NOTICE Check that swing lock monitor 2 goes out at the same time 2 Operate left work equipment control lever 3 to swing the upper structure 3 When not operating the swing turn swing lock switch 1 ON ACTUATED AW349440B 1 2 A B AM090650A ...

Page 126: ...ht When the levers are released they automatically return to the neutral position and the work equip ment is held in place If the work equipment control lever is returned to the neutral position when the machine is stopped even if the fuel control dial is set to FULL the auto deceleration mechanism will act to reduce the engine speed to a mid range speed If the levers are operated within 15 second...

Page 127: ...ied out without needing to set the mode Set the most effective mode according to the type of work using working mode selector switch Bucket operation AD157770A H O G O F O L O B O H M Working mode Applicable work Power max Swift slow down speed down Power Speed Heavy duty operation mode H O Large amount of digging and loading in a short time 8 up Approx 6 down General operation mode G O Normal dig...

Page 128: ...ction effectively in combi nation with working mode 1 When starting switch is turned ON the power up lamp turns on When SET switch is pressed once the speed down lamp turns on and the power up lamp goes out and when pressed again the opposite occurs 2 When the left knob button is given a single click keep depressed after initially pressing power keeps increasing while depressed However power up au...

Page 129: ... break earth mounds or walls When swinging do not dig the bucket teeth into the soil These operations will damage the work equipment Prohibited operations using travel force Do not leave the bucket dug into the ground and use the travel force to excavate This will bring excessive force to bear on the rear of the machine Precautions when operating hydraulic cylinders to end of stroke If the cylinde...

Page 130: ...r digging Digging rocky ground It is better to excavate hard rocky ground after breaking it up by some other means This will not only reduce damage to the machine but make for better economy PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELING When traveling over obstacles such as boulders or tree stumps the machine in particular the undercarriage is subjected to a large shock so reduce the travel...

Page 131: ... DOWN HILLS WARNING When traveling raise the bucket approx 20 30 cm from the ground Do not travel downhill in reverse When traveling over ridges or other obstacles keep the work equipment close to the ground and travel slowly It is dangerous to turn on slopes or to travel across slopes Always go down to a flat place to perform these operations It may be longer but it will ensure safety If the mach...

Page 132: ...chine is on a slope never use the left work equipment control lever to carry out swing opera tions The upper structure will swing under its own weight Do not open or close the door on the cab if the machine is on a slope This may cause a sudden change in the operating force Always keep the door locked HOW TO ESCAPE FROM MUD Always operate carefully to avoid getting stuck in mud If the ma chine doe...

Page 133: ...ition of the machine is as shown in the diagram at right each cylinders maximum pushing excavation force is obtained when the bucket cylinder and link arm cylinder and arm are at 90 When excavating use this angle effectively to optimize your work efficiency The range for excavating with the arm is from a 45 angle away from the machine to a 30 toward the machine There may be some differences depend...

Page 134: ...front of the dump truck body than if loading is done from the side REPLACEMENT AND INVERSION OF BUCKET WARNING When knocking the pin in with a hammer metal particles may fly and cause serious injury particularly if they get into your eyes When carrying out this operation always wear goggles helmet gloves and other protective equipment When the bucket is removed place it in a stable condi tion Stop...

Page 135: ...MARK When installing the bucket the O rings are easily damaged so fit the O rings on the boss of the arm end as shown in the dia gram When knocking the pin move the O ring down to the regular groove 4 Install the stopper bolts and nuts for each pin then grease the pin INVERSION 1 Place the bucket in contact with a flat surface REMARK When removing the pins place the bucket so that it is in light c...

Page 136: ... and 2 and stabilise the bucket securely 4 Align the arm with holes 1 and the link with holes 2 then coat with grease and install pins A and B REMARK Install the O rings into retaining hole 1 of the arm and bucket When installing the bucket the O rings are easily damaged so fit the O rings on the boss of the arm end as shown in the diagram When knocking the pin move the O ring down to the regular ...

Page 137: ...e wheels As an additional safety measure thrust the bucket into the ground If the control lever is touched by accident the work equipment or the machine may move suddenly and this may lead to a serious accident Before leaving the opera tor s compartment always set the control lever pad safety lock lever securely to LOCK position 1 Depress the brake pedal 1 until machine stops 2 Turn fuel control d...

Page 138: ...engine is abruptly stopped before it has cooled down engine Iife may be greatly shortened Consequently do not abruptly stop the engine apart from an emergency In particular if the engine has overheated do not abruptly stop it but run it at medium speed to allow it to cool gradu ally then stop it 1 Run the engine at low idling speed for about 5 minutes to allow it to gradually cool down 2 Turn the ...

Page 139: ...nd close all these places OVERLOAD WARNING DEVICE Excavators are provided with this device to warn the operator about tipping over while lifting loads A buzzer will sound when the machine is in LO mode and the machine nears its lifting capacity NOTE Only conduct lifting operations in LO mode as the over load warning system is only active in this mode HANDLING THE WHEELS WARNING Incorrect handling ...

Page 140: ... always be refitted following disassembly as it ensures that the inner wheel assembly can be deflated whilst fitted to the hub 2 Before starting to remove the wheels 1 Depress the brake pedal fully until it locks 2 Raise the chassis with the boom so that the tyres are raised above the ground Then place axle stands below the front and rear axles 3 Loosen wheel nuts with a wheel wrench Wheel nuts ha...

Page 141: ...o remove the tyre from the rim first remove the lock ring by progressively levering it from the gutter groove Do not exert excessive force as this may deform the retaining ring Remove the loose flange and then the tyre tube Re assembly inflation Check thoroughly the condition of the wheel and rim for signs of wear or damage Discard any defective or doubtful parts and replace with approved replacem...

Page 142: ...e is no clearance between it and the loose flange Fig 3 If the lock ring is not in the correct position stop the procedure as the lock ring may be ejected from the groove resulting in possible injury Deflate the tyre and repeat the procedure If the lock ring is correctly positioned continue to inflate the tyre to the value given in the previous table Before removing the wheel assembly from the saf...

Page 143: ... a corresponding 1 piece wheel rim Care should still be taken to suitably guard the tyre during inflation and as with the other rim types no attempt should be made to modify or repair damaged parts 6 Maintenance Periodically remove the road wheels following the procedure de tailed previously and perform the following checks Remove all dirt especially in the area of the tyre bead seat and check the...

Page 144: ...OPERATION OPERATION 143 7 Wheel spacer WARNING Wheel spacers must not be used with radial ply tyres 8 Rotating tyres Consult your local Komatsu distributor for advice on rotating tyres ...

Page 145: ...hine Remove the mud from the undercarriage to prevent the machine from slipping to the side on slopes Be sure the ramp surface is clean and free of grease oil ice and loose materials Never change the direction of travel when on the ramps If it is necessary to change direction drive off the ramps and correct the direction then drive on to the ramps again When turning the machine on the trailer the ...

Page 146: ... 2 Set the travel speed switch to the Mi position 3 Turn the auto deceleration switch OFF and return the fuel control dial to reduce the engine speed 4 Turn the swing lock switch ON to apply the swing lock 5 Set in the direction of the ramps lower the work equipment as far as possible without letting it hit the trailer then travel slowly to load or unload the machine When on the ramps do not opera...

Page 147: ...ng switch 3 Lock all the control levers securely with the control lever pad safety lock 4 When transporting the machine place rectangular timber underneath the front and rear wheels to prevent the machine from moving about Also hold it down with chains or rope Be particularly careful to ensure that the machine does not slip sideways NOTICE When transporting the machine place rectangular timber und...

Page 148: ...e right boom at the top stroke end arm bucket fully retracted Direct the top revolving super structure straight forward 2 Set the control lever pad safety lock in the lock position 3 Stop the engine Confirm safety around the operator seat Get off the machine Be sure to close the cab door windshield right and left doors engine hood etc 4 Mount a shackle to the lifting hook on the boom and the count...

Page 149: ...Always retract the car radio antenna Obey all state and local laws governing the weight width and length of a load Observe all regulations governing wide loads 1 Height for transport 2 Overall height 3 height of trailer platform Weights and dimensions will vary according to specification Consult your Komatsu distributor if in doubt Specifications Overall length A mm Overall width B mm Overall heig...

Page 150: ...4 Fully extract the second boom cylinders 5 Adjust the arm cylinder such that the boom and arm pointers are aligned 6 Disable the work equipment levers by moving the control lever pad safety lock to the locked position 7 Close manual lock valves 1 For the bucket cylinder located on the arm 2 For the arm cylinder located on the first boom After setting the machine in the travelling posture confirm ...

Page 151: ...freeze Do not mix one antifreeze with a different brand For details of the antifreeze mixture when changing the coolant see see WHEN REQUIRED on page 188 Use a Permanent Antifreeze ethylene glycol mixed with corro sion inhibitor antifoam agent etc meeting the standard require ments as shown below With permanent antifreeze no change of coolant is required for a year If it is doubtful that an availa...

Page 152: ...F WORK To prevent mud water or the undercarriage from freezing and making it impossible for the machine to move the following morn ing always observe the following precautions Mud and water on the machine body should be completely removed This is to prevent damage to the seal caused by mud or dirt getting inside the seal with frozen drops of water Park the machine on hard dry ground If this is imp...

Page 153: ...e battery from freezing in the night AFTER COLD WEATHER When season changes and the weather becomes warmer do as follows Replace the fuel and oil for all parts with oil of the viscosity specified For details see USE FUEL COOLANT AND LUBRI CANTS ACCORDING TO AMBIENT TEMPERATURE on page 173 If for any reason permanent antifreeze cannot be used and an ethyl glycol base antifreeze winter one season ty...

Page 154: ...battery and cover it or remove it from the machine and store it separately If the ambient temperature is expected to drop below 0 C always add antifreeze to the cooling water Lock each control lever with the lock lever Set the stop valve to the lock position on machines ready for attachments Install the blind plugs to the elbows Set the selector valve to the Crusher and general attach ment positio...

Page 155: ...ipe off the grease from the hydraulic cylinder rods Add oil and grease to all places STARTING MACHINE AFTER LONG TERM STORAGE When starting the machine after a long term storage first cancel the automatic warming up function as follows 1 Turn the starting switch key to the ON position 2 Turn the fuel control dial from the low idling MIN position to the full MAX position hold it there for 3 seconds...

Page 156: ...ulled in the speed of movement will drop momentarily when the arm is more or less vertical 2 The arm speed will drop momentarily when the bucket teeth are more or less horizontal 3 When starting or stopping the swing noise will be emitted from the brake valve 4 When going down a steep slope at low speed a noise will be emitted from the travel motor ...

Page 157: ...ect use a wire rope as shown in the diagram WHEN USING THE FRONT OF CHASSIS WHEN USING THE REAR OF THE CHASSIS PRECAUTIONS ON PARTICULAR JOBSITES 1 When carrying out digging operations in water if the work equipment mounting pin goes into the water carry out greas ing every time the operation is carried out 2 For heavy duty operations and deep digging carry out greas ing of the work equipment moun...

Page 158: ...y always wear protective goggles When removing the battery first disconnect the cable from the ground normally from the negative termi nal When installing install the positive terminal first If a tool touches the cable connecting the positive ter minal and the chassis there is danger that it will cause sparks If the terminals are loose there is danger that the defec tive contact may generate spark...

Page 159: ...se care when removing the cables from the machine that has been started Do not allow the cable ends to con tact each other or the machine to avoid hydrogen explo sion NOTICE The size of the booster cable and clip should be suitable for the battery size The battery of the normal machine must be the same capacity as that of the engine to be started Check the cables and clips for damage or corrosion ...

Page 160: ...ive terminal of the normal machine 3 Remove one clip of booster cable A from the positive ter minal of the normal machine 4 Remove the other clip of booster cable A from the positive terminal of the problem machine OTHER TROUBLE ELECTRICAL SYSTEM Always contact your Komatsu distributor when dealing with these items In cases of abnormalities or causes which are not listed below please contact your ...

Page 161: ...fective monitor Check repair Replace Replace Oil pressure monitor does not light up when engine is stopped start ing switch at ON position Defective monitor Defective caution lamp Replace Replace Outside of electrical heater is not is warm when touched by hand Defective wiring Disconnection in electric heater Defective operation of heater relay switch Check repair Replace Replace Problem Main caus...

Page 162: ...thermostat Tighten cap or replace packing Replace sensor Radiator water level monitor lights up Engine does not start when start ing motor is turned Lack of fuel Air in fuel system Defective fuel injection pump or nozzle Starting motor cranks engine sluggishly Preheating monitor does not light up Defective compression Defective valve clearance Add fuel see CHECK BEFORE STARTING Repair place where ...

Page 163: ...release the brake If applying the swing brake manually operate the swing brake using the swing holding brake switch In this case immedi ately have the swing brake system inspected by your Komatsu distributor E05 Governor system error Governor will not execute the control function Manually operate the governor lever To fix the governor lever at the full stroke position use the retaining bolt holes ...

Page 164: ...163 MAINTENANCE ...

Page 165: ...iners of the oil and grease clean Keep foreign materials away from oil and grease Keeping the machine clean Always keep the machine clean This makes is easier to find parts causing problems Keep in particular grease fittings breathers and oil level gauges clean and avoid foreign matters from getting in them Be careful of hot water and oil Draining hot oils and coolants and removing their filters i...

Page 166: ... Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point Fire prevention Use nonflammable cleaner or light oil for cleaning parts Keep flame or cigarette light away from light oil Clamp faces When O rings or gaskets are removed clean the clamp faces and replace the 0 rings and gaskets with new ones Be sure to fit 0 rings and gaskets when assembling Obje...

Page 167: ... lubricate work equipment pins daily if they are sub merged in water Dusty worksites When working at dusty worksites do as follows Inspect the air cleaner clogging monitor to see whether the air cleaner is blocked Clean the air cleaner at shorter intervals than specified Clean the radiator core frequently to avoid clogging Clean and replace the fuel filter frequently Clean electrical components es...

Page 168: ...ponds to blood in the human body so always be careful when handling it to prevent any impurities water metal particles dirt etc from getting in The majority of problems with machine are caused by the entry of such impurities Take particular care not to let any impurities get in when storing or adding oil Never mix oils of different grades or brands Always add the specified amount of oil Having too...

Page 169: ...sture in the air from condensing and form ing water inside the fuel tank always fill the fuel tank after completing the day s work Before starting the engine or when 10 minutes have passed after adding fuel drain the sediment and water from the fuel tank If the engine runs out of fuel or if the filters have been replaced it is necessary to bleed the air from the circuit COOLANT River water contain...

Page 170: ...r other impurities from getting in When keeping drum cans for a long period put the drum on its side so that the filler port of the drum can is at the side To prevent moisture from being sucked in If drum cans have to be stored outside cover them with a waterproof sheet or take other measures to protect them To prevent any change in quality during long term storage be sure to use in the order of f...

Page 171: ...n the seashore carefully clean the electric system to prevent corrosion When installing a car cooler or an other electrical equipment connect it to an independent power source connector The optional power source must never be connected to the fuse starting switch or battery relay OUTLINE OF HYDRAULIC SYSTEM During operation and immediately after operation is ended the temperature of the hydraulic ...

Page 172: ...d refilling of hydraulic oil When the high pressure hose etc is removed check the O ring for damage If necessary replace it After the hydraulic filter element and strainer are cleaned or replaced or after the hydraulic system is repaired or replaced or the hydraulic piping is removed bleed air from the hydrau lic circuit The accumulators are charged with high pressure nitrogen gas Incorrect handli...

Page 173: ...hen ordering parts please check the part number in the parts book The parts in parentheses are to be replaced at the same time Item Part No Part Name Q ty Replacement frequency Hydraulic oil filter 07063 51100 07000 05155 Element O ring 1 1 Every 500 hours service Air cleaner 203 01 K1130 203 01 K1290 Single element Safety element 1 1 When required Engine oil filter 6733 51 5140 Cartridge 1 Every ...

Page 174: ... more or less in the day time Reservoir Kind of fluid AMBIENT TEMPERATURE Type OF OIL CAPACITY Min Max Specified Refill Engine oil pan Engine oil API CE or CF 4 0 C 20 C 15 C 30 C 30 C 10 C 50 C 30 C SAE 30 SAE 10W SAE 15W 40 SAE 10W 30 16 liter 16 liter Swing machinery case Engine oil 20 C 30 C SAE 30 2 5 liter 2 5 liter PTO gear case 0 75 liter 0 75 liter Hydraulic system Bio oil 20 C 30 C SAE 1...

Page 175: ...system during nor mal inspection and maintenance Abbreviations ASTM American Society of Testing and Material SAE Society of Automotive Engineers API American Petroleum Institute USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE CONT TYPE CLASS VISCOSITY REF NO Engine oil CF 4 CF 4 SAE15W 40 SAE10W 30 EO 1540 EO 1030 TRANSMISSION OIL CD SAE10W TO 10 GEAR BOX OIL CD CD CD SAE10W SAE30...

Page 176: ...ormance 3C Performance 3C Tranself EP Tranself EP type 2 Glacelf 11 EXXON ESSO Essolube D3 Essolube XD 3 Essolube XD 3 Extra Esso heavy duty Exxon heavy duty Gear oil GP Gear oil GX Beacon EP2 All season coolant 12 GULF Super duty motor oil Super duty plus Multi purpose gear lubricant Gulfcrown EP2 Gulfcrown EP special Antifreeze and coolant 13 MOBIL Delvac 1300 Delvac super 10W 30 15W 40 Mobilube...

Page 177: ...ium Multigear Multifak EP2 Starplex 2 Code 2055 startex antifreeze coolant 19 TOTAL Rubia S Rubia X Total EP Total transmission TM Multis EP2 Antigel antifreeze 20 UNION Guardol MP gear lube LS Unoba EP 21 VEEDOL Turbostar Diesel star MDC Multigear Multigear B Multigear C Antifreeze No Supplier Engine Oil CD or CE SAE10W 30 40 10W30 15W40 The 15W40 oil marked is CE Gear Oil GL 4 or GL 5 SAE80 90 1...

Page 178: ...th across flats S1 S2 8mm 10mm 12mm 14mm 13mm 17mm 19mm 22mm 24mm 27mm 30mm 32mm 2 Screwdriver 09033 00190 Crosshead flat head interchangeable type 3 Socket wrench set 09020 10282 Applicable width across flats set 10 mm 13 mm 14 mm 17 mm 19 mm 22 mm 24 mm 27 mm 30 mm 32 mm Extension Handle Joint Ratchet handle bar 4 Wrench 09002 03641 Applicable width across flats 36 mm 41 mm 5 Pliers 09036 00150 ...

Page 179: ... was replaced NOTICE When tightening panels or other parts having tightening fixtures made of plastic be careful not to use excessive tightening torque doing so will damage the plastic parts Thread diameter of bolt mm a Width across flats mm b N m kgf m 6 8 10 12 14 10 13 17 19 22 13 2 1 4 31 4 2 9 65 7 6 8 112 9 8 177 19 1 35 0 15 3 2 0 3 6 7 0 7 11 5 1 0 18 0 2 0 16 18 20 22 24 24 27 30 32 36 27...

Page 180: ...ily wear or deteriorate However it is difficult to judge the con dition of the parts simply by periodic maintenance so they should always be replaced after a fixed time has passed regardless of their condition This is necessary to ensure that they always main tain their function completely However if these parts show any abnormality before the replace ment interval has passed they should be repair...

Page 181: ...lacement Q ty Replacement interval 1 Fuel hose fuel tank water separator 1 Every 2 years or 4000 hours which ever comes sooner 2 Fuel hose water separator engine lift pump 1 3 Fuel hose engine lift pump fuel filter 1 4 Fuel hose fuel filter injection pump 1 5 Spill hose engine fuel tank 1 6 Hydraulic hose main pump delivery 1 ...

Page 182: ...e 195 CHECK START MOTOR page 196 REPLACE BUCKET SIDE CUTTERS page 196 REPLACE BUCKET TEETH page 197 ADJUST BUCKET CLEARANCE page 197 CHECK WINDOW WASHER FLUID LEVEL ADD FLUID page 198 CHECK AND ADJUST AIR CONDITIONER page 198 DRAIN ENGINE BREATHER OIL CATCHER page 199 CHECK BEFORE STARTING CHECK COOLANT LEVEL ADD WATER page 200 CHECK OIL LEVEL IN ENGINE OIL PAN ADD OIL page 200 CHECK FUEL LEVEL AD...

Page 183: ...utrigger leg pivot 2 or 4 points page 206 Outrigger foot pivot 2 or 4 points page 206 Propshaft page 206 Boom adjust cylinder foot pin 1 point page 207 Boom adjust cylinder rod end 1 point page 207 Dozer blade cylinder rod end 2 points page 207 Dozer blade pivot pin 2 points page 207 Dozer blade cylinder foot pin 2 points page 207 Axle pivot 1 point page 207 Hub pivot 4 points page 207 Steer links...

Page 184: ... FINS ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER page 219 REPLACE HYDRAULIC TANK BREATHER ELEMENT page 220 REPLACE HYDRAULIC FILTER ELEMENT page 220 EVERY 1000 HOURS SERVICE CHANGE OIL IN SWING MACHINERY CASE page 221 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER page 222 CHECK PLAY OF TURBOCHARGER ROTOR page 222 CHECK ADJUST VALVE CLEARANCE page 222 CHECK FAN BELT TENSIONER BEARING BELT AND FAN...

Page 185: ... Outrigger leg pivot grease 9 Bucket cylinder foot pin grease 31 Outrigger cylinder foot pin grease 10 Bucket cylinder rod end grease 32 Transmission oil check level change oil 11 Bucket link coupling pin grease 33 Wheel hubs front check level change oil 12 Arm bucket coupling pin grease 34 Wheel hubs rear check level change oil 13 Arm link coupling pin grease 35 Front axle check level change oil ...

Page 186: ...MAINTENANCE MAINTENANCE SCHEDULE CHART 185 Interval of service Change filter Lubrication by greasing G Amount of oil required at change liters Check oil level change EO ...

Page 187: ...s follows Replacing hydraulic filter element On new machines replace the element after the first 100 to 150 hours then carry out further replacement of the element according to the table on the right Changing oil in hydraulic tank Change the oil according to the table on the right AD31373D Replacement interval for hydraulic oil Breaker operation ratio Hydraulic Fillerelement Replacement interval H...

Page 188: ...he first 250 hours REPLACE FUEL FILTER CARTRIDGE see REPLACE FUEL FILTER CARTRIDGES on page 215 CHECK ENGINE VALVE CLEARANCE ADJUST see CHECK ADJUST VALVE CLEARANCE on page 222 For details of the method of replacing or maintaining see the section on EVERY 500 HOURS and 2000 HOURS SER VICE CHANGE OIL IN TRANSMISSION HUBS AXLES ...

Page 189: ... dirt or dust from entering use tape or a clean cloth to cover the inner element of the air cleaner body 3 Clean the air cleaner body interior and the cover 4 Direct dry compressed air less than 700 kPa 7 kg cm to element 7 from inside along its folds then direct it from out side along its folds and again from inside Remove one seal from the outer element whenever the outer element has been cleane...

Page 190: ...er element 2 To prevent dust from getting in use a clean cloth or tape to cover the air connector outlet side 3 Clean the air cleaner body interior then remove the cover installed in Step 2 4 Fit a new inner element to the connector and tighten it with the nuts Do not clean and reinstall a inner element 5 Install the outer element and fix it with the wing nut CLEAN INSIDE OF COOLING SYSTEM WARNING...

Page 191: ...system is filled to the proper level Selection and maintenance of the engine coolant is important to long engine life The following information provides recommenda tions for selecting the engine coolant maintaining the coolant inhibitors and servicing the cooling system The system operates successfully with a water antifreeze mixture or inhibited conditioned water as the coolant Water alone allows...

Page 192: ...lant can spray out if the radiator cap is removed suddenly Relieve system pressure by slowly turning the cap to the first notch or lifting the safety lever if equipped Remove the cap only after the pressure is relirved Use extreme caution when adding coolant to the radiator to avoid being burned Wear gloves and goggles and keep face away from the filler neck To remove the cap turn the cap to the l...

Page 193: ...tarting Wear hand and eye protection when draining hot fluids 1 Run the engine until it reaches operating temperature then stop the engine 2 Remove the radiator cap as outlined in this section 3 Remove the crankcase coolant drain plug located on the bot tom of the coolant inlet 1 4 Open the radiator drain valve 2 5 Allow the system to completely drain into a suitable container Do not let drain out...

Page 194: ... valve 4 and add coolant until it overflows from the water filler When the coolant comes up to near the water filler port close the air drain valve For cool ant specifications see COOLANT SYSTEM 4 Start engine and run until normal operating temperature is reached Add coolant when needed to keep proper level in reserve tank 5 After all air is removed and level remains fixed install the radiator cap...

Page 195: ...rom the radiator core using air or water under pressure Direct the flow through the core opposite to the normal direction of air flow CLEANING THE RADIATOR PRE SCREEN 1 Remove the bolts retaining the radiator pre screen and remove the pre screen 2 Clean the pre screen with water under pressure 3 Reinstall the pre screen and retaining bolts THERMOSTATS REMOVAL 1 Drain the cooling system Refer to DR...

Page 196: ...orque to 450 Nm CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season once a year contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections CHECK ALTERNATOR GENERAL The alternator requires no lubrication since its bearings are fac tory lubricated for life and require attention only at the time of major overhaul The alt...

Page 197: ...normal operating conditions no maintenance is required between engine overhaul periods At the time of engine overhaul the motor should be disassembled inspected cleaned and tested Contact your distributor for detailed information REPLACE BUCKET SIDE CUTTERS WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced Set the work equipment in a stable condition ...

Page 198: ...CKET CLEARANCE WARNING It is dangerous if the work equipment moves by mistake when the clearance is being adjusted Set the work equipment in a stable condition then stop the engine and lock control lever pad safety lock 1 Set the work equipment to the position shown in the diagram at right stop the engine and set the safety lock lever to the lock position 2 Shift 0 ring 1 of the linkage and measur...

Page 199: ...ow washer tank 1 If showing under the level fill with automobile window washer fluid When adding fluid be careful not to let dirt or dust get in Mixture ratio of pure washer fluid and water Since the ratio should be varied depending on atmospheric temperature replenish washer fluid at the following mixture ratio taking temperature into account Pure washer fluid comes in two types for 10 C for gene...

Page 200: ...l from the engine breather catcher and when ever it is necessary to remove the engine undercover 1 Remove plug 1 from engine undercover 3 and allow oil to drain out 2 Replace plug 1 Ensure that the breather hose 2 is positioned onto catcher res ervoir whenever the undercover is removed Inspection and maintenance items Contents Maintenance interval Refrigerant gas Filling quantity Twice a year spri...

Page 201: ...pect for water leaks and then fill the radiator and the reserve tank with water CHECK OIL LEVEL IN ENGINE OIL PAN ADD OIL 1 Open the engine hood 2 Remove dipstick G and wipe the oil off with a cloth 3 Insert dipstick G fully in the oil gauge pipe then take it out again 4 The oil level should be between the H and L marks on dipstick G If the oil level is below the L mark add engine oil through oil ...

Page 202: ...ht gauge G on the front face of the fuel tank to check that the tank is full 2 If the fuel level is not within the sight gauge add fuel through filler port F while watching sight gauge G Fuel capacity 240 l For details of the fuel to use see USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER ATURE on page 173 3 After adding fuel tighten the cap securely REMARK If breather hole 1 on the ca...

Page 203: ...mal if between the H and L marks NOTE Do not add oil if the level is above the H line This will damage the hydraulic equipment and cause the oil to spurt out 3 If the level is below the L mark remove cap F from the hydraulic tank and add oil For details of the oil to use see USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER ATURE on page 173 REMARK The oil level will vary depending upon ...

Page 204: ...r Komatsu distributor for investigation and cor rection of the cause CHECK FOR WATER AND SEDIMENT IN SEDIMEN TOR DRAIN WATER AND SEDIMENT A fuel sedimentor is mount in the radiator compartment and is accessed by the door on the left hand side of the machine Entrapped sediment and water can be seen through the glass bow 1 Loosen drain plug 1 and drain water and sediment until none is visible in bow...

Page 205: ...get fuel on your self 4 When only clean fuel comes out close drain valve 1 NOTE Never use trichlene for washing the inside of the tank EVERY 100 HOURS SERVICE Maintenance every 50 hours should be carried out at the same time LUBRICATING The minimum greasing interval is 100 hours however more fre quent greasing will be required depending on conditions environ ment 1 Set the work equipment in the gr...

Page 206: ...er greasing wipe off any old grease that was pushed out 1 Boom cylinder foot pin 2 points 2 Boom foot pin 2 points 3 Boom cylinder rod end 2 points 4 Arm cylinder foot pin 1 point 5 Boom Arm coupling pin 1point 6 Arm cylinder rod end 1 point ...

Page 207: ...m Bucket coupling pin 1 point 10 Link coupling pin 1 point 11 Bucket cylinder rod end 1 point 12 Bucket Link coupling pin 2 points 13 Outrigger cylinder foot pin 2 or 4 points 14 Outrigger cylinder rod end 2 or 4 points 15 Outrigger leg pivot 2 or 4 points 16 Outrigger foot pivot 2 or 4 points 17 Propshaft ...

Page 208: ...r blade cylinder rod end 2 points 21 Dozer blade pivot pin 2 points 22 Dozer blade cylinder foot pin 2 points 23 Axle pivot 1 point 24 Hub pivot 4 points 25 Steer links 4 points 26 Parallel link pivot pin 2 points 27 Dozer blade cylinder rod end 2 points 28 Single link pivot pin 2 points 29 Dozer blade pivot pins 6 points ...

Page 209: ...ing remove bleeding plug 1 For details of the oil to use see USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER ATURE on page 173 5 If the oil level exceeds the H mark on the dipstick loosen drain plug P to drain the excess oil 6 After checking oil level or adding oil insert the dipstick into the hole and install air bleeding plug 1 CLEAN FRESH AIR INTAKE FILTER 1 Remove two wings nuts ho...

Page 210: ...if the machine is used in a dusty environment shorten this inter val EVERY 250 HOURS SERVICE CHECK OIL LEVEL IN WHEEL HUBS ADD OIL Prepare a hexagonal wrench 1 Set so that plug 1 is at the horizontal position 2 Remove plug 3 If no oil emerges turn hub so that hole is at the top and add oil 4 Turn hub so that hole is horizontal 5 Repeat steps 3 and 4 For details of the oil to use see USE FUEL COOLA...

Page 211: ...lace plug 1 For details of the oil to use see USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER ATURE on page 173 CHECK OIL LEVEL IN TRANSMISSION ADD OIL 1 Remove level plug 2 2 If oil emerges replace plug 2 3 If no oil emerges remove plug 1 and add oil until oil emerges from plug hole 2 4 Replace plugs For details of the oil to use see USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIEN...

Page 212: ...e in the battery cap then tighten the cap securely When adding distilled water in cold weather add it before starting operations in the morning to prevent the electrolyte from freezing LUBRICATE SWING CIRCLE 2 points 1 Lower the work equipment to the ground 2 Using a grease pump pump in grease through the grease fit tings shown by arrows 3 After greasing wipe off all the old grease that was pushed...

Page 213: ... every 250 hours If the tension falls below the required minimum the belt slips and damages the belts and pulley grooves REMARK When operating in abrasive conditions check tension every 100 hours Visually inspect the belts for intersecting cracks Transverse across the belt width cracks are acceptable Longitudinal direc tion of belt length cracks that intersect with transverse cracks are not accept...

Page 214: ...auge must be used because of the wide drive belt Proper tension should be 355 to 455 N m gauge value If a Gates type gauge is not available tension may be checked by belt deflection Press the belt with your finger at the longest span and measure the deflection Maximum deflection 9 5 to 12 7 mm ADJUSTMENT With the automatic belt tensioner no adjustment is required REPLACEMENT To replace the drive b...

Page 215: ...compressor 3 to adjust 2 When the deflection is correct tighten bolts 1 and 2 to hold the compressor in position 3 Check each pulley for damage and check the V groove and V belt for wear In particular check that the V belt is not con tacting the bottom of the V groove 4 If the V belt is streched and cannot be adjusted any further or if there are any cuts or cracks replace the V belt 5 After replac...

Page 216: ...ges with clean fuel coat the packing surface with engine oil then install them to the filter holders 4 When installing tighten until the packing surface contacts the seal surface of the filter holder then tighten it up 1 2 to 3 4 of a turn If the filter cartridge is tightened too far the packing will be damaged and this will lead to leakage of fuel If the filter car tridge is too loose fuel will a...

Page 217: ...er s Venting 1 Open the bleed screw 2 Operate the plunger on the lift pump until the fuel flowing from the fitting is free of air Tighten the bleed screw Torque Value 9 N m CAUTION When using the starting motor to vent the system do not engage it for more than 30 seconds at a time Wait two 2 minutes between engagements WARNING It is necessary to put the engine in the Run position Be cause the engi...

Page 218: ...gine and vent one line at a time until the engine runs smoothly CHECK SWING PINION GREASE LEVEL ADD GREASE Prepare a scale 1 Remove bolts 1 2 bolts on the top of the revolving frame and remove cover A 2 Check the colour of the grease If it is milky white it is neces sary to change the grease Please contact your Komatsu dis tributor The total amount of grease is 33 L 29 7 kg 3 Insert a rule into th...

Page 219: ...ributor 4 Tighten drain valve P 5 Using the filter wrench turn filter cartridge 1 counterclock wise to remove it In particular if this operation is carried out immediately after stopping the engine a large amount of oil will come out so wait for 10 minutes before starting the operation 6 Clean the filter holder REMARK Confirm that no remnants of old packing still adhere to the fil ter holder as th...

Page 220: ... wear protective glasses mask and safety shoes 1 Remove the engine hood and open rear door on the left side of the machine Loosen bolts 1 and remove the radiator front cover 2 Blow off mud dust or leaves clogging the radiator fins and oil cooler fins using compressed air At the same time clean the net in front of the oil cooler Clean the condenser fins on machines equipped with the air condi tione...

Page 221: ...e the internal pressure before removing it 1 Remove the cap from oil filler F and release the internal pressure 2 Loosen 4 bolts then remove cover 1 When doing this the cover may fly out under the force of spring so hold the cover down when removing the bolts 3 After removing spring 2 and valve 3 take out element 4 4 Clean the removed parts in diesel oil 5 Install a new element in the place where ...

Page 222: ...HOURS SERVICE Maintenance for every 100 250 and 500 hours should be car ried out at the same time CHANGE OIL IN SWING MACHINERY CASE WARNING The oil is at high temperature immediately after the machine has been operated Wait for the oil to cool down before carry ing out maintenance Container to catch drained oil Min 2 5 l capacity Refill capacity 2 5 l 1 Set an oil container under drain plug P und...

Page 223: ...ach the L mark add more oil through oil filler F 8 If the oil level exceeds the H mark drain the excess engine oil from drain plug P and check the oil level again CHECK ALL TIGHTENING PARTS OF TURBO CHARGER Contact your Komatsu distributor to have the tightening portions checked CHECK PLAY OF TURBOCHARGER ROTOR Ask Komatsu distributor to check the play of the turbocharger rotor CHECK ADJUST VALVE ...

Page 224: ...t valves with engine cold below 60 C NOTE The clearance is correct when some resitance is felt when the feeler gauge is slipped between the valve stem and the rocker lever With the engine in TDC position check and adjust the following valve clearances Intake I cylinders 1 2 Exhaust E cylinders 1 3 1 Camshaft gear 2 Engine timing pin 3 Gear housing ...

Page 225: ...LT TENSIONER BEARING BELT AND FAN HUB Check the tensioner bearing With the fan belt removed rotate fan hub The tensioner pulley should spin freely with no rough spots defected under hand pressure Check the tensioner bearing Replace bearing if damaged Check fan hub With the drive belt removed rotate fan hub NOTE The fan hub should spin freely without excessive end play Check the fan hub bearing Rep...

Page 226: ...set 1 Loosen 4 bolts then remove cover 1 When doing this the cover may fly out under the force of spring 2 so push the cover down when removing the bolts 2 Pull up the top of rod 3 and remove spring and strainer 4 3 Remove the dirt stuck to strainer 4 then wash it in clean die sel oil or flushing oil If strainer 4 is damaged replace it with a new one 4 Refit strainer 4 by inserting it into tank pr...

Page 227: ...ub B and the inertia member C If the lines are more than 1 59 mm out of alignment replace the damper CHANGE OIL IN AXLES 1 Remove plugs 1 and 2 to drain oil 2 Replace plug 2 3 Attach tube and funnel to plug 1 hole and add oil until oil emerges when tube is removed 4 Replace plug 1 Vibration damper ...

Page 228: ...otate until hole is horizontal 7 Repeat steps 4 5 6 8 Replace plug CHANGE OIL IN TRANSMISSION ASSEMBLY TRANSMISSION 1 Remove plugs 1 2 3 and allow oil to drain out 2 Replace plug 3 3 Add oil approx 1 l until oil emerges from plug 2 hole 4 Replace plugs 1 2 CLUTCH 1 Remove plugs 4 5 6 and allow oil to drain out 2 Replace plugs 5 6 3 Add oil measure 0 5 l 4 Replace plug 4 CHANGE ANTIFREEZE Follow th...

Page 229: ... every 100 250 500 and 1000 hours should be carried out at the same time CHANGE OIL IN HYDRAULIC TANK WARNING The oil is at high temperature immediately after the machine has been operated Wait for the oil to cool down before changing the oil When removing the oil filler cap turn it slowly to release the internal pressure then remove it care fully Prepare the following Container to catch drained o...

Page 230: ...oving drain plug P be careful not to get oil on your self 6 Add the specified amount of engine oil through oil filler port F Check that the oil level is between H and L on the sight gauge For type of oil to be used see USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER ATURE on page 173 NOTICE When the hydraulic breaker is installed the hydraulic oil deteriorates earlier than in normal bu...

Page 231: ...00 mm before the end of the stroke 2 Next operate each cylinder to the end of its stroke 3 4 times 3 After this operate each cylinder 4 5 times to the end of its stroke to completely bleed the air NOTICE If at first the engine is run at high speed or the cylinder is operated to the end of its stroke the air inside the cylinder may cause damage to the piston packing or other parts 4 Bleeding air fr...

Page 232: ...231 SPECIFICATIONS ...

Page 233: ...pacity standard bucket SAE CECE 0 44 m 0 40 m With of opening standard bucket 833 mm with side cutter 954 mm Travel speed Low speed 3 5 km h 2 7 km h middle speed 10 km h 8 km h High speed 30 km h 20 km h Swing speed 12 5 rpm ENGINE Model Komatsu SA4D102E 1 diesel engine Flywheel horsepower NET 76 kW 102 HP 2250 rpm Starting motor 24 V 5 5 kW Alternator 24 V 45 A Battery 12 V 95 Ah x 2 pieces ...

Page 234: ...SPECIFICATIONS SPECIFICATIONS 233 1 PIECE BOOM ...

Page 235: ...SPECIFICATIONS SPECIFICATIONS 234 2 PIECE BOOM ...

Page 236: ... 2500 A Max digging height 8660 8900 B Max dumping height 6290 6530 C Max digging depth 4730 5130 D Max vertical wall digging 4175 4560 E Max digging depth of cut for 8 level 4495 4925 F Max digging reach 7895 8265 F Max digging reach at ground level 7690 8070 H Min swing radius 2320 2400 ...

Page 237: ... 2500 A Max digging height 8930 9190 B Max dumping height 6540 6905 C Max digging depth 5010 5411 D Max vertlcal wall digging 3978 4365 E Max digging depth of cut for 8 level 4779 5202 F Max digging reach 8142 8518 F Max digging reach at ground level 7945 8331 H Min swing radius 2605 2650 ...

Page 238: ...237 OPTIONS ATTACHMENTS ...

Page 239: ... firm ground surface When the operation is carried out by two or more work ers determine signals and follow these during the opera tion When carrying heavy objects more than 25 kg use a crane When removing heavy parts always support the part before removing it When lifting such heavy parts with a crane always pay careful attention to the position of the centre of gravity It is dangerous to carry o...

Page 240: ...point where the upper structure stops completely so there is danger of mistaking the distance and hitting something Always operate so that there is an ample margin to the stopping point Furthermore the hydraulic drift also becomes larger when the work equipment is stopped in mid air it will gradually move down under its own weight Always follow the correct procedure when installing the boom and ar...

Page 241: ... out lifting operations reduce the engine speed and use the lifting operation mode Depending on the posture of the work equipment there is danger that the wire or load may slip off the hook Always be careful to maintain the correct hook angle to prevent this from happening Never steer the machine while lifting a load If the bucket with hook is turned and used for operations it will hit the arm dur...

Page 242: ... MACHINES READY FOR ATTACHMENTS 241 MACHINES READY FOR ATTACHMENTS GENERAL LOCATIONS Important Ensure valve 2 is closed at all times except when using attach ments requiring low back pressure Oil flow by passes oil cooler ...

Page 243: ...AL 3 This is used to operate the attachment Pedal for two line attachment with auto deceleration mechanism The breaker is operated with right pedal 1 4 ACCUMULATOR FOR CONTROL CIRCUIT 4 WARNING The accumulator is charged with high pressure nitrogen gas and it is extremely dangerous if it is handled mistakenly For details of handling see HANDLING ACCUMULA TOR on page 246 This is installed to releas...

Page 244: ... in side ditches or confined spaces How to install clamshell bucket 1 Clamshell cylinder head 2 Clamshell cylinder bottom 3 Rotate left 4 Rotate right Ensure valve A both sides is closed and valve B is open both sides How to operate Open and close Move the right working equipment lever to operate clamshell 3 Open 4 Close Rotate ...

Page 245: ...e switch in the deceleration range The engine speed will rise suddenly Do not press the switch except when operating the switch If the switch is depressed by accident the attach ment may move suddenly and cause serious damage or injury Operate the attachment as follows WHEN USING BREAKER Depress the switch 1 of the wrist control lever right hand to operate the breaker Set the working mode to the B...

Page 246: ...and use correctly the instruction manual provided by the breaker manufacturer When using the breaker the hydraulic oil deteriorates more rapidly than for normal operations so change the hydraulic oil and replace the element at a shorter interval For details see MAINTENANCE WHEN USING HYDRAU LIC BREAKER on page 186 Open ...

Page 247: ... Never make any hole in the accumulator or expose it to flame or fire Do not weld anything to the accumulator When disposing of the accumulator it is necessary to release the gas from the accumulator so please contact your Komatsu distributor This machine is equipped with the accumulators in the control and brake circuit The accumulator is a device to store the pres sure in the control and brake c...

Page 248: ...k the control levers and attachment control pedal Note that this does not completely release the pressure so when removing the accumulator in the control circuit loosen the connections slowly and do not stand in the direction where the oil spurs out LONG TERM STORAGE If the machine is not to be used for a long time do as follows Set the stop valve in the LOCK condition Install a blind plug to the ...

Page 249: ...consult your Komatsu distributor HYDRAULIC BREAKER MAIN FIELDS OF APPLICATION Crushed rock Demolition work Road construction This attachment can be used for a wide range of work including demolition of buildings breaking up of road surfaces tunnel work breaking up slag rock crushing and breaking operations in quar ries Keep the chisel pushed perpendicularly against the impact sur face when carryin...

Page 250: ... move out of line with each other so always adjust the bucket cylinder to keep them aligned Always keep the chisel pressed against the impact surface prop erly to prevent using the impact force when there is no resistance MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the following ways...

Page 251: ...sel while carrying out impacting operations Holding the chisel horizontal or pointed up when carrying out impacting operations Twisting the chisel when it has penetrated the rock Pecking operations Extending the bucket cylinder fully and thrusting to raise the machine off the ground AL069830A AL069850A ...

Page 252: ... wooden houses and buildings and crushing foundation and roadbeds MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stroke Always leave approx 5 cm to spare Impact operations using attachment Impact operations using swing for...

Page 253: ...e of work including collecting or loading demolition waste materials and debris timber grass MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stroke Always leave approx 5 cm to spare Operations using the swing force Operatio...

Page 254: ...s bucket is widely used for demolition including breaking up work grading and digging clean up work after natural disasters dumping industrial waste and forestry work etc MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stro...

Page 255: ...MAIN FIELDS OF APPLICATION Disposal of rock or debris This attachment is mounted to the arm end and used to grasp rock debris etc by opening and closing the claws 3 to 5 corre sponding to the extension and retraction of the hydraulic cylinder MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any ...

Page 256: ... EXTENDING MACHINE SERVICE LIFE 255 Do not operate the cylinder to the end of its stroke Always leave approx 5 cm to spare Operations using the swing force Operations using one side of work equipment Catching and dragging with claw end Gouging AM092360A ...

Page 257: ...ks and rock etc The unique blade shape provides heavy crushing power MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stroke Always leave approx 5 cm to spare Operations using cutting tip on one side only Impact operation wi...

Page 258: ... chuck unit This facilitates operations such as driving and movable by 360 orners vertical driving e removing long piles driving in piles at corners vertical driving etc MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its strok...

Page 259: ...be carried out without removing the bucket This machine is used for laying U section gutters and hume pipes for water supply and sewerage as well as river and canal work agricultural civil engineering work and site preparation MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the following...

Page 260: ...OPTIONS ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE 259 Operating other work equipment during crane operation Excessive lengthening of wire rope ...

Page 261: ...wer boom 2 Bucket cylinder 7 Boom lift cylinders 3 Rotating arm 8 Boom adjusting cylinder 4 Arm cylinder 9 Front wheel 5 Upper boom 10 Rear wheel OPERATING WEIGHT 13 100 kg PERFORMANCE Bucket capacity SAE 0 44 m CECE 0 40 m Travel speed Forward Max 20 0 km h 30 0 km h Reverse Max 20 0 km h 30 0 km h Swing speed 12 5 RPM Arm rotation speed 7 8 RPM ENGINE Komatsu SA4D102E 1 Turbocharged diesel engin...

Page 262: ... the deceleration range the engine speed will suddenly increase so be careful when operating the levers This lever is used to operate the arm and upper structure 1 Control lever pad safety lock 4 Knob button 2 Left work equipment control lever 5 Indicators 3 Right work equipment control lever 6 Two piece boom pedal AM089560A Arm operation Swing operation A Arm OUT C Swing to right B Arm IN D Swing...

Page 263: ...anism When the travel lever and work equipment control levers are at neutral even if the fuel control dial is above the mid range position the engine speed will drop to a mid range speed If any of the levers are operated the engine speed will rise to the speed set by the fuel control dial If all control levers are set to neutral the engine speed will drop by approx 100 rpm and after approx 4 secon...

Page 264: ...OR S WORK In addition to the following it is possible to further increase the range of applications by using various attachments BACK HOE WORK A back hoe is suitable for excavation at a position lower the machine It is possible to effectively move the arm through 30 in the direction towards the machine and 45 in the direction away from the machine making for efficient work SHOVEL WORK A shovel is ...

Page 265: ...h water supply and drainage pipes can be done without changing the machines posi tion LIFTING SPOIL The rotating arm enables working from all directions Even if there is a structure between the excavator and the bucket the work can be done without hitting it BOX DIGGING Perfect corners can be dug without having to change position of excavators SCRAPING With bucket reversed the excavator can scrape...

Page 266: ...ht Do not fit a bucket larger than those listed overleaf for com bination of undercarriage attachments material to be exca vated Fitting of lager bucket will cause machine to tip over 3 Couple the arm to hole 1 then connect the link to hole 2 4 After mounting the stop bolt and nut for each pin apply grease toeach pin c ...

Page 267: ...quipped This bucket is used in sloped ditch digging work The three different ditch inclination can be obtained by changing the angle of the attached plate The angles available are 45 40 and 38 Shape of ditch by 45 bucket Shape of ditch 40 bucket 45 ditch hole 45 40 38 ditch hole 40 ditch hole 38 ditch hole 38 40 ditch hole ...

Page 268: ... this plate horizontal when digging TRAVELLING POSTURE Before starting to travel be sure to pull in and lock the outriggers and or raise the dozer blade Before travelling on public roads the work equipment should be positioned as follows 1 Remove the bucket or attachment refer to section see REPLACEMENT OF BUCKET on page 264 2 Position the upper structure so that it is facing the front of the unde...

Page 269: ...the first boom After setting the machine in the travel posture confirm that its height is below 4 m and that the distance between the centre of the steering wheel and the front of the work equipment is less than 3 5 m Before moving off lock all machine cover and toolbox doors to prevent accidents MAINTENANCE REQUIREMENT The following maintenance should be carried out in addition to that in the PW1...

Page 270: ...f plughole If oil level is below this point refill with SAE 90 gear oil through plug hole see EVERY 1000 HOURS SERVICE on page 270 Tightening torque 56 kgm The type of lubricant used depends on the ambient tempera ture Select according to the table see USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER ATURE on page 173 EVERY 250 HOURS SERVICE 2 Arm rotation circle LUBRICATING Apply greas...

Page 271: ...4 Refill the grease bath with grease 5 Replace the swing motor an and tighten the 12 bolts Apply liquid gasket LG 6 to the mating faces and bolt holes 6 Reconnect the hoses 1 2 and 3 to the swing motor EVERY 1000 HOURS SERVICE Maintenance for every 250 and 500 hours service should be carried out at the same time 4 ARM ROTATION MACHINERY CASE 1 Remove plug 1 drain the oil 2 Add 1 6 liters of SAE 90...

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