Komatsu PW160-7K Series Operation And Maintenance Manual Download

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MAINTENANCE SCHEDULE CHART

MAINTENANCE

244

EVERY 250 HOURS SERVICE

"CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL"

280

"CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Front Axle)"

281

"CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Rear Axle)"

281

"CHECK OIL LEVEL IN AXLES, ADD OIL"

281

"CHECK OIL LEVEL IN TRANSMISSION, ADD OIL"

282

"CHECK LEVEL OF BATTERY ELECTROLYTE"

282

"BELTS, GENERAL"

283

"CHECK FAN BELT TENSION, ADJUST TENSION"

283

"CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT"

284

EVERY 500 HOURS SERVICE

"LUBRICATE SWING CIRCLE (2 POINTS)"

286

"REPLACE FUEL FILTER CARTRIDGE"

287

"CHECK SWING PINION GREASE LEVEL, ADD GREASE"

288

"CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE"

289

"CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS"

290

"CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM"

291

"CLEANING RECIRCULATED AIR FILTER"

292

"REPLACE HYDRAULIC TANK BREATHER ELEMENT"

293

"CHECK VALVE RUBBER MOUNTS"

293

EVERY 1000 HOURS SERVICE

"REPLACE HYDRAULIC FILTER ELEMENT"

294

"CHANGE OIL IN SWING MACHINERY CASE."

295

"CHECK ALL TIGHTENING PARTS OF TURBOCHARGER."

295

"CHECK PLAY OF TURBOCHARGER ROTOR."

296

"CHECK & ADJUST VALVE CLEARANCE"

296

"CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB"

296

"CHECK FAN BELT TENSION AND REPLACE FAN BELT"

296

"CHANGE OIL IN AXLES"

297

"CHANGE OIL IN HUBS"

298

"CHANGE OIL IN TRANSMISSION ASSEMBLY"

299

EVERY 2000 HOURS SERVICE

"CLEAN HYDRAULIC TANK STRAINER"

300

SERVICE ITEM

PAGE

Summary of Contents for PW160-7K Series

Page 1: ... injury or death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodically reviewed by all personnel who will come into contact with the machine Operation Maintenance Manual UEAM003203 WARNING ...

Page 2: ......

Page 3: ...3 FOREWORD ...

Page 4: ...ardous and 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...

Page 5: ...s not 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 co...

Page 6: ...ibration levels When used for its intended purpose levels of vibration for the earth moving machine transmitted from the operator s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096 The actual acceleration value for the hands and arms is less than or equal to 2 5 m s The actual acceleration value for the body is less than or equal to...

Page 7: ...his manual q Tire pressures for wheeled machines tension of crawler for crawler machines q Brake and steering systems q Controls hydraulic system and linkages 3 Keep the terrain where the machine is working and traveling in good condition q Remove any large rocks or obstacles q Fill any ditches and holes q Site manager should provide machine operators with machine and schedule time to maintain ter...

Page 8: ...ath as large as possi ble q Travel at low speed when traveling around sharp curves 7 Minimize vibrations for long work cycle or long distance trav eling q Reduce speed to prevent bounce q Transport machines long distances between worksites 8 The following guidelines can be effective to minimize risks of low back pain q Operate the machine only when you are in good health q Provide breaks to reduce...

Page 9: ...ystem raise the front wheels off the ground using the work equipment and with the engine off turn the steering wheel and check movement of the wheels EMERGENCY BRAKING This machine is equipped with an emergency braking system and complies to ISO 3450 In the advent of failure of the source of power for the braking system engine failure whilst travelling the brakes can be actuated from stored energy...

Page 10: ...nance and self diagnosis Working mode travel speed are selectable Digging and lifting force can be increased by light touch con trol For details see operation section Adjustable wrist control levers make operations smooth and easy Fresh filtered air conditioner assures comfortable operation Low noise level and smart urban style design and colouring Superb operation performance provided by powerful...

Page 11: ...cases of emer gency Additionally for the first 20 hours Avoid operating engine for prolonged periods at constant speed including idle Avoid high speed travelling for periods of more than 5 min utes Pay particular attention to oil pressure and temperature indicators check coolant and oil levels frequently during breaking in The precautions given in this manual for operating maintenance and safety p...

Page 12: ... POSITION On the front left 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 Product Identification Number Manufacturer s name Komatsu UK Ltd Address Durham Road Birtley Chester Le Street County Durham DH32QX United Kingdom Distributor Address Phone ...

Page 13: ... Komatsu Ltd Tokyo Japan MAX DRAWBAR PULL N Model Serial number Manufacturing year Weight Engine power Max drawbar pull Manufactured by Komatsu UK Ltd Birtley Co Durham United Kingdom under License from Komatsu Ltd Product Identification Number 20G 00 K2392 TYP FABR NR BAUJAHR LEISTUNG ZUL ACHSLAST VORN Produkt Identifizierung Nummer HERSTELLER Hergestellt vom Komatsu UK Ltd Birtley Co Durham Unit...

Page 14: ...LOCATIONS OF PLATES TABLE TO ENTER SERIAL NO AND DISTRIBUTOR FOREWORD 14 ...

Page 15: ...D DISTRIBUTOR 12 MACHINE SERIAL PLATES 13 SAFETY 21 GENERAL PRECAUTIONS 22 PRECAUTION DURING OPERATION 29 BEFORE STARTING ENGINE 29 OPERATING MACHINE 30 TRANSPORTATION 37 BATTERY 38 TOWING 39 BUCKET WITH HOOK OR BUCKET LINK WITH LIFTING EYE 40 PRECAUTIONS FOR MAINTENANCE 44 BEFORE CARRYING OUT MAINTENANCE 44 DURING MAINTENANCE 47 POSITION FOR ATTACHING SAFETY LABELS 50 POSITION FOR ATTACHING SAFET...

Page 16: ...AIR CONDITIONER 131 FUSIBLE LINK 144 CONTROLLER 144 TOOL BOX CHASSIS 145 REFUELLING PUMP 145 WARNING LAMPS 147 HANDLING ACCUMULATORS 148 OPERATION 149 CHECK BEFORE STARTING ENGINE 149 OPERATIONS AND CHECKS BEFORE STARTING ENGINE 160 STARTING ENGINE 162 MOVING MACHINE OFF 171 STEERING 174 TRAVELLING ON PUBLIC HIGHWAY 175 STOPPING PARKING 176 SWINGING Slewing the upper carriage 178 OPERATION OF WORK...

Page 17: ...ORK 208 AFTER COLD WEATHER 208 LONG TERM STORAGE 209 BEFORE STORAGE 209 DURING STORAGE 209 AFTER STORAGE 210 STARTING MACHINE AFTER LONG TERM STORAGE 210 TROUBLESHOOTING 211 PHENOMENA THAT ARE NOT FAILURES 211 METHOD OF TOWING MACHINE 212 PRECAUTIONS ON PARTICULAR JOBSITES 212 DISCHARGED BATTERY 213 OTHER TROUBLE 217 MAINTENANCE 223 GUIDES TO MAINTENANCE 224 OUTLINE OF SERVICE 227 OUTLINE OF OIL F...

Page 18: ...NUTS 260 CHECK ELECTRICAL INTAKE AIR HEATER 260 CHECK ALTERNATOR 260 REPLACE BUCKET SIDE CUTTERS 261 REPLACE BUCKET TEETH 262 ADJUST BUCKET CLEARANCE 266 CHECK WINDOW WASHER FLUID LEVEL ADD FLUID 267 CHECK AND ADJUST AIR CONDITIONER 268 CHECK BEFORE STARTING 269 CHECK COOLANT LEVEL ADD WATER 269 EVERY 50 HOURS 274 EVERY 100 HOURS SERVICE 274 EVERY 250 HOURS MAINTENANCE 280 EVERY 500 HOURS SERVICE ...

Page 19: ...G THE CLAMSHELL BUCKET 320 OPERATION 322 METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR 325 LONG TERM STORAGE 325 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE 326 HYDRAULIC BREAKER 326 POWER RIPPER 329 FORK GRAB 330 GRAPPLE BUCKET 331 SCRAP GRAPPLE 332 CRUSHER SMASHER 334 HYDRAULIC PILE DRIVER 335 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE...

Page 20: ...20 ...

Page 21: ...21 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 22: ...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 clothes because they are flammable Wear a hard hat safety glasses safety shoes mask or gloves when operating or maintaining the machine Always wear safety goggles hard hat and heavy gloves if ...

Page 23: ...e machine Always take the key with you WARNING If the control lever is touched by accident the work equip ment or the machine may move suddenly and this may lead to a serious accident Before leaving the operator s compart ment always raise the safety lock lever to lock the work equipment controls MOUNTING AND DISMOUNTING NEVER jump on or off the machine NEVER get on or off a moving machine When mo...

Page 24: ...rised persons to enter PRECAUTIONS WHEN HANDLING AT HIGH TEMPERA TURES Immediately after operations are stopped the engine coolant engine oil and hydraulic oil are at high temperatures and are still under pressure Attempting to remove the cap drain the oil or water or replace the filters may lead to serious burns Always wait for the temperature to go down and follow the specified procedures when c...

Page 25: ...ved NEVER use compressed air for cleaning Use water for cleaning to keep down the dust Operate the machine with the wind to your back whenever possible Use an approved respirator if necessary CRUSHING OR CUTTING PREVENTION Do not enter or put your hand or arm or any other part of your body between movable parts such as between the work equip ment and cylinders or between the machine and work equip...

Page 26: ...rib utor Also even for other types of work if there is any danger of being hit by falling or flying objects or of objects entering the operator s cab select and install a guard that matches the working condi tions Be sure to close the front window before commencing work When carrying out the above operations make sure to keep all persons other than the operator outside the range of falling or fly ...

Page 27: ... weld anything to the accumulator When carrying out disassembly or maintenance of the accu mulator or when disposing of the accumulator it is necessary to release the gas from the accumulator A special bleed valve is necessary for this operation so please contact your Komatsu distributor Gas in accumulator see HANDLING ACCUMULATORS 148 EMERGENCY EXIT When exit by normal means is prevented in an em...

Page 28: ...ety always follow these safety precautions The display on the monitor panel may behave erratically The warning buzzer may sound These effects do not signify a malfunction and the machine will return to normal as soon as the source of interference is removed ...

Page 29: ... each utility and identify their locations Be careful not to sever or cut any of these lines Check the depth and flow of water before operating in water or crossing a river NEVER be in water which is in excess of the permissible water depth Permissible water depth see PRECAUTIONS FOR OPERATION 184 FIRE PREVENTION Thoroughly remove wood chips leaves paper and other flammable things accumulated in t...

Page 30: ...s 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 othe...

Page 31: ...gram and keep it at a height of 40 50 cm from the ground level before starting to travel Before travelling on public roads fully raise dozer blade and outriggers lock the outriggers in position with the safety pin lock the bucket and arm cylinder with isolation valves and insert swing lock pin For details see TRAVELLING ON PUBLIC HIGHWAY 175 When travelling on public roads the safety lock lever sh...

Page 32: ...e the ground In case of emergency quickly lower the bucket to the ground to help the machine stop and prevent it from tipping over Do not turn on slopes or travel across slopes Always go down to a flat place to perform these operations Method of travelling on slopes see PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS 186 Do not travel up and down on grass fallen leaves and wet steel plates These mate...

Page 33: ...ays maintain the safe distance given below between the machine and the electric cable The following actions are effective in preventing accidents 1 Wear shoes with rubber or leather soles 2 Use a signalman to give warning if the machine approaches too close to the electric cable If the work equipment should touch the electric cable the operator should not leave the operator s compartment When carr...

Page 34: ... sudden starting stopping or turning When there has been heavy snow the road shoulder and objects placed beside the road are buried in the snow and cannot be seen so always carry out snow clearing operations carefully WORKING ON LOOSE GROUND Avoid operating your machine too close to the edge of cliffs overhangs and deep ditches If these areas collapse your machine could fall or tip over and result...

Page 35: ...ated Always carry out these operations carefully Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded This operation is dangerous See the upper diagram on the right If the machine has to be used on a slope pile the soil to make a platform that will keep the machine as horizontal as possi ble See the lower diagram on the right Piled soil on slope see P...

Page 36: ...ty lock lever to contact the left hand arm rest on the operator seat To avoid this always ensure that the left hand arm rest is stowed in the fully up position before operating the safety lock lever When leaving the machine lower the work equipment com pletely to the ground raise the safety lock lever to the LOCK position then stop the engine and use the key to lock the machine Always take the key...

Page 37: ... one another Be sure the ramp surface is clean and free of grease oil ice and loose materials Remove dirt from the machine wheels NEVER correct your steering on the ramps If necessary drive away from the ramps and climb again Swing the upper structure with extreme care on the trailer to avoid a possible accident caused by body instability After loading block the machine wheels and secure the machi...

Page 38: ... oil Call a doctor or poison pre vention centre immediately When working with batteries ALWAYS wear safety glasses or goggles Batteries generate hydrogen gas Hydrogen gas is very EXPLOSIVE and is easily ignited with a small spark or flame Before working with batteries stop the engine and turn the starting switch to the OFF position Avoid short circuiting the battery terminals through accidental co...

Page 39: ...D BAT TERY 213 TOWING WHEN TOWING ATTACH WIRE TO FRAME Injury or death could result if a disabled machine is towed incorrectly If your machine is towed by another machine ALWAYS use a wire rope with a sufficient towing capacity NEVER allow a disabled machine to be towed on a slope Do not use a chinked or frayed wire rope If towing on the highway a rigid tow bar should be used and not a tow rope of...

Page 40: ...E BOLT A 2 Turn park brake release bolt B 180 degrees so that indicator mark is located at the top position 3 Re tighten bolt A Torque 20Nm WARNING Operator must not operate the travel system i e rotate the travel motor when the transmission disengagement pin is rotated to towing position BUCKET WITH HOOK OR BUCKET LINK WITH LIFTING EYE GENERAL PRECAUTIONS SPECIAL HOOK When carrying out lifting wo...

Page 41: ... Confirm that the machine can be safely operated without toppling or rolling PROHIBITED OPERATIONS OTHER THAN MAIN APPLICA TIONS When performing lifting operation never raise or lower a per son NO PERSONS SHALL BE PERMITTED TO ENTER THE WORKING AREA Due to the possible danger of the load falling or of collision with the load no persons shall be allowed in the working area OPERATION SUPERVISOR Befo...

Page 42: ...rations 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 TRAVEL WHILE LIFTING A LOAD Never travel while carrying a load OPERATING POSTURE If the machine posture is not correct the wire ropes or ring may detach from the hook Confirm that the hook angle is cor rect to a...

Page 43: ...e to follow these safety precautions may lead to a serious accident Refer to manufacturers data sheet for handling and storage precautions HANDLING OF FLUIDS For antifreeze and grease refer to manufacturers data sheet for handling and storage precautions ...

Page 44: ... REPLACEMENT OF SAFETY CRITICAL PARTS Replace the following fire related components periodically Fuel system Fuel hose spilling hose and fuel tube cap Hydraulic system Pump outlet hose Replace these components periodically with new ones regardless of whether or not they appear to be defective These components deteriorate over time Replace or repair any such components if any defect is found event ...

Page 45: ...ouch any lever by mistake Touch the levers only when they have to be operated The worker carrying out the maintenance should be extremely careful not to touch or get caught in the moving parts RULES TO FOLLOW WHEN ADDING FUEL OR OIL Spilt fuel and oil may cause you to slip so always wipe it up immediately Always tighten the cap of the fuel and oil fillers securely Never use fuel for washing any pa...

Page 46: ...o 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 USE OF LIGHTING When checking fuel oil coolant or battery electrolyte always use lighting with anti explosion specifications If such lighting equipment is not used there is danger of explosion ...

Page 47: ... lowest position before performing service or repairs under the machine Always chock the wheels of the machine securely Never work under the machine if the machine is poorly sup ported KEEP THE MACHINE CLEAN Spilt oil or grease or scattered tools or broken pieces are dangerous because they may cause you to slip or trip Always keep your machine clean and tidy If water gets into the electrical syste...

Page 48: ...ick gloves and use a piece of cardboard or a sheet of wood to check for oil leakage If you are hit by a jet of high pressure oil consult a doctor immediately for medical attention PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE Immediately after stopping operations the engine cooling water and oil at all parts is at high temperature and under high pressure In this co...

Page 49: ...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 MATERIALS Never dump waste oil in a sewer system rivers etc Always put oil drained from your machine in containers Never drain oil directly on the ground Obey appropriate laws and regulations when disposing of harmful materials such as oil fuel coolant solvent filters b...

Page 50: ...these labels clean If they are lost or damaged 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 1 2 2 2 2 3 2 4 5 6 7 8 8 9 10 12 13 14 15 15 17 18 11 19 2 5 15 15 ...

Page 51: ...s and labels on the machine Keep this manual in the machine cab near operator If this manual is lost please contact Komatsu distributor for replacement Always raise safety lock lever when leaving operators seat Normal steering can only be operated when the engine is run ning Emergency steering is only to be used when stopping the machine safely Serious injury or death can occur if the machine or a...

Page 52: ...dling accumulator Explosion hazard Keep away from flame Do not weld or drill Read operation manual before operation 5 Warning for staying clear 20K 00 31280 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 ...

Page 53: ... the machine 20K 00 31181 Read operation manual before operation With safety lock lever raised the control levers and pedals are disabled With safety lock lever lowered and control lever lock switch on the machine can travel With safety lock lever lowered and control lever lock switch off work equipment and travel can be operated REMARK In certain conditions it may be possible for the safety lock ...

Page 54: ...ne is on or near machine or in the swing area Rotate cab for full view of travel path if it can be done safely Use spotter if view is obstructed Follow above even if machine equipped with travel alarm and mirrors 9 Falling from upper structure warning This is located on the front of the fuel tank on inside of walkway door top of the counterweight 20E 00 K1110 WARNING falling from upper structure K...

Page 55: ...5 10 Stop engine warning 20E 00 K1310 Do not open cover while engine is running 11 Front window lock warning This is located on the rear win dow 09803 A0481 Always lock window in raised or lowered position 12 High pressure oil warning 20E 00 K1270 ...

Page 56: ...p of the radiator unit 14 20K 00 31360 Read operation manual before operation This is located inside the cab 15 Red reflector 20G 47 K1690 16 20Y 00 K2220 Emergency exit Read operation manual before operation 17 Travel Height UK spec only This is fitted to the top right hand corner of the front window 20E 00 K1720 ...

Page 57: ...NG SAFETY LABELS 57 18 Operation of attachments is located on the right hand window 20K 00 31140 19 Lift warning plate This is located on the right hand window 20E 00 K1450 Do not lift more than the specified load of the machine ...

Page 58: ...ucket linkage or cylinder lifting capacities can be increased by their respective weights A Reach from swing center B Bucket hook height C Lifting capacities including bucket 495 kg linkage 120 kg and bucket cylinder 109 kg OF Lifting capacity Rating over front OS Lifting capacity Rating over side MAX Rating at maximum reach ...

Page 59: ...5m 1800 1800 6 0m 1600 1600 3150 2200 4 5m 1550 1350 2000 1400 3100 2150 3 0m 1600 1150 2050 1350 3000 2050 4750 3250 9500 6050 1 5m 1700 1100 1950 1300 2850 1900 4450 2950 0 0m 1750 1150 1900 1250 2750 1800 4250 2750 4400 4400 1 5m 1950 1250 2700 1750 4150 2700 7100 5050 3 0m 2400 1600 2700 1800 4200 2750 7550 5150 3 0m 7 5m 1450 1450 2350 2150 6 0m 1300 1300 1450 1350 2900 2200 4 5m 1200 1100 20...

Page 60: ...m 7 5m 1800 1800 6 0m 1600 1600 3200 2600 4 5m 1550 1550 2000 1700 4100 2550 3 0m 1600 1450 3300 1650 4900 2450 6400 3900 10050 7350 1 5m 1700 1400 4000 1600 5300 2300 7350 3600 0 0m 1950 1400 3950 1550 5400 2200 7550 3400 4400 4400 1 5m 2400 1600 5050 2150 6950 3300 7100 6250 3 0m 3150 1950 3850 2200 5550 3350 7550 6400 3 0m 7 5m 1450 1450 2350 2350 6 0m 1300 1300 1450 1450 2900 2650 4 5m 1200 12...

Page 61: ...5m 1800 1800 6 0m 1600 1600 3200 2950 4 5m 1550 1550 2000 1950 4100 2900 3 0m 1600 1600 3300 1900 4900 2800 6400 4450 10050 8550 1 5m 1700 1600 4150 1850 5300 2650 7350 4100 0 0m 1950 1650 4050 1800 5400 2550 7350 3900 4400 4400 1 5m 2400 1850 5050 2500 6950 3850 7100 7100 3 0m 3150 2250 3850 2550 5550 3900 7550 7500 3 0m 7 5m 1450 1450 2350 2350 6 0m 1300 1300 1450 1450 2900 2800 4 5m 1200 1200 2...

Page 62: ... 1800 1800 6 0m 1600 1600 3200 3200 4 5m 1550 1550 2000 2000 4100 3850 3 0m 1600 1600 3300 2550 4900 3700 6400 5900 10050 10050 1 5m 1700 1700 4150 2500 5300 3550 7350 5550 0 0m 1950 1950 4050 2450 5400 3450 7550 5350 4400 4400 1 5m 2400 2400 5050 3400 6950 5250 7100 7100 3 0m 3150 3050 3850 3400 5550 5300 7550 7550 3 0m 7 5m 1450 1450 2350 2350 6 0m 1300 1300 1450 1450 2900 2900 4 5m 1200 1200 27...

Page 63: ...0 4150 7450 6500 1 5m 2750 2750 4850 4100 6650 6450 6900 6900 3 0m 2900 2900 3200 3200 5050 5050 6550 6550 2 5m 7 5m 1800 1800 6 0m 1600 1600 3200 3200 4 5m 1550 1550 2000 2000 4100 4100 3 0m 1600 1600 3300 3050 4900 4400 6400 6400 10050 10050 1 5m 1700 1700 4150 3000 5300 4250 7350 6750 0 0m 1950 1950 4050 2950 5400 4150 7550 6550 4400 4400 1 5m 2400 2400 5050 4100 6950 6450 7100 7100 3 0m 3150 3...

Page 64: ... cylinder lifting capacities can be increased by their respective weights A Reach from swing center B Bucket hook height C Lifting capacities including bucket 495 kg linkage 120 kg and bucket cylinder 109 kg OF Lifting capacity rating over front OS Lifting capacity Rating over side MAX Rating at maximum reach ...

Page 65: ...0 6 0m 1500 1500 3150 2200 3450 3450 4 5m 1400 1300 1750 1350 3850 2150 4000 3600 3500 3500 3 0m 1400 1150 3150 1300 5000 2050 6450 3350 1 5m 1500 1100 3900 1250 5500 1900 7550 3000 0 0m 1650 1100 3850 1200 5700 1800 8000 2850 4050 4050 1 5m 2000 1250 5400 1750 7550 2750 6900 5300 3 0m 4150 1800 6150 2800 3 0m 7 5m 1400 1400 2050 2050 2850 2850 6 0m 1200 1200 2800 2250 2700 2700 4 5m 1100 1100 250...

Page 66: ...50 3350 6 0m 1500 1500 3150 2300 3450 3450 4 5m 1400 1400 1750 1450 3850 2250 4000 3750 3500 3500 3 0m 1400 1200 3150 1400 5000 2150 6450 3500 1 5m 1500 1150 3900 1350 5500 2000 7550 3200 0 0m 1650 1200 3850 1300 5700 1900 8000 3000 4050 4050 1 5m 2000 1350 5400 1850 7550 2900 6900 5500 3 0m 4150 1900 6150 2950 3 0m 7 5m 1400 1400 2050 2050 2850 2850 6 0m 1200 1200 2800 2400 2700 2700 4 5m 1100 11...

Page 67: ...350 6 0m 1500 1500 3150 2350 3450 3450 4 5m 1400 1400 1750 1450 3850 2300 4000 3800 3500 3500 3 0m 1400 1250 3150 1450 5000 2200 6450 3550 1 5m 1500 1200 3900 1400 5500 2050 7550 3250 0 0m 1650 1200 3850 1350 5700 1950 8000 3050 4050 4050 1 5m 2000 1400 5400 1900 7550 2950 6900 5650 3 0m 4150 1950 6150 3000 3 0m 7 5m 1400 1400 2050 2050 2850 2850 6 0m 1200 1200 2800 2400 2700 2700 4 5m 1100 1100 2...

Page 68: ...0 6 0m 1500 1500 3150 2450 3450 3450 4 5m 1400 1400 1750 1550 3850 2400 4000 4000 3500 3500 3 0m 1400 1350 3150 1500 5000 2300 6450 3700 1 5m 1500 1250 3900 1450 5500 2150 7550 3400 0 0m 1650 1300 3850 1400 5700 2050 8000 3200 4050 4050 1 5m 2000 1450 5400 2000 7550 3150 6900 5950 3 0m 4150 2050 6150 3200 3 0m 7 5m 1400 1400 2050 2050 2850 2850 6 0m 1200 1200 2800 2550 2700 2700 4 5m 1100 1100 250...

Page 69: ...00 1500 5800 2150 8050 3350 1 5m 2600 1700 5300 2150 7400 3300 7400 6200 3 0m 5700 3350 2 5m 7 5m 1750 1750 3350 3350 6 0m 1500 1500 3150 2500 3450 3450 4 5m 1400 1400 1750 1550 3850 2450 4000 4000 3500 3500 3 0m 1400 1350 3150 1550 5000 2350 6450 3750 1 5m 1500 1300 3900 1500 5500 2200 7550 3450 0 0m 1650 1350 3850 1450 5700 2100 8000 3250 4050 4050 1 5m 2000 1500 5400 2050 7550 3200 6900 6050 3 ...

Page 70: ... 500 1800 850 3900 1500 3950 3000 2500 2500 3700 3700 1 5 1450 500 4050 800 5350 1450 6600 3000 5700 15250 4900 4900 3 0m 3950 850 5550 1500 8250 3200 5700 7800 5700 5700 2PB Rear Outrigger 7 5m 1400 1400 2750 2750 6 0m 1150 850 1450 1450 3150 2800 4 5m 1050 600 1850 700 2000 1350 3350 2550 3000 3000 3 0m 1050 450 1700 650 1300 1200 3200 2150 5550 4450 1 5m 1100 400 1900 550 1700 1000 3150 1750 47...

Page 71: ... 700 2000 1350 3350 2550 3000 3000 3 0m 1050 450 1700 650 1300 1200 1200 2150 5550 4450 1 5m 1100 400 1900 550 1700 1000 3150 1750 5200 3550 3700 3700 0 m 1200 400 2150 500 1850 850 3900 1500 3950 3000 2500 2500 3700 3700 1 5 1450 500 4050 800 5350 1450 6600 3000 5700 15250 4900 4900 3 0m 3950 850 5600 1500 8250 3200 5700 7800 5700 5700 ...

Page 72: ...nside 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 position sen...

Page 73: ...73 OPERATION WARNING Please read and make sure that you understand the safety volume before reading this section ...

Page 74: ...INE 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 B D C A 1 2 4 3 5 6 7 1 Bucket 5 Boom 2 Bucket cylinder 6 Boom Cylinder 3 Arm 7 Undercarriage 4 Arm cylinder ...

Page 75: ...al Option extra 7 Fuel control dial 24 Indicator stalk horn windscreen wash wipe direc tion indicators roadlight dip main beam flash 8 Park brake switch 25 Steering wheel 9 Swing lock 26 Turn indicator warning lights 10 Quick coupler 27 Park light override 11 Pump override 28 Driving light 12 Swing override 29 Brake pedal 13 Travel override 30 Travel pedal 14 Override F N R 31 Clamshell rotate lef...

Page 76: ...ctly and safely it is important to understand fully the methods of operating the equipment and the meanings of the displays MACHINE MONITOR A Basic check Items D Meter Display Portion Pilot Display Portion B Caution Items E Monitor Switches C Emergency Stop Items D A A D C B B D E D B C A D B B D All lights up screen Maintenance interval warning screen Normal operation screen A B C D ...

Page 77: ...reen After displaying the check before starting screen for 2 sec onds the screen changes to the maintenance interval warn ing screen After displaying the maintenance interval warning screen for 30 seconds the screen returns to the normal screen After displaying the check before starting screen for 2 sec onds the screen changes to the warning screen or error screen Check before starting screen Main...

Page 78: ...normal opera tion screen changes to warning screen 1 or the error screen After displaying warning screen 1 for 2 seconds the screen automatically changes to warning screen 2 with exception of low brake pressure when warning screen 1 remains per manently active Normal operation screen Warning screen 1 Warning screen 2 Error screen ...

Page 79: ...s the basic items that must be checked before starting the engine If there is any abnormality the monitor for the location of the abnormality will light up 1 RADIATOR WATER LEVEL MONITOR This monitor 1 warns the operator that there has been a drop in the radiator water level If the radiator water level is low the lamp lights up red so check the water level in the radiator and the sub tank and add ...

Page 80: ...ne oil pan and add oil 3 MAINTENANCE INTERVAL MONITOR This monitor 3 lights up to warn the operator that the set time has passed since the maintenance was last carried out This monitor screen goes out after 30 seconds and returns to the normal operation screen For details of the method of checking the maintenance interval see FRONT AND REAR WORKLIGHTS SWITCH 104 If it is desired to change the sett...

Page 81: ...that should be observed while the engine is run ning If any abnormality occurs the screen displays the item that needs immediate action If there is an abnormality the monitor for the abnormal location lights up red 1 Charge level monitor 6 Overload Caution Monitor 2 Fuel level monitor 7 Engine oil level low 3 Air cleaner clogging monitor 8 Service machine over due 4 Engine water temperature monito...

Page 82: ... will remain lit and will go off once the engine is started REMARK When the engine is started or stopped with the starting switch at the ON position the lamp may light up and the buzzer may sound momentarily but this does not indicate any abnormality 2 FUEL LEVEL MONITOR This monitor 2 lights up to warn the operator that the level in the fuel tank is low If the remaining amount of fuel goes down t...

Page 83: ...ONITOR If this monitor 5 lights up white in low temperatures carry out the warming up operation For details see WARMING UP OPERATION 165 6 OVERLOAD CAUTION When lifting This monitor warns that the machine is close to tipping due to the load an audible warning is also given if the warning is given lower the load Refer the lifting capacity chart for safe load 7 ENGINE OIL LEVEL LOW When monitor 7 li...

Page 84: ...PERATION 84 8 SERVICE MACHINE OVERDUE This monitor 8 lights red when the machine service is overdue The machine should be serviced immediately or damage may occur 9 PARK BRAKE When park brake is applied this lamp will illuminate ...

Page 85: ...ocation and carry out the necessary action These are items that should be observed while the engine is run ning If there is an abnormality the monitor for the abnormal loca tion lights up red and the buzzer sounds so carry out action immediately 1 Engine water temperature monitor 3 Engine oil pressure monitor 2 Hydraulic oil temperature monitor 4 Low brake pressure 2 1 3 4 ...

Page 86: ... 2 warns the operator that the hydraulic oil tempera ture has risen If it lights up red during operations run the engine at low idle or stop the engine and wait until the oil temperature goes down and the monitor changes to green 3 ENGINE OIL PRESSURE MONITOR This monitor 3 lights up red if the engine lubrication oil pressure goes below the normal level If it lights up red stop the engine and chec...

Page 87: ...ncy stop items is as follows Type of monitor Color when monitor lights up When normal When abnormal At low temperature Radiator water level monitor OFF Red Engine oil level monitor OFF Red Maintenance interval monitor OFF Red Charge monitor OFF Red Fuel level monitor Green Red Air cleaner clogging monitor OFF Red Engine water temperature monitor Green Red White Hydraulic oil temperature monitor Gr...

Page 88: ... 1 Engine Pre heating Monitor 8 Fuel Gauge 2 Swing Lock Monitor 9 Hydraulic oil temperature gauge 3 Auto deceleration monitor 10 Service Meter and clock 4 Working mode monitor 11 Travel direction monitor 5 Travel mode monitor 12 Undercarriage attachment monitor 6 One touch power up monitor 13 Main beam monitor 7 Engine water temperature gauge 12 10 6 9 7 11 2 3 1 5 4 8 13 ...

Page 89: ...he swing holding brake cancel switch is turned on REMARK The swing motor is equipped with a disc brake that mechani cally stops the rotation When the swing lock monitor lamp is lit up the brake remains applied 3 AUTO DECELERATION MONITOR This monitor 3 shows if the auto deceleration function has been actuated The monitor display when the auto deceleration switch is oper ated is as follows Auto dec...

Page 90: ...ed METERS 7 ENGINE WATER TEMPERATURE GAUGE This meter 7 indicates the engine cooling water temperature During normal operations the indicator should be in the black range If the indicator enters the red range during operations the overheat prevention system is actuated The overheat prevention system acts as follows Red range position A Engine water temperature monitor 1 turns red Red range positio...

Page 91: ...uld be in the black range If the indicator enters red range A during operations the hydrau lic oil temperature has gone above 102 C Stop the engine or run it at low idle and wait for the hydraulic oil temperature to go down REMARK When the indicator is in the red range A to B the hydraulic oil temperature is as follows Red range position A More than 102 C Red range position B More than 105 C When ...

Page 92: ...y hour of operation regardless of the engine speed 11 TRAVEL DIRECTION SELECTION This monitor 11 displays the set travel direction When one of the travel direction switches is selected the monitor displays one of the following selections 12 UNDERCARRIAGE ATTACHMENT MONITOR When undercarriage attachment is selected from right control lever switch 3 monitor 12 will be displayed This symbol will rema...

Page 93: ... low speed select 15 Hazard warning 4 Menu select key 16 Rear left outrigger blade 5 Undo key 17 Front left outrigger blade 6 Service menu 18 Select all chassis attachment 7 Scroll up 19 Front right outrigger 8 Scroll down 20 Rear right outrigger 9 Accept key 21 Lower wiper 10 Suspension auto lock 22 Heated seat 11 Suspension lock 23 Front and rear worklights 12 Control lever lock 24 Beacon warnin...

Page 94: ...ly to A mode When the switch is pressed the system will scroll through each mode in turn The display on the monitor display portion changes for each mode If you require a default setting other than A mode please consult your Komatsu distributor or dealership to have the setting amended REMARK When the mode selector switch is pressed the mode is dis played in the centre of the monitor display and t...

Page 95: ...CTOR SWITCH This switch 3 is used to set the travel speed to 3 stages When the engine is started the speed is automatically set to the last value before engine was stopped Each time that the switch is pressed the display changes Lo Hi At Lo in turn When travelling in auto mode At if more travel torque is needed such as when traveling on soft ground or on slopes the speed automatically switches to ...

Page 96: ...fter 2 seconds 4 MENU SELECT SWITCH This switch 4 is used to select the hydraulic flow setting in each of the working modes A E and B When the working mode is A or E 1 Press select switch 4 and the normal screen on the monitor display changes to the flow setting screen shown in the dia gram on the right Press up switch 7 or down switch 8 to adjust to the desired flow Each segments value is shown b...

Page 97: ...esired flow 3 After completing the flow setting press input confirmation switch 9 4 With the operation in Step 3 the flow setting screen changes to the fine flow adjustment screen shown in the dia gram on the right 5 Press up switch 7 or down switch 8 to adjust to the desired flow 6 After completing the flow setting press input confirmation switch 9 The monitor display will return to the normal sc...

Page 98: ...White display More than 30 hours remaining to maintenance Yellow display Less than 30 hours remaining to maintenance Red display Maintenance time has already passed NOTICE If the monitor display changes to the maintenance warn ing screen when the engine is started or when the machine is being operated stop operations immediately When this happens the monitor corresponding to the maintenance warnin...

Page 99: ...k REMARK It is possible to enter the number of the item from the keypad i e enter 12 for transmission oil 2 After highlighting the monitor item press input confirmation switch 9 The display screen will switch to the time remain ing to maintenance Press back switch 5 to return to the previous screen Monitor No Maintenance item Default set screen H 01 Change engine oil 500 02 Replace engine oil filt...

Page 100: ...ill switch to the default setting screen 4 After checking the time on the default setting screen press input confirmation switch 9 The screen will return to the maintenance screen Press back switch 5 to return to the previous screen 7 SCROLL UP 8 SCROLL DOWN Press up switch 7 or down switch 8 when in the menu screens will allow you to move up and down the menu options In certain menus they can als...

Page 101: ...and automatic suspension lock cannot be active at the same time Each mode can be turned on and off by their individual switches In the case that auto mode is on and permanent switch is pressed auto mode will cancel to allow permanent activation and vice versa 11 PERMANENT SUSPENSION LOCK SWITCH Press switch 11 in order to engage permanent front axle lock Front axle will be fixed in place when enga...

Page 102: ...d When activated the switch lamp is also illuminated REMARK When the auto deceleration switch is pressed and the auto deceleration is actuated the mode is displayed in the centre of the monitor display and the screen returns to the normal screen after 2 seconds 14 BUZZER CANCEL SWITCH This is used to stop the alarm buzzer when it has sounded to warn of some abnormality that has occurred whilst the...

Page 103: ...ger or rear blade Light illuminates when active 17 FRONT LEFT OUTRIGGER BLADE SWITCH This switch enables selection of front left outrigger front blade Light illuminates when active 18 SELECT ALL CHASSIS ATTACHMENT SWITCH This switch enables selection of all outriggers and or dozer blade simultaneously Lights on switches 16 17 19 and 20 will illuminate to show selec tion A second press will deactiv...

Page 104: ...TCH This switch is used to switch on the heated seat OFF seat not heated ON seat heated Light will illuminate when active 23 FRONT AND REAR WORKLIGHTS SWITCH Switch operates the front and rear worklights of the machine All optional extra lamp units will be included Machine at startup Front lights off and rear lights off 1st button press Front lights on and rear lights off 2nd button press Front li...

Page 105: ...his switch 6 to adjust the brightness and contrast of the monitor display screen Adjustment screens 1 When monitor adjustment switch 6 is pressed the monitor display screen changes to the screen shown in the diagram on the right A Adjusting contrast 2 Use the brightness contrast screen and press up switch 7 or down switch 8 to select the contrast monitor The selected monitor is inverted to black 2...

Page 106: ...ormal within any menu press switch 5 to return to the previous screen at any time B Adjusting brightness 1 Use the adjustment screen and press up switch 7 or down switch 8 to select the brightness monitor The selected monitor is inverted to black 2 When the screen changes to the brightness adjustment screen press up switch 7 or down switch 8 to adjust the brightness 3 After completing adjustment o...

Page 107: ...ll return you to the above menu and store the new setting D Adjusting background colour 1 Use the adjustment screen and press up switch 7 or down switch 8 to select the background colour monitor The selected monitor is inverted to black 2 When the screen changes to the background colour adjust ment screen press up switch 7 or down switch 8 to adjust the colour day time and for night time the diffe...

Page 108: ...ption extra 7 Fuel control dial 24 Indicator stalk horn windscreen wash wipe direc tion indicators roadlight dip main beam flash 8 Park brake switch 25 Steering wheel 9 Swing lock 26 Turn indicator warning lights 10 Quick coupler 27 Park light override 11 Pump override 28 Driving light 12 Swing override 29 Brake pedal 13 Travel override 30 Travel pedal 14 Override F N R 31 Clamshell rotate left 15...

Page 109: ...in winter set the key to this position When the key is set to the HEAT position the pre heating symbol on the monitor lights up Keep the key at this position until the monitor lamp begins to flash Immediately after the pre heating symbol flashes release the key The key automatically returns to the OFF position Then start the engine by turning the key to the START position FUEL CONTROL DIAL WITH AU...

Page 110: ...will not swing even if the swing lever is activated In this condition the swing lock switch lamp and monitor switch light up OFF position cancelled The swing lock switch should only be activated when the upper structure is motionless and with the swing lock lever in the neutral position HORN BUTTON When the lower button on the left control lever 18 is pressed the horn will sound Note Additional ho...

Page 111: ...p control override switch is designed to allow operations to be carried out for a short period when there is an abnormality in the pump control system EPC valve system error The abnormality must be repaired immediately SWING LOCK OVERRIDE SWITCH When normal Switch 12 is down 1 When abnormal When the monitor display shows E03 swing brake system error the brake is cancelled and it becomes possi ble ...

Page 112: ...ight control lever will no longer function The emergency F N R switch located at the rear of the right pod should be used in conjunction with the Emergency Travel Switch in a situation of emergency PARK BRAKE SWITCH This switch 8 is used to apply and release park brake OFF Park brake released warning light not illuminated ON Park brake applied warning light illuminated REMARK When moving off from ...

Page 113: ... Switch 10 is used for the quick changeover of the bucket BOOM UNDERCARRIAGE ATTACHMENT SWITCH Switch 3 changes the function of the right control lever between boom and undercarriage attachment operation WARNING Lights on the monitor panel indicate when the undercarriage attachments are in operation CLAMSHELL ROTATION CLOCKWISE BREAKER SWITCH Switch 2 operates clockwise rotation of clamshell if fi...

Page 114: ... SWITCH This switch 24c has two functions To alternate between headlight dipped and main beams For main beam push steering column stalk fully downwards Note road lights switch 28 must be at position 3 for this function Reverse operation to return to dipped beam Warning light 13 will illuminate on the monitor panel when main beam headlights are illuminated To flash headlights pull steering column s...

Page 115: ...ITCHES 115 12V POWER SUPPLY The 12V socket 19 provided on the cab rear left panel may be used only for electrical accessories drawing 1 5 A maximum Any accessories attached to this socket must carry the EC mark 19 ...

Page 116: ... Boom pedal Option extra 7 Fuel control dial 24 Indicator stalk horn windscreen wash wipe direc tion indicators roadlight dip main beam flash 8 Park brake switch 25 Steering wheel 9 Swing lock 26 Turn indicator warning lights 10 Quick coupler 27 Park light override 11 Pump override 28 Driving light 12 Swing override 29 Brake pedal 13 Travel override 30 Travel pedal 14 Override F N R 31 Clamshell r...

Page 117: ... care not to touch the work equipment control lever In certain conditions it may be possible for the safety lock lever to contact the left hand arm rest on the opera tor seat to avoid this always ensure that the left hand arm rest is stowed in the fully up position before operating the safety lock lever SAFETY LOCK LEVER The safety lock lever LOCKS the work equipment swing attach ment controls and...

Page 118: ... the travel pedal 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 seconds the eng...

Page 119: ... depressing pedal 29 To lock the service brakes in the ON position fully depress the brake pedal To unlock the service brakes depress latch A STEERING WHEEL The machine can be steered by turning steering wheel in the desired direction The position of the steering column can be adjusted fore and aft by depressing pedal 1 moving column to desired position and releasing pedal 1 WARNING Steering actio...

Page 120: ...he legal requirement in some countries to use a mechanical swing lock when driving on public roads The mechanical swing lock should be operated as follows Line the machine up in the correct driving position with the pin in the raised free position Once the machine is correctly aligned lower the pin into the locked position To disengage the mechanical swing lock raise the pin from the lock position...

Page 121: ...tely to the ground stop the engine then carry out the operation When opening the front window hold the grip securely with both hands pull up and do not let go until the auto matic lock catch is locked When closing the front window the window will move quicker under its own weight Hold the grips securely with both hands when closing it It is possible to store pull up the front window top in the roo...

Page 122: ...m left and right of the front window and pull lock lever B to release the lock at the top of the front window The top of the front window will come out 5 Hold lower knob C with your left hand from inside the opera tor s cab and with your right hand grip top knob D pull it up and firmly push it against lock catch E at the rear of the cab to securely lock the window 9JH02594AA1 9JH02402AA1 ...

Page 123: ...case F does not line up with the arrow on lock lever B the lock is not properly engaged Repeat the operation in Step 5 to engage the lock When closing WARNING When closing the window lower it slowly and be careful not to get your hand caught 1 Place the work equipment on flat ground and stop the engine 2 Raise the safety lock lever 3 Grip left and right knobs A and pull down lock lever B to releas...

Page 124: ...aches the top of the lower window push the top of the window forward to engage the locks against catches G 6 Check that lock lever B is secured at the LOCK position The lock is engaged if the arrow on lock case F lines up with the arrow on lock lever B Check it visually If the arrow on lock case F does not line up with the arrow on lock lever B the lock is not engaged Repeat the opera tion in Step...

Page 125: ...R S CAB If for some reason the cab door does not open open the rear window and use it as an emergency escape exit Remove the rear window as follows 1 Pull ring 1 and completely remove seal 2 from the rubber core 2 When the corner of the front window glass is pushed strongly it can be removed to the outside 3 Do not remove the rear window except when using it as an emergency exit CEILING WINDOW The...

Page 126: ...e 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 DOOR LOCK Use the door lock to fix the door in position after opening it 1 The door will become fixed in place wh...

Page 127: ...ey clockwise align the match mark on the cap with the rotor groove then remove the cap To lock the cap 1 Turn the cap into place 2 Turn the key and take the key out Insert the key as far as it will go If the key is turned before it is inserted all the way it may break METHOD OF OPENING AND CLOSING COVER WITH LOCK cover with lock To open the cover locked cover 1 Insert the key 2 Turn it countercloc...

Page 128: ...rcuit 1 10 A Controller switched power 2 20 A Solenoid controller 3 10 A PPC lock axle lock park brake and f n r 4 10 A Window washer cigar lighter and quick coupler 5 30 A Head lights main beam and horn 6 10 A Lower wiper 7 10 A Beacon 8 10 A Travel sensor and low brake pressure 9 5 A Power max switch 10 10 A Refuelling pump 11 25 A A C unit 12 20 A Monitor switched power 13 20 A Work lights 14 1...

Page 129: ...ways ensure when cigarettes are extin guished they are put in the ashtray and the lid closed CUP HOLDER A cup holder is provided to the left of the operator for holding cups or cans Drinks should not be left in the cup holder whilst operat ing the machine because spillage may occur HOT AND COOL BOX The box is at the rear right of the operator s seat It is intercon nected with the air conditioner i...

Page 130: ... audible Ensure no water is splashed over the speaker case or cab radio to prevent malfunction Never use solution such as benzine or thinners to clean the dial or buttons These should be wiped with a dry soft cloth Use a cloth dipped in alcohol for very dirty surfaces At battery replacement all the memory pre set with the pre set buttons will be cleared Perform pre setting again POWER PICK UP PORT...

Page 131: ...sed the set temperature and air flow display on display monitor 7 and the lamps above auto switch 5 and air conditioner switch 8 go out and operation stops 1 OFF switch 6 FRESH RECIRC selector switch 2 Fan switch 7 Display monitor 3 Temperature control switch 8 Air conditioner switch 4 Vent selector switch 9 Defroster selector lever 5 Auto switch Air conditioner control panel 9 9EH02410AA1 ...

Page 132: ...the cab The temperature can be set between 18 C and 32 C Press the switch to raise the set temperature press the switch to lower the set temperature The temperature is generally set at 25 C The temperature can be set in stages of 0 5 C Monitor display and the function Monitor display and air flow Liquid crystal display Air flow Air flow low Air flow medium 1 Air flow medium 2 Air flow medium 3 Air...

Page 133: ...ce vent 1 place C Foot vent 1 place D1 Front window vent 1 place D2 Front window vent 1 place Front window vent D2 can be opened or closed by hand A C B D1 D2 Liquid crystal display Vent mode Vent Remarks A B C D Front and rear vents including defroster vent O O O Front and rear vents including defroster vent O O O O Foot vent O Foot foot vents including defroster vent O O O Cannot be selected for...

Page 134: ...h goes out RECIRC FRESH SELECTOR SWITCH This switch 6 is used to switch the air source between recircula tion of the air inside the cab and intake of air from the outside When switch 6 is pressed the lamp at the top of the selector switch lights up to show that air is being blown out During automatic operation the selection of inside air RECIRC and outside air FRESH is carried out automati cally D...

Page 135: ... tioner switch goes out The air conditioner cannot be operated while the fan is stopped DEFROSTER SELECTOR LEVER This switch 9 is used in cold or rainy weather to remove the mist that forms on the front glass Selector lever forward To defroster open Selector lever back Closed The defroster can be used when the vent selector switch is set to face or face and foot METHOD OF OPERATION The air conditi...

Page 136: ...nditioner is operated automati cally to provide the set temperature REMARK When vent display monitor c displays d or e and the engine water temperature is low the air flow is automatically lim ited to prevent cold air from blowing out STOPPING AUTOMATIC OPERATION Press OFF switch 1 The displays for temperature setting a and air flow b on the display monitor and the lamps above auto switch 5 and ai...

Page 137: ...flow When doing this check that temperature setting a and air flow b are dis played on the display monitor 2 Turn air conditioner switch 8 ON Check that the lamp at the top of the air conditioner switch lights up 3 Press the temperature setting switch and adjust the tempera ture inside the cab ...

Page 138: ...ing to the selection 5 Press RECIRC FRESH selector switch 6 and select recircu lation of the air inside the cab RECIRC or intake of fresh air from outside FRESH STOPPING MANUAL OPERATION Press OFF switch 1 The displays for temperature setting a and air flow b on the display monitor and the lamps above auto switch 5 and air conditioner switch 8 go out and the operation stops ...

Page 139: ...s 1 Press fan switch 2 and adjust the air flow When doing this check that temperature setting a and air flow b are dis played on the display monitor 2 Press vent selector switch 4 and set the vent display on the display monitor to the display shown in the diagram on the right 3 Turn air conditioner switch 8 ON When this is done the lamp above the air conditioner switch lights up ...

Page 140: ...2 temperature setting switch 3 and FRESH RECIRC selector switch 6 to the desired positions DEFROSTER OPERATION 1 Press fan switch 2 and adjust the air flow When doing this check that temperature setting a and air flow b are dis played on the display monitor ...

Page 141: ...on the display monitor to the display shown in f or g in the dia gram on the right 3 Press FRESH RECIRC selector switch 6 and set it to take in fresh air 4 Press temperature setting switch 3 and set the set tempera ture display on the display monitor to the maximum heating temperature of 32 C ...

Page 142: ... addition never bring any flame near these parts For the auto function of the air conditioner to work prop erly always keep the sunlight sensor clean and do not leave anything around the sunlight sensor that may inter fere with its sensor function Ventilate the cab from time to time when using the cooler If you smoke when the cooler is on the smoke may start to hurt your eyes so open the window an...

Page 143: ...tor display and failure mode When more than one failure is detected press the or portion of temperature setting switch 3 to display the failures in turn After completing the troubleshooting press OFF switch 1 again to return to the normal display If any abnormality is detected by the self diagnostic function ask your Komatsu distributor to carry out inspection and repair Display Failure mode E No ...

Page 144: ...disconnection of wire type fusible link Open the battery box cover front right hand side of machine to inspect the fusible link and if necessary replace it REMARK A fusible link is a large sized fuse wire installed in the high current flow portion of the circuit to protect electrical components and wiring from burning similar to an ordinary fuse CONTROLLER A pump and governor controller is provide...

Page 145: ...es place away from hazardous areas PROCEDURE 1 When the machine is operated on sites with no fuel container and pump the machine may be refuelled using the refuelling pump from fuel barrels 2 The refuelling pump is located in the compartment at the rear right hand side of the machine 3 Stop the machine engine 4 Open the cap on the foot valve by unscrewing fully 5 Check strainer on the fuel hose en...

Page 146: ...ill overheat the motor If the barrel is emptied during the refuelling stop the pump immedi ately The maximum permitted running time for the pump is 30 minutes The tank should be full well within this time Do not allow the pump to run for longer than this as damage will occur to the motor MAINTENANCE Weekly Clean the suction filter Monthly Check hose joints electrical cables and clean the pump body...

Page 147: ...RNING LAMP When the indicator is pulled fully backward warning light A will flash to indicate the driver s intention to turn to the left When the indicator is pushed fully forward warning light B will flash to indicate the driver s intention to turn to the right A B ...

Page 148: ...ressure in the circuit and when it is installed the circuit can be operated for a short time even after the engine is stopped The accumulators are installed to the position shown in the dia gram on the right Control circuit accumulator B This machine is equipped with an accumulator in the control cir cuit The accumulator is a device to store the pressure in the con trol circuit and when it is inst...

Page 149: ...he 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 linkage hoses Check tha...

Page 150: ...k for damage to handrail and for loose bolts Repair any damaged handrails and tighten any loose bolts 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 to the rear view mi...

Page 151: ... is low add water through the water filler of reserve tank to the FULL level 2 After adding water tighten the cap securely 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 ...

Page 152: ...hin filler neck will rise according to fuel level Check that the fuel tank is full by looking into tank and checking float gauge 5 If the tank is not full add fuel through the fuel filler until the float gauge G rises to the maximum position Fuel tank capacity 290 litres Position of tip of float gauge G when tank is full Approx 50 mm from top of surface of fuel tank 6 After adding fuel push float ...

Page 153: ...e run the engine at low speed retract the arm and bucket cylinders then lower the boom set the bucket teeth in contact with the ground and stop the engine 2 Check sight gauge G The oil level is normal if midway between the H and L marks NOTICE Do not add oil if the level is above the H line This will damage the hydraulic equipment and cause oil to spurt out 3 If the level is below the L mark remov...

Page 154: ...gged with dirt or dust wash the battery cap to clean the breather hole Check for damage wrong fuse capacity and any sign of discon nection or short circuit in the electric wiring Check for loose termi nals and tighten any loose parts In particular check the wiring of the battery starting motor and alternator carefully When carrying out walk around checks or checks before starting always check if t...

Page 155: ...rained FUEL 5 Secure fuel line to prevent leakage 6 Remove air bleed plug 5 at the top of the water separator 7 Loosen drain valve 1 at the bottom of the water separator and drain the water and sediment into the container 8 Loosen ring nut 2 then remove filter case 3 9 Remove element 4 from the separator base 10 Wash element 4 in clean diesel oil 11 Check element 4 and replace it if it is damaged ...

Page 156: ...ment of seat and base Pull lever 2 sideways After the seat is set to the desired position release the lever REMARK This operation will not affect relative position of seat and wrist control levers C Adjustment of reclining seat The backrest is adjusted using the locking lever 3 Once locking lever 3 is in locked position it should not be possible to move onto another position D Adjustment of arm re...

Page 157: ...tomatic and height adjuster 6 with the vehicle at a standstill and the driver sitting on the seat the driver must sit absolutely still during adjustment G Lumbar adjustment The curve of the backrest cushion can be individually adjusted by pressing the upper and lower switches 7 H Height adjustment The height can be altered by pulling or pressing the actuator lever fully out or in 8 if the adjustme...

Page 158: ...t belt so that it is not twisted FASTENING AND REMOVING SEAT BELT This seat belt has a retractor so it is not necessary to adjust the length Fastening seat belt Hold grip 2 and pull the belt out from the retractor 1 check that the belt is not twisted then insert tongue 3 into buckle 4 securely Pull the belt lightly to check that it is properly locked Removing belt Press button 5 in buckle 4 and re...

Page 159: ...ustment The seat should be adjusted for the drivers weight by turning the weight adjuster lever 6 with the seat empty The set weight can be read from the indicator G Lumbar adjustment By turning the adjustment knob 7 to the left or right both the height and curvature of the backrest cushion can be individually adjusted H Height adjustment For details see H Height adjustment 157 I Seat depth adjust...

Page 160: ...y lock lever 16 is in the LOCK position REMARK In certain conditions it may be possible for the safety lock lever to contact the left hand arm rest on the operator seat to avoid this always ensure that the left hand arm rest is stowed in the fully up position before operating the safety lock lever 2 Select neutral on the right control lever 3 Insert the key in starting switch 7 turn the key to the...

Page 161: ...es not sound there is probably a broken bulb or disconnection in the monitor wiring so contact your Komatsu distributor for repairs After approx 3 sec the following gauges will remain on and the other monitors will go out The buzzer will sound intermittently and the monitor will show the low brake pressure symbol if the machine has been idle for some time Engine water temperature gauge 17 Fuel gau...

Page 162: ...xic when starting the engine in con fined spaces ensure adequate ventilation at all times 1 Set fuel control dial at the low idling MIN position 2 Turn the key in starting switch to the START position The engine will start 3 When the engine starts release the key in starting switch The key will return automatically to the ON position 6 7 8 9 10 MIN 7 Heat Off On Start Heat Off On Start 6 Heat Off ...

Page 163: ...minutes When starting in low temperatures do as follows 1 Set fuel control dial 7 at the low idling MIN position 2 Hold the key in starting switch 6 at the HEAT position and check that preheating monitor lights up After about 30 seconds preheating monitor will flash for about 10 seconds to indicate that preheating is finished REMARK The monitor and gauge also light up when the key is at the HEAT p...

Page 164: ...ing switch 6 to the START position to start the engine 4 When the engine starts release the key in starting switch 6 The key will return automatically to the ON position Heat Off On Start Ambient temperature Preheating time Above 0 C 0 C to 10 C 20 seconds 10 C to 20 C 30 seconds Heat Off On Start Heat Off On Start ...

Page 165: ... 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 at low idling or high idling continu ously for more than 20 minutes This will cause leakage of oil from the turbocharger oil supply piping If it is necessary to run the engine at idling apply a load from time to time or run the engine at a mid range s...

Page 166: ... 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 9 is set to the ON actuated position and swing control lever is operated at full stroke oil tempera ture rise can be increased quicker NOTICE When the work equipment is retracted take care that it does not interfere with the machine body...

Page 167: ...il pressure monitor 5 off Charge level monitor 6 off Fuel level monitor 7 green Air cleaner clogging monitor 8 off Engine pre heating lamp 9 green Engine oil level monitor 10 off Hydraulic oil temperature 11 green Hydraulic oil temperature gauge 12 inside black range Replacement monitor of engine oil off 13 6 Check that there is no abnormal exhaust gas colour noise or vibration If any abnormality ...

Page 168: ...w temperature do not carry out operations or move the levers suddenly Work equipment control will be slower and less responsive than normal therefore always carry out the warming up operation first to ensure safe operation of the machine and help extend the machine life Do not suddenly accelerate the engine before the warm ing up operation is completed Do not run the engine at low idling or high i...

Page 169: ...wing 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 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 Boom operation RAISE LOWER Arm operation IN OUT Bucket operation CURL DUMP...

Page 170: ... mode switch 1 on the monitor panel to switch to 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 to the full speed MAX position and hold it for 3 seconds 2 When fuel control dial is returned to the low idling MIN...

Page 171: ...outriggers dozer blade are up If the lever is moved inside auto decel speed engine speed will rise suddenly Operate the levers carefully Note the direction of undercarriage before moving off Check that low brake pressure warning lamp is off Check service brake just after moving off Always fasten seat belt 1 Set swing lock switch to the ON actuated position and con firm that swing lock monitor lamp...

Page 172: ...operation required as follows for details see CREEP SPEED SELECTOR SWITCH 95 Creep mode see CREEP SPEED SELECTOR SWITCH 95 for fine control speed is restricted to 2 5 km h REMARK Creep can be engaged from any other mode by pressing the Creep button Press High Low speed select switch to dis engage Creep Creep mode will only engage fully when the machine comes to a stop Lo mode for travelling on rou...

Page 173: ...brake to prevent machine rolling REMARK If starting to travel on a steep uphill slope first press the travel pedal fully then release the park brake this will minimise rolling backwards when staring 10 Press the travel pedal 30 smoothly The machine will move off in the selected direction REMARK Engine speed will automatically increase when travel pedal is depressed 11 When changing direction from ...

Page 174: ...s and check wheels turn fully Do not press travel pedal until the safety lock lever is fully down UNLOCKED 1 The machine can be steered by turning steering wheel in the desired direction The position of the steering column can be adjusted fore and aft by depressing pedal 1 moving column to desired position and releasing pedal 1 WARNING If it becomes necessary to tow the machine the operator must n...

Page 175: ...es B Arm Cyl inder rear of boom with isolation valves provided 1 Before travelling on a Public Highway with the safety lock lever lowered in the UNLOCK position engage the control lever lock switch to prevent accidental use of the work equip ment the rear brake lights will now become active 2 Before travelling fold the work equipment and raise to 40 50 cm from the ground 3 Before travelling on a p...

Page 176: ...he opera tor seat to avoid this always ensure that the left hand arm rest is stowed in the fully up position before operating the safety lock lever When parking the machine select flat hard ground and avoid dangerous places If it is unavoidable to park the machine on a slope insert chocks underneath the wheels As an additional safety measure thrust the bucket into the ground Before travelling re a...

Page 177: ...must be serviced prior to further operation ONLY USE IT IN AN EMERGENCY REMARK In the event of service brake failure 1 Release travel pedal 2 Depress service brake pedal to confirm no braking 3 Brace yourself before engaging emergency brake A seatbelt is fitted for your safety and comfort Please wear this at all times 4 Press park break switch 8 to on position machine will very quickly come to a h...

Page 178: ... do so may result in damage to the machine When operating the swing check that the area around the ma chine is safe 1 Before operating the swing turn swing lock switch 9 OFF CANCELLED NOTICE Check that swing lock monitor goes out at the same time 2 Operate left work equipment control lever to swing the upper structure 3 When not operating the swing turn swing lock switch 9 ON ACTUATED 4 Before tra...

Page 179: ...y 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 for 4 seconds even if the fuel control dial is set to FULL the auto deceleration mechanism will act to reduce the engine speed to auto decel speed If the levers are operated within 15 seconds after the engine stops it s possible to lower th...

Page 180: ...AND CHECKS BEFORE STARTING ENGINE OPERATION 180 Hydraulic adjust boom operation Depress front of pedal 23 to extend the boom and the rear of the pedal to retract the boom Hydraulic adjust boom pedal Raise Lower 23 ...

Page 181: ...y WARNING When moving the machine confirm that the chassis attach ment is raised PRECAUTIONS FOR USING THE DOZER 1 When using the dozer blade as stabiliser Use the dozer blade in the same way as an outrigger How ever use it only on level ground so that uneven loads will not be applied to the blade 2 When using the dozer blade with the upper structure facing the rear of the undercarriage the steeri...

Page 182: ...e the breaker only in B mode ONE TOUCH POWER MAX SWITCH The one touch power max switch can be used during operations to increase the power Make effective use of this function when ever necessary in combination with the working mode 1 Press top right hand switch on the left lever The power is increased for up to 8 5 seconds The increased power is auto matically cancelled after 8 5 seconds After whi...

Page 183: ...ng 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 cylinder is operated to the end of its stroke d...

Page 184: ...er 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 TRAVELLING When travelling over obstacles such as boulders or tree stumps ensure sufficient clearance to avoid undercarriage damage As far as possible remove such obstacles or avoid travelling over them Do n...

Page 185: ...ine in water by more than the permissi ble depth axle centre In addition for parts that have been immersed in water for a long time pump in grease until the old grease comes out from the bearings i e the bucket pins WHEN LIFTING A LOAD Front axle of machine must be locked as machine will become unstable REMARK Precautions when using the work equipment Do not use the park brake to reduce movement o...

Page 186: ...pile soil to make platform on the slope so that the machine can be kept horizontal when operating Do not travel on slopes of over 20 as there is danger that the machine may overturn before travelling down steep slopes stop machine engage low gear 1 When travelling down hills of more than 5 first stop and select Low travel mode Release the service brake and pro ceed full hydraulic braking will then...

Page 187: ...dures to get the machine out WHEN ONE SIDE IS STUCK When only one side is stuck in mud use the bucket to raise the wheels then lay boards or logs and drive the machine out If nec essary put a board under the bucket also NOTICE When using the boom or arm to raise the machine always have the bottom of the bucket in contact with the ground Never push with the teeth The angle between the boom and arm ...

Page 188: ...cavating with the arm is from a 45 angle away from the machine to a 30 toward the machine There may be some differences depending on the excavation depth but try to use within the above range rather than going all the way to the extreme end of the cylinder stroke SHOVEL WORK A shovel is suitable for excavating at a position higher than the machine Shovel work is performed by attaching the bucket i...

Page 189: ...d other protective equipment When the bucket is removed place it in a stable condi tion Stop the machine on a firm flat surface When performing joint work make clear signals to each other and work carefully for safety s sake REPLACEMENT 1 Place the bucket in contact with a flat surface REMARK When removing the pins place the bucket so that it is in light contact with the ground If the bucket is lo...

Page 190: ...all the bucket inversely After the bucket is reversed correct the inclination and direc tion of the retaining pin holes 1 and 2 and stabilise the bucket securely 4 Align the arm with holes 1 and the link with holes 2 then install pins A and B WARNING 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 leavin...

Page 191: ...ool down 2 Turn the key in starting switch 6 to the OFF position and stop the engine 3 Remove the key from starting switch 6 CHECK AFTER FINISHING WORK 1 Check the engine water temperature engine oil pressure and fuel level on the monitor 2 Walk around the machine and check the work equipment and undercarriage and check also for leakage of oil or water If any abnormalities are found repair them 3 ...

Page 192: ...orrect handling of wheels and tyres can result in serious injury or death Particular care is required when working on twin wheel assemblies Before any attempt is made to remove the road wheels the tyres must be fully deflated 1 General information Always replace damaged parts with new parts from your Komatsu distributor Never attempt to repair damaged items Use the appropriate tools in a good cond...

Page 193: ...accordance with the following procedure paying attention to the information specific to the type of wheel assembly fitted to the machine on which you are working WARNING Failure to observe the following procedure may result in seri ous injury or death 3 Twin wheel assembly 3 part rim Deflation and removal Before loosening the wheel retaining nuts completely deflate the tyres by removing the valve ...

Page 194: ...ndition of the wheel and rim for signs of wear or damage Discard any defective or doubtful parts and replace with approved replacement parts Clean the rims with a hard brush paying particular attention to the bottom of the rim gutter groove Fit the tyre to the rim base and fit the tube ensuring that the valve is correctly located in its through hole Place the loose flange against the tyre bead in ...

Page 195: ...ing 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 safety cage repeat the visual check When refitting the wheel assemblies tighten at least 2 diago nally opposite wheel nuts and then tighten...

Page 196: ...ad 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 condition of the rim If there are any signs of deformation or cracks the wheel must be replaced Check carefully the wheel attachment holes if you notice signs of ovalization or the presence of cracks the wheel must be replaced If the fix...

Page 197: ...carriage 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 Mechanical swing lock pin should always be engaged during transportation When ...

Page 198: ...ition For details see HIGH LOW SPEED SELECTOR SWITCH 95 3 Turn the auto deceleration switch OFF and return the fuel control dial 7 to reduce the engine speed For details see AUTO DECELERATION SWITCH 102 4 Turn the swing lock switch 9 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 lo...

Page 199: ...ety lock lever to LOCK position REMARK In certain conditions it may be possible for the safety lock lever to contact the left hand arm rest on the operator seat to avoid this always ensure that the left hand arm rest is stowed in the fully up position before operating the safety lock lever 4 When transporting the machine hold it down with chains or rope Be particularly careful to ensure that the m...

Page 200: ...hen lifting a vehicle Otherwise the machine may be unbalanced Lifting a machine must be performed on a flat place with the fol lowing procedure 1 Start the engine and set the machine in the position shown in the figure at the right boom at the top stroke end arm bucket fully retracted Direct the top revolving super structure straight forward REMARK When lifting a machine fitted with 2 piece boom y...

Page 201: ... lifting angle must be as shown in the figure on the right 7 When lifting make sure that there is no change in the position due to possible leakage in the hydraulic circuit on the boom cylinder head side 8 When the machine leaves the ground stop the machine and make sure sufficiently that the machine is balanced Then lift the machine slowly ...

Page 202: ...ked before transporting the machine NOTICE Always retract the radio antenna retract or remove the driving mirrors before transportation Obey all state and local laws governing the weight width and length of a load Observe all regulations governing wide loads Monoboom with blade 1 Height for transport D Overall height 3 height of trailer platform Weights and dimensions will vary according to specif...

Page 203: ... 3 height of trailer platform Weights and dimensions will vary according to specification Consult your Komatsu distributor if in doubt Arm Length mm Driving Position Transport Position Weight A B C D 2100 6000 4211 8188 3439 15 765 2500 5862 3978 8225 3208 15 800 3000 5878 3978 8211 3191 15 930 ...

Page 204: ...ders OR b Extend the first boom cylinders until the boom positioning decals A are aligned correctly 4 Fully retract the second boom cylinders 5 Adjust the arm cylinder such that the front of the arm is verti cle 6 Disable the work equipment levers by switching on the control lever lock switch 7 Close manual lock valves 1 For the bucket cylinder located on the arm 2 For the arm cylinder located on ...

Page 205: ...OPERATION TRANSPORTATION 205 Before moving off lock all machine cover and toolbox doors to prevent accidental opening ...

Page 206: ...ur Komatsu distributor or ask your local antifreeze dealer Be careful not to let the water flow into drainage ditches or spray on to the ground surface Antifreeze is flammable so do not bring any flame close Do not smoke when handling antifreeze NOTICE Never use methanol ethanol or propanol based anti freeze Absolutely avoid using any water leak preventing agent weather it is used independently or...

Page 207: ...ratio is low the battery electro lyte may freeze Maintain the battery charge as close as possible to 100 and insulate it against cold temperature so that the machine can be started easily the next morning REMARK Measure the specific gravity and calculate the rate of charge from the following conversion table Because the battery capacity drops markedly in low tempera tures cover the battery or remo...

Page 208: ...ble park the machine on wooden boards The boards help protect the wheels from being frozen in soil and the machine can start next morning Open the drain valve and drain any water collected in the fuel system to prevent it from freezing After operation in water or mud remove water from undercar riage to extend undercarriage service life AFTER COLD WEATHER When season changes and the weather becomes...

Page 209: ...ve terminals of the battery and cover it or remove it from the machine and store it separately If the ambient temperature is expected to drop below 0ºC add antifreeze to the cooling water Raise safety lock lever to the LOCK position Set the stop valve to the LOCK position on machines which can install attachments Install a plug in the elbow DURING STORAGE WARNING If it is unavoidably necessary to ...

Page 210: ...een stored for a long time the mois ture in the atmosphere will get into the oil Check the oil at all parts before and after starting the engine If there is water in the oil change all the oil 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...

Page 211: ...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 212: ...ope as shown in the diagram WHEN USING THE FRONT OF CHASSIS WHEN USING THE REAR OF THE CHASSIS For towing method see TOWING 39 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 wor...

Page 213: ...ool touches the positive terminal and the chassis there is danger that it will cause a spark be extremely careful If the terminals are loose there is danger that the defec tive contact may generate sparks that will cause an explosion When installing the terminals install them tightly When removing or installing the terminals check which is the positive terminal and which is the negative terminal G...

Page 214: ... of the battery then connect the negative charger clip of the charger to the negative terminal of the battery Be sure to connect the clips securely Set the charging current to 1 10 of the value of the rated bat tery capacity when doing rapid charging set it to less than the rated battery capacity If the charger current is too high the electrolyte will leak or dry up and this may cause the battery ...

Page 215: ... structure frame but sparks will be generated when this is done so connect to a place as far as possible from the battery However avoid connecting the cable to the work equipment as conduction is poor Use care when removing the cables from a machine that has been started To avoid hydrogen explosion do not allow the cable ends to contact each other or the machine NOTICE The starting system for this...

Page 216: ...k lever to contact the left hand arm rest on the opera tor seat to avoid this always ensure that the left hand arm rest is stowed in the fully up position before operating the safety lock lever 1 Make sure the clips are firmly connected to the battery termi nals 2 Start the engine of the normal machine and keep it to running at high idling speed 3 Turn the starting switch of the problem machine to...

Page 217: ... when starting switch is turned to ON Defective wiring Defective starting motor Insufficient battery charge Check repair Replace Charge Pinion of starting motor keeps going and out Insufficient battery charge Defective safety relay Charge Replace Starting motor turns engine slug gishly Insufficient battery charge Defective starting motor Charge Replace Starting motor disengages before engine start...

Page 218: ...erates abnormal noise sucking in air Clogged element in hydraulic tank strainer lack of oil Clean see EVERY 2000 HOURS SERVICE Excessive rise in hydraulic oil tem perature Loose fan belt Dirty oil cooler Lack of hydraulic oil Check fan belt tension replace Clean see EVERY 500 HOURS SERVICE Add oil to specified level see CHECK BEFORE STARTING Bucket rises slowly does not rise Lack of hydraulic oil ...

Page 219: ...STARTING Check fan belt tension adjust replace Change coolant flush inside of cooling system see WHEN REQUIRED Radiator water level monitor lights up Clogged radiator fins or dam aged fins Defective thermostat Loose radiator filler cap high altitude operations Defective water level sensor Defective monitor Clean or repair see EVERY 500 HOURS SERVICE Replace thermostat Tighten cap or replace packin...

Page 220: ...ective compression above Clean or replace turbocharger Combustion noise occasionally make breathing sound Defective nozzle Replace nozzle Abnormal noise generated com bustion or mechanical Low grade fuel being used Overheating Damage inside muffler Excessive valve clearance Change to specified fuel Refer to Radiator water level monitor lights up as above Replace muffler Adjust clearance Problem Ma...

Page 221: ...rate the swing lock manually Depending on the cause of the failure it may be impossible to release the brake In any case have the system inspected immediately 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 on bracket In this ca...

Page 222: ...TROUBLESHOOTING OPERATION 222 ...

Page 223: ...223 MAINTENANCE WARNING Please read and make sure that you understand the safety volume before reading this section ...

Page 224: ...ient temperature Always use clean washer fluid Use automobile window washer fluid and be careful not to let any dirt get into it Always use clean oil and grease Use clean oil and grease Also keep containers 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 p...

Page 225: ...rings from being between the area to be welded and the position of grounding 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 g...

Page 226: ... to protect components from rusting Lubricate com ponents more frequently than usual Be sure to 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 frequentl...

Page 227: ...gress of impurities water metal particles dirt etc 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 much oil or too little oil are both causes of prob lems If the oil in the work equipment is ...

Page 228: ...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 air from the circuit COOLANT River water contains large amounts of calcium and other impurities so if it is used scale will stick to the engine and radiator and this will cause defective heat exchange and overheating Do not use water that is not s...

Page 229: ...ly sis KOWA is a maintenance service that makes it possible to prevent machine failures and down time With KOWA the oil is periodi cally sampled and analyzed This enables early detection of wear of the machine drive parts and other abnormalities Periodic use of KOWA makes the following possible It enables abnormalities to be detected early leading to reduction of repair costs and machine downtime ...

Page 230: ...o protect them To prevent any change in quality during long term storage be sure to use in the order of first in first out use the oldest oil or fuel first FILTERS Filters are extremely important safety parts They prevent impurities in the fuel and air circuits from entering important equipment and causing problems Replace all filters periodically For details see the Operation and Maintenance Manu...

Page 231: ...ectric components other than these speci fied by Komatsu Be careful to keep the electric system free of water when washing the machine or when it rains Since the controller for the control system may cause mal function due to external wave interference before installing a radio receiver and a walkie talkie or citizen band consult your Komatsu distributor When working on the seashore carefully clea...

Page 232: ...e under internal pressure so when loosening the plug or screw or the hose joint do not stand in front of the part Loosen it slowly to release the internal pressure before removing it When carrying out inspection or maintenance of the hydraulic circuit always bleed the air from the hydraulic tank to remove the internal pressure Periodic maintenance includes the inspection of the hydraulic oil level...

Page 233: ... 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 20Y 60 31171 07000 15195 Element Strainer O ring 1 1 Every 1000 hours service Air cleaner 600 185 2520 600 185 2510 600 184 1280 Single element Safety element O ring 1 1 1 When required Engine oil filter 6736 51 5140 Car...

Page 234: ...il If API classi fication CD is used reduce the engine oil change interval to half 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 20 C 15 C 30 C 10 C 50 C 50 C SAE 30 CD SAE 10W SAE 10W 30 SAE 15W 40 16 litre 16 litre Swing machinery case Engine oil 20 C 40 C SAE 30 4 5 litre 4 5 litre Hydraulic system Bio...

Page 235: ...cified capacity Total amount of oil including oil for compo nents and oil in piping Refill capacity Amount of oil needed to refill system during nor mal inspection and maintenance Abbreviations ASTM American Society of Testing and Material SAE Society of Automotive Engineers API American Petroleum Institute TYPE CLASS VISCOSITY REF NO Engine oil CF 4 CF 4 SAE15W 40 SAE10W 30 EO 1540 EO 1030 TRANSM...

Page 236: ...KON premium grease 4 ARCO Arcofleet S3 plus Arco HD gear oil Litholine HEP 2 Arco EP moly D 5 BP Vanellus C3 Gear oil EP Hypogear EP Energrease LS EP2 6 CALTEX RPM delo 400 RPM delo 450 Universal thuban Universal thuban EP Marfak all purpose 2 Ultra duty grease 2 7 CASTROL Turbomax RX super CRD EP EPX Hypoy Hypoy B Hypoy C MS3 Spheerol EPL2 8 CHEVRON Delo 400 Universal gear Ultra duty grease 2 9 C...

Page 237: ... duty Albania EP grease 17 SUN Sunoco GL5 gear oil Sunoco ultra prestige 2EP Sun prestige 742 18 TEXACO Ursa super plus Ursa premium Multigear Multifak EP2 Starplex 2 Texaco Havoline XLC 19 TOTAL Rubia S Rubia X Total EP Total transmission TM Multis EP2 Total Fina Elf Glacelf CHP Supra 20 UNION Guardol MP gear lube LS Unoba EP 21 VEEDOL Turbostar Diesel star MDC Multigear Multigear B Multigear C 2...

Page 238: ...h 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 6...

Page 239: ... mm Width across flat b mm Tightening torque Target value Service limit N m kgf m N m kgf m 6 10 13 2 1 35 11 8 14 7 1 2 1 5 8 13 31 3 2 27 34 2 8 3 5 10 17 66 6 7 59 74 6 0 7 5 12 19 11 11 5 98 123 10 0 12 5 14 22 177 18 157 196 16 0 20 0 16 24 279 28 5 245 309 25 0 31 5 18 27 382 39 343 425 35 0 43 5 20 30 549 56 490 608 50 0 62 0 22 32 745 76 662 829 67 5 84 5 24 36 927 94 5 824 1030 84 0 105 0...

Page 240: ...t they always maintain their function completely However if these parts show any abnormality before the replace ment interval has passed they should be repaired or replaced immediately If the hose clamps show any deterioration such as deformation or cracking replace the clamps at the same as the hoses When replacing the hoses always replace the O rings gaskets and other such parts at the same time...

Page 241: ...tlet hose Pump Control valve 2 6 Work equipment hose Boom cylinder inlet 4 7 Work equipment hose Bucket cylinder line Boom foot section 2 8 Work equipment hose Bucket cylinder inlet 2 9 Work equipment hose Arm cylinder line Boom foot section 2 10 Work equipment hose Arm cylinder inlet 2 11 Additional attachment line hose Boom foot section 2 12 Additional attachment line hose Boom top section 2 13 ...

Page 242: ...ECK ALTERNATOR 260 CHECK START MOTOR 261 REPLACE BUCKET SIDE CUTTERS 261 REPLACE BUCKET TEETH 262 ADJUST BUCKET CLEARANCE 266 CHECK WINDOW WASHER FLUID LEVEL ADD FLUID 267 CHECK AND ADJUST AIR CONDITIONER 268 DRAIN ENGINE BREATHER OIL CATCHER 269 CHECK BEFORE STARTING CHECK COOLANT LEVEL ADD WATER 269 CHECK OIL LEVEL IN ENGINE OIL PAN ADD OIL 270 CHECK FUEL LEVEL ADD FUEL 271 CHECK OIL LEVEL IN HY...

Page 243: ...igger cylinder foot pin 2 or 4 points 276 Outrigger cylinder rod end 2 or 4 points 276 Outrigger leg pivot 2 or 4 points 276 Outrigger foot pivot 2 or 4 points 276 Propshaft 3 points 276 Boom adjust cylinder foot pin 1 point 277 Boom adjust cylinder rod end 1 point 277 Axle pivot 2 point with outriggers attached 277 Axle pivot 2 point without outriggers 277 Hub pivot 4 points 278 Steer links 4 poi...

Page 244: ...ANGE OIL IN ENGINE OIL PAN REPLACE ENGINE OIL FILTER CARTRIDGE 289 CLEAN AND INSPECT RADIATOR FINS OIL COOLER FINS AND CONDENSER FINS 290 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM 291 CLEANING RECIRCULATED AIR FILTER 292 REPLACE HYDRAULIC TANK BREATHER ELEMENT 293 CHECK VALVE RUBBER MOUNTS 293 EVERY 1000 HOURS SERVICE REPLACE HYDRAULIC FILTER ELEMENT 294 CHANGE OIL IN SWING...

Page 245: ... TURBOCHARGER 300 CHECK ALTERNATOR STARTING MOTOR 300 CHANGE ANTIFREEZE 300 CHANGE ANTIFREEZE 300 CHECK AND ADJUST VALVE CLEARANCE 301 EVERY 4000 HOURS SERVICE CHECK WATER PUMP 301 EVERY 5000 HOURS SERVICE CHANGE OIL IN HYDRAULIC TANK 302 SERVICE ITEM PAGE ...

Page 246: ...nder rod end grease 32 Transmission oil check level change oil 11 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 14 Bucket link coupling pin grease 36 Rear axle check level change oil 15 Swing machinery oil check level change oil 37 H...

Page 247: ...MAINTENANCE MAINTENANCE SCHEDULE CHART 247 Interval of service Change filter Lubrication by greasing G Amount of oil required at change litres Check oil level change EO ...

Page 248: ...t 250 hours REPLACE FUEL FILTER CARTRIDGE For details see REPLACE FUEL FILTER CARTRIDGE 287 CHECK ENGINE VALVE CLEARANCE ADJUST For details see CHECK ENGINE VALVE CLEARANCE ADJUST 248 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 249: ...the outer element Checking If air cleaner clogging monitor H on the monitor panel lights up clean the air cleaner element Replacing Replacing element O ring If one year has passed since installing the element or if air cleaner clogging monitor H on the monitor panel flashes immediately after the element is cleaned replace the outer element inner element and O ring Replacing evacuator valve Replace...

Page 250: ... right and rotate the element to the left and right to pull it out NOTICE Never remove the inner element It will allow dirt to enter and cause failure of the engine Do not use a screwdriver or other tool 1 After removing the outer element cover the air connector inside the air cleaner body with a clean cloth or tape to pre vent dirt or dust from entering 2 Wipe off or brush off the dirt stuck to c...

Page 251: ...ce the inner element at the same time Replace both inner and outer elements when the monitor lamp H lights up soon after installing the cleaned outer element even though it has not been cleaned 5 times When replacing the element new stick on seal is packed in the same box as the element Stick the seal in the posi tion 5 Remove the cloth or tape cover installed in Step 3 6 If small holes or thin cr...

Page 252: ... 3 Push the outer element in straight with your hand when installing it to the air cleaner body If the element is held and rocked lightly up and down and to the left and right while pushing it in the element can be inserted easily NOTICE When inserting the element if the rubber at the tip is swollen or the outer element is not pushed in straight and cover 6 is assembled by force to hook 2 there is...

Page 253: ...r tape 3 Clean the air cleaner body interior then remove the cover from the air intake port in Step 2 4 Install a new inner element to the connector then tighten the nut NOTICE The inner element must not be cleaned and used again When replacing the outer element replace the inner element at the same time 5 Set the outer element in position then lock cover 6 with hooks 2 6 2 Top GL Evacuator valve ...

Page 254: ...d on the work equipment do not impede the engine hood when it is opened closed GENERAL The cooling system operates under pressure which is controlled by the pressure relief valve in the radiator cap The belt driven water pump circulates the coolant through the engine block cylinder heads radiator and engine oil cooler Cir culation is controlled by the thermostat which by passes coolant flow around...

Page 255: ...leaning or changing the coolant Use a permanent type of antifreeze If for some reason it is impossible to use permanent type anti freeze use an antifreeze containing ethylene glycol Super Coolant AF ACL has an anti corrosion effect as well as an antifreeze effect The ratio of antifreeze to water depends on the ambient tempera ture but to obtain the corrosion resistance effect a minimum ratio of 30...

Page 256: ...moving drain plug avoid pouring coolant on your self REMOVAL WARNING Hot scalding coolant 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 relieved Use extreme caution when adding coolant to the radiator to avoid being burned Wear gloves and go...

Page 257: ...ing on the engine or electrical system dis connect the negative ground battery cable Tag the cable and controls to warn against starting 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 undercover Place a container below drain plug 4 Remove the coolan...

Page 258: ...n the heater 1 Be sure the radiator drain is closed and tightened 2 Fill the cooling system to maximum capacity Fill with anti freeze For coolant specifications see COOLANT 228 See Precautions when filling radiator 226 3 Start engine and run until normal operating temperature is reached Add coolant when needed to keep proper level in reserve tank 4 After all air is removed and level remains fixed ...

Page 259: ... radiator core using air or water under pressure Direct the flow through the core opposite to the normal direction of air flow THERMOSTAT REMOVAL 1 Drain the cooling system Refer to DRAINING THE SYSTEM 257 in this section 2 Remove the components and housing to access the thermo stat 3 Remove the thermostat and clean all gasket material from either mating surfaces INSTALLATION 1 Install new thermos...

Page 260: ...ed for life and require attention only at the time of major overhaul The alternator is equipped with an integral transistorized voltage regulator If the alternator fails to operate properly consult your distributor PRECAUTIONS REMARK The unit electrical system is negative ground Be CERTAIN the ground polarity is correct when a Installing a new battery b Connecting a battery charger c Using a boost...

Page 261: ...ment moves by mistake when the teeth are being replaced Set the work equip ment in a stable condition then stop the engine and apply the control lever pad safety lock In certain conditions it may be possible for the safety lock lever to contact the left hand arm rest on the opera tor seat to avoid this always ensure that the left hand arm rest is stowed in the fully up position before operating th...

Page 262: ...es gloves and other protective equipment 1 To make it possible to knock out the pin of tooth 1 set the bottom surface of the bucket on a block check that the work equipment is in a stable condition raise the safety lock lever to the LOCK position Set so that the bottom face of the bucket is horizontal 2 Use a hammer and drift to knock out lock pin 2 If the drift is set against rubber pin lock 3 wh...

Page 263: ...h will not enter the adapter properly and there will not be proper contact at the mating portion 7 Fit tooth 1 to adapter 4 and confirm that when the tooth is pressed strongly the rear face of the hole for the pin of the tooth 1 is at the same level as the rear face of the hole for the pin of the adapter If the rear face of the hole for the pin of tooth 1 is protruding to the front from the rear f...

Page 264: ...in 2 in the reverse direction from which it was hit in Lightly hit the tip of the point from above and below and hit its sides from right and left Confirm that rubber pin lock 3 and lock pin 2 are set as shown in the figure The life of the teeth can be lengthened and the frequency of their replacement can be reduced by turning them upside down so that they will wear evenly Replace the rubber pin l...

Page 265: ...ding area Pieces will often fly during the replacement operation so wear safety glasses gloves and other protective equip ment 1 Set the bottom of the bucket on a block to make it possible to remove pin 1 check that the work equipment is stable then raise the safety lock lever to the LOCK position Set so that the bottom of the bucket is horizontal 2 Place a bar on the pin head and strike the bar w...

Page 266: ... 2 Shift O ring 1 of the linkage and measure the amount of play a Measurement is easier if you move the bucket to one side or the other so all the play can be measured in one place In the diagram this is on the left hand side Use a gap clearance gauge for easy and accurate measure ment 3 Loosen the four plate fixing bolts 2 and loosen plate 3 Because it uses split shims you can carry out the opera...

Page 267: ...nce the ratio should be varied depending on atmospheric tem perature replenish washer fluid at the following mixture ratio tak ing temperature into account Pure washer fluid comes in two types for 10ºC for general use and for 30ºC cold regions Use pure washer fluid according to operation area and season 1 Operation area and season Mixture ratio Freezing temperature Normal Pure washer fluid 1 3 wat...

Page 268: ...REMARK When there are bubbles the refrigerant gas level is low so contact your refrigerant dealer to have refrigerant added If the air conditioner is run with the refrigerant gas level low it will cause damage to the compressor Check in off season When not being used for a long period operate the cooler for 3 to 5 minutes once a month to supply lubricant to each component of the compressor Inspect...

Page 269: ... the radiator cap unless necessary When check ing the coolant always check the radiator reserve tank when the engine is cold 1 Open the rear door on the left side of the machine and check that the cooling water level is between the FULL and LOW marks on radiator reserve tank 1 shown in the diagram on the right If the water level is low add water through the water filler of reserve tank 1 to the FU...

Page 270: ...ly in the oil gauge pipe then take it out again 4 The oil level should be between the H and L marks on dipstick K If the oil level is below the L mark add engine oil through oil filler F For details of the oil to use Refer to USE FUEL COOL ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM PERATURE 234 5 If the oil is above the H mark drain the excess engine oil from drain plug P and check the oil level ...

Page 271: ...full 2 If the fuel level is below the E mark on the fuel gauge add fuel through filler port F while watching the float in the filler port Fuel capacity 290 litres For details of the fuel to use see USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER ATURE 234 3 After adding fuel tighten the cap securely REMARK If breather hole 1 on the cap is clogged the pressure in the tank will drop and ...

Page 272: ... level is normal if between the H and L marks REMARK 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 234 REMARK The oil level will vary dependin...

Page 273: ...water separator and check if the ring inside has risen to the marked line 3 If the ring has risen to the marked line carry out the proce dure from Step 4 4 Set a container under the water separator to catch the drained fuel 5 Secure fuel line to prevent leakage 6 Remove air bleed plug 5 at the top of the water separator 7 Loosen drain valve 1 at the bottom of the water separator and drain the wate...

Page 274: ...om together with fuel When doing this be careful not to get fuel on your self 4 When only clean fuel comes out close drain valve 1 REMARK 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 ...

Page 275: ...ld 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 1st to 2nd boom pin 1 point 5 1st to 2nd boom pin 2 points 6 Arm cylinder foot pin 1 point 1 2 3 4 5 6 7 8 9 10 11 12 14 13 1 1 3 4 3 2 2 5 5 6 ...

Page 276: ...pin 1 point 11 Arm Bucket coupling pin 1 point 12 Link coupling pin 1 point 13 Bucket cylinder rod end 1 point 14 Bucket Link coupling pin 2 points 15 Outrigger cylinder foot pin 2 or 4 points 16 Outrigger cylinder rod end 2 or 4 points 17 Outrigger leg pivot 2 or 4 points 18 Outrigger foot pivot 2 or 4 points 19 Propshaft 3 points 15 16 17 18 19 19 19 ...

Page 277: ...CE SERVICE PROCEDURE 277 20 Boom adjust cylinder foot pin 1 point 21 Boom adjust cylinder rod end 1 point 22 Axle pivot 2 point with outriggers attached 23 Axle pivot 2 point without outriggers 20 21 22 22 23 23 ...

Page 278: ...ry 2 points 27 Cylinder mount 2 points 28 Top link blade pivot pin 2 points 29 Lower link blade pivot 2 points 30 Dozer blade cylinder rod end 2 points 31 Lower link pivot pin 2 points 32 Top link pivot pin 2 points 33 Cylinder guard pin remove and apply coating of grease 24 24 25 25 26 32 31 27 28 30 29 27 28 32 31 30 29 33 ...

Page 279: ...ere is oil on the filter or if the filter is extremely dirty wash it in a neutral agent After rinsing it in water dry it thoroughly before using it again If the clogging of the filter cannot be removed by blowing with air or washing in water replace the filter with a new part 4 After cleaning insert the filter in filter case 3 again open the cover at the bottom left of the operator s cab by hand r...

Page 280: ... and wipe the oil from the dipstick with a cloth 2 Insert dipstick G fully in the guide 3 When dipstick G is pulled out if the oil level is between the H and L marks of the gauge oil level is correct 4 If the oil does not reach the L mark on dipstick G remove oil filler F and add engine oil 5 If the oil level exceeds the H mark on the dipstick loosen drain plug P to drain the excess oil 6 After ch...

Page 281: ...ATURE 234 CHECK OIL LEVEL IN WHEEL HUBS ADD OIL Rear Axle Prepare a hexagonal wrench 1 Rotate hub until the oil level line marked rear is horizontal 2 2 Remove plug 1 3 If no oil emerges add oil until there is an excess Allow excess to drain off and re install plug 1 For details of the oil to use see USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER ATURE 234 CHECK OIL LEVEL IN AXLES ADD...

Page 282: ...EMPER ATURE 234 CHECK LEVEL OF BATTERY ELECTROLYTE WARNING To avoid gas explosions do not bring fire or sparks near the battery Battery electrolyte is dangerous If it gets in your eyes or on your skin wash it off with large amounts of water and consult a doctor Carry out this check before operating the machine 1 Open the battery box door on the front right hand side of the machine 2 Remove cap 1 a...

Page 283: ... 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...

Page 284: ...e new belt REMARK The belt tensioner is spring loaded and must be pivoted away from the belt Pivoting in the wrong direction can result in damage to the belt tensioner CHECK ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT Checking Press the belt at a point midway between the drive pulley and compressor pulley with a finger force of approx 58 8 N 6 kgf and check that the deflection is 5 8 mm Adju...

Page 285: ...cket 4 4 Loosen bolt 6 to remove from bracket 4 5 Tighten nut 6 Check for damage to the pulleys and wear of the V groove and V belt Be particularly careful to check that the V belt is not in contact with the bottom of the V groove 7 If the belt has elongated and there is no more allowance for adjustment or if the belt is cut or cracked replace the belt 8 After replacing the V belt operate for one ...

Page 286: ...rated Wait for engine to cool down before replacing the filter Keep naked flames sparks away from fuel When cranking the engine ensure all safety procedures have been followed as the engine may start LUBRICATE SWING CIRCLE 2 POINTS 1 Lower the work equipment to the ground 2 Use a grease gun to pump grease in through the grease fit tings shown by the arrows 3 After greasing wipe off all the old gre...

Page 287: ... contact with the seal surface of the filter holder tighten it a further 1 2 turns 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 leak from the packing so tighten it carefully 5 After replacing the fuel filter cartridge bleed the air from the system Bleed the air as follows 6 Fill the fu...

Page 288: ...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 10 5 litres 3 Insert a rule into the grease and check that the depth of the grease is at least 25 mm Add more grease if necessary 4 Replace cover A with bolts 1 2 bolts A 1 ...

Page 289: ...hen install the plug tightly 3 Remove centre partition then use a filter wrench to turn filter cartridge 1 counter clockwise to remove it 4 Clean the filter holder fill the new filter cartridge with clean engine oil coat the packing surface and thread of the filter cartridge with engine oil or coat it thinly with grease then install the filter cartridge to the filter holder 5 Drain breather bottle...

Page 290: ... marks on dipstick G For details see CHECK OIL LEVEL IN ENGINE OIL PAN ADD OIL 270 9 Install the undercover CLEAN AND INSPECT RADIATOR FINS OIL COOLER FINS AND CONDENSER FINS WARNING If compressed air high pressure water or steam hit your body directly or they cause dirt or dust to be blown up there is a danger of serious injury Use safety glasses dust mask or other protective equipment NOTICE Whe...

Page 291: ... dispose of the dirt dust dry leaves etc which have fallen on it CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM WARNING If compressed air high pressure water or steam hit your body directly or they cause dirt or dust to be blown up there is danger of serious injury Use safety glasses dust mask or other protective equipment NOTICE The interval for cleaning the filter is 500 hours...

Page 292: ...on the inside of the operator s cab then take out the recirculated air filter 2 Clean the filter with compressed air If there is oil on the filter or if the filter is extremely dirty wash and dry it thoroughly before using it again If the clogging of the filter cannot be removed by blowing with air or washing with water replace with new one ...

Page 293: ...n it slowly to release the internal pressure then remove it carefully 1 Remove the cap of oil filter F 2 Replace element 1 inside the cap with a new one For component part numbers see WEAR PARTS LIST 233 CHECK CONDITION OF MAIN VALVE RUBBER MOUNTS If main valve bracket mounting rubbers 1 appear cracked or worn replace them If unsure then contact your komatsu distributor for advice F F 1 ...

Page 294: ...e the cap from oil filler F and release the internal pressure 3 Loosen 6 bolts then remove cover 1 When doing this the cover may fly out under the force of spring 2 so hold the cover down when removing the bolts 4 After removing spring 2 valve 3 and strainer 4 take out element 5 Inspect the bottom of the filter case for dirt and remove it if any Be very careful not to let dirt fall into the hydrau...

Page 295: ...ed the drain hose from the drain valve into the container 3 Loosen drain valve P and drain the oil Then tighten the drain valve again 4 Remove the cap from oil filler F and add the specified amount of engine oil through oil filler F 5 Pull out dipstick G and wipe the off oil from it with a clean cloth 6 Insert dipstick G into the gauge pipe as far as it will go and then pull out it again 7 If the ...

Page 296: ... 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 REMARK The fan hub should spin freely without excessive end play Check the fan hub bearing Replace bearing if damaged CHECK FAN BELT TENSION AND REPLACE FAN BELT Special tools are required for inspection and repl...

Page 297: ... 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 REMARK The oil must be replaced after first hundred hours then main tenance is thousand hours Rear Axle 1 Remove plugs 1 and 2 to drain oil 2 Replace plug 2 2 1 1 A A 2 ...

Page 298: ...off and re install plug 1 6 If no oil emerges add oil until there is an excess Allow excess to drain off and re install plug 1 REMARK The oil must be replaced after first hundred hours then main tenance is thousand hours 2 Rear Axle 1 Position hub with plug 2 at bottom and remove plug 1 and 2 2 When all oil has drained out re install plug 2 3 Rotate hub until the oil level line marked Rear is hori...

Page 299: ...N ASSEMBLY TRANSMISSION 1 Remove plugs 1 2 and allow oil to drain out 2 Replace plug 2 3 Add oil approx 4 85 l until oil emerges from plug 1 hole 4 Replace plug 1 REMARK The oil must be replaced after first hundred hours then main tenance is thousand hours 1 2 ...

Page 300: ...lts 3 Pull up the top of rod 3 and remove spring 2 and strainer 4 4 Remove the dirt stuck to strainer 4 then wash it in clean die sel oil or flushing oil 5 If strainer 4 is damaged replace it with a new one 6 Refit strainer 4 by inserting it into the tank projecting part 5 7 Assemble it so that the protruding part at the bottom of cover 1 holds spring 2 then tighten the cover with the bolts CLEAN ...

Page 301: ...omatsu distributor for service EVERY 4000 HOURS SERVICE Maintenance for every 100 250 500 1000 and 2000 hours should be carried out at the same time CHECK WATER PUMP Since the pulley may have play oil may leak water may leak and the drain hole A may be clogged contact your Komatsu distribu tor for inspection overhaul or replacement 9JH02451A ...

Page 302: ...he arm and bucket cylinders to the stroke end then lower the boom and put the bucket teeth in contact with the ground 2 Lock the safety lock lever and stop the engine 3 After the tank has cooled remove the cap from oil filler F on the hydraulic tank 4 Set an empty oil container under the drain plug under the machine Remove drain plug P and drain the oil Check the O ring installed on plug P If it i...

Page 303: ...engine according to STARTING ENGINE 162 keep running the engine at low idling for 10 minutes and carry out the following procedure 3 Bleeding air from cylinders 1 Run the engine at low idling for 5 minutes after engine start Extend and retract each cylinder 4 5 times without operating it to the end of its stroke Stop approx 100 mm before the end of the stroke 2 Next alter engine speed to Max and o...

Page 304: ...SERVICE PROCEDURE MAINTENANCE 304 ...

Page 305: ...305 SPECIFICATIONS ...

Page 306: ...capacity standard bucket SAE 0 8 m Travel speed Creep speed 2 5 km h Low speed 10 km h High speed Non German specifi cation 35 km h German specification 20 km h Swing speed 11 5 rpm ENGINE Model Komatsu SAA4D102E 2 diesel engine Flywheel horsepower NET 87 5 kW 119 PS 2200 rpm Starting motor 24 V 4 5 kW Alternator 24 V 45 A Battery 12 V 95 AH x 2 STD 12 V 120AH x 2 OPTION ...

Page 307: ...SPECIFICATIONS SPECIFICATIONS 307 1 PIECE BOOM ...

Page 308: ...SPECIFICATIONS SPECIFICATIONS 308 2 PIECE BOOM ...

Page 309: ...M Arm length mm 2100 2500 3000 A Max digging height 8 730 8 930 9 285 B Max dumping height 6 335 6 555 6 911 C Max digging depth 4 925 5 320 5 600 D Min swing radius 3 205 3 160 3 180 E Max digging reach GL 8 620 8 885 9 315 E Max digging reach 8 640 9 070 9 485 ...

Page 310: ... Arm length mm 2100 2500 3000 A Max digging height 9 745 10 118 10 575 B Max dumping height 7 285 7 655 8 117 C Max digging depth 4 960 5 465 5 770 D Min swing radius 2 215 2 385 2 590 E Max digging reach GL 8 310 8 745 9 225 E Max digging reach 8 505 8 930 9 410 ...

Page 311: ...ECIFICATIONS 311 WORKING RANGE ROTATING ARM Arm length mm A Max digging height 10 170 B Max dumping height 7 695 C Max digging depth 5 525 D Min swing radius 2 345 E Max digging reach GL 8 825 E Max digging reach 9 005 ...

Page 312: ...SPECIFICATIONS SPECIFICATIONS 312 ...

Page 313: ...313 OPTIONS ATTACHMENTS WARNING Please read and make sure that you understand the safety volume before reading this section ...

Page 314: ... 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 315: ...his sec tion as a refresher every time attachments change WARNING Long work equipment reduces the stability of the chassis so if the swing is operated on a slope or when going down a steep hill the machine may lose its balance and overturn The following operations are particularly dangerous so never operate the machine in these ways Going downhill with the work equipment raised Traveling across sl...

Page 316: ...opping 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 arm If the correct procedure is not followed this may lead to serious damage or injury so please con sult your Komatsu distributor before carrying out instal lation If long wo...

Page 317: ... 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 318: ...NES READY FOR ATTACHMENTS GENERAL LOCATIONS Clamshell Operation Selector valves to be in position shown for clamshell operation Selector valve in normal position to bucket cylinder Selector valve turned to clamshell operation Both valves must be in same position ...

Page 319: ... set this valve to the LOCK position 2 SELECTOR VALVE 2 This switches the flow of the hydraulic oil Position 1 When clamshell is used Position 2 When normal operation to bucket cylinder 3 CONTROL PEDAL 20 This is used to operate the attachment Pedal for two line attachment with auto deceleration mechanism The breaker is operated by right control lever button 2 and 31 The breaker is operated with r...

Page 320: ...S 148 This is installed to release any remaining pressure in the attach ment circuit after the engine is stopped Normally do not touch it HANDLING THE CLAMSHELL BUCKET This bucket is used for digging and loading in side ditches or confined spaces How to install clamshell bucket 1 Clamshell cylinder head feed 2 Clamshell cylinder bottom return 3 Rotate left 4 Rotate right Ensure valves A are open o...

Page 321: ... travelling swing and stopping When mounting a clamshell bucket the bucket cylinder must be positioned at mid stroke to allow access to quick release couplers Connect couplers and retract bucket cylinder REMARK Isolate cylinder using lock valve and secure bucket links Do not swing the bucket to crush the rock or to cut through soil Do not use the bucket for hammering or pulling out piles etc Befor...

Page 322: ...nges to screen B so if it is neces sary to make fine adjustment press up switch 3 or down switch 4 to move the bar graph showing the oil flow up or down then press input confirmation switch 2 It is possible to change the oil flow in segments of approx 10 litres min If fine adjustment is not necessary simply press input confir mation switch 2 The default setting is 140 litres min Even if the starti...

Page 323: ... on the monitor is pressed the screen changes to screen C so press up switch 3 or down switch 4 to move the bar graph showing the oil flow up or down then press input confirmation switch 2 The default setting is the full flow approx 320 litres min Even if the starting switch is turned OFF the set oil flow when the engine is next started will be the value set by the above procedure Precautions when...

Page 324: ...d in the heavy duty operation mode there is danger that the hydraulic equipment may be damaged Precautions when using Check that the stopper valve is in the OPEN position Consult with the attachment maker to decide whether it is necessary to install an accumulator for the attachment circuit For details of other precautions when handling the breaker read and use correctly the instruction manual pro...

Page 325: ...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 valve Set the selector valve to the position...

Page 326: ...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 327: ... 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 328: ...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 329: ... 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 330: ...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 331: ...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 332: ... 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 of the following ways Do not operate the cy...

Page 333: ...ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE 333 Operations using the swing force Operations using one side of work equipment Catching and dragging with claw end Gouging AM092360A ...

Page 334: ...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 335: ...chuck unit This facilitates operations such as driving and movable by 360 corners vertical driving and 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 str...

Page 336: ...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 337: ...OPTIONS ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE 337 Operating other work equipment during crane operation Excessive lengthening of wire rope ...

Page 338: ...CHMENTS 338 GENERAL VIEW OF CONTROLS 1 2 3 4 5 6 8 7 9 10 11 1 Clamshell rotate right 7 Power max button 2 Boom and chassis attachment select 8 HCU pedal option 3 Right control lever 9 Spare 4 Safety lock lever 10 Boom pedal 5 Left control lever 11 Clamshell rotate left 6 Horn ...

Page 339: ...ange the engine speed will suddenly increase so be careful when operating the levers This lever is used to operate the boom and bucket When the right control lever in this position the boom and the bucket will be retained in the position in which they stop For levers 3 and 5 the engine speed changes as follows because of the auto deceleration mechanism When the right control levers are at neutral ...

Page 340: ...ively 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 suitable for excavating at a position higher than the machine LOADING WORK About half of the time spent during excavating and loading work is taken up by swinging Maximum work efficiency can be attained by carrying out work is such a way...

Page 341: ...ARY DIGGING The excavation of trenches for main and branch 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 excavato...

Page 342: ...in extract pins A and B After removing the pins make sure that they do not become contaminated with sand or mud and that the seals of bushing on both sides do not become damaged CAUTION Bucket size bucket weight 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 Coupl...

Page 343: ...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 344: ...ACHMENTS 344 Shape of ditch 38 bucket How to perform excavation Operate the boom the arm and the bucket to make the line A of the side plate of the bucket vertical To check this position guide plate B is installed beside the bucket pins Hold this plate horizontal when digging ...

Page 345: ... 345 ROTATING ARM GENERAL LOCATION AND SPECIFICATIONS 1 2 3 4 5 6 7 8 9 10 1 Bucket 6 Boom lift cylinders 2 Bucket cylinder 7 Lower boom 3 Rotating arm 8 Boom adjusting cylinder 4 Arm cylinder 9 Rear wheel 5 Upper boom 10 Front wheel ...

Page 346: ...g weight without operator 16 400 kg PERFORMANCE Bucket capacity standard bucket SAE 0 8 m3 Travel speed Creep speed 1 5 km h Low speed 10 km h High speed Non German specification 35 km h German specification 20 km h Swing speed 11 5 RPM Arm rotation speed 7 8 RPM Engine Komatsu SAA4D102E 2 diesel engine Flywheel horsepower 87 5 KW 119 PS 2200 RPM ...

Page 347: ...so be careful when operating the levers This lever is used to operate the arm and upper structure When the lever in this position the upper structure and the arm will be retained in the position in which they stop 5 4 3 1 2 6 1 Safety lock lever 4 Rotate left 2 Left control lever 5 Rotate right 3 Right control lever 6 Two piece boom pedal Arm operation Swing operation A Arm OUT C Swing to right B ...

Page 348: ... if the fuel control dial is above the mid range position the engine speed will drop to a mid range speed If any of the levers are operated the engine speed will rise to the speed set by the fuel control dial If all control levers are set to neutral the engine speed will drop by approx 100 rpm and after approx 4 seconds the engine speed will drop to the deceleration speed approx 1400 rpm ARM ROTAT...

Page 349: ...g the machine or when carrying out maintenance always lock the boom adjust and arm rotation pedal 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 REPLACEMENT OF BUCKET 342 2 Position the upper st...

Page 350: ...vers by disengaging ppc lock switch 10 Screw in the lock pin on the Boom Adjust and Arm Rotate pedals 11 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 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 eq...

Page 351: ... this point refill with SAE 90 gear oil through plug hole EVERY 1000 HOURS SERVICE 353 Tightening torque 56 kgm The type of lubricant used depends on the ambient tempera ture Select according to the table USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA TURE 234 NO ITEM SERVICE PAGE EVERY 100 HOURS SERVICE 1 Arm rotation machinery case Check and supply 351 EVERY 250 HOURS SERVICE 2 Arm...

Page 352: ...ROTATING ARM OPTIONS ATTACHMENTS 352 EVERY 250 HOURS SERVICE 1 ARM ROTATING CIRCLE LUBRICATING Apply grease to the grease fittings shown by the arrows 3 points ...

Page 353: ...ff 4 Refill the greasebath with grease 5 Replace the swing motor an and tighten the 14 bolts Apply liquid gasket LG 6 to the mating faces and bolt holes 6 Reconnect the hoses 2 5 and 6 to the swing motor EVERY 1000 HOURS SERVICE Maintenance for every 250 and 500 hours service should be carried out at the same time 3 ARM ROTATION MACHINERY CASE 1 Remove plug 1 drain the oil 2 Add 1 6 liters of SAE ...

Page 354: ...ROTATING ARM OPTIONS ATTACHMENTS 354 ...

Page 355: ...ERVICE 274 EVERY 1000 HOURS SERVICE 294 EVERY 2000 HOURS SERVICE 300 EVERY 250 HOURS MAINTENANCE 280 EVERY 4000 HOURS SERVICE 301 EVERY 50 HOURS 274 EVERY 500 HOURS SERVICE 286 EVERY 5000 HOURS SERVICE 302 EXPLANATION OF COMPONENTS 76 F FEATURES 10 FILTERS 230 FIRE EXTINGUISHER 25 FIRE PREVENTION 24 FIRST AID KIT 25 FOREWORD 3 4 FRONT WINDOW 121 FUEL 228 FUEL GAUGE 91 FUSE 128 FUSIBLE LINK 144 G G...

Page 356: ... LOCK LEVER 117 SAFETY MESSAGES 5 SAFETY RULES 22 SEAT BELT 158 SPECIFICATIONS 306 STARTING ENGINE 162 STARTING IN COLD WEATHER 163 STARTING SWITCH 109 STEERING 174 STOPPING PARKING 176 STOPPING MACHINE EMERGENCY 177 STORING OIL AND FUEL 230 SWITCHES 108 T TIGHTENING TORQUE LIST 239 TIGHTENING TORQUE SPECIFICATIONS 239 TOWING 39 TRANSPORTATION 197 TRAVELLING ON PUBLIC HIGHWAY 175 TROUBLESHOOTING 2...

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Komatsu PW160-7K Series, Operation And Maintenance Manual

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