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1-1
FOREWORD
If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details regarding the machine serial No. you will need to provide your Komatsu distributor, see "YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR (PAGE 1-8)". This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in ( ). The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of its publication. Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual. The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example:1 (1)) Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
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FOREWORD
SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the precautions and warnings included in this manual and the safety signs attached to the machine must always be followed. To identify important safety messages in the manual and on the machine labels, the following signal words are used. The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message. This signal word indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. This signal word indicates a potentially hazardous situation exists which, if not avoided, may result in minor or moderate injury. The following signal words are used to alert you to information that must be followed to avoid damage to the machine. This precaution is given where the machine may be damaged or the service life reduced if the precaution is not followed. This word is used for information that is useful to know.
1-3
. INTRODUCTION
FOREWORD
INTRODUCTION
USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work: Digging work Leveling work Ditching work Loading work Demolition work See the section "RECOMMENDED APPLICATIONS (PAGE 3-166)" for further details.
DIRECTIONS OF MACHINE
(E) (F)
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when the operator's seat is facing the front and the sprocket is at the rear of the machine.
1-4
FOREWORD
INTRODUCTION
PROXIMITY VISIBILITY
The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown in the diagram below. The hatched area (A) shows the area where the view is blocked by part of the machine when mirrors or other aids to visibility are installed as standard. Please be fully aware that there are places that cannot be seen when operating the machine.
1-5
. INTRODUCTION
FOREWORD
1-6
FOREWORD
PRODUCT INFORMATION
PRODUCT INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items.
1-7
. PRODUCT INFORMATION
FOREWORD
1-8
FOREWORD
CONTENTS
CONTENTS
FOREWORD BEFORE READING THIS MANUAL SAFETY INFORMATION INTRODUCTION USE OF MACHINE DIRECTIONS OF MACHINE VISIBILITY FROM OPERATOR'S SEAT PRODUCT INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ENGINE SERIAL NUMBER PLATE AND ITS LOCATION SERVICE METER LOCATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR SAFETY SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE PRECAUTIONS BEFORE STARTING OPERATION PREPARATIONS FOR SAFE OPERATION FIRE PREVENTION PRECAUTIONS WHEN GETTING ON OR OFF MACHINE DO NOT GET CAUGHT IN WORK EQUIPMENT PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS UNAUTHORIZED MODIFICATION PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS PRECAUTIONS RELATED TO CAB GLASS PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE STARTING ENGINE OPERATION TRANSPORTATION TOWING LIFTING OBJECTS WITH BUCKET PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE PRECAUTIONS FOR INSPECTION AND MAINTENANCE OPERATION MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES MONITORING SYSTEM SWITCHES CONTROL LEVERS AND PEDALS SUN ROOF WINDSHIELD 11111111111122222222222222222222222222233333333331 2 3 4 4 4 5 7 7 7 8 8 1 2 5 6 7 13 13 13 15 16 18 18 18 19 19 19 19 20 20 22 24 32 33 34 35 35 39 1 2 2 3 5 5 70 75 78 78
1-9
. CONTENTS
FOREWORD
EMERGENCY ESCAPE HAMMER DOOR LOCK CAP WITH LOCK DRINK BOX MAGAZINE BOX ASHTRAY AIR CONDITIONER CONTROLS RADIO AUXILIARY ELECTRIC POWER FUSE FUSIBLE LINK CONTROLLER TOOL BOX GREASE PUMP HOLDER FIRE EXTINGUISHER MACHINE OPERATIONS AND CONTROLS BEFORE STARTING ENGINE STARTING ENGINE AFTER STARTING ENGINE STOPPING THE ENGINE MACHINE OPERATION STEERING THE MACHINE SWINGING WORK EQUIPMENT CONTROLS AND OPERATIONS WORKING MODE PROHIBITED OPERATIONS GENERAL OPERATION INFORMATION TRAVELING ON SLOPES ESCAPE FROM MUD RECOMMENDED APPLICATIONS BUCKET REPLACEMENT AND INVERSION PARKING MACHINE MACHINE INSPECTION AFTER DAILY WORK LOCKING TRANSPORTATION TRANSPORTATION PROCEDURE LOADING AND UNLOADING WITH TRAILER LIFTING MACHINE TRANSPORTATION POSTURE PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE COLD WEATHER OPERATION COLD WEATHER OPERATION INFORMATION AFTER DAILY WORK COMPLETION AFTER COLD WEATHER SEASON LONG TERM STORAGE BEFORE STORAGE DURING STORAGE AFTER STORAGE STARTING MACHINE AFTER LONG-TERM STORAGE TROUBLES AND ACTIONS
3- 84 3- 84 3- 85 3- 87 3- 87 3- 87 3- 88 3-101 3-106 3-107 3-108 3-108 3-109 3-109 3-109 3-110 3-110 3-130 3-133 3-144 3-145 3-149 3-151 3-152 3-154 3-156 3-161 3-163 3-165 3-166 3-168 3-172 3-173 3-174 3-175 3-175 3-176 3-185 3-187 3-189 3-191 3-191 3-193 3-193 3-194 3-194 3-194 3-195 3-195 3-196
1 - 10
FOREWORD
CONTENTS
RUNNING OUT OF FUEL PHENOMENA THAT ARE NOT FAILURES TOWING THE MACHINE LIGHTWEIGHT TOWING HOLE SEVERE JOB CONDITION DISCHARGED BATTERY OTHER TROUBLE MAINTENANCE MAINTENANCE INFORMATION OUTLINE OF SERVICE HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ELECTRIC SYSTEM MAINTENANCE WEAR PARTS WEAR PARTS LIST RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE LIST SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS LIST MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE CHART MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER MAINTENANCE PROCEDURE INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS) WHEN REQUIRED CHECK BEFORE STARTING EVERY 50 HOURS MAINTENANCE EVERY 250 HOURS MAINTENANCE EVERY 500 HOURS MAINTENANCE EVERY 1000 HOURS MAINTENANCE EVERY 2000 HOURS MAINTENANCE EVERY 4000 HOURS MAINTENANCE EVERY 5000 HOURS MAINTENANCE EVERY 8000 HOURS MAINTENANCE SPECIFICATIONS SPECIFICATIONS ATTACHMENTS AND OPTIONS GENERAL PRECAUTIONS FOR SAFETY PRECAUTIONS WHEN SELECTING READ THE INSTRUCTION MANUAL THOROUGHLY PRECAUTIONS WHEN REMOVING OR INSTALLING PRECAUTIONS WHEN USING BUCKET WITH HOOK HOOK CONDITION PROHIBITED OPERATIONS MACHINE READY FOR ATTACHMENT LOCATIONS HYDRAULIC CIRCUIT
1 - 11
. CONTENTS
FOREWORD
ATTACHMENT REMOVAL AND INSTALLATION ATTACHMENT OPERATIONS LONG TERM STORAGE SPECIFICATIONS ATTACHMENT GUIDE ATTACHMENT COMBINATIONS TRACK SHOES SELECTION RECOMMENDED ATTACHMENT OPERATIONS HYDRAULIC BREAKER HANDLING MACHINES EQUIPPED WITH KOMTRAX BASIC PRECAUTIONS INDEX
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13 17 18 18 19 19 21 22 22 26 26 1
1 - 12
2-1
. SAFETY
SAFETY
SAFETY
SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE PRECAUTIONS BEFORE STARTING OPERATION ENSURING SAFE OPERATION UNDERSTANDING THE MACHINE PREPARATIONS FOR SAFE OPERATION PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT INSPECTING MACHINE WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT KEEP MACHINE CLEAN PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT IF ANY PROBLEM IS FOUND FIRE PREVENTION ACTION IF FIRE OCCURS PRECAUTIONS TO PREVENT FIRE PRECAUTIONS WHEN GETTING ON OR OFF MACHINE USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE NO JUMPING ON OR OFF MACHINE NO PEOPLE ON ATTACHMENTS PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT PRECAUTIONS WHEN LEAVING MACHINE EMERGENCY EXIT FROM OPERATOR'S CAB DO NOT GET CAUGHT IN WORK EQUIPMENT PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS UNAUTHORIZED MODIFICATION PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS PRECAUTIONS RELATED TO CAB GLASS PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 222222222222222222222222222222225 6 7 13 13 13 13 13 13 13 13 14 14 14 14 15 15 15 16 16 17 17 17 17 17 18 18 18 19 19 19 19
2-2
SAFETY
SAFETY
PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS WORKING ON LOOSE GROUND DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES ENSURE GOOD VISIBILITY CHECKING SIGNS AND SIGNALMAN'S SIGNALS BEWARE OF ASBESTOS DUST STARTING ENGINE USE WARNING TAGS INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE PRECAUTIONS WHEN STARTING ENGINE PRECAUTIONS IN COLD AREAS STARTING WITH BOOSTER CABLES OPERATION CHECKS BEFORE OPERATION PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE AND SWINGING PRECAUTIONS WHEN TRAVELING TRAVELING ON SLOPES OPERATING ON SLOPES PROHIBITED OPERATIONS TRAVELING ON SNOW-COVERED OR FROZEN SURFACES PARKING MACHINE TRANSPORTATION LOADING AND UNLOADING TOWING PRECAUTIONS WHEN TOWING LIFTING OBJECTS WITH BUCKET PRECAUTIONS FOR LIFTING OPERATIONS
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20 20 20 20 21 21 21 22 22 22 23 23 23 24 24 24 25 26 27 28 28 30 31 32 32 33 33 34 34
2-3
. SAFETY
SAFETY
PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE KEEP WORKPLACE CLEAN AND TIDY SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE ONLY AUTHORIZED PERSONNEL APPOINT LEADER WHEN WORKING WITH OTHERS STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING INSTALLING, REMOVING, OR STORING ATTACHMENTS PRECAUTIONS WHEN WORKING AT HIGH PLACES PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT PROPER TOOLS PRECAUTIONS FOR INSPECTION AND MAINTENANCE PRECAUTIONS WHEN WELDING HANDLING BATTERY PRECAUTIONS WHEN USING HAMMER PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT PRECAUTIONS WITH HIGH-TEMPERATURE OIL PRECAUTIONS WITH HIGH-PRESSURE OIL PRECAUTIONS WITH HIGH-PRESSURE FUEL HANDLING HIGH-PRESSURE HOSES AND PIPING PRECAUTIONS FOR HIGH VOLTAGE NOISE PRECAUTIONS WITH HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION DO NOT DISASSEMBLE RECOIL SPRING HANDLING ACCUMULATOR AND GAS SPRING PRECAUTIONS WITH COMPRESSED AIR MAINTENANCE OF AIR CONDITIONER DISPOSING OF WASTE MATERIALS METHOD OF SELECTING WINDOW WASHER FLUID PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
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35 35 35 35 35 35 35 36 37 37 37 38 38 39 39 39 40 40 40 41 41 41 42 42 42 43 43 43 43 44 44 44
2-4
SAFETY
SAFETY LABELS
SAFETY LABELS
The following warning signs and safety labels are used on this machine. Be sure that you fully understand the correct position and content of labels. To ensure that the content of labels can be read properly, be sure that they are in the correct place and always keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to peel off. There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same way. If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
2-5
. SAFETY LABELS
SAFETY