Komatsu PW160-7K Series Operation And Maintenance Manual
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Komatsu PW160-7K Series Operation And Maintenance Manual

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Operation &
Maintenance Manual
WHEELED EXCAVATOR
SERIAL NUMBER
PW160-7K
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
PW160-7K
- K40001
and up
UEAM003203

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Summary of Contents for Komatsu PW160-7K Series

  • Page 1 Operation & UEAM003203 Maintenance Manual PW160-7K WHEELED EXCAVATOR SERIAL NUMBER PW160-7K - K40001 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 3: Foreword

    FOREWORD...

  • Page 4: 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 5: Safety Information

    Safety precautions are described in SAFETY from page 21. 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 6: Noise Emission Levels

    SAFETY INFORMATION FOREWORD Noise emission levels Two labels indicating the machine noise level are affixed on the machine. Sound pressure level at the operator’s station, measured ● according to ISO6396 (Dynamic test method, simulated work- ing cycle). Sound power level emitted by the machine, measured ●...
  • Page 7 FOREWORD SAFETY INFORMATION Operating condition: (WHEEL LOADER:) V-shape loading (HYDRAULIC EXCAVATORS:) Excavating (Digging-loading-rotat- ing-unloading-rotating) (TRACTOR DOZER:) Dozing and spreading material through for- ward/reversing motion (Rigid/Articulate dumper:) Work cycle (including waiting, travel- ling, loading, travelling with load, unloading, and travelling without load) Guide to Reduce Vibration Levels on Machine The following guides can help an operator of this machine to...
  • Page 8 SAFETY INFORMATION FOREWORD 6. Adjust the machine speed and travel path to minimize the vibration level q When pushing with bucket or blade, avoid sudden load- ing; load gradually q Drive around obstacles and rough terrain conditions q Slow down when it is necessary to go over rough terrain q Make the curve radius of traveling path as large as possi- q Travel at low speed when traveling around sharp curves 7.

  • Page 9: Emergency Steering

    FOREWORD SAFETY INFORMATION EMERGENCY STEERING This machine is equipped with an emergency steering system and complies to ISO 5010 (BSEN 12643). 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 10: Introduction

    INTRODUCTION FOREWORD 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 see "WORK POSSIBLE USING HYDRAU- LIC EXCAVATOR (188)" for further details...

  • Page 11: Breaking In Your New Machine

    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 12: Locations Of Plates, Table To Enter Serial No. And Distributor

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

  • Page 13: Machine Serial Plates

    Engine power Manufactured by Komatsu UK Ltd. MANUFACTURER for Komatsu Ltd.,Tokyo,Japan Product 20G-00-K2382 Identification Number Manufactured by Komatsu UK Ltd. Birtley, Co. Durham, United Kingdom, under License from Komatsu Ltd. GERMANY SERIAL PLATE FABR. NR. BAUJAHR ZUL. ZUGKRAFT ZUL.GESAMTGEWICHT LEISTUNG ZUL.ACHSLAST VORN...
  • Page 14 LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD...

  • Page 15: Table Of Contents

    CONTENTS FOREWORD......................3 FOREWORD ................................4 SAFETY INFORMATION ............................5 SAFETY MESSAGES ........................... 5 NOISE EMISSION LEVELS .......................... 6 VIBRATION LEVELS ............................ 6 EMERGENCY STEERING ........................... 9 INTRODUCTION ..............................10 INTENDED USE ............................10 FEATURES ..............................10 BREAKING IN YOUR NEW MACHINE ...................... 11 LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO.
  • Page 16 OPERATION....................... 73 GENERAL VIEW ..............................74 GENERAL VIEW OF MACHINE ......................... 74 GENERAL VIEW OF CONTROLS AND GAUGES ..................75 EXPLANATION OF COMPONENTS ........................76 MACHINE MONITOR ..........................76 BASIC CHECK ITEMS ..........................79 SWITCHES ................................. 108 CONTROL LEVERS, PEDALS .......................... 116 FRONT WINDOW .............................
  • Page 17 REPLACEMENT AND INVERSION OF BUCKET ..................189 STOPPING ENGINE ..........................191 CHECK AFTER FINISHING WORK ......................191 CHECK AFTER STOPPING ENGINE ........................ 192 LOCKING ..............................192 OVERLOAD WARNING DEVICE ......................192 HANDLING THE WHEELS ........................192 TRANSPORTATION ............................197 LOADING, UNLOADING WORK ......................197 PRECAUTIONS FOR LOADING ......................
  • Page 18 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE CONT....236 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS ..............238 INTRODUCTION OF NECESSARY TOOLS .................... 238 TIGHTENING TORQUE SPECIFICATIONS ...................... 239 TIGHTENING TORQUE LIST ........................239 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ................240 SAFETY CRITICAL PARTS ........................
  • Page 19 OPTIONS, ATTACHMENTS ................313 GENERAL PRECAUTIONS ..........................314 PRECAUTIONS RELATED TO SAFETY ....................314 PRECAUTIONS WHEN INSTALLING ATTACHMENTS ................... 315 HANDLING BUCKET WITH HOOK ........................317 CHECKING FOR DAMAGE TO BUCKET WITH HOOK ................317 PROHIBITED OPERATIONS ........................317 PRECAUTIONS DURING OPERATIONS ....................317 MACHINES READY FOR ATTACHMENTS ......................

  • Page 21: 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 22: General Precautions

    (249)" in service procedure. UNAUTHORISED MODIFICATION Any modification made without authorisation from Komatsu ● can create hazards. Before making a modification, consult your Komatsu distribu- ● tor. Komatsu will not be responsible for any injury or damage caused by any unauthorised modification.
  • Page 23 SAFETY GENERAL PRECAUTIONS WARNING: Failure to follow these safety precautions may lead to a serious accident. ALWAYS APPLY (RAISE) SAFETY LOCK LEVER WHEN LEAVING OPERATOR’S SEAT When standing up from the operator’s seat, always raise the ● safety lock lever to the LOCK position. If you accidentally touch the travel or swing lever when they are not locked, the machine may suddenly move and cause serious injury or damage.
  • Page 24 GENERAL PRECAUTIONS SAFETY WARNING: For reasons of safety, always follow these safety precautions. FIRE PREVENTION FOR FUEL AND OIL Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particu- larly FLAMMABLE and can be HAZARDOUS. Keep flames away from flammable fluids. ●...
  • Page 25 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 26 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 27 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 28 GENERAL PRECAUTIONS SAFETY WARNING: For reasons of safety, always follow these safety precautions. The display on the monitor panel may behave erratically. ● The warning buzzer may sound. ● These effects do not signify a malfunction and the machine will return to normal as soon as the source of interference is removed.

  • Page 29: Precaution During Operation

    SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. 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- ●...

  • Page 30: Operating Machine

    PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. 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 31 SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. 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.
  • Page 32 PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. 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 ●...
  • Page 33 SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. PROHIBITED OPERATIONS INCORRECT Do not dig the work face under an overhang. This may cause ● the overhang to collapse and fall on top of the machine. Do not carry out deep digging under the front of the machine.
  • Page 34 PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. DO NOT HIT WORK EQUIPMENT When working in places where there are height limits, such as ● in tunnels, under bridges, under electric cables, or in garages, be extremely careful not to hit the boom or arm.
  • Page 35 SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. OPERATIONS ON SLOPES When working on slopes, there is danger that the machine ● may lose its balance and turn over when the swing or work INCORRECT equipment are operated.
  • Page 36 PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. PARKING THE MACHINE Park on level ground whenever possible. If not possible, chock the wheels, lower the bucket to the ground and thrust the bucket CORRECT in the ground.

  • Page 37: Transportation

    SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. TRANSPORTATION LOADING AND UNLOADING Loading and unloading the machine always involves potential ● hazards. EXTREME CAUTION SHOULD BE USED. Ramp When loading or unloading the machine, run the engine at low idling and travel at low speed.

  • Page 38: Battery

    PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid and can quickly ● burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water.

  • Page 39: Towing

    SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. STARTING WITH BOOSTER CABLES ALWAYS wear safety glasses or goggles when starting the ● machine with booster cables. INCORRECT When starting from another machine, do not allow the two ●...

  • Page 40: Bucket With Hook Or Bucket Link With Lifting Eye

    PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. View on transmission Releasing the park brake before towing: 1. Unscrew bolt (A) 2-3 turns which will allow bolt (B) to rotate (DO NOT REMOVE BOLT ’A’). 2.
  • Page 41 SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. CHECKING HOOK When lifting a load, carry out the following checks to confirm ● that there is no abnormality before starting operations. Check that there are no cracks or deformation in the lift- ❍...
  • Page 42 PRECAUTION DURING OPERATION SAFETY WARNING: For reasons of safety, always follow these safety precautions. PRECAUTIONS FOR LIFTING OPERATION GRADUAL LIFTING OPERATION When carrying out lifting operations, run the engine at low ● idling and use the L (lifting operation mode). Avoid sudden lever shifting and acceleration.
  • Page 43 SAFETY PRECAUTION DURING OPERATION WARNING: Failure to follow these safety precautions may lead to a serious accident. Refer to manufacturers data sheet for handling and storage ● precautions. HANDLING OF FLUIDS For antifreeze and grease refer to manufacturers data sheet ●...

  • Page 44: Precautions For Maintenance

    ALWAYS attach the WARNING TAG to the control lever in the ● operator’s cab to alert others that you are working on the machine. Attach additional warning tags around the machine, if necessary. These tags are available from your Komatsu distributor. (Part ● no. 20E-00-K1340) PROPER TOOLS ●...
  • Page 45 SAFETY PRECAUTIONS FOR MAINTENANCE WARNING: Failure to follow these safety precautions may lead to a serious accident. One worker should sit in the operator’s seat so that he can ● stop the engine immediately if necessary. He should also be extremely careful not to touch any lever by mistake.
  • Page 46 PRECAUTIONS FOR MAINTENANCE SAFETY WARNING: For reasons of safety, always follow these safety precautions. RADIATOR WATER LEVEL If it is necessary to add water to the radiator, stop the engine ● and allow the engine and radiator to cool down before adding the water.

  • Page 47: During Maintenance

    SAFETY PRECAUTIONS FOR MAINTENANCE WARNING: Failure to follow these safety precautions may lead to a serious accident. DURING MAINTENANCE PERSONNEL Only authorised personnel can service and repair the ● machine. Extra precaution should be used when grinding, welding, and using a sledge-hammer. ATTACHMENTS Place attachments that have been removed from the machine ●...
  • Page 48 PRECAUTIONS FOR MAINTENANCE SAFETY WARNING: For reasons of safety, always follow these safety precautions. HANDLING HIGH-PRESSURE HOSES Do not bend high-pressure hoses or hit them with hard ● objects. Do not use any bent or cracked piping, tubes or hoses. They may burst during use. Always repair any loose or broken fuel hoses or oil hoses.
  • Page 49 SAFETY PRECAUTIONS FOR MAINTENANCE WARNING: Failure to follow these safety precautions may lead to a serious accident. ROTATING FAN AND BELT Keep away from rotating parts and be careful not to let any- ● thing get caught in them. If your body or tools touch the fan blades or fan belt, they may ●...

  • Page 50: 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 51 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 raise safety lock lever when leaving operators seat. ●...
  • Page 52 POSITION FOR ATTACHING SAFETY LABELS SAFETY 2. There are 6 amber reflectors located on the revolving frame and arm of the machine (20G-46-K1681) 3. Warning for unsafe machine. Located on the left or right hand levers (20E-00-K1340) Do not start the engine. ●...
  • Page 53 SAFETY POSITION FOR ATTACHING SAFETY LABELS 6. 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. ● Allow water to cool. ●...
  • Page 54 POSITION FOR ATTACHING SAFETY LABELS SAFETY 8. Warning for staying clear. This is fitted on both sides of arm (20E-00-K1140) Keeping out of moving area. To prevent SEVERE INJURY or DEATH. Do the following before moving the machine or its attachments: Sound horn to alert people nearby.
  • Page 55 SAFETY POSITION FOR ATTACHING SAFETY LABELS 10. Stop engine warning (20E-00-K1310) Do not open cover while engine is running. ● 11. Front window lock warning. This is located on the rear win- dow (09803-A0481) Always lock window in raised or lowered position. ●...
  • Page 56 POSITION FOR ATTACHING SAFETY LABELS SAFETY 13. (20G-00-31030) Radiator fill volume warning. This is located on top of the radiator unit. 14. (20K-00-31360) Read operation manual before operation.This is located inside the cab. 15. Red reflector (20G-47-K1690) 16. (20Y-00-K2220) Emergency exit ●...
  • Page 57 SAFETY POSITION FOR ATTACHING SAFETY LABELS 18. Operation of attachments is located on the right hand window (20K-00-31140) 19. Lift warning plate. This is located on the right hand window (20E-00-K1450) Do not lift more than the specified load of the machine. ●...

  • Page 58: Lifting Capacity Chart Pw160-7K

    LIFTING CAPACITY CHART PW160-7K SAFETY LIFTING CAPACITY CHART PW160-7K ONE PIECE BOOM Lift capacity tables 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 (495 kg), linkage (120 kg) and bucket cylinder (109 kg) OF: Lifting capacity (Rating over front)
  • Page 59 SAFETY LIFTING CAPACITY CHART PW160-7K Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2450 *2450 6.0m *2100 *1800 3150 2200 4.5m *1950 1450 3100 2150 5050 3500 3.0m 1900 1250 2050 1350 2950 2050 4700 3200 1.5m 1850 1200 2000 1300 2850 1900 4350...
  • Page 60 LIFTING CAPACITY CHART PW160-7K SAFETY Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2450 *2450 6.0m *2100 *2100 *3750 2600 4.5m *1950 1750 *4700 2550 *5250 4150 3.0m *1950 1550 *3350 1650 *5100 2450 *6700 3800 1.5m *2050 1500 4000 1600 *5400 2300 *7500...
  • Page 61 SAFETY LIFTING CAPACITY CHART PW160-7K Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2450 *2450 6.0m *2100 *2100 *3750 2950 4.5m *1950 *1950 *4700 2900 *5250 4700 3.0m *1950 1800 *3350 1900 *5100 2800 *6700 4350 1.5m *2050 1700 *4150 1850 *5400 2650 *7500...
  • Page 62 LIFTING CAPACITY CHART PW160-7K SAFETY Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2450 *2450 6.0m *2100 *2100 *3750 *3750 4.5m *1950 *1950 *4700 3800 *5250 *5250 3.0m *1950 *1950 *3350 2550 *5100 3700 *6700 5800 1.5m *2050 *2050 *4150 2500 *5400 3550 *7500...
  • Page 63 SAFETY LIFTING CAPACITY CHART PW160-7K Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2450 *2450 6.0m *2100 *2100 *3750 *3750 4.5m *1950 *1950 *4700 4550 *5250 *5250 3.0m *1950 *1950 *3350 3050 *5100 4400 *6700 *6700 1.5m *2050 *2050 *4150 3000 *5400 4250 *7500...

  • Page 64: Two Piece Boom Lift Capacity Tables

    LIFTING CAPACITY CHART PW160-7K SAFETY TWO PIECE BOOM Lift capacity tables 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 (495 kg), linkage (120 kg) and bucket cylinder (109 kg) OF: Lifting capacity (rating over front) OS: Lifting capacity (Rating over side)
  • Page 65 SAFETY LIFTING CAPACITY CHART PW160-7K Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2300 *2300 *3650 *3650 6.0m *1900 *1900 *3250 2200 *4200 3700 4.5m *1800 1500 *4550 2150 *5100 3600 *5000 *5000 3.0m *1800 1300 *2400 1350 *5300 2050 *6900 3300 1.5m *1900...
  • Page 66 LIFTING CAPACITY CHART PW160-7K SAFETY Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2300 *2300 *3650 *3650 6.0m *1900 *1900 *3250 2300 *4200 3900 4.5m *1800 1600 *4550 2300 *5100 3750 *5000 *5000 3.0m *1800 1400 *2400 1450 *5300 2200 *6900 3500 1.5m *1900...
  • Page 67 SAFETY LIFTING CAPACITY CHART PW160-7K Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2300 *2300 *3650 *3650 6.0m *1900 *1900 *3250 2350 *4200 3950 4.5m *1800 1600 *4550 2300 *5100 3800 *5000 *5000 3.0m *1800 1400 *2400 1450 *5300 2200 *6900 3550 1.5m *1900...
  • Page 68 LIFTING CAPACITY CHART PW160-7K SAFETY Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2300 *2300 *3650 *3650 6.0m *1900 *1900 *3250 2450 *4200 4100 4.5m *1800 1700 *4550 2450 *5100 3950 *5000 *5000 3.0m *1800 1500 *2400 1550 *5300 2350 *6900 3700 1.5m *1900...
  • Page 69 SAFETY LIFTING CAPACITY CHART PW160-7K Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2300 *2300 *3650 *3650 6.0m *1900 *1900 *3250 2500 *4200 4150 4.5m *1800 1750 *4550 2450 *5100 4000 *5000 *5000 3.0m *1800 1550 *2400 1550 *5300 2350 *6900 3750 1.5m *1900...

  • Page 70: Rotating Arm Capacity Tables

    LIFTING CAPACITY CHART PW160-7K SAFETY ROTATING ARM capacity tables MAX REACH 7.5m 6.0m 4.5m 3.0m 1.5m 0.0m 7.5m 1400 1400 2750 2750 6.0m 1150 1450 1450 3150 2800 4.5m 1050 1850 2000 1350 3350 2550 3000 3000 3.0m 1050 1700 1300 1200 1200...
  • Page 71 SAFETY LIFTING CAPACITY CHART PW160-7K 7.5m 1450 1450 2750 2750 6.0m 1150 1450 1450 3150 2800 4.5m 1050 1850 2000 1350 3350 2550 3000 3000 3.0m 1050 1700 1300 1200 1200 2150 5550 4450 1.5m 1100 1900 1700 1000 3150 1750 5200 3550...

  • Page 72: Overload Caution

    LIFTING CAPACITY CHART PW160-7K 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 lift capacity of the machine (active in L mode only).

  • Page 73: Operation

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

  • Page 74: 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 75: General View Of Controls And Gauges

    OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES 1. Machine monitor 18. Horn 2. Clamshell rotate right 19. 12V power supply 3. Boom and chassis attachment select 20. HCU Pedal (Option extra) 4. Right control lever 21. Power max button 5.

  • Page 76: Explanation Of Components

    EXPLANATION OF COMPONENTS OPERATION 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 important to understand fully the methods of operating the equipment and the meanings of the displays.
  • Page 77 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR If there is abnormality when starting engine Maintenance interval Check before starting screen Normal operation screen warning screen Warning screen Error screen If there is any abnormality when starting the engine, the ●...
  • Page 78 EXPLANATION OF COMPONENTS OPERATION If any abnormality occurs during operation Warning screen 2 Normal operation screen Warning screen 1 Error screen If any abnormality occurs during operation, the normal opera- ● tion screen changes to warning screen (1) or the error screen. After displaying warning screen (1) for 2 seconds, the screen ●...

  • Page 79: Basic Check Items

    OPERATION EXPLANATION OF COMPONENTS BASIC CHECK ITEMS WARNING These monitors are not a guarantee of the condition of the machine. Do not simply rely on the monitors when carrying out checks before starting (daily checks). Always get off the machine and check each item directly. This displays the basic items that must be checked before starting the engine.
  • Page 80 This monitor screen goes out after 30 seconds and returns to the normal operation screen. For details of the method of checking the maintenance interval, see "FRONT AND REAR WORKLIGHTS SWITCH (104)". If it is desired to change the setting of the maintenance interval, please consult your Komatsu distributor.
  • Page 81 OPERATION EXPLANATION OF COMPONENTS CAUTION ITEMS CAUTION If the warning monitor lights up red, stop operations as soon as possible and carry out inspection and maintenance at the applicable location. If the warning is ignored, it may lead to failure. These are items that should be observed while the engine is run- ning.
  • Page 82 EXPLANATION OF COMPONENTS OPERATION 1. CHARGE MONITOR This monitor (1) warns the operator that there is an abnormality in the charging system when the engine is running. If the battery is not being charged properly while the engine is running, it lights up red.
  • Page 83 OPERATION EXPLANATION OF COMPONENTS 4. ENGINE WATER TEMPERATURE MONITOR If this monitor (4) lights up white in low temperatures, carry out the warming-up operation. For details, see "WARMING UP OPERATION (165)". Continue the warming-up operation until monitor (4) changes to green.
  • Page 84 EXPLANATION OF COMPONENTS OPERATION 8. SERVICE MACHINE - OVERDUE This monitor (8) lights red when the machine service is overdue. The machine should be serviced immediately or damage may occur. 9. PARK BRAKE When park brake is applied, this lamp will illuminate.
  • Page 85 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STOP ITEMS CAUTION If the monitor lights up red, stop the engine immediately or run it at low idle, then check the applicable location and carry out the necessary action. These are items that should be observed while the engine is run- ning.
  • Page 86 EXPLANATION OF COMPONENTS OPERATION 1. ENGINE WATER TEMPERATURE MONITOR This monitor (1) warns the operator that the engine water temper- ature has risen. If the engine water temperature becomes abnormally high, the monitor lights up red, the overheat prevention system is automati- cally actuated, and the engine speed goes down.
  • Page 87 OPERATION EXPLANATION OF COMPONENTS 4. LOW BRAKE PRESSURE When brake system hydraulic pressure is abnormal, this lamp will illuminate. CAUTION Do not drive machine with low brake pressure warning lamp illuminated. REMARK The color when the monitor lights up for the basic check items, caution items, and emergency stop items is as follows.
  • Page 88 EXPLANATION OF COMPONENTS OPERATION METER DISPLAY PORTION (1) Engine Pre-heating Monitor (8) Fuel Gauge (2) Swing Lock Monitor (9)Hydraulic oil temperature gauge (3) Auto-deceleration monitor (10) Service Meter and clock (4) Working mode monitor (11) Travel direction monitor (5) Travel mode monitor (12) Undercarriage attachment monitor (6) One touch power up monitor (13) Main beam monitor...
  • Page 89 OPERATION EXPLANATION OF COMPONENTS 1. ENGINE PRE-HEATING MONITOR This monitor lamp (1) indicates the pre-heating time required when starting the engine at an ambient temperature below 0°C. The monitor lamp lights when the starting switch is turned to the HEAT position and flashes after about 30 seconds to show that the pre-heating is completed.
  • Page 90 EXPLANATION OF COMPONENTS OPERATION 5. TRAVEL MODE MONITOR This monitor (5) displays the set mode for the travel speed. When one of the travel mode selector switches is operated the monitor displays one of the following selections. Creep mode Low mode High mode Automatic mode 6.
  • Page 91 OPERATION EXPLANATION OF COMPONENTS 8. FUEL GAUGE This meter (8) displays the level of fuel in the fuel tank. During operations, the indicator should be in the black range. If the indicator enters red range (A) during operations, there are less than 100 litres of fuel remaining in the tank, so check and add fuel.
  • Page 92 EXPLANATION OF COMPONENTS OPERATION 10. SERVICE METER AND CLOCK This monitor (10) displays the total time that the machine has been operated. When the engine is running this display changes to a clock. Use the time display to set the maintenance interval. When the starting switch is ON, the service meter advances even if the machine is not moving.
  • Page 93 OPERATION EXPLANATION OF COMPONENTS MONITOR SWITCHES 19 20 16 17 (1) Working mode select (13) Engine auto deceleration (2) Creep speed (14) Buzzer cancel (3) High/low speed select (15) Hazard warning (4) Menu select key (16) Rear left outrigger/blade (5) Undo key (17) Front left outrigger/blade (6) Service menu (18) Select all chassis attachment...
  • Page 94 If you require a default setting other than ’A mode’ please ● consult your Komatsu distributor or dealership to have the setting amended. REMARK When the mode selector switch is pressed, the mode is dis-...
  • Page 95 OPERATION EXPLANATION OF COMPONENTS 2. CREEP SPEED SELECTOR SWITCH This switch (2) is used to set the travel mode to creep. Display portion CR lights up: Creep mode travel (0-1.5kph). To cancel creep speed, press Hi/Lo switch. REMARK When creep speed is selected the mode is displayed in the centre of the screen for 2 seconds before returning to the normal screen display.
  • Page 96 EXPLANATION OF COMPONENTS OPERATION ● When loading or unloading from a trailer, always travel at low speed. Never operate the travel speed selector switch during the loading or unloading operation. REMARK Each time that the travel speed selector switch is operated, Monitor display portion the mode is displayed in the centre of the monitor display, and the screen returns to the normal screen after 2 seconds.
  • Page 97 OPERATION EXPLANATION OF COMPONENTS REMARK The flow can be adjusted for the attachment installed. When the working mode is B mode ● 1. Press select switch (9) and the normal screen on the monitor display changes to the flow setting screen shown in the dia- gram on the right.
  • Page 98 EXPLANATION OF COMPONENTS OPERATION 6. SERVICE MENU SWITCH This switch (6) is used to check the time remaining to mainte- ● nance. When this switch (6) is pressed, the screen on the monitor ● display changes to the maintenance screen shown in the dia- gram on the right.
  • Page 99 1000 Axles 1000 If it is desired to change the setting for the maintenance interval, please contact your Komatsu distributor. The method of checking the time remaining to maintenance is ● as follows. 1. Look at the maintenance screen, press up switch (7) or down switch (8) on the monitor switch portion, until required item is highlighted.
  • Page 100 EXPLANATION OF COMPONENTS OPERATION 3. Check the time remaining to maintenance. (a): Time remaining to maintenance (b): Default setting for maintenance interval When only checking the time remaining to maintenance, press back switch (5) twice. The screen will return to the normal operation monitor screen. When canceling the time remaining to maintenance and returning to the default time setting, press input confirmation switch (9).
  • Page 101 OPERATION EXPLANATION OF COMPONENTS 10. AUTOMATIC SUSPENSION LOCK SWITCH Release the front axle suspension lock, using switch. Press switch (10) for Front axle suspension ‘auto’ mode i.e. when travel pedal is depressed, front axle suspension travels freely and when travel pedal is not depressed, front axle suspension is locked, as long as machine is stationary.
  • Page 102 EXPLANATION OF COMPONENTS OPERATION 13. AUTO-DECELERATION SWITCH Monitor display portion When this auto-deceleration switch (13) is depressed, the auto- deceleration is actuated, if the control levers and foot pedals are in the neutral position, the engine speed is automatically lowered to reduce fuel consumption.
  • Page 103 OPERATION EXPLANATION OF COMPONENTS 15. HAZARD WARNING SWITCH This button is used to switch on the hazard warning lights. OFF: Hazard warning lights off. ON: Hazard warning lights on. (Warning light within switch will flash when switched on). Keep pressing the switch for 2 seconds, when starter switch is off. 16.
  • Page 104 EXPLANATION OF COMPONENTS OPERATION 20. REAR RIGHT OUTRIGGER SWITCH Allows operation of rear right outrigger. Light on switch illuminates when activated. 21. LOWER WIPER SWITCH This switch (21) actuates the front lower wiper. The lamp on the switch will illuminate when wiper is activated. OFF: wiper stops ON: wiper moves continuously NB.
  • Page 105 OPERATION EXPLANATION OF COMPONENTS 24. BEACON WARNING LIGHT SWITCH This switch is used to switch on the rotating beacon. OFF: beacon light not illuminated. ON: beacon light illuminates and rotates. Light on switch illuminates when activated. LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH Press this switch (6) to adjust the brightness and contrast of the monitor display screen.
  • Page 106 EXPLANATION OF COMPONENTS OPERATION 3. When the screen changes to the contrast adjustment screen, press up switch (7) or down switch (8) to adjust the contrast. 4. After completing adjustment of the contrast, press input con- firmation switch (9). This will store the new setting and return you to the adjustment menu.
  • Page 107 OPERATION EXPLANATION OF COMPONENTS (C). Adjusting the clock ● 1. Use the adjustment screen and press up switch (7) or down switch (8) to select the clock monitor. (The selected monitor is inverted to black.) 2. When the screen changes to the clock adjustment screen, press up switch (7) or down switch (8) to adjust the year, to move to the date press input confirmation switch (9), the order in which the cursor moves is shown below:...

  • Page 108: Switches

    SWITCHES OPERATION SWITCHES 1. Machine monitor 18. Horn 2. Clamshell rotate right 19. 12V power supply 3. Boom and chassis attachment select 20. HCU Pedal (Option extra) 4. Right control lever 21. Power max button 5. cigarette lighter 22. Spare 6.
  • Page 109 This is used to light cigarettes. To use, push the lighter in. After a few seconds it will spring back. Pull out the lighter (5) and light your cigarette. No other equipment may be connected to the cigarette lighter without the prior permission of an authorized Komatsu distributor.
  • Page 110 SWITCHES OPERATION SWING LOCK SWITCH WARNING When the machine is travelling under its own power, or ● when the swing is not being operated, always set the switch to the ON (ACTUATED) position. On a slope, the work equipment may swing to the down ●...
  • Page 111 OPERATION SWITCHES CAB LAMP SWITCH This lights up the cab lamp. 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. PUMP CONTROL OVERRIDE SWITCH When normal: Switch (11) is down Position...
  • Page 112 SWITCHES OPERATION The swing lock override switch is designed to allow operations to be carried out for a short period when there is an abnormality in the swing brake electrical system (swing brake system error). The abnormality must be repaired immediately. TRAVEL OVERRIDE SWITCHES Emergency Travel Switch - If there is a problem with the controller or the signals being supplied to the controller and travel is not...
  • Page 113 OPERATION SWITCHES PARK LIGHT OVERRIDE To operate the parking lights when the ignition is switched "OFF" use switch (27) located on the steering column cover. ADDITIONAL DRIVING LIGHT SWITCH Switch (28) has three functions Sidelights Dipped Headlights REMARK Engine compartment light will only illuminate when sidelights are on.
  • Page 114 SWITCHES OPERATION WINDSCREEN WASH SWITCH When the sleeve switch on the steering column stalk (24b) is pushed towards the steering column the windscreen wash will operate. DIRECTION INDICATOR SWITCH This switch (24) is used to indicate the driver’s intention to change direction.
  • Page 115 OPERATION SWITCHES 12V POWER SUPPLY The 12V socket (19) provided on the cab rear left panel may be used only for electrical accessories drawing 1,5 A. maximum. Any accessories attached to this socket must carry the EC mark.

  • Page 116: Control Levers, Pedals

    CONTROL LEVERS, PEDALS OPERATION CONTROL LEVERS, PEDALS 1. Machine monitor 18. Horn 2. Clamshell rotate right 19. 12V power supply 3. Boom and chassis attachment select 20. HCU Pedal (Option extra) 4. Right control lever 21. Power max button 5. cigarette lighter 22.
  • Page 117 OPERATION CONTROL LEVERS, PEDALS WARNING When leaving the operator’s compartment, switch con- ● trol lever lock switch to OFF position, raise the safety lock lever to the LOCK position. If the control levers are not locked, and they are touched by mistake, this may lead to a serious accident.
  • Page 118 CONTROL LEVERS, PEDALS OPERATION 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 operating the levers.
  • Page 119 OPERATION CONTROL LEVERS, PEDALS TRAVEL PEDAL The travel pedal is used in conjunction with the Forward / Neutral / Reverse (F / N / R) switch (32) located on the right control lever. Select the direction required using F / N / R switch then depress travel pedal (30) to commence travel.
  • Page 120 CONTROL LEVERS, PEDALS OPERATION HYDRAULIC ADJUST BOOM PEDAL Pedal (23) is used to operate the second boom. (1) Raise: Pedal pushed forward (2) Lower: Pedal pushed back Raise Neutral Neutral position: Boom is stopped and held in the same position. Lower CAUTION Do not rest foot on the pedal unless in use.

  • Page 121: Front Window

    OPERATION CONTROL LEVERS, PEDALS FRONT WINDOW WARNING When opening or closing the ceiling window, front win- ● dow, bottom window, or door, always set the safety lock lever to the LOCK position. If the control levers are not locked and they are touched by accident, a serious accident may occur.
  • Page 122 CONTROL LEVERS, PEDALS OPERATION WARNING When the front window is open, there is danger that it will fall, so always lock it with left and right lock pins (A). 4. Grip knobs (A) at the top, bottom, left, and right of the front window, and pull lock lever (B) to release the lock at the top of the front window.
  • Page 123 OPERATION CONTROL LEVERS, PEDALS 6. Check that lock lever (B) is secured at the LOCK position. The lock is engaged if the arrow on lock case (F) lines up with ● the arrow on lock lever (B). Check it visually. If the arrow on lock case (F) does not line up with the arrow ●...
  • Page 124 CONTROL LEVERS, PEDALS OPERATION 4. Grip knob (C) at the bottom of the front window with your left hand and knob (D) at the top with your right hand, push the window to the front, then lower it slowly. 9JH02402AA1 5.

  • Page 125: Emergency Exit From Operator's Cab

    OPERATION CONTROL LEVERS, PEDALS Removing front bottom window 1. Open the front window, then hold grip (A), pull up, and remove the bottom window. 9JH01582AA1 2. After removing the bottom window, store it at the rear of the operator's cab and lock it securely with left and right locks (B). When removing, always hold the glass with one hand and ●...

  • Page 126: Door Lock

    CONTROL LEVERS, PEDALS OPERATION CLEAR RAIN VISOR The cab is fitted with a clear rain visor to prevent rainfall on the windscreen above the area cleared by the wiper. PULL DOWN SUN VISOR The operator cab is fitted with a pull down sun visor. The visor is simply pulled down and hooked into the retainers mounted on the front window.

  • Page 127: Cap, Cover With Lock

    OPERATION CONTROL LEVERS, PEDALS CAP, COVER WITH LOCK The fuel filler, hydraulic tank 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 128: Fuse

    CONTROL LEVERS, PEDALS OPERATION FUSE REMARK 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 129: Luggage Tray

    OPERATION CONTROL LEVERS, PEDALS LUGGAGE TRAY This tray is located to the rear of the operator’s seat. Always keep the operation & maintenance manual in this tray for easy reading access. ASHTRAY The ashtray is under the machine monitor at the front right of the operator compartment.

  • Page 130: Cab Radio

    CONTROL LEVERS, PEDALS OPERATION CAB RADIO Located to rear left of the operator’s seat. Refer to the separate operations manual for radio cassette. REMARK Ensure radio is switched off when leaving the machine for long periods to prevent draining of battery charge. NOTICE Before transporting the machine or putting inside a building store the antenna to prevent any interference.

  • Page 131: Handling Air Conditioner

    OPERATION CONTROL LEVERS, PEDALS HANDLING AIR CONDITIONER GENERAL LOCATIONS OF CONTROL PANEL Air conditioner control panel 9EH02410AA1 (1) OFF switch (6) FRESH/RECIRC selector switch (2) Fan switch (7) Display monitor (3) Temperature control switch (8) Air conditioner switch (4) Vent selector switch (9) Defroster selector lever (5) Auto switch OFF SWITCH...
  • Page 132 CONTROL LEVERS, PEDALS OPERATION FAN SWITCH This switch (2) is used to adjust the air flow. The air flow can be adjusted to six levels. Press the ∧ switch to increase the air flow; ● press the ∨ switch to reduce the air flow. During auto operation, the air flow is automatically adjusted.
  • Page 133 OPERATION CONTROL LEVERS, PEDALS VENT SELECTOR SWITCH This switch (4) is used to select the vents. When switch (4) is pressed, the display on monitor display (7) ● switches and air blows out from the vents displayed. If AUTO operation is selected, the vents are selected auto- ●...
  • Page 134 CONTROL LEVERS, PEDALS OPERATION AUTO SWITCH With this switch (5), the air flow, vents, and air source (RECIRC/ FRESH) are automatically selected according to the set tempera- ture. This switch also acts as the air conditioner main switch. When auto switch (5) is pressed, the lamp at the top of the ●...
  • Page 135 OPERATION CONTROL LEVERS, PEDALS AIR CONDITIONER SWITCH This switch (8) is used to turn the air conditioner (cooling, dehu- midifying, heating) ON or OFF. When the fan is actuated (the display monitor shows (b)) and ● air conditioner switch (8) is pressed, the air conditioner is switched ON, the lamp at the top of the air conditioner switch lights up, and the air conditioner starts.
  • Page 136 CONTROL LEVERS, PEDALS OPERATION 2. Use temperature set switch (3) to set to the desired tempera- ture. The air flow, combination of vents, and selection of fresh or recirculated air is automatically selected according to the set temperature, and the air conditioner is operated automati- cally to provide the set temperature.
  • Page 137 OPERATION CONTROL LEVERS, PEDALS MANUAL OPERATION 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are dis- played on the display monitor. 2. Turn air conditioner switch (8) ON. Check that the lamp at the top of the air conditioner switch lights up.
  • Page 138 CONTROL LEVERS, PEDALS OPERATION 4. Press vent selector switch (4) and select the desired vents. When this is done, the display for vent (c) of the display mon- itor changes according to the selection. 5. Press RECIRC/FRESH selector switch (6) and select recircu- lation of the air inside the cab (RECIRC) or intake of fresh air from outside (FRESH).
  • Page 139 OPERATION CONTROL LEVERS, PEDALS OPERATION WITH COLD AIR TO FACE AND WARM AIR TO FEET To operate with cold air blowing to the face and warm air blowing to the feet, set as follows. 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are dis- played on the display monitor.
  • Page 140 CONTROL LEVERS, PEDALS OPERATION 4. Adjust fan switch (2), temperature setting switch (3) and FRESH/RECIRC selector switch (6) to the desired positions. DEFROSTER OPERATION 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are dis- played on the display monitor.
  • Page 141 OPERATION CONTROL LEVERS, PEDALS 2. Press vent selector switch (4) and set the vent display on the display monitor to the display shown in (f) or (g) in the dia- gram on the right. 3. Press FRESH/RECIRC selector switch (6) and set it to take in fresh air.
  • Page 142 CONTROL LEVERS, PEDALS OPERATION 5. Adjust vents (A), (B), and (D2) so that the air blows onto the window glass. (Vents (C) and (D1) are fixed and cannot be adjusted.) When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air, turn air conditioner switch (8) ON.
  • Page 143 (3) to display the failures in turn. After completing the troubleshooting, press OFF switch (1) ● again to return to the normal display. If any abnormality is detected by the self-diagnostic function, ask your Komatsu distributor to carry out inspection and repair.

  • Page 144: Fusible Link

    NOTICE Never splash or spill water, mud or drink over the con- ● troller as this may cause a fault. If a fault occurs in the controller, do not attempt repair, ● but consult your Komatsu distributor.

  • Page 145: Tool Box (Chassis)

    OPERATION CONTROL LEVERS, PEDALS TOOL BOX (CHASSIS) This is used for keeping the tools. REFUELLING PUMP SAFETY Do not bring fire or sparks near fuel - smoking is prohibited. ● In event of ingested fuel - do not induce vomiting. Drink large ●...
  • Page 146 CONTROL LEVERS, PEDALS OPERATION 10. When the level indicator(1) shows the tank to be full, stop the pump. Take care not to allow fuel to overflow from the tank. 11. Close the cap on the foot valve by screwing fully. 12.

  • Page 147: Warning Lamps

    OPERATION CONTROL LEVERS, PEDALS WARNING LAMPS 1. INDICATOR WARNING LAMP When the indicator is pulled fully backward, warning light (A) will flash to indicate the driver’s intention to turn to the left. When the indicator is pushed fully forward, warning light (B) will flash to indicate the driver’s intention to turn to the right.

  • Page 148: Handling Accumulators

    When disposing of accumulators, it is necessary to re- ● lease the gas from the accumulators, so please contact your Komatsu distributor. Brake circuit accumulators (A) X 3 This machine is equipped with accumulators in the brake circuits. 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.

  • Page 149: 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 150 9. Check lifting eye for damage Check the lifting eye (or hook and safety latch) for damage. If damage is found, contact your Komatsu distributor for repair. 10. Check seat belt and mounting clamps. Check there is no abnormality in the seat belt or mounting...
  • Page 151 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 ● checking the coolant, always check the radiator reserve tank when the engine is cold.
  • Page 152 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 fuel is spilled, thoroughly clean up any spillage. 1.
  • Page 153 OPERATION OPERATION REMARK If breather holes (1) on the cap is clogged, the pressure in the tank will drop and fuel will not flow. Clean the holes from time to time. CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING When removing the oil filler cap, oil may spurt out, so ●...
  • Page 154 If the fuses frequently blow, if there are traces of short circuits in the electrical wiring, locate the cause immedi- ately and carry out repairs, or contact your Komatsu dis- tributor for repairs. Keep the top surface of the battery clean and check the ●...
  • Page 155 OPERATION OPERATION CHECK FOR WATER AND SEDIMENT IN WATER SEPARA- TOR, DRAIN WATER Do not over tighten the valve. Over tightening can damage the threads. 1. Open the door at the rear right of the machine. 2. Inspect the water separator (A), and check if the ring inside has risen to the marked line.
  • Page 156 OPERATION OPERATION ADJUSTMENT OF OPERATOR’S SEAT (AIR SUS- PENSION SEAT) (A) Fore-and-aft adjustment of seat Pull lever (1) up. After the seat is set to the desired position, release the lever. REMARK This operation will affect relative position of seat and wrist control levers.
  • Page 157 OPERATION OPERATION (E) Adjustment of tilting seat angle To adjust the tilt of the seat lift left hand handle (5). By exerting pressure on or off the seat it can be moved to the desired angle position. (F) Suspension adjustment The seat should be adjusted for the drivers weight by briefly pull- ing the actuator lever of the automatic and height adjuster (6) with the vehicle at a standstill and the driver sitting on the seat, the...
  • Page 158 OPERATION OPERATION (I) Seat depth adjustment To adjust the depth of the seat cushion, lift the right hand handle (9). By moving the seat cushion backwards or forwards the desired seating position can be reached. SEAT BELT Before fitting the seat belt, check that there is no abnormality ●...
  • Page 159 OPERATION OPERATION (C) Adjusting of reclining seat For details, see "(C) Adjustment of reclining seat (156)" (D) Adjustment of arm rest height For details, see "(D) Adjustment of arm rest height (156)" (E) Adjustment of tilting seat angle For details, see "(E) Adjustment of tilting seat angle (157)"...

  • Page 160: Operations And Checks Before Starting Engine

    OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING If the control lever is touched by accident, the work ● equipment or the machine may move suddenly. When leaving the operator’s compartment, always raise ● the safety lock lever to the LOCK position.
  • Page 161 If the monitors or gauges do not light up or the buzzer does not sound, there is probably a broken bulb or disconnection in the monitor wiring, so contact your Komatsu distributor for repairs. After approx. 3 sec., the following gauges will remain on and the other monitors will go out.

  • Page 162: Starting Engine

    OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION STARTING ENGINE NORMAL STARTING WARNING Check that there are no persons or obstacles in the sur- ● rounding area, then sound the horn and start the engine. ● Exhaust gas is toxic, when starting the engine in con- fined spaces, ensure adequate ventilation at all times.
  • Page 163 OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE STARTING IN COLD WEATHER WARNING Check that there are no persons or obstacles in the sur- ● rounding area, then sound the horn and start the engine. Never use starting aid fluids as they may cause explo- ●...
  • Page 164 OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION 3. When preheating monitor flashes, turn the key in starting switch (6) to the START position to start the engine. Heat Ambient temperature Preheating time Above 0° C Start 0°C to -10°C 20 seconds -10°C to -20°C 30 seconds 4.
  • Page 165 OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE 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 ●...
  • Page 166 OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION 2. Lower the safety lock lever to the UNLOCK position, switch OFF the control lever lock switch and raise the bucket from the ground. Control lever LOCK UNLOCK lock switch 3. Operate bucket control - right control lever, and arm control - left control lever (slowly to move the bucket cylinder and arm cylinder to the end of the stroke.
  • Page 167 OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE 5. After carrying out the warming-up operation, check that each gauge and monitor lamp is in the following condition. Engine water temperature gauge (1): Inside black range ● Fuel gauge (2): Inside green range ●...
  • Page 168 OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION) When starting the engine in cold areas, carry out the automatic warming-up operation after starting the engine. When the engine is started, if the engine water temperature is low (below 30°), the warming-up operation is carried out automati- cally.
  • Page 169 OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE 3. Turn fuel control dial to the mid-range speed position and turn swing lock switch ON. 4. Lower safety lock lever to the UNLOCK position, put control lever lock switch to OFF position and raise the bucket from the ground.
  • Page 170 OPERATIONS AND CHECKS BEFORE STARTING ENGINE 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 (1) on the monitor panel to switch to the working mode to be used.

  • Page 171: Moving Machine Off

    OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE 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. ●...
  • Page 172 OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION 3. Lower the safety lock lever to the UNLOCK position, fold the work equipment, and raise it 40 - 50 cm from the ground. LOCK UNLOCK 4. Raise the stabilisers/dozer blade (when fitted). See Section on operation of dozer &...
  • Page 173 OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE 8. Select travel direction on right control lever (32) If the undercarriage is not facing the normal forward direction ● - then the travelling direction will be opposite to that which is Forward Neutral selected.

  • Page 174: Steering

    Failure to comply with this notice will result in severe damage to the transmission unit. If you are uncertain about how to tow the machine, ● please contact your local komatsu distributor for advice.

  • Page 175: Travelling On Public Highway

    Failure to comply with this notice will result in severe damage to the transmission unit. If you are uncertain about how to tow the machine, ● please contact your local komatsu distributor for advice.

  • Page 176: Stopping & Parking

    OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION STOPPING & PARKING WARNING Avoid stopping suddenly. Give yourself ample room ● when stopping. If the control lever is touched by accident, the work ● equipment or the machine may move suddenly, and this may lead to a serious accident.
  • Page 177 Failure to comply with this notice will result in severe damage to the transmission unit. If you are uncertain about how to tow the machine, ● please contact your local komatsu distributor for advice.

  • Page 178: Swinging (Slewing The Upper Carriage)

    OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION SWINGING (Slewing the upper carriage) WARNING Never apply swing brake when machine is swinging as this is a static brake only. (damage may occur otherwise) Ensure the mechanical swing lock pin is disengaged before swinging.

  • Page 179: Operation Of Work Equipment

    OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION OF WORK EQUIPMENT WARNING If any lever is operated when the engine is at auto decelera- tion speed, 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 180 OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION Hydraulic adjust boom operation: Depress front of pedal ● (23) to extend the boom and the rear of the pedal to retract Hydraulic adjust boom pedal the boom. Raise Lower...
  • Page 181 OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION OF DOZER + OUTRIGGERS REMARK Ensure safety lock lever is lowered (UNLOCKED). 1. Press switch (3) on right control lever to change from boom operation to dozer/outrigger operation (attachment).The mon- itor will now display symbol (12) indicating the dozer/outrigger option has been selected 2.

  • Page 182: Working Mode Selection

    OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION WORKING MODE SELECTION WORKING MODE By using the working mode selector switch "WORKING MODE SELECTOR SWITCH (BASIC SWITCH) (94)" to select a working mode that matches the operating condition, it is possible to carry out operations efficiently.

  • Page 183: Prohibitions For Operation

    OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE 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. Never operate the machine on a rock bed (hard or soft ●...

  • Page 184: Precautions For Operation

    OPERATIONS AND CHECKS BEFORE STARTING ENGINE 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 185 OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE PRECAUTIONS AT Hi-SPEED TRAVEL On uneven roadbeds such as rock beds or uneven roads with large rocks, travel in Lo speed mode and adjust the speed of the machine to prevent loss of control. PERMISSIBLE WATER DEPTH Do not immerse the machine in water by more than the permissi- ble depth (axle centre).

  • Page 186: Precautions When Travelling Up Or Down Hills

    OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS WARNING When travelling, raise the bucket approx. 20 - 30 cm from ● the ground. Do not travel downhill with the upper carriage travelling ● in the reverse direction. When traveling over ridges or other obstacles, keep the ●...

  • Page 187: How To Escape From Mud

    If you are uncertain about how to tow the machine, ● please contact your local komatsu distributor for advice. HOW TO ESCAPE FROM MUD Always operate carefully to avoid getting stuck in mud. If the ma- chine does get stuck in mud, use the following procedures to get the machine out.

  • Page 188: Work Possible Using Hydraulic Excavator

    OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION WORK POSSIBLE USING HYDRAULIC EXCAVATOR In addition to the following, it is possible to further increase the range of applications by using various attachments. BACKHOE WORK When condition of the machine is as shown in the diagram at right, each cylinders maximum pushing excavation force is obtained when the bucket cylinder and link, arm cylinder and arm are at 90°.

  • Page 189: Replacement And Inversion Of Bucket

    OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE LOADING WORK In places where the swing angle is small, work efficiency can be enhanced by locating the dump truck in a place easily visible to the operator. Loading is easier and capacity greater if you begin from the front of the dump truck body than if loading is done from the side.
  • Page 190 OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATION INVERSION Bucket 1. Place the bucket in contact with a flat surface. cylinder REMARK When removing the pins, place the bucket so that it is in light Link contact with the ground. If the bucket is lowered strongly to the ground, the resistance will be increased and it will be difficult to remove the pins.

  • Page 191: Stopping Engine

    OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE STOPPING ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, engine Iife may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency. In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradu- ally, then stop it.

  • Page 192: Check After Stopping Engine

    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...
  • Page 193 OPERATION CHECK AFTER STOPPING ENGINE ● On machines fitted with twin wheel assemblies a valve exten- sion is fitted to the inner wheel to facilitate deflation. This part should always be refitted following disassembly as it ensures that the inner wheel assembly can be deflated whilst fitted to the hub.
  • Page 194 CHECK AFTER STOPPING ENGINE OPERATION ● Release 8 of the wheel retaining nuts leaving 2 diagonally opposed nuts to hold the assembly in position. Check that there is no remaining pressure being exerted on these rema- ing nuts by either the internal or external wheel assembly. Once satisfied that the remaining nuts are under no pressure, remove them.
  • Page 195 OPERATION CHECK AFTER STOPPING ENGINE WARNING It is essential that the lock-ring is seated correctly. Put the wheel assembly into a safety cage and inflate the tyre ● to a pressure of 1 - 1.5 Bar. Visually check the lock-ring is still seated correctly and there ●...
  • Page 196 OPERATION 4. Twin wheel assembly - 2 part rim Some Komatsu 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.

  • Page 197: Transportation

    OPERATION TRANSPORTATION 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 198 TRANSPORTATION OPERATION 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 centres of the trailer and the machine.

  • Page 199: Precautions For Loading

    OPERATION TRANSPORTATION 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 200 TRANSPORTATION OPERATION HOW TO LIFT THE MACHINE CAUTION Personnel who perform lifting using a crane must be quali- fied. 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.
  • Page 201 OPERATION TRANSPORTATION 5. Mount a shackle to boom pins and the counter weight. Hang the wire rope. 6. The length off the wire rope and the lifting angle must be as shown in the figure on the right. 7. When lifting, make sure that there is no change in the position due to possible leakage in the hydraulic circuit on the boom cylinder head side.

  • Page 202: Precautions For Transportation

    2100 15,375 2500 8,365 3,240 8,410 3,200 15,410 3000 15,540 (1) Height for transport = (D) Overall height + (3) height of trailer platform * Weights and dimensions: will vary according to specification. Consult your Komatsu distributor if in doubt.
  • Page 203 3978 8225 3208 15,800 3000 5878 3978 8211 3191 15,930 (1) Height for transport = (D) Overall height + (3) height of trailer platform * Weights and dimensions: will vary according to specification. Consult your Komatsu distributor if in doubt.

  • Page 204: Travelling Posture

    TRANSPORTATION OPERATION TRAVELLING POSTURE Before starting to travel, be sure to raise and lock the outriggers, and raise the dozer blade. Before travelling on public roads, the work equipment should be positioned to comply with local legal requirements for travel space envelope.
  • Page 205 OPERATION TRANSPORTATION Before moving off, lock all machine cover and toolbox doors to prevent accidental opening.

  • Page 206: Cold Weather Operation

    When replacing coolant containing antifreeze or when handling coolant when repairing the radiator, contact your Komatsu distributor or ask your local antifreeze dealer. Be careful not to let the water flow into drainage ditches or spray on to the ground surface.
  • Page 207 OPERATION COLD WEATHER OPERATION BATTERY WARNING The battery generates flammable gas, so 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 208: Precautions After Completion Of Work

    COLD WEATHER OPERATION OPERATION PRECAUTIONS AFTER COMPLETION OF WORK WARNING After completion of operations, fill the fuel tank to prevent the formation of water caused by condensation of moisture in the empty space in the tank when the temperature goes down.

  • Page 209: 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 210: 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 211: 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 212: 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 213: Discharged Battery

    OPERATION TROUBLESHOOTING DISCHARGED BATTERY WARNING It is dangerous to charge the battery while it is still ● When removing, disconnect the cable mounted on the machine. Always remove the battery from the ground terminal first. before charging it. When checking or handling the battery, stop the engine ●...
  • Page 214 TROUBLESHOOTING OPERATION When replacing the battery, attach the battery securely with ● the battery mounting clamp. Tightening torque of mounting bolts: 9.8 to 14.7 N•m (1 to 1.5 ● kgf•m) BATTERY CHARGES When charging the battery, there is danger that the battery may explode if it is mishandled.
  • Page 215 OPERATION TROUBLESHOOTING STARTING ENGINE WITH BOOSTER CABLES When starting the engine with a booster cable, do as follows: CONNECTING AND DISCONNECTING BOOSTER CABLES WARNING When connecting the cables, never contact the positive ● (+) and negative (-) terminals. ● When starting the engine with a booster cable, always wear safety glasses.
  • Page 216 TROUBLESHOOTING OPERATION BOOSTER CABLE CONNECTION Keep the starting switch of the normal machine and problem machine at the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. 1. Make sure that the starting switches of the normal machine Battery of the and problem machine are both at the OFF position.

  • Page 217: Other Trouble

    OPERATION TROUBLESHOOTING 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. Problem Main causes...
  • Page 218 TROUBLESHOOTING OPERATION 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 Main causes Remedy Speed of travel, swing, boom, arm,...
  • Page 219 OPERATION TROUBLESHOOTING ENGINE ( ) 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 Main causes Remedy Engine oil pan oil level is low Add oil to specified level, see ●...
  • Page 220 TROUBLESHOOTING OPERATION Problem Main causes Remedy Clogged air cleaner element Clean or replace, see WHEN ● ● REQUIRED Exhaust gas occasionally turns Defective nozzle (Replace nozzle) ● ● black Defective compression (See defective compression ● ● above) Defective turbocharger Clean or replace turbocharger ●...
  • Page 221 Countermeasure Place the machine in a safe posture, then have it Suspension lock system error inspected immediately by your Komatsu distribu- If the pump override switch is set to the ON posi- tion, operation can be carried out. However, TVC valve system error immediately have the PC-EPC valve system inspected by your Komatsu distributor.
  • Page 222 TROUBLESHOOTING OPERATION...

  • Page 223: Maintenance

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

  • Page 224: 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 225 MAINTENANCE GUIDES TO MAINTENANCE Fuel strainer: If your machine is equipped with a fuel strainer, do not remove it while fueling. 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-...
  • Page 226 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. Precautions when filling radiator When refilling the cooling system with fluid via the radiator ●...

  • Page 227: Outline Of Service

    MAINTENANCE OUTLINE OF SERVICE OUTLINE 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 228 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 ●...
  • Page 229 Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts. CARRYING OUT KOWA (Komatsu Oil Wear Analy- sis) KOWA is a maintenance service that makes it possible to prevent machine failures and down-time.
  • Page 230 Do not carry out sampling on rainy or windy days when ❍ water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distrib- utor. STORING OIL AND FUEL Keep indoors to prevent ingress of water, dirt, or other impuri- ●...

  • Page 231: Outline Of Electric System

    ● installed in the machine. Never install any electric components other than these speci- ● fied by Komatsu. Be careful to keep the electric system free of water when ● washing the machine or when it rains. Since the controller for the control system may cause mal- ●...

  • Page 232: Outline Of Hydraulic System

    OUTLINE OF SERVICE MAINTENANCE OUTLINE OF HYDRAULIC SYSTEM During operation and immediately after operation is ended, ● the temperature of the hydraulic system still remains high. In addition, high hydraulic pressure is applied to the system. Take care when inspecting and maintaining the hydraulic sys- tem.

  • Page 233: 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 234: Use Fuel, Coolant And Lubricants According To Ambient Temperature

    40° C 20W-40 Rear 2.0 litre 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- ●...
  • Page 235 There is no problem if single grade oil is mixed with multi- grade oil (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 236: Use Fuel, Coolant And Lubricants According To Ambient Temperature Cont

    10W30, 15W40 SAE80, 90, 140 NLGI No. 2 Base] (The 15W40 oil Permanent Type marked * is CE.) EO10-CD EO30-CD GO90 G2-LI Komatsu KOMATSU EO10-30CD GO140 G2-LI-S Anti-freeze EO15-40CD Diesel sigma S Super diesel multi- AGIP Rotra MP GR MU/EP...
  • Page 237 MAINTENANCE USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE CONT. 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.)

  • Page 238: 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 09054-00009 Socket 20E-98-K1110 33 mm drive socket If any of the above tools are broken, please order them from your Komatsu distributor.

  • Page 239: Tightening Torque Specifications

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

  • Page 240: Periodic Replacement Of Safety Critical Parts

    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. Interval Check items...

  • Page 241: Safety Critical Parts

    MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q’ty Replacement interval Fuel hose (Fuel tank - Water separator) Fuel hose (Water separator - Fuel pump) Fuel return hose (Fuel injection pump - Fuel tank) Spill hose (Engine output connector - Fuel tank) Pump outlet hose (Pump - Control valve) Work equipment hose (Boom cylinder inlet)

  • Page 242: Maintenance Schedule Chart

    MAINTENANCE SCHEDULE CHART MAINTENANCE MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE INITIAL 250 HOURS SERVICE (only after the first 250 hours) "REPLACE FUEL FILTER CARTRIDGE" "CHECK ENGINE VALVE CLEARANCE, ADJUST" "CHANGE OIL IN TRANSMISSION, HUBS + AXLES." WHEN REQUIRED "CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT" "CLEAN INSIDE OF COOLING SYSTEM"...
  • Page 243 MAINTENANCE MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE "Boom cylinder foot pin (2 points)." ● "Boom foot pin (2 points)." ● "Boom cylinder rod end (2 points)." ● "1st to 2nd boom pin (1 point)." ● "1st to 2nd boom pin (2 points)." ●...
  • Page 244 MAINTENANCE SCHEDULE CHART MAINTENANCE SERVICE ITEM PAGE EVERY 250 HOURS SERVICE "CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL" "CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Front Axle)" "CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Rear Axle)" "CHECK OIL LEVEL IN AXLES, ADD OIL" "CHECK OIL LEVEL IN TRANSMISSION, ADD OIL"...
  • Page 245 MAINTENANCE MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE "CLEAN, CHECK TURBOCHARGER" "CHECK ALTERNATOR, STARTING MOTOR" "CHANGE ANTIFREEZE" "CHANGE ANTIFREEZE" "CHECK AND ADJUST VALVE CLEARANCE" EVERY 4000 HOURS SERVICE "CHECK WATER PUMP" EVERY 5000 HOURS SERVICE "CHANGE OIL IN HYDRAULIC TANK"...

  • Page 246: Key To Lubrication Points

    MAINTENANCE SCHEDULE CHART MAINTENANCE KEY TO LUBRICATION POINTS check level 1. Engine oil 23.Rear propshaft grease change oil check level 2. Hydraulic oil 24. Front propshaft grease change oil 3. Boom cylinder foot pin grease 25. Cylinder mounts grease 4. Boom foot pin grease 26.
  • Page 247 MAINTENANCE MAINTENANCE SCHEDULE CHART Interval of service Change filter Lubrication by greasing (G) Amount of oil required at change (litres) Check oil level/change (EO)

  • Page 248: Service Procedure

    SERVICE PROCEDURE MAINTENANCE SERVICE PROCEDURE INITIAL 250 HOURS SERVICE Carry out the following maintenance only after the first 250 hours. REPLACE FUEL FILTER CARTRIDGE ● For details, see "REPLACE FUEL FILTER CARTRIDGE (287)" CHECK ENGINE VALVE CLEARANCE, ADJUST ● For details, see "CHECK ENGINE VALVE CLEARANCE, ADJUST (248)"...

  • Page 249: When Required

    MAINTENANCE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING If inspection, cleaning, or maintenance is carried out with ● the engine running, dirt will enter the engine and cause damage to the engine. Stop the engine before carrying out these operations.
  • Page 250 SERVICE PROCEDURE MAINTENANCE Outer Element - Clean 1. Open the door at the left side of the machine, remove 3 hooks (2), then remove cover (6). NOTICE Before and after cleaning the element, do not leave or keep it in direct sunlight. 2.
  • Page 251 MAINTENANCE SERVICE PROCEDURE 3. Remove any dirt or dust that is accumulated in the evacuator valve installed to cover. Evacuator valve ² 4. Direct dry compressed air (less than 0.69 MPa (7 kgf/cm ) to the outer element from inside along its folds, then direct it from outside along its folds and again from inside.
  • Page 252 SERVICE PROCEDURE MAINTENANCE Air Cleaner Element - Install NOTICE Do not use any damaged gasket or seal or element with ● damaged pleats. Cleaning the element or O-ring after one year has passed ● and using them again will cause problems. Replace them with new parts.
  • Page 253 MAINTENANCE SERVICE PROCEDURE Air Cleaner Inner Element - Replace 1. First remove the outer element, and then remove the inner element. 2. Cover the air connector side (outlet side) with a clean cloth or tape. 3. Clean the air cleaner body interior, then remove the cover from the air intake port in Step 2.
  • Page 254 SERVICE PROCEDURE MAINTENANCE CLEAN INSIDE OF COOLING SYSTEM WARNING Soon after the engine has been stopped, the coolant is ● hot and can cause personal injury. Allow the engine to cool before draining water. Since cleaning is performed while the engine is running, ●...
  • Page 255 30% by volume is necessary. In areas where the water is hard, add Komatsu genuine corrosion resistor agent KI. One packet of corrosion resistor agent contains 100g. The standard density of the mixture should be 7 g/litres.
  • Page 256 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 257: Checking Coolant Level

    MAINTENANCE SERVICE PROCEDURE 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 258 SERVICE PROCEDURE MAINTENANCE CLEANING THE SYSTEM At 2000 hours clean the cooling system as follows: 1. Drain the system into a suitable container. Refer to "DRAIN- ING THE SYSTEM (257)". 2. Drain and clean the reserve tank. 3. Close the radiator plug. 4.
  • Page 259 MAINTENANCE SERVICE PROCEDURE See "Precautions when filling radiator (226)". 4. Remove the reserve tank cap. 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.

  • Page 260: Check And Tighten Wheel Nuts

    Tighten the bolts in the order shown in the diagram. Torque to 80kgm. CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections. CHECK ALTERNATOR GENERAL...

  • Page 261: Replace Bucket Side Cutters

    MAINTENANCE SERVICE PROCEDURE REMARK Do not short across or ground any terminals of the alternator. Do not connect any cable to the “R” terminal on the alternator. This will result in severe damage to the harness and radiator. CHECK START MOTOR Under normal operating conditions, no maintenance is required between engine overhaul periods.

  • Page 262: Replace Bucket Teeth

    SERVICE PROCEDURE MAINTENANCE REPLACE BUCKET TEETH REPLACE BUCKET TEETH (VERTICAL PIN TYPE) Replace the point before the adapter starts to wear. WARNING • It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equip- ment in a stable position, then stop the engine and apply the locks securely to the levers.
  • Page 263 MAINTENANCE SERVICE PROCEDURE ● The rubber of the rubber pin lock is torn, and the steel balls may come out. The rubber is broken and the steel balls come out easily The steel balls are buried when they are pressed by hand. ●...
  • Page 264 SERVICE PROCEDURE MAINTENANCE 8. Insert lock pin (2) in the hole of the tooth and hit it until its top is the same level as the surface of tooth (1). 9. After replacing a bucket tooth, check the following. ❍ After the lock pin has been knocked in completely, check that it is secured by the point and surface.
  • Page 265 MAINTENANCE SERVICE PROCEDURE REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) Replace the point before the wear reaches the adapter. WARNING It is dangerous if the work equipment moves by mistake ● when the teeth are being replaced. Set the work equip- ment in a stable position, then stop the engine and raise the safety lock lever to the LOCK position.

  • Page 266: Adjust Bucket Clearance

    SERVICE PROCEDURE MAINTENANCE ADJUST BUCKET CLEARANCE WARNING It is dangerous if the work equipment moves by mistake ● when the clearance is being adjusted. Set the work equipment in a stable position, then stop ● the engine and raise the safety lock lever to the LOCK position.

  • Page 267: Check Window Washer Fluid Level, Add Fluid

    MAINTENANCE SERVICE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID If there is air in the window washer fluid, check the level of the fluid in window washer tank (1). Add automobile window washer fluid if necessary. When adding fluid, be careful not to let any dust get in. Mixture ratio of pure washer fluid and water Since the ratio should be varied depending on atmospheric tem- perature, replenish washer fluid at the following mixture ratio, tak-...

  • Page 268: Check And Adjust Air Conditioner

    SERVICE PROCEDURE MAINTENANCE CHECK AND ADJUST AIR CONDITIONER CHECK LEVEL OF REFRIGERANT (GAS) WARNING If the refrigerant used in the cooler gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit.

  • Page 269: Check Before Starting

    MAINTENANCE SERVICE PROCEDURE DRAIN ENGINE BREATHER OIL CATCHER Periodically drain oil from the engine breather catcher and when- ever it is necessary to remove the engine undercover. 1. Remove undercover (1) and allow oil to drain out. 2. Remove plug (2). Replace undercover (1).
  • Page 270 SERVICE PROCEDURE MAINTENANCE CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL Open the engine hood. REMARK Opening Engine Compartment Hood Whenever access is required to the engine compartment via the hood, always ensure that the work equipment is tipped as far for- ward as possible.
  • Page 271 MAINTENANCE SERVICE PROCEDURE CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If fuel is spilled, thoroughly clean up any spillage. 1. Use fuel gauge (G) on the monitor panel to check that the tank is full.
  • Page 272 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 ●...
  • Page 273 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 1. Open the cover at the rear right of the machine.

  • Page 274: Every 50 Hours

    SERVICE PROCEDURE MAINTENANCE CHECK FOR WATER IN PRIMARY FUEL FILTER, DRAIN WATER For information on this see "CHECK FOR WATER IN FUEL SEDIMENTOR". EVERY 50 HOURS DRAIN WATER AND SEDIMENT FROM FUEL TANK 1. Carry out this procedure before operating the machine. 2.
  • Page 275 MAINTENANCE SERVICE PROCEDURE 3. After greasing, wipe off any old grease that was pushed out. 2, 3, 4 1. Boom cylinder foot pin (2 points). 2. Boom foot pin (2 points). 3. Boom cylinder rod end (2 points). 4. 1st to 2nd boom pin (1 point). 5.
  • Page 276 SERVICE PROCEDURE MAINTENANCE 7. Boom-Arm coupling pin (1point). 8. Arm cylinder rod end (1 point). 9. Bucket cylinder foot pin (1 point). 10. Arm-Link coupling pin (1 point). 11. Arm-Bucket coupling pin (1 point). 12. Link coupling pin (1 point). 13.
  • Page 277 MAINTENANCE SERVICE PROCEDURE 20. Boom adjust cylinder foot pin (1 point). 21. Boom adjust cylinder rod end (1 point). 22. Axle pivot (2 point) (with outriggers attached) 23. Axle pivot (2 point) (without outriggers)
  • Page 278 SERVICE PROCEDURE MAINTENANCE 24. Hub pivot (4 points) 25. Steer links (4 points) 26. Axle pads (If noise heard grease as necessary) (2 points) 27. Cylinder mount (2 points) 28. Top link blade pivot pin (2 points) 29. Lower link blade pivot (2 points) 30.
  • Page 279 MAINTENANCE SERVICE PROCEDURE CLEANING FRESH AIR FILTER 1. Pull up the lock release lever under the door release lever to release the lock. 2. Open cover (2) at the bottom left of the operator's cab by hand, pull out filter case (3) from the inside, then remove the filter.

  • Page 280: Every 250 Hours Maintenance

    SERVICE PROCEDURE MAINTENANCE EVERY 250 HOURS MAINTENANCE CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the tempera- ture to go down before starting the operation. 1.
  • Page 281 MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Front Axle) Prepare a hexagonal wrench ● 1. Rotate hub until the oil level line marked front is horizontal (2). 2. Remove plug (1). 3. If no oil emerges, add oil until there is an excess. Allow excess to drain off and re-install plug (1).
  • Page 282 SERVICE PROCEDURE MAINTENANCE 3. Replace plug (1). For details of the oil to use, see "USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER- ATURE (234)" CHECK OIL LEVEL IN TRANSMISSION, ADD OIL 1. Remove level plug (1). 2. If oil emerges replace plug (1) 3.
  • Page 283 MAINTENANCE SERVICE PROCEDURE 3. Clean the air hole in the battery cap, then tighten the cap securely. When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from freezing. BELTS, GENERAL WARNING Before working on the engine or electrical system, discon- nect the negative (ground) battery cable.
  • Page 284 SERVICE PROCEDURE MAINTENANCE 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 285 MAINTENANCE SERVICE PROCEDURE 2. Loosen nut (5) attached to fixed bracket (3), and then tighten bolt (6). ❍ Tighten bolt (6) so that the deflection of the belt will be 5 ~ 8 mm (approx. 58.8N (6kgf) 3. Tighten bolts (1) and (2) to secure bracket (4). 4.

  • Page 286: Every 500 Hours Service

    SERVICE PROCEDURE MAINTENANCE EVERY 500 HOURS SERVICE Maintenance for every 50, 100 and 250 hours should be car- ried out at the same time. WARNING Engine is at high temperature immediately after the ● machine has been operated. Wait for engine to cool down before replacing the filter.
  • Page 287 ● Prepare a filter wrench and a container to catch the fuel. Use a genuine Komatsu filter cartridge. 1. Set the container to catch the fuel under the filter cartridge. 2. Using a filter wrench, turn filter cartridge (1) counterclockwise to remove it.
  • Page 288 1. Remove bolts (1) (2 bolts) on the top of the revolving frame and remove cover (A). 2. Check the colour of the grease. If it is milky white, it is neces- sary to change the grease. Please contact your Komatsu dis- tributor. The total amount of grease is 10.5 litres.
  • Page 289 MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the tempera- ture to go down before starting the operation. Prepare the following: Refill capacity of oil pan: 16 litres ●...
  • Page 290 SERVICE PROCEDURE MAINTENANCE 7. After replacing the filter cartridge, open the engine hood and add engine oil through oil filler (F) to between the H and L marks on dipstick (G). REMARK Opening Engine Compartment Hood Whenever access is required to the engine compartment via the hood, always ensure that the work equipment is tipped as far for- ward as possible.
  • Page 291 MAINTENANCE SERVICE PROCEDURE 2. Inspect the front and rear of the oil cooler fins (4), radiator fins (7), after-cooler fins (8), and condenser fins (9) for dirt, dust, dry leaves, etc. Blow them away with compressed air. Steam or water may be used instead of compressed air. 3.
  • Page 292 SERVICE PROCEDURE MAINTENANCE CLEANING RECIRCULATED AIR FILTER 1. Remove wing bolts (1) from the inspection window at the bot- tom rear left on the inside of the operator’s cab, then take out the recirculated air filter. 2. Clean the filter with compressed air. If there is oil on the filter, or if the filter is extremely dirty, wash and dry it thoroughly before using it again.
  • Page 293 2. Replace element (1) inside the cap with a new one. For component part numbers, see "WEAR PARTS LIST (233)" CHECK CONDITION OF MAIN VALVE RUBBER MOUNTS If main valve bracket mounting rubbers (1) appear cracked or worn, replace them. If unsure then contact your komatsu distributor for advice.

  • Page 294: Every 1000 Hours Service

    SERVICE PROCEDURE MAINTENANCE EVERY 1000 HOURS SERVICE Maintenance for every 100, 250 and 500 hours should be car- ried out at the same time. REPLACE HYDRAULIC FILTER ELEMENT WARNING ● The parts and oil are at high temperature after the engine is stopped, and may cause serious burns.
  • Page 295 (P), and check the oil level again. 9. Close the drain valve and allow excess oil to drain from the drain tube. Stow the hose and reinstall the undercover. CHECK ALL TIGHTENING PARTS OF TURBO- CHARGER. Contact your Komatsu distributor to have the tightening portions checked.
  • Page 296 SERVICE PROCEDURE MAINTENANCE CHECK PLAY OF TURBOCHARGER ROTOR. Ask Komatsu distributor to check the play of the turbocharger rotor. CHECK & ADJUST VALVE CLEARANCE As a special tool is required for removing and adjusting the parts contact your Komatsu distributor for service.
  • Page 297 MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN AXLES Front Axle 1. Remove plugs (1) and (2) to drain oil. 2. Replace plug (2). 3. Attach tube and funnel to plug (1) hole and add oil until oil emerges when tube is removed. 4.
  • Page 298 SERVICE PROCEDURE MAINTENANCE 3. Attach tube and funnel to plug (1) hole and add oil until oil emerges when tube is removed. 4. Replace plug (1). REMARK The oil must be replaced after first hundred hours then main- tenance is thousand hours. CHANGE OIL IN HUBS 1.
  • Page 299 MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN TRANSMISSION ASSEMBLY TRANSMISSION 1. Remove plugs (1)+(2) and allow oil to drain out. 2. Replace plug (2). 3. Add oil (approx. 4.85 l) until oil emerges from plug (1) hole. 4. Replace plug (1). REMARK The oil must be replaced after first hundred hours then main- tenance is thousand hours.

  • Page 300: 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 301: Every 4000 Hours Service

    CHECK WATER PUMP Since the pulley may have play, oil may leak, water may leak and the drain hole (A) may be clogged, contact your Komatsu distribu- tor for inspection, overhaul or replacement. 9JH02451A...

  • Page 302: Every 5000 Hours Service

    SERVICE PROCEDURE MAINTENANCE EVERY 5000 HOURS SERVICE Maintenance for every 100, 250, 500 and 1000 hours should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK WARNING ● The parts and oil are still at high temperature after the engine is stopped, and may cause serious burns.
  • Page 303 MAINTENANCE SERVICE PROCEDURE Procedure for bleeding air Follow steps 1 & 2 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 304 SERVICE PROCEDURE MAINTENANCE...

  • Page 305: Specifications

    SPECIFICATIONS...

  • Page 306: Specifications

    High speed German specification 20 km/h** Swing speed 11.5 rpm ● ENGINE Model Komatsu SAA4D102E-2 diesel engine ● Flywheel horsepower (NET) 87.5 kW (119 PS /2200 rpm) ● Starting motor 24 V 4.5 kW ● Alternator 24 V 45 A ●...

  • Page 307: Piece Boom

    SPECIFICATIONS SPECIFICATIONS 1 - PIECE BOOM...

  • Page 308: Piece Boom

    SPECIFICATIONS SPECIFICATIONS 2 - PIECE BOOM...

  • Page 309: Working Range: One Piece Boom

    SPECIFICATIONS SPECIFICATIONS WORKING RANGE: ONE PIECE BOOM Arm length mm 2100 2500 3000 Max. digging height 8,730 8,930 9,285 Max. dumping height 6,335 6,555 6,911 Max. digging depth 4,925 5,320 5,600 Min. swing radius 3,205 3,160 3,180 E’ Max. digging reach GL 8,620 8,885 9,315...

  • Page 310: Working Range: Two Piece Boom

    SPECIFICATIONS SPECIFICATIONS WORKING RANGE: TWO PIECE BOOM Arm length mm 2100 2500 3000 Max.digging height 9,745 10,118 10,575 Max.dumping height 7,285 7,655 8,117 Max digging depth 4,960 5,465 5,770 Min. swing radius 2,215 2,385 2,590 E’ Max. digging reach GL 8,310 8,745 9,225...

  • Page 311: Working Range: Rotating Arm

    SPECIFICATIONS SPECIFICATIONS WORKING RANGE: ROTATING ARM Arm length mm Max.digging height 10,170 Max.dumping height 7,695 Max digging depth 5,525 Min. swing radius 2,345 E’ Max. digging reach GL 8,825 Max. digging reach 9,005...
  • Page 312 SPECIFICATIONS SPECIFICATIONS...

  • Page 313: Options, Attachments

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

  • Page 314: 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 315: Precautions When Installing Attachments

    OPTIONS, ATTACHMENTS PRECAUTIONS WHEN INSTALLING ATTACHMENTS PRECAUTIONS WHEN INSTALLING ATTACHMENTS If options or attachments are modified or changed, the driving characteristics of the machine may change. Always read this sec- tion as a refresher every time attachments change. WARNING Long work equipment reduces the stability of the chassis, so if the swing is operated on a slope, or when going down a steep hill, the machine may lose its balance and overturn.
  • Page 316 If the correct procedure is not followed, Platform 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 ●...

  • Page 317: 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 318: Machines Ready For Attachments

    MACHINES READY FOR ATTACHMENTS OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS GENERAL LOCATIONS Clamshell Operation Selector valves to be in position shown for clamshell operation. Selector valve in normal position to bucket cylinder Selector valve turned to clamshell operation. Both valves must be in same position...
  • Page 319 OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS 1. STOP VALVE (1) This valve stops the flow of the hydraulic oil. There is one on both sides of the arm (1) FREE: Hydraulic oil flows. (2) LOCK: Hydraulic oil stops. When removing or installing attachments, set this valve to the LOCK position.

  • Page 320: Handling The Clamshell Bucket

    MACHINES READY FOR ATTACHMENTS OPTIONS, ATTACHMENTS 4. ACCUMULATOR (FOR CONTROL CIRCUIT) (4) WARNING The accumulator is charged with high-pressure nitrogen gas, and it is extremely dangerous if it is handled mistakenly. For details of handling, see "HANDLING ACCUMULA- TORS (148)" This is installed to release any remaining pressure in the attach- ment circuit after the engine is stopped.
  • Page 321 OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS HOW TO OPERATE Open and close Move the right control lever to operate clamshell 3. Open (move to right) 4. Close (move to left) Rotate Right control Press button on right control lever lever 2.

  • Page 322: Operation

    MACHINES READY FOR ATTACHMENTS OPTIONS, ATTACHMENTS OPERATION WARNING Be careful when pressing the switch in the deceleration ● range. The engine speed will rise suddenly. Do not press the switch except when operating the ● attachment. If the switch is depressed by accident, the attachment may move suddenly and cause serious dam- age or injury.
  • Page 323 OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS ● The deterioration of the hydraulic oil when using the breaker is much faster than for normal operations, so reduce the maintenance interval for the hydraulic oil and element. For details, see "MAINTENANCE SCHEDULE CHART (242)".
  • Page 324 MACHINES READY FOR ATTACHMENTS OPTIONS, ATTACHMENTS WHEN USING BREAKER Right control Depress the switch (2) of the right control lever to operate the lever breaker. Set the working mode to the B (breaker mode) mode. NOTICE Do not use the heavy-duty operation mode for breaker operations.

  • Page 325: Method For Releasing Pressure In Control Circuit Of Machines Equipped With Accumulator

    OPTIONS, ATTACHMENTS MACHINES READY FOR ATTACHMENTS METHOD FOR RELEASING PRESSURE IN CONTROL 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 safety lock lever completely in the FREE position, operate the right control lever and attachment control pedal fully to the front, rear, left, and right, to release the pressure in the control circuit.

  • Page 326: Introduction Of Attachments And Extending Machine Service Life

    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 ●...
  • Page 327 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 328 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 329: 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 330: 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 331: 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 ●...

  • Page 332: 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 ●...
  • Page 333 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE Operations using the swing force Operations using one side of work equipment AM092360A Catching and dragging with claw end Gouging.

  • Page 334: 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 335: 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 336: 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 ●...
  • Page 337 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE Operating other work equipment during crane operation Excessive lengthening of wire rope.
  • Page 338 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS GENERAL VIEW OF CONTROLS 1. Clamshell rotate right 7.Power max button 2. Boom and chassis attachment select 8. HCU pedal (option) 3. Right control lever 9. Spare 4. Safety lock lever 10.
  • Page 339 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE LEFT CONTROL LEVER (with auto-deceleration device) WARNING If any lever is operated when in the deceleration range, the engine speed will suddenly increase, so be careful when operating the levers. This lever is used to operate the arm and upper structure.
  • Page 340 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS ● If all control levers are set to neutral, the engine speed will drop by approx. 100 rpm, and after approx. 4 seconds, the engine speed will drop to the deceleration speed (approx. 1400 rpm).
  • Page 341 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPERATION ON SLOPES Vertical ditches can be dug on sloping surfaces. DITCH DIGGING Combination of rotating arm and upper boom make possible the precise digging of offset ditch. STATIONARY DIGGING The excavation of trenches for main and branch water supply and drainage pipes can be done without changing the machines posi- tion.
  • Page 342 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS REPLACEMENT OF BUCKET Stop the machine on a firm, flat surface. When performing work with another person, make clear signals to each other and work carefully for safety’s sake. Bucket cylinder 1.
  • Page 343 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE 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 344 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE OPTIONS, ATTACHMENTS 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 345: Rotating Arm

    OPTIONS, ATTACHMENTS ROTATING ARM ROTATING ARM GENERAL LOCATION AND SPECIFICATIONS. 1. Bucket 6. Boom lift cylinders 2. Bucket cylinder 7. Lower boom 3. Rotating arm 8. Boom adjusting cylinder 4. Arm cylinder 9. Rear wheel 5. Upper boom 10. Front wheel...
  • Page 346 German specification 20 km/h Swing speed 11.5 RPM Arm rotation 7 ~ 8 RPM speed Komatsu SAA4D102E-2 diesel engine Engine Flywheel horsepower 87.5 KW (119 PS) 2200 RPM REMARK Specifications are subject to change without notice. * Dependent on machine specification.

  • Page 347: General View Of Controls

    OPTIONS, ATTACHMENTS ROTATING ARM GENERAL VIEW OF CONTROLS 1. Safety lock lever 4. Rotate left 2. Left control lever 5. Rotate right 3. Right control lever 6. Two piece boom pedal LEFT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device) WARNING If any lever is operated when in the deceleration range, the engine speed will suddenly increase, so be careful when operating the levers.
  • Page 348 ROTATING ARM OPTIONS, ATTACHMENTS 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. This lever is used to operate the boom and bucket. Boom operation Bucket operation (1) RAISE...

  • Page 349: Travelling Posture

    OPTIONS, ATTACHMENTS ROTATING ARM 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. CAUTION Do not rest your food on the pedal unless using the pedal. PEDAL LOCK FOR BOOM ADJUST 1.
  • Page 350 ROTATING ARM OPTIONS, ATTACHMENTS 4. Fully retract the bucket cylinder. 5. Align arrows & on swing circle. (Fig. 2) 6. Retract the arm cylinder approximately half-way. (Fig. 2) 7. Fully retract first and second boom cylinders. 8. Carefully lower the arm down onto the undercarriage. (Fig. 3) 9.

  • Page 351: Maintenance

    OPTIONS, ATTACHMENTS ROTATING ARM MAINTENANCE MAINTENANCE REQUIREMENT The following maintenance should be carried out in addition to that in the PW160-7K Operation & Maintenance Manual. ITEM SERVICE PAGE EVERY 100 HOURS SERVICE Arm rotation machinery case Check and supply EVERY 250 HOURS SERVICE Arm rotation circle Lubricate 1 point EVERY 500 HOURS SERVICE...
  • Page 352 ROTATING ARM OPTIONS, ATTACHMENTS EVERY 250 HOURS SERVICE 1. ARM ROTATING CIRCLE LUBRICATING Apply grease to the grease fittings shown by the arrows (3 points).
  • Page 353 OPTIONS, ATTACHMENTS ROTATING ARM EVERY 500 HOURS SERVICE Maintenance for every 100 and 250 hours service should be carried out at the same time. 2. ARM ROTATION MACHINERY CASE 1. Disconnect hoses (2), (5) and (6) from the swing motor. 2.
  • Page 354 ROTATING ARM OPTIONS, ATTACHMENTS...
  • Page 355 INDEX INDEX Numerics <F> 12V POWER SUPPLY ......... 115 FEATURES ............10 24V power source..........130 FILTERS .............. 230 FIRE EXTINGUISHER ........... 25 FIRE PREVENTION ..........24 <A> FIRST AID KIT ............25 ACCUMULATOR (FOR CONTROL CIRCUIT) ..320 FOREWORD ............
  • Page 356 INDEX <P> TWO PIECE BOOM ........310 POSITION FOR ATTACHING SAFETY LABELS .. 50 POWER PICK-UP PORT ........130 PRECAUTION DURING OPERATION ....29 PRECAUTIONS FOR MAINTENANCE ....44 PRECAUTIONS WHEN INSTALLING ATTACHMENTS ..........315 PRECAUTIONS WHEN TRAVELLING ....31 PROHIBITED OPERATIONS .........
  • Page 358 PW160-7K WHEELED EXCAVATOR Form No. UEAM003203 © 2005 KOMATSU All Rights Reserved Printed in Belgium 10-05...

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