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Komatsu PW130ES-6K Operation & Maintenance Manual

Hydraulic excavator
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Operation &
Maintenance Manual
PW130ES-6K
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PW130ES-6K
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personel who
will come into contact with the machine.
- K34001
and up
UEAM000902

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Summary of Contents for Komatsu PW130ES-6K

  • Page 1 Operation & UEAM000902 Maintenance Manual PW130ES-6K HYDRAULIC EXCAVATOR SERIAL NUMBER PW130ES-6K - K34001 and up WARNING Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.

  • Page 2: Foreword

    Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information for your machine or for questions regarding information in this manual.

  • Page 3: Safety Information

    Safety precautions are described in SAFETY from page 1-1. Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety message in this manual and on the machine may not include all possible safety precautions.

  • Page 4: Noise

    SAFETY INFORMATION NOISE Valid until 31 December 2001 Operator ears noise value (Sound pressure level) 95/27/EC Ambient noise value (Sound power level) Noise level indicated is the guaranteed value measured by the dynamic test method as specified in the directive 86/662/EEC, as amended by 95/27/EC.

  • Page 5: Vibration

    SAFETY INFORMATION Valid as of 1 January 2002 Sound pressure level at the operator's station, measured according to ISO6396 (Dynamic test method, simulated work- ing cycle) Sound power level emitted. This is the guaranteed value as specified in European directive 2000/14/EC. This machine complies with the requirements of RAL (German Institute for quality assurance and marking) pertaining to the award of the environmental mark (blue angel) for low noise.

  • Page 6: Emergency Steering

    SAFETY INFORMATION These results were obtained by accelerometers during trench dig- ging. EMERGENCY STEERING This machine is equipped with an emergency steering system and complies to ISO 5010. In the advent of failure of the source of power for the steering system (engine failure) whilst travelling the machine can be steered allowing the machine to be safely stopped.

  • Page 7: Introduction

    INTRODUCTION INTRODUCTION INTENDED USE This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following work: Digging Smoothing work Ditching work Loading work See the section “WORK POSSIBLE USING HYDRAULIC EXCAVATOR” on page 132 for further details Features This Komatsu HYDRAULIC EXCAVATOR is equipped with various controls based on an advanced electronics system.
  • Page 8 If the machine is used for a pur- pose that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of safety in such opera- tions is the responsibility of the user.

  • Page 9: Locations Of Plates, Table To Enter Serial No. And Distributor

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

  • Page 10: Machine Serial Plates

    LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR MACHINE SERIAL PLATES STANDARD SERIAL PLATE GERMANY SERIAL PLATE ITALIAN SERIAL PLATE...
  • Page 11 LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...

  • Page 12: Table Of Contents

    CONTENTS FOREWORD ................................1 SAFETY INFORMATION ............................2 SAFETY MESSAGES ........................... 2 NOISE ................................3 VIBRATION ..............................4 EMERGENCY STEERING ........................... 5 INTRODUCTION ..............................6 INTENDED USE ............................6 Features ................................ 6 BREAKING IN YOUR NEW MACHINE ......................6 LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ..........8 MACHINE SERIAL NO.
  • Page 13 EXPLANATION OF COMPONENTS ........................59 MACHINE MONITOR ..........................59 SWITCHES ..............................70 CONTROL LEVERS, PEDALS ........................80 ROOF HATCH ............................83 FRONT WINDOW ............................85 DOOR LOCK .............................. 88 CAP, COVER WITH LOCK ......................... 89 FUSE ................................90 LUGGAGE TRAY ............................91 ASHTRAY ..............................
  • Page 14 TRAVELLING POSTURE ......................... 149 COLD WEATHER OPERATION ........................150 PRECAUTIONS FOR LOW TEMPERATURE ..................150 PRECAUTIONS AFTER COMPLETION OF WORK ................151 AFTER COLD WEATHER ........................152 LONG-TERM STORAGE ............................ 153 BEFORE STORAGE ..........................153 DURING STORAGE ..........................153 AFTER STORAGE ............................ 154 STARTING MACHINE AFTER LONG-TERM STORAGE ................
  • Page 15 EVERY 50 HOURS ........................... 204 EVERY 100 HOURS SERVICE ........................ 204 EVERY 250 HOURS SERVICE ........................ 209 EVERY 500 HOURS SERVICE ........................ 215 EVERY 1000 HOURS SERVICE ......................221 EVERY 2000 HOURS SERVICE ......................225 EVERY 4000 HOURS SERVICE ......................228 EVERY 5000 HOURS SERVICE ......................

  • Page 16: Safety

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

  • Page 17: General Precautions

    Check also that there is no one near the machine. Driving in pins, see “REPLACEMENT AND INVERSION OF BUCKET” on page 133. Cleaning of air cleaner element, see “WHEN REQUIRED” on page 188. in service procedure. UNAUTHORISED MODIFICATION Any modification made without authorisation from Komatsu can create hazards.
  • Page 18 WARNING: Failure to follow these safety precautions may lead to a serious accident. Before making a modification, consult your Komatsu distribu- tor. Komatsu will not be responsible for any injury or damage caused by any unauthorised modification. ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT When standing up from the operator’s seat, always raise the...
  • Page 19 GENERAL PRECAUTIONS SAFETY WARNING: For reasons of safety, always follow these safety precautions. Tighten all fuel and oil caps securely. Refuelling and oiling should be carried out in well ventilated areas. Keep oil and fuel in a secure place and do not allow unautho- rised persons to enter.
  • Page 20 ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled. Your Komatsu machine and genuine Komatsu spare parts do not contain any asbestos. Use only genuine Komatsu spare parts. If spare parts containing asbestos are used, the following precau- tions must be observed: NEVER use compressed air for cleaning.
  • Page 21 By all means you should put on other guards if required by conditions at your particular site. For details of safety guards, please contact your Komatsu distrib- 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...
  • Page 22 When the machine is operated on or beside a road, a rotating beacon is required to avoid a traffic accident. Contact your Komatsu distributor to install beacon lamp. ELECTROMAGNETIC INTERFERENCE When this machine is operating close to a source of high electro- magnetic interference, such as a radar station, some abnormal phenomena may be observed.

  • Page 23: Precaution During Operation

    PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. PRECAUTION DURING OPERATION BEFORE STARTING ENGINE SAFETY AT WORKSITE Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous. Before starting the engine, examine the terrain and soil condi- tions of the worksite.

  • Page 24: Operating Machine

    SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. VENTILATION FOR ENCLOSED AREAS If it is necessary to start the engine within an enclosed area, pro- vide adequate ventilation. Exhaust fumes from the engine can KILL.
  • Page 25 PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. CHECK THAT NO ONE IS IN THE AREA BEFORE SWINGING OR TRAVELLING IN REVERSE Always position a signalman when operating in dangerous places or places where the view is not clear. Make sure that no one comes inside the swing radius or direction of travel.
  • Page 26 SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. TRAVELLING ON SLOPES Downhill Travelling on hills, banks or slopes that are steep could result in the machine tipping over or slipping. On hills, banks or slopes, carry the bucket closer to the ground, approximately 20 to 30 cm above the ground.
  • Page 27 PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Going close to high-voltage cables can cause electric shock. Always maintain the safe distance given below between the machine and the electric cable. The following actions are effective in preventing accidents.
  • Page 28 SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. 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.

  • Page 29: Transportation

    PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. 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- CORRECT...

  • Page 30: Battery

    SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. Be sure that the ramps are securely positioned and fastened, and that the two sides are at the same level as one another. Be sure the ramp surface is clean and free of grease, oil, ice and loose materials.

  • Page 31: Towing

    PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. When removing or installing, check which is the positive (+) terminal and negative (-) terminal. Tighten the battery cap securely. Tighten the battery terminals securely. Loosened terminals can generate sparks and lead to an explosion.
  • Page 32 SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. Set the towing machine and the towing connection of the equipment being towed in a straight line when connecting it. Place pieces of wood between the wire ropes and body to protect them from wear of damage.

  • Page 33: Bucket With Hook Or Bucket Link

    PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. BUCKET WITH HOOK OR BUCKET LINK GENERAL PRECAUTIONS SPECIAL HOOK When carrying out lifting work, the special lifting hook is or lift- ing eye is necessary. The following operations are prohibited.
  • Page 34 SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. OPERATION SUPERVISOR Before performing lifting operation, designate an operation supervisor. Always execute operation according to his instructions. Execute operating methods and procedures under his ❍...
  • Page 35 PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. Swing speed is three to four times that of movable cranes. Therefore, be especially careful when performing swing oper- ation. NEVER LEAVE THE OPERATOR’S SEAT Never leave the operator’s seat while lifting a load. NEVER CARRY OUT EXCESSIVE OPERATIONS INCORRECT Operation exceeding machine performance may result in...

  • Page 36: Precautions For Maintenance

    Attach additional warning tags around the machine, if necessary. These tags are available from your Komatsu distributor. (Part no. 20E-00-K1340) PROPER TOOLS Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause personal injury.
  • Page 37 PRECAUTIONS FOR MAINTENANCE SAFETY WARNING: For reasons of safety, always follow these safety precautions. STOP THE ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Always stop the machine on firm flat ground and stop the engine before carrying out inspection and maintenance. If it is necessary to run the engine when carrying out mainte- nance, such as when cleaning the inside of the radiator, Raise the tilting arm rest to the LOCK position and carry out...
  • Page 38 SAFETY PRECAUTIONS FOR MAINTENANCE WARNING: Failure to follow these safety precautions may lead to a serious accident. Always tighten the cap of the fuel and oil fillers securely. Never use fuel for washing any parts. Always add fuel and oil in a well-ventilated place. RADIATOR WATER LEVEL If it is necessary to add water to the radiator, stop the engine and allow the engine and radiator to cool down before adding...

  • Page 39: During Maintenance

    PRECAUTIONS FOR MAINTENANCE SAFETY WARNING: For reasons of safety, always follow these safety precautions. 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 40 SAFETY PRECAUTIONS FOR MAINTENANCE WARNING: Failure to follow these safety precautions may lead to a serious accident. If water gets into the electrical system, there is danger that the machine may not move or may move unexpectedly. Do not use water or steam to clean the sensors, connectors, or the inside of the operator’s compartment.
  • Page 41 SAFETY PRECAUTIONS FOR MAINTENANCE WARNING: Failure to follow these safety precautions may lead to a serious accident. drained, or the filters are replaced, this may result in burns or other injury. Wait for the temperature to go down, then carry out the inspection and maintenance in accordance with the procedures given in this manual.

  • Page 42: Position For Attaching Safety Labels

    There are other labels in addition to the safety labels listed as fol- lows, so handle them in the same way. Safety labels are available from your Komatsu distributor. POSITION FOR ATTACHING SAFETY LABELS...
  • Page 43 Follow instructions and warnings in the manuals 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 apply lock when leaving operators seat. Normal steering can only be operated when the engine is run- ning.
  • Page 44 SAFETY POSITION FOR ATTACHING SAFETY LABELS WARNING: Failure to follow these safety precautions may lead to a serious accident. 3. Amber reflector (20G-46-K1680) 4. Warning for unsafe machine (20E-00-K1340) Do not start 5. Warning for accumulator (20E-00-K1210) Warnings for handling accumulator. Explosion hazard Keep away from flame.
  • Page 45 POSITION FOR ATTACHING SAFETY LABELS SAFETY WARNING: For reasons of safety, always follow these safety precautions. 7. Warning for hot objects (20E-00-K1190) Warning for high temperature coolant and oil, hot water and oil hazard. To prevent hot water and oil from spurting out: Turn engine off.
  • Page 46 SAFETY POSITION FOR ATTACHING SAFETY LABELS WARNING: Failure to follow these safety precautions may lead to a serious accident. 10. Warnings for staying clear (20G-00-K2350) R.H. (20G-00-K2360) L.H. 11. Falling from upper structure warning (20E-00-K1110) WARNING falling from upper structure. Keep away from sides of machine.
  • Page 47 POSITION FOR ATTACHING SAFETY LABELS SAFETY 13. Front windows lock back warning (20E-00-K1230) Always apply lock when leaving operator’s seat. 14. High pressure oil warning (20E-00-K1270) 15. 20E-00-K1280 Pump control override switch and swing lock override switch. Read operation manual before operation. 16.
  • Page 48 SAFETY POSITION FOR ATTACHING SAFETY LABELS 18. Travel Height -UK spec only (20E-00-K1720) 19. Operation of attachments (20G-00-K2273) ONE PIECE BOOM Arm length 2,10 m When removing bucket, 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 (462 kg),...
  • Page 49 POSITION FOR ATTACHING SAFETY LABELS SAFETY 7,5 m 6,0 m 4,5 m 3,0 m 1,5 m 7.5 m * 2800 * 2800 6.0 m * 2300 * 2300 * 3450 * 3450 4.5 m * 2150 * 2150 * 3550 2950 * 3800 * 3800...
  • Page 50 SAFETY POSITION FOR ATTACHING SAFETY LABELS - Rating at maximum reach 7,5 m 6,0 m 4,5 m 3,0 m 1,5 m 7.5 m * 2200 * 2200 * 2500 * 2500 6.0 m * 1850 * 1850 * 2000 1950 4.5 m * 1750 1500...
  • Page 51 POSITION FOR ATTACHING SAFETY LABELS SAFETY TWO PIECE BOOM Arm length 2,10 m When removing bucket, 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 (462 kg), linkage (84 kg) and bucket cylinder (92 kg) OF: Lifting capacity (rating overfront) OS: Lifting capacity (Rating overside)
  • Page 52 SAFETY POSITION FOR ATTACHING SAFETY LABELS 7,5 m 6,0 m 4,5 m 3,0 m 1,5 m 7.5 m * 2700 * 2700 * 3450 2750 6.0 m * 2200 * 2200 3050 1600 * 3800 2700 4.5 m * 2050 * 2050 3000 1550...
  • Page 53 POSITION FOR ATTACHING SAFETY LABELS SAFETY 7,5 m 6,0 m 4,5 m 3,0 m 1,5 m 7.5 m * 2100 * 2100 6.0 m * 1800 * 1800 * 2900 * 2900 4.5 m * 1650 * 1650 * 3000 3000 * 3200 * 3200...
  • Page 54 SAFETY POSITION FOR ATTACHING SAFETY LABELS ROTATING ARM 7.5 m 6.0 m 4.5 m 3.0 m 7.5 m *1950 * 1950 6.0 m * 1600 * 1600 * 2600 * 2600 4.5 m * 1500 * 1500 * 2650 * 2650 * 2850 * 2850 3.0 m...
  • Page 55 POSITION FOR ATTACHING SAFETY LABELS SAFETY OVERLOAD CAUTION This machine is equipped with an overload caution system which gives a visual warning (on monitor) and an audible warning when lifting a load close to the to the lift capacity of the machine (active in L.o.

  • Page 56: Operation

    OPERATION...

  • Page 57: General View

    GENERAL VIEW OPERATION GENERAL VIEW GENERAL VIEW OF MACHINE If directions are indicated in this section, they refer to the direc- tions shown by in the arrows in the diagram below. A: FRONT B: REAR C: RIGHT D: LEFT 1. Bucket 5.

  • Page 58: General View Of Controls And Gauges

    OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES 1. Control lever pad safety lock 15. Swing lock switch 2. Horn 16. Control lever lock switch 3. Left work equipment control 17. Lamp switch 4. Power max. Button 18. Alarm buzzer stop switch 5.
  • Page 59 GENERAL VIEW OPERATION AD32421D 1. Display (for clock and fault indication 11. Service meter 2. Engine water temperature gauge 12. Fuel gauge 3. Engine water temperature monitor 13. Fuel level monitor 4. Radiator water level monitor 14. Engine oil level monitor 5.

  • Page 60: Explanation Of Components

    OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operat- ing the machine. To carry out suitable operations correctly and safely, it is impor- tant to understand fully the methods of operating the equipment and the meanings of the displays.
  • Page 61 EXPLANATION OF COMPONENTS OPERATION B. CAUTION ITEMS CAUTION If these monitor items flash, check and repair the appropriate location as soon as possible. These are items which need to be observed while the engine is running. If any abnormality occurs, items which need to be repaired as soon as possible are displayed.
  • Page 62 OPERATION EXPLANATION OF COMPONENTS A: BASIC CHECK ITEMS AD324230 NOTICE Do not rely on the “BASIC CHECK ITEMS” only for the check before starting Always refer to the periodic maintenance items or "OPERA- TION" to carry out the checks. 1. RADIATOR WATER LEVEL This warns that the radiator cooling water level is too low.
  • Page 63 EXPLANATION OF COMPONENTS OPERATION B: CAUTION ITEMS CAUTION If the caution monitor lamp flashes, repair the problem as soon as possible. 1. CHARGE LEVEL This monitor indicates an abnormality in the charging system while the engine is running. If the monitor lamp flashes, check the V-belt tension.
  • Page 64 OPERATION EXPLANATION OF COMPONENTS C: EMERGENCY STOP ITEMS If any monitor lamp flashes, stop the engine or run it at low idling, and take the following action. 1. ENGINE WATER TEMPERATURE If the temperature of the engine cooling water becomes abnor- mally high, the monitor lamp flashes, and the overheat prevention system is automatically actuated to reduce the engine speed.
  • Page 65 EXPLANATION OF COMPONENTS OPERATION D: METER DISPLAY PORTION AD324240A PILOT DISPLAY When the starting switch is ON, the pilot display lights up when the display items are functioning. 1. ENGINE PRE-HEATING MONITOR This monitor lamp indicates the pre-heating time required when starting the engine at an ambient temperature below 0°C.
  • Page 66 OPERATION EXPLANATION OF COMPONENTS REMARK A disc brake is installed in the swing motor to mechanically stop motor rotation. The brake is always applied while the swing lock is actuated. METERS 3. ENGINE WATER TEMPERATURE GAUGE This gauge indicates the engine cooling water temperature. If the temperature is normal during operation, the green range (A) will light up.
  • Page 67 EXPLANATION OF COMPONENTS OPERATION 5. DISPLAY This normally displays the clock time. If there is any abnormality, the type of failure is indicated when the starting switch is turned Manual setting 1. When the time is displayed, depress clock switch (1) for 2.5 sec.
  • Page 68 OPERATION EXPLANATION OF COMPONENTS 6. SERVICE METER This displays the accumulated hours of operation of the machine. Use the display to determine the intervals for periodic mainte- nance. The service meter will advance while the engine is running even if the machine is not moving.
  • Page 69 EXPLANATION OF COMPONENTS OPERATION When starting the engine, G.O. (general operation) mode is auto- matically selected. Each time the switch is pressed, the mode selection changes. NOTICE When the breaker is used, never select the H.O. (heavy- duty operation) mode. REMARK H switch is also used for setting “hours”...
  • Page 70 OPERATION EXPLANATION OF COMPONENTS 4. POWER MAX./SWIFT SLOW-DOWN SWITCH During operations, the digging power can be increased and the speed reduced by a one-touch operation of the knob button /sin- gle click while pushing). Power max. (power up) lights up: When the working mode is heavy-duty and general operation mode only, the power can be increased while the knob button is being pressed.

  • Page 71: Switches

    EXPLANATION OF COMPONENTS OPERATION SWITCHES 1. STARTING SWITCH This switch is used to start or stop the engine. HEAT OFF OFF position The key can be inserted or withdrawn. Except for the cab lamp, radio (if fitted) and clock, the switches for the electric system are all turned off and the engine is stopped.
  • Page 72 Pull out the lighter and light your cigarette. Nothing may be connected to the cigarette lighter without the prior permission of an authorized Komatsu distributor. 4. SWING LOCK SWITCH WARNING When the machine is travelling under its own power, or when the swing is not being operated, always set the switch to the ON (ACTUATED) position.
  • Page 73 EXPLANATION OF COMPONENTS OPERATION 5. CONTROL LEVER LOCK SWITCH WARNING When travelling on public roads, set this switch to the off position. This prevents operation of the work equipment and activates the rear facing brake lamp circuits. This switch enables operation of the work equipment control levers.
  • Page 74 OPERATION EXPLANATION OF COMPONENTS 9. HORN BUTTON When the lower button on the left work equipment control lever is pressed, the horn will sound. Note: Additional horn switch is switch 25. 10. KNOB BUTTON The upper button of the left work equipment control lever is used to actuate the power max./swift slow-down functions.
  • Page 75 EXPLANATION OF COMPONENTS OPERATION 13. CAB LAMP SWITCH This lights up the cab lamp. AM089510A ON position: Lights up The cab lamp can be turned on even when the starting switch is at the OFF position, so be careful not to leave it on by mistake. AM166910B 14.
  • Page 76 OPERATION EXPLANATION OF COMPONENTS the swing brake electrical system (swing brake system error). The abnormality must be repaired immediately. 16. PARK BRAKE SWITCH This switch is used to apply and release park brake. OFF: Park brake released (warning light not illuminated) ON: Park brake applied (warning light illuminated) Note1: When moving off from a standstill up an incline it will be necessary to depress the travel pedal slightly before releasing...
  • Page 77 EXPLANATION OF COMPONENTS OPERATION 18. ROADLIGHTS SWITCH This switch is used to switch on the side lights and road lights. Sidelights (parking lights) on Road lights on. 19. HAZARD SWITCH This switch is used to switch on the hazard warning lights. OFF: Hazard warning lights off.
  • Page 78 OPERATION EXPLANATION OF COMPONENTS OPERATION OF DOZER + OUTRIGGERS (ensure safety lock lever is unlocked and front axle is locked) A. To operate front attachment(s) 1. Ensure park brake switch (16) is on. 2. Set outrigger left/right switch (20) to appropriate position. 3.
  • Page 79 EXPLANATION OF COMPONENTS OPERATION 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 on outrigger. 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.
  • Page 80 OPERATION EXPLANATION OF COMPONENTS NOTE: Additional horn switch is switch (9). 26. WINDSCREEN WASH SWITCH When the sleeve switch on the left hand steering column stalk is pushed towards the steering column the windscreen wash will operate. 27. DIRECTION INDICATOR SWITCH This switch is used to indicate the driver’s intention to change direction.

  • Page 81: Control Levers, Pedals

    EXPLANATION OF COMPONENTS OPERATION 30. 12V POWER SUPPLY The 12V socket provided on the right hand panel may be used only for electrical accessorIes drawing 1,5 A. maximum. Any accessories attached to this socket must carry the EC mark. CONTROL LEVERS, PEDALS 1.
  • Page 82 OPERATION EXPLANATION OF COMPONENTS the control levers may not be properly locked. Check that the situation is as shown in the diagram. When the control lever pad safety lock lever is raised, take care not to touch the work equipment control lever. If the safety lock lever is not properly locked at the upper position, the work equipment and swing will move, creat- ing a potentially dangerous situation.
  • Page 83 EXPLANATION OF COMPONENTS OPERATION When the lever in this position, the upper structure and the arm will be retained in the position in which they stop. 3. RIGHT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device) WARNING If an lever is operated when in the deceleration range, the engine speed will suddenly increase, so be careful when operating the levers.

  • Page 84: Roof Hatch

    OPERATION EXPLANATION OF COMPONENTS 5. TRAVEL PEDAL Forward Neutral Reverse ROOF HATCH WARNING When leaving the operator’s compartment, set the control lever pad safety lock securely to the LOCK position. If the control levers are not locked, and they are touched by mis-take, this may lead to a serious accident.
  • Page 85 EXPLANATION OF COMPONENTS OPERATION CEILING WINDOW The operator cab is provided with a fixed clear ceiling widow for improved visibility. An optional guard can be provided for working in areas at risk from damage. CLEAR RAIN VISOR PULL DOWN SUN VISOR The operator cab is fitted with a pull down sun visor.

  • Page 86: Front Window

    OPERATION EXPLANATION OF COMPONENTS FRONT WINDOW WARNING When opening the front window, always hold grip firmly with both hands and pull up. If you use only one hand, your hand may slip and get caught. It is possible to store (pull up) the front window (top) in the roof of the operator’s compartment.
  • Page 87 EXPLANATION OF COMPONENTS OPERATION 4. Pull lock pins (A) at the top left and right sides of the front win- dow to the inside to release the lock. AM089670A 5. From the inside of the operator’s cab, hold the bottom grip with the left hand and the top grip with the right hand, pull up the window, and push it in fully until it is locked by catch (C).
  • Page 88 OPERATION EXPLANATION OF COMPONENTS 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 a flat ground and stop the engine. 2. Securely lock control lever pad safety lock. 3.

  • Page 89: Door Lock

    EXPLANATION OF COMPONENTS OPERATION catch (C), push release lever (D) in the direction of the arrow to release the lock. 5. Lock securely (A) with lock pins at the left and right sides AM089670A Removing front window (bottom) Ensure lower wiper (if fitted) is in correct park position. With the front window open, remove lock pins (E), and the bottom part of the front window can be removed.

  • Page 90: Cap, Cover With Lock

    OPERATION EXPLANATION OF COMPONENTS CAP, COVER WITH LOCK The fuel filler, operator’s cab, engine hood, tool box cover, right side door and left side door of the machine body are fitted with locks. Use the starting switch key to lock or unlock these places. METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port) type A...

  • Page 91: Fuse

    EXPLANATION OF COMPONENTS OPERATION FUSE NOTE: Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burn- ing out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.

  • Page 92: Luggage Tray

    OPERATION EXPLANATION OF COMPONENTS LUGGAGE TRAY This tray is located to the rear of the operator’s seat. Always keep the operation & maintenance manual in this box for easy reading access. AM089770A ASHTRAY This is on the side of the operator’s seat. Always make sure that you extinguish the cigarette before closing the lid.
  • Page 93 EXPLANATION OF COMPONENTS OPERATION 2. Air outlet selector slider The operator can select a suitable outlet as required. Sending air to upper area of oper- Sending air to lower area of opera- Purpose ator’s seat and defrosting upper tor’s seat and de-frosting lower part of front window part of front window.

  • Page 94: Air Conditioner

    OPERATION EXPLANATION OF COMPONENTS Defroster is available when air outlet slider is in the position shown marked: FEET DEFROSTER AIR CONDITIONER VIEW OF CONTROL PANEL When a function is activated, the related indicator lamp lights up. 1. AIR OUTLET SELECTOR SWICH The operator can select a suitable outlet as required.
  • Page 95 EXPLANATION OF COMPONENTS OPERATION Sending air to upper area of Sending air to lower area of Purpose operator’s seat operator’s seat Air outlets 2. EXTERNAL/INTERNAL AIR CHANGEOVER SWITCH Changes between internal air circulation and external air intake. Internal air circuit. This is used External air intake when wishing to quickly cool or This is used for fresh air intake or...
  • Page 96 OPERATION EXPLANATION OF COMPONENTS 4. AIR FLOW SELECTOR SWITCH This switch adjusts air flow in three steps. Purpose To "Low" To "intermediate" To "High" Switch 5. AIR CONDITIONER SWITCH This is used to switch the air conditioner ON/OFF. 6. OFF SWITCH This switch is use to stop the fan.

  • Page 97: Fusible Link

    Never splash or spill water, mud or drink over the con- troller as this may cause a fault. If a fault occurs in the controller, do not attempt repair, but consult your Komatsu distributor. TOOL BOX This is used for keeping the tools.

  • Page 98: Cab Radio (Option)

    OPERATION EXPLANATION OF COMPONENTS 3. Switch on refuelling pump using switch (1) on the pump assembly when adding fuel, never let the fuel overflow. This may cause a fires. NOTICE This pump is protected by a fuse (5). If pump fails to function check fuse (10A).

  • Page 99: Warning Lamps

    EXPLANATION OF COMPONENTS OPERATION WARNING LAMPS 1. INDICATOR WARNING LAMP This lamp will flash (and buzzer will sound) when indicator lever is not in neutral. 2. WORKLIGHTS WARNING LAMP This lamp will illuminate when work lamps are switched on. 3. LOW BRAKE PRESSURE LAMP When engine is running and brake system hydraulic pressure is abnormal, this lamp will illuminate.

  • Page 100: Handling The Accumulator

    Do not weld any boss to the accumulators. When disposing of the accumulators, it is necessary to re lease the gas from the accumulators, so please con- tact your Komatsu distributor. Brake circuit accumulators This machine is equipped with the accumulator in the brake cir-...
  • Page 101 EXPLANATION OF COMPONENTS OPERATION The accumulator is a device to store the pressure 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.

  • Page 102: Operation

    Check carefully, and if any abnormality is found, always repair it or contact your Komatsu distributor. Before starting the engine, look around the machine and under the machine to check for loose nut or bolts, or leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
  • Page 103 9. Check bucket with hook for damage Check the hook, catcher and hook foot for damage. If damage is found, contact your Komatsu distributor for repair.
  • Page 104 OPERATION OPERATION CHECK BEFORE STARTING Always carry out the items in this section before starting the engine each day. CHECK COOLANT LEVEL, ADD WATER WARNING Do not open the radiator cap unless necessary. When check- ing the coolant, always check the radiator reserve tank when the engine is cold.
  • Page 105 OPERATION OPERATION WARNING Allow the engine to cool before checking the oil level to avoid burns by touching hot engine parts. CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If spilling fuel, thoroughly clean up any spillage. 1.
  • Page 106 OPERATION OPERATION Fuel capacity: 240 l For details of the fuel to use, see “USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER- ATURE” on page 173. 3. After adding fuel, tighten the cap securely. REMARK If breather holes (1) on the cap is clogged, the pressure in the tank will drop and fuel will not flow.
  • Page 107 Check for damage of the fuse and any sign of disconnection or short circuit in the electric wiring. Check also for loose terminals and tighten any loose parts. Check the following points carefully. Battery Starting motor Alternator Please contact your Komatsu distributor for investigation and cor- rection of the cause.
  • Page 108 OPERATION OPERATION CHECK FOR WATER IN FUEL SEDIMENTOR The fuel sedimentor is mounted in the left hand side compart- ment. The water separator separates water mixed in the fuel. Before the water level reaches line (A), drain the water from drain plug (P). F o r t h e d ra in i n g p ro c ed u r e, se e sec t i o n "...
  • Page 109 OPERATION OPERATION NOTE: This operation will affect relative position of seat and wrist control levers. (C) Adjustment of reclining seat Pull lever (3) up after the seat back is set to the optimum position for easy operation, release the lever. (D) Adjustment of arm rest height Turn thumb wheel (4) to adjust armrest to comfortable height.
  • Page 110 OPERATION OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING If the control lever is touched by accident, the work equip- ment or the machine may move suddenly. When leaving the operator’s compartment, always set the control lever pad safety lock lever securely to the LOCK position. 1.

  • Page 111: Starting Engine

    (2) Press lamp switch (14) to turn on the work lamps. A warning lamp on the steering column will illuminate. If the lamps do not light up, there is probably a broken bulb or dis- connection in the wiring, so contact your Komatsu distributor for repairs. CAUTION It is illegal to travel on the road in certain countries with rear- ward facing worklights illuminated.

  • Page 112: Starting In Cold Weather

    OPERATION OPERATION 1. Set fuel control dial (1) at the low idling (MIN) position. AM090340A 2. Turn the key in starting switch (2) to the START position. The engine will start. AM090350A 3. When the engine starts, release the key in starting switch (2). The key will return automatically to the ON position.
  • Page 113 OPERATION OPERATION 1. Set fuel control dial (1) at the low idling (MIN) position. AM090340A 2. Hold the key in starting switch (1) at the HEAT position, and check that preheating monitor (2) lights up. After about 30 seconds, preheating monitor lamp (3) will flash for about 10 seconds to indicate that preheating is finished.
  • Page 114 OPERATION OPERATION OPERATIONS AND CHECKS AFTER STARTING ENGINE WARNING Emergency stop If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position. If the work equipment is operated without warming the machine up sufficiently, the response of the work equip- ment to the movement of the control lever will be slow, and the work equipment may not move as the operator desires, so always carry out the warming-up operation.
  • Page 115 OPERATION OPERATION After starting the engine, do not immediately start operations. First, carry out the following operations and checks. 1. Turn fuel control dial (1) to the center position between LOW IDLING (MIN) and HIGH IDLING (MAX) and run the engine at medium speed for about 5 minutes with no load.
  • Page 116 OPERATION OPERATION 6. After carrying out the warming-up operation, check that each gauge and monitor lamp is in the following condition. Engine water temperature gauge (7): Inside green range Fuel gauge (8): Inside green range Engine water temperature monitor (9): OUT Radiator water level monitor (10): OUT Engine oil pressure monitor (11): OUT Charge level monitor (12): OUT...
  • Page 117 OPERATION OPERATION NOTICE When the hydraulic oil is at a low temperature, do not carry out operations or move the levers suddenly. Always carry out the warming-up operation. This will help to extend the machine life. Do not suddenly accelerate the engine before the warm- ing-up operation is completed.
  • Page 118 OPERATION OPERATION 4. Lower the control lever pad (4) to the FREE position, put PPC lock switch (7) to on position and raise the bucket from the ground. 5. Operate boom and bucket control lever (5) and arm control lever (6) slowly to operate the boom cylinder, bucket cylinder, and arm cylinder to the end of their stroke.
  • Page 119 OPERATION OPERATION REMARK If the above operation is not carried out, there may be a delay in response when starting or stopping each actuator, so continue the operation until it becomes normal. 9. Use working mode switch (2) on the monitor panel to switch to the working mode to be used.

  • Page 120: Moving Machine Off

    OPERATION OPERATION MOVING MACHINE OFF MOVING MACHINE FORWARD WARNING When moving off, check that the area around the machine is safe, and sound the horn before moving. Clear all personnel from the machine and the area. Clear all obstacles from the path of the machine. If the lever is moved inside the deceleration range, engine speed will rise suddenly.
  • Page 121 OPERATION OPERATION 4. Raise the stabilisers/dozer blade (when fitted). See Section on operation of dozer & outriggers section 5. Ensure that the wheel brake is off by depressing service brake lock release pedal (5). Service brake lock release pedal Service brake pedal Release the front axle suspension lock, using switch (6).

  • Page 122: Steering

    OPERATION OPERATION (e.g. concrete or asphalt roads) maximum speed is available. * (20 km/h specification) 9. Release park brake by using switch (9). 10. Press the travel pedal (10) smoothly. The machine will move off in the selected direction. If the undercarriage is not facing the normal forward direction - then the travelling direction will be opposite to that which is selected.
  • Page 123 OPERATION OPERATION WARNING Before shifting between forward and reverse, stop the machine. If the upper structure is turned 180 degrees (the undercar- riage is re-versed) the machine steers in the opposite direc- tion of the steering wheel. Therefore, take care of the direction of the chassis.

  • Page 124: Stopping

    OPERATION OPERATION STOPPING STOPPING MACHINE (NORMAL) WARNING Avoid stopping suddenly. Give yourself ample room when stopping. CORRECT When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert chocks underneath the wheels.

  • Page 125: Swinging (Slewing The Upper Carriage)

    OPERATION OPERATION NOTICE The park brake internal components will be destroyed during this operation. ONLY USE IT IN AN EMERGENCY. SWINGING (Slewing the upper carriage) When operating the swing, check that the area around the ma- chine is safe. 1. Before operating the swing, turn swing lock switch (1) OFF (CANCELED).

  • Page 126: Operation Of Work Equipment

    OPERATION OPERATION OPERATION OF WORK EQUIPMENT WARNING If any lever is operated when in the deceleration range, the engine speed will suddenly increase, so be careful when operating the levers. The work equipment is operated by the left and right work equip- ment control levers.

  • Page 127: Working Mode Selection

    OPERATION OPERATION Bucket operation 2 pc boom operation WORKING MODE SELECTION WORKING MODE The mode selector switches can be used to switch the mode to match the conditions and purpose of work, thereby enabling effi- cient operation. Use the following procedures to make the most effective use of each mode.
  • Page 128 OPERATION OPERATION NOTICE Never carry out breaker operation in heavy-duty opera- tion mode (H.O.) as this may result in breakage of hydraulic equipment. POWER MAX./SWIFT SLOW-DOWN HEAT OFF During operation, power up/speed down of work equipment can be performed by one-touch. Use this function effectively in combi- nation with working mode.

  • Page 129: Prohibitions For Operation

    OPERATION OPERATION PROHIBITIONS FOR OPERATION WARNING If it is necessary to operate the work equipment control lever when the machine is traveling, stop the machine before operating the work equipment control lever. If the lever is moved inside the deceleration range, engine speed will suddenly rise.

  • Page 130: Precautions For Operation

    OPERATION OPERATION Prohibited operations using dropping force of bucket INCORRECT Do not use the dropping force of the bucket as a pickaxe, breaker, or pile driver. This will bring excessive force to bear on the rear of the machine, and will not only damage the machine, but is also dangerous.

  • Page 131: Precautions When Traveling Up Or Down Hills

    OPERATION OPERATION PRECAUTIONS AT Hi-SPEED TRAVEL On uneven roadbeds such as rock beds or uneven roads with large rocks, travel in Mi speedmode and adjust the speed of the machine to prevent loss of control. PRECAUTIONS WHEN TRAVELLING ON PUBLIC ROADS When travelling or public roads the control lever pad safety lock should be down and the control lever lock switch, in the off posi- AD145900A...

  • Page 132: How To Escape From Mud

    OPERATION OPERATION 1. When traveling down steep hills, keep the travel speed low. When traveling down slopes of more than 15°, set the work Downhill equipment in the posture shown in the figure on the right, and lower the engine speed. 2.

  • Page 133: Work Possible Using Hydraulic Excavator

    OPERATION OPERATION WHEN BOTH SIDES ARE STUCK When all wheels are stuck in mud and the machine will not move, lay boards as explained above, and dig the bucket into the ground in front. Then pull in the arm as in normal digging operations and put the travel levers in the FORWARD position to pull the machine out.

  • Page 134: Replacement And Inversion Of Bucket

    OPERATION OPERATION DITCHING WORK Ditching work can be performed efficiently by attaching a bucket to match the width of the ditch and then setting the wheels parallel to the line of the ditch to be excavated. To excavate a wide ditch, first dig out both sides and then finally remove the center portion.
  • Page 135 OPERATION OPERATION If the bucket is lowered strongly to the ground, the resistance will be increased and it will be difficult to remove the pins. 2. Remove the stopper bolts and nuts, then remove pins (A) and (B) and remove the bucket. NOTICE After removing the pins, make sure that they do not become contaminated with sand or mud and that the seals of...
  • Page 136 OPERATION OPERATION NOTICE 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. 3. Install the bucket inversely. After the bucket is inversed, correct the inclination and direc- tion of the retaining pin holes (1) and (2) and stabilise the bucket securely.

  • Page 137: Parking Machine

    OPERATION OPERATION PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert chocks underneath the wheels.

  • Page 138: Check After Finishing Work

    OPERATION OPERATION 3. Operate park brake by using switch(4). 4. Lower the bucket horizontally until the bottom touches the ground. 5. Set control lever pad safety lock (3) to the LOCK position. CHECK AFTER FINISHING WORK Check the engine water temperature, engine oil pressure and fuel level on the monitor.

  • Page 139: Check After Stopping Engine

    OPERATION OPERATION CHECK AFTER STOPPING ENGINE 1. Walk around the machine and check the work equipment, paint work, and undercarriage, and check also for leakage of oil or water. If any abnormalities are found, repair them. 2. Fill the fuel tank. 3.
  • Page 140 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 condition to remove the various pieces of the rim. Never use metallic hammer, use a mallet with a face made from Rubber, Plastic or Copper.
  • Page 141 OPERATION OPERATION WARNING Failure to observe the following procedure may result in seri- ous injury or death. 3. Twin wheel assembly - 3 part rim Rim Base Loose flange Lockring Rim Gutter (groove) Deflation and removal: Before loosening the wheel retaining nuts, completely deflate the tyres by removing the valve with the appropriate tool.
  • Page 142 OPERATION OPERATION Insert the lock-ring with the aid of specific tools or with levers and a suitable mallet. Check correct seating of the lock-ring by measuring the dimension of the gap shown in Fig. 2. If it is not possible to achieve the stated gap with the lock-ring seated correctly renew the rim assembly.
  • Page 143 OPERATION OPERATION 4. Twin wheel assembly - 2 part rim Some KUK machines are fitted with a 2 piece wheel rim of the type shown in Fig. 5. In this case the loose flange and lock-ring are replaced by a single split flange. Split flange Rim base Similar precautions are required to those for the 3 piece rim when...
  • Page 144 OPERATION OPERATION 7. Wheel spacer WARNING Wheel spacers must not be used with radial ply tyres. 8. Rotating tyres Consult your local Komatsu distributor for advice on rotating tyres.

  • Page 145: Transportation

    TRANSPORTATION OPERATION TRANSPORTATION When transporting the machine, observe all related laws and reg- ulations, and be careful to assure safety. LOADING, UNLOADING WORK WARNING Loading or unloading the machine can be a dangerous operation, so be particularly careful. When loading or unloading the machine, run the engine at low idling and travel at low speed.
  • Page 146 OPERATION TRANSPORTATION When loading or unloading, always use ramps or a platform and carry out the operations as follows. 1. Properly apply the brakes on the trailer and insert blocks(2) beneath the tyres to ensure that it does not move. Then fix the ramps in line with the centers of the trailer and the machine.

  • Page 147: Precautions For Loading

    TRANSPORTATION OPERATION PRECAUTIONS FOR LOADING WARNING When loading the machine, park the trailer on a flat firm road- bed. Keep a fairly long distance between the road shoulder and the machine. After loading to the specified position, secure the machine as fol- lows.
  • Page 148 OPERATION TRANSPORTATION WARNING Contact your distributor to get instructions of lifting a machine. Some parts are required and are available as optional parts. WARNING Do not lift a vehicle with personnel in it. The rope used for lifting must have sufficient strength to with stand the weight of this machine.

  • Page 149: Precautions For Transportation

    2490 3080 12200 2 piece boom 7800 2490 3080 13100 (1) Height for transport = (2) Overall height + (3) height of trailer platform * Weights and dimensions: will vary according to specification. Consult your Komatsu distributor if in doubt.

  • Page 150: Travelling Posture

    OPERATION TRANSPORTATION 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. Position the upper structure so that it is facing the front of the undercarriage (the oscillation lock cylinders can be seen) and insert the swing lock pin.

  • Page 151: Cold Weather Operation

    COLD WEATHER OPERATION OPERATION COLD WEATHER OPERATION PRECAUTIONS FOR LOW TEMPERATURE If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows. FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see “USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE”...

  • Page 152: Precautions After Completion Of Work

    OPERATION COLD WEATHER OPERATION BATTERY 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.

  • Page 153: After Cold Weather

    COLD WEATHER OPERATION OPERATION As the battery capacity drops markedly in low temperatures, cover the battery or remove it from the machine, keep it in a warm place, and install it again the next morning. If electrolyte level is found low, add distilled water in the morn- ing before beginning work.

  • Page 154: Long-Term Storage

    OPERATION LONG-TERM STORAGE LONG-TERM STORAGE BEFORE STORAGE NOTICE To protect the cylinder rod when the machine is not being used, set the work equipment in the posture shown in the diagram. (This prevents rusting of the cylinder rod) When putting the machine in storage for a long time, do as fol- lows.

  • Page 155: After Storage

    OPERATION AFTER STORAGE NOTICE If the machine is stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service. Carry out the following procedure when taking the machine out of long-term storage. Wipe off the grease from the hydraulic cylinder rods.

  • Page 156: Troubleshooting

    OPERATION TROUBLESHOOTING TROUBLESHOOTING PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: 1. When the arm is pulled 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.

  • Page 157: Method Of Towing Machine

    TROUBLESHOOTING OPERATION METHOD OF TOWING MACHINE WARNING When towing the machine, use a wire rope that has ample strength for the weight of the machine that is being towed. If the machine sinks in mud and cannot get out under its own power, or if the drawbar pull of the excavator is being used to tow a heavy object, use a wire rope as shown in the diagram.

  • Page 158: If Battery Is Discharged

    OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position before starting. The battery generates hydrogen gas, so there is danger of explosion. Do not bring lighted cigarettes near the bat- When removing tery, or do anything that will cause sparks.
  • Page 159 TROUBLESHOOTING OPERATION Precautions when connecting and disconnecting booster cable WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, always wear safety glasses. Be careful not to let the normal machine and problem machine contact each other.

  • Page 160: Other Trouble

    (+) terminal of the problem machine. OTHER TROUBLE ELECTRICAL SYSTEM ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs.
  • Page 161 Defective operation of heater (Replace) relay switch CHASSIS ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem...
  • Page 162 OPERATION TROUBLESHOOTING In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pan oil level is low Add oil to specified level, see (sucking in air)

  • Page 163: Electronic Control System

    However, TVC valve system error immediately have the TVC valve system inspected by your Komatsu distributor. (*) Set the swing override switch to the ON position to release the brake. If applying the swing brake,...

  • Page 164: Maintenance

    MAINTENANCE.

  • Page 165: Guides To Maintenance

    Check the service meter reading every day to see if the time has come for any necessary maintenance to be carried out. Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu genuine oils: Use Komatsu genuine oils and grease.
  • Page 166 MAINTENANCE. GUIDES TO MAINTENANCE Oil change: Check or change oils in the places where dust is scarce to keep foreign materials away from oils. Warning tag: Attach the warning tag to the starting switch or other appropriate control lever to avoid someone who is not aware of the circum- stances from starting the engine.
  • Page 167 GUIDES TO MAINTENANCE MAINTENANCE. Do not allow water to get on the monitors and controllers inside the operator’s cab. Never spray steam or water directly at the radiator or oil cooler portions. Pre-and post-work checks: Before starting work in mud, rain, snow or at seashore, check plugs and valves for tightness.

  • Page 168: Outlines Of Service

    MAINTENANCE. OUTLINES OF SERVICE OUTLINES OF SERVICE Use Komatsu genuine parts for replacement. When changing or adding oil, do not use a different type of oil. Unless otherwise specified, the oil and coolant used at the time of shipment from the factory are as shown in the table below.
  • Page 169 We recommend you to have an analysis made of the oil peri- odically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distrib- utor. FUEL The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.

  • Page 170: Storing Oil And Fuel

    Never try to clean the filters (cartridge type) and use them again. Always replace with new filters. When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found, please contact your Komatsu distributor.

  • Page 171: Outline Of Electric System

    MAINTENANCE. Do not open packs of spare filters until just before they are to be used. Always use Komatsu genuine filters. OUTLINE OF ELECTRIC SYSTEM If the wiring gets wet or the insulation is damaged, the electric system leaks and this could result in hazardous malfunction of the machine.
  • Page 172 MAINTENANCE. OUTLINES OF SERVICE 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, replacement of the filter and refilling of hydraulic oil. When the high pressure hose, etc.

  • Page 173: Wear Parts List

    The wear parts should be changed correctly in order to use the machine economically. For part change, Komatsu genuine parts of excellent quality should be used. When ordering parts, please check the part number in the parts book.

  • Page 174: Use Fuel, Coolant And Lubricants According To Ambient Temperature

    40° C SAE 80W-90 Rear 2.7 liter REMARK We recommend Komatsu genuine oil which has been specifi- cally formulated and approved for use in engine and hydraulic work equipment applications. Only use high quality oils which meet internationally recog- nized specifications.
  • Page 175 (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table. We recommend Komatsu genuine oil which has been specifi- cally formulated and approved for use in engine and hydraulic SPECTRUM XXX work equipment applications.
  • Page 176 MAINTENANCE. USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40 SAE80, 90, 140 NLGI No. 2 Base] (The 15W40 oil Permanent Type marked * is CE.) Diesel sigma S...
  • Page 177 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE. Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40 SAE80, 90, 140 NLGI No. 2 Base] (The 15W40 oil Permanent Type marked * is CE.) Spirax EP...

  • Page 178: Standard Tightening Torques For Bolts And Nuts

    For greasing work Nozzle 07951-11400 Grease cartridge 07950-90403 (Lithium base grease: 400 g) Hammer 09039-00150 Pinch bar 09055-00520 Gauge 09054-0009 Socket 20E-98-K1110 33 mm drive socket If any of the above tools are broken, please order them from your Komatsu distributor.

  • Page 179: Torque List

    The tightening torque is determined by the width across the flats (B) of the nut and bolt. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

  • Page 180: Periodic Replacement Of Safety Critical Parts

    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. Ask your Komatsu distributor to replace the safety critical parts.

  • Page 181: Safety Critical Parts

    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS MAINTENANCE. SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q’ty Replacement interval Fuel hose (fuel tank - water separator) Fuel hose (water separator - engine lift pump Fuel hose (engine lift pump - fuel filter) Every 2 years or 4000 hours which ever comes sooner.

  • Page 182: Maintenance Schedule Chart

    MAINTENANCE. MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE INITIAL 250 HOURS SERVICE (only after the first 250 hours) "REPLACE FUEL FILTER CARTRIDGE" page 187 "CHECK ENGINE VALVE CLEARANCE, ADJUST" page 187 "CHANGE OIL IN TRANSMISSION, HUBS + AXLES." page 187 WHEN REQUIRED "CHECK, CLEAN AND REPLACE THE AIR CLEANER ELEMENT"...
  • Page 183 MAINTENANCE SCHEDULE CHART MAINTENANCE. SERVICE ITEM PAGE "Boom cylinder foot pin (2 points)" page 205 "Boom foot pin (2 points)" page 205 "Boom cylinder rod end (2 points)" page 205 "Arm cylinder foot pin (1 point)." page 205 "Boom-Arm coupling pin (1point)" page 205 "Arm cylinder rod end (1 point)"...
  • Page 184 MAINTENANCE. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE "CHECK OIL LEVEL IN TRANSMISSION, ADD OIL" page 210 "CHECK LEVEL OF BATTERY ELECTROLYTE" page 211 "LUBRICATE SWING CIRCLE (2 points)" page 211 "BELTS, GENERAL" page 211 "CHECK FAN BELT TENSION, ADJUST CHECKING TENSION" page 212 "CHECK ALTERNATOR AND WATER PUMP BELT TENSION, ADJUST CHECKING TENSION"...
  • Page 185 MAINTENANCE SCHEDULE CHART MAINTENANCE. SERVICE ITEM PAGE EVERY 5000 HOURS SERVICE "CHANGE OIL IN HYDRAULIC TANK" page 228 KEY TO LUBRICATION POINTS check level 1. Engine oil 23. Rear propshaft grease change oil check level 2. Hydraulic oil 24. Rear propshaft grease change oil 3.
  • Page 186 MAINTENANCE. MAINTENANCE SCHEDULE CHART Interval of service Change filter Lubrication by greasing (G) Amount of oil required at change (liters) Check oil level/change (EO)

  • Page 187: Maintenance When Using Hydraulic Breaker

    MAINTENANCE SCHEDULE CHART MAINTENANCE. MAINTENANCE WHEN USING HYDRAULIC BREAKER For machines equipped with a hydraulic breaker, the hydraulic oil deteriorates faster than for normal bucket digging operations, so set the maintenance intervals as follows. Replacing hydraulic filter element On new machines, replace the element after the first 100 to 150 hours, then carry out further replacement of the element according to the table on the right.

  • Page 188: Service Procedure

    MAINTENANCE. SERVICE PROCEDURE SERVICE PROCEDURE INITIAL 250 HOURS SERVICE Carry out the following maintenance only after the first 250 hours. REPLACE FUEL FILTER CARTRIDGE s e e “ R E P L A C E F U E L F I LT E R C A R T R I D G E S ” o n page 215.

  • Page 189: When Required

    SERVICE PROCEDURE MAINTENANCE. WHEN REQUIRED CHECK, CLEAN AND REPLACE THE AIR CLEANER ELEMENT WARNING Never clean or replace the air cleaner element with the engine running. When using pressured air to clean the element, wear safety glasses or goggles to protect the eyes. Checking If air cleaner clogging monitor flashes, clean the air cleaner ele- ment.
  • Page 190 MAINTENANCE. SERVICE PROCEDURE Check inner element mounting nuts for looseness and, if ❍ necessary, retighten. 5. If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning, replace the element. NOTICE Do not use an element whose folds or gasket or seal are damaged.
  • Page 191 SERVICE PROCEDURE MAINTENANCE. cool until the radiator filler cap is cool enough to touch with your hand. Remove the filler cap slowly to allow pressure to be relieved. 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.
  • Page 192 Antifreeze is flammable, so keep it away from any flame. Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control the mixing proportions.

  • Page 193: Checking Coolant Level

    SERVICE PROCEDURE MAINTENANCE. CHECKING COOLANT LEVEL REMARK Check the coolant level before starting the engine. 1. Check the coolant level in the radiator reserve tank (5). The coolant level should be between the FULL and LOW mark- ings on the tank. 2.
  • Page 194 MAINTENANCE. SERVICE PROCEDURE 4. Fill the system with clean water, refer to “FILLING THE SYS- TEM” on page 193 and add a flushing compound that is com- patible with aluminium. Flush the system in accordance with the instructions furnished with the compound. 5.
  • Page 195 SERVICE PROCEDURE MAINTENANCE. 5. Add coolant to the reserve tank until the level is between FULL and LOW marking on the tank. 6. When coolant level remains fixed between the FULL and LOW on the reserve tank, install the reserve tank cap. 7.
  • Page 196 Tighten the bolts in the order shown in the diagram. Torque to 450 CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections. CHECK ALTERNATOR...
  • Page 197 SERVICE PROCEDURE MAINTENANCE. a. Installing a new battery. b. Connecting a battery charger. c. Using a booster. Failure to observe proper polarity will result in damage to the alternator. NEVER use a fast charger as a booster to start the engine. NEVER unhook a battery terminal while the engine is running.
  • Page 198 MAINTENANCE. SERVICE PROCEDURE REPLACE BUCKET TEETH Replace the teeth before the wear reaches the adaptor. WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and apply the con- trol lever pad safety lock.
  • Page 199 SERVICE PROCEDURE MAINTENANCE. 3. Loosen the four plate fixing bolts of (2) and loosen plate (3). Because it uses split shims, you can carry out the operation without removing the bolts entirely. 4. Remove shim (4) corresponding to the amount of play (a) measured above.
  • Page 200 MAINTENANCE. SERVICE PROCEDURE which disable the system if the pressure is too high or low, to pre- vent damage to the system. If the air conditioner fails to operate it may be due to: a) Low pressure i) Check for leaks. ii) Consult your distributor to recharge system.

  • Page 201: Check Before Starting

    SERVICE PROCEDURE MAINTENANCE. CHECK BEFORE STARTING CHECK COOLANT LEVEL, ADD WATER WARNING Do not open 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).
  • Page 202 MAINTENANCE. SERVICE PROCEDURE WARNING Allow the engine to cool before checking the oil level to avoid burns by touching hot engine parts. CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If spilling fuel, thoroughly clean up any spillage. 1.
  • Page 203 SERVICE PROCEDURE MAINTENANCE. CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING When removing the oil filler cap, oil may spurt out, so turn the cap slowly to release the internal pressure before removing the cap. If oil has been added to above the H mark, stop the engine and wait for the hydraulic oil to cool down, then drain the excess oil from drain plug (P).
  • Page 204 Check the following points carefully. Battery Starting motor Alternator Please contact your Komatsu distributor for investigation and cor- rection of the cause. CHECK FOR WATER AND SEDIMENT IN SEDIMEN- TOR. DRAIN WATER AND SEDIMENT A fuel sedimentor is mount in the radiator compartment and is accessed by the door on the left hand side of the machine.

  • Page 205: Every 50 Hours

    SERVICE PROCEDURE MAINTENANCE. EVERY 50 HOURS DRAIN WATER AND SEDIMENT FROM FUEL TANK 1. Carry out this procedure before operating the machine. 2. Prepare a container to catch the fuel that is drained. 3. Open valve (1) at the bottom of the tank and drain the sedi- ment and water that has accumulated at the bottom together with fuel.

  • Page 206: Boom Cylinder Foot Pin (2 Points)

    MAINTENANCE. SERVICE PROCEDURE 3. After greasing, wipe off any old grease that was pushed out. 1. Boom cylinder foot pin (2 points) 2. Boom foot pin (2 points) 3. Boom cylinder rod end (2 points) 4. Arm cylinder foot pin (1 point). 5.

  • Page 207: Bucket Cylinder Foot Pin (1 Point)

    SERVICE PROCEDURE MAINTENANCE. 7. Bucket cylinder foot pin (1 point) 8. Arm-Link coupling pin (1 point) 9. Arm-Bucket coupling pin (1 point) 10. Link coupling pin (1 point) 11. Bucket cylinder rod end (1 point) 12. Bucket-Link coupling pin (2 points) 13.

  • Page 208: Boom Adjust Cylinder Foot Pin (1 Point)

    MAINTENANCE. SERVICE PROCEDURE 18. Boom adjust cylinder foot pin (1 point) 19. Boom adjust cylinder rod end (1 point) 20. Dozer blade cylinder rod end (2 points) 21. Dozer blade pivot pin (2 points) 22. Dozer blade cylinder foot pin (2 points) 23.

  • Page 209: Check Oil Level In Swing Machinery Case, Add Oil

    SERVICE PROCEDURE MAINTENANCE. CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before carrying out this check. 1. Remove dipstick (G) and wipe the oil from the dipstick with a cloth.

  • Page 210: Every 250 Hours Service

    MAINTENANCE. SERVICE PROCEDURE Rinse filter with clean water from the fine filter side. 4. Dry filter, compressed air may be used, but apply air from fine filter side. 5. Refit filter element ensuring coarse filter side is facing out- wards. NOTICE The normal cleaning interval is 100 hours, however if the machine is used in a dusty environment, shorten this inter-...

  • Page 211: Check Oil Level In Axles, Add Oil

    SERVICE PROCEDURE MAINTENANCE. CHECK OIL LEVEL IN AXLES, ADD OIL 1. Ensure axle is horizontal and remove plug (1). 2. If no oil emerges attach tube and funnel and add oil until oil emerges from the hole after removing tube. 3.
  • Page 212 MAINTENANCE. SERVICE PROCEDURE 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.
  • Page 213 SERVICE PROCEDURE MAINTENANCE. All pulley support bearings, shafts and brackets must be in work- ing order. When replacing belts and pulleys, pulley alignment must be checked with belts tensioned and brackets securely clamped. A misalignment that can be detected by the naked eye is detrimen- tal to belt performance.
  • Page 214 MAINTENANCE. SERVICE PROCEDURE ADJUSTING With the automatic belt tensioner, no adjustment is required. REPLACEMENT To replace the drive belt, place a 3/8 in. drive rachet (2) in the 3/8 in. square drive hole in the belt tensioner. Push the rachet “UP” to loosen the tensioner.
  • Page 215 SERVICE PROCEDURE MAINTENANCE. CHECK AND ADJUST TENSION OF AIR CONDI- TIONER COMPRESSOR BELT Testing The belt should deflect 14-16 mm when pressed with a finger force of approx. 6 kg at a point midway between the crankshaft pulley and the compressor pulley. Adjusting Compressor pulley 1.

  • Page 216: Every 500 Hours Service

    MAINTENANCE. SERVICE PROCEDURE EVERY 500 HOURS SERVICE Maintenance for every 50, 100 and 250 hours should be car- ried out at the same time. REPLACE FUEL FILTER CARTRIDGES WARNING Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing the filter.
  • Page 217 SERVICE PROCEDURE MAINTENANCE. Fuel injection pump is replaced. ❍ High pressure fuel line connections are loosened or fuel ❍ lines replaced. Initial engine start up or start up after an extended period ❍ of no engine operation. Vehicle fuel tank has been run until empty. ❍...
  • Page 218 1. Remove bolts (1) (2 bolts) on the top of the revolving frame and remove cover (A). 2. Check the colour of the grease. If it is milky white, it is neces- sary to change the grease. Please contact your Komatsu dis- AM091710A tributor.
  • Page 219 SERVICE PROCEDURE MAINTENANCE. CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE WARNING The oil is at high temperature after the engine has been oper- ated, so never change the oil immediately after finishing operations. Wait for the oil to cool down before changing it. Prepare the following Container to catch drained oil: Min.
  • Page 220 MAINTENANCE. SERVICE PROCEDURE NOTICE Even if the machine has not been operated for 500 hours, the oil and filter cartridge must be replaced when the machine has been operated for 6 months. In the same way, even if the machine has not been operated for 6 months, the oil and filter cartidge must be replaced when the machine has been operated for 500 hours.
  • Page 221 SERVICE PROCEDURE MAINTENANCE. water leakage or overheating. In a dusty site, check the fins daily, irrespective of the maintenance interval. REPLACE HYDRAULIC TANK BREATHER ELE- MENT WARNING Wait for the oil to cool down before replacing the breather element. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it carefully.

  • Page 222: Every 1000 Hours Service

    MAINTENANCE. SERVICE PROCEDURE 10. Stop the engine. REMARK Operate the machine after halting for more than 5 minutes to eliminate bubbles in the oil inside the tank. 11. Check for oil leakage and wipe off any spilled oil. When the hydraulic breaker is installed, the hydraulic oil deterio- rates earlier than in normal bucket digging work.
  • Page 223 CHARGER Contact your Komatsu distributor to have the tightening portions checked. CHECK PLAY OF TURBOCHARGER ROTOR. Ask Komatsu distributor to check the play of the turbocharger rotor. CHECK & ADJUST VALVE CLEARANCE FIRST 1000 HOURS ONLY 1. Adjusting the valves Remove the valve covers.
  • Page 224 MAINTENANCE. SERVICE PROCEDURE Camshaft gear Engine timing pin Gear housing CAUTION Be sure to disengage the pin after locating TDC. Valve clearance intake: 0-254 mm exhaust: 0-508 mm Check/set valves with engine cold - below 60°C NOTE: The clearance is correct when some resitance is ‘felt’ when the feeler gauge is slipped between the valve stem and the rocker lever.
  • Page 225 SERVICE PROCEDURE MAINTENANCE. Tighten the lock nut to 24 N.m and re-check the valve lash Mark the pulley and rotate the crankshaft 360° degrees. Be sure timing pin is sisengaged, before rotating. The timing pin will not engage in this position. With the engine in this position, check and adjust the following valve clearances.

  • Page 226: Every 2000 Hours Service

    Contact your Komatsu distributor for cleaning or inspection. CHECK ALTERNATOR, STARTING MOTOR The brush may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
  • Page 227 SERVICE PROCEDURE MAINTENANCE. CHECK VIBRATION DAMPER Check the index lines (A) on the damper hub (B) and the inertia member (C). If the lines are more than 1.59 mm out of alignment, replace the damper. Vibration damper CHANGE OIL IN AXLES 1.
  • Page 228 MAINTENANCE. SERVICE PROCEDURE CHANGE OIL IN HUBS 1. Position hub with plug (1) at bottom and remove plug (1). 2. When all oil has drained out, rotate hub until plug hole is at the top. 3. Add oil (2.5 l each hub, front axle, 2.7 l each hub, rear axle) and rotate hub until filling hole is horizontal.

  • Page 229: Every 4000 Hours Service

    CHECK WATER PUMP Check that there is oil leakage, water leakage, or clogging of the drain hole. If any abnormality is found, contact your Komatsu dis- tributor for disassembly and repair or replacement. EVERY 5000 HOURS SERVICE Maintenance for every 100, 250, 500 and 1000 hours should be carried out at the same time.
  • Page 230 MAINTENANCE. SERVICE PROCEDURE 2. Retract the arm and bucket cylinders to the stroke end, then lower the boom and put the bucket teeth in contact with the ground. 3. Lock the control lever pad safety lock lever and stop the engine.
  • Page 231 SERVICE PROCEDURE MAINTENANCE. Procedure for bleeding air Follow steps 1 to 7 to bleed the air. 1. Bleeding air from pump 1. Loosen air bleeder (1) installed to the drain port, and check that oil oozes out. (Completion of air bleeding) 2.

  • Page 232: Specifications

    SPECIFICATIONS.

  • Page 233: Specifications

    10 km/h / 8 km/h** High speed 30 km/h / 20 km/h** Swing speed 12.5 rpm ENGINE Model Komatsu SA4D102E-1 diesel engine Flywheel horsepower (NET) 76 kW (102 HP)/2250 rpm Starting motor 24 V 5.5 kW Alternator 24 V 45 A...
  • Page 234 SPECIFICATIONS. SPECIFICATIONS 1 - PIECE BOOM...
  • Page 235 SPECIFICATIONS SPECIFICATIONS. 2 - PIECE BOOM...
  • Page 236 SPECIFICATIONS. SPECIFICATIONS WORKING RANGE: ONE PIECE BOOM Arm length mm (Tt/In) 2100 2500 Max.digging height 8660 8900 Max.dumping height 6290 6530 Max digging depth 4730 5130 Max.vertical wall digging 4175 4560 Max. digging depth of cut for 8’ level 4495 4925 Max.
  • Page 237 SPECIFICATIONS SPECIFICATIONS. WORKING RANGE: TWO PIECE BOOM Arm length mm (Tt/In) 2100 2500 Max.digging height 8930 9190 Max.dumping height 6540 6905 Max digging depth 5010 5411 Max.vertlcal wall digging 3978 4365 Max. digging depth of cut for 8’ level 4779 5202 Max.

  • Page 238: Options, Attachments

    OPTIONS, ATTACHMENTS...

  • Page 239: General Precautions

    When installing attachments not listed in this Operation and Main- tenance Manual, please contact your Komatsu distributor first. If you do not contact Komatsu, we cannot accept any responsibil- ity for any accident or failure. WARNING...

  • Page 240: Precautions When Installing Attachments

    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 work equipment is installed, the working range will suddenly become larger, so there is danger of mis- taking the distance and hitting something.

  • Page 241: Handling Bucket With Hook

    HANDLING BUCKET WITH HOOK CHECKING FOR DAMAGE TO BUCKET WITH HOOK Check that there is no damage to the hook, stopper, or hook mount. If any abnormality is found, please contract your Komatsu distributor. PROHIBITED OPERATIONS The standard work equipment must not be used for lifting loads. If this machine is to be used for lifting loads, it is necessary to install the special bucket with hook.

  • Page 242: Machines Ready For Attachments

    OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS MACHINES READY FOR ATTACHMENTS GENERAL LOCATIONS Important Ensure valve (2) is closed at all times except when using attach- ments requiring low back pressure. (Oil flow by-passes oil cooler).
  • Page 243 MACHINES READY FOR ATTACHMENTS OPTIONS, ATTACHMENTS 1. STOP VALVE (1) This valve stops the flow of the hydraulic oil. (1) FREE: Hydraulic oil flows. (2) LOCK: Hydraulic oil stops. When removing or installing attachments, set this valve to the LOCK position. 2.

  • Page 244: Handling The Clamshell Bucket

    OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS 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 2. Clamshell cylinder bottom 3. Rotate left 4. Rotate right Ensure valve (A) (both sides) is closed and valve (B) is open (both sides) How to operate...

  • Page 245: Operation

    MACHINES READY FOR ATTACHMENTS OPTIONS, ATTACHMENTS Press button on working equipment lever 3. Clockwise Right hand 4. Counter clockwise wrist lever For safety, always avoid abrupt 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.
  • Page 246 OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS For details of other precautions when handling the breaker, read and use correctly the instruction manual provided by the breaker manufacturer. When using the breaker, the hydraulic oil deteriorates more rapidly than for normal operations, so change the hydraulic oil Open and replace the element at a shorter interval.

  • Page 247: Handling Accumulator

    When disposing of the accumulator, it is necessary to release the gas from the accumulator, so please contact your Komatsu distributor. This machine is equipped with the accumulators in the control and brake circuit. The accumulator is a device to store the pres-...

  • Page 248: Long-Term Storage

    OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS METHOD FOR RELEASING PRESSURE IN CON- TROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR 1. Lower the work equipment to the ground. Close any attach- ment such as the crusher. 2. Stop the engine. 3. Set the lock control lever pad safety lock completely in the FREE position, operate the work equipment control lever and attachment control pedal fully to the front, rear, left, and right, to release the pressure in the control circuit.

  • Page 249: Introduction Of Attachments And Extending Machine Service Life

    NOTICE Select the attachment most suited to the machine body. The machine models to which attachments can be mounted vary. For selection of attachment and machine model, consult your Komatsu distributor. HYDRAULIC BREAKER MAIN FIELDS OF APPLICATION Crushed rock Demolition work...
  • Page 250 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE When applying continuous impact to the same impact surface, if the chisel does not penetrate or break the surface within 1 minute, change the point of impact and carry out breaking opera- tions closer to the edge.
  • Page 251 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS Moving the chisel while carrying out impacting operations AL069830A Holding the chisel horizontal or pointed up when carrying out impacting operations Twisting the chisel when it has penetrated the rock AL069850A Pecking operations Extending the bucket cylinder fully and thrusting to raise the...

  • Page 252: Power Ripper

    OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE POWER RIPPER MAIN FIELDS OF APPLICATIONS Road repair work Demolition work This attachment can be used for a wide range of work including peeling off and crushing pavement roads, demolishing wooden houses and buildings, and crushing foundation and roadbeds.

  • Page 253: Fork Grab

    INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS Operations using attachment to grip at an angle. FORK GRAB MAIN FIELDS OF APPLICATION Disposing of industrial waste Disposing of demolition waste This can be used for a wide range of work including collecting or loading demolition waste materials and debris, timber, grass.

  • Page 254: Grapple Bucket

    OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE Pushing fork into ground surface to jack up and change direction of machine Impact operation with no load. AM092280A GRAPPLE BUCKET MAIN FIELDS OF APPLICATION Demolition Disposing of industrial waste Forestry This bucket is widely used for demolition including breaking-up work, grading and digging, clean-up work after natural disasters,...

  • Page 255: Scrap Grapple

    INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS Grabbing a object using buckets on only one side AM092310A Closing the sub-bucket with the boom and arm fully extended. Impact operation with no load. SCRAP GRAPPLE MAIN FIELDS OF APPLICATION Disposal of rock or debris This attachment is mounted to the arm end and used to grasp rock, debris etc.
  • Page 256 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE Do not operate the cylinder to the end of its stroke. Always leave approx. 5 cm to spare. Operations using the swing force Operations using one side of work equipment AM092360A Catching and dragging with claw end Gouging.

  • Page 257: Crusher & Smasher

    INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS CRUSHER & SMASHER MAIN FIELDS OF APPLICATION Demolition Road repair work This is the optimum attachment for demolition of steel frame rein- forced structures, and for crushing of concrete blocks and rock, etc.

  • Page 258: Hydraulic Pile Driver

    OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE Sudden gripping and breaking operations. AM092430A HYDRAULIC PILE DRIVER MAIN FIELDS OF APPLICATION Foundation work River work Water supply and sewerage This is a piling machine employing the hydraulic power source of the excavator.

  • Page 259: Hydraulic Excavator With Multipurpose Crane

    INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS Work other than standard works Loading or unloading a machine equipped with hydraulic pile driver. AM092470A HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE MAIN FIELDS OF APPLICATION Site preparation Water supply and sewerage River work Agricultural, civil engineering work Crane operation can be carried out without removing the bucket.
  • Page 260 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE Operating other work equipment during crane operation Excessive lengthening of wire rope.

  • Page 261: Rotating Arm

    *Max. 20.0 km/h - 30.0 km/h Swing speed 12.5 RPM Arm rotation speed 7 ~ 8 RPM Komatsu SA4D102E-1 Turbocharged diesel engine ENGINE Flywheel horsepower 76 KW (102HP)/2250 RPM NOTE: Specifications are subject to change without notice. * Dependent on machine specification.
  • Page 262 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE GENERAL VIEW OF CONTROLS 1. Control lever pad safety lock 4. Knob button 2. Left work equipment control lever. 5. Indicators 3. Right work equipment control lever 6. Two piece boom pedal LEFT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device) WARNING...
  • Page 263 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS When the lever in this position, the upper structure and the arm will be retained in the position in which they stop. RIGHT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device) WARNING If an lever is operated when in the deceleration range, the engine speed will suddenly increase, so be careful when...
  • Page 264 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE UPPER BOOM CONTROL PEDAL This is used to operate the upper boom. (1)RAISE: Pedal pushed forward (2) LOWER: Pedal pushed back NEUTRAL: The upper boom is stopped and held in the same position.
  • Page 265 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS SPECIAL OPERATIONS The rotating arm and 2-piece boom facilitate the following special operations. PIT EXCAVATION FOR FOUNDATIONS OF BUILDINGS Shafts with vertical walls can be excavated in all directions and soil can be removed from around sheet piles.
  • Page 266 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE 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.
  • Page 267 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS HANDLING THE TRAPEZOIDAL BUCKET (If equipped) 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°...
  • Page 268 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE 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.
  • Page 269 3.5 m. Before moving off, lock all machine cover and toolbox doors to prevent accidents. MAINTENANCE REQUIREMENT The following maintenance should be carried out in addition to that in the PW130ES-6K Operation & Maintenance Manual. ITEM SERVICE PAGE EVERY 100 HOURS SERVICE...
  • Page 270 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE EVERY 100 HOURS SERVICE 1. Arm rotation machinery case 1. Set the arm horizontal. 2. Remove plug (1)and check whether final drive case is filled with oil to lower edge of plughole. If oil level is below this point, refill with SAE 90 gear oil through plug hole.(see “EVERY 1000 HOURS SERVICE”...
  • Page 271 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS EVERY 500 HOURS SERVICE Maintenance for every 100 and 250 hours service should be carried out at the same time. 3. ARM ROTATION MACHINERY CASE 1. Disconnect hoses(1), (2) and (3) from the swing motor. 2.

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