Safety 2.3.

Precautions for maintenance

2.3. Precautions for maintenance

2.3.1. Personnel
Do not service or repair the machine unless you are an appropri-
ately qualified technician or have been appropriately instructed by
a qualified technician.

2.3.2. Before carrying out maintenance

Warning sign

While the machine is being serviced, the engine must not be

started and the control elements must not be actuated without
prior agreement, since this could cause accidents with serious
injury.

Always attach the warning sign to the control lever for the work
hydraulic system to warn other persons that work is being
performed on the machine. If required, put up additional warning
signs around the machine.

You may purchase these warning signs from your Komatsu

dealer.

Tools

Only use tools which are suitable for the task you want to carry
out. If you use damaged or makeshift tools or tools which are of
inferior quality, injuries may occur.

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2.3. Precautions for maintenance Safety

Safety-related parts

The quality of these parts is subject to normal wear and tear. For
this reason, replace safety-related parts by new ones at regular
intervals, regardless of whether they are defective or not.

Safety-related parts are:

● Fuel system:

❍ fuel hose,

❍ overflow hose,

❍ tank cap

● Hydraulic system:

❍ all hydraulic hoses

Immediately replace defective parts, even if the interval for

replacement has not elapsed.

Replace hydraulic hoses every 6 years.

Prior to start of inspection and maintenance

Prior to start of inspection and maintenance operations, park the

machine on solid, even ground. Lower the work unit.

If your machine is provided with E.C.S.S., you must switch off the
E.C.S.S..

Switch off the engine and safeguard the machine.

If the engine has to be running during maintenance, e.g. for

pressure checks of the hydraulic system, proceed with particular
care. Carry out such measures with two persons with whom you
have arranged clear hand signs beforehand.

One person must be seated on the driver's seat to ensure that the
engine can be immediately switched off, if required. This person
must always ask the second person before actuating the control
levers.

The person performing the maintenance measures must take

care not to touch or get caught by moving parts.

Securing the articulated steering

Before starting maintenance, secure the articulated steering

against accidental movement using the locking bar on the right
side (position 'A').

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Safety 2.3. Precautions for maintenance

Supporting the boom

When work needs to be conducted under a raised boom then the

boom must be supported against the danger of suddenly falling.

NOTE
Use only the prescribed supporting prop to support the work
unit. Never use other objects as supports.

1. Park the machine on a piece of level, solid ground.

2. Put the parking brake on.

3. Place the wheel chock in front of the wheels to prevent the

machine from rolling away.

4. Raise the boom to the desired height.

5. Switch the engine off.

WARNING
Danger of injury caused by boom! It is only permitted to step
into the area below the boom if the boom is supported.

6. Position the supporting prop underneath the boom.

7. With the engine switched off, lower the boom slowly until it
rests safely on the supporting prop.

8. Set the drive direction selector to "N" and move the working
hydraulic's catch lever to position "1".

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2.3. Precautions for maintenance Safety

Tipping up the driver's cab

1. Park the machine on solid, level ground.

2. Lower the work unit to the ground and switch off the engine.

3. Close the cab door.

4. Use the locking bolt to secure the articulated steering (cross-

reference "Securing the articulated steering", Page 2-24).

NOTE
The machine has to be positioned straight and the articu-
lated steering has to be secured with the locking bolt! If the
driver's cab is tipped up while the machine is bent, the front
frame can cause damage to the windscreen!

5. Open the bonnet.

6. On both sides, remove the safety pins (1) and the fastening
screws (2) for the cab.
1
2

7. Take the hand pump lever out of its holder on the radiator (2)
and insert it into the receptacle of the pump (3).

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Safety 2.3. Precautions for maintenance

8. Set the lever at the pump to "pump up" and pump the cab
upward until it reaches the limit stop.

9. Move the safety rod on the right side upward until it reaches
the pin at the cab floor.

10. Set the lever at the pump to "pump down" and pump the cab
downward until the safety rod is secure against the right side
of the cab floor.

11. Take the lever out of the pump.

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2.3. Precautions for maintenance Safety

Tipping down the driver's cab

1. Insert the lever into the pump. Set the lever at the pump to
"pump up" and pump the cab upward until it reaches the limit
stop.

2. Fold down the safety rod on the right side and fasten it in this
position (arrow).

3. Set the lever to "pump down" and pump the cab downward
until the cylinder is entirely retracted (the resistance at the
lever increases markedly).

4. Remove the lever from the pump and fasten it to the radiator.

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Safety 2.3. Precautions for maintenance

5. Screw in the fastening screws (2) for the cab (1 left, 1 right),
tighten them and secure them with the safety pins (1).

Torque = 50 kpm (500 Nm).

6. Close the bonnet.

2 1
1

Tipping up the driver's cab (option with electric actuator)

1. Park the machine on solid, level ground.

2. Lower the work unit to the ground and switch off the engine.

3. Close the cab door.

4. Use the locking bolt to secure the articulated steering (cross-

reference "Securing the articulated steering", Page 2-24).

NOTE
The machine has to be positioned straight and the articu-
lated steering has to be secured with the locking bolt! If the
driver's cab is tipped up while the machine is bent, the front
frame can cause damage to the windscreen!

5. Open the bonnet.

6. On both sides, remove the safety pins (1) and the fastening
screws (2) for the cab.
1
2

7. Press the "On" (3) and "Lift" (4) buttons simultaneously, until
the cab reaches the upper limit stop.

3
4

G0090003

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2.3. Precautions for maintenance Safety

8. The top final position has been reached if the slipping clutch
of the electric actuator (6) is activated, with a clearly audible
sound.

9. Move the safety rod (7) on the right side upward until it
7 7
reaches the cylinder linkage.

10. Press the "On" (3) and "Lower" (5) buttons simultaneously,
until the safety rod is secure against the cab floor.

3
5

G0090003

Tipping down the driver's cab (option with electric actuator)

1. Press the "On" (3) and "Lift" (4) buttons simultaneously, until
the cab reaches the upper limit stop. Remove the safety rod.
3
4

G0090003

2. Fold down the safety rod on the right side and fasten it in this
position (arrow).

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Safety 2.3. Precautions for maintenance

3. Press the "On" (3) and "Lower" (5) buttons simultaneously,

until the cab reaches the lower limit stop. The "Retracted"
position has been reached if the slipping clutch of the electric
actuator (6) is activated, with a clearly audible sound.

3 G0090003

4. Screw in the fastening screws (2) for the cab (1 left, 1 right),
tighten them and secure them with the safety pins (1).

Torque = 50 kpm (500 Nm).

2 1
1

5. Close the bonnet.

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2.3. Precautions for maintenance Safety

2.3.3. During maintenance

Attachments

Attachments removed from the machine must be put down in a

safe location in such a way that they cannot tip over.

CAUTION
Caution - risk of injury!

Working under the machine

● Always lower all movable work units onto the ground or set
them to their lowest positions before you start to perform
maintenance or repair measures under the machine.

● Block the wheels of the machine using wheel chocks.

● Do not work under a machine that is not appropriately sup-

ported.

Keeping the machine clean

● Always keep the machine clean and tidy.

● Oil, grease, and tools lying around involve danger, since they
may cause slipping or tripping over.

● Do not clean sensors, plugs, and the interior of the driver's

cab with water or steam. If water seeps into the electric sys-
tem, there is danger of uncontrolled and unintentional move-
ment of the machine which may cause accidents.

Specific measures

Always wear appropriate safety clothes and safety goggles when

you perform grinding, welding, use a sledge hammer or carry out
similar work.

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